Asphalt Paver Technical Manual

PAVER
TECHNICAL MANUAL
49999-150 (12/04)
PAVER
TECHNICAL MANUAL
NOTICE!
This manual is intended to assist with the trouble-shooting
and repair of Terex Cedarapids pavers and screeds. It is a
guide only and NOT all-inclusive.
ALWAYS refer to the specific serial numbered assembly
for your particular machine.
24 Hour Service Number

(800) 821-5600
Serial Number
Date
3500 ......................................... 9/35
4000 ......................................... 4/37
4500 ......................................... 5/39
5500 ....................................... 12/41
6000 ......................................... 4/42
7000 ....................................... 11/43
7500 ....................................... 12/44
8500 ......................................... 8/45
9500 ......................................... 7/46
10500 ......................................... 3/47
11500 ......................................... 6/48
12000 ......................................... 4/49
12500 ......................................... 2/50
13000 ......................................... 1/51
14500 ......................................... 7/52
15000 ......................................... 7/53
15650 ......................................... 6/54
16400 ......................................... 6/55
17300 ......................................... 3/56
18900 ......................................... 6/57
19900 ......................................... 6/58
20920 ......................................... 3/59
22260 ......................................... 6/60
22850 ......................................... 1/61
23650 ......................................... 1/62
24500 ......................................... 1/63
25400 ......................................... 1/64
26300 ......................................... 1/65
27400 ......................................... 1/66
28550 ......................................... 1/67
29540 ......................................... 1/68
30300 ......................................... 1/69
31000 ......................................... 1/70
31750 ......................................... 1/71
32300 ......................................... 1/72
32870 ......................................... 1/73
33450 ......................................... 1/74
16093 (12/04)
Serial Number/Date Record

Approximate Manufacturing Dates
Serial Number
Date
34120 ......................................... 1/75
34720 ......................................... 1/76
35190 ......................................... 1/77
35790 ......................................... 1/78
36326 ......................................... 1/79
37180 ......................................... 1/80
37910 ......................................... 1/81
38460 ......................................... 1/82
38760 ......................................... 1/83
39090 ......................................... 1/84
39420 ......................................... 1/85
39810 ......................................... 1/86
40290 ......................................... 1/87
40918 ......................................... 1/88
41526 ......................................... 1/89
42195 ......................................... 1/90
42772 ......................................... 1/91
43248 ......................................... 1/92
43637 ......................................... 1/93
44062 ......................................... 1/94
44630 ......................................... 1/95
45400 ......................................... 1/96
45735 ......................................... 1/97
47214 ......................................... 1/98
48187 ......................................... 1/99
48729 ......................................... 7/99
49198 ....................................... 12/99
50434 ....................................... 12/00
51203 ....................................... 12/01
51800 ....................................... 12/02
52361 ....................................... 12/03
52500 ....................................... 12/04
TIER II Machines
60001 thru 60005 ..................... 12/02
60055 ....................................... 12/03
60158 ....................................... 12/04
Hydraulic Hose
Assembly Coding
Technical Manual
Coding System for Re-useable End Type

Hydraulic Hose Assemblies
HOSE TYPE CODE

5- Parker Type 421 or Equal
9- All Types NOT Designated Above
HOSE SIZE CODE

0- 1/4 I.D.
5- 1-1/4 I.D.
1- 3/8 I.D.
6- 1-1/2 I.D.
2- 1/2 I.D.
7- 2 I.D.
3- 3/4 I.D.
8- Not Assigned
4- 1 I.D.
9- Hose Sizes Not Listed Such As 7/16 I.D.
7550 THRU 7599 ARE FOR HYDRAULIC HOSE ASSEMBLIES. THE HOSE ASSEMBLIES
ARE CODED PER THE FOLLOWING SYSTEM.
Hose Coding (22483)
(12/04)
Technical Manual

HOSE END CLAMP

1- Male Pipe
2- Flareless Swivel (Female)
3- JIC (37) Swivel- Straight
4- JIC (37) Swivel- 45 Elbow
5- JIC (37) Swivel- 90 Elbow
6- Flange Head- 45 Elbow
7- Flange Head- 90 Elbow
8- Not Assigned
9- Not Assigned
0- Hose Ends NOT Listed Above
HOSE ASSEMBLY VARIATIONS

No number listed- hose assemblies with both ends the same size as the hose and at least
one straight end.
-01 thru 49- variations of standard hose:
Example: Hose end or ends of a different size than the hose I.D., hose end requiring orietation
such as both ends being elbows, etc.
-50- standard hose except 1/2 longer than the length code would indicate (See Note #1)
-51 thru 99- same as 01 thru 49 except hose length would be 1/2 longer than length code
would indicate. (See Note #1)
Hose Coding (22483)
(12/04)
Technical Manual

NOTE #1
On hose lengths longer than 24 the 1/2 length increments should not be used except in very
special situations. Generally speaking, cutting lengths are not accurate enough to warrant calling for
hose in 1/2 increments. Under 24 the 1/2 length may be used when necessary but should be avoided
if possible.
EXAMPLES
1/2 I.D. #301 hose 69 long with 1/2 male pipe fitting on one end and 1/2 JIC (37) swivel
45 elbow on the other end, part # would be 7562-069-14.
The same hose but with a 3/8 male pipe fitting instead of 1/2 would be 7562-069-14-01.
The same hose but with a 3/8 male pipe fitting and 69-1/2 long would be 7562-069-14-51.
The same hose with 90 flange head elbows would show the orientation of the elbows to each
other and would be 7562-069-77-01.
Each hose number assignment should be cross-checked against the aperture card file to prevent
duplication of part number assignments and/or duplication of hose drawings.
Hose Coding (22483)
(12/04)
Technical Manual
Coding System for Crimped Type

CODE NUMBER ASSIGNMENTS

HOSE TYPE CODE
1&2.
Not Assigned
3.
SAE100R4 Suction Hose
4.
Medium Pressure
SAE100R5 Single wire braid-cotton braid cover
5.
Medium Pressure
SAE100R1 Single Wire Braid/ Abrasion Resistant Synthetic Cover
6.
High Pressure
SAE100R2 Two Wire Braid/ Abrasion Resistant Synthetic Cover
7.
Very High Pressure
SAE100R9 Four Wire Spiral/ Abrasion Resistant Synthetic Cover
8.
Extremely High Pres. Hose Rated Greater Than SAE100R9
9.
All Hose Types Not Assigned
HOSE SIZE CODE

0.
1/4 I.D.
5.
1-1/4 I.D.
1.
3/8 I.D.
6.
1-1/2 I.D.
2.
1/2 I.D.
7.
2 I.D.
3.
3/4 I.D.
8.
Not Assigned
4.
1 I.D.
9.
Hose Sizes Not Listed (Such As 7/16 I.D.)
Hose Coding (22483)
(12/04)
Technical Manual

HOSE END CODE
1. Male Pipe
2. Not Assigned
3. JIC (37) Swivel- Straight
4. JIC (37) Swivel- 45 Elbow
5. JIC (37) Swivel- 90 Elbow (SAE Short Drop)
6. Flange Head- 45 Elbow Code 61
7. Flange Head- 90 Elbow Code 61
8. JIC (37) Swivel- 90 Elbow (SAE Long Drop)
9. Flange Head- Straight
0. Hose Ends Not Listed Above
HOSE ASSEMBLY VARIATIONS
No number listed- hose asemblies with both ends the same size as the hose and at least
one straight end.
01 thru 49- variations of standard hose
Examples: Hose end or ends of a different size than the hose I.D., hose end requiring orientation
such as both ends being elbows, etc.
50- standard hose except 1/2 longer han the length code would indicate. (See Note #1)
51 thru 99- same as 01 thru 49 except hose length code would be 1/2 longer than length
code would indicate. (See Note#1)
NOTE #1
On hose lengths longer than 24 the 1/2 length increments should not be used except in
very special situations. Gnerally Speaking, cutting length are not accurate enough to warrant
calling for hose in 1/2 increments. Under 24 the 1/2 length may be used when necessary but
should be avoided if possible.
Hose Coding (22483)
(12/04)
Technical Manual

ANGULAR ORIENTATION
READING CLOCKWISE FROM 0 TO 360
SHOW INLINE ORIENTATION AS 0
EXAMPLES:
1/2 I.D. :Type 5 hose 69 long with 1/2 male pipe fitting on one end and 1/2 JIC (37) swivel
45 elbow on the other end, part number would be 7652-069-14.
The same hose but with a 3/8 male pipe fitting instead of 1/2 would be 7652-069-14-01.
The same hose but with a 3/8 male pipe fitting and 69-1/2 long would be 7652-069-14-51.
The same hose with a 90 flange head elbows would show the orientation of the elbows to each
other and would be 7652-069-77-01.
Each hose number assignment should be cross-checked against the aperture card file to prevent
duplication of part number assignments and/or duplication of hose drawing.
Hose Coding (22483)
(12/04)
Rubber Track
Operating Hints
Technical Manual
Rubber Track Operating Hints
Do Not Allow Asphalt Build-up on Track
The following are some specific considerations for

operation of asphalt pavers equipped with rubber
tracks. While not all-inclusive, following these
recommendations should reduce the risk of
problems and improve rubber track durability and
reliability.
During paving, asphalt sometimes flows down to

the rear drive wheel and become packed between
the track and wheel. This may cause the following
problems:
Oil in the asphalt will cause the rubber in the

track to soften and reduce the durability.
Aggregate will abrade the rubber in the track

and shorten its life.
Asphalt material build-up in the undercarriage

will cause additional tension on the track.
Asphalt Build-up
May Cause........
Guide Crush
Material retaining
plates retracted
will allow material
to carry back
around to tracks.
Guide Wear
Extend plates to
prevent this.
Inner Rubber Wear
Figure 1 Asphalt on Track & Wear

22762 (12/04)
Technical Manual

Proper Installation of Material Retaining
Plates
Machines are shipped with the material retaining
plates as shown in (Figure 2). 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.
Before paving begins, loosen nuts, slide plate out

from frame and re-tighten nuts to hold plate in
position. (Figure 3)
Material retaining
plates
repositioned.
Figure 3
Figure 2
22762 (12/04)
Technical Manual

Maneuvering On Hot Asphalt
Pavers are not normally operated on newly paved
hot asphalt as it will damage the surface of the mat.
There may however be certain conditions when this
becomes unavoidable. If it is necessary to drive on
newly paved asphalt, be aware this could be
problematic.
De-tracking
Damage
Temporary
De-tracking
Rubbing
Marks on
Frame
Figure 4 De-tracking
22762 (12/04)
Technical Manual

Generally, de-tracking occurs when the paver
turns. If rubbing marks are noted on track frame,
check track inner surfaces for signs of scarring
caused by temporary de-tracking. To avoid detracking, it is recommended:
Do not turn on or near hot asphalt. Move to

a cold area and turn there. If turning on the hot
asphalt is necessary, use forward as much as
permissible and keep the turn gradual in as
large an arc as possible. Maneuvering should
be done at as slow a speed as possible.
Do not park on hot asphalt. High

temperature can deteriorate the track rubber. It
is recommended to remain on the hot area of
asphalt no longer than twenty (20) minutes.
Figure 5 Do Not Park On Hot Asphalt
22762 (12/04)
Technical Manual

Maneuvering On Uneven Surface
Caution - If a turn is attempted on an

edge, track damage or de-tracking
could occur.
Uneven terrain such as curbs, concrete ridges or

joints of paved and unpaved surfaces (step in
elevation) may affect machine maneuverability.
One concern is the stress concentration caused by
the sharp edges of the surface and another is when
a track is parallel to an edge. (Figure 6)
Paver
Edge
of
Mat
Manhole
Figure 6 Steps in Elevation & Uneven Surfaces
Do not turn on or near sharp edges of

uneven surfaces. It is best to make a turn
while on an even surface. If a turn is made
with a portion of the track on an edge or the
track comes into contact with an edge during
the turn, it could cause a cut, tear, or even detracking. If this situation is unavoidable, keep
the turn gradual in as large an arc as possible,
at slow speed, in forward and with a spotter to
watch the track safety.
22762 (12/04)
Do not approach a step in elevation at a

sharp angle. If it is necessary to move from
one level of elevation to another, it is
recommended the approach angle should be
more than 45 degrees. The best method is to go
perpendicular to it.
Do not park on a step in elevation. When

parking, make sure the tracks are not resting
on an edge or any sharp object. This may cause
damage to the track.
Technical Manual
Tearing
Chunking
Figure 7 Damage From Steps in Elevation & Uneven Surfaces
22762 (12/04)
Technical Manual

Maintenance of Track
To maintain and preserve the life of the rubber

track it is important to follow these
recommendations:
Do not use solvents to wash the rubber

track. Solvents including kerosene, gasoline,
diesel fuel, or oils cannot be used to wash the
surface of track rubber. The track rubber
absorbs these solvents and will gradually
soften and reduce its durability. Soap and
water are recommended for cleaning the
rubber track.
Covering track for long term outdoor

storage. Rubber is affected by exposure to
sunlight (ozone). Covering the track with
something like a vinyl sheet if the machine is
idle for an extended length of time, such as
over Winter, will help keep the surface in good
condition. This is especially true where the
rubber is bent and stretched around wheels.
NOTICE
If you scrape the rubber track surface to
clean it, be careful to not damage or cut it
when cleaning.
Figure 8 Cover Track for Outdoor Storage
22762 (12/04)
Technical Manual
Releasing track tension for long term

storage. As is true for covering the track,
releasing the track tension when the machine is
idle for an extended length of time, such as
over Winter, will prolong its life.
Track Tension Valve

Charge Cartridge
Test Port
NOTICE
Before releasing track tension, make sure
machine is parked on level ground.
Release 300 Series Rubber Track Tension
Track Tension Valve
Discharge Cartridge
1) Shut off engine and remove key from ignition.

2) Loosen jam nut on track tension valve
discharge cartridge (Figure 9).
3) Insert an allen wrench into the adjusting screw,
slowly turn it counter-clockwise to open the
shut-off valve and release hydraulic pressure.
Track Tension
Valve
Figure 9 Release 300 Series Rubber Track Tension
4) Insert an allen wrench into the adjusting screw

on the discharge valve cartridge and slowly
turn it clockwise to close the valve.
5) Tighten jam nut on track tension valve
discharge cartridge (Figure 10).
6) Repeat for the other track.
The 300 series pavers will require tracks to be retensioned after removal from long term storage.
This is not done automatically, see procedure in
Operation and Maintenance Manual.
22762 (12/04)
Technical Manual

Release 400 & 500 Series Rubber Track Tension
4) Insert an allen wrench into the adjusting screw

and turn it clockwise to close the valve.
1) Shut off engine and remove key from ignition.

5) Tighten jam nut on tension release valve
cartridge (Figure 10).
2) Loosen jam nut on tension release valve

cartridge (Figure 10).
6) Repeat for the other track.

valve and release hydraulic pressure.
The 400 and 500 series pavers will require the

tracks to be re-tensioned after removal from long
term storage. They are automatically tensioned
when the engine is started. See procedure in
Tension
Release
Cartridge
Figure 10 Release 400 & 500 Series Rubber Track

Tension
22762 (12/04)
Technical Manual
4) Periodically check that any steel cable or ply

cord are not exposed.
Check 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 11) If one side is worn more than the
other side, one or more of the following
conditions could exist. Factors such as asphalt
build-up on the track inner surface, road
crown, track tensioning, etc. If any of the
above is present, correct the situation before
excessive track wear occurs.
5) Periodically check that track is properly

tensioned. A loose track could cause detracking. (Refer to Tension information in the
Guide
Lug
Wear
on One
Side
Figure 12 Rubber Track Identification
You may use the following table to record the

information off the tracks on your machine.
Figure 11 Rubber Track Alignment
Data
Visual Inspection. Unlike pneumatic tires, the

rubber track is not as sensitive to chippings
and cracks on the surface unless they extend to
the separation of rubber from belt. The rubber
track is not a 100% maintenance free product.
The following items will be helpful to
maintain and inspect your rubber tracks:
Left
6 inches
6 inches
Machine Serial
Number
Hour Meter
Reading
Date of Track 1st
Use
Track Width
1) Record track serial numbers.
Number of
Pitches
2) Record the date and hour meter reading when

you mount tracks on machine.
Pitch
Track Serial
Number
3) Periodically check condition of tread, guide

lugs, and inner surface for wear, cracks,
chipping and chunking.
22762 (12/04)
Right
Table 12 - 1 Rubber Track Data

10
PAVER
TECHNICAL MANUAL
300 Series & 411

Electrical Section
Technical Manual
A Terex Company
Table of Contents
Grayhound 300 Series/CR411
Component Location Maps ......................................................................................... 1 - 10
Engine Starting System .................................................................................................... 11
Charging System .............................................................................................................. 12
Throttle & Fuel .......................................................................................................... 13 - 14
Engine Start & Fuel - Elite Engine ................................................................................... 15
Horn .................................................................................................................................. 16
Gauges .............................................................................................................................. 17
Lights ................................................................................................................................ 18
Brakes ............................................................................................................................... 19
Travel/Pave (P2) System CR361 ...................................................................................... 20
Front Wheel Assist CR351/CR411 .................................................................................. 21
Travel Control CR351/CR411 .................................................................................. 22 - 24
Travel Control & Steer Assist - Rubber Tire Pavers 1999 & After........................... 25 - 27
Travel Control Adj. Procedure-3 Pot Controller Grayhound Tire Pavers ................. 28 - 29
Travel Control Adj. Procedure-3 Pot Controller Grayhound Track Pavers .............. 30 - 32
Travel Control Adj. Procedure-4 Pot Controller Grayhound Tire Pavers ................. 33 - 34
Differential Lock CR351/CR411...................................................................................... 35
Steer Assist CR351/CR411 ....................................................................................... 36 - 37
LH Travel Speed Control CR361 .............................................................................. 38 - 39
RH Travel Speed Control CR361 .............................................................................. 40 - 41
Travel Control Adj. Procedure-4 Pot Controller Grayhound Track Pavers .............. 42 - 44
Susmic 10 Dual Path Control Calibration Procedures............................................... 45 - 49
Hopper .............................................................................................................................. 50
Truck Hitch (Optional) ..................................................................................................... 51
Frame Raise CR351/CR411 ............................................................................................. 52
LH Flow Gate ................................................................................................................... 53
RH Flow Gate ................................................................................................................... 54
Material Flow Indicators 1999 & Before .................................................................. 55 - 56
Material Flow Indicators 1999 & After ..................................................................... 57 - 58
Screed Lift ........................................................................................................................ 59
Screed Assist .................................................................................................................... 60
Power Main Crown ........................................................................................................... 61
Vibrators ........................................................................................................................... 62
300 Series & CR411 Electrical Troubleshooting
22478 (11/00)
Technical Manual
A Terex Company
Table of Contents
LH Hydraulic Strike-Off Extend ...................................................................................... 63
RH Hydraulic Strike-Off Extend ...................................................................................... 64
LH Hydraulic Strike-Off Slope ........................................................................................ 65
RH Hydraulic Strike-Off Slope ........................................................................................ 66
LH Match Height .............................................................................................................. 67
RH Match Height ............................................................................................................. 68
LH Main Burner #1 .......................................................................................................... 69
RH Main Burner #2 .......................................................................................................... 70
LH Ext. Burner #3 ............................................................................................................ 71
RH Ext. Burner #4 ............................................................................................................ 72
Rear Frame Compensator Adjustment ............................................................................. 73
Remote Oil Cooler Motors ............................................................................................... 74
ii
22478 (11/00)
Technical Manual
A Terex Company
Component Location Map Fastach 8 & 10
1 ........... Screed burner fan and glow plug

2 ........... Controls for glow plugs, fans and horn
3 ........... Burner and spray down control valves
22478 (11/00)
Technical Manual
A Terex Company
Component Location Map Fastach II
Cedarapids
EXTEND
FEED
OVER
RIDE
STOP
SLOPE
MATCH
HEIGHT
BERM
TOWPOINT
MAN
MAN
SETUP
AUTO
HORN
Cedarapids
EXTEND
FEED
OVER
RIDE
STOP
SLOPE
E
TEMPERATUR
RH MAIN
MATCH
RH EXT
HEIGHT
LH MAIN
LH EXT
CONTROL
HEAT
OUTLET
HEAT
OUTLET
HEAT
HEAT
HEAT
BERM
GENERATOR
ON
OFF
ON
OFF
TOWPOINT
MAN
MAN
SETUP
AUTO
HORN
HORN
CROWN
E
INCREAS
E
DECREAS
1 ........... Screed Heater Control Panel

2 ........... Screed Generator
22478 (11/00)
Technical Manual
A Terex Company
Component Location Map Stretch 16 & 18
1 ........... Screed burner fan and glow plug

2 ........... Controls for glow plugs, fans and horn
3 ........... Burner and spray down control valves
22478 (11/00)
Technical Manual
A Terex Company
Component Location Map

DIN Connector
Earlier Version
Travel Controller
Low Threshold
Reverse
Maximum Pot
Forward
Maximum Pot
Manual Override
DIN Connector
Current Version
Travel Controller
MINIMUM Forward Pot
MINIMUM Reverse Pot
MAXIMUM Forward Pot
MAXIMUM Reverse Pot
22478 (11/00)
Technical Manual
A Terex Company

L4
L2
L1
L3
L5
L6
Front
Bulkhead
L17
L9
L12
L8
L7
L16
L11
L13
L10
Rear
Bulkhead
L14
L15
L1 ......... Slope sensor

L2 ......... Front wheel assist
L3 ......... LH pull point solenoid
L4 ......... Truck hitch solenoid
L5 ......... LH material flow gate
L6 ......... RH material flow gate
L7 ......... Main electrical junction box
L8 ......... Hopper wing solenoid
L9 ......... RH pull point solenoid
L10 ....... Screed lift solenoid
L11 ....... Frame raise solenoid
L12 ....... Brake solenoid
L13 ....... Vibrator solenoid
L14 ....... LH feed sensor
L15 ....... RH feed sensor
L16 ....... Travel/Pave solenoid
L17 ....... Burner/Spraydown pump & motor
22478 (11/00)
Technical Manual
A Terex Company

1st Generation Version
Grayhound 300 Series Analog Display
24 23 22 21 20 19 18 17 16 15
1
2
3
4
5
6
7
8
9
12
14
13
10
11
1 ........... Engine breaker: 15 amp

2 ........... Screed breaker: 15 amp
3 ........... Control breaker: 15 amp
4 ........... F/G/S breaker: 15 amp
5 ........... Spraydown breaker: 15 amp
6 ........... Light breaker: 15 amp
7 ........... Flasher breaker: 15 amp
8 ........... Gate breaker: 30 amp
9 ........... Burner breaker: 50 amp
10 ......... Key switch
11 ......... K2 relay
12 ......... K22 relay
13 ......... RH auger/conveyor proportional module

14 ......... LH auger/conveyor proportional module
15 ......... K3 relay
16 ......... K4 relay
17 ......... K5 relay
18 ......... K6 relay
19 ......... K15 relay
20 ......... K16 relay
21 ......... K17 relay
22 ......... K18 relay
23 ......... Spare relay
24 ......... Flasher relay
22478 (11/00)
Technical Manual
A Terex Company

10
11
12
20
21
30
31
13
16
19
18
14 15 17
22
29
23
24
4 3 2
25
26
27
28
36
32
37
33
34
35
28
30
31
29
16
1 ............. Travel control

2 ............. Differential lock switch
3 ............. Travel speed pot
4 ............. Rear frame compensator switch
5 ............. Screed assist switch
6 ............. Screed lift switch
7 ............. Screed vibrator switch
8 ............. Engine stop/start/run switch
9 ............. RH conveyor switch
10 ........... LH conveyor switch
11 ........... RH conveyor speed pot
12 ........... LH conveyor speed pot
13 ........... Permissive start switch
14 ........... LH screed extension switch
15 ........... RH screed extension switch
16 ........... Frame raise switch
17 ........... Steer assist switch
18 ........... Flasher switch
19 ........... RH flow gate switch

20 ........... LH flow gate switch
21 ........... Hopper wing switch
22 ........... Truck hitch switch
23 ........... Light switch
24 ........... Travel range switch
25 ........... Brake switch
26 ........... Horn switch
27 ........... Throttle switch
28 ........... Audible alarm silence switch
29 ........... Low engine oil pressure indicator light
30 ........... RH mix no flow indicator light
31 ........... LH mix no flow indicator light
32 ........... Oil temperature gauge
33 ........... Voltmeter
34 ........... Fuel level gauge
35 ........... Tachometer
36 ........... Water temperature gauge
37 ........... Oil pressure gauge
7
22478 (11/00)
Technical Manual
A Terex Company

2nd Generation Version
23 22 21 20 19 18 17 16 15 14
1
2
3
4
5
6
7
8
9
13
10
11
12

4 ........... F/G/S breaker: 15 amp
10 ......... Key switch
11 ......... K2 relay
12 ......... Cooler breaker: 50 amp
13 ......... Feed Interface Module

14 ......... Cooler relay
15 ......... K3 relay
16 ......... K4 relay
17 ......... K5 relay
18 ......... K6 relay (flasher)
19 ......... K15 relay
20 ......... K16 relay
21 ......... K17 relay
22 ......... K18 relay
23 ......... K22 relay
22478 (11/00)
Technical Manual
A Terex Company

10
13
20
19
18
21
30
31
22
29
23
4 3 2
16
14 15
25
26
27
24
28
36
37
32
35
33
34
28
30
31
29
16

2 ............. Steer assist switch
11 ........... N/A
12 ........... N/A
17 ........... N/A

26 ........... Horn switch
33 ........... Voltmeter
9
22478 (11/00)
Technical Manual
A Terex Company

Throttle
Solenoid
Alternator
Murphy Temp
Sensor
Engine Temp
Sensor
Engine Oil
Pressure Sensor
RPM Pickup
Starter Solenoid
K2 Starter
Relay
Starter
10
22478 (11/00)
Technical Manual
A Terex Company
Engine Starting System

Grayhound CR411
ENGINE DOES NOT START

Main key switch ON
Brake switch ENGAGED
Travel switch in NEUTRAL position
Control circuit breaker SET
Stop/Start switch held in START position
Permissive start switch held closed
ENGINE DOES NOT CRANK

Check for low battery voltage, loose starter connections or faulty starter.
If no voltage
1 to 3 .........
20 to 3 ........
21 to 3 ........
13 to 3 ........
14 to 3 ........
16 to 3 ........
15 to 3 ........
2 to 3 .........
Defective main key switch.

Defective or tripped engine circuit breaker.
Defective engine start/stop switch.
Defective brake switch.
Limit switch 3 on LH travel switch defective. (Track)
Limit switch 3 on RH travel switch defective.
Defective starter relay (K2).
If voltage, check starter motor.
11
22478 (11/00)
Technical Manual
A Terex Company
Charging System
Grayhound CR411
ALTERNATOR NOT CHARGING (12.5 Vdc or less at battery)

Main key switch ON
Engine running at FULL THROTTLE
Voltage should be 13.5 Vdc to 15.5 Vdc from 1 to 3
If no voltage
1 to 3 .......... If no voltage or high voltage (>16 Vdc), defective main key switch or wiring.
20 to 3 ........ If no voltage, defective or tripped engine circuit breaker
21 to 3 ........ If no voltage, defective main key switch
22 to 3 ........ If no voltage, defective engine start/stop switch, loose connection or bad wire.
22 to 3 ........ If no voltage, at terminal of alternator, defective resistor or wiring.
If voltage is 12.5 volts or less at alternator (1to 3), repair or replace alternator.
If voltage at battery is more than 16 Vdc, check for defective ground connection(s) between
battery, frame, engine, and alternator before replacing alternator.
BATTERIES
Each battery should have about 12.6 Vdc with engine off. Lower readings than this is indicative
of a weak battery and should be serviced.
12
22478 (11/00)
Technical Manual
A Terex Company
Throttle & Fuel

Grayhound CR411
ENGINE RUNS AT IDLE BUT NOT FULL THROTTLE

Main key switch ON, engine RUNNING, control circuit breaker SET.
1 to 3 .......... If no voltage, defective main key switch.
46 to 3 ........ If no voltage, defective control circuit breaker.
Throttle switch to FULL
48 to 3 ........ If no voltage, defective throttle switch.
If voltage, defective throttle solenoid or open wiring in solenoid.
ENGINE CRANKS BUT DOES NOT START
Main key switch ON, brake switch to ENGAGE, hold permissive start switch closed,
engine switch to RUN
If no voltage:
1 to 3 .......... defective main key switch
20 to 3 ........ defective or tripped engine breaker
21 to 3 ........ defective main key switch
22 to 3 ........ defective engine start switch
23 to 3 ........ broken wire or defective permissive start switch or relay
23 to 3 ........ If voltage defective fuel solenoid
ENGINE STOPS WHEN PERMISSIVE START SWITCH IS RELEASED
Main key switch ON, brake switch ENGAGED, hold permissive start switch CLOSED
After engine starts, the engine light should remain lit until the engine pressure rises above 5 psi
and the engine temperature is below 223 F.
Release permissive start switch after engine light goes out.
22 to 3 ........ If no voltage and engine dies, defective permissive start relay
13
22478 (11/00)
Technical Manual
A Terex Company
Throttle & Fuel

Grayhound CR411
ENGINE LIGHT WILL NOT GO OUT AFTER ENGINE STARTS
If continuity across engine water temperature switch, check for overheated engine or defective
water temperature switch.
If continuity across engine oil pressure switch, check for low engine oil pressure or defective
engine oil pressure switch.
ENGINE DOES NOT STOP
Engine stop/start switch to STOP.
23 to 3 ........ If voltage, defective engine stop/start switch.
If no voltage, defective fuel solenoid.
ENGINE SHUTS OFF AFTER A PERIOD OF TIME
Check the engine oil pressure and water temperature. One of these has exceeded limits and
tripped the shutdown system.
14
22478 (11/00)
Technical Manual
A Terex Company
Engine Start & Fuel - Elite Engine

Grayhound CR300 Series
Rubber Tire Pavers
Track Pavers

engine switch to START
If no voltage:
23A to 3 ..... defective K22 relay
Note: Pull-in coil (wire 23A) has 12VDC only while cranking engine
15
22478 (11/00)
Technical Manual
A Terex Company
Horn
Grayhound CR411
Main
Keyswitch
1
12 VDC
3
0
Horn
Power
1
100
19
18
30 A
100
Horn Relay
Horn Switch
HORN DOES NOT WORK

Hold horn switch ON.
100 to 3 ...... If no voltage, defective power circuit breaker.
If voltage, check:
19 to 3 ........ If voltage, defective horn.
If no voltage, check:
100 to 18 ..... If 12 Vdc, replace K3 relay
18 to 3 ........ If no voltage, defective K3 relay.
If voltage, defective horn switch
16
22478 (11/00)
Technical Manual
A Terex Company
Gauges
Grayhound CR411
NO GAUGES WORK
20 to 3 ........ If no voltage, check engine circuit breaker
22 to 3 ........ If no voltage, check for defective start/stop switch, loose connection, or bad wiring.
INDIVIDUAL GAUGES DO NOT WORK
Water temperature:
7 to 3 .......... 1500 ohms at 100 F, 125 ohms at 210 F
Oil pressure:
8 to 3 .......... 0 to 80 ohms at 0 to 80 PSI.
Hydraulic temperature:
9 to 31 ........ 1500 ohms at 100 F, 125 ohms at 210 F
Fuel level:
10 to 3 ........ 0 to 90 ohms = empty to full
Hourmeter/tachometer: (requires a functional alternator for proper operation)
11 to 3 ........ If voltage at tachometer is approximately. 8 Vac with engine running, replace
tachometer.
11 to 3 ........ If no voltage at tach., check at alternator, if no voltage, replace alternator.
17
22478 (11/00)
Technical Manual
A Terex Company
Lights
Grayhound CR411
FLASHER LIGHTS/OPTIONAL STROBE DO NOT WORK

Main key switch ON, flasher and engine circuit breaker SET, flasher switch ON
engine switch to RUN position.
If no voltage:
20 to 3 ........ defective engine breaker
22 to 3 ........ defective engine switch
113 to 3 ...... defective flasher switch
113A to 3 ... defective flasher circuit breaker
If voltage 113 to 3 and if no voltage 114 to 3, defective flasher relay
111 to 3 ...... If no voltage, defective flasher. If voltage, check for bad light bulb
LIGHTS DO NOT WORK
Main key switch ON, lights and engine circuit breaker SET, light switch ON,
If no voltage:
109 to 3 ...... defective light switch
109A to 3 ... defective light circuit breaker
If voltage 109 to 3 and no voltage 110 to 3, defective lights relay
110 to 3 ...... If no voltage, defective light switch. If voltage, check for bad light bulb
18
22478 (11/00)
Technical Manual
A Terex Company
Brakes
Grayhound CR411
Main
Keyswitch
Control
46
15 A
12 VDC
3
Engage
Brake
34
34
Brake Release Sol.
'A' Release
BRAKES WILL NOT RELEASE

If SWITCH is defective, the brakes WILL remain ENGAGED. Travel speed controllers,
vibrators, automatic feed and screed control WILL NOT function.
If SOLENOID is defective, the brakes WILL NOT RELEASE. Travel speed controllers,
vibrators, automatic feed and screed control WILL function.
Check brake solenoid DIN connector for light. If light is ON:
(1) Check ground jumper pin 2 to GND pin on DIN connector for loose connection.
(2) Defective solenoid coil or hydraulic problem
If NO light:
34 to 3 ........ If no voltage is present, switch is defective.
If voltage, defective solenoid or DIN connector.
19
22478 (11/00)
Technical Manual
A Terex Company
Travel/Pave (P2) System

Grayhound CR361 Analog Display
Main
Keyswitch
12 VDC
3
Range
1
Control
46
15 A
P/2
42
42 Range Sol.
Travel
Range
46
Range Switch
Rubber Tire
P/4
P/2
27
42
Travel
RANGE SWITCH DOES NOT WORK

If range switch does not function:
Range switch in TRAVEL.
Check travel range solenoid valve DIN connector for light.
If light:
(1) Check ground jumper pin 2 to GND pin on DIN connector for loose or bad
connection.
(2) Defective solenoid coil or auxiliary hydraulic problem.
20
22478 (11/00)
Technical Manual
A Terex Company
Front Wheel Assist

Grayhound CR411
Main
Keyswitch
Control
1
46
15 A
12 VDC
3
Range
P/4
P/2
27
42
Fwd Sol.
Range Sol.
3
3
Travel
RANGE SWITCH DOES NOT WORK IN TRAVEL

Check range solenoid DIN connector for light. If light is ON:
Check ground jumper pin 2 to GND pin for loose or bad connection.
If connection is good, defective solenoid or hydraulic problem.
If NO light:
RANGE SWITCH DOES NOT WORK IN P4 (Front wheel assist only)
Range switch to P4 (front wheel assist).
Check front wheel assist solenoid DIN connector for light. If light is ON:
If NO light:
If DIN connector light is on, defective solenoid.
21
22478 (11/00)
Technical Manual
A Terex Company
Travel Control
Grayhound CR411
Main
Keyswitch
1
12 VDC
3
0
Control
46
15 A
46
Brake
Engage
34
'A' Release
4 Pin Packard
77
C
B
D
Travel
3
RH
A
B
Reverse
Coils
73
3
LH
A
B
3
3
34
73
3
74
74
Speed
B
Controller
C
A
CW
Max
Paver
Speed
1K
3
LH
D
C
Forward
Coils
78
3
RH
D
C
3 Pin Packard
TRAVEL SPEED CONTROL DOES NOT WORK (Neither drive wheel moves)
Main key switch ON, engine RUNNING, control circuit breaker SET, brakes RELEASED.
Carefully actuate the manual override lever on each travel pump. If pumps operate using the
manual override levers, proceed with checks. If pumps do not operate, refer to the Hydraulic
Troubleshooting section.
Without starting engine, main key switch ON, engine start/stop switch to RUN, control circuit
breaker SET.
1 to 3 .......... If no voltage, defective Main Key switch.
Release BRAKES, set the max paver speed dial to MAX and travel lever fully FORWARD.
34 to 3 ........ If no voltage, defective brake switch.
74 to 3 ........ Voltage should be 1.6 Vdc.
If no voltage, check the S1 limit switch on the travel speed controller.
If voltage is 12 Vdc, check for an open pump coil or wiring to coil.
Set the max paver speed dial to MIN. Voltage should decrease to 0.15 Vdc.
If the voltage does not decrease to 0.15 Vdc, turn the main key switch off and remove wires 74
and 78 from the console terminal block.
Check the resistance of the console cable wiring:
74 to 3 ........ Resistance should be 15 ohms.
If wires are open or shorted, disconnect the harness from the appropriate pump.
Check resistance across pins C and D on the pump. Resistance should be 15 to 25 ohms.
78 to 3 ........ Resistance should be 15 to 25 ohms.
22
22478 (11/00)
Technical Manual
A Terex Company
Travel Control
Grayhound CR411
Check resistance across pins D and C on the pump. Resistance should be 15 to 25 ohms.
Release BRAKES, set the max paver speed dial to MAX and the travel lever fully REVERSE.
If voltage does not decrease to 0.15 Vdc, turn the main key switch off and remove wires 73
Check resistance across pins A and B on the pump. Resistance should be 15 to 25 ohms. Replace
EDCif open or shorted.
EDC if open or shorted
CHECKING THE TRAVEL SPEED POT
Disconnect the plug to the travel speed pot and check the resistance of the pot.
A to B ........ 1000 100 ohms at all times
A to C ........ Ohms should vary as dial is rotated.
B to C ......... Ohms should vary as dial is rotated.
PAVER PULLS TO ONE SIDE
If paver turns severely to left:
Operate manual override on left pump. If left pump operates proceed with electrical checks. If not,
refer to hydraulic section.
Electrical Checks:
EDC if open or shorted.
23
22478 (11/00)
Technical Manual
A Terex Company
Travel Control
Grayhound CR411
If paver turns severely to right:
Operate manual override on right pump. If right pump operates, proceed with electrical checks. If
not refer to hydraulic section.
Electrical checks:
24
22478 (11/00)
Technical Manual
A Terex Company
Travel Control & Steer Assist

Grayhound Rubber Tire Pavers
1999 & After w/46065-500-34 Module
25
22478 (11/00)
Technical Manual
A Terex Company

1999 & After w/46065-500-34 Module
breaker SET.
74 to 3 ........ For 351, voltage should be 1.6 VDC. For 451/551, voltage should be 2.2 VDC.
If voltage does not decrease to 0.15 Vdc, turn the main key switch off and remove wires 73 and
77 from the console terminal block.
EDCif open or shorted.
26
22478 (11/00)
Technical Manual
A Terex Company

1999 & After w/46065-500-34 Module
PAVER PULLS TO LEFT OR RIGHT
Move harness plug-in connector from ASSIST position to BYPASS position. This eliminates
STEER ASSIST circuitry on Steer Assist Module.
If this corrects problem, replace Steer Assist Module.
If not, re-check wire connections between console and traction pumps as described above.
STEER ASSIST DOES NOT WORK IN P/2 OR P/4 RANGE
Steer assist is operational only in P/2 or P/4 Range.
Proper operation is indicated when paver pivot turns in the direction that STEER ASSIST switch is
held. DIFF. LOCK must also be functional. If DIFF. LOCK is not working, refer to that section first
before proceeding.
STEER ASSIST DOES NOT WORK IN LEFT POSITION
Range switch in P/2 or P/4
STEER ASSIST switch held in Left direction
79 to 3...........If no voltage, replace STEER ASSIST switch. If 12VDC:
Check connections at Steer Assist Module, if OK replace Steer Assist Module.
STEER ASSIST DOES NOT WORK IN RIGHT POSITION
STEER ASSIST switch held in Right direction
79 to 3 ..........If no voltage, replace STEER ASSIST switch. If 12VDC:
27
22478 (11/00)
Technical Manual
A Terex Company
Travel Control Adjustment Procedure

3 Pot Controller
Grayhound Tire Pavers
3 Pot
Travel Controller
Low Threshold
Reverse
Maximum Pot
Forward
Maximum Pot
CONTROL HANDLE ADJUSTMENT PROCEDURE

Initial Adjustment: (Electrical centering)
Main key switch ON; Engine switch ON; Brake switch RELEASED; Engine not running:
1. Turn both MAX adjustment pots on controller fully clockwise.
2. Travel lever full FORWARD, MAX PAVER SPEED dial to MIN: Adjust Low Threshold Pot
for 0.2 VDC from wire 74 to 3.
3. Travel lever full FORWARD, MAX PAVER SPEED dial to MAX: Adjust MAX Forward Pot
for 2.0 VDC from wire 74 to 3
4. Travel lever full REVERSE, MAX PAVER SPEED dial to MAX: Adjust MAX Reverse Pot for
2.0 VDC from wire 73 to 3
28
22478 (11/00)
Technical Manual
A Terex Company

3 Pot Controller
Operational Adjustment:
Note: Center pumps prior to operational adjustments!
Wheels off ground; Engine at Full Throttle; Brake switch RELEASED:
1. With Control Handle full forward and MAX PAVER SPEED dial at MIN; wheels should not
turn. Adjust Low Threshold Pot so that wheels start to creep at dial setting of '1' to '1.5' but stop
at MIN.
2. Turn MAX PAVER SPEED dial to MAX with Control Handle full forward: Check speed of
wheel hubs with a tachometer and adjust Max Forward Pot until actual speed is at Maximum. If
in doubt, turn pot CCW until speed decreases then back to max speed.
3. Put Control Handle full reverse: Check speed of wheel hubs with a tachometer and adjust Max
Reverse Pot. until actual speed is at Maximum. If in doubt, turn pot CCW until speed decreases
then back to max speed.
4. Repeat steps 1-3 until adjustment is not necessary.
Bias Adjustment
Wheels off ground; Engine at Full Throttle; Brake switch RELEASED, balance lines blocked:
1. Control Handle full forward, MAX PAVER SPEED dial at MIN; Slowly increase MAX PAVER
SPEED dial until one or both wheels start to turn.
2. If one wheel is not turning carefully adjust neutral of non-turning side pump until both wheels are
turning the same speed.
29
22478 (11/00)
Technical Manual
A Terex Company

3 Pot Controller
Grayhound Track Pavers
3 Pot
Travel Controller
Low Threshold
Reverse
Maximum Pot
Forward
Maximum Pot
LH CONTROL HANDLE ADJUSTMENT PROCEDURE

30
22478 (11/00)
Technical Manual
A Terex Company

3 Pot Controller
3 Pot
Travel Controller
Low Threshold
Reverse
Maximum Pot
Forward
Maximum Pot
RH CONTROL HANDLE ADJUSTMENT PROCEDURE

31
22478 (11/00)
Technical Manual
A Terex Company

3 Pot Controller
Engine at Full Throttle; Brake switch RELEASED, hydraulic fluid at operating temperature:
1. With Control Handle full forward and MAX PAVER SPEED dial at MIN; tracks should not
move.
2. Adjust Low Threshold Pot so that both tracks start to creep at dial setting of '1' to '1.5' but stop
at MIN.
3. Turn MAX PAVER SPEED dial slowly to MAX with Control Handles full forward: Adjust
each MAX Forward Pot so that track speeds match (Paver goes straight) and paver is at
maximum attainable speed. If in doubt, turn pot CCW until speed decreases then back to max
speed.
4. Turn MAX PAVER SPEED dial slowly to MAX with Control Handles full reverse: Adjust
each MAX Reverse Pot so that track speeds match (Paver goes straight) and paver is at
speed.
32
22478 (11/00)
Technical Manual
A Terex Company

Grayhound Tire Pavers Analog Display
w/Lever Control
MINIMUM Forward Pot
MINIMUM Reverse Pot
MAXIMUM Forward Pot
MAXIMUM Reverse Pot

. Turn both MAX adjustment pots on controller fully clockwise.
. Travel lever full FORWARD, MAX PAVER SPEED dial to MIN: Adjust MIN Forward Pot for 0.2
VDC from wire 74 to 3.
. Travel lever full REVERSE, MAX PAVER SPEED dial to MIN: Adjust MIN Reverse Pot Clockwise until voltage increases from wire 73 to 3 then turn back. Should be about 0.2 VDC
. Travel lever full FORWARD, MAX PAVER SPEED dial to MAX: Adjust MAX Forward Pot for
. Travel lever full REVERSE, MAX PAVER SPEED dial to MAX: Adjust MAX Reverse Pot for 2.0
VDC from wire 73 to 3
. While measuring voltage from 73 to 3, turn MAX PAVER SPEED dial slowly down from MAX to
MIN with handle in full reverse: Voltage should decrease smoothly down to about 0.2 VDC. If not
repeat steps 1-5.
MIN with handle in full forward: Voltage should decrease smoothly down to about 0.2 VDC. If not
repeat steps 1-5.
33
22478 (11/00)
Technical Manual
A Terex Company

w/Lever Control
. With Control Handle full forward and MAX PAVER SPEED dial at MIN; wheels should not turn.
Adjust MIN Forward Pot so that wheels start to creep at dial setting of '1' to '1.5' but stop at MIN.
. With Control Handle full reverse and MAX PAVER SPEED dial at MIN; wheels should not turn.
Adjust MIN Reverse Pot so that wheels start to creep at dial setting of '1' to '1.5' but stop at MIN.
. Turn MAX PAVER SPEED dial to MAX with Control Handle full forward: Check speed of wheel
hubs with a tachometer and adjust Max Forward Pot until actual speed is at Maximum. If in doubt,
turn pot CCW until speed decreases then back to max speed.
. Put Control Handle full reverse: Check speed of wheel hubs with a tachometer and adjust Max
Reverse Pot. until actual speed is at Maximum. If in doubt, turn pot CCW until speed decreases then
back to max speed.
. Repeat steps 1-5 until adjustment is not necessary.
Bias Adjustment
34
22478 (11/00)
Technical Manual
A Terex Company
Differential Lock
Grayhound CR411
DIFFERENTIAL LOCK DOES NOT WORK IN P/2 OR P/4 RANGE

Differential Lock is operational only in P/2 or P/4 Range.
Proper operation is indicated when steering becomes difficult to impossible other than in a straight line.
To troubleshoot a suspected problem:
DIFF. LOCK switch held in ON position
Check Diff. Lock solenoid DIN connector for light
If light is ON, check for magnetic field with a small screwdriver at the solenoid coil. If no field,
check ground jumper from pin 2 to GND pin in DIN connector for tightness. If connection is good,
check coil resistance for about 6 ohms. Replace solenoid if bad. If there was a magnetic field, refer
to Hydraulic Troubleshooting.
If no light check:
46A to 3.........If no voltage, replace K20 relay. If 12 VDC, check:
79 to 3............If no voltage, replace DIFF. LOCK switch. If 12 VDC
79 to Ground at solenoid.....No voltage indicates defective wiring to solenoid.
12 VDC at the solenoid without a light indicates either a bad Ground or defective DIN connector.
DIFFERENTIAL LOCK FUNCTIONS IN TRAVEL RANGE
Differential Lock should NOT work in TRAVEL RANGE. If it is, check:
DIN connector for light. If ON check:
46A to 3.........If no voltage, check wire 79 for cross short to 12 VDC
If 12 VDC, check:
42 to 3 at K20 relay.....If 12 VDC, unplug K20 relay. If Diff. Lock solenoid drops out, replace
K20 relay.
If no voltage, check for defective wiring in console.
If DIN light is OUT, refer to Hydraulic Troubleshooting.
35
22478 (11/00)
Technical Manual
A Terex Company
Steer Assist
Grayhound CR411

Proper operation is indicated when paver pivot turns in the direction that STEER ASSIST switch is held.
DIFF. LOCK must also be functional. If DIFF. LOCK is not working, refer to that section first before
proceeding.
79 to 3 with .If no voltage, replace STEER ASSIST switch. If 12VDC:
Is KL relay pulling in? If not, replace or swap with KR relay to check.
If KL relay does pull in, check 74 to 3 in Forward or 73 to 3 in Reverse. Voltage should be 0. If
not, replace or swap KL relay with KR relay to check.
36
22478 (11/00)
Technical Manual
A Terex Company
Steer Assist
Grayhound CR411
Is KR relay pulling in? If not, replace or swap with KL relay to check.
If KR relay does pull in, check 78 to 3 in Forward or 77 to 3 in Reverse. Voltage should be 0. If
not, replace or swap KR relay with KL relay to check.
PAVER PULLS TO LEFT WITH STEER ASSIST IN RELEASED (OFF) POSITION
STEER ASSIST switch released
75 to 3 .........If 12VDC, replace STEER ASSIST switch. If no voltage check:
74 to 3 in Forward, 73 to 3 in Reverse. If voltage is 0, replace or swap KL relay with KR relay to
check. If voltage is identical to 78 to 3 in Forward or 77 to 3 in Reverse, refer to Hydraulic
Troubleshooting.
PAVER PULLS TO RIGHT WITH STEER ASSIST IN RELEASED (OFF) POSITION
78 to 3 in Forward, 77 to 3 in Reverse. If voltage is 0, replace or swap KR relay with KL relay to
Troubleshooting.
37
22478 (11/00)
Technical Manual
A Terex Company
LH Travel Speed Control

Main
Keyswitch
Control
46
46
12 VDC
0
Brake
15 A
3
Engage
34
'A' Release
4 Pin Packard
C
A
D
Left
Travel
Speed
Controller
B
B
C
A
Forward
Coil
73
3
LH
A
B 3
3
74
74
34
73
CW
Max
Paver
Speed
1K
LH
D
C
Reverse
Coil
3 Pin Packard
Dual Speed Pot
LH TRAVEL SPEED CONTROL DOES NOT WORK

Without starting the engine, main key switch to ON, engine start/stop switch to RUN, control
circuit breaker SET.
Release BRAKES. Set the max paver speed dial to MAX and the LH travel lever fully FORWARD.
If no voltage, check the S1 limit switch on the LH travel speed controller.
If the voltage does not decrease to 0.15 Vdc, turn main key switch OFF and remove wire 73 from
the console terminal block.
Check resistance across pins A and B on the pump. Resistance should be 15 to 25 ohms.
Release BRAKES. Set the max paver speed dial to MAX and the LH travel lever fully REVERSE.
38
22478 (11/00)
Technical Manual
A Terex Company

If voltage does not decrease to 0.15 Vdc, turn main key switch OFF and remove wire 74 from
39
22478 (11/00)
Technical Manual
A Terex Company
RH Travel Speed Control

RH TRAVEL SPEED CONTROL DOES NOT WORK

Without starting engine, main key switch to ON, engine start/stop switch to RUN, control circuit
breaker is SET.
Release the BRAKES, max paver speed dial to MAX and the RH travel lever fully FORWARD.
34 to 3 ........ If no voltage, defective Brake switch.
If no voltage, check the S1 limit switch on the RH travel speed controller.
40
22478 (11/00)
Technical Manual
A Terex Company

Release BRAKES, set max paver speed dial to MAX and the RH travel lever fully REVERSE.
Set max paver speed dial to MIN. Voltage should decrease to 0.15 Vdc.
41
22478 (11/00)
Technical Manual
A Terex Company

Grayhound Track Pavers Analog Display
w/Lever Controls
MINIMUM Forward Pot
MINIMUM Reverse Pot
MAXIMUM Forward Pot
MAXIMUM Reverse Pot

. Turn both MAX adjustment pots on controller fully counterclockwise.
MIN with handle in full reverse: Voltage should decrease smoothly down to about 0.2 VDC If not
repeat steps 1-5.
MIN with handle in full forward: Voltage should decrease smoothly down to about 0.2 VDC If not
repeat steps 1-5.
42
22478 (11/00)
Technical Manual
A Terex Company

w/Lever Controls
MINIMUM Forward Pot
MINIMUM Reverse Pot
MAXIMUM Forward Pot
MAXIMUM Reverse Pot

repeat steps 1-5.
repeat steps 1-5.
43
22478 (11/00)
Technical Manual
A Terex Company

w/Lever Controls
. With Control Handles full forward and MAX PAVER SPEED dial at MIN, tracks should not move.
. Both tracks should start moving at the same speed with a dial setting of '1' to '1.5'. If not, adjust each
MIN Forward Pot so that both tracks start to creep at dial setting of '1' to '1.5' but stop at MIN.
. With Control Handle full reverse and MAX PAVER SPEED dial at MIN, tracks should not move.
MIN Reverse Pot so that both tracks start to creep at dial setting of '1' to '1.5' but stop at MIN.
. Turn MAX PAVER SPEED dial slowly to MAX with Control Handles full forward.
. Adjust each MAX Forward Pot so that track speeds match (Paver goes straight) and paver is at
maximum attainable speed. Maximum attainable speed is when turning the MAX Forward pot CW
does not cause paver to turn but turning CCW will cause a turn.
. Turn MAX PAVER SPEED dial slowly to MAX with Control Handles full reverse.
. Adjust each MAX Reverse Pot so that track speeds match (Paver goes straight) and paver is at
maximum attainable speed. Maximum attainable speed is when turning the MAX Reverse pot CW
44
22478 (11/00)
Technical Manual
A Terex Company
Susmic 10 Dual Path Control

Calibration Procedures
Pavers 1999 & Before
Pavers 1999 & After
Scope
This document covers the calibration procedures for asphalt pavers equipped with the Sauer-Sunstrand
Susmic 10 dual path controller.
When to Calibrate
These procedures are to be performed after initial vehicle assembly and when a sensor, EDC, pump or
motor is replaced. Before beginning these procedures, check to make sure that the Susmic 10 (S10) is
properly wired and all inputs are as expected. Table 1 shows all controller inputs and loads and their
expected ranges.
45
22478 (11/00)
Technical Manual
A Terex Company

Input
Forward switch
Reverse switch
Wire
351
35 2
Counter rotation
353
Calibrate
Brake switch
Steer sensor signal
Speed pot signal
Battery +
Battery +
Ignition
355
34
332
342
22
22
22
Output
Steer sensor power
Speed pot power
Left forward EDC
Left reverse EDC
Right forward EDC
Right reverse EDC
Wire
331
341
73
74
77
78
Pin Value
P1-9 Zero volts in forward
P1-27 Zero volts in reverse
Zero volts in counter rotate
P1-8
(pave mode only)
P1-15 Zero volts when calibrate held
P1-25 12 volts when brake is released
P1-18
1 to 4 volts, left to right
P1-19
0.5 to 4.5 volts, min. to max.
P1-1
12 volts
P1-10
12 volts
P1-12
12 volts
Pin Value
P1-23 5 volts
P1-24 5 volts
P1-7
0 to 3 volts*
P1-20
0 to 3 volts*
P1-6
0 to 3 volts*
P1-21
0 to 3 volts*
* Depends on Speed Pot Position

All Voltage measured made with respect to ground.
Ground @ pin P1-2, P1-3, P1-22, P1-13 and EDC Pins B & C.
System Function Check
A system function check should be performed whenever a component is changed and prior to
calibration. Check that all components are installed and that wiring is attached properly. Make sure that
all persons are clear of the machine and that space for machine movement exists to the front, rear and
both sides. The engine should be at low idle setting and the machine in the work range of operation.
1) Center the steering wheel. Turn the speed set potentiometer to its MINIMUM position. Move
the throttle switch to the IDLE position. Move the pave mode switch to the PAVE position.
Move the Counter Rotate switch to the NORMAL position. Move the FNR switch to the neutral
(N) position.
2) Start the vehicle. The tracks should not move.
3) Move the BRAKE switch to the RELEASE position. The tracks should not move.
4) Slowly turn the SPEED SET potentiometer clockwise. Neither track should move.
46
22478 (11/00)
Technical Manual
A Terex Company

5) Turn the SPEED SET potentiometer to the MINIMUM position. Move the FNR switch to the
forward (F) position. The tracks should not move.
6) Slowly turn the SPEED SET potentiometer clockwise. Both tracks should begin to move slowly
forward (clockwise). As the SPEED SET pot is increased, the track speed should increase.
7) Slowly turn the STEERING WHEEL to the left. The left track should slow to stop as the wheel
is turned. Slowly center the STEERING WHEEL. The left track should speed up to its original
rate.
8) Slowly turn the STEERING WHEEL to the right. The right track should slow to stop as the
wheel is turned. Slowly center the STEERING WHEEL. The right track should speed up to its
original rate.
9) Move the FNR switch to the neutral (N) position. Both tracks should stop.
10) Move the FNR switch to the reverse (R) position. Both tracks should begin turning in reverse.
rate.
original rate.
13) Slowly turn the SPEED SET potentiometer counterclockwise towards minimum. Both tracks
should slow to a stop by the time the speed pot is at its minimum position.
14) Move the FNR switch to the neutral (N) position. Both tracks should be stopped.
If the vehicle performs as described above, the system is prepared for calibration.
47
22478 (11/00)
Technical Manual
A Terex Company

CALIBRATION: Calibration procedures are to be performed after initial vehicle assembly and when a
sensor, speed set dial, EDC, pump or motor is replaced. Before beginning these procedures, check to
make sure that the controller is properly wired and that all test values are as expected. Before beginning
calibration, move the vehicle to an open area with 30+ yard run-out.
1) ENGINE switch in STOP. PAVER SPEED dial at minimum. THROTTLE switch in IDLE.
RANGE switch in PAVE. COUNTER ROTATE switch in NORMAL. FNR switch in
neutral (N). STEERING WHEEL MUST BE CENTERED.
2) Hold the CAL-RUN switch in the CAL position while starting the vehicle. Do not release
CAL switch until Engine is brought to FULL THROTTLE.
3) Move the BRAKE switch to the RELEASE position.
4) Turn the STEERING WHEEL all the way to the left and hold.
5) Move the FNR switch to the forward (F) position. Watch the left track closely. As soon as the
track begins to move, flip the FNR switch back to neutral (N).
6) Move the FNR switch to the reverse (R) position. Watch the left track closely. As soon as the
7) Turn the STEERING WHEEL all the way to the right and hold.
8) Move the FNR switch to the forward (F) position. Watch the right track closely. As soon as the
9) Move the FNR switch to the reverse (R) position. Watch the right track closely. As soon as the
10) Center the STEERING WHEEL.
11) Move the FNR switch to the forward (F) position.
12) Slowly turn the PAVER SPEED dial to MAXIMUM. Slowly turn PAVER SPEED dial
counterclockwise until the vehicle just starts to slow down. Make sure the paver will respond to
slight movements of the STEERING WHEEL. Steer paver in a straight path. After 5 seconds
without moving the STEERING WHEEL or PAVER SPEED dial, move the FNR switch to
the neutral (N) position.
13) Turn the PAVER SPEED dial to MINIMUM.
14) Move the FNR switch to the reverse (R) position.
17) Press and release the CAL-RUN. Move the THROTTLE switch to the IDLE position. Move
the BRAKE switch to the ENGAGE position.
18) Wait 5 seconds.
19) Shut off the engine to store values.
48
22478 (11/00)
Technical Manual
A Terex Company

Error Checks
There are four (4) indicator lights (LED's) located on the side of the track steer controller module located
inside of the console; 2 green LED's, 1 yellow and 1 red. Their function is as follows:
1st Green
Power Input
OK if Lit
2nd Green
Yellow
Power Output
Kernal (Program)
OK if Lit
Blinks if functional
Red
Error
Error if lit
On earlier controllers, the red error light would be either ON or OFF, indicating an error. As of software
version S0029109 and later, an error code has been assigned to the red LED. The code is a series of
short and long flashes consisting of 4 flashes per error with a pause between each error(s). A short flash
indicates a "0" and a long flash represents a "1". The following table lists the error codes along with the
error associated with it:
Error Code
1000*
1100*
1010*
1110*
0100*
0010*
0110*
0001*
1001*
0101*
1101*
0011*
1011
0111
1111
Error Description
Steering sensor input is higher than calibrated
Steering sensor input is lower than calibrated
Steering sensor calibrated too high
Steering sensor calibrated too low
Speed dial input is higher than calibrated
Speed dial input is lower than calibrated
Speed dial input is calibrated too high
Speed dial input is calibrated too low
LH FWD EDC calibration fault
RH FWD EDC calibration fault
LH REV EDC calibration fault
RH REV EDC calibration fault
Sensor power fault
LH EDC fault
RH EDC fault
*Attempt to clear errors by re-calibrating first per complete calibration procedure.
49
22478 (11/00)
Technical Manual
A Terex Company
Hopper
Grayhound CR411
Main
Keyswitch
CONTROL Hopper
46 Wings
1
15 A
12 VDC
Raise
65
Raise Sol.
Lower
66
Lower Sol.
HOPPER WINGS DO NOT RAISE

Press Manual Override button on solenoid valve.
If not functional, refer to Hydraulic Troubleshooting.
If functional, proceed with Electrical checks.
Check DIN connector for light.
If light is ON:
Check for 12 Vdc from pin 1 to pin 2 on DIN connector.
If voltage, check solenoid resistance. Should be approximately 6 ohms. Replace if open.
If no voltage, Check ground jumper from pin 2 to GND pin for tightness.
If NO light:
Check 65 to 3.....If no voltage, replace switch.
If voltage, (12 Vdc) check pin 1 of DIN to frame ground.
If no voltage, check harness.
If voltage, check ground through solenoid to frame for continuity. Correct if necessary.
Replace DIN connector if above checks are OK but problem persists.
HOPPER WINGS DO NOT LOWER
If light is ON:
If NO light:
50
22478 (11/00)
Technical Manual
A Terex Company
Truck Hitch (Optional)

Grayhound CR411
Main
Keyswitch
Control
1
12 VDC
Optional
46 Truck Hitch
15 A
Engage
61
Engage Sol.
Release
62
Release Sol.
TRUCK HITCH DOES NOT ENGAGE

If light is ON:
If NO light:
TRUCK HITCH DOES NOT RELEASE
If light is ON:
If NO light:
51
22478 (11/00)
Technical Manual
A Terex Company
Frame Raise
Grayhound CR411
Main
Keyswitch
Control
Rear
46 Frame
15 A
12 VDC
3
Raise
70
Raise Sol.
Lower
71
Lower Sol.
REAR FRAME DOES NOT RAISE

If light is ON:
If NO light:
REAR FRAME DOES NOT LOWER
If light is ON:
If NO light:
52
22478 (11/00)
Technical Manual
A Terex Company
LH Flow Gate
Grayhound CR411
Main
Keyswitch
12 VDC
3
Control
46
15 A
Power
LH
Gate
30 A
Raise
103
Lower
104
K16
K16
100
100
K15
K15
101 YEL
102
RED 102
K16
3
3
LH Gate
Motor 3
3
101
K15
LH GATE DOES NOT GO UP

LH gate switch to RAISE. Check for mechanical bind on motor.
100 to 3 ...... If no voltage, defective circuit breaker.
103 to 3 ...... If no voltage, defective LH gate switch or console cable.
Relay K15 should pull in. If not, check for defective relay coil or faulty ground.
101 to 102 .. If no voltage, defective K15 contacts.
101 to 102 .. LH gate motor leads.
If no voltage, there is a break in front harness.
If voltage, check for open motor. Motor resistance should be 0.5 ohms.
LH GATE DOES NOT GO DOWN
LH gate switch to LOWER. Check for mechanical bind on motor.
102 to 101 .. LH gate motor leads.
53
22478 (11/00)
Technical Manual
A Terex Company
RH Flow Gate
Grayhound CR411
Main
Keyswitch
1
12 VDC
3
Control
1
46
RH
Gate
15A
Raise
107
Lower
108
Power
1
100
K18
K18
100
30A
K17
K17
105
YEL
106
RED 106
K18
3
3
RH Gate
Motor
3
3
105
K17
RH GATE DOES NOT GO UP

RH gate switch to RAISE. Check for mechanical bind on motor.
107 to 3 ...... If no voltage, defective RH gate switch or console cable.
105 to 106 .. RH gate motor leads:
RH GATE DOES NOT GO DOWN
RH gate switch to LOWER. Check for mechanical binds on motor.
106 to 105 .. RH gate motor leads.
54
22478 (11/00)
Technical Manual
A Terex Company
Material Flow Indicators

Grayhound Pavers 1999 & Before
Material flow is sensed by switches mounted on the bottom edge of each flow gate. The switches can be
manually actuated for testing purposes.
Main key switch ON, control circuit breakers SET.
LIGHT AND HORN DO NOT ACTIVATE WHEN MATERIAL IS NOT PRESENT
Flow switch in down position (not contacting material)
Left Side
88 to 3 ........ If no voltage, defective flow switch
88 to 3 ........ If voltage, defective light bulb
89 to 3 ........ If no voltage, defective diode or loose wire
89A to 3 ..... If no voltage, defective alarm silence relay
89A to 3 ..... If voltage, defective audible alarm
Right Side
55
22478 (11/00)
Technical Manual
A Terex Company

ALARM CANNOT BE SILENCED
89 to 3 ........ (at switch) If no voltage, loose wire
Push alarm silence switch
89B to 3 ..... If no voltage, defective alarm silence switch
89B to 3 ..... If voltage, defective alarm silence relay
ALARM CAN ONLY BE SILENCED WHILE SWITCH IS HELD CLOSED
Release alarm silence switch
If alarm continues to sound, defective alarm silence relay or loose wire
LIGHT AND HORN ACTIVATE WHEN MATERIAL IS PRESENT
The flow switch mounted on the flow gate may stick in the closed position if not cleaned
properly as part of daily cleaning procedure. Make sure flow switch is free to move.
56
22478 (11/00)
Technical Manual
A Terex Company

Grayhound Pavers 1999 & After
Alarm will not sound unless: At least 1 No Flow Light is ON, Screed in LOWER, Paver moving
FORWARD, and Alarm Switch is ON.
Flow switch in down position (not contacting material), Brake RELEASED, Travel in FORWARD,
Screed Lift in LOWER, and Alarm Switch ON.
Left Side
89C to 3 ..... If no voltage, defective screed lift switch
89B to 3 ..... If no voltage, defective alarm switch
89A to 3 ..... If no voltage, defective CRFA relay
89A to 3 ..... If voltage, defective alarm
Right Side
57
22478 (11/00)
Technical Manual
A Terex Company

58
22478 (11/00)
Technical Manual
A Terex Company
Screed Lift
Grayhound CR411
Main
Keyswitch
Control
1
46
Screed
Lift
15 A
12 VDC
Raise
63
Raise Sol.
64
Lower Sol.
Lower
SCREED DOES NOT RAISE

If light is ON:
If NO light:
SCREED DOES NOT LOWER
If light is ON:
If NO light:
59
22478 (11/00)
Technical Manual
A Terex Company
Screed Assist
Grayhound CR411
SCREED ASSIST WILL NOT COME ON

Screed lift switch to LOWER, screed assist switch ON.
46 to 3 ........ If no voltage, defective engine stop/start switch.
64 to 3 ........ If no voltage, defective screed lift switch.
33 to 3 ........ If no voltage, defective screed assist switch.
If voltage, check ground wire from solenoid to ground for bad connection.
Check for magnetic field with small screwdriver at top of solenoid coil.
If no magnetic field, defective screed assist solenoid.
If system checks OK using above checks but system is not controlling screed properly,
refer to hydraulic troubleshooting or adjustment procedures.
60
22478 (11/00)
Technical Manual
A Terex Company
Power Main Crown

Grayhound CR411
Main
Keyswitch
Control
46
1
15 A
12 VDC
Main
Crown
Increase
189
Increase Sol.
Decrease
190
Decrease Sol.
CROWN DOES NOT INCREASE

If light is ON:
If NO light:
CROWN DOES NOT DECREASE
If light is ON:
If NO light:
61
22478 (11/00)
Technical Manual
A Terex Company
Vibrators
Grayhound CR411
Main
Keyswitch
1
12 VDC
3
Note: Closed in forward (Travel Control)

Control
46
1
15 A
Brake
Engage
34
Release
Vibrators
Off
47
Forward L.S.
50
Vibrator Sol.
On
VIBRATORS WILL NOT COME ON

Vibrator switch ON, brakes RELEASED, travel lever(s) FORWARD.
Check DIN connector for light. If light is ON:
Check pin 2 to GND pin on DIN connector for loose or bad connection.
If NO light:
47 to 3 ........ If no voltage, defective limit switch(es) on control handle(s).
50 to 3 ........ If no voltage, defective vibrator switch.
If voltage but no light, check ground jumper pin 2 to GND pin for loose or bad connection.
If good connection, check solenoid coil resistance. It should be approximately 6 ohms.
VIBRATORS WILL NOT STOP
Vibrator switch OFF.
50 to 3 ....... If voltage present, defective vibrator switch.
If no voltage, defective vibrator solenoid valve.
62
22478 (11/00)
Technical Manual
A Terex Company
LH Hydraulic Strike-Off Extend

All Grayhound Pavers
Retract
Extend
CYLINDER DOES NOT EXTEND

If light is ON:
If NO light:
CYLINDER DOES NOT RETRACT
If light is ON:
If NO light:
63
22478 (11/00)
Technical Manual
A Terex Company
RH Hydraulic Strike-Off Extend

Retract
Extend

If light is ON:
If NO light:
If light is ON:
If NO light:
64
22478 (11/00)
Technical Manual
A Terex Company
LH Hydraulic Strike-Off Slope

SLOPE DOES NOT INCREASE

If light is ON:
If NO light:
SLOPE DOES NOT DECREASE
If light is ON:
If NO light:
65
22478 (11/00)
Technical Manual
A Terex Company
RH Hydraulic Strike-Off Slope


If light is ON:
If NO light:
If light is ON:
If NO light:
66
22478 (11/00)
Technical Manual
A Terex Company
LH Match Height
MATCH HEIGHT DOES NOT RAISE

If light is ON:
If NO light:
MATCH HEIGHT DOES NOT LOWER
If light is ON:
If NO light:
67
22478 (11/00)
Technical Manual
A Terex Company
RH Match Height

If light is ON:
If NO light:
If light is ON:
If NO light:
68
22478 (11/00)
Technical Manual
A Terex Company
LH Main Burner #1
Grayhound CR411
Main
Keyswitch
1
12 VDC
0
Fastach Screed Burner Control

Burner
1
115
60A
115
Fuel Pump
Off
On
Fan No.1
Off
117
117
LH Main Burner (No.1)

116
116
118
Glow Plug No.1

118
On
115
Fuel Pump Motor

3
Fan Motor No.1
Glow Plug No.1
NO BURNERS LIGHT
If fans work but no burners light, the problem is in the fuel delivery.
If fuel pump is running, the problem is in the fuel line.
If unsure if fuel pump is running, check the following:
Main key switch ON, burner circuit breaker SET, burner fuel valve ON, fuel pump switch ON.
115 to 3 ...... If no voltage, defective burner circuit breaker
117 to 3 ...... If no voltage, defective fuel pump switch.
If voltage, check for open motor.
If motor is operative, refer to screed system section of instructions to check fuel line.
LEFT BURNER DOES NOT LIGHT
Main key switch ON, burner circuit breaker SET, burner fuel valve ON,
correct glow plug button DEPRESSED.
If voltage present but no fuel to burner nozzle, defective fuel pump motor.
118 to 3 ...... If no voltage, defective glow plug push button or cable to glow plug.
If voltage, but glow plug does not warm, defective glow plug or poor glow plug ground.
LEFT BURNER FAN DOES NOT OPERATE
116 to 3 ...... If no voltage, defective fan switch.
If voltage, defective fan motor.
69
22478 (11/00)
Technical Manual
A Terex Company
RH Main Burner #2
Grayhound CR411
Main
Keyswitch
1
12 VDC
0
Burner
1
115
60A
115
Fuel Pump
Off
On
Fan No.2
Off
RH Main Burner (No.2)

126
126
128
Glow Plug No.2

128
On
115
117
117
Fuel Pump Motor

3
Fan Motor No.2
Glow Plug No.2
NO BURNERS LIGHT
115 to 3 ...... If no voltage, defective burner circuit breaker.
RIGHT BURNER DOES NOT LIGHT
RIGHT BURNER FAN DOES NOT OPERATE.
70
22478 (11/00)
Technical Manual
A Terex Company
LH Ext. Burner #3
Grayhound CR411
Main
Keyswitch
1
12 VDC
0

Burner
1
115
60A
115
Fuel Pump
Off
On
Fan No.3
Off
Lt. Ext. Burner (No.3)

136
136
138
Glow Plug No.3

138
On
115
117
117
Fuel Pump Motor

3
Fan Motor No.3
Glow Plug No.3
NO BURNER LIGHT
115 to 3 ..... If no voltage, defective burner circuit breaker
If voltage present but on fuel to burner nozzle, defective fuel pump motor.
LEFT BURNER FAN DOES NOT OPERATE.
71
22478 (11/00)
Technical Manual
A Terex Company
RH Ext. Burner #4
Grayhound CR411
Main
Keyswitch
1
12 VDC
0
Burner
1
115
60A
115
Fuel Pump
Off
On
Fan No.4
Off
RH Ext. Burner (No.4)

146
146
148
Glow Plug No.4

148
On
115
117
117
Fuel Pump Motor

3
Fan Motor No.4
Glow Plug No.4
NO BURNER LIGHT
115 to 3 ..... If no voltage, defective burner circuit breaker
If voltage present but on fuel to burner nozzle, defective fuel pump motor.
RIGHT BURNER FAN DOES NOT OPERATE.
72
22478 (11/00)
Technical Manual
A Terex Company
Rear Frame Compensator Adjustment

1) Raise or lower frame to about mid range.

2) While holding Comp Switch, adjust pot of Frame Oscillator Module for no net Raise or Lower.
Clockwise rotation on pot will cause frame to raise.
Counter-clockwise rotation on pot will cause frame to lower.
Adjustment must be done between full up and full down on the frame.
3) If properly adjusted, the frame will raise slightly immediate after Comp switch is actuated then
stabilize at a "fixed" position.
73
22478 (11/00)
Technical Manual
A Terex Company
Remote Oil Cooler Motors

Grayhound CR300 Series Pavers
COOLER FAN MOTORS ARE TO RUN WHEN ENGINE IS RUNNING
Wires
Voltage
23...3
12VDC
30...3
12VDC
31...3
12VDC
Function
Comment
Cooler
Relay Coil Voltage Readings with:
Engine Running or...
Cooler
Main Switch in RUN position and
Breaker
Permissive Start Switch held ON
Cooler
Relay
74
22478 (11/00)
PAVER
TECHNICAL MANUAL
300 Series & 411

Hydraulic Section
Technical Manual
A Terex Company
Table of Contents
Cedarapids Lubricants ........................................................................................................ 1
Pressure Test Kit ................................................................................................................. 2
Component Location Map ............................................................................................. 3 - 4
Throttle ............................................................................................................................... 5
Brake System ...................................................................................................................... 6
Steering .......................................................................................................................... 7 - 8
Truck Hitch (Optional) ................................................................................................ 9 - 10
Hopper Wings ............................................................................................................ 11 - 12
Track Tension - Steel Track Pavers ........................................................................... 13 - 15
Rubber Track Hydraulic System ............................................................................... 17 - 21
Frame Raise CR351/CR411 Pavers ........................................................................... 22 - 23
Frame Raise CR361 Pavers ....................................................................................... 24 - 25
Screed Lift ................................................................................................................. 26 - 27
Screed Assist ............................................................................................................. 28 - 29
Tow Point .................................................................................................................. 30 - 31
Main Screed Power Crown ........................................................................................ 32 - 33
Screed Extend: 8 - 14 Screed ........................................................................................... 34
Screed Extend: Fastach 8' Screed .................................................................................... 35
Vibrator: Fastach 8' Screed .............................................................................................. 36
Vibrator: Fastach 10' Screed ............................................................................................ 37
Vibrators: 8 - 14 Screed ................................................................................................... 38
Conveyor - Grayhound 300 Series ................................................................................... 39
Conveyor - CR411 ............................................................................................................ 41
Traction System/Differential Lock - Grayhound 300 Series ..................................... 42 - 43
Traction System - CR411 ................................................................................................. 44
Front Wheel Assist (Optional) .......................................................................................... 45
300 Series & CR411 Hydraulic Troubleshooting
22479 (11/00)
Technical Manual
A Terex Company
ii
22479 (11/00)
Greases
Hydraulic
Oils
EP
Gear Oils
Non-EP
Gear Oils
Starfak 2201
Starfak 2202
Multifak EP 2
Starfak 00
Multifak HD 00
Multifak EP 1
Pinnacle 68
Rando HD 68
Pinnacle 32
Rando HD 32
Pinnacle 46
Pinnacle EP 320
Meropa 320
Rando HD 46
Pinnacle EP 220
N/A
Meropa 100
Meropa 220
N/A
Meropa 68
Pinnacle EP 150
Pinnacle 220
Regal R&O 220
Meropa 150
Pinnacle 150
Regal R&O 150
Pinnacle 68
Regal R&O 68
Pinnacle 100
Pinnacle 46
Regal R&O 46
Regal R&O 100
Synthetic
Mineral
Texaco
Alvania EP 2
Alvania EP 1
Synthetic
Albida SLC 220
N/A
Retinax TL 00
Tellus HD 68
Tellus HD 46
Tellus HD 32
Omala HD 320
Omala HD 220
N/A
N/A
N/A
Omala RL 220
Omala RL 150
Omala RL 100
Omala RL 68
Omala RL 46
Shell
Alvania EP 00
Tellus 68
Tellus 46
Tellus 32
Omala 320
Omala 220
Omala 150
Omala 100
Omala 68
Molina 220
Molina 150
Molina 100
Turbo T 068
Turbo T 046
Mineral
Mobilux EP 2
Mobilux EP 1
Mobilux EP 023
DTE 26
DTE 25
DTE 24
Mobilgear 632
Mobilgear 630
Mobilgear 629
Mobilgear 627
Mobilgear 626
Spartan EP 320
Mobilgear
SHC 320
Mobilith SHC 220
N/A
Mobilith SHC 007
SHC 526
SHC 525
Lidok EP 2
Lidok EP 1
Lidok EP 000
Nuto H 68
Nuto H 46
Nuto H 32
Spartan EP 220
Mobilgear
SHC 220
SHC 524
Spartan EP 150
Spartan EP 100
Spartan EP 68
Teresstic 220
Teresstic 150
Teresstic 100
Teresstic 68
Dura-Lith EP 2
Dura-Lith EP 1
Ulti-Plex Synthetic
EP 1.5
Ulti-Plex Synthetic
EP 1.5
N/ A
Rykon Premium
Oil 68*
Rykon Premium
Oil 46*
Rykon Premium
Oil 32*
Tegra Synthetic
Gear EP 320
Tegra Synthetic
Gear EP 220
Tegra Synthetic
Gear EP 150
*A refined mineral oil with properties

between mineral and synthetic
Unirex SHP 220
Unirex SHP 460
Dura-Lith EP 00
Hydraulic Oil
AW 68
Teresstic
SHP 68
Unirex SHP 00
Hydraulic Oil
AW 46
Hydraulic Oil
AW 32
Teresstic
SHP 32
Teresstic
SHP 46
Gear Compound
EP 320
Gear Compound
EP 220
Spartan Synthetic
EP 320
Spartan Synthetic
EP 220
Gear Compound
EP 150
Gear Compound
EP 100
Spartan Synthetic
EP 100
Spartan Synthetic
EP 150
N/A
Gear Compound
EP 68
N/A
N/A
N/A
Industrial Oil 220
Teresstic
SHP 220
N/A
N/A
N/A
Industrial Oil 150
Industrial Oil 100
Industrial Oil 68
N/A
Teresstic
SHP 150
Teresstic
SHP 100
Teresstic
SHP 68
Industrial Oil 46
Teresstic
SHP 46
Synthetic
Chevron
Mineral
Synthetic
Exxon
Teresstic 46
Mineral
Mobilgear
SHC 150
N/A
N/A
SHC 630
SHC 629
DTE Oil
Extra Heavy
DTE Oil BB
SHC 627
DTE Oil Heavy
SHC 626
DTE Oil
Heavy Medium
Synthetic
N/A
Mobil
DTE Oil Medium
Mineral
List of mineral/synthetic interchanges for industrial lubricants used on Cedarapids equipment.
Technical Manual
A Terex Company
Cedarapids Lubricants
22479 (11/00)
Technical Manual
A Terex Company
Pressure Test Kit

45865-001-41
45865-002-27
45865-002-33
Gauge
Gauge
Guage
0-6000-PSI
0-100 PSI
0-600 PSI
45080-527-05
Adapter Gauge
Not Illustrated
7430-416
7430-344
7430-345
45080-527-14
45080-527-07
45080-527-15
Hose 36"
Hose 10'
45080-527-17
45080-527-18
45080-527-16
45080-527-031
45080-527-061
45080-527-04
Fitting
Tee
Tee
Test Hose Union
#4 FS JIC Test Port

#6 FS JIC Test Port
#8 FS JIC Test Port
8" NPT Test Port

4" NPT Test Port
#4 SAE Test Port
22479 (11/00)
Technical Manual
A Terex Company

Front Bulkhead
L35
L37
L36
L39
L38
L40
L41
L35 ................
L36 ................
L37 ................
L38 ................
L39 ................
L40 ................
L41 ................
Front wheel assis solenoid valve

LH pull point solenoid valve
Truck hitch solenoid valve
LH front wheel assist 5 way valve
Hopper soleonid valve
RH pull point solenoid vavle
RH front wheel assist 5 way valve
22479 (11/00)
Technical Manual
A Terex Company

Rear Bulkhead
L30
L27
L31
L27 ................ Vibrator solenoid valve

L30 ................ Screed lift solenoid valve
L31 ................ Frame raise solenoid valve
22479 (11/00)
Technical Manual
A Terex Company
Throttle
THROTTLE
CYLINDER
FULL
IDLE
SOLENOID
VAVLE
LH CONVEOYR
CHARGE PUMP
RETURN
SUCTION
.85
CID
200 MESH
STRAINER
HYDRAULIC TANK
ENGINE WILL NOT COME TO FULL THROTTLE

Engine running
Throttle switch to FULL THROTTLE.
Check left conveyor to see if it operates. If it does not, refer to conveyor troubleshooting.
Watch throttle cylinder. If it extends, refer to engine troubleshooting.
Place a small screw driver next to the throttle solenoid. If no magnetic field is felt, refer to electrical.
If a magnetic field is felt, throttle switch to IDLE.
Remove hose from the rod end of the throttle cylinder.
If oil comes out of the rod end port, blown packing.
If no oil comes out rod end port, check flow restrictor for being plugged.
If flow restrictor is not plugged, defective solenoid.
ENGINE GOES TO FULL THROTTLE WITH SWITCH IN IDLE POSITION
Refer to electrical troubleshooting.
Check RH conveyor charge pressure. If no pressure refer to conveyor troubleshooting.
(Charge pressure is required to hold throttle cylinder in Idle position.)
22479 (11/00)
Technical Manual
A Terex Company
Brake System
TO TRACTION PUMP
TORQUE
HUB
Note: Charge Pressure suppled to

traction pump and conveyor pumps
from a common charge pump.
BRAKE
ASSEMBLY
TO TRACTION PUMP
HYDRAULIC
MOTOR
COOLER
CHARGE PRESSURE
TANK
RANGE & BRAKE LINE TO
OTHER TORQUE HUB
BRAKE SYSTEM
The brakes are SPRING APPLIED and HYDRAULIC RELEASED. Pressure is supplied by the
charge pump of the LH trandem pump. A brake solenoid valve when energized allows pressure
to be applied to the brake piston, allowing the brakes to release.
Engine at FULL THROTTLE.
Brake switch to RELEASE.
Travel speed dial set above (2).
Travel engage/disengage switch to ENGAGE. (500 series only)
Check brake solenoid DIN connector for light. If NO light refer to electrical troubleshooting.
If light is ON.
(1)Refer to electrical for checking ground connection.
(2)Install a 600 psi gauge on RH conveyor or traction charge pump (depending on model) high
pressure test port. (Do not engage conveyor or traction.) Pressure should be 218 to 265 psi for the
brakes to release. If low refer to conveyor or traction system.
(3)Install a 600 psi gauge between brake solenoid and brake hose.
If no pressure or low, check flow orifice for obstruction or defective solenoid valve.
(4)If correct pressure, check brake assembly for warped disks.
EMERGENCY BRAKE RELEASE
If machine has to be moved and the brakes are locked, refer to instruction decal located on the tool
box lid of the paver.
22479 (11/00)
Technical Manual
A Terex Company
Steering
TEST
PORT
Series: 300
*Full Load (RPM): 2100
*Max Flow (GPM): 8.4-11.0
Pressure (PSI): 2500
*Varies depending on vintage.
CASE DRAIN
SUCTION
PRESSURE
PRESSURE FILTER
200 MESH
STRAINER
RETURN
HYDRAULIC TANK
AUXILIARY SYSTEM
Check hydraulic fluid level.
Check other auxiliary functions for operation (screed raise/lower, any extend/ retract function, pull point
functions, etc.) If other functions work, this indicates the problem is only in the effected function and the
general auxiliary system is working. If paver is equipped with SCREED ASSIST, check manual dump
needle valve to insure it is closed. If no other function is working, install a 3000 psi gauge in the test port.
Refer to pressure setting above for each series of paver.
If pressure can not be obtained, check and clean suction strainer, check suction hose for loose fittings,
damaged hose, and obstructions.
STEERING WILL NOT TURN LEFT OR RIGHT
Remove the hose going to the left steering cylinder base end. Install a 3000 psi gauge on the end of the hose.
Turn steering wheel to the left, pressure reading should be system pressure.
If low or no pressure, defective steering valve.
Remove the hose going to the right steering cylinder base end. Install a 3000 psi gauge on the end of the hose.
Turn steering wheel to the right, pressure reading should be system pressure.
If problem occurs only after cylinders have been fully extended or retracted, check rephase ports
Check ball not seating.
22479 (11/00)
Technical Manual
A Terex Company
Steering
STEERING WHEELS DRIFT APART
It is normal for the wheel to drift apart over a period of time. To get them back in unison, steer against limits
in either direction. If the wheels drift apart quickly, preform checks listed above. The cause is usually leaking
piston packing on one or both steering cylinders.
STEERING CYLINDER TEST
With the steering cylinders at mid stroke, remove the rod end hoses. Cap the rod end ports of the cylinders
and plug the hoses. Turn the steering wheel to the left. If the right steering cylinder rod starts to move outward
the the packing of the right cylinder may be bad and need to be replaced, or the inner wall of the cylinder tube
has a scratch or gouge in it, allowing the hydraulic fluid to go around the packing. Remove the cylinder and
replace it. Turn the steering wheel to the right. If the left steering cylinder rod starts to move outward then
the packing of the left cylinder may be bad and need to be replaced, or the inner wall of the cylinder tube has
a scratch or gouge in it, allowing the hydraulic fluid to go around the packing. Remove the cylinder and
replace it.
Always remember to flush the hydraulic steering circuit before replacing the hoses onto the cylinders. This
is done by coupling the hoses of each cylinder together and turning the steering wheel in one direction for
several rotations and then in the other direction for several rotations.
22479 (11/00)
Technical Manual
A Terex Company

Truck Hitch
(Optional)
<<< Pressure <<<
Pressure Filter
Pressure Reducing Valve

900 PSI
2050
RPM
.913
CID
Solenoid Valve
200 Mesh
Strainer
<<< Case Drain <<<
<<< Return <<<
Series: 300
>>> Suction >>>
Manifold LH Front
Auxiliary Pump
Test Port
Test Port
2500 PSI
Holding Valve
AUXILIARY SYSTEM
Hydraulic Tank
Check other auxiliary functions for operation. (screed raise/lower, any extend/ retract function, pull point
functions and etc.) If other functions work, this indicates the problem in only in the effected function and the
needle valve to ensure it is closed.
If no other function is working, install a 3000 psi gauge in the test port. Refer to pressure setting above for
each series of paver. If pressure can not be obtained, check and clean suction strainer, check suction hose
for loose fittings, damaged hose, and obstructions.
TRUCK HITCH WILL NOT EXTEND
Manual needle valve open (this controls cylinder speed an needs to be open to some extent)
Truck hitch switch to the EXTEND position.
Check for DIN connector light, if no light refer to electrical troubleshooting.
If light is ON:
(1) Refer to electrical for testing ground connection.
(2) Press MANUAL OVERRIDE button on solenoid valve. If truck hitch cylinder extends, defective
solenoid.
If truck hitch cylinder does not extend:
(1) Install a 3000 psi gauge in-line, between hose going to rod end of cylinder and manifold block. If
full pressure reading but no cylinder movement plugged or defective holding valve.
(2) Retract cylinder all the way, disconnect the hose going to the BASE END of the cylinders at the
manifold. Carefully push the switch to RETRACT. If fluid comes out of the hose going to the base
end of the cylinder, check cylinder for blown piston packing.
If no fluid, defective solenoid.
22479 (11/00)
Technical Manual
A Terex Company

TRUCK HITCH WILL NOT RETRACT
Truck hitch switch to the RETRACT position.
Check for DIN connector light. If no light refer to electrical troubleshooting.
If light is ON:
(2) Press MANUAL OVERRIDE button on solenoid valve. If truck hitch retracts, defective solenoid.
If truck hitch does not retract:
(1) Install a 3000 psi gauge in-line, between hose going to base end of cylinder and manifold block.
If full pressure reading but no cylinder movement, plugged or defective holding valve.
(2) Extend cylinder all the way, disconnect the hose going to the ROD END of the truck hitch cylinders
at manifold. Carefully push switch to EXTEND. If fluid comes out of the hose going to the truck
hitch cylinders, check cylinder for blown piston packing.
If no fluid, install a 3000 psi gauge on test port of the truck hitch valve stack.
Pressure should be 900 psi.
If no pressure, defective solenoid.
If low pressure, adjust.
TRUCK HITCH DRIFTS OUT
Engine at FULL THROTTLE
Install a 3000 psi gauge on test port of the truck hitch valve stack.
Truck hitch switch to RETRACT.
Pressure should be 900 psi at end of stroke.
If trucks are not staying aligned in front of the paver they can force oil over relief, causing the hitch to open.
If this is not the case proceed with checks.
Extend cylinders all the way, disconnect the hose going to the ROD END of the truck hitch cylinders at
manifold.
Carefully push switch to EXTEND. If fluid comes out of the hose going to the truck hitch cylinders, check
cylinder for blown piston packing.
10
22479 (11/00)
Technical Manual
A Terex Company
Hopper Wings
Hopper Wings
<<< Pressure <<<
Pressure Filter
.913
CID
Solenoid Valve
Throttle Valve
Auxiliary Pump
Holding Valve
2050
RPM
2500 PSI
Restrictor
Test Port
200 Mesh
Strainer
<<< Case Drain <<<
<<< Return <<<
Series: 300
>>> Suction >>>
Manifold RH Front
AUXILIARY SYSTEM
Hydraulic Tank
functions and etc.) If other functions work, this indicates the problem is only in the effected function and
the general auxiliary system is working. If paver is equipped with SCREED ASSIST, check manual dump
needle valve to insure it is closed.
If no other function is working, install a 3000 psi gauge in the test port.
If pressure can not be obtained, check and clean suction strainer, check suction hose for loose fittings ,
damaged hose, or obstructions.
HOPPER WINGS WILL NOT RAISE
Hopper wing switch to the RAISE position.
If light is ON:
(2) Press MANUAL OVERRIDE button on solenoid valve. If hopper wings raise, defective solenoid.
If hopper wings DO NOT raise:
(1) Install a 3000 psi gauge in-line, between the hose going to the rod end of the cylinder and the
manifold block. If full pressure reading but no cylinder movement, plugged or defective holding
valve.
(2) Disconnect the hose going to the base of the hopper cylinders at manifold. Carefully push the
hopper switch to RAISE. If fluid comes out of the hose, check cylinders for blown piston packing.
11
22479 (11/00)
Technical Manual
A Terex Company
Hopper Wings
HOPPER WINGS WILL NOT LOWER
Hopper wing switch to the LOWER position.
If light is ON:
(2) Press MANUAL OVERRIDE button on solenoid valve. If hopper wings lower, defective solenoid.
If hopper wings do not lower, carefully crack the hose going to the base of the hopper cylinders.
If hopper wings do not start to lower, check for bent or damaged cylinders.
If hopper wings lower as fluid is bleed out of the hose, allow to go completely down.
(1) Install a 3000 psi gauge in-line between the hose going to the base end of the cylinder and the
manifold block.
(2) Raise the hopper wings, then try to lower.
If full pressure reading, but no cylinder movement, plugged or defective holding valve or plugged flow
restrictor.
12
22479 (11/00)
Technical Manual
A Terex Company
Track Tension
Steel Track Pavers
Tensioning Track
The track is designed to be virtually maintenance

free. Proper cleaning and lubrication at the end of
each paving day will maintain trouble free operation.
However, neglect of the tracks can be expensive.
Every time paver is cleaned, the track pins should be
sprayed with light oil to lubricate them preventing
them from rusting and binding.
If the track looks like it may be getting loose, it can

be tested by placing a board or straight edge on the
track between the front idler and the first top roller.
If the gap between the bottom of the board and the
top edge of the track is greater than 34", the track
tension must be adjusted. (Figure 2)
The Grayhound track paver uses a tension cylinder

mounted above the final drive that maintains a
constant volume of pressurized oil to the track
adjusting cylinders. When the track encounters an
obstacle, the system allows the tensioning idler to
recoil rather than stretch or break the track. When the
obstacle is cleared the system returns to the previous
track tension adjustment.
3/4"
Figure 2 - Checking Track Tension
Important: Perform track tension checks

and adjustments when the paver is at running
temperature. Adjusting track tension when
the paver is cold could lead to over-tensioning
of the track.
1
3
Adjust track tension as follows:
4
5
From traction S
charge pump
1) Start the engine.
2) Open the needle valve slowly to allow the

track to retension. (Figure 4)
3) Drive the paver forward and backward slowly.
4 - Needle valve
1 - Counterbalance valve
2 - Rodless piston cylinder 5 - Idler tension cylinders
3 - Tensioning cylinder assy.
Warning: Be very careful when reaching

over the moving track. Keep feet and loose
clothing away from the moving track and
rollers.
Figure 1 - Track tension hydraulic circuit
The track tensioning cylinder assembly consists of a

cylinder with a rodless piston, a needle valve, and a
counterbalance valve. (Figure 1) The piston keeps
the oil from the idler tensioning cylinders separated
from the main oil supply. When the track encounters
an obstacle, it forces oil from the idler cylinders into
the bottom side of the rodless cylinder. When the
obstruction is cleared, pressurized oil from the
traction charge pump forces the tensioning cylinder
down which forces idler cylinders to move back to
original position.
4) Stop the paver and close needle valve.

5) A properly tensioned track should have a 38" to
1
2" gap between a straightedge and the track.
(Figure 3)
3/8" to 1/2"
Figure 3 - Proper Track Tension
The needle valve is used during track tensioning to

bring the volume of oil on the bottom side of the
rodless cylinder back to the proper level. The
counterbalance valve allows oil to flow freely from
the top side of the rodless cylinder to the tank when
the track encounters an obstacle.
13
22479 (11/00)
Technical Manual
A Terex Company
Track Tension
Steel Track Pavers
Warning: Overtightening the track can
cause serious damage to the track, idler or
drive.
7) If oil continues to flow into the bucket, the

tension cylinder piston or needle valve is
leaking and must be repaired.
Track over-pressurizing
8) Turn the engine off and reconnect the hydraulic

line to the "T" port.
If the track adjusting system is over-pressurizing

during operation, the following procedure must be
performed. It is a good idea to perform this check
once each season to verify the tensioning cylinder is
in good condition.
Track Relief Pressure

In addition to adjusting the track tension, the track
relief pressure should be checked at least once each
season. Check track relief pressure as follows:
Notice: Do not run the paver while the system

is over-pressurized. Running with an overpressurized system could damage the track
and sprockets.
1) Perform "Track over-pressurizing" procedure

above.
2) Stop engine.
"T" Port
"T" Port
Needle
Valve
Needle
Valve
Test Port
Counter-Balance
Valve
Tension
Cylinder
Figure 5 - Checking Track Relief Pressure Setting
3) Close needle valve.

4) Bleed off pressure on tension cylinder by
installing pressure gauge hose only onto test
port and draining fluid into a bucket.
Figure 4 - Bottoming Tension Cylinder
1) Disconnect the line from the "T" port on the

track tension cylinder. Install a plug into the
disconnected line. (Figure 4)

2) Attach a drain line to the "T" port and run the

other end into a bucket.
6) Install a 3000 PSI gauge on the hose which is

connected to the tension cylinder test port.
3) Close the needle valve by rotating clockwise.

4) Start the engine and run at full throttle.
7) Connect a hand operated hydraulic pump to

the "T" port on the tension cylinder.
5) If the track was tensioned properly, no oil will

flow into the bucket.
8) Start and run engine at full throttle.
6) If only a small amount of oil drains into the

bucket, the tension cylinder piston and needle
valve are working properly and track will
tension properly.
14
22479 (11/00)
Technical Manual
A Terex Company
Track Tension
Steel Track Pavers
9) Pump the hand pump to apply pressure to the
counter balance valve. The counter balance
valve will relieve the pressure generated by the
pump at the track relief pressure setting. Note
the pressure on the gauge when the counter
balance valve relieves.
10) The track relief pressure setting should be
2050 psi +/- 100 psi. If pressure is outside this
range, the counter balance valve requires
adjustment.
11) To adjust track relief pressure:
a) Loosen jam nut on counter balance valve.
b) Rotate the valve counterclockwise to
increase the pressure setting. Clockwise
rotation will decrease the pressure setting.
c) Tighten jam nut.
12) If the pressure can not be set, the counter
balance valve is defective and must be replaced.
Note - Replacement counter balance valves
are factory set and should not require
adjustment.
15
22479 (11/00)
Technical Manual
A Terex Company
16
22479 (11/00)
Technical Manual
A Terex Company
Rubber Track Hydraulic System
When the paver is started, oil is directed from the

auxiliary pump to the track tension valves at 2500
psi. When tension pressure needs to be adjusted, oil
is then routed to the piston side of the track tension
cylinders by opening the tension valve charge
cartridge needle valves allowing oil pressure to rise
to 2500 psi. An accumulator for each track is placed
in the circuit between the tension valve and the
piston side of the track tensioning cylinders. The
accumulator is pre-charged with dry nitrogen at
2250 psi to allow the track tension cylinders to
retract and return if an impact is encountered.
The rubber track hydraulic system, see schematic,

provides pressurized oil to the piston ends of track
tension cylinders. Each track is independent and
supplied by the auxiliary pump.
Pressurized oil is held in the piston end of each track
tension cylinder between tension valves and tension
cylinders.
TRACK TENSION
ACCUMULATOR
ACCUMULATOR
CHARGE VALVES
TEST
PORT
TRACK TENSION
ACCUMULATOR
TEST
PORT
TEST
PORT
TO OTHER <<<<<<<<<<
AUXILIARY FUNCTIONS
PUMP INLET
CASE DRAIN
Rubber Track Hydraulic System Schematic
17
22479 (11/00)
Technical Manual
A Terex Company
Track Tension Valve

Charge Cartridge
Test Port
Accumulator
Track Tension
Valve
Track Tension Valve

Discharge Cartridge
Pressure To
Tension Cylinder
Track Tension
Cylinder
45678
Rubber Track Hydraulic System Components
18
22479 (11/00)
Technical Manual
A Terex Company
8) The gauge reading at the point where it drops

quickly to 0 psi should be 2250 psi at 68 degrees
F. This reading may be slightly more or less
depending the ambient temperature and the hydraulic system temperature.
Checking Rubber Track Hydraulic System

The rubber track hydraulic system contains
components which will automatically maintain track
tension. To check out the system, follow the steps
below:
9) If the accumulator dry nitrogen pre-charge is at

2250 psi, then tighten the discharge needle valve
screw by turning it clockwise until snug on its
seat.
Auxiliary System Pump Pressure

First check the auxiliary pump pressure compensator
adjustment to be sure the system is set to 2500 +/100 psi. See tractor O&M Manual for this procedure.
10) Re-tighten jam nut on discharge cartridge.

11) Charge the tension circuit to 2500 psi as described below.
Track Tension Accumulator
12) If the pressure is below 2250 psi when it drops

quickly to 0 psi, re-charge the accumulator with
dry nitrogen.
Check pre-charge of track tension accumulators on

each side.
1) Install pressure gauge (3000 psi) at test port
marked G on the Track Tension Valve.
3) Pressure should read 2500 psi.
4) Shut engine off. Pressure on gauge should not
change.
5) Loosen jam nut on discharge cartridge of track
tension valve.
discharge needle valve and release hydraulic
pressure while carefully watching the gauge.
7) The pressure reading should drop off slowly
until it reaches the accumulator dry nitrogen precharge pressure. When the pressure reaches the
accumulator pre-charge point, the gauge will
drop quickly to 0 psi.
13) If pressure is above 2250 psi, bleed off some dry

nitrogen from the accumulator.
14) If the pressure drops steadily all the way to 0 psi
and re-charging the accumulator does not work,
then replace the accumulator.
Track Tension Pressure

Check the track tension pressure on each side.
marked G on the Track Tension Valve.
2) Pressure should read 2500 psi.
19
22479 (11/00)
Technical Manual
A Terex Company
If pressure is not to 2500 psi, then do the following:
If pressure does not hold, do the following:

2) Loosen jam nut on charge cartridge of track
tension valve.
charge needle valve and allow hydraulic pressure to build to 2500 psi while carefully watching the gauge.
4) When the gauge reaches 2500 psi, close the
charge needle valve by turning it clockwise until
snug on its seat.
5) Shut off engine and note pressure.
1) Remove and cap lines from auxiliary pump-totension valve and from tension valve-to-tank.
Caution: Escaping fluid under pressure
can penetrate the skin causing serious
injury. Be very careful when disconnecting hydraulic or other lines. Search for
leaks with a piece of cardboard. Protect
hands and body from high pressure fluids. Any fluid injected into the skin must
be removed immediately by a doctor.
Pressure should hold at 2500 psi.

Track Tension Valve Cartridges & Track Tension Cylinder
If the track tension cylinder bounces during operation
as if there is air in the lines, do the following:
1) Loosen jam nuts on both charge and discharge
cartridges of track tension valve.
3) Insert an allen wrench into the adjusting screws
on the needle valves.
4) Alternately open and close each needle valve.
Start with the discharge and then the charge.
5) Do step 4 until air is eliminated.
6) Tighten both needle valves snug on their seats.
7) Tighten jam nuts on each needle valve.
8) Shut off engine and note pressure.
From Auxiliary Pump

To Tank
To Tension Cylinder
Track Tension Valve Hydraulic Lines
Pressure should hold at 2500 psi.

2) Observe pressure on gauge.
20
22479 (11/00)
Technical Manual
A Terex Company

3) If pressure drops from 2500 psi, observe which

tension valve cartridge port (charge or discharge)
is leaking hydraulic fluid.
4) Verify that both tension valve cartridge needle
valves are completely shut as described above.
5) If one of the cartridge ports leaks, replace that
cartridge.
6) If none of the cartridge ports is leaking, but the
pressure still drops off, check the breather on the
track tension cylinder.
From Track Tension Valve
Track Tension Cylinder
Tension Cylinder
Rod End Breather
Track Tension Cylinder
7) If hydraulic fluid is leaking from breather, the

cylinder packing or cylinder wall may be damaged. Remove and repair or replace tension
cylinder as necessary.
8) Remove caps from lines installed in Step 1
above and reinstall lines to tension valve.
21
22479 (11/00)
Technical Manual
A Terex Company
Frame Raise
Grayhound CR351/CR411 Pavers
Rear Wheel Suspension
<<< Pressure <<<
Pressure Filter
<<< Return <<<
Series: 300
>>> Suction >>>
Manifold Left Rear
200 Mesh
Strainer
Auxiliary Pump
.913
CID
Solenoid Valve
2500 PSI
2050
RPM
<<< Case Drain <<<
Holding Valve
Test Port
AUXILIARY SYSTEM
Hydraulic Tank
general auxiliary system is working.
If paver is equipped with SCREED ASSIST, check manual dump needle valve to ensure it is closed.
If no other function is working, install a 3000 psi gauge in the test port. Refer to pressure setting above for
for loose fittings, damaged hose, and obstructions.
FRAME WILL NOT RAISE
Frame raise switch to the RAISE position.
If light is ON:
(2) Press MANUAL OVERRIDE button on solenoid valve.
If frame raises, defective solenoid.
If frame does not raise:
(1) Install a 3000 psi gauge in-line, between the hose going to the base end of the cylinders and the
valve.
(2) Extend cylinder all the way, disconnect the hose going to the BASE END of the cylinder. Carefully
push the frame switch to RAISE. If fluid comes out of the fitting on the cylinder, check cylinder
for blown piston packing.
22
22479 (11/00)
Technical Manual
A Terex Company
Frame Raise
Grayhound CR351/CR411 Pavers
FRAME WILL NOT LOWER
Frame switch to the LOWER position.
If light is ON:
If frame lowers, defective solenoid.
If frame does not lower:
valve.
(2) Retract cylinder all the way, disconnect the hose going to the ROD END of the frame cylinder.
Carefully push the frame switch to lower, If fluid comes out of the fitting on the cylinder, check
FRAME DRIFTS DOWN
Check DIN connectors for lights. If any light on, electrical system is telling the cylinder to move.
If no lights are flashing on, proceed with checks.
Retract cylinder all the way, disconnect the hose going to the BASE END of the frame cylinders.
Carefully push the frame switch to RAISE. If fluid comes out of the fitting on the cylinder, check cylinder
If no fluid, defective holding valve.
FRAME LOWERS TOO QUICKLY
Plugged or defective throttle valve.
23
22479 (11/00)
Technical Manual
A Terex Company
Frame Raise
Grayhound CR361 Pavers
REAR WHEEL
SUSPENSION
PRESSURE
FILTER
TEST
PORT
Series: 361
*Max Flow (GPM): 8.4 - 11.0
FLOW
DIVIDER
HOLDING VALVE
.913
CID
2500 PSI
2500
RPM
THROTTLE VALVE
AUXILIARY
PUMP
SOLENOID VALVE
MANIFOLD LH REAR
200 MESH
STRAINER
AUXILIARY SYSTEM
HYDRAULIC TANK
functions and etc.) If other functions work, this indicates the problem in only in the effected function and
the general auxiliary system is working.
If no other function is working, install a 3000 psi gauge in the test port. Refer to pressure setting above
for each series of paver. If pressure can not be obtained, check and clean suction strainer, check suction
hose for loose fittings, damaged hose, and obstructions.
If light is ON:
valve.
(2) Retract cylinder all the way, disconnect the hose going to the BASE END of the cylinder.
24
22479 (11/00)
Technical Manual
A Terex Company
Frame Raise
Grayhound CR361 Pavers
If light is ON:
(2) Press MANUAL OVERRIDE button on solenoid valve. If frame lowers, defective solenoid.
valve.
cylinder for blown piston packing. If no fluid, defective solenoid.
FRAME DRIFTS DOWN
ONE SIDE RAISES SLOWER OR NOT AT ALL
(1) Lower frame raise.
(2) Bypass flow divider.
(3) Push frame raise switch to raise. Both sides should raise at the same speed although one side may
stop raising while other side continues to raise. If both sides move at same speed, plugged or
defective flow divider.
25
22479 (11/00)
Technical Manual
A Terex Company
Screed Lift
with Fastach Screeds
Screed Lift
Holding Valve
2050
RPM
.913
CID
Solenoid Valve
Series: 300
200 Mesh
Strainer
<<< Case Drain <<<
>>> Suction >>>
Manifold LH Rear
Auxiliary Pump
Restrictor
Test Port
2500 PSI
<<< Pressure <<<
<<< Return <<<
Pressure Filter
AUXILIARY SYSTEM
Hydraulic Tank
Refer to pressure setting above for each series of paver. If pressure can not be obtained, check and clean
suction strainer, check suction hose for loose fittings, damaged hose, and obstructions.
SCREED LIFT WILL NOT RAISE
Screed lift switch to the RAISE position.
If light is ON:
If screed lift raises, defective solenoid.
If screed lift does not raise:
valve.
(2) Disconnect hoses from Base end of the screed lift cylinders. Carefully push the screed lift switch
to RAISE. If fluid comes out of the fitting on the cylinders, check cylinder for blown piston
packing.
26
22479 (11/00)
Technical Manual
A Terex Company
Screed Lift
SCREED LIFT WILL NOT LOWER
Screed lift switch to the LOWER position.
If light is ON:
If screed lift lowers, defective solenoid.
If screed lift does not lower, check for plugged flow restrictor or defective solenoid valve.
27
22479 (11/00)
Technical Manual
A Terex Company
Screed Assist
175 PSI Nitrogen

Precharge
Optional
Screed Assist
(Suppled with
Extendable Screed)
Screed Lift
Pressure Filter
Holding Valve
I
2050
RPM
.913
CID
Solenoid Valve
200 Mesh
Strainer
<<< Case Drain <<<
Series: 300
>>> Suction >>>
Manifold LH Rear
Auxiliary Pump
Restrictor
Test Port
2500 PSI
<<< Pressure <<<
AUXILIARY SYSTEM
Hydraulic Tank
Check other auxiliary functions for operation, (screed raise/lower, any extend/ retract function, tow-point
Refer to pressure setting above for each series of paver. If pressure can not be obtained, check & clean suction
strainer, check suction hose for loose fittings, damaged hose, and obstructions.
Screed assist switch OFF.
If light is ON:
(2) Press MANUAL OVERRIDE button on solenoid valve. If screed lift raises, defective solenoid.
full pressure reading but no cylinder movement, plugged or defective holding valve.
(2) Disconnect hoses from base end of the screed lift cylinders. Carefully push the screed lift switch
packing.
28
22479 (11/00)
Technical Manual
A Terex Company
Screed Assist
If light is ON:
Screed lift switch in LOWER.
Screed assist switch ON.
Place a small screw driver next to the top of the screed assist solenoid valve. If no magnetic field is felt, refer
to electrical troubleshooting.
If solenoid attracts screw driver continue with checks:
Install a 2000 psi gauge in-line at the ROD end of the screed lift cylinder (either cylinder).
Pressure should read same as gauge mounted on bottom of accumulator. If pressure is lower, defective
solenoid valve.
With gauge in same place, adjust screed assist pressure reducing valve clockwise.
The pressure readings should increase.
If no increase, defective pressure reducing valve.
The working pressure is 200 to 600 psi on the screed assist system.
SCREED ASSIST SYSTEM PRESSURE IS NOT STABLE
Run checks listed above.
Shut machine OFF.
OPEN manual dump valve to bleed all pressure from system.
Check accumulator for 175 psi pre charge.
If no pre-charge remove hose from bottom of accumulator, charge cylinder and listen for blown bladder.
REMOVING SCREED ASSIST FROM SYSTEM & CHECKING SCREED LIFT CYLINDERS
Shut machine OFF.
OPEN manual dump valve to bleed all pressure from the system.
Disconnect hoses from ports E and V on screed assist manifold.
Connect the two hoses together.
Plug ports E and V on screed assist manifold to prevent entry of debris.
Screed lift switch in RAISE position.
If screed lowers, defective screed lift cylinder packings.
29
22479 (11/00)
Technical Manual
A Terex Company
Tow Point
Pull Point
.913
CID
Solenoid Valve
Series: 300
>>> Suction >>>
Manifold RH Front
200 Mesh
Strainer
Auxiliary Pump
Dual Throttle Valve
2050
RPM
2500 PSI
Holding Valve
Test Port
<<< Case Drain <<<
<<< Pressure <<<
Pressure Filter
AUXILIARY SYSTEM
Hydraulic Tank
Check other auxiliary functions for operation. (screed raise/lower, any extend/ retract function, tow point
functions and etc.) If other functions work, this indicates the problem is only in the effected function and the
If paver is equipped with SCREED ASSIST, check manual dump needle valve to insure it is closed. If no
other function is working, install a 3000 psi gauge in the test port. Refer to pressure setting above for each
series of paver. If pressure can not be obtained, check and clean suction strainer, check suction hose for lose
fittings, damaged hose, or obstructions.
TOW POINT WILL NOT INCREASE
Tow point increase/decrease switch to the INCREASE position.
If light is ON:
(2) Press MANUAL OVERRIDE button on solenoid valve. If tow point cylinder increases, defective
solenoid.
If tow point cylinder does not increase:
(2) Extend cylinder all the way, disconnect the hose going to the ROD END of the tow point cylinder.
Carefully push the increase/decrease switch to DECREASE. If fluid comes out of the fitting on
the cylinder, check cylinder for blown piston packing.
30
22479 (11/00)
Technical Manual
A Terex Company
Tow Point
TOW POINT WILL NOT DECREASE
Tow point increase/decrease switch to the DECREASE position.
If light is ON:
If tow point cylinder decreases, defective solenoid.
If tow point cylinder does not decrease:
(2) Retract cylinder all the way, disconnect the hose going to the BASE END of the tow point cylinder.
Carefully push the increase/decrease switch to INCREASE, If fluid comes out of the fitting on the
cylinder, check cylinder for blown piston packing.
TOW POINT CYLINDER DRIFTS UP OR DOWN
Check DIN connectors for lights, If any light on, electrical system is telling the cylinder to move.
Extend cylinder all the way, disconnect the hose going to the ROD END of the tow point cylinder.
Carefully push the increase/decrease switch to DECREASE, if fluid comes out of the fitting on the cylinder,
check cylinder for blown piston packing.
31
22479 (11/00)
Technical Manual
A Terex Company
Main Screed Power Crown

POWER CROWN
(OPTIONAL)
Test Port
2050
RPM
.913
CID
P
Auxiliary Pump
2500 PSI
<<< Pressure <<<
Pressure Filter
200 Mesh
Strainer
<<< Case Drain <<<
Series: 300
>>> Suction >>>
AUXILIARY SYSTEM
Hydraulic Tank
If paver is equipped with SCREED ASSIST, check manual dump needle valve to ensure it is closed. If no
series of paver. If pressure can not be obtained, check & clean suction strainer, check suction hose for lose
fittings, damaged hose, and obstructions.
CROWN WILL NOT INCREASE
Crown increase/decrease switch to the INCREASE position.
If light is ON:
(2) Press MANUAL OVERRIDE button on solenoid valve. If crown increases, defective solenoid.
If crown does not move, disconnect hose from port B of the manifold valve.
Crown switch to INCREASE, if oil comes out of hose and crown does not move, defective motor.
If no oil, reconnect hose and install 3000 psi gauge between port A and hose A.
Crown switch to INCREASE, if pressure, check for interference on mechanical components or defective
motor.
32
22479 (11/00)
Technical Manual
A Terex Company

CROWN WILL NOT DECREASE
Crown increase/decrease switch to the DECREASE position.
Check for DIN connector light, if NO light refer to electrical troubleshooting.
If light is ON:
If crown does not move, disconnect hose from port A of the manifold valve.
Crown switch to DECREASE, if oil comes out of hose and crown does not move, defective motor.
If no oil, reconnect hose and install 3000 psi gauge between port B and hose B.
Crown switch to DECREASE. If pressure, check for interference on mechanical components or defective
motor.
33
22479 (11/00)
Technical Manual
A Terex Company
Screed Extend
8 - 14 Screed
Pressure Return
AUXILIARY SYSTEM
series of paver. If pressure can not be obtained, check & clean suction strainer, check suction hose for loose
SCREED WILL NOT EXTEND
Push manual control valve lever to extend position. If lever can not be moved, defective valve.
Install a 3000 psi gauge in-line on the base end of the screed extend cylinder,
If no pressure, defective manual control valve OK pressure relief.
Remove hose from rod end of cylinder, if oil comes out rod end port, blown piston packing.
SCREED WILL NOT RETRACT
Push manual control valve lever to retract position.
If lever cannot be moved, defective valve.
Install a 3000 psi gauge in-line on the rod end of the screed extend cylinder. If no pressure, defective control
valve or pressure relief.
Remove hose from base end of cylinder, if oil comes out rod end port, blown piston packing.
34
22479 (11/00)
Technical Manual
A Terex Company
Screed Extend
Fastach 8 Screed
Series: 300
LH Extend Cylinder
2000
PSI
2000
PSI
Test Port
2050
RPM
5/64" Dia.
200 Mesh
<<< Case Drain <<<
>>> Suction >>>
.913
CID
Auxiliary Pump
Counterbalance
Valve
2500 PSI
<<< Pressure <<<
Pressure Filter
Strainer
AUXILIARY SYSTEM
Hydraulic Tank
series of paver. If pressure can not be obtained, check & clean suction strainer, check suction hose for loose

Tow manual control valve lever to extend position. If lever can not be moved, defective valve.
Install a 3000 psi gauge in-line on the base end of the screed extend cylinder,
If no pressure, plugged flow restrictor.
If system pressure, defective counterbalance valve.
Remove hose from rod end of cylinder, if oil comes out rod end port, blown piston packing.
Push manual control valve lever to retract position.
If lever cannot be moved, defective valve.
Install a 3000 psi gauge in-line on the rod end of the screed extend cylinder. If no pressure, plugged flow
restrictor.
If system pressure, defective counterbalance valve.
Remove hose from base end of cylinder, if oil comes out rod end port, blown piston packing.
35
22479 (11/00)
Technical Manual
A Terex Company
Vibrator
Fastach 8 Screed
>>Suction>>
<<Return <<
<< Pressure <<
200 Mesh
Strainer

Brakes RELEASED.
Vibrator switch ON.
Travel lever FORWARD.
Vibrator speed valve turned clockwise all the way.
Check vibrator DIN connector for light. If no light refer to electrical.
If light is ON:
(2) Place a small screw driver next to the solenoid, if no magnetic field is felt refer to electrical. If
magnetic field is present, proceed with checks:
Turn vibrator shaft by hand, It should turn freely with little resistance.
If it can not be turned by hand, check for mechanical failure or bind.
If only one shaft vibrates, defective motor on one that does not.
Install a 3000 psi gauge in test port, Unplug quick couplings from rear bulk head.
Pressure should be 1500 psi. If no pressure, check pump. If low pressure, defective solenoid valve
If pressure is correct, reconnect quick couplings.
Check pressure, if pressure is 1500 psi, defective flow divider.
Remove return hose from vibrator speed valve and cap hose.
If a great amount of oil comes out speed valve port, defective speed valve.
36
22479 (11/00)
Technical Manual
A Terex Company
Vibrator
Fastach 10 Screed
>> Suction >>
<< Return <<
<< Pressure <<
200 Mesh
Strainer

Brakes RELEASED.
Vibrator switch ON.
If light is ON:
Install a 3000 psi gauge in test port.
Unplug quick couplings from rear bulk head. Pressure should be 1500 psi.
If no pressure, check pump. If low pressure, defective solenoid valve
If pressure is correct, reconnect quick couplings. Remove case drain hose from motor and cap hose.
If a great amount of oil is coming out of case drain port, the motor is bad.
If very little oil comes out of case drain, disconnect return hose from vibrator speed valve and cap hose.
If great amount of oil comes out of return port on speed valve, defective speed valve.
37
22479 (11/00)
Technical Manual
A Terex Company
Vibrators
8-14 Screed
Return
Pressure
Speed
Control
Valve
Motor
Flow Divider
Motor
Motor

Brakes RELEASED.
Vibrator switch ON.
If light is ON:
Turn vibrator shafts by hand, They should turn freely with little resistance. If it can not be turned by hand.
Check for mechanical failure or bind. If all but one vibrator is turning, check for defective motor on the one
that is not turning, install a 3000 psi gauge in test port.
Unplug quick couplings from rear bulk head.
Disconnect return hose from vibrator speed valve and cap hose.
38
22479 (11/00)
Technical Manual
A Terex Company
Conveyor
Grayhound 300 Series
33.6 GPM Max
390 PSI
2.8
CID
2100 RPM
Max.
<< Case Drain <<
>> Suction >>
<< Case Drain <<
2.8
1.4
CID CID
10
2 Filter
Hydraulic Tank
CONVEYOR DOES NOT WORK

Refer to conveyor electrical troubleshooting checks.
Push manual override lever in both directions, (one direction will turn the conveyor in forward, the other will
turn the conveyor in reverse.) If conveyor does not move in either direction, check pump drive for damaged
splines. If drive is ok, install a 600 psi gauge on High pressure test port. Pressure reading will be charge
pressure. (Do not engage conveyor)
Charge pressure is 400 psi.
If no or low pressure reading, refer to pump service manual.
If pressure is ok, install a 6000 psi gauge in the conveyor high pressure test port.
Block or chain conveyor to prevent turning.
Conveyor switch to manual.
Pressure reading should be 3045 psi.
If pressure is OK, check for over loading auger conveyor system (Head of material in auger chamber) chain
adjustments or mechanical binds.
CONVEYOR STALLS WHEN UNDER LOAD
Install a 6000 psi gauge in the high pressure test port.
Conveyor switch to MANUAL.
If low pressure reading, refer to pump service manual.
39
22479 (11/00)
Technical Manual
A Terex Company
40
22479 (11/00)
Technical Manual
A Terex Company
Conveyor
Grayhound CR411
33.6 GPM Max
390 PSI
29.9
CID
230 RPM
Max.
2.8
1.4
CID CID
Note: High Pressure Relief: 3400 PSI

Charge Pressure 400 PSI
10
2 Filter
Cooler
Hydraulic Tank

Push manual override lever in both directions, (one direction will turn the conveyor in forward, the
other will turn the conveyor in reverse.) If conveyor does not move in either direction, check pump
drive for damaged splines. If drive is ok, install a 600 psi gauge on High pressure test port. Pressure reading will be charge pressure. (Do not engage conveyor)
Charge pressure for 400 & 500 series 330 psi, 300 series is 400 psi.
Pressure reading should be 3800 psi on 400 & 500 series, and 3045 psi on 300 series.
If pressure is OK, check for over loading auger conveyor system (Head of material in auger chamber)
chain adjustments or mechanical binds.
Pressure reading should be 3800 psi on 400 & 500 series, and 3045 psi on 300 series.
If low pressure reading, refer to pump service manual. If pressure is OK, check for over loading auger
conveyor system (Head of material in auger chamber) chain adjustments or mechanical binds.
41
22479 (11/00)
Technical Manual
A Terex Company
Traction System/Differential Lock

Differental
Lock
LH Traction Drive
Parking Brake
To RH Traction
System
(Rubber Tire Only)
Charge Pressure
LH Traction Pump
Range Shift
390 PSI
2500 RPM
2.8
1.4
CID CID
200 Mesh
Strainer
Hydraulic Tank
TRACTION SYSTEM WILL NOT WORK (Refer to traction electrical troubleshooting.)

TRACTION SYSTEM TOWS TO ONE SIDE ONLY
Refer to traction electrical troubleshooting.
Disconnect and cap cross over lines and ports between LH & RH FORWARD & REVERSE HIGH
PRESSURE PORTS ON CR351 MODELS.
Install 600 psi gauges in FORWARD & REVERSE high pressure test ports, on side that is not towing.
Pressure should be 350 psi and within 40 psi of each other.
If low refer to pump service manual.
If charge pressure cannot be adjusted, disconnect case drain hose and check for oil flow from motor.
If oil is flowing out of motor, disconnect high pressure hoses (forward & reverse) to motor & cap.
Recheck charge pressure.
If pressure is ok, refer to motor service manual.
If pressure still low, refer to pump service manual.
If pressure greater than 40 psi of each other, refer to pump service manual for pump centering.
Install 6000 psi gauges in the FORWARD & REVERSE high pressure test ports.
Unplug Brake DIN connector from brake solenoid valve. (this will lock up the brakes)
Brake switch to OFF.
42
22479 (11/00)
Technical Manual
A Terex Company

Travel speed pot to 10.
Travel lever or lever on slow side, FORWARD. Then lever to REVERSE.
Pressure should be 5400 psi. If low refer to pump service manual.
Push manual override in each direction.
DIFFERENTIAL LOCK DOES NOT FUNCTION
Check DIN connector light
If no light, refer to electrical troubleshooting
If light is on
(1) refer to electrical troubleshooting for ground connection.
(2) If valve has a good ground and differential lock does not function, replace valve.
43
22479 (11/00)
Technical Manual
A Terex Company
Traction System
Grayhound CR411
LH Traction Drive
Parking Brake
Charge Pressure
LH Traction Pump
Range Shift
390 PSI
2100 RPM
2.8
1.4
CID CID
50.4 Ratio
10
2 Filter
33.6 GPM Max

Cooler
Hydraulic Tank

Disconnect and cap cross over lines and ports between LH & RH FORWARD & REVERSE high
pressure ports on CR351 models.
44
22479 (11/00)
Technical Manual
A Terex Company
Front Wheel Assist (Optional)

All Grayhound Rubber Tire Pavers
FROM
TRACTION
PUMP
DRIVE
MOTOR
>>CASE DRAIN>>
FRONT WHEEL ASSIST

4WD PILOT
VALVE
FROM
TRACTION
PUMP
DRIVE
MOTOR
>> CASE DRAIN >>
FRONT WHEEL ASSIST (P4)

The front wheel assist system should not be confused with or considered as a four wheel drive system. When
the front wheel assist solenoid valve is energized pressure is applied to separate 5 way valves. When the 5way valves are open, pressure from the main traction pump is applied to both the main drive motor and the
front wheel assist motor on that side of the machine. The amount of tractive effort increase will depend on
the amount of traction the front wheels have in a given ground condition.
FRONT WHEEL ASSIST WILL NOT ENGAGE
Travel/P2/P4 switch to P4.
Check front wheel assist solenoid valve DIN connector for light.
If NO light, refer to electrical troubleshooting.
If light is ON,
(1) Refer to electrical troubleshooting for ground connection
(2) Install a 600 psi gauge in the LH conveyor high pressure test port. (Do not engage conveyor)
Refer to conveyor charge pressure above for pressure required. If pressure is low, refer to
conveyor.
(3) If pressure is correct, install 600 psi gauge between A port and hose going to the 5 way valves. If
no or low pressure, defective solenoid valve.
(4) If pressure is correct, install 6000 psi gage between 5-way valve and motor. Move machine. If very
low or no pressure, defective 5-way valve on that side. Both sides will need to be checked.
45
22479 (11/00)
Technical Manual
A Terex Company
46
22479 (11/00)
PAVER
TECHNICAL MANUAL
400 & 500 Series

Electrical Section
Technical Manual
A Terex Company
Table of Contents
400 & 500 Series Electrical Section
Component Location Map ............................................................................................ 1 - 16
Engine Starting System ..................................................................................................... 17
Charging System................................................................................................................ 18
Throttle & Fuel ........................................................................................................... 19 - 20
Engine Start & Fuel - Elite Engine .................................................................................... 21
Horn ................................................................................................................................... 22
Gauges ............................................................................................................................... 23
Lights ................................................................................................................................. 24
Brakes ................................................................................................................................ 25
Travel Pave (P2) System .................................................................................................... 26
Front Wheel Assist CR451 and CR551 ............................................................................. 27
Travel Control CR451 and CR551 ............................................................................. 28 - 30
Travel Control & Steer Assist - Rubber Tire Pavers 1999 & After ............................. 31 - 33
Travel Control Adj. Procedure 3 Pot Controller Tire Pavers ...................................... 34 - 35
Travel Control Adj. Procedure 3 Pot Controller Track Pavers .................................... 36 - 38
Travel Control Adj. Procedure Tire Pavers w/Lever Controls .................................... 39 - 40
Differential Lock CR451 and CR551 ................................................................................ 41
Steer Assist CR451 and CR551 .................................................................................. 42 - 43
LH Travel Speed Control CR461 and CR561 ............................................................ 44 - 45
RH Travel Speed Control CR461 and CR561 ............................................................ 46 - 47
Travel Control Adj. Procedure Track Pavers w/Lever Controls ................................. 48 - 50
Susmic 10 Dual Path Control Calibration Procedures ................................................ 51 - 55
Hopper ............................................................................................................................... 56
Truck Hitch (Optional) ...................................................................................................... 57
Frame Raise ....................................................................................................................... 58
LH Flow Gate .................................................................................................................... 59
RH Flow Gate .................................................................................................................... 60
Material Flow Indicators 1999 & Before .................................................................... 61 - 62
Material Flow Indicators 1999 & After ...................................................................... 63 - 64
Screed Lift ......................................................................................................................... 65
Screed Assist ...................................................................................................................... 66
Power Main Crown ............................................................................................................ 67
400 & 500 Series Electrical Troubleshooting
22480 (11/01)
Technical Manual
A Terex Company
Table of Contents
400 & 500 Series Electrical Section
LH Screed Extend Stretch 20 & Fastach 10 Hydraulic Strike-Off .................................... 68
RH Screed Extend Stretch 20 & Fastach 10 Hydraulic Strike-Off .................................... 69
LH Screed Slope Stretch 20 & Fastach 10 Hydraulic Strike-Off ...................................... 70
RH Screed Slope Stretch 20 & Fastach 10 Hydraulic Strike-Off ...................................... 71
LH Match Height Stretch 20 ............................................................................................. 72
RH Match Height Stretch 20 ............................................................................................. 73
Vibrators ............................................................................................................................ 74
LH Main Burner #1 ........................................................................................................... 75
RH Main Burner #2 ........................................................................................................... 76
LH Ext. Burner #3 ............................................................................................................. 77
RH Ext. Burner #4 ............................................................................................................. 78
Rear Frame Compensator Adjustment ............................................................................... 79
ii
22480 (11/01)
Technical Manual
A Terex Company

Fastach 10'
Grayhound 400 & 500 Series
L33
L34
L32
L35
L31
L37
L36
L39
L38
L31 ....... LH extend/retract solenoid

L32 ....... LH slope solenoid
L33 ....... Slope control module
L34 ....... Controls for glow plugs, fans, crown and horn
L35 ....... Burner and spray down control valves
L36 ....... RH slope solenoid
L37 ....... RH extend/retract solenoid
L38 ....... LH screed burner fan and glow plug
L39 ....... RH screed burner fan and glow plug
22480 (10/01)
Technical Manual
A Terex Company
Component Location Map Fastach II
Cedarapids
EXTEND
FEED
OVER
RIDE
STOP
SLOPE
MATCH
HEIGHT
BERM
TOWPOINT
MAN
MAN
SETUP
AUTO
HORN
Cedarapids
EXTEND
FEED
OVER
RIDE
STOP
SLOPE
E
TEMPERATUR
RH MAIN
MATCH
RH EXT
HEIGHT
LH MAIN
LH EXT
CONTROL
HEAT
OUTLET
HEAT
OUTLET
HEAT
HEAT
HEAT
BERM
GENERATOR
ON
OFF
ON
OFF
TOWPOINT
MAN
MAN
SETUP
AUTO
HORN
HORN
CROWN
E
INCREAS
DECREAS
1 ........... Screed Heater Control Panel

2 ........... Screed Generator
22480 (10/01)
Technical Manual
A Terex Company

Fastach 10' & Stretch 20
L22
L20
L18
L23
L24
L21
L19
L26
L25
L30
L29
L28
L27
L18 ....... LH extend/retract solenoid

L19 ....... LH match height solenoid
L20 ....... LH slope solenoid
L21 ....... Crown solenoid
L22 ....... RH slope solenoid
L23 ....... RH match height solenoid
L24 ....... RH extend/retract solenoid
L25 ....... LH remote control switch assembly
L26 ....... RH remote control switch assembly
L27 ....... LH extension burner fan and glow plug
L28 ....... LH main screed burner fan and glow plug
L29 ....... RH main screed burner fan and glow plug
L30 ....... RH extension burner fan
Note: L25, L26, L33, L34 and L35 are the same on both the Fastach 10' and Stretch 20 screeds.
22480 (10/01)
Technical Manual
A Terex Company

DIN Connector
Earlier Version
Travel Controller
Low Threshold
Manual
Override
Reverse
Maximum Pot
Forward
Maximum Pot
DIN Connector
Current Version
Travel Controller
MINIMUM Forward Pot
MINIMUM Reverse Pot

MAXIMUM Forward Pot
MAXIMUM Reverse Pot
22480 (10/01)
Technical Manual
A Terex Company

L4
L2
L1
L3
L5
L6
Front
Bulkhead
L17
L9
L12
L8
L7
L16
L11
L13
L10
Rear
Bulkhead
L14
L15

22480 (10/01)
Technical Manual
A Terex Company

Grayhound 400/500 Series Digital Display
L44
L42
L43
L40
L46
L45
L41
L47
L48
L49
L50
L54
L51
L53
L40 ....... Master key

L41 ....... Detroit governor card/feeder resistor card
L42 ....... 60 amp breaker (burner)
L43 ....... 15 amp breaker (power)
L44 ....... 15 amp breaker (control)
L45 ....... 15 amp breaker (flasher)
L46 ....... 15 amp breaker (Lights)
L47 ....... RH flow gate relay (lower)
L48 ....... LH flow gate relay (raise)

L51 ....... Proportional module
L52 ....... Horn relay
L53 ....... Terminal block
L54 ....... Murphy timer relay
22480 (10/01)
Technical Manual
A Terex Company

Grayhound 400/500 Series Digital Display
L55 L56
L57
L58
L60
L76
L59
L62
L63
L65
L66
L68
L61
L64
L67
L70
L69
L71
L72 L73
L76
L74
L55 .......... Lights

L56 .......... Vibrator
L57 .......... Frame raise
L58 .......... Strobe light
L59 .......... Horn
L60 .......... Screed lift
L61 .......... Screed assist
L62 .......... RH flow gate
L63 .......... LH flow gate
L64 .......... Brake
L65 .......... RH conveyor speed
L75
L66 .......... LH conveyor speed

L67 .......... Travel/Pave (travel/P2/P4)
L68 .......... RH conveyor manual/auto
L69 .......... LH conveyor manual/auto
L70 .......... Engine start/run/stop
L71 .......... Truck hitch
L72 .......... Hopper
L73 .......... Throttle
L74 .......... Digital meter
L75 .......... Travel speed pot
L76 .......... Travel lever(s)
7
22480 (10/01)
Technical Manual
A Terex Company

Grayhound 400/500 Series Analog Display
13 12 11 10
9 8
14
15
16
1 ........... Timing relay

2 ........... Engine breaker 15 amp
3 ........... Light breaker 15 amp
4 ........... Flasher breaker 15 amp
5 ........... Control breaker 15 amp
6 ........... Power breaker 30 amp
7 ........... Burner breaker 60 amp
8 ........... Spare relay
9 ........... K3 relay
10 ......... K15 relay
11 ......... K16 relay
12 ......... K17 relay
13 ......... K18 relay
16 ......... K1 relay
22480 (10/01)
Technical Manual
A Terex Company

8
9
10
11
13
17
18
12
11
15
16
21
23
22
19
26
20
25
24
1 ........... Travel control(s)

2 ........... Travel speed pot
5 ........... RH conveyor switch
9 ........... Brake
10 ......... Engine stop/start/run switch
11 ......... LH conveyor speed pot
12 ......... RH conveyor speed pot
13 ......... Horn switch
14 ......... Vibrator switch

15 ......... RH flow gate switch
16 ......... LH flow gate switch
17 ......... Screed lift switch
18 ......... Screed assist switch
19 ......... Light switch
20 ......... Flasher switch
21 ......... Oil temperature gauge
22 ......... Water temperature gauge
23 ......... Tachometer
24 ......... Volt meter
25 ......... Fuel level gauge
26 ......... Oil pressure gauge
9
22480 (10/01)
Technical Manual
A Terex Company

24 23 22 21 20 19 18 17 16 15
1
2
3
4
5
6
7
8
9
12
14
13
10
11

4 ........... F/G/S breaker: 15 amp
10 ......... Key switch
11 ......... K2 relay
12 ......... K22 relay

15 ......... K3 relay
16 ......... K4 relay
17 ......... K5 relay
18 ......... K6 relay
19 ......... K15 relay
20 ......... K16 relay
21 ......... K17 relay
22 ......... K18 relay
10
22480 (10/01)
Technical Manual
A Terex Company

10
11
12
20
21
30
31
13
16
19
18
14 15 17
22
29
23
24
4 3 2
25
26
27
28
36
32
37
33
34
35
28
30
31
29
16

4 ............. Rear frame compensator switch
11 ........... RH conveyor speed pot
12 ........... LH conveyor speed pot
17 ........... Steer assist switch

26 ........... Horn switch
33 ........... Voltmeter
11
22480 (10/01)
Technical Manual
A Terex Company

3rd Generation Version
22 21 20 1918 17 16 15 14 13
1
2
3
4
5
6
7
8
9
12
10
11

13 ......... K3 relay
14 ......... K4 relay
15 ......... K5 relay
16 ......... K6 relay
17 ......... K15 relay
18 ......... K16 relay
19 ......... K17 relay
20 ......... K18 relay
21 ......... K22 relay

4 ........... F/G/S breaker: 15 amp
10 ......... Key switch
11 ......... K2 relay
12
22480 (10/01)
Technical Manual
A Terex Company

10
13
20
19
18
21
30
31
22
29
23
4 3 2
16
14 15
25
26
27
24
28
36
37
32
35
33
34
28
30
31
29
16

11 ........... N/A
12 ........... N/A
17 ........... N/A

26 ........... Horn switch
33 ........... Voltmeter
13
22480 (10/01)
Technical Manual
A Terex Company

Grayhound 400/500 Series Remix Pavers
21 19 18 17 16
K3
20
K4
K5
K6
A
SP
15
13
14
FEED INTERFACE
MODULE
1
2
3
4
5
6
7
8
9
10
11
12
12 ......... RH & LH Feed Interface Module

13 ......... Spare Feed Interface Module
14 ......... RH Remix Controller
15 ......... LH Remix Controller
16 ......... K3 relay
17 ......... K4 relay
18 ......... K5 relay
19 ......... K6 relay
20 ......... K22 relay

3 ........... Console breaker: 15 amp
4 ........... F/G/S breaker: 15 amp
10 ......... Key switch
11 ......... K2 relay
14
22480 (10/01)
Technical Manual
A Terex Company

10
12
11
13
20
19
18
21
22
23
4 3 2
16
14 15
25
26
27
24
29
36
37
32
35
33
34
32
33
34
35
37
36
29
23
21
22
20
19
26
14 15
24 25 27
18
16
12
11
13
4
10
3 2
19 ........... RH remix/delivery screw switch

20 ........... LH remix/delivery screw switch
26 ........... Horn switch
29 ........... Engine indicator light
30 ........... N/A
31 ........... N/A
33 ........... Voltmeter

9 ............. RH spreading auger switch
10 ........... LH spreading auger switch
11 ........... RH remix ratio dial
12 ........... LH remix ratio dial
17 ........... N/A
15
22480 (10/01)
Technical Manual
A Terex Company

Throttle
Solenoid
Alternator
Murphy Temp
Sensor
Engine Temp
Sensor
Engine Oil
Pressure Sensor
RPM Pickup
Starter Solenoid
K2 Starter
Relay
Starter
16
22480 (10/01)
Technical Manual
A Terex Company
Engine Starting System

ENGINE DOES NOT START

Main key switch ON
Brake switch ENGAGED
Travel switch in NEUTRAL position
Control circuit breaker SET
Stop/Start switch held in START position
Permissive start switch held closed
ENGINE DOES NOT CRANK

Check for low battery voltage, loose starter connections or faulty starter.
If no voltage
1 to 3 .........
20 to 3 ........
21 to 3 ........
13 to 3 ........
14 to 3 ........
16 to 3 ........
15 to 3 ........
2 to 3 .........

Defective or tripped engine circuit breaker.
Defective engine start/stop switch.
Defective brake switch.
Limit switch 3 on LH travel switch defective. (Track)
Limit switch 3 on RH travel switch defective.
Defective starter relay (K2).
If voltage, check starter motor.
17
22480 (10/01)
Technical Manual
A Terex Company
Charging System
ALTERNATOR NOT CHARGING (12.5 Vdc or less at battery)

Main key switch ON
Engine running at FULL THROTTLE
Voltage should be 13.5 Vdc to 15.5 Vdc from 1 to 3
If no voltage
1 to 3 .......... If no voltage or high voltage (>16 Vdc), defective main key switch or wiring.
20 to 3 ........ If no voltage, defective or tripped engine circuit breaker
22 to 3 ........ If no voltage, defective engine start/stop switch, loose connection or bad wire.
22 to 3 ........ If no voltage, at terminal of alternator, defective resistor or wiring.
If voltage is 12.5 volts or less at alternator (1to 3), repair or replace alternator.
If voltage at battery is more than 16 Vdc, check for defective ground connection(s) between
battery, frame, engine, and alternator before replacing alternator.
BATTERIES
Each battery should have about 12.6 Vdc for a total system voltage of 12 to 13 Vdc with
engine off. Lower readings than this is indicative of a weak battery and should be serviced.
18
22480 (10/01)
Technical Manual
A Terex Company
Throttle & Fuel

ENGINE RUNS AT IDLE BUT NOT FULL THROTTLE

48 to 3 ........ If no voltage, defective throttle switch.
If voltage, defective throttle solenoid or open wiring in solenoid.
engine switch to RUN
If no voltage:
ENGINE STOPS WHEN PERMISSIVE START SWITCH IS RELEASED
Main key switch ON, brake switch ENGAGED, hold permissive start switch CLOSED
After engine starts, the engine light should remain lit until the engine pressure rises above 5 psi
and the engine temperature is below 223 F.
Release permissive start switch after engine light goes out.
22 to 3 ........ If no voltage and engine dies, defective permissive start relay
19
22480 (10/01)
Technical Manual
A Terex Company
Throttle & Fuel

ENGINE LIGHT WILL NOT GO OUT AFTER ENGINE STARTS
If continuity across engine water temperature switch, check for overheated engine or defective
water temperature switch.
If continuity across engine oil pressure switch, check for low engine oil pressure or defective
engine oil pressure switch.
ENGINE DOES NOT STOP
Engine stop/start switch to STOP.
23 to 3 ........ If voltage, defective engine stop/start switch.
If no voltage, defective fuel solenoid.
ENGINE SHUTS OFF AFTER A PERIOD OF TIME
Check the engine oil pressure and water temperature. One of these has exceeded limits and
tripped the shutdown system.
20
22480 (10/01)
Technical Manual
A Terex Company
Engine Start & Fuel - Elite Engine

Grayhound 400/500 Series
Rubber Tire Pavers
Track Pavers

engine switch to START
If no voltage:
23A to 3 ..... defective K22 relay
Note: Pull-in coil (wire 23A) has 12VDC only while cranking engine
21
22480 (10/01)
Technical Manual
A Terex Company
Horn
Main
Keyswitch
1
12 VDC
3
0
Horn
Power
1
100
19
18
30 A
100
Horn Relay
Horn Switch
HORN DOES NOT WORK

Hold horn switch ON.
If voltage, check:
19 to 3 ........ If voltage, defective horn.
100 to 18 ..... If 12 Vdc, replace K3 relay
18 to 3 ........ If no voltage, defective K3 relay.
If voltage, defective horn switch
22
22480 (10/01)
Technical Manual
A Terex Company
Gauges
NO GAUGES WORK
20 to 3 ........ If no voltage, check engine circuit breaker
INDIVIDUAL GAUGES DO NOT WORK
Water temperature:
7 to 3 .......... 1500 ohms at 100 F, 125 ohms at 210 F
Oil pressure:
8 to 3 .......... 0 to 80 ohms at 0 to 80 PSI.
Hydraulic temperature:
9 to 31 ........ 1500 ohms at 100 F, 125 ohms at 210 F
Fuel level:
10 to 3 ........ 0 to 90 ohms = empty to full
Hourmeter/tachometer: (requires a functional alternator for proper operation)
11 to 3 ........ If voltage at tachometer is approximately. 8 Vac with engine running, replace
tachometer.
11 to 3 ........ If no voltage at tach., check at alternator, if no voltage, replace alternator.
If frequency meter available, frequency should be 250 Hz at idle, 680 Hz at full throttle.
23
22480 (10/01)
Technical Manual
A Terex Company
Lights
FLASHER LIGHTS/STROBE DO NOT WORK

Main key switch ON, flasher and engine circuit breaker SET, flasher switch ON
If no voltage:
113 to 3 ...... defective flasher switch
113A to 3 ... defective flasher circuit breaker
If voltage 113 to 3 and if no voltage 114 to 3, defective flasher relay
LIGHTS DO NOT WORK
Main key switch ON, lights and engine circuit breaker SET, light switch ON,
If no voltage:
109 to 3 ...... defective light switch
109A to 3 ... defective light circuit breaker
If voltage 109 to 3 and no voltage 110 to 3, defective lights relay
110 to 3 ...... If no voltage, defective light switch. If voltage, check for bad light bulb
24
22480 (10/01)
Technical Manual
A Terex Company
Brakes
Main
Keyswitch
Control
46
15 A
Brake
12 VDC
3
Engage
34
34
Brake Release Sol.
'A' Release

If SWITCH is defective, the brakes WILL remain ENGAGED. Travel speed controllers,
vibrators, automatic feed and screed control WILL NOT function.
If SOLENOID is defective, the brakes WILL NOT RELEASE. Travel speed controllers,
vibrators, automatic feed and screed control WILL function.
Check brake solenoid DIN connector for light. If light is ON:
(1) Check ground jumper pin 2 to GND pin on DIN connector for loose connection.
(2) Defective solenoid coil or hydraulic problem
If NO light:
25
22480 (10/01)
Technical Manual
A Terex Company
Travel Pave (P2) System


If NO light:
26
22480 (10/01)
Technical Manual
A Terex Company
Front Wheel Assist

CR451 & CR551 Grayhound Pavers
Main
Keyswitch
Control
1
46
15 A
12 VDC
3
Range
P/4
P/2
27
Fwd Sol.
42
Range Sol.
Travel

If NO light:
RANGE SWITCH DOES NOT WORK IN P4 (Front wheel assist only)
Range switch to P4 (front wheel assist).
Check front wheel assist solenoid DIN connector for light. If light is ON:
If NO light:
If DIN connector light is on, defective solenoid.
27
22480 (10/01)
Technical Manual
A Terex Company
Travel Control
Main
Keyswitch
1
12 VDC
3
0
Control
46
15 A
46
Brake
Engage
34
'A' Release
4 Pin Packard
77
C
B
D
Travel
3
RH
A
B
Reverse
Coils
73
3
LH
B
3 A
3
34
73
3
74
74
Speed
B
Controller
C
A
CW
Max
Paver
Speed
1K
3
LH
D
C
Forward
Coils
78
3
RH
D
C
3 Pin Packard
breaker SET.
74 to 3 ........ For 411, voltage should be 1.6 Vdc. For 451, voltage should be 2.2 VDC .
78 to 3 ........ For 411, voltage should be 1.6 Vdc. For 451, voltage should be 2.2 VDC.
28
22480 (10/01)
Technical Manual
A Terex Company
Travel Control
73 to 3 ........ For 411, voltage should be 1.6 VDC. For 451, voltage should be 2.2 VDC.
77 to 3 ........ For 411, voltage should be 1.6 VDC. For 451, voltage should be 2.2 VDC.
PAVER PULLS TO ONE SIDE
If paver turns severely to left:
Operate manual override on left pump. If left pump operates proceed with electrical checks. If not,
refer to hydraulic section.
Electrical Checks:
73 to 3 ........ Resistance should be 19.5 ohms.
29
22480 (10/01)
Technical Manual
A Terex Company
Travel Control
If paver turns severely to right:
Operate manual override on right pump. If right pump operates, proceed with electrical checks. If
not refer to hydraulic section.
Electrical checks:
30
22480 (10/01)
Technical Manual
A Terex Company

1999 & After w/46065-500-34 Module
31
22480 (10/01)
Technical Manual
A Terex Company

1999 & After w/46065-500-34 Module
breaker SET.
32
22480 (10/01)
Technical Manual
A Terex Company

1999 & After w/46065-500-34 Module
PAVER PULLS TO LEFT OR RIGHT
Move harness plug-in connector from ASSIST position to BYPASS position. This eliminates
STEER ASSIST circuitry on Steer Assist Module.
If this corrects problem, replace Steer Assist Module.
If not, re-check wire connections between console and traction pumps as described above.
Proper operation is indicated when paver pivot turns in the direction that STEER ASSIST switch is
held. DIFF. LOCK must also be functional. If DIFF. LOCK is not working, refer to that section first
before proceeding.
33
22480 (10/01)
Technical Manual
A Terex Company

3 Pot Controller
3 Pot
Travel Controller
Low Threshold
Reverse
Maximum Pot
Forward
Maximum Pot

34
22480 (10/01)
Technical Manual
A Terex Company

3 Pot Controller
1. With Control Handle full forward and MAX PAVER SPEED dial at MIN; wheels should not
turn. Adjust Low Threshold Pot so that wheels start to creep at dial setting of '1' to '1.5' but stop
at MIN.
2. Turn MAX PAVER SPEED dial to MAX with Control Handle full forward: Check speed of
wheel hubs with a tachometer and adjust Max Forward Pot until actual speed is at Maximum. If
in doubt, turn pot CCW until speed decreases then back to max speed.
3. Put Control Handle full reverse: Check speed of wheel hubs with a tachometer and adjust Max
Reverse Pot. until actual speed is at Maximum. If in doubt, turn pot CCW until speed decreases
then back to max speed.
Bias Adjustment
35
22480 (10/01)
Technical Manual
A Terex Company

3 Pot Controller
3 Pot
Travel Controller
Low Threshold
Reverse
Maximum Pot
Forward
Maximum Pot

36
22480 (10/01)
Technical Manual
A Terex Company

3 Pot Controller
3 Pot
Travel Controller
Low Threshold
Reverse
Maximum Pot
Forward
Maximum Pot

37
22480 (10/01)
Technical Manual
A Terex Company

3 Pot Controller
1. With Control Handle full forward and MAX PAVER SPEED dial at MIN; tracks should not
move.
2. Adjust Low Threshold Pot so that both tracks start to creep at dial setting of '1' to '1.5' but stop
at MIN.
3. Turn MAX PAVER SPEED dial slowly to MAX with Control Handles full forward: Adjust
each MAX Forward Pot so that track speeds match (Paver goes straight) and paver is at
speed.
4. Turn MAX PAVER SPEED dial slowly to MAX with Control Handles full reverse: Adjust
each MAX Reverse Pot so that track speeds match (Paver goes straight) and paver is at
speed.
38
22480 (10/01)
Technical Manual
A Terex Company

w/Lever Control
MINIMUM Forward Pot
MINIMUM Reverse Pot
MAXIMUM Forward Pot
MAXIMUM Reverse Pot

. Turn both MAX adjustment pots on controller fully clockwise.
MIN with handle in full reverse: Voltage should decrease smoothly down to about 0.2 VDC. If not
repeat steps 1-5.
MIN with handle in full forward: Voltage should decrease smoothly down to about 0.2 VDC. If not
repeat steps 1-5.
39
22480 (10/01)
Technical Manual
A Terex Company

w/Lever Control
With Control Handle full forward and MAX PAVER SPEED dial at MIN; wheels should not turn.
Adjust MIN Forward Pot so that wheels start to creep at dial setting of '1' to '1.5' but stop at MIN.
With Control Handle full reverse and MAX PAVER SPEED dial at MIN; wheels should not turn.
Adjust MIN Reverse Pot so that wheels start to creep at dial setting of '1' to '1.5' but stop at MIN.
Turn MAX PAVER SPEED dial to MAX with Control Handle full forward: Check speed of wheel
hubs with a tachometer and adjust Max Forward Pot until actual speed is at Maximum. If in doubt,
turn pot CCW until speed decreases then back to max speed.
Put Control Handle full reverse: Check speed of wheel hubs with a tachometer and adjust Max
Reverse Pot. until actual speed is at Maximum. If in doubt, turn pot CCW until speed decreases then
back to max speed.
Repeat steps 1-5 until adjustment is not necessary.
Bias Adjustment
40
22480 (10/01)
Technical Manual
A Terex Company
Differential Lock
CR451 and CR551 Grayhound Pavers
DIFFERENTIAL LOCK DOES NOT WORK IN P/2 OR P/4 RANGE

Differential Lock is operational only in P/2 or P/4 Range.
Proper operation is indicated when steering becomes difficult to impossible other than in a straight line.
To troubleshoot a suspected problem:
DIFF. LOCK switch held in ON position
Check Diff. Lock solenoid DIN connector for light
If light is ON, check for magnetic field with a small screwdriver at the solenoid coil. If no field,
check ground jumper from pin 2 to GND pin in DIN connector for tightness. If connection is good,
check coil resistance for about 6 ohms. Replace solenoid if bad. If there was a magnetic field, refer
to Hydraulic Troubleshooting.
If no light check:
46A to 3.........If no voltage, replace K20 relay. If 12VDC, check:
79 to 3............If no voltage, replace DIFF. LOCK switch. If 12VDC:
79 to Ground at solenoid.....No voltage indicates defective wiring to solenoid.
12VDC at the solenoid without a light indicates either a bad Ground or defective DIN connector.
DIFFERENTIAL LOCK FUNCTIONS IN TRAVEL RANGE
Differential Lock should NOT work in TRAVEL RANGE. If it is, check:
DIN connector for light. If ON check:
46A to 3.........If no voltage, check wire 79 for cross short to 12VDC.
If 12VDC, check:
42 to 3 at K20 relay.....If 12VDC, unplug K20 relay. If Diff. Lock solenoid drops out, replace
K20 relay.
If no voltage, check for defective wiring in console.
If DIN light is OUT, refer to Hydraulic Troubleshooting.
41
22480 (10/01)
Technical Manual
A Terex Company
Steer Assist

Proper operation is indicated when paver pivot turns in the direction that STEER ASSIST switch is held.
DIFF. LOCK must also be functional. If DIFF. LOCK is not working, refer to that section first before
proceeding.
79 to 3 with .If no voltage, replace STEER ASSIST switch. If 12VDC:
Is KL relay pulling in? If not, replace or swap with KR relay to check.
If KL relay does pull in, check 74 to 3 in Forward or 73 to 3 in Reverse. Voltage should be 0. If
not, replace or swap KL relay with KR relay to check.
42
22480 (10/01)
Technical Manual
A Terex Company
Steer Assist

Is KR relay pulling in? If not, replace or swap with KL relay to check.
If KR relay does pull in, check 78 to 3 in Forward or 77 to 3 in Reverse. Voltage should be 0. If
not, replace or swap KR relay with KL relay to check.
PAVER PULLS TO LEFT WITH STEER ASSIST IN RELEASED (OFF) POSITION
74 to 3 in Forward, 73 to 3 in Reverse. If voltage is 0, replace or swap KL relay with KR relay to
Troubleshooting.
PAVER PULLS TO RIGHT WITH STEER ASSIST IN RELEASED (OFF) POSITION
78 to 3 in Forward, 77 to 3 in Reverse. If voltage is 0, replace or swap KR relay with KL relay to
Troubleshooting.
43
22480 (10/01)
Technical Manual
A Terex Company

Grayhound CR461 and CR561
Main
Keyswitch
Control
46
46
15 A
12 VDC
0
Brake
3
Engage
34
'A' Release
4 Pin Packard
C
A
D
Left
Travel
Speed
Controller
B
B
C
A
Forward
Coil
73
3
LH
B 3
A
3
74
74
34
73
CW
Max
Paver
Speed
1K
LH
D
C
Reverse
Coil
3 Pin Packard
Dual Speed Pot
LH TRAVEL SPEED CONTROL DOES NOT WORK

Without starting the engine, main key switch to ON, engine start/stop switch to RUN, control
circuit breaker SET.
Release BRAKES. Set the max paver speed dial to MAX and the LH travel lever fully FORWARD.
Release BRAKES. Set the max paver speed dial to MAX and the LH travel lever fully REVERSE.
44
22480 (10/01)
Technical Manual
A Terex Company

45
22480 (10/01)
Technical Manual
A Terex Company

RH TRAVEL SPEED CONTROL DOES NOT WORK

Without starting engine, main key switch to ON, engine start/stop switch to RUN, control circuit
breaker is SET.
Release the BRAKES, max paver speed dial to MAX and the RH travel lever fully FORWARD.
34 to 3 ........ If no voltage, defective Brake switch.
46
22480 (10/01)
Technical Manual
A Terex Company

Release BRAKES, set max paver speed dial to MAX and the RH travel lever fully REVERSE.
Set max paver speed dial to MIN. Voltage should decrease to 0.15 Vdc.
47
22480 (10/01)
Technical Manual
A Terex Company

w/Lever Controls
MINIMUM Forward Pot
MINIMUM Reverse Pot
MAXIMUM Forward Pot
MAXIMUM Reverse Pot

repeat steps 1-5.
repeat steps 1-5.
48
22480 (10/01)
Technical Manual
A Terex Company

w/Lever Controls
MINIMUM Forward Pot
MINIMUM Reverse Pot
MAXIMUM Forward Pot
MAXIMUM Reverse Pot

repeat steps 1-5.
repeat steps 1-5.
49
22480 (10/01)
Technical Manual
A Terex Company

w/Lever Controls
. With Control Handles full forward and MAX PAVER SPEED dial at MIN, tracks should not move.
MIN Forward Pot so that both tracks start to creep at dial setting of '1' to '1.5' but stop at MIN.
. With Control Handle full reverse and MAX PAVER SPEED dial at MIN, tracks should not move.
MIN Reverse Pot so that both tracks start to creep at dial setting of '1' to '1.5' but stop at MIN.
. Turn MAX PAVER SPEED dial slowly to MAX with Control Handles full forward.
. Adjust each MAX Forward Pot so that track speeds match (Paver goes straight) and paver is at
maximum attainable speed. Maximum attainable speed is when turning the MAX Forward pot CW
. Turn MAX PAVER SPEED dial slowly to MAX with Control Handles full reverse.
. Adjust each MAX Reverse Pot so that track speeds match (Paver goes straight) and paver is at
maximum attainable speed. Maximum attainable speed is when turning the MAX Reverse pot CW
50
22480 (10/01)
Technical Manual
A Terex Company

Pavers 1999 & Before
Pavers 1999 & After
Scope
This document covers the calibration procedures for asphalt pavers equipped with the Sauer-Sunstrand
Susmic 10 dual path controller.
When to Calibrate
These procedures are to be performed after initial vehicle assembly and when a sensor, EDC, pump or
motor is replaced. Before beginning these procedures, check to make sure that the Susmic 10 (S10) is
properly wired and all inputs are as expected. Table 1 shows all controller inputs and loads and their
expected ranges.
51
22480 (10/01)
Technical Manual
A Terex Company

Input
Forward switch
Reverse switch
Wire
351
35 2
Counter rotation
353
Calibrate
Brake switch
Steer sensor signal
Speed pot signal
Battery +
Battery +
Ignition
355
34
332
342
22
22
22
Output
Steer sensor power
Speed pot power
Left forward EDC
Left reverse EDC
Right forward EDC
Right reverse EDC
Wire
331
341
73
74
77
78
Pin Value
P1-9 Zero volts in forward
P1-27 Zero volts in reverse
Zero volts in counter rotate
P1-8
(pave mode only)
P1-15 Zero volts when calibrate held
P1-25 12 volts when brake is released
P1-18
1 to 4 volts, left to right
P1-19
0.5 to 4.5 volts, min. to max.
P1-1
12 volts
P1-10
12 volts
P1-12
12 volts
Pin Value
P1-23 5 volts
P1-24 5 volts
P1-7
0 to 3 volts*
P1-20
0 to 3 volts*
P1-6
0 to 3 volts*
P1-21
0 to 3 volts*
* Depends on Speed Pot Position

All Voltage measured made with respect to ground.
Ground @ pin P1-2, P1-3, P1-22, P1-13 and EDC Pins B & C.
System Function Check
A system function check should be performed whenever a component is changed and prior to
calibration. Check that all components are installed and that wiring is attached properly. Make sure that
all persons are clear of the machine and that space for machine movement exists to the front, rear and
both sides. The engine should be at low idle setting and the machine in the work range of operation.
1) Center the steering wheel. Turn the speed set potentiometer to its MINIMUM position. Move
the throttle switch to the IDLE position. Move the pave mode switch to the PAVE position.
Move the Counter Rotate switch to the NORMAL position. Move the FNR switch to the neutral
(N) position.
2) Start the vehicle. The tracks should not move.
3) Move the BRAKE switch to the RELEASE position. The tracks should not move.
4) Slowly turn the SPEED SET potentiometer clockwise. Neither track should move.
52
22480 (10/01)
Technical Manual
A Terex Company

5) Turn the SPEED SET potentiometer to the MINIMUM position. Move the FNR switch to the
forward (F) position. The tracks should not move.
6) Slowly turn the SPEED SET potentiometer clockwise. Both tracks should begin to move slowly
forward (clockwise). As the SPEED SET pot is increased, the track speed should increase.
rate.
original rate.
9) Move the FNR switch to the neutral (N) position. Both tracks should stop.
10) Move the FNR switch to the reverse (R) position. Both tracks should begin turning in reverse.
rate.
original rate.
13) Slowly turn the SPEED SET potentiometer counterclockwise towards minimum. Both tracks
should slow to a stop by the time the speed pot is at its minimum position.
14) Move the FNR switch to the neutral (N) position. Both tracks should be stopped.
If the vehicle performs as described above, the system is prepared for calibration.
53
22480 (10/01)
Technical Manual
A Terex Company

CALIBRATION: Calibration procedures are to be performed after initial vehicle assembly and when a
sensor, speed set dial, EDC, pump or motor is replaced. Before beginning these procedures, check to
make sure that the controller is properly wired and that all test values are as expected. Before
beginning calibration, move the vehicle to an open area with 30+ yard run-out.
1) ENGINE switch in STOP. PAVER SPEED dial at minimum. THROTTLE switch in IDLE.
RANGE switch in PAVE. COUNTER ROTATE switch in NORMAL. FNR switch in
neutral (N). STEERING WHEEL MUST BE CENTERED.
2) Hold the CAL-RUN switch in the CAL position while starting the vehicle. Do not release
CAL switch until Engine is brought to FULL THROTTLE.
3) Move the BRAKE switch to the RELEASE position.
4) Turn the STEERING WHEEL all the way to the left and hold.
5) Move the FNR switch to the forward (F) position. Watch the left track closely. As soon as the
6) Move the FNR switch to the reverse (R) position. Watch the left track closely. As soon as the
7) Turn the STEERING WHEEL all the way to the right and hold.
8) Move the FNR switch to the forward (F) position. Watch the right track closely. As soon as the
9) Move the FNR switch to the reverse (R) position. Watch the right track closely. As soon as the
10) Center the STEERING WHEEL.
11) Move the FNR switch to the forward (F) position.
14) Move the FNR switch to the reverse (R) position.
17) Press and release the CAL-RUN. Move the THROTTLE switch to the IDLE position. Move
the BRAKE switch to the ENGAGE position.
18) Wait 5 seconds.
19) Shut off the engine to store values.
54
22480 (10/01)
Technical Manual
A Terex Company

Error Checks
There are four (4) indicator lights (LED's) located on the side of the track steer controller module located
inside of the console; 2 green LED's, 1 yellow and 1 red. Their function is as follows:
1st Green
Power Input
OK if Lit
2nd Green
Yellow
Power Output
Kernal (Program)
OK if Lit
Blinks if functional
Red
Error
Error if lit
On earlier controllers, the red error light would be either ON or OFF, indicating an error. As of software
version S0029109 and later, an error code has been assigned to the red LED. The code is a series of
short and long flashes consisting of 4 flashes per error with a pause between each error(s). A short
flash indicates a "0" and a long flash represents a "1". The following table lists the error codes along
with the error associated with it:
Error Code
1000*
1100*
1010*
1110*
0100*
0010*
0110*
0001*
1001*
0101*
1101*
0011*
1011
0111
1111
Error Description
Steering sensor input is higher than calibrated
Steering sensor input is lower than calibrated
Steering sensor calibrated too high
Steering sensor calibrated too low
Speed dial input is higher than calibrated
Speed dial input is lower than calibrated
Speed dial input is calibrated too high
Speed dial input is calibrated too low
LH FWD EDC calibration fault
RH FWD EDC calibration fault
LH REV EDC calibration fault
RH REV EDC calibration fault
Sensor power fault
LH EDC fault
RH EDC fault
*Attempt to clear errors by re-calibrating first per complete calibration procedure.
55
22480 (10/01)
Technical Manual
A Terex Company
Hopper
Main
Keyswitch
CONTROL Hopper
46 Wings
1
15 A
12 VDC
Raise
65
Raise Sol.
Lower
66
Lower Sol.
HOPPER WINGS DO NOT RAISE

If light is ON:
If NO light:
HOPPER WINGS DO NOT LOWER
If light is ON:
If NO light:
56
22480 (10/01)
Technical Manual
A Terex Company

Main
Keyswitch
Control
1
12 VDC
Optional
46 Truck Hitch
15 A
Engage
61
Engage Sol.
Release
62
Release Sol.
TRUCK HITCH DOES NOT ENGAGE

If light is ON:
If NO light:
TRUCK HITCH DOES NOT RELEASE
If light is ON:
If NO light:
57
22480 (10/01)
Technical Manual
A Terex Company
Frame Raise
Main
Keyswitch
Control
Rear
Frame
46
15 A
12 VDC
3
Raise
70
Raise Sol.
Lower
71
Lower Sol.
REAR FRAME DOES NOT RAISE

If light is ON:
If NO light:
REAR FRAME DOES NOT LOWER
If light is ON:
If NO light:
58
22480 (10/01)
Technical Manual
A Terex Company
LH Flow Gate
Main
Keyswitch
12 VDC
3
Control
46
15 A
Power
LH
Gate
30 A
Raise
103
Lower
104
K16
K16
100
100
K15
K15
101 YEL
102
RED 102
K16
3
3
LH Gate
Motor 3
3
101
K15
LEFT GATE DOES NOT GO UP

Main key switch ON, engine RUNNING, control circuit breaker SET, power circuit breaker SET.
LH gate switch to UP. Check for mechanical bind on motor or gate.
101 to 102 .. If no voltage, defective K15 relay or faulty ground.
101 to 102 .. LH motor leads.
LEFT GATE DOES NOT GO UP
46 to 3 ........ If no voltage, defective Control circuit breaker.
LH Gate switch to DOWN. Check for mechanical bind on motor or gate.
102 to 101 .. LH motor leads.
59
22480 (10/01)
Technical Manual
A Terex Company
RH Flow Gate
Main
Keyswitch
1
12 VDC
3
Control
1
46
RH
Gate
15A
Raise
107
Lower
108
Power
1
100
K18
K18
100
30A
K17
K17
105
YEL
106
RED 106
K18
3
3
RH Gate
Motor
3
3
105
K17
RIGHT GATE DOES NOT GO UP

RH gate switch to UP. Check for mechanical bind on motor or gate.
105 to 106 .. RH motor leads:
RIGHT GATE DOES NOT GO DOWN
1 to 3 .......... If no voltage, defective main keyswitch.
RH Gate switch to DOWN. Check for mechanical bind on motor or gate.
106 to 105 .. RH motor leads:
60
22480 (10/01)
Technical Manual
A Terex Company

Main key switch ON, control circuit breakers SET.
Ensure flow switch is clean and moves freely before proceeding.
Flow switch in down position (not contacting material)
Left Side
Right Side
61
22480 (10/01)
Technical Manual
A Terex Company

ALARM CANNOT BE SILENCED
89 to 3 ........ (at switch) If no voltage, loose wire
Push alarm silence switch
89B to 3 ..... If no voltage, defective alarm silence switch
89B to 3 ..... If voltage, defective alarm silence relay
ALARM CAN ONLY BE SILENCED WHILE SWITCH IS HELD CLOSED
Release alarm silence switch
If alarm continues to sound, defective alarm silence relay or loose wire
62
22480 (10/01)
Technical Manual
A Terex Company

Alarm will not sound unless: At least 1 No Flow Light is ON, Screed in LOWER, Paver moving
FORWARD, and Alarm Switch is ON.
Flow switch in down position (not contacting material), Brake RELEASED, Travel in FORWARD,
Screed Lift in LOWER, and Alarm Switch ON.
Left Side
Right Side
63
22480 (10/01)
Technical Manual
A Terex Company

64
22480 (10/01)
Technical Manual
A Terex Company
Screed Lift
Main
Keyswitch
Control
1
46
Screed
Lift
15 A
12 VDC
Raise
63
Raise Sol.
64
Lower Sol.
Lower
SCREED DOES NOT RAISE

If light is ON:
If NO light:
SCREED DOES NOT LOWER
If light is ON:
If NO light:
65
22480 (10/01)
Technical Manual
A Terex Company
Screed Assist

Screed lift switch to LOWER, screed assist switch ON.
46 to 3 ........ If no voltage, defective engine stop/start switch.
64 to 3 ........ If no voltage, defective screed lift switch.
33 to 3 ........ If no voltage, defective screed assist switch.
If voltage, check ground wire from solenoid to ground for bad connection.
Check for magnetic field with small screwdriver at top of solenoid coil.
If no magnetic field, defective screed assist solenoid.
If system checks OK using above checks but system is not controlling screed properly,
refer to hydraulic troubleshooting or adjustment procedures.
66
22480 (10/01)
Technical Manual
A Terex Company
Power Main Crown

Main
Keyswitch
Control
46
1
15 A
Main
Crown
12 VDC
Increase
189
Increase Sol.
Decrease
190
Decrease Sol.
CROWN DOES NOT INCREASE

If light is ON:
If NO light:
CROWN DOES NOT DECREASE
If light is ON:
If NO light:
67
22480 (10/01)
Technical Manual
A Terex Company
LH Screed Extend Stretch 20 & Fastach 10

Hydraulic Strike-Off

If light is ON:
If NO light:
If light is ON:
If NO light:
68
22480 (10/01)
Technical Manual
A Terex Company
RH Screed Extend Stretch 20 & Fastach 10


If light is ON:
If NO light:
If light is ON:
If NO light:
69
22480 (10/01)
Technical Manual
A Terex Company
LH Screed Slope Stretch 20 & Fastach 10


If light is ON:
If NO light:
If light is ON:
If NO light:
70
22480 (10/01)
Technical Manual
A Terex Company
RH Screed Slope Stretch 20 & Fastach 10


If light is ON:
If NO light:
If light is ON:
If NO light:
71
22480 (10/01)
Technical Manual
A Terex Company
LH Match Height
Stretch 20

If light is ON:
If NO light:
If light is ON:
If NO light:
72
22480 (10/01)
Technical Manual
A Terex Company
RH Match Height
Stretch 20

If light is ON:
If NO light:
If light is ON:
If NO light:
73
22480 (10/01)
Technical Manual
A Terex Company
Vibrators
Main
Keyswitch
12 VDC
Note: Closed in forward (Travel Control)

Control
46
1
15 A
Brake
Engage
34
Release
Vibrators
Off
47
50
Vibrator Sol.
On
Forward L.S.

Vibrator switch ON, brakes RELEASED, travel lever(s) FORWARD.
Check DIN connector for light. If light is ON:
Check pin 2 to GND pin on DIN connector for loose or bad connection.
If NO light:
47 to 3 ........ If no voltage, defective limit switch(s) on control handle(s).
50 to 3 ........ If no voltage, defective vibrator switch.
If voltage but no light, check ground jumper pin 2 to GND pin for loose or bad connection.
If good connection, check solenoid coil resistance. It should be approximately 6 ohms.
VIBRATORS WILL NOT STOP
Vibrator switch OFF.
50 to 3 ....... If voltage present, defective vibrator switch.
If no voltage, defective vibrator solenoid valve.
74
22480 (10/01)
Technical Manual
A Terex Company
LH Main Burner #1
Main
Keyswitch
1
12 VDC
0

Burner
1
115
60A
115
Fuel Pump
Off
On
Fan No.1
Off
LH Main Burner (No.1)

116
116
118
Glow Plug No.1

118
On
115
117
117
Fuel Pump Motor

3
Fan Motor No.1
Glow Plug No.1
NO BURNERS LIGHT
1 to 3 .......... If no voltage, defective main keyswitch
118 to 3 ...... If no voltage, defective glow plug push bottom or cable to glow plug.
If voltage, but glow plug does not warm, defective glow plug.
75
22480 (10/01)
Technical Manual
A Terex Company
RH Main Burner #2
Main
Keyswitch
1
12 VDC
0
Burner
1
115
60A
115
Fuel Pump
Off
On
Fan No.2
Off
RH Main Burner (No.2)

126
126
128
Glow Plug No.2

128
On
115
117
117
Fuel Pump Motor

3
Fan Motor No.2
Glow Plug No.2
NO BURNERS LIGHT
RIGHT BURNER FAN DOES NOT OPERATE
76
22480 (10/01)
Technical Manual
A Terex Company
LH Ext. Burner #3
Main
Keyswitch
1
12 VDC
0

Burner
1
115
60A
115
Fuel Pump
Off
On
Fan No.3
Off
Lt. Ext. Burner (No.3)

136
136
138
Glow Plug No.3

138
On
115
117
117
Fuel Pump Motor

3
Fan Motor No.3
Glow Plug No.3
NO BURNERS LIGHT
77
22480 (10/01)
Technical Manual
A Terex Company
RH Ext. Burner #4
Main
Keyswitch
1
12 VDC
0
Burner
1
115
60A
115
Fuel Pump
Off
On
Fan No.4
Off
RH Ext. Burner (No.4)

146
146
148
Glow Plug No.4

148
On
115
117
117
Fuel Pump Motor

3
Fan Motor No.4
Glow Plug No.4
NO BURNERS LIGHT
RIGHT BURNER FAN DOES NOT OPERATE
78
22480 (10/01)
Technical Manual
A Terex Company
Rear Frame Compensator Adjustment

1) Raise or lower frame to about mid range.

2) While holding Comp Switch, adjust pot of Frame Oscillator Module for no net Raise or Lower.
Clockwise rotation on pot will cause frame to raise.
Counter-clockwise rotation on pot will cause frame to lower.
Adjustment must be done between full up and full down on the frame.
3) If properly adjusted, the frame will raise slightly immediate after Comp switch is actuated then
stabilize at a "fixed" position.
79
22480 (10/01)
Technical Manual
A Terex Company
80
22480 (10/01)
PAVER
TECHNICAL MANUAL
400 & 500 Series

Hydraulic Section
Technical Manual
A Terex Company
Table of Contents
400 & 500 Series Hydraulic Section
Cedarapids Lubricants ......................................................................................................... 1
Pressure Test Kit .................................................................................................................. 2
Component Location Map .............................................................................................. 3 - 8
Throttle ................................................................................................................................ 9
Brake System ..................................................................................................................... 11
Steering ....................................................................................................................... 12 - 13
Truck Hitch (Optional) ............................................................................................... 14 - 15
Hopper Wings ............................................................................................................. 16 - 17
Track Tension - Steel Track Pavers ............................................................................. 18 - 20
Track Tension - Rubber Track Pavers ......................................................................... 21 - 26
Frame Raise - CR451/CR551 ..................................................................................... 28 - 29
Frame Raise - CR461/CR561 ..................................................................................... 30 - 31
Screed Lift - Fastach Screeds ..................................................................................... 32 - 33
Screed Assist - Stretch 20 Screeds .............................................................................. 34 - 35
Tow Point .................................................................................................................... 36 - 37
Main Screed Power Crown ......................................................................................... 38 - 39
Screed Extend - Fastach 10' Screed ............................................................................ 40 - 41
Screed Extend - Stretch 20 Screed.............................................................................. 42 - 43
Sloping Strike-Off: Fastach 10' Screed ...................................................................... 44 - 45
Screed Extension Slope - Stretch 20 Screed ............................................................... 46 - 47
Match Height - Stretch 20 Screed & EZ Screed ......................................................... 48 - 49
Vibrator - Fastach 10' Screed ............................................................................................. 50
Vibrator - Stretch 20 Screed .............................................................................................. 51
Slat Conveyor Feed ............................................................................................................ 52
Remix Spreading Auger..................................................................................................... 53
Remix Delivery Augers .............................................................................................. 54 - 55
Travel/Pave (P2) - Slat Conveyor Pavers ........................................................................... 57
Traction System/Differential Lock - Slat Conveyor Pavers ........................................ 58 - 59
Travel/Pave (P2) - Remix Pavers ....................................................................................... 61
Traction System/Differential Lock - Remix Pavers .................................................... 62 - 63
Front Wheel Assist (Optional) ........................................................................................... 64
4 Kw Hydraulic Drive Generator ...................................................................................... 65
Remote Oil Cooler Driven From Dedicated Pump ........................................................... 66
Remote Oil Cooler Driven From Vibrator Pump .............................................................. 67
400 & 500 Series Hydraulic Troubleshooting
22481 (11/01)
Technical Manual
A Terex Company
Table of Contents
400 & 500 Series Hydraulic Section
ii
22481 (11/01)
Greases
Hydraulic
Oils
EP
Gear Oils
Non-EP
Gear Oils
Starfak 2201
Starfak 2202
Multifak EP 2
Starfak 00
Multifak HD 00
Multifak EP 1
Pinnacle 68
Rando HD 68
Pinnacle 32
Rando HD 32
Pinnacle 46
Pinnacle EP 320
Meropa 320
Rando HD 46
Pinnacle EP 220
N/A
Meropa 100
Meropa 220
N/A
Meropa 68
Pinnacle EP 150
Pinnacle 220
Regal R&O 220
Meropa 150
Pinnacle 150
Regal R&O 150
Pinnacle 68
Regal R&O 68
Pinnacle 100
Pinnacle 46
Regal R&O 46
Regal R&O 100
Synthetic
Mineral
Texaco
Alvania EP 2
Alvania EP 1
Alvania EP 00
Tellus 68
Tellus 46
Tellus 32
Omala 320
Omala 220
Omala 150
Omala 100
Omala 68
Molina 220
Molina 150
Molina 100
Turbo T 068
Turbo T 046
Mineral
Synthetic
Albida SLC 220
N/A
Retinax TL 00
Tellus HD 68
Tellus HD 46
Tellus HD 32
Omala HD 320
Omala HD 220
N/A
N/A
N/A
Omala RL 220
Omala RL 150
Omala RL 100
Omala RL 68
Omala RL 46
Shell
Mobilux EP 2
Mobilux EP 1
Mobilux EP 023
DTE 26
DTE 25
DTE 24
Mobilgear 632
Mobilgear 630
Mobilgear 629
Mobilgear 627
Mobilgear 626
Spartan EP 320
Mobilgear
SHC 320
Mobilith SHC 220
N/A
Mobilith SHC 007
SHC 526
SHC 525
Lidok EP 2
Lidok EP 1
Lidok EP 000
Nuto H 68
Nuto H 46
Nuto H 32
Spartan EP 220
Mobilgear
SHC 220
SHC 524
Spartan EP 150
Spartan EP 100
Spartan EP 68
Teresstic 220
Teresstic 150
Teresstic 100
Teresstic 68
Teresstic 46
Mineral
Dura-Lith EP 2
Dura-Lith EP 1
Ulti-Plex Synthetic
EP 1.5
Ulti-Plex Synthetic
EP 1.5
N/ A
Rykon Premium
Oil 68*
Rykon Premium
Oil 46*
Rykon Premium
Oil 32*
Tegra Synthetic
Gear EP 320
Tegra Synthetic
Gear EP 220
Tegra Synthetic
Gear EP 150

Unirex SHP 220
Unirex SHP 460
Dura-Lith EP 00
Hydraulic Oil
AW 68
Teresstic
SHP 68
Unirex SHP 00
Hydraulic Oil
AW 46
Hydraulic Oil
AW 32
Teresstic
SHP 32
Teresstic
SHP 46
Gear Compound
EP 320
Gear Compound
EP 220
Spartan Synthetic
EP 320
Spartan Synthetic
EP 220
Gear Compound
EP 150
Gear Compound
EP 100
Spartan Synthetic
EP 100
Spartan Synthetic
EP 150
N/A
Gear Compound
EP 68
N/A
N/A
N/A
Industrial Oil 220
Teresstic
SHP 220
N/A
N/A
Industrial Oil 150
Industrial Oil 100
N/A
N/A
Synthetic
Teresstic
SHP 150
Teresstic
SHP 100
Industrial Oil 68
Industrial Oil 46
Teresstic
SHP 68
Mineral
Teresstic
SHP 46
Chevron
Synthetic
Exxon
Mobilgear
SHC 150
N/A
N/A
SHC 630
SHC 629
DTE Oil
Extra Heavy
DTE Oil BB
SHC 627
SHC 626
DTE Oil
Heavy Medium
DTE Oil Heavy
N/A
Synthetic
DTE Oil Medium
Mineral
Mobil
Technical Manual
A Terex Company
22481 (11/01)
Technical Manual
A Terex Company
Pressure Test Kit

45865-001-41
45865-002-27
45865-002-33
Gauge
Gauge
Guage
0-6000-PSI
0-100 PSI
0-600 PSI
45080-527-05
Adapter Gauge
Not Illustrated
7430-416
7430-344
7430-345
45080-527-14
45080-527-07
45080-527-15
Hose 36"
Hose 10'
45080-527-17
45080-527-18
45080-527-16
45080-527-031
45080-527-061
45080-527-04
Fitting
Tee
Tee
Test Hose Union
#4 FS JIC Test Port

#6 FS JIC Test Port
#8 FS JIC Test Port
8" NPT Test Port

4" NPT Test Port
#4 SAE Test Port
22481 (11/01)
Technical Manual
A Terex Company

Fastach 10'
L7
L6
L1
L2
L9
L8
L10
L5
L3
L4
L11
L1 ...............
L2 ...............
L3 ...............
L4 ...............
L5 ...............
L6 ...............
L7 ...............
L8 ...............
L9 ...............
L10 .............
L11 .............
LH screed extend valve

LH screed slope valve
LH slope cylinder
LH extend cylinder
Crown solenoid valve
Crown motor
RH screed extend valve
RH screed slope valve
RH slope cylinder
RH extend cylinder
Vibrator motor
22481 (11/01)
Technical Manual
A Terex Company

Fastach II
3
2
7
4
1
10
5
Cedarapids
EXTEND
FEED
OVER
RIDE
STOP
SLOPE
MATCH
HEIGHT
BERM
TOWPOINT
MAN
MAN
SETUP
AUTO
HORN
Cedarapids
EXTEND
FEED
OVER
RIDE
STOP
SLOPE
E
TEMPERATUR
RH MAIN
MATCH
RH EXT
HEIGHT
LH MAIN
LH EXT
CONTROL
HEAT
OUTLET
HEAT
OUTLET
HEAT
HEAT
HEAT
BERM
GENERATOR
ON
OFF
ON
OFF
TOWPOINT
MAN
MAN
SETUP
AUTO
HORN
HORN
CROWN
E
INCREAS
DECREAS
11
12
14
1 .................
2 .................
3 .................
4 .................
5 .................
6 .................
7 .................
8 .................
9 .................
13
LH berm valve
LH match height valve
LH match height motor
RH match height valve
RH berm valve
10 ...............
11 ...............
12................
13 ...............
14 ...............
Not Shown .............
Not Shown .............
Not Shown .............
Not Shown .............
4
RH match height motor

RH Extension Vibrator Motor
RH Main Screed Vibrator motor
LH Main Screed Vibrator motor
LH Extension Vibrator Motor
Crown motor
LH slope motor
RH slope motor
22481 (11/01)
Technical Manual
A Terex Company

Stretch 20
L14
L12
L16
L13
L17
L15
L19
L20
L18
L21 L23
L22
L24
L24
L24
L12 .............
L13 .............
L14 .............
L15 .............
L16 .............
L17 .............
L18 .............
L19 .............
L20 .............
L21 .............
L22 .............
L23 .............
L24 .............

LH match height valve
RH match height valve
LH match height motor
LH slope motor
Crown motor
RH match height motor
RH slope motor
Vibrator motor
22481 (11/01)
Technical Manual
A Terex Company

Rear Bulkhead
L30
L33
L34
L27
L31
L28
L29
L26
L25
L25 ..........
L26 ..........
L27 ..........
L28 ..........
L29 ..........
L30 ..........
L31 ..........
L33 ..........
L34 ..........
LH traction high pressure filter

LH conveyor high pressure filter
Vibrator solenoid valve
Brake solenoid valve
Travel/Pave solenoid valve
Screed lift solenoid valve
Frame raise solenoid valve (rubber)
RH traction high pressure filter
RH conveyor high pressure filter
22481 (11/01)
Technical Manual
A Terex Company

Rear Bulkhead (Remix Paver)
8
7
6
11
10
9
4
1
5
3
2
1 ..............
2 ..............
3 ..............
4 ..............
5 ..............
6 ..............
7 ..............
8 ..............
9 ..............
10 ............
11 ............
LH spreading auger charge filter

LH traction charge filter
Delivery auger charge filter
Brake solenoid valve
Travel/Pave solenoid valve
Vibrator solenoid valve
Screed lift solenoid valve
Frame raise solenoid valve (rubber)
RH delivery auger charge filter
RH traction high pressure filter
RH spreading auger charge filter
22481 (11/01)
Technical Manual
A Terex Company

Front Bulkhead
L35
L37
L36
L39
L38
L40
L35 .............
L36 .............
L37 .............
L38 .............
L39 .............
L40 .............
L41 .............
Front wheel assist solenoid valve

LH pull point solenoid valve
Truck hitch solenoid valve
LH front wheel assist 5-way valve
Hopper solenoid valve
RH pull point solenoid valve
RH front wheel assist 5-way valve
L41
22481 (11/01)
Technical Manual
A Terex Company
Throttle
FULL
THROTTLE
CYLINDER
IDLE
SOLENOID
VALVE
LH CONVEYOR
CHARGE PUMP
>> SUCTION >>
10
FILTER
2
HYDRAULIC TANK
ENGINE WILL NOT COME TO FULL THROTTLE

Engine running
Throttle switch to FULL THROTTLE.
Check left conveyor to see if it operates. If it does not, refer to conveyor troubleshooting.
Watch throttle cylinder. If it extends, refer to engine troubleshooting.
Place a small screw driver next to the throttle solenoid. If no magnetic field is felt, refer to electrical.
If a magnetic field is felt, throttle switch to IDLE.
Remove hose from the rod end of the throttle cylinder.
If oil comes out of the rod end port, blown packing.
If no oil comes out rod end port, check flow restrictor for being plugged.
If flow restrictor is not plugged, defective solenoid.
ENGINE GOES TO FULL THROTTLE WITH SWITCH IN IDLE POSITION
Refer to electrical troubleshooting.
Check RH conveyor charge pressure. If no pressure refer to conveyor troubleshooting.
(Charge pressure is required to hold throttle cylinder in Idle position.)
22481 (11/01)
Technical Manual
A Terex Company
10
22481 (11/01)
Technical Manual
A Terex Company
Brake System
TO TRACTION PUMP
TORQUE
HUB
NOTE: Pressure supplied by

common charge pump.
BRAKE
ASSEMBLY
TO TRACTION PUMP
HYDRAULIC
MOTOR
COOLER
CHARGE PRESSURE
TANK
RANGE & BRAKE LINE TO
OTHER TORQUE HUB
BRAKE SYSTEM
The brakes are SPRING APPLIED and HYDRAULIC RELEASED. Pressure is supplied by the
conveyor or traction charge pump. A brake solenoid valve when energized allows pressure to be
applied to the brake piston, allowing the brakes to release.
Brake switch to RELEASE.
Travel speed dial set above (2).
Travel engage/disengage switch to ENGAGE.
Check brake solenoid DIN connector for light. If NO light refer to electrical troubleshooting.
If light is ON.
(1) Refer to electrical for checking ground connection.
(2) Install a 600 psi gauge on RH conveyor or traction charge pump (depending on model) high
pressure test port. (Do not engage conveyor or traction.) Pressure should be 218 to 265 psi for
the brakes to release. If low refer to conveyor or traction system.
(3) Install a 600 psi gauge between brake solenoid and brake hose.
If no pressure or low, check flow orifice for obstruction or defective solenoid valve.
(4) If correct pressure, check brake assembly for warped disks.
EMERGENCY BRAKE RELEASE
If machine has to be moved and the brakes are locked, refer to instruction decal located on the tool box
lid of the paver.
11
22481 (11/01)
Technical Manual
A Terex Company
Steering
TEST
PORT

*Max Flow (GPM): 8.4 - 11.0
>> RETURN >>
200 MESH
STRAINER
<< CASE DRAIN <<
>> SUCTION >>
PRESSURE FILTER
AUXILIARY SYSTEM
HYDRAULIC TANK
Check other auxiliary functions for operation (screed raise/lower, any extend/ retract function, pull
point functions, etc.) If other functions work, this indicates the problem is only in the effected
function and the general auxiliary system is working. If paver is equipped with SCREED ASSIST,
check manual dump needle valve to insure it is closed. If no other function is working, install a
3000 psi gauge in the test port.
If pressure can not be obtained, check and clean suction strainer, check suction hose for loose fittings,
damaged hose, and obstructions.
STEERING WILL NOT TURN LEFT OR RIGHT
Remove the hose going to the left steering cylinder base end. Install a 3000 psi gauge on the end of
the hose. Turn steering wheel to the left, pressure reading should be system pressure.
Remove the hose going to the right steering cylinder base end. Install a 3000 psi gauge on the end of
the hose. Turn steering wheel to the right, pressure reading should be system pressure.
If problem occurs only after cylinders have been fully extended or retracted, check rephase ports
Check ball not seating.
12
22481 (11/01)
Technical Manual
A Terex Company
Steering
STEERING WHEELS DRIFT APART
It is normal for the wheel to drift apart over a period of time. To get them back in unison, steer against
limits in either direction. If the wheels drift apart quickly, preform checks listed above. The cause is
usually leaking piston packing on one or both steering cylinders.
STEERING CYLINDER TEST
With the steering cylinders at mid-stroke, remove the rod end hoses. Cap the rod end ports of the
cylinders and plug the hoses. Turn the steering wheel to the left. If the right steering cylinder rod
starts to move outward then the packing of the right cylinder may be bad and need to be replaced, or
the inner wall of the cylinder tube has a scratch or gouge in it, allowing the hydraulic fluid to go
around the packing. Remove the cylinder and replace it.
Turn the steering wheel to the right. If the left steering cylinder rod starts to move outward, then the
packing of the left steering cylinder may be bad and need to be replaced, or the inner wall of the
cylinder tube has a scratch or gouge in it, allowing the hydraulic fluid to go around the packing.
Remove the cylinder and replace it.
Always remember to flush the hydraulic steering circuit before replacing the hoses onto the cylinders.
This is done by coupling the hoses of each cylinder together and turning the steering wheel in one
direction for several rotations, and then in the other direction for several rotations.
13
22481 (11/01)
Technical Manual
A Terex Company

Truck Hitch
(Optional)
Pressure Reducing Valve

900 PSI
2050
RPM
.913
CID
Solenoid Valve
200 Mesh
Strainer
<<< Case Drain <<<
<<< Return <<<

*Max Flow (GPM): 8.4 - 11.0
>>> Suction >>>
Manifold LH Front
Auxiliary Pump
Test Port
Test Port
2500 PSI
Holding Valve
<<< Pressure <<<
Pressure Filter
AUXILIARY SYSTEM
Hydraulic Tank
Check other auxiliary functions for operation. (screed raise/lower, any extend/ retract function, pull
point functions and etc.) If other functions work, this indicates the problem in only in the effected
function and the general auxiliary system is working. If paver is equipped with SCREED ASSIST,
check manual dump needle valve to ensure it is closed.
If no other function is working, install a 3000 psi gauge in the test port. Refer to pressure setting
above for each series of paver. If pressure can not be obtained, check and clean suction strainer,
check suction hose for loose fittings, damaged hose, and obstructions.
TRUCK HITCH WILL NOT EXTEND
Manual needle valve open (this controls cylinder speed an needs to be open to some extent)
Truck hitch switch to the EXTEND position.
If light is ON:
(2) Press MANUAL OVERRIDE button on solenoid valve. If truck hitch cylinder extends, defective solenoid.
If truck hitch cylinder does not extend:
(1) Install a 3000 psi gauge in-line, between hose going to rod end of cylinder and manifold block.
If full pressure reading but no cylinder movement plugged or defective holding valve.
(2) Retract cylinder all the way, disconnect the hose going to the BASE END of the cylinders at
the manifold. Carefully push the switch to RETRACT. If fluid comes out of the hose going to
the base end of the cylinder, check cylinder for blown piston packing.
14
22481 (11/01)
Technical Manual
A Terex Company

TRUCK HITCH WILL NOT RETRACT
Truck hitch switch to the RETRACT position.
If light is ON:
(2) Press MANUAL OVERRIDE button on solenoid valve. If truck hitch retracts, defective solenoid.
If truck hitch does not retract:
(2) Extend cylinder all the way, disconnect the hose going to the ROD END of the truck hitch cylinders
at manifold. Carefully push switch to EXTEND. If fluid comes out of the hose going to the truck
hitch cylinders, check cylinder for blown piston packing.
If no fluid, install a 3000 psi gauge on test port of the truck hitch valve stack.
Pressure should be 900 psi.
If no pressure, defective solenoid.
If low pressure, adjust.
TRUCK HITCH DRIFTS OUT
Install a 3000 psi gauge on test port of the truck hitch valve stack.
Truck hitch switch to RETRACT.
Pressure should be 900 psi at end of stroke.
If trucks are not staying aligned in front of the paver they can force oil over relief, causing the hitch to open.
If this is not the case proceed with checks.
Extend cylinders all the way, disconnect the hose going to the ROD END of the truck hitch cylinders at
manifold.
Carefully push switch to EXTEND. If fluid comes out of the hose going to the truck hitch cylinders, check
15
22481 (11/01)
Technical Manual
A Terex Company
Hopper Wings
Hopper Wings
<<< Pressure <<<
Pressure Filter
.913
CID
Solenoid Valve
Throttle Valve
Auxiliary Pump
Holding Valve
2050
RPM
2500 PSI
Restrictor
Test Port
200 Mesh
Strainer
<<< Case Drain <<<
<<< Return <<<

*Max Flow (GPM): 8.4 - 11.0
>>> Suction >>>
Manifold RH Front
AUXILIARY SYSTEM
Hydraulic Tank
the general auxiliary system is working. If paver is equipped with SCREED ASSIST, check manual
dump needle valve to insure it is closed.
If no other function is working, install a 3000 psi gauge in the test port.
If pressure can not be obtained, check and clean suction strainer, check suction hose for loose fittings ,
damaged hose, or obstructions.
HOPPER WINGS WILL NOT RAISE
Hopper wing switch to the RAISE position.
If light is ON:
(2) Press MANUAL OVERRIDE button on solenoid valve. If hopper wings raise, defective solenoid.
If hopper wings DO NOT raise:
valve.
(2) Disconnect the hose going to the base of the hopper cylinders at manifold. Carefully push the
hopper switch to RAISE. If fluid comes out of the hose, check cylinders for blown piston packing.
16
22481 (11/01)
Technical Manual
A Terex Company
Hopper Wings
HOPPER WINGS WILL NOT LOWER
Hopper wing switch to the LOWER position.
If light is ON:
If hopper wings lower, defective solenoid.
If hopper wings do not lower, carefully crack the hose going to the base of the hopper cylinders.
If hopper wings do not start to lower, check for bent or damaged cylinders.
If hopper wings lower as fluid is bleed out of the hose, allow to go completely down.
(1) Install a 3000 psi gauge in-line between the hose going to the base end of the cylinder and the
manifold block.
(2) Raise the hopper wings, then try to lower. If full pressure reading, but no cylinder movement,
plugged or defective holding valve or plugged flow restrictor.
17
22481 (11/01)
Technical Manual
A Terex Company
Track Tension
Steel Track Pavers
Tensioning Track
The track is designed to be virtually maintenance

free. Proper cleaning and lubrication at the end of
each paving day will maintain trouble free operation.
However, neglect of the tracks can be expensive.
Every time paver is cleaned, the track pins should be
sprayed with light oil to lubricate them preventing
them from rusting and binding.
If the track looks like it may be getting loose, it can

be tested by placing a board or straight edge on the
track between the front idler and the first top roller.
If the gap between the bottom of the board and the
top edge of the track is greater than 34", the track
tension must be adjusted. (Figure 2)
The Grayhound track paver uses a tension cylinder

mounted above the final drive that maintains a
constant volume of pressurized oil to the track
adjusting cylinders. When the track encounters an
obstacle, the system allows the tensioning idler to
recoil rather than stretch or break the track. When the
obstacle is cleared the system returns to the previous
track tension adjustment.
3/4"
Figure 2 - Checking Track Tension
Important: Perform track tension checks

and adjustments when the paver is at running
temperature. Adjusting track tension when
the paver is cold could lead to over-tensioning
of the track.
1
3
Adjust track tension as follows:
4
5
From traction S
charge pump
1) Start the engine.
2) Open the needle valve slowly to allow the

track to retension. (Figure 4)
3) Drive the paver forward and backward slowly.
4 - Needle valve
1 - Counterbalance valve
2 - Rodless piston cylinder 5 - Idler tension cylinders
3 - Tensioning cylinder assy.
Warning: Be very careful when reaching

over the moving track. Keep feet and loose
clothing away from the moving track and
rollers.
Figure 1 - Track tension hydraulic circuit
The track tensioning cylinder assembly consists of a

cylinder with a rodless piston, a needle valve, and a
counterbalance valve. (Figure 1) The piston keeps
the oil from the idler tensioning cylinders separated
from the main oil supply. When the track encounters
an obstacle, it forces oil from the idler cylinders into
the bottom side of the rodless cylinder. When the
obstruction is cleared, pressurized oil from the
traction charge pump forces the tensioning cylinder
down which forces idler cylinders to move back to
original position.
4) Stop the paver and close needle valve.

5) A properly tensioned track should have a 38" to
1
2" gap between a straightedge and the track.
(Figure 3)
3/8" to 1/2"
Figure 3 - Proper Track Tension
The needle valve is used during track tensioning to

bring the volume of oil on the bottom side of the
rodless cylinder back to the proper level. The
counterbalance valve allows oil to flow freely from
the top side of the rodless cylinder to the tank when
the track encounters an obstacle.
Warning: Overtightening the track can

cause serious damage to the track, idler or
drive.
18
22481 (11/01)
Technical Manual
A Terex Company
Track Tension
Steel Track Pavers
Track over-pressurizing
8) Turn the engine off and reconnect the hydraulic

line to the "T" port.
If the track adjusting system is over-pressurizing

during operation, the following procedure must be
performed. It is a good idea to perform this check
once each season to verify the tensioning cylinder is
in good condition.
Track Relief Pressure

In addition to adjusting the track tension, the track
relief pressure should be checked at least once each
season. Check track relief pressure as follows:
Notice: Do not run the paver while the system

is over-pressurized. Running with an overpressurized system could damage the track
and sprockets.
1) Perform "Track over-pressurizing" procedure

above.
2) Stop engine.
"T" Port
"T" Port
Needle
Valve
Needle
Valve
Test Port
Counter-Balance
Valve
Tension
Cylinder
Figure 5 - Checking Track Relief Pressure Setting
3) Close needle valve.

4) Bleed off pressure on tension cylinder by
installing pressure gauge hose only onto test
port and draining fluid into a bucket.
Figure 4 - Bottoming Tension Cylinder


2) Attach a drain line to the "T" port and run the

other end into a bucket.
6) Install a 3000 PSI gauge on the hose which is

connected to the tension cylinder test port.
3) Close the needle valve by rotating clockwise.

4) Start the engine and run at full throttle.
7) Connect a hand operated hydraulic pump to

the "T" port on the tension cylinder.
5) If the track was tensioned properly, no oil will

flow into the bucket.
6) If only a small amount of oil drains into the

bucket, the tension cylinder piston and needle
valve are working properly and track will
tension properly.
9) Pump the hand pump to apply pressure to the

counter balance valve. The counter balance
valve will relieve the pressure generated by the
pump at the track relief pressure setting. Note
the pressure on the gauge when the counter
balance valve relieves.
7) If oil continues to flow into the bucket, the

tension cylinder piston or needle valve is
leaking and must be repaired.
19
22481 (11/01)
Technical Manual
A Terex Company
Track Tension
Steel Track Pavers
10) The track relief pressure setting should be
2050 psi +/- 100 psi. If pressure is outside this
range, the counter balance valve requires
adjustment.
11) To adjust track relief pressure:
a) Loosen jam nut on counter balance valve.
b) Rotate the valve counterclockwise to
increase the pressure setting. Clockwise
rotation will decrease the pressure setting.
c) Tighten jam nut.
12) If the pressure can not be set, the counter
balance valve is defective and must be replaced.
Note - Replacement counter balance valves
are factory set and should not require
adjustment.
20
22481 (11/01)
Technical Manual
A Terex Company
Track Tension
Rubber Track Pavers

The rubber track hydraulic system maintains a constant volume of pressurized oil to the piston ends of
track tension cylinders. Each track is independent
and supplied by the auxiliary pump.
When the paver is started, oil is directed from the

auxiliary pump to the pressure reducing valves. Oil
pressure is reduced from 2500 psi to 1900 psi and
directed on to the take-up valves where two separate
sections, a charging/isolation cartridge and a direction sensing cartridge, route the oil to the track
tension shut-off valves connected to the track
tensioning cylinders. A check valve and accumulator for each track are placed between the take-up
valve charging/isolation cartridge and the piston
side of the track tension shut-off valve. The accumulator is pre-charged with dry nitrogen at 1800 psi to
allow the track tensioning cylinders to retract and
return if a severe impact is encountered.
REVERSE
LH TRACTION DRIVE
LH TRACTION PUMP
FORWARD
AUX
SENSING LINES
FROM TRACTION
PUMP
SENSING LINES
FROM PARKING
BRAKES
FROM AUXILIARY PUMP
AUX
SENSING LINES
FROM TRACTION
PUMP
FORWARD
RH TRACTION DRIVE
RH TRACTION PUMP
REVERSE
Figure 6 - Rubber Track Hydraulic System Schematic

21
22481 (11/01)
Technical Manual
A Terex Company
Track System Components

Rubber Track Pavers
Track Tension
Shut-off Valve
Take-up Valve
Track
Rotated
90 for
Clarity
Pressure
Reducing
Valves
Check Valve
Front
Accumulator
Figure 7 - Rubber Track Hydraulic System Components
22
22481 (11/01)
Technical Manual
A Terex Company
Track Hydraulic System Tests

Rubber Track Pavers
Checking Rubber Track Hydraulic System
The rubber track hydraulic system contains components which will automatically maintain track tension. To check out the system, follow the steps
below:
Auxiliary System Pump Pressure
Adjusting
First check the auxiliary pump pressure compensator adjustment to be sure the system is set to
2500 +/- 100 psi. See Operation & Maintenance
Manual for this procedure.
Screws
Pressure
Reducing
Valves
Pressure Reducing Valves

Check the pressure reducing valves on each side
(Figure 8).
Test
Ports
1) Install pressure gauge (3000 psi) at each test

port.
Figure 8 - Pressure Reducing Valves

3) Pressure should read 1900 psi. If not, confirm
that the Auxiliary System Pump is putting out
2500 +/- 100 psi as described above.
4) Adjust pressure on reducing valve by loosening
jam nut on the valve cartridge, insert an allen
wrench into the adjusting screw, and turn the
screw clockwise to increase pressure, or counterclockwise to decrease pressure.
5) If 1900 psi still cannot be attained, replace pressure reducing valve.
23
22481 (11/01)
Technical Manual
A Terex Company

Rubber Track Pavers
11) If the pressure is below 1800 psi when it drops
quickly to 0 psi, re-charge the accumulator
with dry nitrogen as described in Track Tension Accumulator Pre-Charging procedure in
the Paver Technical Manual, then test again.
Track Tension Accumulator

Check pre-charge of track tension accumulators on
each side.
marked BTM on the Track Tension Shut-off
Valve.
12) If the pressure drops steadily all the way to 0

psi and re-charging the accumulator does not
work, then replace the accumulator.

3) Pressure should read 1900 to 2200 psi.
4) Shut engine off. Pressure on gauge should not
change.
Direction of
Oil Flow
5) Loosen jam nut on shut-off valve cartridge.

shut-off valve and release hydraulic pressure
while carefully watching the gauge.
Disconnect
& Plug
Accumulator
Check Valve
Hose Here
7) The pressure reading should drop off slowly

until it reaches the accumulator dry nitrogen precharge pressure. When the pressure reaches the
pre-charge point, the gauge will drop quickly to
0 psi.
Figure 9 - Track Tension Accumulator
Track Tension Check Valve and Shut-off Valve
8) The gauge reading at the point where it drops

quickly to 0 psi should be 1800 psi at 68 degrees
F. This reading may be slightly more or less
depending the ambient temperature and the hydraulic system temperature.
Check the operation of the check valve and shut-off

valve on each side.
9) If the accumulator dry nitrogen pre-charge is at

1800 psi, then tighten the shut-off valve screw
by turning it clockwise until snug on its seat.
10) Re-tighten jam nut on shut-off valve cartridge.
4) Shut off the engine.

marked BTM on the shut-off valve.
3) Pressure should read 1900 to 2200 psi.
5) Remove the hose going to the check valve and

plug the end of the hose.
24
22481 (11/01)
Technical Manual
A Terex Company

Rubber Track Pavers
Track Tensioning Cylinders

Check track tensioning cylinders on each side.
1) With engine off, remove lines from shut-off
valve to the rod ends of the cylinders.
6) Check the gauge reading to see if it drops off.

7) If the gauge reading drops off and oil is leaking
from the check valve, replace the check valve.
8) If the gauge reading drops off, no oil is leaking
from the check valve and the shut-off valve is
closed, replace the shut-off valve.
2) Cap the fittings on the shut-off valves.

9) Re-test as described above until gauge reading

does not drop off.
4) With the paver in reverse, brakes released, and

the paver moving, there should be no oil leaking
from the cylinder rod ports.
10) Re-install the hose to the check valve.
5) If oil is leaking from the cylinder(s) rod ports, the

cylinder(s) must be repaired or replaced.
BTM Port
ROD
Port
Shut-off
Cartridge
Cap
Fittings
Tensioning
Cylinders
Figure 10 - Track Tension Shut-off Valve
Remove Cylinder Rod End Lines

Figure 11 - Track Tensioning Cylinders
25
22481 (11/01)
Technical Manual
A Terex Company

Rubber Track Pavers
11) Have another person at the paver console
cycle the brake switch on and off several
times.
Track Take-up Valve

Check track take-up valve on each side.
1) Install pressure gauge (3000 psi) at test ports
marked BTM and ROD on the shut-off valve.
12) Each time the brakes are applied, you should

be able to feel the hose pulse.
13) If you cannot feel it pulse, remove the accumulator charging cartridge assembly, inspect,
clean, and re-install in valve body.
3) With the paver in travel mode, in forward, brakes

released, and the paver moving, there should be
1900 psi at the ROD port and 1900 - 2200 psi at
the BTM port.
14) Perform the above test once again.

15) If you still cannot feel a pulse in the hose,
replace the cartridge assembly in the take-up
valve.
Note: To achieve the pressure readings in

forward, some resistance/load must be
present. Travel up a slight incline if necessary. Slowly increase speed until take-up
valve shifts.
4) With the paver in reverse or stopped, brakes
released, and on level ground, there should be
1900 psi at the BTM port only.
5) Shut the engine off.
Accumulator
Charging Valve
Cartridge Assembly
6) With the engine off, the pressure on the BTM

port should hold at 1900 psi.
Track Tensioning
Valve Cartridge
Assembly
7) If the pressure bleeds off, check the shut-off

valve as described above.
8) The take-up valve charges the BTM port side of
the track tension cylinders each time the brakes
are applied. To check this operation:
10) Place your hand on the hose running to the check
valve.
Figure 12 - Track Take-up Valve
26
22481 (11/01)
Technical Manual
A Terex Company
27
22481 (11/01)
Technical Manual
A Terex Company
Frame Raise
Grayhound CR451 and CR551 Pavers
Rear Wheel Suspension
<<< Pressure <<<
Pressure Filter
<<< Return <<<

*Max Flow (GPM): 8.4 - 11.0
>>> Suction >>>
Manifold Left Rear
200 Mesh
Strainer
Auxiliary Pump
.913
CID
Solenoid Valve
2500 PSI
Holding Valve
2050
RPM
<<< Case Drain <<<
Throttle Valve
Test Port
AUXILIARY SYSTEM
Hydraulic Tank
If light is ON:
valve.
(2) Extend cylinder all the way, disconnect the hose going to the BASE END of the cylinder.
28
22481 (11/01)
Technical Manual
A Terex Company
Frame Raise
If light is ON:
valve.
FRAME DRIFTS DOWN
Carefully push the frame switch to LOWER. If fluid comes out of the fitting on the cylinder, check cylinder
29
22481 (11/01)
Technical Manual
Frame Raise
REAR WHEEL
SUSPENSION
PRESSURE
FILTER

*Max Flow (GPM): 8.4 - 11.0
TEST
PORT
2500
RPM
HOLDING VALVE
.913
CID
2500 PSI
THROTTLE VALVE
AUXILIARY
PUMP
SOLENOID VALVE
MANIFOLD LH REAR
200 MESH
STRAINER
AUXILIARY SYSTEM
HYDRAULIC TANK
If light is ON:
valve.
(2) Retract cylinder all the way, disconnect the hose going to the BASE END of the cylinder.
30
22481 Rev A (12/04)
Technical Manual
Frame Raise
If light is ON:
valve.
FRAME DRIFTS DOWN
31
22481 Rev A (12/04)
Technical Manual
A Terex Company
Screed Lift
PRESSURE FILTER
2500
RPM
.913
CID
SOLENOID VALVE
AUXILIARY PUMP
HOLDING VALVE
TEST PORT
2500 PSI
RESTRICTOR
<< PRESSURE <<
SCREED LIFT

*Max Flow (GPM): 8.4 - 11.0
200 MESH
STRAINER
<<CASE DRAIN<<
MANIFOLD LH REAR
AUXILIARY SYSTEM
HYDRAULIC TANK
functions, etc.) If other functions work, this indicates the problem is only in the effected function and
dump needle valve to insure it is closed. If no other function is working, install a 3000 psi gauge in the
test port. Refer to pressure setting above for each series of paver. If pressure can not be obtained, check
and clean suction strainer, check suction hose for loose fittings, damaged hose, and obstructions.
If light is ON:
valve.
(2) Disconnect hoses from Base end of the screed lift cylinders. Carefully push the screed lift switch
packing.
32
22481 (11/01)
Technical Manual
A Terex Company
Screed Lift
If light is ON:
33
22481 (11/01)
Technical Manual
A Terex Company
Screed Assist
with Stretch 20 Screeds
175 PSI Nitrogen
Precharge
Screed Lift
E
Pressure Filter
Holding Valve
I
T
Solenoid Valve
2500
RPM
.913
CID
<<< Case Drain <<<

>>> Suction >>>
Manifold LH Rear
Auxiliary Pump
Restrictor
Test Port
2500 PSI
D
A
<<< Pressure <<<
AUXILIARY SYSTEM
Hydraulic Tank
Check other auxiliary functions for operation, (screed raise/lower, any extend/ retract function, tow-point
Refer to pressure setting above for each series of paver. If pressure can not be obtained, check & clean
suction strainer, check suction hose for loose fittings, damaged hose, and obstructions.
If light is ON:
(2) Disconnect hoses from base end of the screed lift cylinders. Carefully push the screed lift switch
packing.
34
22481 (11/01)
Technical Manual
A Terex Company
Screed Assist
with Stretch 20 Screeds
If light is ON:
Screed lift switch in LOWER.
Screed assist switch ON.
Place a small screw driver next to the top of the screed assist solenoid valve. If no magnetic field is felt,
refer to electrical troubleshooting.
If solenoid attracts screw driver continue with checks:
Install a 2000 psi gauge in-line at the ROD end of the screed lift cylinder (either cylinder). Pressure should
read same as gauge mounted on bottom of accumulator. If pressure is lower, defective solenoid valve.
With gauge in same place, adjust screed assist pressure reducing valve clockwise.
The pressure readings should increase. If no increase, defective pressure reducing valve. The working
pressure is 200 to 600 psi on the screed assist system.
SCREED ASSIST SYSTEM PRESSURE IS NOT STABLE
Run checks listed above.
Shut machine OFF.
Check accumulator for 175 psi pre charge.
If no pre-charge remove hose from bottom of accumulator, charge cylinder and listen for blown bladder.
REMOVING SCREED ASSIST FROM SYSTEM & CHECKING SCREED LIFT CYLINDERS
Shut machine OFF.
Disconnect hoses from ports E and V on screed assist manifold.
Connect the two hoses together.
Plug ports E and V on screed assist manifold to prevent entry of debris.
Screed lift switch in RAISE position.
If screed lowers, defective screed lift cylinder packings.
35
22481 (11/01)
Technical Manual
A Terex Company
Tow Point
Pull Point
.913
CID
Solenoid Valve
<<< Return <<<

*Max Flow (GPM): 8.4 - 11.0
>>> Suction >>>
Manifold RH Front
200 Mesh
Strainer
Auxiliary Pump
2050
RPM
2500 PSI
Dual Throttle Valve
Test Port
<<< Case Drain <<<
Holding Valve
<<< Pressure <<<
Pressure Filter
AUXILIARY SYSTEM
Hydraulic Tank
other function is working, install a 3000 psi gauge in the test port. Refer to pressure setting above for
for lose fittings, damaged hose, or obstructions.
TOW POINT WILL NOT INCREASE
Tow point increase/decrease switch to the INCREASE position.
If light is ON:
(2) Press MANUAL OVERRIDE button on solenoid valve. If tow point cylinder increases, defective
solenoid.
(2) Extend cylinder all the way, disconnect the hose going to the ROD END of the tow point cylinder.
the cylinder, check cylinder for blown piston packing. If no fluid, defective solenoid.
36
22481 (11/01)
Technical Manual
A Terex Company
Tow Point
TOW POINT WILL NOT DECREASE
Tow point increase/decrease switch to the DECREASE position.
If light is ON:
(2) Press MANUAL OVERRIDE button on solenoid valve. If tow point cylinder decreases, defective
solenoid.
(2) Retract cylinder all the way, disconnect the hose going to the BASE END of the tow point cylinder.
Carefully push the increase/decrease switch to INCREASE, If fluid comes out of the fitting on the
cylinder, check cylinder for blown piston packing. If no fluid, defective solenoid.
TOW POINT CYLINDER DRIFTS UP OR DOWN
Extend cylinder all the way, disconnect the hose going to the ROD END of the tow point cylinder.
Carefully push the increase/decrease switch to DECREASE, if fluid comes out of the fitting on the cylinder,
check cylinder for blown piston packing. If no fluid, defective holding valve.
37
22481 (11/01)
Technical Manual
A Terex Company

POWER CROWN
(OPTIONAL)
Test Port
2050
RPM
.913
CID
P
Auxiliary Pump
2500 PSI
<<< Pressure <<<
Pressure Filter
200 Mesh
Strainer
<<< Case Drain <<<

>>> Suction >>>
AUXILIARY SYSTEM
Hydraulic Tank
If paver is equipped with SCREED ASSIST, check manual dump needle valve to ensure it is closed. If
no other function is working, install a 3000 psi gauge in the test port. Refer to pressure setting above for
each series of paver. If pressure can not be obtained, check & clean suction strainer, check suction hose
for lose fittings, damaged hose, and obstructions.
CROWN WILL NOT INCREASE
Crown increase/decrease switch to the INCREASE position.
If light is ON:
If crown does not move, disconnect hose from port B of the manifold valve.
Crown switch to INCREASE, if oil comes out of hose and crown does not move, defective motor.
If no oil, reconnect hose and install 3000 psi gauge between port A and hose A.
Crown switch to INCREASE, if pressure, check for interference on mechanical components or defective
motor.
38
22481 (11/01)
Technical Manual
A Terex Company

CROWN WILL NOT DECREASE
Crown increase/decrease switch to the DECREASE position.
Check for DIN connector light, if NO light refer to electrical troubleshooting.
If light is ON:
If crown does not move, disconnect hose from port A of the manifold valve.
Crown switch to DECREASE, if oil comes out of hose and crown does not move, defective motor.
If no oil, reconnect hose and install 3000 psi gauge between port B and hose B.
Crown switch to DECREASE. If pressure, check for interference on mechanical components or defective
motor.
39
22481 (11/01)
Technical Manual
A Terex Company
Screed Extend
Fastach 10' Screed
LH Extend Cylinder
Counterbalance
Pressure Filter
<<<Return<<<
Manifold LH Screed
.913
CID
Auxiliary Pump
Throttle
Test Port
2050
RPM
2500 PSI
Solenoid
<<< Case Drain <<<
2000
PSI
>>> Suction >>>
2000
PSI
<<< Pressure <<<

*Max Flow (GPM): 8.4 - 11.0
200 Mesh
AUXILIARY SYSTEM
Strainer
Hydraulic Tank
functions and etc.) If other functions work, this indicates the problem in only is the effected function and
each series of paver. If pressure can not be obtained, check & clean suction strainer, check suction hose
for loose fittings, damaged hose or obstructions.
STRIKE-OFF WILL NOT EXTEND

Strike-off extend/retract switch to the Extend position.
If light is ON:
(2) Press MANUAL OVERRIDE button on solenoid valve. If strike-off cylinder extends, defective
solenoid.
If strike-off cylinder does not extend:
(2) Retract cylinder all the way, disconnect the hose going to the BASE END of the strike-off cylinder.
Carefully push the extend/retract switch to RETRACT. If fluid comes out of the fitting on the
40
22481 (11/01)
Technical Manual
A Terex Company
Screed Extend
Fastach 10' Screed
STRIKE-OFF WILL NOT RETRACT
Strike-off switch to the Retract position.
If light is ON:
(2) Press MANUAL OVERRIDE button on solenoid valve. If strike-off cylinder retracts, defective
solenoid.
If strike-off cylinder does not retract,
(2) Extend cylinder all the way, disconnect the hose going to the ROD END of the strike-off cylinder.
Carefully push the extend/retract switch to EXTEND. If fluid comes out of the fitting on the
STRIKE-OFF CYLINDER DRIFTS IN OR OUT
Check DIN connectors for lights, If any light ON, electrical system is telling the cylinder to move.
If NO lights are flashing, proceed with checks.
Extend cylinder all the way, disconnect the hose going to the ROD END of the strike-off cylinder.
Carefully push the strike-off switch to EXTEND. If fluid comes out of the fitting on the cylinder, check
41
22481 (11/01)
Technical Manual
A Terex Company
Screed Extend
Stretch 20 Screed
<<< Pressure <<<
Pressure Filter
2050
RPM
.913
CID
<<< Case Drain <<<
>>> Suction >>>

*Max Flow (GPM): 8.4 - 11.0
<<<Return<<<
Manifold LH Screed
Auxiliary Pump
Solenoid Valve
Test Port
2500 PSI
Holding Valve
200 Mesh
Strainer
AUXILIARY SYSTEM
Hydraulic Tank
Screed extend/retract switch to the INCREASE position.
If light is ON:
(2) Press MANUAL OVERRIDE button on solenoid valve. If screed cylinder extends, defective
solenoid.
If screed cylinder does not extend:
(1) Install a 3000 psi gauge in-line, between hose going to rod end of cylinder and the manifold block.
(2) Retract cylinder all the way, disconnect the hose going to the BASE END of the screed cylinder.
Carefully push the increase/decrease switch to RETRACT. If fluid comes out of the fitting on the
42
22481 (11/01)
Technical Manual
A Terex Company
Screed Extend
Stretch 20 Screed
Screed extend/retract switch to the RETRACT position.
If light is ON:
(1) Refer to electrical for testing ground connection
(2) Press MANUAL OVERRIDE button on solenoid valve. If screed cylinder retracts, defective
solenoid.
If screed cylinder does not retract:
(2) Extend cylinder all the way, disconnect the hose going to the ROD END of the screed cylinder.
Carefully push the screed switch to extend. If fluid comes out of the fitting on the cylinder, check
SCREED CYLINDER DRIFTS IN OR OUT
Extend cylinder all the way, disconnect the hose going to the ROD END of the screed cylinder.
Carefully push the strike-off switch to EXTEND.
If fluid comes out of the fitting on the cylinder, check cylinder for blown piston packing.
43
22481 (11/01)
Technical Manual
A Terex Company
Sloping Strike-Off
Fastach 10' Screed
Slope
A
NOTE: EZ Screed II
has A & B ports reversed.
Counterbalance
<<< Pressure <<<
Pressure Filter
2050
RPM
.913
CID
Auxiliary Pump
Throttle
Test Port
2500 PSI
Solenoid
<<< Case Drain <<<
<<<Return<<<

*Max Flow (GPM): 8.4 - 11.0
>>> Suction >>>
Manifold RH Screed
200 Mesh
AUXILIARY SYSTEM
Strainer
Hydraulic Tank
functions, etc.) If other functions work, this indicates the problem is only in the effected function and
and clean suction strainer, check suction hose for loose fittings, damaged hose, or obstructions.
SLOPE WILL NOT INCREASE
Slope increase/decrease switch to the INCREASE position.
If light is ON:
(2) Press MANUAL OVERRIDE button on solenoid valve. If slope cylinder increases, defective
solenoid.
If slope cylinder does not increase:
(2) Decrease cylinder all the way, disconnect the hose going to the BASE END of the slope cylinder.
the cylinder, check cylinder for blown piston packing.
44
22481 (11/01)
Technical Manual
A Terex Company
Sloping Strike-Off
Fastach 10' Screed
SLOPE WILL NOT DECREASE
Slope increase/decrease switch to the DECREASE position.
If light is ON:
If slope cylinder decreases, defective solenoid.
If slope cylinder does not decrease:
(2) Increase cylinder all the way, disconnect the hose going to the ROD END of the slope cylinder.
Carefully push the increase/decrease switch to INCREASE. If fluid comes out of the fitting on the
cylinder, check cylinder for blown piston packing. If no fluid, defective solenoid.
45
22481 (11/01)
Technical Manual
A Terex Company
Screed Extension Slope

Stretch 20 Screed
Note: Port "A" on

motor is next to ID
tag on side of motor.
.913
CID
<<<Return<<<
Manifold RH Screed

*Max Flow (GPM): 8.4 - 11.0
Auxiliary Pump
Single Throttle Valve
2050
RPM
2500 PSI
Solenoid Valve
Test Port
<<< Case Drain <<<
>>> Suction >>>
Pressure Filter
<<< Pressure <<<
Hydraulic Motor
200 Mesh
Strainer
Hydraulic Tank
AUXILIARY SYSTEM
and clean suction strainer, check suction hose for loose fittings, damaged hose or obstructions.
SLOPE WILL NOT INCREASE
Slope increase/decrease switch to the INCREASE position.
If light is ON:
(2) Press MANUAL OVERRIDE button on solenoid valve. If slope increases, defective solenoid.
If slope does not move, disconnect hose from port B of the manifold valve.
Slope switch to INCREASE, if oil comes out of hose and slope does not move, defective motor.
If no oil, reconnect hose and install 3000 psi gauge between port A and hose .
Slope switch to INCREASE. If pressure, check for interference on mechanical components or defective
motor.
46
22481 (11/01)
Technical Manual
A Terex Company
Screed Extension Slope

Stretch 20 Screed
SLOPE WILL NOT DECREASE
Slope increase/decrease switch to the DECREASE position.
If light is ON:
(2) Press MANUAL OVERRIDE button on solenoid valve. If slope increases, defective solenoid. If
slope does not move, disconnect hose from port A of the manifold valve.
Slope switch to DECREASE, if oil comes out of hose and slope does not move, defective motor.
If no oil, reconnect hose and install 3000 psi gauge between port B and hose.
Slope switch to DECREASE.
If pressure, check for interference on mechanical components or defective motor.
47
22481 (11/01)
Technical Manual
A Terex Company
Match Height
Stretch 20 Screed & EZ Screed
Hydraulic Motor
Note: "B" port on the motor

is next to the name tag on
the side of the motor.
Solenoid Valve
Single Throttle Valve
Test Port
2050
RPM
.913
CID
Auxiliary Pump
2500 PSI
<<< Pressure <<<
Pressure Filter
<<< Case Drain <<<

*Max Flow (GPM): 8.4 - 11.0
>>> Suction >>>
<<<Return<<<
Hydraulic Motor
200 Mesh
Strainer
Hydraulic Tank
AUXILIARY SYSTEM
& clean suction strainer, check suction hose for loose fittings, damaged hose or obstructions.
MATCH HEIGHT WILL NOT RAISE
Match height up/down switch to the UP position.
If light is ON:
(2) Press MANUAL OVERRIDE button on solenoid valve. If match height goes up, defective
solenoid. If match height does not move, disconnect hose from port B of the manifold valve.
Match height switch to UP, if oil comes out of hose and match height does not move, defective motor.
If no oil, reconnect hose and install 3000 psi gauge between port A and hose .
Match height switch to UP.
If pressure, check for interference on mechanical components or defective motor.
48
22481 (11/01)
Technical Manual
A Terex Company
Match Height
Stretch 20 Screed & EZ Screed
MATCH HEIGHT WILL NOT LOWER
Match height up/down switch to the DOWN position.
If light is ON:
(2) Press MANUAL OVERRIDE button on solenoid valve. If match height goes up, defective
solenoid. If match height does not move, disconnect hose from port A of the manifold valve.
Match height switch to DOWN. If oil comes out of hose and match height does not move, defective motor.
If no oil, reconnect hose and install 3000 psi gauge between port B and hose .
Match height switch to DOWN. If pressure, check for interference on mechanical components or defective
motor.
49
22481 (11/01)
Technical Manual
A Terex Company
Vibrator
Fastach 10' Screed
>>>Return>>>
Quick Coupling
1500
PSI
<<<Return<<<
>>>Return>>>
Speed Control
>>Suction>>
Vibrators
200 Mesh
Strainer
Quick Coupling
<<<Pressure<<<
<<<Pressure<<<
Hydraulic Tank

Brakes RELEASED.
Travel engage/disengage to ENGAGE.
Speed dial set above 2
Vibrator switch ON.
If light is ON:
(2) Place a small screw driver next to the solenoid, if no magnetic field is felt refer to electrical.
If magnetic field is present, proceed with checks:
Install a 3000 psi gauge in test port.
Unplug quick couplings from rear bulk head. Pressure should be 1500 psi.
If no pressure, check pump. If low pressure, defective solenoid valve
If pressure is correct, reconnect quick couplings. Remove case drain hose from motor and cap hose.
If a great amount of oil is coming out of case drain port, the motor is bad.
If very little oil comes out of case drain, disconnect return hose from vibrator speed valve and cap hose.
50
22481 (11/01)
Technical Manual
A Terex Company
Vibrator
Stretch 20 Screed
>>>Return>>>
1500
PSI
<<<Pressure<<<
Quick
Coupling
<<<Return<<<
Speed Control
>>Suction>>
Quick
Coupling
LH Front
Vibrator
200 Mesh
Strainer
RH Front
Vibartor
Hydraulic Tank
LH Rear
Vibrator
RH Rear
Vibartor

Brakes RELEASED.
Vibrator switch ON.
If light is ON:
(2) Place a small screw driver next to the solenoid, if no magnetic field is felt refer to electrical.
If magnetic field is present, proceed with checks:
Turn vibrator shafts by hand, They should turn freely with little resistance. If it can not be turned by hand.
Check for mechanical failure or bind. If all but one vibrator is turning, check for defective motor on the
one that is not turning, install a 3000 psi gauge in test port.
Unplug quick couplings from rear bulk head.
Disconnect return hose from vibrator speed valve and cap hose.
51
22481 (11/01)
Technical Manual
A Terex Company
Slat Conveyor Feed

Grayhound 400 and 500 Series
Charge Filter
5
2
Test Port Charge Pressure

Test Port High Pressure
30.3 GPM Max.
9.2 GPM
>>>Pressure>>>
2500
RPM
3800 PSI
220 PSI
2.8 CID
.85
CID
Hydraulic Motor
2500 RPM Max.
2.8 CID
>>>Case Drain>>>
Cooler
<<<Suction<<<
<<<Case Drain<<<
<<<Return<<<
200 Mesh
Strainer

Hydraulic Tank
Push manual override lever in both directions, (one direction will turn the conveyor in forward, the other
will turn the conveyor in reverse.) If conveyor does not move in either direction, check pump drive for
damaged splines. If drive is ok, install a 600 psi gauge on High pressure test port. Pressure reading will
be charge pressure. (Do not engage conveyor)
Charge pressure should be 220 psi.
52
22481 (11/01)
Technical Manual
A Terex Company
Remix Spreading Auger

Charge Filter
Test Port Charge Pressure
5
2

>>>Pressure>>>
Flushing
Valve
Hydraulic Motor
2500 RPM Max.
<<<Return<<<
<<<Suction<<<
200 Mesh
Strainer
Hydraulic Tank

Push manual override lever in both directions, (one direction will turn the auger in forward, the other will
turn the auger in reverse.) If auger does not move in either direction, check pump drive for damaged
splines. If drive is ok, install a 600 psi gauge on High pressure test port. Pressure reading will be charge
pressure. (Do not engage spreading auger)
If pressure is ok, install a 6000 psi gauge in the high pressure test port.
Disconnect the hose from the pressure side of the hydraulic motor. Cap and plug the end of the hose and
port in the motor. This will prevent fluid flow to allow high pressure setting to be checked.
Feed conveyor switch to override.
If pressure is OK, check for overloaded spreading auger system.
Feed conveyor switch to override.
If pressure is OK, check for over loaded spreading auger system.
53
22481 (11/01)
Technical Manual
Remix Delivery Augers

Grayhound 400 and 500 SeriesRemix
DELIVERY AUGERS DO NOT WORK

Push manual override lever on pump EDC in both directions, (one direction will turn the conveyor in
forward, the other will turn the conveyor in reverse.) If conveyor does not move in either direction, check
pump drive for damaged splines. If drive is ok, install a 600 psi gauge on High pressure test port. Pressure
reading will be charge pressure. (Do not engage conveyor)
If pressure is ok, install a 10,000 psi gauge in the conveyor high pressure test port.
Remix conveyor switch to ON.
If pressure is OK, check for over loading auger conveyor system (Head of material in auger chamber) or
mechanical binds.
DELIVERY AUGER STALLS WHEN UNDER LOAD
Install a 10,000 psi gauge in the high pressure test port.
Remix conveyor switch to ON.
If pressure is OK, check for over loading auger conveyor system (Head of material in auger chamber) or
mechanical binds.
54
22481 RevA (12/04)
Technical Manual
A Terex Company

This Page Intentionally Left Blank
55
22481 (11/01)
Technical Manual
A Terex Company

56
22481 (11/01)
Technical Manual
A Terex Company
Travel/Pave (P2)
Grayhound Slat Conveyor Pavers
Pressure limiter hose (rubber tire only)
Range Shift
Pressure
Filter
Traction Pump
Strainer
Hydraulic Tank
Motor and Torque Hub

Rubber Tire Only
TRAVEL/PAVE (P2) SPEED SELECT

All Grayhound pavers have variable displacement traction drive motors. If the range shift solenoid is
energized pressure is applied to each Hydraulic Displacement control, causing the motor to turn faster at the
same pump output. Rubber tired paver with the Front Wheel Assist option are marked Travel, P2, P4. The
systems are the same, for Travel and P/2 In P4 a front wheel assist system is used. Refer to Front Wheel Assist
for questions concerning it.
PAVER WILL NOT SHIFT TO TRAVEL
Brakes released.
Travel/Pave (Travel/P2/P4) switch to TRAVEL.
Check range shift solenoid DIN connector for light.
If NO light , refer to electrical troubleshooting.
If light is ON:
(1) Refer to electrical troubleshooting for ground connection.
(2) Install a 600 psi gauge on the RH (traction or conveyor depending on model) high pressure test port.
(Do not engage conveyor or travel.)
(3) Pressure should be 265 psi to change the hydraulic displacement controls on the motors. If low,
refer to conveyor or traction depending on model.
(4) Install a 600 psi gauge between the range shift solenoid and the hose going to the motors. If no
pressure or low, check flow restricter for obstruction or defective solenoid. If pressure is correct,
refer to hydraulic motor manual of your model of paver.
57
22481 (11/01)
Technical Manual
A Terex Company

Differental
Lock
LH Traction Drive
Parking Brake
To RH Traction
System
(Rubber Tire Only)
Charge Pressure
LH Traction Pump
Range Shift
390 PSI
2500 RPM
2.8
1.4
CID CID
200 Mesh
Strainer
Hydraulic Tank

Disconnect and cap cross over lines and ports between LH & RH FORWARD & REVERSE high pressure
ports.
58
22481 (11/01)
Technical Manual
A Terex Company

If light is on
RUBBER TIRE TRACTION HYDRAULIC SYSTEM
Balance lines should be capped when troubleshooting rubber tire paver traction hydraulic system. This
will prevent fluid from flowing between the left and right pump during testing.
If the differential lock valve is functioning properly you only need to engage the Differential Lock Switch.
But to ensure that there is no chance of fluid passing between the left side pump and the right side pump
you need to plug the hoses and cap the ports of one side of the valve.
Left Side Traction System
Pressure Port 'B'
Left Side Traction System

Pressure Port 'A'
Plug
Differential Lock Valve
Cap
Cap
Plug
Right Side Traction

System Pressure Port 'A'
Right Side Traction System Pressure Port 'B'
59
22481 (11/01)
Technical Manual
A Terex Company

60
22481 (11/01)
Technical Manual
A Terex Company
Travel/Pave (P2)
Grayhound Remix Pavers
TRAVEL/PAVE (P2) SPEED SELECT

All Grayhound pavers have variable displacement traction drive motors. If the range shift solenoid is
energized pressure is applied to each Hydraulic Displacement control, causing the motor to turn faster at the
same pump output. Rubber tired paver with the Front Wheel Assist option are marked Travel, P2, P4. The
systems are the same, for Travel and P/2 In P4 a front wheel assist system is used. Refer to Front Wheel Assist
for questions concerning it.
PAVER WILL NOT SHIFT TO TRAVEL
Brakes released.
Travel/Pave (Travel/P2/P4) switch to TRAVEL.
Check range shift solenoid DIN connector for light.
If NO light , refer to electrical troubleshooting.
If light is ON:
(1) Refer to electrical troubleshooting for ground connection.
(2) Install a 600 psi gauge on the RH (traction or conveyor depending on model) high pressure test port.
(Do not engage conveyor or travel.)
(3) Pressure should be 295 psi to change the hydraulic displacement controls on the motors. If low,
refer to conveyor or traction depending on model.
(4) Install a 600 psi gauge between the range shift solenoid and the hose going to the motors. If no
pressure or low, check flow restricter for obstruction or defective solenoid. If pressure is correct,
refer to hydraulic motor manual of your model of paver.
61
22481 (11/01)
Technical Manual
A Terex Company

TO RH TRACTION SYSTEM

Disconnect and cap cross over lines and ports between LH & RH FORWARD & REVERSE high pressure
ports.
62
22481 (11/01)
Technical Manual
A Terex Company

If light is on
63
22481 (11/01)
Technical Manual
A Terex Company
Front Wheel Assist (Optional)

All Grayhound Rubber Tire Pavers
FROM
TRACTION
PUMP
DRIVE
MOTOR
>>CASE DRAIN>>
FRONT WHEEL ASSIST

4WD PILOT
VALVE
FROM
TRACTION
PUMP
DRIVE
MOTOR
>> CASE DRAIN >>
FRONT WHEEL ASSIST (P4)

The front wheel assist system should not be confused with or considered as a four wheel drive system.
When the front wheel assist solenoid valve is energized pressure is applied to separate 5 way valves.
When the 5-way valves are open, pressure from the main traction pump is applied to both the main drive
motor and the front wheel assist motor on that side of the machine. The amount of tractive effort increase
will depend on the amount of traction the front wheels have in a given ground condition.
FRONT WHEEL ASSIST WILL NOT ENGAGE
Travel/P2/P4 switch to P4.
Check front wheel assist solenoid valve DIN connector for light.
If NO light, refer to electrical troubleshooting.
If light is ON,
(1) Refer to electrical troubleshooting for ground connection
(2) Install a 600 psi gauge in the LH conveyor high pressure test port. (Do Not engage conveyor) Refer
to conveyor charge pressure above for pressure required. If pressure is low, refer to conveyor.
(3) If pressure is correct, install 600 psi gauge between A port and hose going to the 5 way valves. If
no or low pressure, defective solenoid valve.
(4) If pressure is correct, install 6000 psi gage between 5-way valve and motor. Move machine. If very
low or no pressure, defective 5-way valve on that side. Both sides will need to be checked.
64
22481 (11/01)
Technical Manual
A Terex Company
4 Kw Hydraulic Drive Generator

400 & 500 Series Grayhound Pavers
From screed
vibrators
1500 PSI
Solenoid
RH Reservoir
CF
RH Reservoir
3600 RPM
To screed
vibrators
EF
Gen Set
.38 Motor
CID
Flow
Control
Valve
RH Reservoir
17 GPM
IN
Priority Flow Divider
2300 PSI
RH Reservoir
1.53
CID
2500 RPM
GENERATOR DOES NOT PRODUCE ELECTRICITY

RH Reservoir
Engine at full throttle, generator switch to ON.
Check for light on solenoid DIN connector.
If no light, refer to electrical troubleshooting.
If light is lit, press manual override button on solenoid. If generator runs, defective solenoid.
Run the screed vibrators. If vibrators run, check speed of motor/generator.
If speed is greater than 3600 RPM, refer to electrical troubleshooting.
If speed is less than 3600 RPM, adjust the flow control valve until the motor/generator speed is 3600 RPM
If 3600 RPM speed cannot be acheived by adjusting the flow control valve,
(1) Clean suction strainer, check stuction hose for loose fittings, damaged hose or obstructions.
(2) Check output pressure on the pump.
If pressure is less than 2300 PSI, adjust pressure regulator to bring pressure up to 2300 PSI.
(3) Retest generator/motor speed. Adjust flow control to maintain 3600 RPM at motor/generator.
65
22481 (11/01)
Technical Manual
A Terex Company
11 GPM
Remote Oil Cooler

Driven From Dedicated Pump
400/500 Series Grayhound Pavers
2150 RPM
1.17
CID
2800 PSI
LH Reservoir
1.2
CID
LH Reservoir
LH Reservoir
2100 RPM
RH rotation pump
driven off front
engine pad
REMOTE OIL COOLER FAN DOES NOT RUN OR RUNS SLOW

Clean remote oil cooler fins to remove dirt, leaves or other air flow obstructions.
Engine at full throttle.
If remote cooler fan motor does not run at 2150 RPM:
(1) Install at 3000 PSI gauge in-line between the pump and motor. If pressure does not reat 2800 PSI
check and clean suction strainer, check suction hose for loose fittings, damaged hose and
obstructions.
(2) Retest hydraulic pressure. If 2800 PSI cannot be obtained, adjust pressure relief until 2800 PSI
setting is reached.
If 2800 PSI setting cannot be reached, check/repair pump.
If remote cooler fan motor does not ran at 2150 RPM, check/repair motor.
66
22481 (11/01)
Technical Manual
A Terex Company
Remote Oil Cooler

Driven From Vibrator Pump
400/500 Series Grayhound Pavers
2800 PSI
1.17
CID
2800 PSI
REMOTE OIL COOLER FAN DOES NOT RUN OR RUNS SLOW

Clean remote oil cooler fins to remove dirt, leaves or other air flow obstructions.
Engine at full throttle.
If remote cooler fan motor does not run at 2150 RPM:
(1) Install at 3000 PSI gauge in-line between the pump and motor. If pressure does not reat 2800 PSI
check and clean suction strainer, check suction hose for loose fittings, damaged hose and
obstructions.
(2) Retest hydraulic pressure. If 2800 PSI cannot be obtained, adjust pressure relief until 2800 PSI
setting is reached.
If 2800 PSI setting cannot be reached, check/repair pump.
If remote cooler fan motor does not ran at 2150 RPM, check/repair motor.
67
22481 (11/01)
Technical Manual
A Terex Company

68
22481 (11/01)
PAVER
TECHNICAL MANUAL
Pumps-Motors-Drives
Section
Technical Manual
A Terex Company
Table of Contents
Pumps - Motors - Drives
Cedarapids Lubricants ......................................................................................................... 1
Pressure Test Kit .................................................................................................................. 3
Component Location Map 300 Series/CR411 ..................................................................... 4
Hydraulic Pump Data 300 Series/CR411 ............................................................................ 5
Component Location Map 400 and 500 Series ................................................................... 6
Hydraulic Pump Data 400 and 500 Series ...................................................................... 7 - 8
Part Number Matrix - Pumps-Motors-Drives ...................................................................... 9
List of Repair Manuals ...................................................................................................... 10
Series 40 Pumps Information ..................................................................................... 11 - 43
Series 42 Pumps Information ..................................................................................... 44 - 78
Series 90 Pumps Information ................................................................................... 79 - 133
Vibrator Pump - S16 Rexroth .......................................................................................... 134
Auxiliary Pump - Eaton Model 70122 Piston Pump ....................................................... 135
Auxiliary Pump - Sundstrand L15 .......................................................................... 136 - 149
Fastach II Generator Drive Pump - Rexroth A10VO ....................................................... 150
Fastach II Generator Drive Pump Set-Up Procedure .............................................. 151 - 152
Stretch Electric Screed Generator Drive Pump Set-Up Procedure ........................ 153 - 156
Conveyor Drive Motor - Char-Lynn 6000 Series ............................................................ 157
Lohmann & Stolterfoht Travel Drive Unit Assembly ...................................................... 158
Travel Drive Motor .......................................................................................................... 159
Travel Drive Motor Begin of Stroke Adjustment Procedure .................................. 160 - 163
Travel Drive Motor Self-Cleaning Swivel-Time Orifices ................................................ 164
Travel Drive Motor Installation, Start-Up, & Troubleshooting .............................. 165 - 169
Travel Drive Unit Information ................................................................................ 170 - 179
Travel Drive Unit Specification Data ..................................................................... 180 - 183
22483 (01/04)
Technical Manual
A Terex Company
ii
22483 (01/04)
Greases
Hydraulic
Oils
EP
Gear Oils
Non-EP
Gear Oils
Starfak 2201
Starfak 2202
Multifak EP 2
Starfak 00
Multifak HD 00
Multifak EP 1
Pinnacle 68
Rando HD 68
Pinnacle 32
Rando HD 32
Pinnacle 46
Pinnacle EP 320
Meropa 320
Rando HD 46
Pinnacle EP 220
N/A
Meropa 100
Meropa 220
N/A
Meropa 68
Pinnacle EP 150
Pinnacle 220
Regal R&O 220
Meropa 150
Pinnacle 150
Regal R&O 150
Pinnacle 68
Regal R&O 68
Pinnacle 100
Pinnacle 46
Regal R&O 46
Regal R&O 100
Synthetic
Mineral
Texaco
Alvania EP 2
Alvania EP 1
Synthetic
Albida SLC 220
N/A
Retinax TL 00
Tellus HD 68
Tellus HD 46
Tellus HD 32
Omala HD 320
Omala HD 220
N/A
N/A
N/A
Omala RL 220
Omala RL 150
Omala RL 100
Omala RL 68
Omala RL 46
Shell
Alvania EP 00
Tellus 68
Tellus 46
Tellus 32
Omala 320
Omala 220
Omala 150
Omala 100
Omala 68
Molina 220
Molina 150
Molina 100
Turbo T 068
Turbo T 046
Mineral
Mobilux EP 2
Mobilux EP 1
Mobilux EP 023
DTE 26
DTE 25
DTE 24
Mobilgear 632
Mobilgear 630
Mobilgear 629
Mobilgear 627
Mobilgear 626
Spartan EP 320
Mobilgear
SHC 320
Mobilith SHC 220
N/A
Mobilith SHC 007
SHC 526
SHC 525
Lidok EP 2
Lidok EP 1
Lidok EP 000
Nuto H 68
Nuto H 46
Nuto H 32
Spartan EP 220
Mobilgear
SHC 220
SHC 524
Spartan EP 150
Spartan EP 100
Spartan EP 68
Teresstic 220
Teresstic 150
Teresstic 100
Teresstic 68
Dura-Lith EP 2
Dura-Lith EP 1
Ulti-Plex Synthetic
EP 1.5
Ulti-Plex Synthetic
EP 1.5
N/ A
Rykon Premium
Oil 68*
Rykon Premium
Oil 46*
Rykon Premium
Oil 32*
Tegra Synthetic
Gear EP 320
Tegra Synthetic
Gear EP 220
Tegra Synthetic
Gear EP 150

Unirex SHP 220
Unirex SHP 460
Dura-Lith EP 00
Hydraulic Oil
AW 68
Teresstic
SHP 68
Unirex SHP 00
Hydraulic Oil
AW 46
Hydraulic Oil
AW 32
Teresstic
SHP 32
Teresstic
SHP 46
Gear Compound
EP 320
Gear Compound
EP 220
Spartan Synthetic
EP 320
Spartan Synthetic
EP 220
Gear Compound
EP 150
Gear Compound
EP 100
Spartan Synthetic
EP 100
Spartan Synthetic
EP 150
N/A
Gear Compound
EP 68
N/A
N/A
N/A
Industrial Oil 220
Teresstic
SHP 220
N/A
N/A
N/A
Industrial Oil 150
Industrial Oil 100
Industrial Oil 68
N/A
Teresstic
SHP 150
Teresstic
SHP 100
Teresstic
SHP 68
Industrial Oil 46
Teresstic
SHP 46
Synthetic
Chevron
Mineral
Synthetic
Exxon
Teresstic 46
Mineral
Mobilgear
SHC 150
N/A
N/A
SHC 630
SHC 629
DTE Oil
Extra Heavy
DTE Oil BB
SHC 627
DTE Oil Heavy
SHC 626
DTE Oil
Heavy Medium
Synthetic
N/A
Mobil
DTE Oil Medium
Mineral
Technical Manual
A Terex Company
22483 (01/04)
Technical Manual
A Terex Company
22483 (01/04)
Technical Manual
A Terex Company
Pressure Test Kit

45865-001-41
45865-002-27
45865-002-33
Gauge
Gauge
Guage
0-6000-PSI
0-100 PSI
0-600 PSI
45080-527-05
Adapter Gauge
Not Illustrated
7430-416
7430-344
7430-345
45080-527-14
45080-527-07
45080-527-15
Hose 36"
Hose 10'
45080-527-17
45080-527-18
45080-527-16
45080-527-031
45080-527-061
45080-527-04
Fitting
Tee
Tee
Test Hose Union
#4 FS JIC Test Port

#6 FS JIC Test Port
#8 FS JIC Test Port
8" NPT Test Port

4" NPT Test Port
#4 SAE Test Port
22483 (01/04)
Technical Manual
A Terex Company

Hydraulic Pumps - 300 Series/CR411
(Early Units)
Right Side
Left Side
Vibrator Pump
Auxiliary Pump
RH Conveyor Pump
LH Conveyor Pump
Pump EDC
Pump EDC
LH Travel Pump
RH Travel Pump
(Later Units)
Right Side
Left Side
Vibrator Pump
Generator Drive
Pump (Optional)
Auxiliary Pump
RH Conveyor Pump
LH Conveyor Pump
Pump EDC
Pump EDC
RH Travel Pump
LH Travel Pump
22483 (01/04)
Technical Manual
A Terex Company
Hydraulic Pump Data

Auxiliary Pump:
L-15 Sunstrand .913 CID
System Pressure: 2500 psi
Flow: Approx. 10 gpm @ 2100 RPM
Case Pressure: 10 psi maximum continuous (0.7 BAR)
Conveyor/Traction Pump:
MDT-M46 Tandem Sunstrand 2.81 CID (variable) SERIES 40
System Pressure: 5400 psi - Traction
3045 psi - Conveyor
Flow (each section): Approx. 21 gpm @ 2100 RPM
Charge Pressure: 350 psi - Traction
400 psi - Conveyor
Case Pressure: 25 psi continuous (1.7 BAR)
Cold Start: 75 psi (5.2 BAR)
Vibrator Pump:
S16 Rexroth Gear Pump 1.2 CID Size 10
Flow: Approx. 15 gpm @ 2100 RPM
Maximum Continuous Pressure: 3000 psi (210 BAR)
Generator Drive Pump (Optional)
A10VO Rexroth Pump 2.75 CID
Standby Pressure: 400 psi
System Max. Pressure: 4000 psi
22483 (01/04)
Technical Manual
A Terex Company

Hydraulic Pumps
Grayhound 400 and 500 Series Pavers
(Slat Conveyor)
Auxiliary Pump
Generator Drive
Pump (Optional)
Vibrator Pump
Left Side
Right Side
Pump EDC
LH Conveyor Pump
Pump EDC
LH Travel Pump
RH Travel Pump
RH Conveyor Pump
(Remix Conveyor)
Right Side
Auxiliary Pump
Vibrator Pump
Left Side
LH Spreading
Auger Pump
RH Spreading
Auger Pump
LH Travel Pump
RH Travel Pump
LH Delivery
Auger Pump
RH Delivery
Auger Pump
22483 (01/04)
Technical Manual
A Terex Company
Hydraulic Pump Data

Slat & Remix Pavers
Slat Conveyor Pavers
Remix Pavers
Auxiliary Pump
Flow: Approx. 10 gpm @ 2100 rpm
Case Pressure: 10 psi max. continuous (0.7 BAR)
Auxiliary Pump
Case Pressure: 10 psi max. continuous (0.7 BAR)
Conveyor Pump
M46 Sunstrand 2.81 CID (variable) SERIES 40
Flow: Approx. 20.4 gpm @ 2100 rpm
Charge Pressure: 220 psi
Remix Delivery Pump

Case Pressure: 40 psi continuous (3 BAR)
Traction Pump (Tire & Steel Track Pavers)

Remix Traction Pump

Flow: Approx. 20.4 gpm @ 2100 rpm
Traction Pump (Rubber Track Pavers)

Flow: Approx. xx gpm @ 2100 rpm
Remix Spreading Pump

Vibrator Pump
Case Pressure: 3000 psi max. continuous (210 BAR)
Vibrator Pump
Case Pressure: 3000 psi max. continuous (210 BAR)
22483 (01/04)
Technical Manual
A Terex Company
Hydraulic Pump Data

Slat & Remix Pavers
Remix Pavers
Generator Drive Pump (Optional)

A10VO Rexroth Pump 2.75 CID
Standby Pressure: 400 psi
System Max. Pressure: 4000 psi
Generator Drive Pump (Not Available on Remix)

Note: There is no mounting location at this time.
22483 (01/04)
Technical Manual
A Terex Company
Part Number Matrix

PART NUMBER
DESCRIPTION/FUNCTION
FORM # PAVER MODELS
COMMENT
45080-002-10
Auxiliary Pump LH Rot.-Pump Stack
19543
All
Sundstrand L15
45080-002-24
Auxiliary Pump RH Rot.-Engine Mount 19543
All
Sundstrand L15
45080-002-39
Travel/Conveyor Pump
19351
300
Sundstrand Series 40 MTD - M46
45080-002-40
Travel/Conveyor Pump
19351
300
Sundstrand Series 40 MTD - M46
45080-002-42
Travel Pump
19158
400/500
Sundstrand Series 90 - M55
45080-002-43
Conveyor Pump
19159
400/500
45080-002-48
Auxiliary Pump RH Rot.-Engine Mount 20088
All
Obsolete-Substitute 45080-002-24
45080-002-49
Auxiliary Pump LH Rot.-Pump Stack
20088
All
Obsolete-Substitute 45080-002-10
45080-002-55
Remix Auger Drive Pump
21642
400/500
Sundstrand Series 42 - M28 & M41
45080-002-66
Remix Auger Drive Pump
21642
400/500
45080-003-39
Vibrator Pump LH Rot.-Pump Stack
19545
All
Rexroth S16
45080-003-40
Vibrator Pump RH Rot.-Engine Mount
19545
All
Rexroth S16
N/A
All
Used to mount 45080-003-40 to engine
19378
400
Lohmann & Stolterfoht GFT 36E.1040
45080-004-75-08 Travel Motor
19161
400
Rexroth A6VE Series
45080-004-81
Conveyor Motor
19546
All
Char-Lynn 6000 Series
45080-004-85
Final Drive
19353
300
Lohmann & Stolterfoht GFT 25T2.1017
45080-004-88
Final Drive
19376
400
45080-004-89
Final Drive
20267
500
45080-004-98
Final Drive
20410
300/411
45080-006-03
Final Drive
21062
400
45080-006-04
Final Drive
20966
500
45080-006-05
Final Drive
21020
500
45080-006-08
Final Drive
21147
300
45080-006-20
Final Drive
21865
400/500
45080-006-22
Final Drive
21747
300
45080-006-23
Final Drive
21866
400/500
45080-006-29
Final Drive
22190
400R/500R
45080-006-31
Final Drive
22528
500
45930-001-15-08 Pump Drive Adapter Kit

45080-004-75
Final Drive
22483 (01/04)
Technical Manual
A Terex Company
List of Repair Manuals

for Pumps - Motors - Drives
The following list is the available pump, motor, and drive repair manuals should you find it necessary
to completely disassemble and repair one of these components:
PUMPS - MOTORS - DRIVES (CR300 Series/411, CR400 & CR500 Series)

Travel Pump 45080-002-42 ............................................................................... Form 19158
Conveyor Pump 45080-002-43.......................................................................... Form 19159
Travel Motor 45080-004-75-08 ......................................................................... Form 19161
Travel/Conveyor Pump 45080-002-40 & 45080-002-39 .................................. Form 19351
Final Drive 45080-004-85 ................................................................................. Form 19353
Final Drive 45080-004-88 ................................................................................. Form 19376
Final Drive 45080-004-75 ................................................................................. Form 19378
Auxilliary Pump 45080-002-10 & 45080-002-24 ............................................. Form 19543
Vibrator Pump 45080-003-39 ............................................................................ Form 19545
Conveyor Motor 45080-004-81 ......................................................................... Form 19546
Auxiliary Pump 45080-002-48 & 45080-002-49 .............................................. Form 20088
Final Drive 45080-004-89 ................................................................................. Form 20267
Final Drive 45080-004-98 ................................................................................. Form 20410
Final Drive 45080-006-04 ................................................................................. Form 20966
Final Drive 45080-006-05 ................................................................................. Form 21020
Final Drive 45080-006-03 ................................................................................. Form 21062
Final Drive 45080-006-08 ................................................................................ Form 21147
Remix Auger Drive 45080-002-55 & 45080-002-66 ........................................ Form 21642
Final Drive 45080-006-20 ................................................................................. Form 21865
Final Drive 45080-006-22 ................................................................................. Form 21747
Final Drive 45080-006-23 ................................................................................. Form 21866
Final Drive 45080-006-29 ................................................................................. Form 22190
Final Drive 45080-006-31 ................................................................................. Form 22528
The following pages detail some of the more common adjustment and repair procedures to the paver
hydraulic pumps, motors, and drive systems.
As mentioned above, this is not intended to be complete repair instructions for major component
rebuilding. For that purpose, use the above listed complete manuals.
10
22483 (01/04)
Technical Manual
A Terex Company
Slat Conveyor Pumps - Series 40

HDC/EDC Hydraulic
Neutral Adjustment
Cross-Port Line
Servo Port F
500 psi Hose
System Pressure Test
Port B 10,000 psi Gauge
Charge Pressure Port C

1000 psi Gauge
Port A 10,000 psi Gauge
Charge Pressure
Relief Valve
Case Outlet
Port D 1000 psi
Check/Relief Valve
for Port A
By-Pass Valve
Charge Pump
Inlet Vacuum Port E
Charge Pressure Port C

1000 psi Gauge M3
Manual Override
Lever
System Pressure
Port B
Cross-Port Line
Servo Port G M5
500 psi Hose
System Pressure
Port A
Swash Plate
Neutral Adjustment
Case Drain
Alternate Case
Pressure Outlet Port D
11
22483 (01/04)
Technical Manual
A Terex Company
Tandem Pumps - Series 40 (M46)

Conveyor/Traction
Conveyor High-Pressure
Test Port - M2 Rear (for Port D)
Use 6000 psi gauge
Conveyor Neutral Adjustment

Conveyor Equalizer
Servo Port - M4 Rear
Use 500 psi hose
Travel High-Pressure
Test Port - M1 Front (for Port A)
Use 10,000 psi gauge
Charge Pressure
Test Port - M3
Test Port - M2 Front
(for Port B)
Test Port - M1 Rear
(for Port C)
Use 6000 psi gauge
Case Drain
Check/Relief Valve
(for Port C)
Conveyor Bypass Valve
Check/Relief Valve
(for Port B)
Port B
Port A
Manual Override Lever - Travel

Travel Equalizer
Servo Port - M5 Front
Use 500 psi hose
12
Case Drain
Swash Plate Neutral Adjustment
22483 (01/04)
Technical Manual
A Terex Company
Tandem Pumps - Series 40 (M46)

Conveyor/Traction
Charge Pressure
Test Port - M3
(for Port B)
Travel Neutral Adjustment

Travel Equalizer
Servo Port - M5 Front
Use 500 psi hose
Test Port - M1 Rear (for Port C)
Use 6000 psi gauge
(for Port A)
Test Port - M2 Rear
(for Port D)
Use 6000 psi gauge
Charge Pressure Relief Valve

Check/Relief Valve
(for Port A)
Travel Bypass Valve
(Must Be Opened to Pull Paver)
Charge Pump Inlet - S
Check/Relief Valve
(for Port D)
Port D
Port C
Manual Override Lever - Conveyor

Conveyor Case Drain
Conveyor Equalizer
Servo Port - M5 Rear
Use 500 psi hose
13
22483 (01/04)
Technical Manual
A Terex Company
Axial Piston Pumps

All Grayhound Series Pavers
The Following Pages are

Portions of Manuals Form 19159 & 19351
Sunstrand Sauer
Series 40 - M46
Service and Repair Manual
14
22483 (01/04)
Technical Manual
A Terex Company
15
22483 (01/04)
Technical Manual
A Terex Company
16
22483 (01/04)
Technical Manual
A Terex Company
17
22483 (01/04)
Technical Manual
A Terex Company
18
22483 (01/04)
Technical Manual
A Terex Company
19
22483 (01/04)
Technical Manual
A Terex Company
20
22483 (01/04)
Technical Manual
A Terex Company
21
22483 (01/04)
Technical Manual
A Terex Company
* Port M4 may also be labeled "F"

** Port M5 may also be labeled "G"
**
22
22483 (01/04)
Technical Manual
A Terex Company
23
22483 (01/04)
Technical Manual
A Terex Company
24
22483 (01/04)
Technical Manual
A Terex Company
25
22483 (01/04)
Technical Manual
A Terex Company
26
22483 (01/04)
Technical Manual
A Terex Company
27
22483 (01/04)
Technical Manual
A Terex Company
28
22483 (01/04)
Technical Manual
A Terex Company
29
22483 (01/04)
Technical Manual
A Terex Company
30
22483 (01/04)
Technical Manual
A Terex Company
31
22483 (01/04)
Technical Manual
A Terex Company
32
22483 (01/04)
Technical Manual
A Terex Company
33
22483 (01/04)
Technical Manual
A Terex Company
34
22483 (01/04)
Technical Manual
A Terex Company
35
22483 (01/04)
Technical Manual
A Terex Company
36
22483 (01/04)
Technical Manual
A Terex Company
37
22483 (01/04)
Technical Manual
A Terex Company
38
22483 (01/04)
Technical Manual
A Terex Company
39
22483 (01/04)
Technical Manual
A Terex Company
40
22483 (01/04)
Technical Manual
A Terex Company
41
22483 (01/04)
Technical Manual
A Terex Company
42
22483 (01/04)
Technical Manual
A Terex Company
43
22483 (01/04)
Technical Manual
A Terex Company
Remix Spreader Pumps - Series 42 (M28)

Servo Pressure
Port G - M5
500 psi Gauge
Control Neutral
Adjustment (MDC/EDC)
System Pressure Port B

System Pressure
Test Port B - M2
10,000 psi Gauge
System Pressure Port A
System Pressure
Test Port A - M1
10,000 psi Gauge
Displacement Limiter
NOTE: Do Not Adjust
or Touch Unless
Factory Authorized
Case Drain
Port L2
Servo Pressure
Port F - M4
500 psi Gauge
Hydraulic Pump
Neutral Adjustment
NOTE: Do Not Adjust
or Touch Unless
Factory Authorized
To Filter
Port D
Case Drain
Port D - L1
Charge Pressure
Port C - M3
500 psi Gauge
From Filter
Port E
System Check
Relief Valve
Port B
Charge Pump
Inlet Vacuum Port S
44
System Check
Relief Valve
Port A
22483 (01/04)
Technical Manual
A Terex Company
Remix Traction Pumps - Series 42 (M41)

Servo Pressure
Port G - M5
500 psi Gauge
Control Neutral
Adjustment
(MDC/EDC)
System Pressure Port B

System Pressure
Test Port B - M2
10,000 psi Gauge
System Pressure Port A
System Pressure
Test Port A - M1
10,000 psi Gauge
Case Drain
Port L2
Servo Pressure
Port F - M4
500 psi Gauge
Hydraulic Pump
Neutral Adjustment
Charge Pressure
Port C - M3
500 psi Gauge
To Filter
Port D
Case Drain
Port D - L1
System Check
Relief Valve
Port B
From Filter
Port E
Charge Pump
Inlet Vacuum Port S
45
System Check
Relief Valve
Port A
22483 (01/04)
Technical Manual
A Terex Company
Axial Piston Pumps


Portions of Manual Form 21642
Sunstrand Sauer
Series 42 - M28 & M41
46
22483 (01/04)
Technical Manual
A Terex Company
Series 42
Introduction
1. Introduction
1.1
Using This Manual
The Adjustment and Minor Repair procedures detailed herein may be performed by trained personnel
without voiding the unit warranty.
placed. Lightly lubricate all O-rings with clean petroleum jelly prior to assembly. All gasket sealing surfaces must be cleaned prior to installing new gaskets.
Cleanliness is a primary means of assuring satisfactory transmission life. Cleaning parts by using a clean
solvent wash and air drying is usually adequate. As
with any precision equipment, all parts must be kept
free of foreign materials and chemicals. When performing service activities, protect all exposed sealing
surfaces and open cavities from damage and foreign
material.
All exploded view drawings depict the 28cc frame

size. For variances in the 41cc frame size, see the
outline drawings in section 3. Differences in wrench
size and torquing for the two frame sizes are noted in
the text. Note that exterior housing screws are mostly
Torx-type T30 or T45.
These symbols are used within drawings:
Apply petroleum jelly.
Whenever removing a service component, it is recommended that any gaskets and O-rings be re-
1.2
Lubricate with clean hydraulic oil.
Safety Precautions
Always consider safety precautions before beginning a service procedure. Protect yourself and others from injury.
The following general precautions should be taken into consideration whenever servicing a hydrostatic system.
Loss of Hydrostatic Braking Ability
Fluid Under High Pressure
WARNING
When Series 42 units are used in vehicular
hydrostatic drive systems, the loss of hydrostatic drive line power in any mode of operation (e.g. acceleration, deceleration or neutral mode) may cause a loss of hydrostatic
braking capacity. A braking system which is
independent of the hydrostatic transmission
must, therefore, be provided which is adequate
to stop and hold the system should the condition develop.
WARNING
Use caution when dealing with hydraulic fluid
under pressure. Escaping hydraulic fluid under pressure can have sufficient force to penetrate your skin causing serious injury. This
fluid may also be hot enough to burn. Serious
infection or reactions can develop if proper
medical treatment is not administered immediately.
Flammable Cleaning Solvents
Disable Work Function
WARNING
Some cleaning solvents are flammable. To
avoid possible fire, do not use cleaning solvents in an area where a source of ignition may
be present.
WARNING
Certain service procedures may require the
vehicle/machine to be disabled (wheels raised
off the ground, work function disconnected,
etc.) while performing them in order to prevent
injury to the technician and bystanders.
Copyright 1996, Sauer-Sundstrand Company.

All rights reserved. Contents subject to change. Printed in U.S.A.
F100003
47
22483 (01/04)
Technical Manual
A Terex Company
Series 42
Model Code
2. Model Code
Refer to the model code exhibited on the unit's name plate for information regarding the configuration of the unit.
saue
Ames, Iowa, U.S.A.
Model Code
Note: Some options listed here may not currently

be available. Some options on your unit may not
be listed here. This is not an order code. See the
Series 42 Price Book for up-to-date ordering
information.
Neumnster, Germany
Typ
42L28 - C - ANN1 - 01 ANA - 2CNB - NN - NN - N N - N - NNN - NNN

Model No.
Model Code
Ident Nr
428 2051
A 93 23 67890
Serial No.
Serial No.
Fabr Nr
XX
XX
XXXXX
Location
Year
Week
Sequence No.
MADE IN U.S.A.
1 2
A
B
Series
12 34
2
1 Rotation
2 Displacement
123
1 2 34
1 Control Type
= None
= MDC, Linear, Low Force
= MDC, Non-Linear, Low Force
= EDC (Electric Displacmt Contrl)
= FNR (3-Pos Forwrd-Neut-Revrs)
= NFP (Non-Feedback Proport'l)
NSS for MDC

or PCP for EDC
2
or Connector for FNR
or Style for NFP
N = None or Not Applicable

1 = NSS / Weatherpack for MDC,
or PCP Style for EDC
or 12V Electric for NFP
2 = 12 V DIN for FNR
3 = NSS+BAS / CW Handle Rot.
/ Weatherpack for MDC
or Hydraulic for NFP
5 = NSS+BAS / CCW Handle Rot.
/ Weatherpack for MDC
28 = 28 cm3 (1.71 in3)

41 = 41 cm3 (2.50 in3)
N
A
C
E
F
G
Handle for MDC

4 or Connector for EDC
or Connector for NFP
L = CCW
R = CW
= 13T 16/32P Spline

= 15T 16/32P Spline
= 19T 16/32P Spline
= 1.000 in. O.D. Straight Keyed
= 1.000 in. O.D. Tapered (1.5 in/ft)
Solenoid Override with MDC

3 or EDC Input
or Inching/Braking for NFP
L M
Control Response Tim

1 Port Style
2 Loop Flushing/Cooling

A = 12V Override / Weather Pack,
or EDC Input = 14-85 mA
or 400 - 1200 mA or 5-20 bar
for NFP
E = 12V Override / Brake Port
1,6 = Standard Handle fpr MDC
or M/S Connector for EDC
or Amp Connector for NFP
2,5 = Clevis Handle for MDC
or Weather Pack for EDC
48
x1 = Fast
x2 = Medium
x3 = Slow
C
D
E
G
K
Input Shaft Config

s uration
A,J,
= SAE Threaded sO-Ring Bos
N = None
2,3 = Loop Flushing/Cooling Shuttle
= None (Ext. Charge Supply)
= Suction (No Adapter Plate)
= Remote Pressure (Partial Flow)
= Suction (Adapter Plate)
3 Filtration
N
A
C
G
1 Charge Pump
N = None
2 = 11 cm3/rev (0.67 in3/rev)
2 Charge Relief Setting
C = 14 bar (205 psi)

F = 20 bar (280 psi)
3 Special Drive Features
N = None
1 = NFP
4 Rear Auxilliary Moundting Pa
N
A
B
T
High Pressure Relief Setting Port "A"
High Pressure Relief Setting Port "B"
Loop Bypass Valve
NN
14
17
19
21
23
25
28
30
34
00
= None
= SAE-A, 9 Tooth
= SAE-B, 13 Tooth
= SAE-A Special, 11 Tooth
= Check Valve only, No HPRV
= 140 bar (2030 psi)
= 175 bar (2450 psi)
= 190 bar (2755 psi)
= 210 bar (3045 psi)
= 230 bar (3330 psi)
= 250 bar (3625 psi)
= 280 bar (4060 psi)
= 300 bar (4350 psi)
= 345 bar (5000 psi)
= No HPRV, No Check Valves
N = None
B = Yes
Displacement Limiters - Side 1
Displacement Limiters - Side 2
N, 0 = None
A, 1 = Yes, Set at Max Disp
Special Hardware Features
NNN = None
Special Non-Hardware Features
NNN = None
22483 (01/04)
Technical Manual
A Terex Company
Series 42
Component and Port Locations
3. Component and Port Locations

3.1
Component Locations
A pump with a manual displacement control (MDC) and no filtration adapter is shown. With non-feedback and
automotive controls, the positions of the case drains vary (shown in gray). With a filtration adapter, the porting
in the "Filtration Options" area varies (see section 4.16).
Control Neutral Adjustment

(MDC/EDC)
Control Module
(MDC Shown)
Pump Neutral Adjustment
Servo Piston
Covers
System Check
Relief Valves
Displacement
Limiters
Charge
Pump
Shaft
Seal
Filtration Options
(No Filtration Adapter Shown Here)
Auxiliary
Mounting Pad
(Loop Flushing
Valve)
Left Side View (Side "2")
Charge Relief Valve
Right Side View (Side "1")

P100101 E
Series 42 28cc Variable Pump

Control Neutral Adjustment
(MDC/EDC)
Control Module
(MDC Shown)
Servo Piston
Covers
Displacement
Limiters
Charge
Pump
Auxiliary
Mounting
Pad
System Check
Relief Valves
Shaft Seal
(Loop Flushing Valve)

Charge Relief Valve

Filtration Options
(No Filtration Adapter
Shown Here)
P100102 E
Series 42 41cc Variable Pump
49
22483 (01/04)
Technical Manual
A Terex Company
Series 42
3.2
Ports and Pressure Gauges
Proper servicing of pumps and motors requires that

pressure be measured and monitored at various
points in the hydraulic circuit. The Series 42 pump
has several locations at which to take these measure-
Gauge
Pressure Measured
Port Name
ments. The following outlines show the locations of

the various gauge ports. The tables show the recommended gauge size and the fitting size for each port.
Refer to this page when installing pressure gauges.
Fitting
Recommended
Gauge Size
System Pressure for

600 bar or 10,000 psi 9/1618 O-Ring Fitting
Ports A and B
M1 & M2
041
028
9/1618 O-Ring Fitting
M3
Charge Pressure
60 bar or 1000 ps i
M4 & M5
Servo Pressure
Case Pressure
60 bar or 1000 ps i
35 bar or 500 ps i
1-1/1612 O-Ring Fittin g 1-5/1612 O-Ring Fitting
Charge Pump Inlet

Vacuum
1 bar, absolute
or 30 in Hg Vacuum
1-1/1612 O-Ring Fitting
L1 & L2
S
1-5/1612 O-Ring Fitting
P100103 E
System Pressure
Gauge Port M2
Servo Pressure
Gauge Port M5
Servo Pressure
Gauge Port M4
System
Pressure
Port B
Charge Pressure
Gauge Port M3
(Charge Pressure
Supply For
No Charge Pump
Option)
Case Drain Port L2

(Non-Feedback
Controls)
System
Pressure
Port A
Case Drain
Port L1
Case Drain Port L1
(Non-Feedback
Controls)
Charge Pump
Inlet Port S
Case Drain
Port L2
System Pressure
Gauge Port M1
28cc Base Unit with MDC and No Filtration Adapter
50
22483 (01/04)
Technical Manual
A Terex Company
Series 42
Servo Pressure
Gauge Port M5
Servo Pressure
Gauge Port M4
System Pressure
Gauge Port M2
System
Pressure
Port B
Charge Pressure
Gauge Port M3
(Charge Pressure
Supply For
No Charge Pump
Option)
Case Drain
Port L2
System
Pressure
Port A
Charge Pump
Inlet Port S
Case Drain
Port L1
System Pressure
Gauge Port M1
41cc Base Unit with MDC and No Filtration Adapter
P100104 E
To Filter, Port D
(Pressure Filtration)
Charge Pressure
Gauge Port M3
(Full Flow Pressure Filtration)
From Filter, Port E

(Pressure Filtration)
Charge Pressure
Gauge Port M3
(Partial Flow Pressure Filtration)
Charge Pressure
Gauge Port M3
(Suction Filtration)
P100105 E
Filtration Adapter (28cc and 41cc Models)
51
22483 (01/04)
Technical Manual
A Terex Company
Series 42
Adjustments and Minor Repairs
4. Adjustment and Minor Repair Instructions

4.1
Size and Torque for Plugs and Fittings
Plug and fitting sizes are given here. Place a fresh O-ring, lightly lubricated with petroleum jelly, whenever a plug
is removed. Each should be torqued as indicated. A 28cc unit with manual displacement control (MDC) is shown.
Servo Gage
Port M4
11/16 in Hex
27-47 Nm
(20-35 ftlbf)
28cc: 9/16 in Int. Hex

95-135 Nm
(70-100 ftlbf)
125-250 Nm
(90-190 ftlbf)
Case Drain
Port L1
Charge Pressure Gage
Port M3 (Position Varies,
Refer to Filtration Options)
E100001 E
Case Drain
Port L2
Port N
(Unused)
Charge Pump Inlet

Port S
Torque: 115 Nm (85 ftlbf)
11/16 in Hex
27-47 Nm
(20-35 ftlbf)
Servo Gage
Port M5
System Gage
Ports M1 and M2
11/16 in Hex
27-47 Nm
(20-35 ftlbf)
95-135 Nm
(70-100 ftlbf)
125-250 Nm
(90-190 ftlbf)
System Ports
A and B
115 Nm (85 ftlbf)
52
11/16 in Hex
27-47 Nm
(20-35 ftlbf)
22483 (01/04)
Technical Manual
A Terex Company
Series 42
4.2
The pump neutral adjustment sets the position of the

servo piston and pump swashplate relative to the
controlling mechanism.
WARNING
The following procedure requires the vehicle /
machine to be disabled (wheels raised off the
ground, work function disconnected, etc.) while
performing the procedure in order to prevent
1. Disconnect machine function.
2. Connect a hose between gauge ports M4 and M5
to equalize the pressures on both ends of the
pump servo piston.
Pump "Neutral"
Adjustment Screw
Pump "Neutral"
Adjustment Seal
Lock Nut
3. Install pressure gauges in gauge ports M1 and

M2 to measure system pressure.
4. Start the prime mover and operate at normal
speed.
5. Loosen the pump "neutral" adjustment seal lock
nut [28cc13 mm Hex; 41cc17 mm Hex]. Turn
the pump "neutral" adjustment screw [28cc5
E100002 E
mm Hex; 41cc7 mm Hex] until the system
pressure gauge readings are equal.
Pump Neutral Adjustment Screw

(MDC Control Shown)
6. Turn the adjustment screw clockwise until one of

the gauges registers an increase in system pressure. Note the position of the adjustment screw.
Turn the screw counterclockwise until the other
gauge registers an increase in system pressure.
Note the position of the adjustment screw.
7. Turn the adjustment screw clockwise to a position halfway between the positions noted above.
The system pressure gauges should indicate
equal pressures.
8. While holding the adjustment screw in position,
torque the seal lock nut [28cc20-26 Nm (15-19
ftlbf); 41cc28-51 Nm (21-37 ftlbf)] .
9. Stop the prime mover and remove the hose
between gauge ports M4 and M5. Remove the
pressure gauges installed in gauge ports M1 and
M2. Reinstall the plugs in the gauge ports.
10. Reconnect work function.
IMPORTANT
If the pump is equipped with an MDC or EDC,
the CONTROL "neutral" adjustment MUST also
be performed before putting the pump into
service (see next section).
53
22483 (01/04)
Technical Manual
A Terex Company
Series 42
4.3
Control Neutral Adjustment for MDC/EDC Controls
The control neutral adjustment aligns the pump swashplate and the control spool so that a zero angle control
setting provides a zero degree swashplate setting.
This adjustment should be performed whenever any
part of the control or swashplate mechanisms is
adjusted or removed or after the pump neutral setting
(previous section) is adjusted.
MDC / EDC Control

"Neutral" Adjustment Screw
WARNING
The following procedure requires the vehicle /
ground, work function disconnected, etc.) while
performing the procedure in order to prevent
1. Disconnect the work function. Disconnect the
external control linkage (for MDC) or control
signal input (for EDC) from the pump.
2. Install pressure gauges in gauge ports M4 and
M5 to measure pressure on the pump servo
piston.
speed.
MDC / EDC Control "Neutral"

Adjustment Seal Lock Nut
E100003 E
Control Neutral Adjustment Screw

(EDC Control Shown)
4. Loosen the CONTROL "neutral" adjustment seal

lock nut (see drawing) [17 mm Hex] . Turn the
control "neutral" adjustment screw [5 mm Int.
Hex] until the servo piston pressure gauge readings are as close to equal as possible.
5. Turn the adjustment screw clockwise until one of
the gauges registers an increase in pressure on
the servo piston. Note the position of the adjustment screw.
Turn the screw counterclockwise until the other
gauge registers an increase in pressure on the
servo piston. Note the position of the adjustment
screw.
6. Turn the adjustment screw clockwise to a position halfway between the positions noted above.
The servo piston pressure gauges should indicate nearly equal pressures.
7. While holding the adjustment screw in position,
torque the seal lock nut [14-24 Nm (10-18 ftlbf)].
8. Stop the prime mover and remove the pressure
gauges installed in gauge ports M4 and M5.
Reinstall the plugs in the gauge ports.
9. Reconnect the external control linkage (for MDC)
or control signal input (for EDC) to the pump.
Reconnect the work function.
54
22483 (01/04)
Technical Manual
A Terex Company
Series 42
4.4
MDC Control Module
The manual displacement control (MDC) module

provides control of the pump servo piston through a
connection to the summing link pin within the pump
housing. The following procedure shows how to
remove and install the control housing. Section 4.6
explains how to remove and install the control spool
and linkage.
1. Clean the external surfaces of the pump. If necessary, remove the MDC handle.
2. Remove the seven (7) control retaining screws
[Torx T30] that secure the control to the pump
housing. Remove the control and control gasket
from the pump.
Plug for
Visual
Inspection
Nut
Lock Washer
MDC Handle
Control
Retaining
Screws
Control
Gasket
Hold summing link
(and control spool)
in position
Note: See section 4.6 for instructions on removing/installing the control spool and linkage.
3. Clean the sealing surfaces of the control and the
pump housing. Place a new gasket in position on
the housing.
CAUTION
The control orifices are part of the control
gasket. Refer to the appropriate Service Parts
List to determine the correct gasket.
4. Hold the summing link pin in position while installing the control. (The spring on the control spool
will tend to push the link to an extreme position.)
The link pin MUST engage the slot in the control
cam. A plug is provided on the MDC housing to
permit visual inspection of linkage pin engagement.
Note: It may be easiest to lay the servo piston

side of the control down first, then watch the link
pin engage from the charge pump side of the
pump.
E100004 E
MDC Control Module Assembly
Summing
link pin
MUST enter
the slot in
the control
cam!
E100005 E
Link Pin Into Cam Slot
5. Install and torque the control screws [15-17 Nm

(11-13 ftlbf)]. Perform Control Neutral Adjustment (Section 4.3).
WARNING
Failure to properly engage the link pin with the
control cam will result in incorrect control
operation, which may lead to loss of control of
the vehicle / machine.
Link Pin Into Cam Slot

55
F100201
22483 (01/04)
Technical Manual
A Terex Company
Series 42
4.5
EDC Control Module
The Electric Displacement Control (EDC) provides a

control function through connections to the summing
link pin within the pump housing. The following procedure shows how to remove and install the control
housings. The next section explains how to remove
and install the control spool and linkage.
1. Clean the external surfaces of the pump. If necessary, remove control input signal.
EDC Control
Pressure Gauge
Port X1
2. Remove the seven (7) control retaining screws

[Torx T30] that secure the control to the pump
housing. Note the position of the different length
screws. Remove the control and control gasket
from the pump.
Note: See next section for instructions on removing/installing the control spool and linkage.
EDC Control
Pressure Gauge
Port X2
3. Clean the sealing surfaces of the control and the

pump housing. Place a new gasket in position on
the housing.
EDC Module Showing Port Locations
CAUTION
The control orifices are part of the control
gasket. Refer to the appropriate Service Parts
List to determine the correct gasket.
Control Retaining
Screws (note different sizes)
4. Hold the summing link pin in position while installing the control. (The spring on the control spool
will tend to push the link to an extreme position.)
The link pin MUST engage the hole in the control
piston fork.
Note: It may be easiest to lay the servo piston

side of the control down first, then watch the link
pin engage from the charge pump side of the
pump.
5. Install and torque the control screws [15-17 Nm
(11-13 ftlbf)]. Perform Control Neutral Adjustment (Section 4.3).
Control
Gasket
Hold summing
link (and control
spool) in
position
WARNING
Failure to properly engage the link pin with
control piston fork will result in incorrect control operation, which may lead to loss of control of the vehicle / machine.
P100106 E
Summing
link pin
MUST enter
the hole in
the control
piston fork!
E100006 E
EDC Control Module Assembly
56
22483 (01/04)
Technical Manual
A Terex Company
Series 42
4.6
MDC/EDC Control Spool, Control Linkage, and Control Neutral

Adjustment Screw
The control spool, control linkage, and control neutral

adjustment screw can be removed for cleaning and to
change the O-rings or the seal lock nut.
Summing Link
Linkage Pivot Screw
Removal of Spool, Linkage, and Adjustment

Screw
1. Clean the external surfaces of the pump.
Neutral
Adjustment
Link
2. Remove the MDC or EDC module and the control

gasket from the pump housing (see previous two
sections).
Feedback Link
Control Neutral
Adjust Screw
Seal Lock
Nut
Control
Spool
and Spring
Note
orientation!
3. Remove the summing link.

4. Remove the control spool bore plug [5/16 in Int.
Hex] or screws [Torx T30], cover, and gasket.
Remove the opposite bore plug [5/16 in Int. Hex],
and remove the control spool and spring.
5. Remove the linkage pivot screw [4 mm Int. Hex],
feedback link, and neutral adjustment link.
Opposite
Bore Plug
Housing without
Filtration Adapter
Control Spool
Bore Plug
6. Remove the seal lock nut [17 mm Hex] and the

control neutral adjustment screw [5 mm Int. Hex].
Installation of Spool, Linkage, and Adjustment
Screw
1. Install the control neutral adjustment screw and
seal lock nut. Do not tighten the nut.
2. Assemble the "neutral" adjustment link and feedback link, and install as shown. Install and torque
the linkage pivot screw [8-15 Nm (6-11 ftlbf)].
Housing with
Filtration Adapter
Gasket
Control Spool
Bore Cover
3. Lubricate and install the control spool and spring

assembly noting proper orientation.
WARNING
The control spool and spring assembly MUST
be oriented in the housing as shown for proper
control operation.
4. Install and torque the control spool bore plug [4194 Nm (30-70 ftlbf)]. Or install the control spool
cover (with a new gasket) or plug, and torque the
screws [15-17 Nm (11-13 ftlbf)].
5. Install the summing link. Hold the control spool in
position while engaging the fork on the summing
link with the flats on the spool. If necessary, rotate
the spool to engage the summing link.
E100007 E
MDC/EDC Control Spool and Linkage
Feedback link
must enter slot in
servo piston
Pivot screw
Slot in "neutral" adjust link

must engage groove in
adjusting screw
Fork on summing link

must engage flats on
control spool
E100008 E
Servo Piston Linkage and Control Spool

(Internal Parts Shown with Housing Removed)
6. Install a new control gasket. Hold the summing

link and control spool in position while reinstalling
the MDC or EDC (see section 4.4 or 4.5). Perform
Control Neutral Adjustment (section 4.3).
57
22483 (01/04)
Technical Manual
A Terex Company
Series 42
4.7
MDC Neutral Start/Backup Alarm Switch
The Neutral Start Switch (NSS) prevents the engine

and pump from being started when the pump is out of
neutral. The NSS should be wired in series with the
engine starting circuit. The switch contact is closed at
the control handle's neutral position and opens when
the control handle is rotated 1.5 to 2 from neutral.
NSS Cover
NSS Control Nut
NSS Cam
The Backup Alarm Switch (BUA) outputs an electronic signal when the control handle is in a reverse
position. This switch is normally wired in series with
an audio output. The switch contact is open until the
control handle is rotated 2.6 to 3.75 in the reverse
direction.
NSS Cavity
NSS with
Weatherpack
CAUTION
The control handle's neutral position must
agree with the pump's neutral position for the
NSS/BUA to work effectively (see section 4.3).
NSS with Screw

Terminals
E100009 E
The Neutral Start / Backup Alarm Switch assembly

can be configured for three different settings.
i.
NSS Assembly on MDC
A Neutral Start Switch only.
ii. A Neutral Start Switch with Backup Alarm for

units where clockwise (CW) handle rotation results in "reverse" motion.
iii. A Neutral Start Switch with Backup Alarm for
units where counterclockwise (CCW) handle rotation results in "reverse" motion.
Yolk
The setting must be in accordance with the configuration of the unit. See the model code (section 2) if
uncertain of the type of NSS you have.
NSS only
Alignment of the NSS requires a special alignment

tool. Dimensions are given at right.
NSS with BUA

(CW = Reverse)
Control
Cam
NSS with BUA

(CCW = Reverse)
P100107 E
Top View of NSS Showing Cam Positions
(continued)
9/16 -18UNF 2A THD

.04 x 45 Chamfer
R.125
.236.030
Knurl
35.0
1.250
.306
.354
2.000
Material: .75 DIA x 3 ETD150
(All Dimensions in inches)
P100108 E
Alignment Tool
58
22483 (01/04)
Technical Manual
A Terex Company
Series 42
Adjustment is performed by setting the cam position

within the NSS assembly.
1. The MDC module must be removed from the
pump housing. Refer to section 4.4.
NSS Cover
NSS
NSS Control Nut
2. Remove NSS [7/8 in Hex].
NSS Cam
3. Remove the NSS cover by inserting a screwdriver into the NSS cavity and popping off the
cover with a hammer. Be careful not to damage
the internal hardware.
P100109 E
Side View of NSS and NSS Cavity
4. Remove the control nut [8 mm Hex].

5. Use a screwdriver to pop off the cam.
6. Set cam in proper orientation according to the
unit's configuration (i, ii, or iii above).
7. Screw special alignment tool in NSS cavity to
hold cam in place.
8. On the underside of the MDC module, clamp a
pair of locking pliers around the spring contacts of
the control cam. The pliers should hold the nub on
the control cam to the pin underneath. This will
hold the control cam in neutral position.
9. Screw control nut on cam [4.1-6.8 Nm (3-5 ftlbf)].
10. Press new cover on top of cam cavity. This
requires either an arbor press or a full-sized
punch (punch depth = 1.06 mm (0.0417 in),
punch width = 23.3 mm (0.916 in)).
11. Remove the alignment tool and the locking pliers.
Underside of MDC Module Showing Where to Clamp

Locking Pliers
F100202
12. Place a new lubricated O-ring on NSS.

13. Reconnect the NSS [25-29 Nm (18-22 ftlbf)] to
the MDC.
14. Reinstall MDC module onto pump housing (refer
to section 4.4).
59
22483 (01/04)
Technical Manual
A Terex Company
Series 42
4.8
MDC Solenoid Override Valve
The solenoid override valve is a safety feature that

connects both ends of the servo control piston together when the solenoid is de-energized. Thus the
pump can be put into stroke only when the solenoid
is energized.
Port L4
Port X7
The solenoid override with brake release includes

hydraulic control of a safety brake. When de-energized, a spring-applied, hydraulically-released brake
is drained through port X7. For conditions where case
back-pressure on the spring-applied brake is critical,
an external drain to the reservoir can be connected
through port L4.
The solenoid override valve can be removed to
inspect and remove foreign matter.
Removal
1. Remove retaining nut [9/16 in Hex].
Solenoid Override Valve

Assembly
E100010 E
Solenoid Override Valve Assembly
2. Remove solenoid housing.

3. Remove retaining ring at base of solenoid.
Retaining Nut
4. Remove solenoid. This should be connected to

internal spool.
Solenoid
Housing
Installation
1. Replace O-ring.
Washer
Retaining Ring
2. Place spring and plunger inside of solenoid.
Solenoid
3. Attach spool (male notch) to plunger (female

notch).
O-Ring
4. Insert solenoid/spool assembly in solenoid override bore.
Spring
Plunger
5. Snap retaining ring over base of solenoid.

Spool
6. Place washer at base of solenoid.

7. Install housing and retaining nut [2-4 Nm (1.5-3.5
ftlbf)].
E100011 E
Exploded View of Solenoid Override Assembly

60
22483 (01/04)
Technical Manual
A Terex Company
Series 42
4.9
FNR, NFPE, and NFPH Controls
The 3-position FNR control and the electric and

hydraulic non-feedback proportional (NFPE and
NFPH) controls are non-feedback type controls. The
FNR and NFPE controls consist of modules mounted
on the pump housing. The hydraulic input for NFPH
is received through ports on the top of the pump
[9/1618 SAE O-ring fitting].
NFPH Ports
(Ports X1 and X2)
The non-feedback controls are set at the factory. The

control modules can be removed to clean the ports
and change the O-rings.
The orifice plugs for the FNR and NFPE are located
inside the servo piston covers. The orifice plugs for
the NFPH are located in the NFPH ports. Orifice
plugs may be cleaned or replaced.
E100012 E
Position of NFPH Ports
Note: Future models may contain orifice plate

between module and pump housing.
Control Solenoid
Control Module
Removal and Installation of FNR and NFPE

Modules
1. Clean pump and module housings.
2. Remove four (4) screws retaining module to
housing [4 mm Int. Hex], and remove module
from pump housing.
Control Ports
Locator Pin
3. Remove O-rings from the control ports. Examine

ports for cleanliness.
4. Clean sealing surfaces.
5. Replace locator pin.
6. Install new O-rings.
7. Replace screws [4.7-6.1 Nm (3.5-4.5 ftlbf].
E100013 E
Removal and Installation of FNR and NFPE

Control Orifices
NFPE Assembly (FNR Similar)
Note: Future models may contain an orifice plate

between module and pump housing. This will
take the place of the orifice plugs beneath the
servo piston cover.
Non-Feedback
Control Orifice
1. Remove servo piston cover (see section 4.17).

2. Remove orifice plug [1/8 in Int. Hex].
3. Examine orifice and port for cleanliness.
4. Install orifice plug [2.0-3.4 Nm (1.5-2.5 ftlbf)].
E100014 E
Location of Non-Feedback Control Orifice

61
22483 (01/04)
Technical Manual
A Terex Company
Series 42
4.10 System Check Relief Valves (High Pressure Relief, Charge Check,
& Bypass Valves)
The charge check, high pressure relief, and the loop
bypass functions are all contained within the system
check relief (SCR) valve assembly. This assembly
may be removed for cleaning and installation of fresh
O-rings. The model code specifies whether high
pressure relief valves, combination charge check/
high pressure relief valves, and/or loop bypass valves
are present or not.
With
Bypass
Without
Bypass
Valve
Seat
Plug
1. Remove the valve seat plugs [9 mm Int. Hex] or

valve seat/bypass plugs [1 in Hex] from the pump
housing.
Outer
O-Ring
Backup
Ring
2. Remove the check poppet or relief valve assemblies from the pump housing. The smaller end of
each conical spring is crimped to retain it on the
check poppet or relief valve. Do not remove.
Inner
O-Ring
Valve
Seat
Retaining
Ring
Standard
Bypass
Plunger
O-Ring
Valve
Seat
Plug
Outer
O-Ring
Backup
Ring
Inner
O-Ring
3. Inspect the valves and mating seats in the special

plugs for damage or foreign material.
CAUTION
The relief valves are factory set and should not
be tampered with, except for replacing the
entire valve.
4. The O-ring on the standard bypass plunger may
be replaced by removing the retaining ring and
removing the plunger from the special valve seat
plug. Remove the O-ring from the plunger and
install a new O-ring. Reinstall the plunger and
retaining ring.
Check Poppet or
High Pressure
Relief Valve
Conical Spring
5. Install a new outer O-ring, new backup ring, and

new inner O-ring on each valve seat plug.
6. Check that the conical springs are properly retained on the check poppets or relief valves.
Install the check poppet or high pressure relief
valve assemblies into the pump housing .
CAUTION
The conical springs MUST be correctly positioned on the check poppets or relief valves
after installation for proper pump operation.
E100015 E
System Check Relief Valve Components
7. Install the valve seat plugs or valve seat/bypass

plugs into the pump housing and torque [40-95
Nm (30-70 ftlbf)].
62
22483 (01/04)
Technical Manual
A Terex Company
Series 42
4.11 Charge Relief Valve

The charge relief valve may be removed for cleaning
and installation of fresh O-rings. The pressure setting
may be changed. However, note that the setting will
vary for different charge flows which depends on
charge pump size and pump speed. The factory
setting is set relative to case pressure at 1800 rpm.
The actual charge pressure will vary at different
speeds.
Shim Adjustable Style
1. Remove the shim adjustable charge relief valve
plug [1 in Hex] from the pump housing. Remove
the O-ring from the plug.
Shim Adjustable
Charge Relief Valve Plug
O-Ring
Shims
2. Remove the spring and poppet from the housing.
Spring
Poppet
3. Do not alter the shims which may be installed

between the spring and valve plug, or interchange parts with another valve. Inspect the
poppet and mating seat in the housing for damage or foreign material.
4. If desired, the charge relief valve setting can be
changed. An approximate rule of thumb is 4 bar
/ 1.25 mm (58 psi / 0.050 in). The effective setting
will vary.
E100016 E
To confirm the charge relief valve setting, measure charge pressure (port M3) with the pump in
stroke. The charge pressure should level off
when the relief setting is reached.
Shim Adjustable Charge Relief Valve Components
Approximate Relief Setting vs Shim Thickness
5. Install a new O-ring on the valve plug. Reinstall

the poppet, spring, and plug (with shims and Oring) into the pump housing [55-135 Nm (40-100
ftlbf)].
4 bar / 1.25 mm
(58 psi / 0.050 in )
(continued)
63
22483 (01/04)
Technical Manual
A Terex Company
Series 42
Screw Adjustable Style
Charge Relief Lock Nut
1. Before removing the screw adjustable relief valve

plug, mark the plug, lock nut, and housing so as
to approximately maintain the original adjustment when assembling, Remove the screw adjustable charge relief valve plug by loosening the
lock nut [1-1/16 in Hex] and unscrewing the plug
[8 mm Int. Hex]. Remove the O-ring from the plug.
O-Ring
Screw Adjustable
Charge Relief Valve Plug
Spring
Poppet

3. Inspect the poppet and mating seat in the housing for damage or foreign material.
the poppet and spring. Reinstall the plug with its
lock nut [47-57 Nm (34-42 ftlbf)], aligning the
marks made at disassembly.
E100017 E
Screw Adjustable Charge Relief Valve Components
5. Check and adjust, if necessary, the charge pressure. For screw adjustable "anti-stall" charge
relief valves, an approximate rule of thumb is 2.8
bar / quarter turn (40 psi / quarter turn).
Approximate Relief Setting vs Screw Revolution

2.8 bar / 14 turn
To confirm the charge relief valve setting, measure charge pressure (port M3) with the pump in
stroke. The charge pressure should level off
when the relief setting is reached.
64
(40 psi / 14 turn)
22483 (01/04)
Technical Manual
A Terex Company
Series 42
4.12 Loop Flushing Valve

The loop flushing function consists of the loop flushing shuttle valve and the loop flushing relief valve. The
assemblies may be removed for cleaning and installation of new O-rings. The relief valve poppet may be
exchanged for one with a different flow rating, but the
relief valve shims should not be changed out unless
specifically instructed so by Sauer-Sundstrand. The
function also can be defeated.
Loop Flushing
Relief Plug
Loop Flushing Relief
Plug (Defeat)
O-Ring
O-Ring
Shims
Spring
Poppet
Loop Flushing Valve

1. Remove the loop flushing valve plug from the
pump housing [11/16 in Hex]. Remove the O-ring
from the plug.
2. Remove the loop flushing valve spool assembly
from the housing.
3. Inspect the parts for damage or foreign material.
The centering spring must be securely retained to
the spool by the washer.
Loop Flushing
Plug (Defeat)
O-Ring
Defeat
Spool
Loop
Flushing
Plug
O-Ring
Loop
Flushing
Spool
Assembly
4. Install the loop flushing valve spool assembly into

its bore. Install a new O-ring on the loop flushing
plug and install [27-47 Nm (20-35 ftlbf)].
Loop Flushing Relief Valve
1. Remove the loop flushing relief valve internal hex
plug [5/8 in Hex] from the pump housing. Remove
the O-ring from the plug.
E100018 E

3. Do not alter the shims which are installed between the spring and valve plug, or interchange
parts with another valve. Inspect the poppet and
mating seat in the housing for damage or foreign
material. Inspect the orifice in the valve poppet.
the poppet, spring, shims, and plug (with O-ring)
into the pump housing [15-34 Nm (15-25 ftlbf)].
Loop Flushing Valve and Loop Flushing Defeat

Components
Defeating Loop Flushing

1. Remove the loop flushing valve from the pump
housing.
2. Install the defeat spool into the spool bore in the
housing. Install the plain plug with O-ring into the
housing [11/16 in Hex], and torque [27-47 Nm
(20-35 ftlbf)].
3. Remove the charge relief valve (these parts are
not necessary).
4. Install the plain hex plug with O-ring into the end
cap [5/8 in Hex], and torque [15-34 Nm (15-25
ftlbf)].
65
22483 (01/04)
Technical Manual
A Terex Company
Series 42
4.13 Shaft Seal and Shaft Replacement

A lip type shaft seal is used in Series 42 pumps. This
seal and/or the shaft can be replaced without major
disassembly of the unit. Replacement generally requires removal of the pump from the machine.
Retaining
Ring
Seal Carrier
Assembly
1. Position the pump with the shaft facing up.
NOTE: If the unit is positioned horizontally when

the shaft is removed, the cylinder block could
move out of place, making shaft installation difficult.
2. Remove the retaining ring from the housing.
3. Pull out seal carrier assembly.
4. Remove the O-ring from the seal carrier. To
install a new shaft only, proceed to step 8.
5. Place the seal carrier in an arbor press with the
shaft bearing side down, and press out the old
seal. An appropriately sized pipe spacer or socket
wrench can be used as a press tool. Once removed, the seal is not reusable.
E100019 E
Shaft Seal Components
6. Inspect the seal carrier and the new seal for

damage. Inspect the sealing area on the shaft for
rust, wear, or contamination. Polish the sealing
area on the shaft if necessary.
O-Ring
7. Press the new seal into the shaft bearing side of

the seal carrier. The seal lip must face the outside
of the pump. Be careful not to damage the seal.
The outside diameter of the seal may be coated
with a sealant (e.g. Loctite High Performance
Sealant #59231) prior to installation. This aids in
preventing leaks caused by damage to the seal
bore in the seal carrier.
Seal
Sealant may
be used on
outside diameter
Seal Carrier
Inside Lip
(face down)
(continued)
Press Seal
to bottom of Seal Carrier
E100020 E
Installation of Shaft Seal
66
22483 (01/04)
Technical Manual
A Terex Company
Series 42
If the shaft is not being replaced proceed to step

11.
Retaining Ring
8. Remove the shaft and roller bearing assembly

from the pump or motor. The bearing assembly
can be transferred to the new shaft (steps 9 and
10).
9. Remove the retaining ring that secures roller
bearing assembly with a snap ring plier. Remove
the roller bearing assembly.
10. Place roller bearing assembly on new shaft and
secure with the retaining ring.
Roller Bearing
Key
Shaft
OR
Shaft Assembly
OR
11. Wrap the spline or key end of shaft with thin

plastic to prevent damage to the seal lip during
installation. Lubricate the inside diameter of the
shaft seal with petroleum jelly.
12. Place the O-ring onto the shaft bearing and
lubricate with petroleum jelly.
13. Slide the seal carrier assembly over the shaft and
into the housing bore. Press against O-ring. Hold
inward pressure against the shaft to compress
the cylinder block spring while pressing the seal
carrier into place.
14. Install the retaining ring.
E100021 E
Shaft Components
67
22483 (01/04)
Technical Manual
A Terex Company
Series 42
4.14 Auxiliary Mounting Pads

The following procedure can be used to remove and
install a new auxiliary mounting pad or to install a
fresh O-ring for the current auxiliary mounting pad.
Several auxiliary mounting pads are available.
Auxiliary mounting pads are integrated into the charge
pump cover. When nothing is mounted on the pads,
a flange cover is attached to protect the mounting
flange. This cover is removed when mounting a
pump.
Removal of Auxiliary Mounting Pad
1. Remove the auxiliary pump or remove the two
screws retaining the flange cover ["A" Pad9/16
in Hex; "B" Pad3/4 in Hex]. Remove the O-ring.
Pad Cover Screws

Charge
Pump
Cover
Aux Mount Pad Cover

Retaining
Screws
O-Ring
2. Orient pump so that charge pump cover (auxiliary

pad) is facing up.
OR
3. Remove the charge pump cover. The auxiliary

pad is integrated into the charge pump cover.
Use a Torx T45 male driver to remove the screws.
OR
Auxiliary
Mounting
Pad "A"
Note: If a different auxiliary pad is being installed,

then a new drive coupling must be installed. To do
this follow the instructions in the section on removing and installing the charge pump (next
section).
Gasket
Auxiliary
Mounting
Pad "B"
Note: If the charge pump components come out

with the charge pump cover refer to section 4.15
on how to properly reinstall them.
No Charge
Pump Defeat
4. Install a new charge pump cover gasket.
Locating
Pin 1
Charge Pump
Components
5. Install the charge pump cover (auxiliary pump

mounting pad is integrated in cover).
Locating
Pin 2
NOTE: The threaded screw holes in the auxiliary

pump mounting pad used on very early production pumps with the SAE "A" pad option are drilled
through into the area between the gerotor cover
and charge pump cover. Any of these holes
which are not used to attach the flange cover or
auxiliary pump should be plugged with internal
hex set screws installed hand tight to prevent the
entrance of water or dirt into this area.
E100022 E
Auxiliary Pad Options and Components
6. Attach the auxiliary pump. If no pump is to be

attached on an auxiliary mounting pad, the pad
should be protected with a flange cover and Oring to prevent leakage.
68
22483 (01/04)
Technical Manual
A Terex Company
Series 42
4.15 Charge Pump
(Screw used with

"No Pad" and
"A Pad" Only)
Cover
Retaining
Screws
1. Remove auxiliary pump, if necessary.

2. Remove the screws retaining the charge pump
cover to the pump housing [Torx T45] (seven (7)
screws are used with the "no pad" or SAE "A"
auxiliary mounting pad charge pump cover, while
six (6) screws are used with the SAE "B" auxiliary
mounting pad charge pump cover). Remove the
charge pump cover, gasket, and the cover locating pins.
3. Remove the gerotor cover assembly from the
charge pump cover or the back of the pump
housing. Remove the gerotor cover O-rings. Two
(2) O-rings are used on the gerotor cover of all
pumps. (An additional O-ring was used on the
gerotor cover of very early production pumps with
the SAE "A" pad option.)
Gasket
O-Rings
Geroter
Cover
4. Remove the gerotor assembly from the gerotor

cover or pump housing.
5. Remove the gerotor drive pin and drive coupling.
Remove the gerotor cover locating pin from the
pump housing.
6. Each part should be inspected separately if they
are to be reused. If either of the gerotor assembly
parts needs to be replaced, they must both be
replaced. Always replace the O-rings and charge
pump cover gasket. Inspect the journal bearing in
the gerotor cover for excessive wear.
Charge Pump Cover or Auxiliary Pad
Note: For units without integral charge pumps

see the last page of this section for additional
information.
Geroter
Assembly
Drive Coupling
Geroter Cover
Locating Pin
Charge Pump
Cover
Locating
Pin
Geroter Drive Pin

Charge Pump
Cover Locating
Pin
Charge Pump Components
The charge pump may be disassembled to inspect

and clean, or to change the auxiliary shaft drive
coupling.
7. Prior to assembly, lubricate the gerotor assembly

with clean hydraulic oil.
8. Install the gerotor drive pin into the hole in the
drive coupling, and retain with grease or petroleum jelly.
9. Install the drive coupling onto the pump shaft with
the smaller outside diameter oriented away from
the pump shaft. Different couplings are used
with the different auxiliary pad options.
E100023 E
10. Install the gerotor assembly onto the coupling.
(continued)
69
22483 (01/04)
Technical Manual
A Terex Company
Series 42
11. Install the gerotor cover locating pin into the

pump housing. Install the gerotor cover assembly
over the gerotor. The locating pin must engage
the slot in the gerotor cover.
NOTE: The charge pump rotation is determined

by the location of the gerotor recess and pressure
balance hole in the gerotor cover. Different
gerotor covers are used for clockwise and
counterclockwise rotation pumps.
12. Install new pressure balance O-rings onto the
gerotor cover and retain with petroleum jelly or
grease. (An additional O-ring was used on the
gerotor cover of very early production pumps with
the SAE "A" pad option.)
13. Install the charge pump cover locating pins and a
new charge pump cover gasket.
14. Install the charge pump cover. The cover must
engage the gerotor cover and the locating pins.
Install the charge pump cover screws and torque
evenly [36-43 Nm (26-32 ftlbf)].
CW
CCW
P100110 E
Determining Charge Pump Orientation Looking

Inside of Gerotor Pump Cover
15. If necessary, reinstall auxiliary pump.

For units without an integral charge pump see the
next section.
(continued)
70
22483 (01/04)
Technical Manual
A Terex Company
Series 42
Units without Integral Charge Pump

Variable Pumps without an integral charge pump do
not have a gerotor assembly, gerotor drive pin, or
gerotor cover locating pin installed. The charge pump
inlet port is plugged with an O-ring plug.
Cover
Retaining
Screws
For these units that are equipped with housings

without filtration adapters, the gerotor cavity outlet
is plugged with a special plug installed in a housing
passage. The 3/416 charge inlet fitting should be
torqued to 68 Nm (50 ftlbf).
For these units that are equipped with housings that
include filtration adapters, the gerotor cavity outlet
is plugged with an O-ring plug installed in the "To
Filter" port of a "Full Filter Flow" (charge relief valve
after filter) filter adapter. The 7/814 charge inlet
fitting should be torqued to 95 Nm (70 ftlbf).
Gasket
Charge Pump Cover or Auxiliary Pad
(Screw used with

"No Pad" and
"A Pad" Only)
CAUTION
A "Partial Filter Flow" (charge relief valve before filter) adapter must not be used on variable
pumps without an integral charge pump. If this
design adapter is used, the charge relief valve
will be defeated.
Geroter
Cover
E100024 E
Drive Coupling
Charge Pump
Cover Locating
Pin 2
Geroter
Cavity
Outlet Plug
(Charge
Pump Defeat)
Charge Pump
Cover Locating
Pin 1
"No Charge Pump" Components
O-Rings
Charge
Inlet
Charge Pump
Inlet Plug
Charge Pump Inlet Plug
Charge Inlet
(For Wrench Sizes
and Torquing
See Filtration Section)
No Charge Pump Option Components

(Housing with Filtration Adapter)
No Charge Pump Option Components

(Housing without Filtration Adapter)
71
22483 (01/04)
Technical Manual
A Terex Company
Series 42
4.16 Filtration
Filtration of foreign matter from the hydraulic fluid is
of primary importance. Dirt and foreign fluids within
the hydraulic circuit will greatly reduce the life of the
hydraulic equipment.
M3 Gauge
Port Plug
Filtration Plate
Retaining Screws
Filter-Related Pump Hardware

Filtration mechanisms for the Series 42 pump may
be before (suction filtration) or after (charge pressure
filtration) the charge pump. Sauer-Sundstrand provides a filtration adapter to provide for each type of
filtration configuration. If filtration is provided for
elsewhere in the hydraulic circuit, the pump will not
have a filtration adapter.
Partial Flow
Pressure
Filtration
Full Flow
Pressure
Filtration
Suction
Filtration
Pumps equipped with housings without filtration

adapters have an additional construction bore next to
the charge relief valve which is unused and plugged
[5/8 in Hex, 21-33 Nm (15-25 ftlbf)]. When these
pumps are equipped with suction filtration, the external charge inlet is plugged [5/16 in Int. Hex, 41-94 Nm
(30-70 ftlbf)].
Pumps equipped with housings that include filtration
adapters have the appropriate adapter and gasket
fastened to the housing with screws [Torx T30, 16
Nm (12 ftlbf)]. The position of the M3 gauge port [11/
16 in Hex, 11-13 Nm (8-10 ftlbf)] will vary depending
on filtration type.
Housing with
Filtration Adapter
Filter Specifications
Charge Inlet
Plug
The selection of a filter depends on a number of

factors including the contaminant ingression rate,
the generation of contaminants in the system, the
required fluid cleanliness, and the desired maintenance interval. A filter capable of controlling the fluid
cleanliness to ISO 4406 Class 18/13 or better is
recommended and may be located either on the inlet
(suction filtration) or discharge (charge pressure
filtration) side of the charge pump.
Construction
Bore Plug
E100025 E
Housing without
Filtration Adapter (Suction Filtration Only)
Filter capacity depends on desired maintenance

levels. As a rough guide, a capacity in grams equal
to twice the charge flow in gpm or 1/2 charge flow in
l/min has been found to be satisfactory for many
closed circuit systems.
Filtration Type
Closed Circuit Suction Filtration or
Open Circuit Return Line Filtration
Systems Sharing a Reservoir with
Other Gears, Clutches, or Cylinders
Charge Pressure Filtration
Filter efficiency as measured by a "Beta" () ratio*

should be as in the table at right.
See Sauer-Sundstrand publication BLN-9887 or
697581 and ATI-E 9201 for more information on
filtration.
Plug
-ratio
10 2
10 10
10 0
* Filter x-ratio is a measure of filter efficiency defined by ISO

4572. It is defined as the ratio of the number of particles greater
than a given size (x) upstream of the filter to number of particles
greater than the same size downstream of the filter. The x-ratio
applies to a specific particle size, measured in microns.
72
22483 (01/04)
Technical Manual
A Terex Company
Series 42
4.17 Servo Piston Covers

The servo piston cover can be removed to change the
gasket or to inspect/change the control orifices for
NFP or FNR controls (section 4.9).
Pump Neutral Ajustment

Seal Lock Nut
1. On the right side (side 1) of the pump, remove

the pump neutral adjustment seal lock nut [13
mm Hex]. (Not necessary on side "2")
2. Remove the servo piston cover screws [Torx
T30].
Servo Piston
Cover Screw
Servo Piston Cover
Servo Piston Cover

(Non-Feedback and
Automotive controls only)
3. The left side (side "2") servo cover can be removed directly.
Pump "Neutral"
Adjustment Screw
On the right side (side 1) of the pump, the cover

should be pushed away from the pump housing.
It is then necessary to turn the neutral adjustment screw [5 mm Hex] clockwise (inward) far
enough for the servo cover to clear the nearby
drain port. Then pull the cover away from the
housing and turn the cover counterclockwise to
disengage it from the adjustment screw.
Servo Piston Cover Right Side (Side "1")
4. Remove the gasket.
Note: FNR and NFPE control orifice plugs are

located here, see section 4.9 for more information.
5. Install new gasket.
6. On the right side (side "1"), screw the servo piston
cover on the neutral adjustment screw. Then,
while holding the cover, turn the neutral adjustment screw CCW to engage the cover to the
screw threads.
Servo Piston
Cover Screws
E100026 E
Servo Piston
Cover
7. Install servo piston cover screws (15-17 Nm (1113 ftlbf)].

8. On the right side (side "1"), loosely install neutral
adjustment seal lock nut. Perform pump neutral
adjustment (section 4.2).
Servo Piston Cover Left Side (Side "2")
Servo Piston Cover Components
WARNING
After installing the servo piston cover on right
side (side 1) of the pump, the pump neutral
adjustment and control neutral adjustment
MUST be performed before the vehicle / machine is put back into service.
CAUTION
Performance of the above procedure may adjust the position of the displacement limiter
somewhat.
73
22483 (01/04)
Technical Manual
A Terex Company
Series 42
4.18 Displacement Limiter Adjustment

Displacement limiters can limit the maximum swashplate position. For Series 42 pumps, displacement
limiters are available on one or both sides of the servo
piston.
Seal Lock Nut
Servo Piston
Cover
Adjustment of the displacement limiters should be

performed on a test stand.
WARNING
Care should be taken in adjusting displacement limiters to avoid undesirable speed conditions. The limiter screw must have full thread
engagement in the servo piston cover, and the
seal lock nut must be retorqued after every
adjustment to prevent unexpected changes in
operating conditions and external leakage during unit operation.
Displacement Limiter Right Side (Side "1")

(Exploded View, No Need to Remove Limiter or Nut)
1. Mount pump on test stand.

2. Loosen displacement limiter seal lock nut [13 mm
Hex]. Do not remove.
3. Adjust displacement limiter [4 mm Int. Hex].
Tighten the seal lock nut every time the pump
is to be tested [20-26 Nm (15-19 ftlbf)].
Seal Lock Nut
E100027 E
One full turn of the displacement limiter adjustment screw will change the displacement of the
pump approximately as follows.
28cc
3.6 cc/rev
0.22 in3/rev
41cc
5.0 cc/rev
0.31 in3/rev
Servo Piston
Cover
4. After reaching proper displacement tighten the

seal lock nut [20-26 Nm (15-19 ftlbf)].
Displacement Limiter Left Side (Side "2")

(Exploded View, No Need to Remove Limiter or Nut)
If necessary, repeat procedure for displacement limiter on other side.
Displacement
Limiter
Displacement Limiters
74
22483 (01/04)
Technical Manual
A Terex Company
Series 42
Exploded V
5. Exploded View Parts Drawings

5.1
Shaft Options
F096
C020
C017
C018
C015
C005
C002
C003
C001
C015
F001
OR
C001
OR
C001
E100028
75
22483 (01/04)
Technical Manual
A Terex Company
Series 42
5.2
Exploded V
Filtration, Charge Relief, System Relief, and Loop Flushing
(F086)
(F086A)
(F043)
(F043A)
(F040)
(F042)
(F040)
(F042)
(F043)
(F043A)
OR
F043
F043A
OR
F040
F042
K001
OR
K001
K005
F091
F091A
G040
G040A
G041
G043
G042
K001A
K001B
F030 K001C
F030A
K002
K006
K007
F041
K008
K009
K010
G043
G042
G041
G040A
G040
OR
045A
G045
F062
F061
F063
F060A
F060
(F060A)
(F060)
F051
OR
H005
H002
H003
J005
J002
J003
F0511
F0512
F0513
F0514
F0515
F050A
F050
OR
(F091A)
F093
(F091)
(F051)
(F050A)
(F050)
F093A
F093
F093A
N002A
N002
F077
E100029
76
22483 (01/04)
Technical Manual
A Terex Company
Series 42
5.3
Exploded View Parts Drawings
Charge Pump, Auxiliary Pads, and Servo Covers
L010
L010A
F020
F020A
G005
(G075)
G010
G015
G002
G020
(G021)
G022
G065
G075
G030
F009
G023
G001
M001
OR
(M001)
OR
(G001)
M005
M010A
(M005)
(M010A)
G036
M010
OR
(G080)
(M010)
M020
M025
(G001)
(G036)
G085
G090
(G090)
(G036)
(G080)
(G085)
E100030
77
22483 (01/04)
Technical Manual
A Terex Company
Series 42
5.4
Control Options
D039
D038
D037
D081
D003
D003A
(D017)
D080
D082
D019
D016
D002
OR
OR
D017
D056
D040
D010
D012
F035
E001
F035A
D070
OR
OR
D011
D013
F036
F035
D004
E100031
F034
D081
D081
OR
D060
(F010)
F010
D090
D014
D015
D032A
D032
78
22483 (01/04)
Technical Manual
A Terex Company
Slat Traction Pumps &

Remix Delivery Pumps - Series 90
Cross-Port Line
Servo Pressure
Port G 500 psi Hose
Cross-Port Line
Servo Pressure
Port F 500 psi Hose
High Pressure
Ports A (top) & B (bottom)
Use 6000 psi Gauge
Multi-Function Valve
(By-Pass)
Charge Pressure
Port C 500 psi
High Pressure
Ports A (top) & B (bottom)
Use 6000 psi Gauge
(By-Pass)
Case Drain Pressure

100 psi Port D L1
Servo Pressure
Port G 500 psi Hose
Cross-Port Line M5
Servo Pressure
Port F 500 psi Hose
Cross-Port Line M4

Port B 10,000 psi Gauge
M2-B
Charge Pump
Inlet Vacuum Port E
M3

Port A 10,000 psi Gauge
M1-A
79
22483 (01/04)
Technical Manual
A Terex Company
Axial Piston Pumps


Sunstrand Sauer
Series 90 - M55
80
22483 (01/04)
Technical Manual
A Terex Company
Series 90
Introduction
1. Introduction
1.1
Use of This Manual
This manual includes information for the normal

operation, maintenance, and servicing of the Series
90 family of hydrostatic pumps and motors. The
manual includes the description of the units and their
individual components, troubleshooting information,
adjustment instructions, and minor repair procedures.
Unit warranty obligations should not be affected if
maintenance, adjustment, and minor repairs are performed according to the procedures described in this
manual.
be available, and the unit must be thoroughly cleaned

before beginning maintenance, adjustment, or repair
activities. Since dirt and contamination are the greatest enemies of any type of hydraulic equipment,
cleanliness requirements must be strictly adhered to.
This is especially important when changing the system filter and during adjustment and repair activities.
A worldwide network of Sauer-Sundstrand Authorized Service Centers is available should repairs be
needed. Contact any Sauer-Sundstrand Authorized
Service Center for details. A list of all Service Centers
can be found in bulletin BLN-2-40527, or in brochure
SAW (Ident. No. 698266).
Many service and adjustment activities can be performed without removing the unit from the vehicle or
machine. However, adequate access to the unit must
1.2
Safety Precautions
Observe the following safety precautions when using and servicing hydrostatic products.
Loss of Hydrostatic Braking Ability
Fluid Under High Pressure
WARNING
When Series 90 units are used in vehicular
hydrostatic drive systems, the loss of hydrostatic drive line power in any mode of operation (e.g. acceleration, deceleration or neutral mode) may cause a loss of hydrostatic
braking capacity. A braking system which is
independent of the hydrostatic transmission
must, therefore, be provided which is adequate
to stop and hold the system should the condition develop.
WARNING
Use caution when dealing with hydraulic fluid
under pressure. Escaping hydraulic fluid under pressure can have sufficient force to penetrate your skin causing serious injury. This
fluid may also be hot enough to burn. Serious
infection or reactions can develop if proper
medical treatment is not administered immediately.
Flammable Cleaning Solvents
Disable Work Function
WARNING
Some cleaning solvents are flammable. To
avoid possible fire, do not use cleaning solvents in an area where a source of ignition may
be present.
WARNING
Certain service procedures may require the
vehicle/machine to be disabled (wheels raised
off the ground, work function disconnected,
etc.) while performing them in order to prevent
Copyright 1987, 1989, 1990, 1996, Sauer-Sundstrand Company.

All rights reserved. Contents subject to change. Printed in U.S.A. 0196 H
81
F000539
F000451
F000648
22483 (01/04)
Technical Manual
A Terex Company
Series 90
Functional Description
2. Functional Description
This section describes the operation of pumps, motors, and their various serviceable features. It is a useful
reference for readers unfamiliar with the functioning of a specific system.
2.1
General Description and Cross Sectional Views
2.1.1
Variable Displacement Pumps
The Variable Displacement Pump (PV) is designed to

convert an input torque into hydraulic power. The
input shaft turns the pump cylinder which contains a
ring of pistons. The pistons run against a tilted plate,
called the swashplate. This causes the pistons to
compress the hydraulic fluid which imparts the input
energy into the hydraulic fluid. The high pressure fluid
is then ported out to provide power to a remote
function.
The swashplate angle can be varied by the control
piston. Altering the swashplate angle varies the displacement of fluid in a given revolution of the input
shaft. A larger angle causes greater displacement
which yields greater output torque for a given input. A
smaller angle reduces the displacement per revolution and yields greater speed for a given input.
90000346
Series 90 Variable Displacement Pump (PV)

Valve Plate
Piston
Control Piston
Manual Displacement Control
Roller Bearing
Input Shaft
Charge Pump
Cylinder Block
Cradle Swashplate
Series 90 PV Cross Section
2.1.2
90000189
Fixed Displacement Motor
The Fixed Displacement Motor (MF) is designed to

convert an input of hydraulic power into an output
torque. It operates in the reverse manner of the
pump. The high pressure hydraulic fluid enters through
the input port. The fluid pressure builds behind the
pistons causing them to move down the swashplate
(the path of least resistance). As the piston returns up
the swashplate again, the fluid is allowed to exit
through the exit port. The spinning pistons are housed
in a cylinder which is connected to the output shaft.
The output torque can be applied to a mechanical
function.
90000347
Series 90 Fixed Displacement Motor (MF)

82
22483 (01/04)
Technical Manual
A Terex Company
Series 90
Loop Flushing Valve

Valve Plate
In the Fixed Displacement Motor the "swashplate" is

fixed, so any variation in motor speed and torque
must be made by the input mechanism, i.e. the pump.
Piston
Roller Bearing
Output Shaft
Fixed Swashplate
Cylinder Block
90000190
Series 90 MF Cross Section
2.1.3
Variable Displacement Motor
The Variable Displacement Motor (MV) operates in

the same manner as the fixed motor. However, its
swashplate is not fixed; it can be switched between
minimum and maximum angle to amplify torque or
speed like the Variable Displacement Pump.
90000348
Series 90 Variable Displacement Motor (MV)
Valve Plate
Minimum Angle
Control Piston
Piston
Roller Bearing
Cradle Swashplate
Output Shaft
"A"
Partial Section "A-A"

Cradle Swashplate in full
displacement position
"A"
Cradle Swashplate
Cylinder Block
Maximum Angle
Control Piston
Electric 2-Position Control (Option)

(4-Way, 2 Position Valve)
90000234
Series 90 MV Cross Section
83
22483 (01/04)
Technical Manual
A Terex Company
Series 90
2.2
System loop
(low pressure)
Displacement control valve
Control handle
Case drain fluid

Heat exchanger
bypass valve
System loop
Reservoir
Orificed
check valve
(high pressure)
Control fluid
Vacuum gauge
Suction line
Heat exchanger
Reversible
variable
displacement
pump
Servo control
cylinder
Purge relief valve
Charge pressure
Multi-function relief valve
valve
Fixed displacement
motor
to
pump
case
Servo pressure
relief valve
Input
shaft
Charge pump
Pump
swashplate
Multi-function
valve
Servo control
cylinder
Pump
Output
shaft
Motor swashplate
Loop flushing valve
Motor
The System Circuit
90000800
Circuit Diagram for Series 90 PV and Series 90 MF
The Basic Closed Circuit

The main ports of the pump are connected by hydraulic lines to the main ports of the motor. Fluid flows, in
either direction, from the pump to the motor then back
to the pump in this closed circuit. Either of the hydraulic lines can be under high pressure. The position of
the pump swashplate determines which line is high
pressure as well as the direction of fluid flow.
Case
Drain
Line
Input
PV
MV
Output
Case Drain and Heat Exchanger

The pump and motor require case drain lines to
remove hot fluid from the system. The motor should
be drained from its topmost drain port to ensure the
case remains full of fluid. The motor case drain can
then be connected to the lower drain port on the pump
housing and out the top most port. A heat exchanger,
with a bypass valve, is required to cool the case drain
fluid before it returns to the reservoir.
84
Flow (Bi-directional)
Reservoir
90000803
Basic Closed Circuit
22483 (01/04)
Technical Manual
A Terex Company
Series 90
2.3
Common Features of Pumps and Motors

2.3.1
End Caps and Shafts
Series 90 pumps and motors can be supplied with a

variety of end caps and shafts to allow for almost any
configuration. For pumps, end caps are available
with system ports on either side ("side ports") or both
ports on one side ("twin ports"). Motors have end
caps with ports on the face of the end cap ("axial
ports") or both ports on one side ("twin ports"). See
the Series 90 Technical Information manuals (BLN10029 and BLN-10030) or the Series 90 Price Book
(BLN-2-40588) for information on available options.
Removing the end cap will void the warranty on a
Series 90 pump or motor.
2.3.2
Speed Sensors
An optional speed sensor can be installed on Series

90 pumps and motors to provide unit speed information. The sensor reads a magnetic ring wrapped
about the unit's cylinder. See Sec. 4 to locate the
speed sensor port. See Sec. 8.4 and 9.6 to adjust and
install the sensor.
90000810
Speed Sensor
85
22483 (01/04)
Technical Manual
A Terex Company
Series 90
2.4 Pump Features

2.4.1
Charge Pump
The charge pump is necessary to supply cool fluid to

the system, to maintain positive pressure in the main
system loop, to provide pressure to operate the
control system, and to make up for internal leakage.
Charge pressure must be at its specified pressure
under all conditions of driving and braking to prevent
damage to the transmission.
The charge pump is a fixed-displacement, gerotor
type pump installed in the variable displacement
pump and driven off the main pump shaft. Charge
pressure is limited by a relief valve (Sec. 2.4.2).
90000243
The standard charge pump will be satisfactory for

most applications. However, if the charge pump sizes
available for the given main pump size are not adequate, a gear pump may be mounted to the auxiliary
mounting pad (Sec. 2.4.8) and supply the required
additional charge flow. For repairs to the charge
pump see Sec. 9.2.4.
2.4.2
Charge Relief Valve
The charge relief valve on the pump serves to maintain charge pressure at a designated level. A directacting poppet valve relieves charge pressure whenever it surpasses a certain level. This level is nominally set referencing case pressure at 1775 rpm. This
nominal setting assumes the pump is in neutral (zero
flow); in forward or reverse charge pressure will be
lower. The charge relief valve setting is specified on
the model code of the pump (Sec. 8.1.1). For repairs
to the pump charge relief valve see Sec. 9.2.3.
2.4.3
PV with Charge Pump
90000349
Case
Drain
Line
Charge Relief
System Check Valves
The system check valves allow pressurized flow from

the charge pump to enter the low pressure side of the
loop whenever system pressure dips below a certain
level. This is needed as the pump will generally lose
system pressure due to leakage and other factors.
Since the pump can operate in either direction, two
system check valves are used to direct the charge
supply into the low pressure lines. The system check
valves are poppet valves located in the multi-function
valve assembly (next section).
System
Check
Valves
Input
PV
PF
Charge
Pump
Inlet Filter
Reservoir
90000804
Pump Charge System
86
22483 (01/04)
Technical Manual
A Terex Company
Series 90
2.4.4
Multi-Function Valves
All Series 90 pumps include two multi-function valves.

The multi-function valve incorporates the system
check valve, the pressure limiter valve, the high
pressure relief valve, and the bypass valve in a
replaceable cartridge. These functions are described
separately. There are two multi-function valve cartridges in each Series 90 pump to handle functions in
either direction. See Secs. 8.1.2 and 9.2.1 for adjustments and repairs.
NOTE: Some multi-function valves do not include a pressure limiter valve.

90000243
2.4.5
PV showing location of Multi-Function Valves

High Pressure
Relief / Check
Valve Poppet
Pressure Limiter
Housing
Series 90 pumps are designed with a sequenced

pressure limiting system and high pressure relief
valves. When the preset pressure is reached, the
pressure limiter system acts to rapidly destroke the
pump so as to limit the system pressure. For unusually rapid load application, the high pressure relief
valve acts to immediately limit system pressure by
cross-porting system flow to the low pressure side of
the loop. The pressure limiter valve acts as the pilot
for the high pressure relief valve spool. The high
pressure relief valve is sequenced to operate at
approximately 35 bar (500 psi) above the level that
initiates the pressure limiter valve.
Check Valve
Poppet
Pressure Limiter
Lock Nut
Pressure Limiter
Adjustment Screw
Bypass
Actuator
Pressure Limiter
Poppet Seat
Pressure Limiter
Valve Poppet
90000806
Cross Section of Multi-Function Valve
Both the pressure limiter sensing valves and relief

valves are built into the multi-function valves (see
above).
To Control
NOTE: For some applications, such as dual path

vehicles, the pressure limiter function may be
defeated so that only the high pressure relief
valve function remains.
Bypass Hex
Adjustment
Servo Piston
Pressure Limiter and High Pressure

Relief Valves
Port "A"
Servo Pressure
Relief Valves
Port "B"
2.4.6
Bypass Valves
Servo Piston
Charge Pressure
Relief Valve
The bypass valves ("tow") can be operated when it is

desired to move the vehicle or mechanical function
when the pump is not running. The valve is opened by
manually resetting the valve position (Sec. 8.1.3).
90000801
Circuit Diagram Showing Pressure Control

Mechanisms
The bypass valves are built into the multi-function

valves (see above).
87
22483 (01/04)
Technical Manual
A Terex Company
Series 90
2.4.7
Displacement Limiters
Series 90 pumps sizes 042 - 250 are designed for

optional mechanical displacement (stroke) limiters.
The maximum displacement of the pump can be
limited in either direction.
The setting can be set as low as 0 in either direction.
For instructions on adjustment see Sec. 8.1.5.
90000244
PV with Displacement Limiters
2.4.8
Auxiliary Mounting Pads
Auxiliary mounting pads are available on all Series 90

pumps. SAE A through E and H mounts are available
(availability varies by pump size). This pad is used for
mounting auxiliary hydraulic pumps and for mounting
additional Series 90 pumps to make tandem pumps.
The pads allow for full through-torque capability.
90000242
PV with Auxiliary Mounting Pad
2.4.9
Filtration Options
All Series 90 pumps are available with provisions for

either suction or charge pressure filtration (integral or
remote mounted) to filter the fluid entering the charge
circuit. (See Sec. 6 for more information.)
Suction Filtration
The suction filter is placed in the circuit between the
reservoir and the inlet to the charge pump. When
suction filtration is used, a reducer fitting is placed in
the charge pressure gauge port (M3). Filtration devices of this type are provided by the user.
90000243
PV with Suction Filtration

(No filtration device attached)
Charge Pressure Filtration

The pressure filter may be integrally mounted directly
on the pump or a filter may be remotely mounted for
ease of servicing.
A 200 mesh screen, located in the reservoir or the
charge inlet line, is recommended when using this
filtration option. A non-bypass filter is preferred on all
types of filtration.
88
90000246
90000247
PV with Integral Charge Pressure Filtration (left)

PV with Remote Charge Pressure Filtration (right,
filter attached remotely)
22483 (01/04)
Technical Manual
A Terex Company
Series 90
2.4.10 Pressure Override (POR) - 180

Frame Size Only
To Control
Pressure
Override
Control Valve
Bypass Hex
Adjustment
Port "A"
Shuttle
Valve
Port "B"
Charge Pressure
Relief Valve
90000802
Pressure Override - 180 Frame Size Only
89
The pressure override valve (POR) modulates the

control pressure to the displacement control to maintain a pump displacement which will produce a system pressure level less than or equal to the POR
setting. For unusually rapid load application, the high
pressure relief valve function of the multifunction
valves is available to also limit the pressure level.
The pressure override consists of a three-way normally open valve which operates in series with the
pump displacement control. Control supply pressure
is normally ported through the pressure override
valve to the displacement control valve for controlling
the pump's displacement. If the system demands a
pressure above the override setting, the POR valve
will override the control by reducing the control pressure supplied to the displacement control. As the
control pressure reduces, the internal forces tending
to rotate the swashplate overcome the force of the
servo pistons and allow the pump's displacement to
decrease.
22483 (01/04)
Technical Manual
A Terex Company
Series 90
2.5
Pump Control Options
2.5.1
Manual Displacement Control (MDC)
The manual displacement control converts a mechanical input signal to a hydraulic signal using a springcentered four-way servo valve. This valve ports
hydraulic pressure to either side of a dual-acting
servo piston. The servo piston rotates the cradle
swashplate through an angular rotation of 17, thus
varying the pumps displacement from full displacement in one direction to full displacement in the
opposite direction. The MDC is designed so the
angular position of the pump swashplate is proportional to the rotation of the control input shaft. For
adjustments see 8.2.1; for repairs see 9.3.2, 9.3.8.
90000237
PV with Manual Displacement Control
Non-Linear MDC
The non-linear manual displacement control (photo
in Sec. 8.2.2) operates in the same manner as the
regular MDC except that it is designed so the change
in the angular position of the pump swashplate progressively increases as the control input shaft is
rotated toward its maximum displacement position.
For adjustments see Sec. 8.2.2; for repairs see 9.3.2.
90000239
Solenoid Override Valve

A solenoid override valve option (not shown here) is
available for MDC. This safety feature will return the
swashplate to zero displacement position when activated. The valve may be set in either a normally open
or normally closed mode. For repairs see 9.3.3, 9.3.4.
PV with Manual Displacement Control and Neutral

Start Switch
Neutral Start Switch (NSS)

The neutral start switch is an optional feature available with MDC. When connected properly with the
vehicles electrical system, the neutral start switch
ensures that the prime mover can be started only
when the control is in a neutral position. For adjustments see Sec. 8.2.3.
2.5.2 Hydraulic Displacement Control (HDC)

The hydraulic displacement control uses a hydraulic
input signal to operate a spring-centered four-way
servo valve. This valve ports hydraulic pressure to
either side of a dual-acting servo piston. The servo
piston rotates the cradle swashplate through an
angular rotation of 17, thus varying the pumps
displacement from full displacement in one direction
to full displacement in the opposite direction. The
HDC is designed so the angular position of the pump
swashplate is proportional to input pressure. For
adjustments see 8.2.4; for repairs see 9.3.5, 9.3.8.
90
90000240
PV with Hydraulic Displacement Control
22483 (01/04)
Technical Manual
A Terex Company
Series 90
2.5.3
Electric Displacement Control (EDC)
The electric displacement control is similar to the

hydraulic displacement control with the input signal
pressure controlled by a pressure control pilot (PCP)
valve. The PCP valve converts a DC electrical input
signal to a hydraulic signal which operates a springcentered four-way servo valve. This valve ports hydraulic pressure to either side of a dual-acting servo
piston. The servo piston rotates the cradle swashplate through an angular rotation of 17, thus varying the pumps displacement from full displacement
in one direction to full displacement in the opposite
direction. The control is designed so the angular
position of the swashplate is proportional to the EDC
input. For neutral adjustment see Sec. 8.2.4; for
repairs see Sec. 9.3.5, 9.3.6, and 9.3.8.
90000241
PV with Electric Displacement Control
2.5.4
Automotive Control (AC and AC II)
Automotive Control (AC) allows a vehicle to be driven

in a manner similar to an automobile with an automatic transmission.
The AC control includes a three-position electric
control to provide direction control.
90000353
PV with Automotive Control (AC)
The AC II control can be combined with a manual,

hydraulic, or electric displacement control to provide
both direction control and control over maximum
vehicle speed. It may also be combined with a 3position electric control to provide direction control.
2.5.5
3-Position (FNR) Electric Control
This control utilizes a 12 or 24 VDC electrically

operated spool valve to port pressure to either side of
the pump displacement control piston. Energizing
one of the solenoids will cause the pump to go to its
maximum displacement in the corresponding direction.
F000645
PV with Automotive Control Type II (AC II)
All functions of the three-position (FNR) electric control are preset at the factory. For repairs, see Sec.
9.3.7
90000354
PV with 3-Position (FNR) Electric Control

91
22483 (01/04)
Technical Manual
A Terex Company
Series 90
Technical Specifications
3. Technical Specifications
3.1
General Specifications
Design
Variable Pumps and Motors: Axial piston pump of
variable displacement, cradle swashplate design.
Fixed Motors: Axial piston motor with fixed displacement, fixed swashplate design.
Type of Mounting (per SAE J744)
SAE flange, Size "B" mounting pad, 2 bolts
SAE flange, Size "C" mounting pad, 4 bolts
Cartridge flange, 2 bolts (for motor only)
3.2
Port Connections (See Sec. 4.2 for exact specs.)

Main pressure ports: SAE flange, Code 62
Remaining ports: SAE straight thread O-ring boss
Direction of Rotation
Clockwise or counterclockwise (motors are bidirectional)
Installation Position
Installation position is discretionary. The housing
must always be filled with hydraulic fluid, so note
position of drain ports.
Circuit Diagrams
L2
M3
M1
M3
X5
Vg max
A
M1
M5
M4
M2
B
L1
M2
B
L1
MV with electrohydraulic twoposition control
L2
PV with charge pump and manual

displacement control
L2
M3
M1
M2
L1
MF
92
90000811
90000812
90000813
22483 (01/04)
Technical Manual
A Terex Company
Series 90
3.3
Hydraulic Parameters
System Pressure Range
Temperature Range1
Maximum Pressure
480 ba r
[6960 psi]
Minimum, Intermittent
or Cold Start
-40C
[-40F]
Rated Pressure
420 ba r
[6000 psi]
Maximum, Continuous 4 10 C
[220F]
Maximum, Intermittent 5 11 C
[240F]
Charge Pump Inlet Vacuum (on pumps only)

Maximum Vacuum,
Continuous
0.7 bar abs [10 in Hg]
Maximum Vacuum,
Cold Start
0.2 bar abs [25 in Hg]
Fluid Viscosity Limits
Case Pressure
Minimum, Intermittent
5 mm 2/s
[42 SUS]
Minimum, Continuous
6.4 mm2/s
[47 SUS]
Minimum, Optimum
13 mm2/s
[70 SUS]
110 mm2/s
[510 SUS]
Maximum, Continuous
3 ba r
[44 psi]
Maximum, Continuous
Maximum, Intermittent
or Cold Start
5 bar
[73 psi]
Maximum, Intermittent
1600 mm2/s [7400 SUS]
or Cold Start
Hydraulic Fluid
Refer to SAS publication BLN 9887 or Publication
SDF (Id. No. 697581). Also refer to publication ATIE 9101 for information relating to biodegradable
fluids
Filtration
Required cleanliness level: ISO 4406 Class 18/13
or better. Refer to SAS publications BLN 9887 or
Publication SDF (Id. No. 697581) and ATI-E 9201.
1. At hottest point in system, normally the case drain port. Temperature and viscosity limits must be met simultaneously.
93
22483 (01/04)
Technical Manual
A Terex Company
Series 90
3.4
Technical Data
Table 1 - Variable Displacement Pumps

Dimension
Displacement
(maximum)
Minimum speed
Rated speed*
030 PV 042 PV 055 PV 075 PV 100 PV 130 PV 180 PV 250 PV
cm
in3
30.0
1.83
42.0
2.56
55.0
3.35
75.0
4.57
100.0
6.10
130.0
7.93
180.0
10.98
250.0
15.25
min-1 (rpm)
500
500
500
500
500
500
500
500
-1
4200
4200
3900
3600
3300
3100
2600
2300
-1
min (rpm)
Maximum speed*
min (rpm)
4600
4600
4250
3950
3650
3400
2850
2500
Max. attainable speed*

at max. disp.
min-1 rpm)
500
5000
4700
4300
4000
3700
3150
2750
Nm / bar
lbfin/1000 psi
0.48
290
0.67
380
0.88
530
1.19
730
1.59
970
2.07
1260
2.87
1750
3.97
2433
kg
lb
28
62
34
75
40
88
49
108
68
150
88
195
136
300
154
40
Theoretical torque
at max. disp.
Weight
(Base Unit)
Table 2 - Fixed and Variable Displacement Motors

Dimension
3
030 MF 042 M F 055 M F 075 M F 100 M F 130 M F 055 M V 075 M V
Displacement (maximum)
cm
in3
30.03
1.83
42.0
2.56
55.0
3.35
75.0
4.57
100.0
6.10
130.0
7.93
55.0
3.35
75.0
4.57
Displacement (minimum)
cm3
in3
19.0
1.16
26.0
1.59
at max. disp.
mi n-1 (rpm)
420 0
420 0
390 0
360 0
330 0
310 0
390 0
360 0
at min. disp.
mi n-1 (rpm)
4600
425 0
at max. disp.
mi n-1 (rpm)
460 0
460 0
425 0
395 0
365 0
340 0
425 0
395 0
at min. disp.
mi n-1 (rpm)
5100
470 0
min-1 (rpm)
500 0
500 0
470 0
430 0
400 0
370 0
470 0
430 0
Nm / bar
lbfin/1000 psi
0.48
290
0.67
380
0.88
530
1.19
730
1.59
970
2.07
1260
0.88
530
1.19
730
l / min
gal / min
138
36.5
193
51
234
62
296
78
365
96
442
117
234
62
296
78
Max. corner power
kW
hp
111
149
155
208
187
251
237
318
292
392
354
475
224
300
282
378
Weight
(SAE Flange)
kg
lb
11
24
15
34
20
45
26
57
34
74
45
99
39
86
44
98
Weight
(Cartridge Motor)
kg
lb
17
37
26
57
33
72
40
88
46
101
Rated
speed*
Maximum
speed*
Max. attainable speed*

at max. disp.
Theoretical torque
at max. disp.
Maximum flow
at max. disp.
* = Refer to Series 90 Technical Information manual for definitions
94
22483 (01/04)
Technical Manual
A Terex Company
Series 90
Pressure Measurement
4. Pressure Measurement
4.1
Required Tools
The service procedures described in this manual for

Series 90 pumps and motors can be performed using
common mechanic's tools. Special tools, if required
are shown.
4.2
Pressure gauges should be calibrated frequently to

ensure accuracy. Snubbers are recommended to
protect pressure gauges.
Port Locations and Pressure Gauge Installation
The following sections list the ports for each type of

hydraulic unit. The recommended pressure gauge
and fitting are also specified.
4.2.1
Port
M1
M2
Variable Pump
Function
1000 bar or 10 000 psi Gauge

System
Pressure
Port "B"
1000 bar or 10 000 psi Gauge

Servo
Pressure
Port
Recommeneded Gauge Siz

and Fitting
System
Pressure
Port "A"
M3 Charge
(M6) Pressure
M4
M5
Outline drawings showing port locations follow the

tables.
Function
L1 Case
L2 Pressure
Recommeneded Gauge Siz

and Fitting
10 bar or 100 psi Gauge
SAE O-Ring Fitting:
030, 042 7/814
055, 075, 1-1/1612
100
130

1-5/1612
180, 250 1-5/812

X1 HDC / EDC
X2 Pressure

7/16 20 O-Ring Fitting or
9/16 18 O-Ring Fitting
X3 Ext. Control
Pressure

9/16 18 O-Ring Fitting
Vacuum Gauge, Tee into

Inlet Line
Charge
Pump Inlet
SAE O-Ring Fitting:

030, 042 1-1/16 12
055, 075 1-5/16 12
100, 130, 1-5/8 12
180
250
95
1-1/2 SAE Split

Flange
22483 (01/04)
Technical Manual
A Terex Company
Series 90
Servo / Displacement
Cylinder Pressure
Gauge Port M4
External Control
Pressure Supply
Port X3
Charge Pressure
Gauge Port M3
Case Drain
Port L1
System Pressure
Port "B"
Cylinder Pressure
Gauge Port M5
90000814
Top View
System Pressure
Port B
System Pressure
Case Drain Port L1
External Control
Pressure Supply
Port X3
Gauge Port M2
Speed Sensor
Charge Inlet Pressure
System Pressure
Gauge Port M1
Charge Pump
Inlet Port S
System Pressure
Port A
Case Drain Port L2
Left Side View
Charge Pressure
Gauge Port M3
Right Side View
90000815
90000816
PV with Side Port End Cap and Manual Displacement Control
96
22483 (01/04)
Technical Manual
A Terex Company
Series 90
Charge Pressure
Gauge Port M6
(Before Filter)
Port E
(From Filter)
Port D
(To Filter)
Charge Pressure
Gauge Port M3
(After Filter)
Charge Pressure
Gauge Port M3
(After Filter)
Rear View
PV with Side Port End Cap and Remote

Pressure Filtration
Rear View
90000817
90000818
PV with Side Port End Cap and Integral
Pressure Filtration
Charge Pressure
Gauge Port M3
Case Drain
Port L1
System Pressure
Gauge Port M2
External Control
Pressure Supply
Port X3
Case Drain
Port L1
System Pressure
Port B
Cylinder Pressure
Gauge Port M4
Charge Pump Inlet

Port S
System Pressure
Port A
Cylinder Pressure
Gauge Port M5
Top View
System Pressure
Gauge Port M1 Case Drain
Port L2
Left Side View
90000819
90000820
PV with Twin Port End Cap and Manual Displacement Control
97
22483 (01/04)
Technical Manual
A Terex Company
Series 90
Start-Up
5. Initial Start-Up Procedure
The following start-up procedure should always be

followed when starting-up a new Series 90 installation or when restarting an installation in which either
the pump or motor had been removed.
WARNING
The following procedure may require the vehicle/machine to be disabled (wheels raised off
the ground, work function disconnected, etc.)
while performing the procedure in order to
prevent injury to the technician and bystanders.
Take necessary safety precautions before
moving the vehicle/machine.
Prior to installing the pump and/or motor, inspect the
units for damage incurred during shipping and handling. Make certain all system components (reservoir, hoses, valves, fittings, heat exchanger, etc.) are
clean prior to filling with fluid.
Fill the reservoir with recommended hydraulic fluid.
This fluid should be passed through a 10 micron
(nominal, no bypass) filter prior to entering the reservoir. The use of contaminated fluid will cause damage
to the components, which may result in unexpected
vehicle/machine movement. See the publications
BLN-9887 and SDF 697581 for further related information.
The inlet line leading from the reservoir to the pump
must be filled prior to start-up. Check inlet line for
properly tightened fittings and make sure it is free of
restrictions and air leaks.
Be certain to fill the pump and/or motor housing
with clean hydraulic fluid prior to start up. Fill the
housing by pouring filtered oil into the upper case
drain port.
Install a 50 bar (or 1000 psi) pressure gauge in the
charge pressure gauge port (see Sec. 4.2 for location) to monitor the charge pressure during start-up.
It is recommended that the external control input
signal (linkage for MDC, hydraulic lines for HDC, or
98
electrical connections for EDC) be disconnected at

the pump control until after initial start-up. This will
ensure that the pump remains in its neutral position.
WARNING
Do not start prime mover unless pump is in
neutral position (0 swashplate angle). Take
precautions to prevent machine movement in
case pump is actuated during initial start up.
Jog or slowly rotate prime mover until charge pressure starts to rise. Start the prime mover and run at
the lowest possible RPM until charge pressure has
been established. Excess air may be bled from the
high pressure lines through the high pressure system
gauge port.
Once charge pressure has been established, increase speed to normal operating RPM. Charge
pressure should be as indicated in the pump model
code (see Sec. 8.1.1). If charge pressure is inadequate, shut down and determine cause for improper
pressure. Refer to Troubleshooting Sec. 7.
WARNING
Inadequate charge pressure will affect the
operators ability to control the machine.
Shut down the prime mover and connect the external
control input signal. Also reconnect the machine
function if disconnected earlier. Start the prime mover,
checking to be certain the pump remains in neutral.
With the prime mover at normal operating speed,
slowly check for forward and reverse machine operation.
Charge pressure may slightly decrease during forward or reverse operation. Continue to cycle slowly
between forward and reverse for at least five minutes.
Shut down prime mover, remove gauges, and plug
ports. Check reservoir level and add filtered fluid if
needed.
The transmission is now ready for operation.
22483 (01/04)
Technical Manual
A Terex Company
Series 90
Fluid and Filter Maintenance
6. Fluid and Filter Maintenance
To ensure optimum service life of Series 90 products,

regular maintenance of the fluid and filter must be
performed. Contaminated fluid is the main cause of
unit failure. Care should be taken to maintain fluid
cleanliness while performing any service procedure.
ManoVacuummeter
Hydraulic fluid reservoir
Charge pump
Filter
Check the reservoir daily for proper fluid level, the

presence of water (noted by a cloudy to milky appearance, or free water in bottom of reservoir), and rancid
fluid odor (indicating excessive heat). If either of
these conditions occur, change the fluid and filter
immediately.
Adjustable
Charge pressure relief valve
to low
pressure
side and
control
To pump case
It is recommended that the fluid and filter be

changed per the vehicle/machine manufacturers
recommendations or at the following intervals:
P000797 E
Suction Filtration Schematic
System with a sealed-type

reservoir
2000 hours
System with a breathingtype reservoir
500 hours
Screen
Hydraulic fluid reservoir
It may be necessary to change the fluid more frequently than the above intervals if the fluid becomes
contaminated with foreign matter (dirt, water, grease,
etc.) or if the fluid has been subjected to temperature
levels greater than the recommended maximum.
Never reuse fluid.
Adjustable
Charge pressure
relief valve
Charge pump
to low
pressure
side and
control
The filter should be changed whenever the fluid is

changed or whenever the filter indicator shows that it
is necessary to change the filter.
To pump case
Filter
Filters can be in either pressure filtration or suction

filtration configurations. For suction filtration, filters
should have a Beta-ratio of 10>2. For charge pressure filtration, filters should have a Beta-ratio of
10>10. See Sauer-Sundstrand publication BLN-9887
or 697581 and ATI-E 9201 for more information on
filtration.
P000798 E
Charge Pressure Filtration Schematic

(Partial Flow)
99
22483 (01/04)
Technical Manual
A Terex Company
Series 90
Troubleshooting
7. Troubleshooting
This section provides general steps to follow if certain undesirable system conditions are observed. Follow the
steps in a section until the problem is solved. Some of the items will be system specific. For areas covered in this
manual, a section is referenced. Always observe the safety precautions listed in Sec. 1.2 and related to your
specific equipment.
7.1
"Neutral" Difficult or Impossible to Find

Item
Description
Action
1. Check input to pump

control.
Input to control module is operating

improperly.
Check control input and repair or replace

as necessary.
2. Check pump displacement control.
Control linkages are not secure, control orifices are blocked, etc.
Adjust, repair, or replace control module as

necessary (8.2 and 9.3).
3. Repair
pump.
7.2
or
Consult a Sauer-Sundstrand Authorized

Service Center.
replace
System Operating Hot

Item
1. Check oil level in reservoir.
Description
Insufficient hydraulic fluid will not
meet cooling demands of system.
2. Inspect
changer.
ex-
Heat exchanger not sufficiently cooling the system.
Check air flow and input air temperature for

heat exchanger. Clean, repair or replace
heat exchanger.
3. Check charge pressure.
Low charge pressure will overwork

system.
Measure charge pressure (4.2). Inspect

and adjust or replace charge relief valve
(8.1.1 and 9.2.3). Or repair leaky charge
pump (9.2.4).
4. Check charge pump

inlet vacuum.
High inlet vacuum will overwork system. A dirty filter will increase the
inlet vacuum. Inadequate line size
will restrict flow.
Check charge inlet vacuum (4.2). If high,

inspect inlet filter and replace as necessary. Check for adequate line size, length
or other restrictions.
5. Check system relief

pressure settings.
If the system relief settings are too

low, the relief valves will be overworked.
Verify settings of pressure limiters and high

pressure relief valves and adjust or replace
multi-function valves as necessary (8.1.2,
9.2.1)
6. Check for internal leakage in motor.
Leakage will reduce low side system

pressure and overwork the system.
Monitor motor case flow without loop flushing in the circuit (use defeat spool 9.4.1.3).
If flow is excessive, replace motor.
7. Check system pressure.
High system pressure will overheat

system.
Measure system pressure (4.2). If pressure is high reduce loads.
heat
8. Replace transmission.
Action
Fill reservoir to proper level.
Replace pump and motor.

100
22483 (01/04)
Technical Manual
A Terex Company
Series 90
7.3
Troubleshooting
Transmission Operates Normally in One Direction Only

Item
Description
Action

control.

improperly.

as necessary.
Repair or replace control module as necessary (8.2 and 9.3).
3. Interchange system
pressure limiters, high
pressure relief valves,
and system check
valves.
Interchanging the multi-function

valves will show if the problem is
related to the valve functions contained in the multi-function valves.
Interchange multi-function valves. If the

problem changes direction, repair or replace the valve on the side that does not
operate (8.1.2 and 9.2.1).
If charge pressure decays in one

direction the loop flushing valve may
be sticking in one direction.
Measure charge pressure in forward and

reverse (4.2). If pressure decays in one
direction, inspect and repair the motor loop
flushing valve (9.4.1.1).
7.4
System Will Not Operate in Either Direction

Item
Description
Action
Insufficient hydraulic fluid to supply

system loop.

control.

improperly.

as necessary.
4. Ensure bypass valve(s)

are closed.
If bypass valve(s) is open, the system loop will be depressurized.
Close bypass valves (8.1.3). Replace multifunction valve if defective (9.2.1).
5. Check charge pressure

with pump in neutral.
Low charge pressure insufficient to

recharge system loop.
Measure charge pressure with the pump in

neutral (4.2). If pressure is low, go to step
6; otherwise continue with step 5.
6. Check charge pressure

with pump in stroke.
Low charge pressure with the pump

in stroke indicates a motor charge
relief valve or system pressure relief
valve may be improperly set.
Measure charge pressure with pump in

stroke (4.2). If pressure is low, adjust or
replace motor charge relief valve (8.3.1
and 9.4.1.2), otherwise go to step 9.
7. Inspect pump charge

relief valve.
A pump charge relief valve that is

leaky or set too low will depressurize
the system.
Adjust or replace pump charge relief valve

as necessary (8.1.1, 9.2.3)
8. Check charge pump

inlet filter.
A clogged filter will undersupply system loop.
Inspect filter and replace if necessary.
(continued)
101
22483 (01/04)
Technical Manual
A Terex Company
Series 90
Troubleshooting
9. Check charge pump.
A malfunctioning charge pump will

provide insufficient charge flow.
Repair or replace the charge pump (9.2.4).

If OK go to last step.
11. Check system pressure.
Low system pressure will not provide power necessary to move load.
Measure system pressure (4.2). Continue

with next step.
12. Check system multifunction valves.
Defective multi-function valves will

cause system pressure to be low.
Repair or replace multi-function valve(s)

(9.2.1).
7.5
Low Motor Output Torque

Item
Description
Action
1. Check system pressure

at motor.
Low system pressure at the motor

will reduce torque.
Measure system pressure at motor (4.2). If

pressure limiter setting is low, increase
setting.
2. Variable motor stuck at

minimum displacement.
Minimum motor displacement yields

low output torque.
Check control supply pressure (4.2.3) or

repair displacement control (9.5). Check
motor control orifices (9.5.4).
3. Check for internal leakage.
Internal leakage will reduce system

pressure.
Check for leakage in O-rings, gaskets, and

other fittings (9.1.1 and others). Repair unit
as required, or replace leaky unit.
7.6
Improper Motor Output Speed

Item
Description
Insufficient hydraulic fluid will reduce

motor speed.
Fill oil to proper level.
Incorrect charge pressure can result

in a low speed motor.
Measure charge pressure (8.1.1), adjust

charge system as necessary (9.2.3 and
9.2.4).
3. Check pump output

flow.
Incorrect outflow will affect output

speed. Incorrect output flow indicates
the swashplate is out of position.
Measure pump output flow by teeing into

outflow hose. Check for proper pump speed
and see that the pump is in full stroke.
4. Check variable motor

displacement control.
If variable motor displacement control is not functioning correctly, variable motor swashplate may be in
wrong position.
See if variable motor displacement control

is responding. If not, repair or replace control (9.5).
102
Action
22483 (01/04)
Technical Manual
A Terex Company
Series 90
7.7
Troubleshooting
Excessive Noise and/or Vibration

Item
Description
1. Check oil in reservoir.
Insufficient hydraulic fluid will lead to

cavitation.
2. Air in system.
Air bubbles will lead to cavitation.
Look for foam in reservoir. Check for leaks

on inlet side of system loop. Afterwards, let
reservoir settle until bubbles are gone. Run
system at low speed to move system fluid
to reservoir. Repeat.
3. Check pump inlet

vacuum.
High inlet vacuum will create noise. A

dirty filter will increase the inlet
vacuum.
Inspect and replace filter as necessary.

Check for proper suction line size.
4. Inspect shaft couplings.
A loose shaft coupling will cause

excessive noise.
Replace loose shaft coupling in charge

pump (Sec. 9.2.4) or replace pump or motor.
5. Inspect shaft alignment.
Unaligned shafts will create excessive frictional noise.
Align shafts.
7.8
Action
System Response is Sluggish

Item
Description
Insufficient hydraulic fluid will reduce

output pressure.
2. Check multi-function
valves pressure settings.
Incorrect pressure settings will affect

system reaction time.
Adjust or replace multi-function valves

(8.1.2 and 9.2.1).
3. Check pump inlet

vacuum.
High pump inlet vacuum will reduce

system pressure.
Measure charge inlet vacuum (4.2). If high

replace inlet filter.
4. Check prime mover

speed.
Low engine speed will reduce system performance.
Adjust engine speed.
5. Check charge and control pressures.
Incorrect charge or control pressures

will affect system performance.
Measure charge and control pressures and

correct if necessary (4.2 and others).
6. Check system internal

leakage.
Internal leakage will reduce system

pressure.
Check for leakage in O-rings, gaskets, and

other fittings (9.1.1 and others).
Action
103
22483 (01/04)
Technical Manual
A Terex Company
Series 90
Inspections and Adjustments
8. Inspections and Adjustments

This section offers instruction on how to perform inspections and adjustments on pump and motor components.
Read through the entire related section before beginning a service activity. Refer to Sec. 4 for location of gauge
ports and suggested gauge size.
8.1
Pump Adjustments
8.1.1 Charge Relief Valve Adjustment

The following procedure explains how to check and
adjust the charge relief valve. (For description see
Sec. 2.4.2.)
WARNING
The following procedure may require the vehicle/machine to be disabled (wheels raised off
the ground, work function disconnected, etc.)
in order to prevent injury to the technician and
bystanders.
1. To measure pump charge pressure, install a pressure gauge in the pump charge pressure gauge
port (M3). Also install a gauge to measure case
pressure (tee into L1 or L2 or use servo gauge
port). Operate the system with the pump in neutral (zero displacement) when measuring pump
charge pressure.
2. The table on the following page shows the acceptable pump charge pressure range for some nominal charge relief valve settings (see sample model
code at right). These pressures assume 1775
pump rpm and a reservoir temperature of 49C
(120F ), and are referenced to case pressure
(see footnote on next page). Smaller displacement charge pumps will produce charge pressure
readings in the lower portion of the range, while
larger displacement charge pumps will produce
readings in the higher portion of the range.
90000243
Charge Pressure Gauge Port (Reducer fitting shown

- if filtration device attached, see Sec. 4.2.1 for
alternate location of this port)
90L055
EA
1 N
6 S 3 C6 C 03
HNN 35 35 24
Nominal Charge
Pressure Setting
Model Code on Unit Name Plate (24 bar)
(continued)
104
22483 (01/04)
Technical Manual
A Terex Company
Series 90
Model Code Measured Charge Pressure*

Setting
(stated range 1.7 bar [ 25 psi])
20 bar
20.1 to 21.2 bar

[291 to 308 psi]
24 bar
24.0 to 25.2 bar

[348 to 365 psi]
28 bar
27.8 to 29.0 bar

[403 to 420 psi]
NOTE: These pressures assume a pump speed

of 1775 rpm. At higher pump input speeds (with
higher charge flows) the charge pressure will rise
over the rated setting.
3. Earlier production Series 90 pumps are equipped
with a shim adjustable charge relief valve. Shim
kits are available from Sauer-Sundstrand. Adjustment of charge pressure is accomplished by removing the plug [1 inch Hex] and changing the
shim thickness behind the spring. The plug for this
type of charge relief valve should be torqued to 68
Nm (50 lbfft).
90000262
Shim Adjustable Charge

Pressure Relief Valve
(Pump)
Later production Series 90 pumps are equipped

with an external screw adjustable charge relief
valve. Adjustment of the charge pressure is accomplished by loosening the lock nut (with a 1-1/
16 inch hex wrench for 030 through 100 units, or
a 1-5/8 inch hex wrench for 130 through 250
units), and turning the adjustment plug with a
large screwdriver or a 1/2 inch hex wrench. Clockwise rotation of the plug increases the setting, and
counterclockwise rotation decreases the setting
(at a rate of approximately 3.4 bar (50 psi) per
turn). The lock nut for this type of charge relief
valve should be torqued to 52 Nm (38 lbfft).
90000264
Screw Adjustable Charge

Pressure Relief Valve
(Pump)
4. Once the desired charge pressure setting is

achieved, remove the gauges.
* This is the actual charge pressure port gauge reading minus

the case pressure port gauge reading.
105
22483 (01/04)
Technical Manual
A Terex Company
Series 90
8.1.2 Multi-Function Valve Pressure

Adjustment
Adjustment of the pressure limiter setting and the
high pressure relief valve setting is accomplished
simultaneously. The latter is automatically set approximately 35 bar (500 psi) above the former. For
description of multi-function valve see Sec. 2.4.4.
In order to adjust the pressure limiter setting, the
motor output shaft must be locked so it does not
rotate. This may be accomplished by locking the
vehicles brakes or rigidly fixing the work function so
it cannot rotate.
WARNING
Take necessary precautions that the motor
shaft remains stationary during the adjustment procedure.
90000258
Multi-Function Valves on PV
1. Install two 1000 bar (or 10,000 psi) pressure

gauges in the high pressure gauge ports (M1 and
M2). Install a 50 bar (or 1000 psi) pressure gauge
in the pump charge pressure gauge port (M3).
speed.
3. Loosen locking nut (smallest hex on multi-function valve) with a 10 mm wrench for earlier 042
through 100 frame size units, a 19 mm wrench for
030 and later 042 through 100 frame size units, or
a 13 mm wrench for earlier 130 frame size units.
4. Insert a 3 mm (early 042 through 100 units), 5 mm
030 and (late 042 through 100 units), or 4 mm
(earlier 130 units) internal hex wrench into the
pressure adjusting screw.
NOTE: A plastic dust plug is installed in the

adjusting screw on 030 and late 042 through 250
units.
5. The factory preset pressure limiter setting is shown
on the model code as at right. It is referenced to
charge pressure, so the pressure limiter setting is
the difference between the high and low pressure
sides of the system loop. Activate or move the
control input so that pressure increases in the high
pressure side of the closed circuit to the pressure
limiter pressure setting. The pressure limiter setting is reached when the pressure stops increasing and remains steady at a given pressure level
(as shown on the gauges).
(continued)
106
90000259
Loosen Pressure Adjusting Screw Lock Nut
90L055
EA
1 N
6 S 3 C6 C 03
HNN 35 35 24
Pressure Limiter Setting
Ports A and B (differential
pressure in 10s of bars,
e.g. 35 = 350 bar)
22483 (01/04)
Technical Manual
A Terex Company
Series 90
6. Return the pump to its neutral (zero flow) position and adjust the pressure limiter setting by
rotating the pressure adjusting screw with the
internal hex wrench.
Clockwise rotation of the pressure adjustment
screw will increase the pressure setting, and
counterclockwise rotation will decrease the pressure setting. Each complete rotation of the pressure adjusting screw changes the pressure setting by approximately 83 bar (1200 psi) on earlier
042 through 100 units, or by approximately 93 bar
(1350 psi) on 030 and later 042 through 100 units.
7. To verify the actual pressure setting, actuate or
move the control input so that the pump again
develops pressure in the high pressure circuit to
the newly adjusted pressure limiter pressure setting, and read the high pressure gauge. Then
allow the pump to return to its neutral position.
The pressure in the high pressure circuit should
return to the charge pressure setting.
90000260
Rotate Pressure Adjusting Screw
8. While holding the pressure adjusting screw stationary, tighten the pressure adjusting screw lock
nut to 3 Nm (26 inlbf) on early production units, or
16 Nm (12 ftlbf) on late production units. Do not
over-torque.
9. Shut down the prime mover, remove the gauges
and install the gauge port plugs. Replace the
plastic dust plugs (if used).
The same procedure is used for setting the pressure
limit of the other multi-function valve, but the control
input signal must be activated or moved in the opposite direction so that high pressure develops in the
opposite side of the closed circuit.
Tighten Lock Nut
90000260
107
22483 (01/04)
Technical Manual
A Terex Company
Series 90
8.1.3 Engaging the Bypass Function

The bypass function (see Sec. 2.4.6 for description)
is performed by the multi-function valve cartridges.
The prime mover should be shut down when opening
or closing the bypass valves.
The bypass valves on both of the multi-function
valves must be opened to engaged the bypass function.
1. Using a 1-1/16 inch (030 through 100) or 1-3/8
inch (130 through 250) wrench on the middle
sized hex of the multi-function valve cartridge, and
a 1-1/4 inch (030 through 100) or 1-5/8 inch (130
through 250) wrench on the large hex to prevent
rotation of the cartridge assembly, rotate the middle
hex three revolutions counterclockwise to open
the bypass valve. Do not rotate more than 3-1/2
revolutions, as additional rotation will permit external leakage.
2. For units with an MDC-type control, prior to moving the vehicle or otherwise causing the motor
shaft to turn, move the control handle of the
manual displacement control on the pump to the
maximum full forward position. Hold the handle in
this position during bypass valve operation.
WARNING
Tow at extremely low speeds and for short
distances only.
90000266
Loosening and Rotating Bypass Hex on MultiFunction Valve
Bypass
Actuator
Opening Bypass Valve

Allows Flow to Circuit
through Multi-Function Valves
the middle
90000827
Multi-Function Valve with Bypass Function Engaged
3. To close the bypass valve, rotate the middle hex

clockwise until it is seated. Then torque the middle
hex to 41 Nm (30 lbfft).
108
22483 (01/04)
Technical Manual
A Terex Company
Series 90
8.1.5 Displacement Limiter Adjustment

The maximum displacement can be limited in either
direction (see Sec. 2.4.7).
1. Loosen the seal lock nut retaining the displacement limiter adjusting screw.
Frame Size
042 - 100
130
180 - 250
Wrench Size
13 mm
17 m m
19 mm
2. Rotate the adjusting screw.

Frame Size
042 - 100
130
180 - 250
Internal Hex Wrench Size

4 mm
5 mm
6 mm
Loosen Displacement Limiter Lock Nut
90000267
Rotating the adjusting screw clockwise will decrease the maximum displacement of the pump
while rotating the adjusting screw counterclockwise
will increase the maximum displacement.
WARNINGS
Care should be taken in adjusting displacement limiters to avoid undesirable flow or speed
conditions. See Sec. 3 for speed and pressure
limits.
The seal lock nut must be retorqued after every
adjustment to prevent an unexpected change
in operating conditions and to prevent external
leakage during unit operation.
90000268
Rotate Adjusting Screw
3. After establishing the desired maximum displacement setting, tighten the lock nut on the adjusting
screw as follows.
Frame Size
042 - 100
130
180 - 250
Torque
24 Nm [18 lbfft]
48 Nm [35 lbfft]
125 Nm [92 lbfft]
4. One turn of the adjusting screw will change the

maximum displacement approximately as follows.
Frame Size
030
Approx Change in Disp per

Rev of Adjusting Screw
2.8 cm3/rev (0.17 in3/rev)
042
3.4 cm3/rev (0.21 in3/rev)
055
4.0 cm3/rev (0.25 in3/rev)
075
5.0 cm3/rev (0.31 in3/rev)
100
6.0 cm3/rev (0.37 in3/rev)
130
9.0 cm3/rev (0.55 in3/rev)
180
12.5 cm3/rev (0.76 in3/rev)
250
17.3 cm3/rev (1.06 in3/rev)
90000269
Tighten Lock Nut
109
22483 (01/04)
Technical Manual
A Terex Company
Series 90
8.2.4 Hydraulic Displacement Control

(HDC) and Electric Displacement
Control (EDC) Adjustment
The neutral adjustment is the only adjustment that
can be made on hydraulic and electric displacement
controls. All other functions are preset at the factory.
For functional descriptions see Sec. 2.5.2 and 2.5.3.
This adjustment must be made on a test stand or on
the vehicle/machine with the prime mover operating.
The neutral adjustment is performed by adjusting a
neutral adjusting shaft (earlier production EDCs) or a
neutral adjusting screw (HDCs and current production EDCs).
90000240
PV with Hydraulic Displacement Control
WARNING
The following procedure requires the vehicle/
ground, work function disconnected, etc.) in
order to prevent injury to the technician and
bystanders.
1. Install two 50 bar (or 1000 psi) gauges in each of
the two displacement control cylinder gauge ports
(M4 and M5). Disconnect the external control
input (hydraulic or electronic) from the control.
Start the prime mover and operate at normal
speed.
90000241
PV with Electric Displacement Control
2. Loosen the lock nut with a 17 mm hex wrench for

the neutral adjusting shaft or with a 10 mm or 13
mm hex wrench for the neutral adjusting screw.
(continued)
90000249
Install Gauges in Displacement Control Cylinder

Gauge Ports
110
22483 (01/04)
Technical Manual
A Terex Company
Series 90
3. Using a 5 mm internal hex wrench for the neutral

adjusting shaft or a 3 mm or 4 mm internal hex
wrench for the neutral adjusting screw, rotate
clockwise until the pressure increases in one of
the pressure gauges. Note the angular position of
the wrench. Then rotate the neutral adjusting
shaft or screw counterclockwise until the pressure
increases by an equal amount on the other gauge.
Again note the angular position of the wrench.
4. Rotate the neutral shaft or adjusting screw clockwise half the distance between the locations noted
above. The gauges should read the same pressure (case pressure), indicating that the control is
in its neutral position.
90000250
90000252
Rotate Neutral Adjusting Tighten Neutral Adjusting

Shaft (Early Production)
Shaft Lock Nut (Early
Production)
5. Hold the neutral adjusting shaft or screw stationary. Tighten the neutral shaft lock nut (early production controls) to 22 Nm (195 inlbf). Tighten the
neutral adjusting screw lock nut (later production
controls) to 7 Nm (62 inlbf) for the 6 mm screw or
13.6 Nm (120 inlbf) for the 8 mm screw. Do not
overtorque the nut.
6. Once the neutral position is set, stop the prime
mover, remove the gauges, and install the gauge
port plugs. Reconnect the external control input.
90000251
90000318

Screw (Later Production)
Screw Lock Nut (Later
Production)
90000355
90000356

Screw (Current
Screw Lock Nut (Current
Production HDC)
Production HDC)
111
22483 (01/04)
Technical Manual
A Terex Company
Series 90
Minor Repair Instructions
9. Minor Repair Instructions

Minor repairs may be performed, following the procedures in this section, without voiding the unit warranty. Although specific models are shown, these
procedures apply to all series and types of units in the
Series 90 Family.
Cleanliness is a primary means of ensuring satisfactory transmission life, on either new or repaired units.
Cleaning parts by using a solvent wash and air drying
is adequate, providing clean solvent is used. As with
any precision equipment, the internal mechanism
112
and related items must be kept free of foreign materials and chemicals.
Protect all exposed sealing surfaces and open cavities from damage and foreign material.
It is recommended that all gaskets and O-rings be
replaced when servicing. All gasket sealing surfaces
must be cleaned prior to installing new gaskets.
Lightly lubricate all O-rings with clean petroleum jelly
prior to assembly.
22483 (01/04)
Technical Manual
A Terex Company
Series 90
Hydrostatic Unit Outlines for Minor Repair Reference

Charge Pressure
Relief Valve
Filtration Options
Control
Control Orifices
Charge Pump
Shaft
Seal
Main
Shaft
(Auxiliary Pad)
Speed Sensor
Right Side View
Left Side View
90000843
SAE Flange PV
Charge Pressure
Relief Valve
Charge Pressure
Relief Valve
Loop Flushing
Valve
Loop Flushing
Valve
Shaft
Seal
Shaft
Seal
(Speed Sensor)
(Speed Sensor)
Left Side View
Left Side View

90000844
SAE Flange MF
Control Orifices
Charge Pressure
Relief Valve
Loop Flushing
Valve
Cartridge Flange MF
Maximum Angle
Control Orifices
Charge Pressure
Relief Valve
Loop Flushing
Valve
Shaft
Seal
Control
Maximum Angle
Shaft
Seal
Control
Minimum Angle
(Speed Sensor on
Opposite Side of Housing)
Left Side View
Minimum Angle
Left Side View

90000845
SAE Flange MV
Cartridge Flange MV
113
22483 (01/04)
Technical Manual
A Terex Company
Series 90
9.1
Pump and Motor Minor Repair
9.1.1 Plug / Fitting Torques

If any plugs or fittings are removed from the pump or
motor during servicing, they should be torqued as
indicated in the accompanying table.
Always install new O-rings before reinstalling the
plugs or fittings.
CAUTION
Plugs or fittings installed into aluminum housings should always be torqued to the lower
values specified for internal hex plugs of the
same size.
114
Description
Torque
7/16 20 O-Ring
9/16 inch Hex Wrench
20 Nm
(15 lbfft)
7/16 20 O-Ring
3/16 inch Internal Hex Wrench
12 Nm
(9 lbfft)
9/16 18 O-Ring
11/16 inch Hex Wrench
37 Nm
(27 lbfft)
9/16 18 O-Ring
23 Nm
(17 lbfft)
3/4 16 O-Ring
7/8 inch Hex Wrench
68 Nm
(50 lbfft)
3/4 16 O-Ring
68 Nm
(50 lbfft)
7/8 14 O-Ring
1 inch Hex Wrench
95 Nm
(70 lbfft)
7/8 14 O-Ring
68 Nm
(50 lbfft)
1-1/16 12 O-Ring
1-1/4 inch Hex Wrench
163 Nm
(120 lbfft)
1-1/16 12 O-Ring
115 Nm
(85 lbfft)
1-5/16 12 O-Ring
190 Nm
(140 lbfft)
1-5/16 12 O-Ring
129 Nm
(95 lbfft)
1-5/8 12 O-Ring
224 Nm
(165 lbfft)
22483 (01/04)
Technical Manual
A Terex Company
Series 90
9.1.2 Shaft Seal and Shaft Replacement

Lip type shaft seals are used on Series 90 pumps and
motors. These seals and/or the shafts can be replaced without major disassembly of the unit. However, replacement usually requires removal of the
pump or motor from the machine.
1. Position the pump with the shaft facing up.
NOTE: If the unit is positioned horizontally when

the shaft is removed, the cylinder block could
move out of place, making shaft installation difficult.
90000270
Remove Screws Holding

Retainer Plate and Seal
Carrier
2. Remove the three or four screws holding the

retainer plate and seal carrier to the housing,
using a 10 mm hex wrench (030 and 042 units),
a 5 mm internal hex wrench (055 through 100
units), or a 6 mm internal hex wrench (130 through
250 units). Remove the retainer plate.
90000271
Remove Seal Carrier
NOTE: Certain earlier production units use a one

piece retainer plate and seal carrier.
3. After removing the screws, the spring force on the
shaft may move the seal carrier out of its bore by
approximately 5 mm (1/4 inch). If the seal carrier
does not move from its bore after removing the
screws, pry it from its bore as shown and/or lightly
tap the end of the shaft with a soft mallet.
4. Remove the O-ring from the seal carrier.
5. Place seal carrier and seal in an arbor press and
press out old seal.
90000272
Press Out Old Seal
90000273
New Seal Installed in

Carrier
6. Inspect the seal carrier, the new seal and the Oring for any damage or nicks.
7. Using the arbor press, press the new seal into
seal carrier. Be careful not to damage the seal.
Screw
Retaining Plate
Seal Carrier
Seal
Seal Carrier [1 Piece]
The outside diameter of the seal may be lightly

coated with a sealant (such as Loctite High Performance Sealant #59231) prior to installation.
This aids in preventing leaks caused by damage
to the seal bore in the seal carrier.
Screw
Seal
O-Ring
90000846
Series 90 Shaft Seal Components
115
22483 (01/04)
Technical Manual
A Terex Company
Series 90
8. Inspect the sealing area on the shaft for rust,

wear, or contamination. If the shaft is not being
replaced proceed to step 12.
Roller Bearing
Retaining
Assembly
Ring
Tapered
Shaft
Roller Bearing
Splined
Shaft
OR
9. Remove shaft and roller bearing assembly from

pump or motor. The bearing assembly can be
transferred to the new shaft.
10. Remove the retaining ring that secures roller
bearing assembly with a snap ring pliers. Remove the roller bearing assembly.
OR
OR
Straight Key
Shaft
90000866
Fixed Motor Shaft Configuration

Roller Bearing
Assembly
11. Place roller bearing assembly on new shaft and

secure with the retaining ring.
12. Wrap spline or key end of shaft with plastic film to
prevent damage to the sealing lip on the seal
during installation.
Splined
Shaft
OR
Retaining Ring
Roller Bearing
Tapered
Shaft
OR
13. Prior to assembly, lubricate the O-ring on the

O.D. of the seal carrier and the I.D. of the seal with
clean petroleum jelly.
14. Assemble the seal carrier and seal over the shaft
and into the housing bore. Install the retainer
plate (if used).
15. Install the screws and torque to 16 Nm (12 ftlbf)
for 030 through 100 pumps, 32 Nm (24 ftlbf) for
130 through 250 pumps, 9.5 Nm (7 ftlbf) for 055
through 100 motors, and 22.5 Nm (16.6 ftlbf) for
130 motors.
NOTE: Torque the screws in a sequenced pattern

then recheck.
OR
Straight Key
Shaft
90000867
Variable Pump Shaft Configuration
Roller Bearing
Assembly
Splined
Shaft
OR
Retaining
Ring
Tapered
Shaft
90000868
Variable Motor Shaft Configuration
90000274
Install Seal Carrier
116
90000275
Torque Retainer Screws
22483 (01/04)
Technical Manual
A Terex Company
Series 90
9.2
Pump Minor Repairs

9.2.1 Multi-Function Valve Cartridges
1. The multi-function valve cartridge is removed
with a 1-1/4 inch (030 through 100 pumps) or a 15/8 inch (130 through 250 pumps) hex wrench on
the largest hex on the cartridge.
2. Inspect cartridge for damage to parts and Orings.
90000276
Remove Multi-Function
Valve Cartridge
The multi-function valve cartridge may be disassembled for cleaning. However, if the pressure
limiter housing assembly is disassembled, the
pressure settings must be readjusted. Usually, if
there is contamination problem, it will be in the
valve seat assembly. If it is not necessary to clean
the interior of the cartridge, proceed to step 7.
90000277
Install and Torque

Cartridge
NOTE: Multi-function valve components are not

sold separately as service parts (except O-rings).
3. On early versions of the multi-function valves, the
valve seat assembly is held by a retaining ring.
Remove retaining ring with a snap ring pliers.
90000278
Multi-Function Valve Cartridge Components (Earlier

Production)
On late versions, the valve seat section is pressed

over a lip. Place the cartridge in a vise and pry the
lower section off with an appropriate tool. Maintain sufficient control to prevent the contents from
flying loose.
90000279
Multi-Function Valve Cartridge Components (Later

Production)
4. Remove pressure limiter lock nut and bypass

actuator.
High Presssure
Pressure Limiter Relief/Check
Pressure Limiter
Valve Spring
Valve Poppet
Lock Nut
Check Valve
Pressure Limiter
Spring Seat
Poppet
Housing
Pressure Limiter
Adjustment Screw
6. Clean and inspect all disassembled parts.

7. Reassemble with new, lightly lubricated O-rings
by reversing the above procedure. For early
versions assemble with the retaining ring. For
late versions, place the cartridge in a vise and
press on lower assembly.
CAUTION
The pressure settings must be readjusted after
disassembling the pressure limiter housing of
the multi-function valve cartridge (see Sec.
8.2.1)
Spring Valve
Pressure Limiter
Seat
Valve Poppet
Pressure Limiter
Poppet Seat
Bypass
8. Install cartridge in multi-function valve cavity and

torque to 89 Nm (66 ftlbf) for 030 through 100
pumps and 279 Nm (206 ftlbf) for 130 through
250 pumps. Do not overtorque the multi-function valve cartridge.
Actuator
90000869
Multi-Function Valve Cartridge Sectional View
5. Unscrew the pressure limiter adjustment screw

from the bypass actuator.
117
22483 (01/04)
Technical Manual
A Terex Company
Series 90
9.2.2 Pressure Override Valve (Option

for 180 Frame Size)
Pressure Override
Valve
1. Remove the four screws attaching the pressure

override valve to the pump end cap with a 5 mm
internal hex wrench. Remove the O-rings.
Screws
O-rings
2. Inspect valve for damage to parts.

3. Install new O-rings. Install the valve onto the
pump end cap and torque the screws to 16 Nm
(12 ftlbf).
90000870
9.2.3 Charge Relief Valve

Pressure Override Valve Components
The pump charge relief valve may be shim adjustable

(early models) or screw adjustable (late models).
1. Remove the shim adjustable charge relief valve
plug with a 1 inch hex wrench.
Before removing the screw adjustable relief valve
plug, mark the plug, lock nut, and housing so as
to approximately maintain the original adjustment when assembling. Remove the screw adjustable charge relief valve plug by loosening the
lock nut with a 11/16 inch wrench for 030 through
100 units or a 1-5/8 inch for 130 through 250
units. Unscrew the plug with a large screwdriver
or 1/2 inch hex wrench.
2. Remove the spring and relief valve poppet.
90000280
Remove Charge Relief

Valve (Shim Adjustable)
90000262
Shim Adjustable Charge

Relief Valve
3. Inspect the poppet and mating seat in the end cap

for damage or foreign material.
When inspecting shim adjustable valves, do not
alter the shims or interchange parts with another
valve.
4. Install the poppet and spring. For shim adjustable
valves, install the plug and torque to 68 Nm (50
ftlbf). For screw adjustable valves, install the
plug with its lock nut, aligning the marks made at
disassembly, and torque the lock nut to 52 Nm
(38 ftlbf).
90000264
90000265
Remove Charge Relief

Screw Adjustable Charge
Valve (Screw Adjustable)
Relief Valve
Check the charge pressure and adjust, if necessary

(8.1.1).
118
22483 (01/04)
Technical Manual
A Terex Company
Series 90
9.2.4 Charge Pump

The following procedure shows how to remove and
install a charge pump.
1. For pumps with an auxiliary mounting pad, remove the four screws holding the pad to the end
cap and remove the pad. Refer to the Auxiliary
Mounting Pad Installation instructions (next section) for details.
90000282
Remove Retainer Screws
Discharge
Gerotor Assembly
NOTE: Late production pumps may not have the

smaller screws installed to secure the end cap to
the pump housing when the large screws are
removed. On these pumps, secure the end cap to
the pump housing with a clamp to avoid gasket
damage.
90000284
Remove Charge Pump

Cover
Discharge
Alignment Pin
CAUTION
Do not allow the force of the cylinder block
spring and swashplate leveler springs to separate the end cap from the pump housing. Gasket damage and external leakage may result.
Inlet
Inlet
Alignment Pin
Gerotor Assembly
Outer Eccentric Ring
Left Hand Rotation
(Outside Looking Into Pump)
Orienting Gerotor Outer

Ring and Alignment Pin
(CCW Rotation)

Right Hand Rotation
90000871
2. Using a 10 mm (030 through 100 pumps) or a 13

mm (130 through 250 pumps) hex wrench, remove the six screws holding the charge pump
cover retainer.

(CW Rotation)
3. Remove the retainer and the charge pump cover.

For pumps with an auxiliary mounting pad, remove the auxiliary drive coupling. Note the orientation of the gerotor.
(continued)
119
22483 (01/04)
Technical Manual
A Terex Company
Series 90
Standard End Cap Screw
4. Remove the charge pump shaft and charge pump

drive key.
Alignment Pin
Charge Pump Assembly
5. Remove the spacer plate(s), if present (intermediate production pumps only).
Thin Port Plate

Key
Remove the charge pump outer port plate, if

present (early and intermediate production
pumps).
Thick Port Plate
Shaft
Eccentric Ring
Gerotor Assembly
O-ring
Cover
Journal Bearing
Remove the charge pump gerotor assembly.

6. Remove the outer eccentric ring and alignment
pin.
Cover Retainer
90000872
Retainer Screw
Charge Pump Components (Early Production)
7. Remove the inner port plate.

8. Inspect all parts for abnormal wear or damage.
NOTE: If a different displacement charge pump is

being installed, the gerotor assembly, gerotor
outer eccentric ring, and inner port plate (early
and late production pumps) or outer spacer plate(s)
(intermediate production pumps) must be replaced
together. If different thickness port plates are used
in an early production charge pump assembly, the
thicker plate is the inner port plate (installed next
to the pump end cap).
Alignment Pin
Thin Port Plate
Eccentric Ring
Key
Gerotor Assembly
Shaft
Thin Port Plate
O-ring
Spacer Plate(s)
Cover
Journal Bearing
Cover Retainer
Retainer Screw
90000873
Charge Pump Components (Intermediate

Production)
Alignment Pin
Key
Shaft
Port Plate
O-ring
Eccentric Ring
Gerotor Assembly
Cover
Journal Bearing
Cover Retainer
Retainer Screw
90000874
Charge Pump Components (Late Production)

Spacer
Shaft
O-ring
Cover
Plug
Journal Bearing
Cover Retainer
Retainer Screw
90000875
"No Charge Pump" Components

120
22483 (01/04)
Technical Manual
A Terex Company
Series 90
Discharge
Gerotor Assembly
Alignment Pin
Installing the Charge Pump

Be sure to install the charge pump in the proper
orientation. If unsure of charge pump rotation, refer to
the model code.
Discharge
Inlet
Inlet
NOTE: The charge pump rotation is determined

by the orientation of the gerotor assembly outer
eccentric ring and the location of the alignment pin
in the end cap.
Alignment Pin
Gerotor Assembly
Left Hand Rotation

Right Hand Rotation
90000871

(CCW Rotation)
NOTE: Do not mix charge pump piece parts from

different production periods. Always install as a
complete assembly.

(CW Rotation)
1. Install the inner port plate and the gerotor assembly outer ring.
2. Install the alignment pin to properly orient the port
plates and outer eccentric ring for corresponding
pump rotation.
3. Prior to installation, apply a small quantity of
petroleum jelly to the I.D., O.D., and side faces of
the gerotor assembly to provide initial lubrication.
4. Install the gerotor assembly.
90000285
Install Inner Port Plate
90000286
5. Install the outer port plate (early production and

intermediate production pumps only).
Install Gerotor Assembly

Outer Ring
6. Install the spacer plate, if present (intermediate

production pumps).
(continued)
90000287
Install Alignment Pin
90000289
Install Outer Port Plate

(Early and Intermediate
Production Only)
90000288
Install Gerotor Assembly
90000290
Install Spacer Plate

(Intermediate Production
Only)
121
22483 (01/04)
Technical Manual
A Terex Company
Series 90
7. Install the charge pump drive key into the charge

pump shaft and retain with petroleum jelly.
NOTE: Intermediate production 75 cc and 100 cc

pumps use the same charge pump drive shaft.
Two keyways are provided in the drive shaft for
the charge pumps used in these units. The rear
keyway (with identifier groove) is used in 75 cc
pumps. The front keyway (closest to the internally
splined end of the shaft) is used in 100 cc pumps.
100 cc 75 cc
8. Install the charge pump shaft. The internally

splined end of the shaft must engage the main
pump shaft.
NOTE: The outside diameter of the internally

splined end of some early production charge
pump shafts was chamfered. Early production
end caps may not be machined to accept a nonchamfered shaft. Always use a chamfered charge
pump shaft in pumps with the early end cap.
90000291
Keyways in Charge Pump

Shaft (Intermediate
Production 075 and 100)
90000292
Install Charge Pump

Shaft
9. For pumps with an auxiliary mounting pad, install

the auxiliary drive coupling.
10. Install a new O-ring onto the non-auxiliary pad
charge pump cover. (If an auxiliary pad is installed, an O-ring is not used on the cover.)
11. Carefully remove the alignment pin from the
charge pump parts. Install the pin in its hole in the
charge pump cover (see previous page for correct orientation) and retain with petroleum jelly.
Install the cover (with alignment pin) into the end
cap and aligned charge pump parts. (Take care
not to damage the cover O-ring, if used.)
CAUTION
In order to avoid loss of charge pressure in
pumps with an auxiliary mounting pad, always
install the charge pump cover with the pad
drain hole located on the same side of the end
cap as the charge inlet port. Refer to Sec. 9.2.5
Auxiliary Pad Installation for details.
90000293
Aligning Pin Installed in

Cover
90000294
Install Charge Pump

Cover
12. Install the charge pump cover retainer and the six
hex screws and torque the screws to 13.5 Nm (10
ftlbf) for 030 through 100 pumps, and 32 Nm (24
ftlbf) for 130 through 250 pumps.
13. For pumps with auxiliary mounting pads, install
the O-ring and auxiliary mounting pad adaptor
onto the end cap. Refer to Sec. 9.2.5 for instructions on auxiliary pad installation.
90000283
Install Cover Retainer
122
90000295
Torque Retainer Screws
22483 (01/04)
Technical Manual
A Terex Company
Series 90
9.2.5 Auxiliary Pad Installation

1. Using a 10 mm (030 through 100 pumps) or a 13
mm (130 through 250 pumps) hex wrench, remove the six screws holding the charge pump
cover retainer. Remove the retainer.
2. Remove the charge pump cover and its O-ring.
NOTE: The original charge pump cover will not be

used when installing the auxiliary pad.
3. Remove the four large screws which fasten the
end cap to the pump housing.
90000282
90000284
Remove Screws and

Retainer
Frame Size
Remove Charge Pump

Cover
Hex Wrench Size

Internal Hex
030 & 042 (early)
8 mm
042 (late)
10 m m
External Hex
055
19 m m
075 & 100
24 m m
100 & 130
14 m m
180 & 250
17 m m
NOTE: Late production pumps may not have the

smaller screws installed to secure the end cap to
the pump housing when the large screws are
removed. On these pumps, secure the end cap to
the pump housing with a clamp to avoid gasket
damage.
90000296
Remove Large End Cap Screws
CAUTION
Do not allow the force of the cylinder block
spring and swashplate leveler springs to separate the end cap from the pump housing. Gasket damage and external leakage may result.
Charge Pump Parts
4. Take care to assure the surfaces are clean and

free of any foreign material or paint prior to
installing the auxiliary pad.
Cover Assembly
Coupling
(Typical)
Journal Bearing
Special Washer
(continued)
End Cap Screw

O-ring
Auxiliary Pad
(Typical)
O-ring
Pad Cover
Auxiliary Pad Kit
Cover Retainer
Retainer Screw
Screw
90000876
Auxiliary Pad Components (Typical)
123
22483 (01/04)
Technical Manual
A Terex Company
Series 90
5. Install the auxiliary drive coupling onto the pump

drive shaft spline (auxiliary drive spline must be
toward the rear of the pump).
6. Carefully remove the alignment pin from the
charge pump parts. Install the pin in its hole in the
new charge pump cover (with hole for the auxiliary coupling) and retain with petroleum jelly.
Install the new charge pump cover with alignment
pin into the end cap and the aligned charge pump
parts.
CAUTION
In order to avoid loss of charge pressure,
always install the charge pump cover with the
pad drain hole located on the same side of the
end cap as the charge inlet port.
90000297
Install Drive Coupling
90000298-
Install Alignment Pin in

Cover (CCW Rotation
shown)
7. Install the charge pump cover retainer and the six

hex screws and torque the screws to 13.5 Nm (10
ftlbf) for 030 through 100 pumps, and 32 Nm (24
ftlbf) for 130 through 250 pumps.
8. Install O-ring on end cap pilot.
9. Install the auxiliary mounting pad adapter on
external pilot on rear of end cap.
10. Install four new large screws and washers through
the mounting pad and end cap into the housing.
Torque per the accompanying table.
90000299
90000300
Install New Charge Pump Install Screws and Cover

Cover
Retainer
Torque
Frame Size
Wrench Size
(Internal Hex)
Nm
lbfft
030 & 042 (early)
8 mm
75
55
042 (late) & 055
10 mm
122
90
075
14 mm
256
189
100 & 130
14 m m
298
220
180 & 250
17 m m
580
429
90000302
11. Install the O-ring and flange cover or auxiliary

pump.
Install O-Ring on End

Cap Pilot
90000303
Install Auxiliary Pad

Adapter
Auxiliary Pad Conversion

To convert an auxiliary mounting pad to a different
size mounting pad, use the above procedure with the
following additions:
After removing the charge pump cover (step 2),
remove the old auxiliary drive coupling.
After removing the four end cap retaining screws
(step 3), remove the old auxiliary mounting pad
adapter.
124
90000281
Install Auxiliary Pad

Adapter Screws
90000305
Torque Pad Adapter

Screws
22483 (01/04)
Technical Manual
A Terex Company
Series 90
Minor Repair
9.2.6 Filtration Options

9.2.6.1 Suction Filtration Installation
1. Install the hydraulic fitting to connect the external
suction filter to the charge pump inlet port.
2. The reducer fitting (placed on the charge pressure
gauge port) is installed as follows.
90000310
Charge Pump Inlet
90000243
Reducer Fitting
Torque
Frame Size
Wrench Siz e
042
11/4"
70 Nm
055 - 130
11/2"
122 Nm
[90 lbfft]
180 & 250
11/2"
156 Nm
[115 lbfft]
[52 lbfft]
The gauge port plug is torqued to 27 Nm (20

ftlbf).
9.2.6.2 Remote Charge Pressure Filtration

or Integral Charge Pressure
Filtration
Install either of these two filtration devices as follows.
1. Remove the reducer fitting, located at charge
pressure gauge port, from pump end cap (this part
will not be used).
90000311
Remote Pressure Filter

Manifold
90000314
2. Install the filter manifold or filter head into the port.

The hydraulic tube should enter its mating bore in
the pump end cap with a low force.
Integral Pressure Filter

Head
3. After rotating the filter manifold or filter head

clockwise so that the threads engage with the
threads in the end cap, continue to rotate it clockwise between 6 and 7 revolutions. Face manifold
or head to the desired position.
90000312
Install Remote Pressure

Filter Manifold
CAUTION
Failure to install the filter manifold or filter
head to a sufficient depth in the end cap will
result in insufficient engagement of the tube in
the end cap bore. This may allow unfiltered oil
to bypass the filter and enter the charge system.
90000315
Install Integral Pressure

Filter Head
4. While holding the filter manifold or filter head in the

desired position, tighten the swivel lock nut.
90000313
90000316
Wrench Size
042
13/8"
70 Nm
055 - 130
15/8"
122 Nm
90 lbfft
180 & 250
15/8"
156 Nm
115 lbfft
Torque
52 lbfft
5. After installing the integral pressure filter head

assembly, install the filter canister per the instructions on the filter canister.
Tighten Remote Pressure Tighten Integral Pressure

Filter Manifold Lock Nut
Filter Head Lock Nut
Frame Size
125
22483 (01/04)
Technical Manual
A Terex Company
Series 90
Minor Repair
9.3.5 Hydraulic and Electric

Displacement Controls
1. Thoroughly clean external surfaces prior to removal of control.
2. Using a 5 mm internal hex wrench, remove the
eight control mounting screws. Remove the control (with orifice check valve and spring) and
control gasket from housing.
90000325
Remove Mounting
Screws
CAUTION
Protect exposed surfaces and cavities from
damage and foreign material.
90000326
Remove Control
3. In preparation for installing the control, place a

new gasket on the housing. Inspect to ensure that
the control orifice check valve and spring are in
their proper position in the control.
4. While setting the control into position, engage the
pin on the control linkage into the mating hole in
the link attached to the swashplate.
90000327
Inner Face of Control
5. With the control in position, move control assembly left and right to check engagement of pin in the
link. Proper engagement will be indicated by an
increasing resistance as the control is moved
away from center position. Non-engagement of
pin will be indicated by lack of spring force. In case
of non-engagement, remove control and repeat
the above procedure.
90000328
Assemble Control to
Linkage
6. Align the control gasket and install the screws.

Torque the screws to 16 Nm (12 ftlbf).
NOTE: A sealing washer must be installed under

the head of any mounting screws that are installed
into "through" holes in the housing.
90000329
Install Mounting Screws
9.3.6 Pressure Control Pilot (PCP) for

Electric Displacement Control
90000330
Torque Mounting Screws
1. Thoroughly clean external surfaces of control.

four screws and remove the PCP.
3. Check surfaces for nicks or damage. Clean internal screens.
4. Install new O-rings in PCP Housing. Place PCP
against EDC housing and install the screws.
Torque to 5.4 Nm (48 inlbf).
90000332
PCP Components
NOTE: Do not remove black plastic cover from

the aluminum plate. This is not a serviceable item
and will void the product warranty.
90000334
Torque PCP Valve

Screws
126
22483 (01/04)
Technical Manual
A Terex Company
Series 90
Minor Repair
9.3.7 3-Position (FNR) Electric Control

1. Thoroughly clean external surfaces prior to removal of control.
four solenoid valve mounting screws. Remove the
solenoid valve (with O-rings and orifice) from the
adapter plate.
eight adapter plate mounting screws. Remove the
adapter plate and gasket from housing.
CAUTION
Protect exposed surfaces and cavities from
damage and foreign material.
90000362
4. Inspect the orifice installed between the valve and

adapter plate. This orifice MUST be installed in
the case drain passage for proper pressure limiter
operation.
3-Position Electric Control Components
5. In preparation for installing the adapter plate,

place a new gasket on the housing. Place the
adapter plate into position and install the screws.
Torque the screws to 16 Nm (12 ftlbf).
NOTE: A sealing washer must be installed under

the head of any mounting screws that are installed
into "thru" holes in the housing.
6. Install new O-rings and the orifice onto the solenoid valve assembly and install the solenoid valve
onto the adapter plate. Install the screws and
torque to 5.4 Nm (48 inlbf).
127
22483 (01/04)
Technical Manual
A Terex Company
Series 90
Minor Repair
9.3.8 Displacement Control

Components
9.3.8.1 Displacement Control Adapter Plate
(Early Production 130 Pumps Only)
The screws fastening the control adapter plate to the
housing have retaining compound on the threads.
They are removed with a 6 mm internal hex wrench.
When installing the adapter plate, ensure the O-rings
are in the proper position and torque the screws to 32
Nm (24 ftlbf).
9.3.8.2 Displacement Control Filter Screens

If the pump is equipped with control filter screens in
the pump housing (late production), they should be
pressed into position (with the rounded edge of the
filter screens facing the control) until they are flush to
2.0 mm (0.08 inch) below the surface of the housing.
90000847
Displacement Control Adapter Plate (Early

Production 130cc Pumps Only)
9.3.8.3 Displacement Control Orifice Check

Valve
TA
TB
1. Remove the control assembly as described in the

instructions for the specific displacement control
(9.3.2, 9.3.6, or 9.3.7).
2. The orifice check valve is located in the control
assembly, at the surface of the pump housing
face. Remove the spring retainer and spring from
the orifice check valve cavity and then remove the
orifice check valve.
Orifice Plugs
3. Install the desired orifice check valve in the cavity

and then install the spring and spring retainer to
hold the orifice check valve in position.
Orifice Check Valve

90000848
4. Assemble the control onto the pump. Refer to the

instructions for the specific control (9.3.2, 9.3.6, or
9.3.7).
The Underside of an MDC Module Showing Orifice

Locations
A
9.3.8.4 Displacement Control Orifices
B
TA
1. Remove the control assembly as described in the

instructions for the specific displacement control
(9.3.2, 9.3.6, or 9.3.7).
TB
2. Orifice plugs may be located in the control assembly, at the pump housing face surface. Remove
the orifice plugs with a 4 mm internal hex wrench.
Note the location of each plug, do not interchange
plugs. Torque the orifice plugs to 3 Nm (32 inlbf).
Orifice Plugs
Orifice Check Valve
90000849
3. Assemble the control onto the pump. Refer to the

instructions for the specific control.
The Underside of an HDC/EDC Module Showing

Orifice Locations
128
22483 (01/04)
Technical Manual
A Terex Company
Series 90
10
10. Exploded View Parts Drawings

10.1 Variable Pumps
10.1.1 Name Plates
saue
Ames, Iowa, U.S.A.
Model Code
saue
Neumnster, Germany
Typ
Ames, Iowa, U.S.A.

Model Code
90L055
EA
1 N
6 S 3 C6 C 03
HNN 35 35 24
Model
Number
Model No.
Serial
Number
90L055
EA
1 N
6 S 3 C6 C 03
HNN 35 35 24
Model
Code
Model
Number
Ident Nr
94 2029
A 88 26 67890
Model No.
Model
Code
Ident Nr
687459
N 88 26 67890
Serial
Number
Serial No.
Fabr Nr
MADE IN U.S.A.
Neumnster, Germany
Typ
Serial No.
Fabr Nr
MADE IN GERMANY
Place of Manufacture
Place of Manufacture
Name Plate (U.S.A. Production)
Name Plate (German Production)
90000860
10.1.2 Minor Repair Parts
K90
B83
OR
B83
K10
B70
G532
G536
K50
K70
G542
G546
B82
K018
THRU
K042
L35
(Early Production
075 Frame Size)
(L70)
(L40)
K80
L60
(B80)
(B90)
L30
P2B_
(B70)
P30
L70
L40
B90
P06
P13
L50
P30
B71
P2A_
P06
P13
(K018
THRU
K042)
G512
G516
G502
G506
G522
G526
G531
G538
G501
G508
G511
G518
G172
G176
B80
(G502
G506)
G541
G548
(G502
G506)
(G63)
(G64)
G63
(CODE 61 OPTION)
G521
G528
(G501
G508)
(G501
G508)
BOTH SIDES
G63
(CODE 61 OPTION)
OR
G64
(CODE 61 OPTION)
129
(G63)
(G64)
G64
(CODE 61 OPTION)
22483 (01/04)
Technical Manual
A Terex Company
Series 90
10
10.1.3 Controls
M9ME
M0MA M0ME
M0MB M0MF
M0MC M0MG
M0MD M0M9
M74M
M78M
M76M
M0CA
OR
M90D
M1DC
M1DD
MODC
MODD
M1CA
M11C
M90C
M87C
M92M
M11D
M97M
M98M
M95M
M96M
T001
THRU
T009,
T022
T050
OR
M91E
M75M
M72M
M71M
M90M
M1MA M880
M1MB
M1MC
M1MD
M1ME
M1MF
M1MG
T201
THRU
T209,
T222
T250
T301
THRU
T309,
T322
T350
M0EA
M0EF
M0EP
M77M
T401
THRU
T409,
T422
T450
M7MA
M7MB
M7MC
M7MD
M7ME
M7MF
M7MG
M1HA, M1HC
M1HF, M1HG
M1HH, M1HJ
M1HK, M1HL
M1HM, M1HN
M11H
M90H
M880
M87H
M90E
M1EA M880
M1EF
M1EP
M9EA
M9EP
M98E
M95E
M97E
M96E
M11E
M87E
M87M M11M
OR
M870
M860
M850
OR
M0HA, M0HC
M0HF, M0HG
M0HH, M0HJ
M0HK, M0HL
M0HM, M0HN
M840
M840
REF
M830
S40
M810
M840
REF
M820
EARLY PRODUCTION
130CC PUMPS ONLY
90000861
130
22483 (01/04)
Technical Manual
A Terex Company
Series 90
10
10.1.4 Filtration Options, Charge Pump Options, Auxiliary Pad Options
N40P
N40L
N00M
N00S
N35M
REF
N35S
N10S
OR
N10M
N30R
N35M
N00R
N25M
N20M
N15M
N31R
N10R
N20R
N15R
N25R
N35R
OR
90000862
H50L
H50
H40
H05
OR
H30
H60
H50
H40
OR H05
H30
(H30)
J80N
H40
H05
H60
H50
OR
H60
H50
H90L
J40N
J15N
H70
J15_, J15L, OR J15R

J10_
J30
J30
J70_
H80
H70
OR
J80_
J50_
J60_
J90_
H80
J00_, JL0_, OR JR0_
J92_
J95_
131
90000863
22483 (01/04)
Technical Manual
A Terex Company
Series 90
10
10.1.5 Pump Parts List
Item
Description
Qty
B70
B71
B80
B82
B90
Plug
Plug
Plug
Plug
Control Filter Screen
2
1
1
1
3
G63
G64
Split Clamp
Screw - Shipping Cover
4
4
G172
G176
G501
G502
G506
G508
G511
G512
G516
G518
G521
G522
G526
G528
G531
G532
G536
G538
G541
G542
G546
G548
Plug
Plug
Plug
Plug
Plug
Plug
Plug
Plug
Plug
Plug
Plug
Plug
Plug
Plug
Plug
Plug
Plug
Plug
Plug
Plug
Plug
Plug
1
1
3
3
3
3
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
H05B-H
H05L
H30
H40
H50
H60
H70
H80
H90L
Kit - Charge pump

Spacer (No Charge pump)
Port plate
Pin
Charge pump shaft
Key
Retaining plate
Screw
Plug
1
1
2
1
1
1
1
6
1
J00A
J00B
J00C
J00D
J00T
J00V
J00N
J10A-V
J15
J15N
J30
Aux. mtg. A flange

Aux. mtg. B flange
Aux. mtg. C flange
Aux. mtg. D flange
Aux. mtg. A flange (11T)
Aux. mtg. B-B flange
Aux. mtg. flange - none
Coupling
Charge pump cover assembly
Charge pump cover assembly
Bushing
1
1
1
1
1
1
1
1
1
1
1
132
Item
Description
Qty
J50A-V
J60A/T
J60B/V
J60C
J60D
J70A-V
J80A-V
J80N
J90A-V
J92A-V
J95A-V
O ring
Flange adaptor
Flange adaptor
Flange adaptor
Flange adaptor
Washer
Screw
Screw
O ring
Cover plate
Screw
1
1
1
1
1
4
4
4
1
1
2/4
K10
K50
K70
K80
K90
Plug Assembly
O ring
Spring
Poppet
Nut
1
1
1
1
1
L30
L35
L40
L50
L60
L70
Seal carrier
Seal carrier
Lip seal
O ring
Retainer
Screw
1
1
1
1
1
3
L8
L9
Key
Slotted nut
1
1
M0CA
M1CA
M11C
M87C
M90C
Control - Cover Plate Kit

Cover plate
Control gasket
Washer, seal (042)
Screw
1
1
1
1
6
M0DC
M0DD
M1DC
M1DD
M80
M87D
M90D
Control kit 3 position FNR 12v

Control kit 3 position FNR 24v
Control 3 position FNR 12v
Control 3 position FNR 24v
Control gasket
Washer, seal (042)
Screw
1
1
1
1
1
1
6
M0EA
M0EP
M1EA
M1EP
M9EA
M9EA
M80
M87E
M90E
M91E
M95E
EDC kit w/MS connector

EDC kit w/Packard connector
EDC w/MS connector
EDC w/Packard connector
PCP type 3 oil filled (MS)
PCP type 3 oil filled (Packard)
Control gasket
Washer, seal (042)
Screw
Plastic cap (MS)
O ring
1
1
1
1
1
1
1
1
6
1
2
22483 (01/04)
Technical Manual
A Terex Company
Series 90
Item
Description
Qty
Item
Description
M810
M820
M830
M840
M850
M860
M870
Adapter Plate - Control (130 cc)

O-ring (130 cc)
O-ring (130 cc)
O-ring (130 cc)
Plug (130 cc)
Screw (130 cc)
Plug (130 cc)
1
1
1
2
1
6
1
N00M
N10M
N15M
N20M
N25M
N30M
N40L
N40P
Filtration manifold kit (Int)

Manifold
O ring
Nut
Tube
Plug
Filter
Filter
1
1
2
1
1
2
1
1
N00R
N10R
N15R
N20R
N25R
N30R
N00R
Filtration manifold kit (Rmt)

Manifold
O ring
Nut
Tube
Plastic plug
Plug
1
1
1
1
1
2
1
N00S
N10S
N30S
Filtration kit (Suction Flt)

Reducer fitting (Suction Flt)
Plug
1
1
1
P2A
P2B
P6
P13
P30
Multi-function valve assembly

Multi-function valve assembly
O ring
O ring
Plastic plug
1
1
2
2
2
T001-9
T201-9
T301-9
T401-9
Control orifice kit

Orificed check valve
Spring
Spring retainer
1
1
1
1
M96E
M97E
M98E
O ring
O ring
Screw
1
1
4
M0HA
M0HC
M1HA
M1HC
M80
M87H
M90H
HDC kit
HDC kit
HDC
HDC
Control gasket
Washer, seal (042)
Screw
1
1
1
1
1
1
6
M0MA
M7M
M71M
M72M
M80
M87M
M90M
MDC w/o neutral start switch

Control handle
Washer
Nut
Control gasket
Washer, seal (042)
Screw
1
1
1
1
1
1
6
M0MB
M7M
M71M
M72M
M80
M87M
M90M
S40
MDC w/neutral start switch

Control handle
Washer
Nut
Control gasket
Washer, seal (042)
Screw
Neutral start switch kit
1
1
1
1
1
1
6
1
M0MC
M7M
M71M
M72M
M74M
M75M
M77M
M78M
M80
M87M
M90M
MDC w/sol. valve

Control handle
Washer
Nut
Solenoid valve
Control manifold
Manifold gasket
Screw
Control gasket
Washer, seal (042)
Screw
1
1
1
1
1
1
1
2
1
1
6
M0MD
M7M
M71M
M72M
M75M
M76M
M77M
M78M
M80
M87M
M90M
S40
MDC w/sol. valve, nss

Control handle
Washer
Nut
Control manifold
Solenoid valve
Manifold gasket
Screw
Control gasket
Washer, seal (042)
Screw
Neutral start switch kit
1
1
1
1
1
1
1
2
1
1
6
1
10
133
Qty
22483 (01/04)
Technical Manual
A Terex Company
Vibrator Pump - S16 Rexroth

LH Rotation
P/N 45080-003-39
Pump Mounted on back of Pump Stack
RH Rotation
P/N 45080-003-40
Pump Mounted on Engine
134
22483 (01/04)
Technical Manual
A Terex Company
Auxiliary Pump
Eaton Model 70122 Piston Pump
This model pump is no longer available.

Substitute with L-15 Sundstrand
RH Rotation
P/N 45080-002-48
Pump Mounted on Engine
LH Rotation
P/N 45080-002-49
Pump Mounted on back of Pump Stack
135
22483 (01/04)
Technical Manual
A Terex Company
Auxiliary Pump
L-15 Sundstrand

Sunstrand Sauer
L15 Open Circuit Pump
Auxiliary Pump
45080-002-10
45080-002-24
136
22483 (01/04)
Technical Manual
A Terex Company
Maintenance Information
Fluids
Hydraulic fluids used with Sauer-Sundstrand products should be carefully selected with assistance
from a reputable supplier following the guidelines
presented in the "Hydraulics Fluid Requirements"
bulletin BLN-9987.
Incorrect alignment may result in eventual damage

to the drive shaft, drive shaft bearings, or the drive
shaft seal which can cause external oil leakage.
Start Up Procedure
Fill the reservoir with recommended hydraulic fluid
which should be passed through a 25 micron (nominal) filter prior to entering the reservoir. Never reuse
fluid.
The following types of fluids have been used successfully in Sauer-Sundstrand hydrostatic products:
1)Anti wear hydraulic oil.
2)Type F Automatic Transmission Fluid.
3)Engine oils meeting the requirements of
API classification CD.
4)Hydraulic transmission fluid of the type
used by the agricultural industry for
combined transmission, hydraulic and wet
brake system.
The fluid selected should provide a viscosity between 150 and 275 SSU at 100F.
The inlet line leading from the pump to the reservoir

must be filled prior to start-up. Check inlet line for
properly tightened fittings and be certain it is free of
restrictions and air leaks.
Be certain to fill the main pump housing with clean
hydraulic fluid prior to start up. Fill main pump
housing by pouring the filtered oil in the upper most
case drain hole.
Caution! Operation of the pump with less
than 160 PSI discharge pressure may reduce
the life of the unit.
Caution! As with any hydraulic system, a

key to successful operation and predicted
life is cleanliness of the various components
and the fluid. Strict compliance with component cleanliness recommendations and
fluid filtration requirements are a must. Failure to follow such recommendations and
requirements can result in excessive pump
flow loss and control valve malfunctions
that can render an complete system inoperative or even cause catastrophic failure.
See machine operating manual for machine start-up

procedures.
On mobile applications, run at the lowest possible
speed, with a minimum of 160 PSI until system
pressure has been established. Once system pressure is positive, increase the speed to full RPM. On
electric motor drives jog the motor several times
before initial start-up. In both cases if system pressure is not maintained, shut down the system and
determine cause.
Installation
Prior to installing the pump, inspect for damage
during shipment and handling. Make certain all
system components (reservoir, hoses, valves, fittings, heat exchanger, etc.) are clean prior to filling
with fluid.
The hydraulic system should be operated for at least

fifteen (15) minutes under light load conditions.
Shut down the system and remove the pressure
gauge. Check fluid level in the reservoir and add
fluid if necessary.
The pump should be connected to the prime mover

so that the centers of both drive shafts are aligned.
The pump is now ready for operation.
137
22483 (01/04)
Technical Manual
A Terex Company
Maintenance Information
System Maintenance
For satisfactory service, regular maintenance of fluid
and filters must be performed.
Check fluid level daily. Change fluid more often if
it becomes contaminated with any foreign matter
(dirt, water, grease, etc.)
Change Inlet and Return filter whenever fluid is
changed and whenever filter indicator shows a change
is necessary. Replace all fluid lost during filter
change.
138
22483 (01/04)
Technical Manual
A Terex Company
Troubleshooting
Troubleshooting
The information contained in this section provides a
guide for troubleshooting Sauer-Sundstrand Series
L pumps. It is a problem solving tool aimed at
reducing unnecessary machine downtime. Following the fault-logic approach will assist in the expedient correction of system problems.
SYSTEM PRESSURE
(TEE 5,000 OR 10,000 PSI GAUGE
INTO OUTLET HOSE)
INLET VACUUM
(TEE VACUUM GAUGE
INTO INLET HOSE)
CASE DRAIN
(CASE PRESSURE)
Various pressure and vacuum gauge readings can be

a great asset in troubleshooting problems with the
pump or support system.
INLET
It will be necessary to tee a high pressure gauge into

the system pressure line to check the setting of the
system relief valve as well as control settings.
RESERVOIR
INLET
SCREEN
Measuring the inlet pressure will help locate restrictions in the inlet lines, filter, etc.
Note: Snubbers are recommended to protect gauges. Gauge calibration is also necessary to insure accuracy of readings.
A. EXCESSIVE NOISE AND/OR VIBRATION

CHECK OIL
LEVEL IN
RESERVOIR
OK
AIR
IN
SYSTEM
OK
CHECK PUMP
INLET
PRESSURE
OK
INSPECT
SHAFT
COUPLING
OK
INSPECT
SHAFT
ALIGNMENT
LOW
LOOSE FITTING
IN SUCTION LINE
OR RETURN LINE
DEFECTIVE
DEFECTIVE
DEFECTIVE
FILL TO
PROPER
LEVEL
PURGE
AIR AND
TIGHTEN FITTING
CORRECT
REPAIR
OR
REPLACE
ALIGN
SHAFTS
139
22483 (01/04)
Technical Manual
A Terex Company
Troubleshooting
B. SYSTEM OPERATING HOT
CHECK OIL
LEVEL IN
RESERVOIR
OK
INSPECT
HEAT
EXCHANGER
LOW
OK
DEFECTIVE
FILL TO
PROPER
LEVEL
OK
CHECK PUMP
INLET
PRESSURE
LOW
(SEE NOTE 1)
LOW
CHECK SYSTEM
RELIEF VALVE
SETTING
REPAIR
OR
REPLACE
ADJUST
SETTING
OK
CHECK
CONTROL
VALVE
OK
SEE
NOTE 2
CORRECT
(REFER TO F)
REPAIR
CHECK FOR
INTERNAL
SYSTEM
LEAKS
1)If System Relief Valve is set below the Pressure

Compensator control, the valve can open prematurely
and result in heat buildup. The relief valve should be set
at least 300 PSI above desired pressure compensator
setting.
2)In the same manner, if the compensator is inoperable
the relief valve will open in response to excessive pressure
and create heat in the system.
HIGH
REPAIR
AS
REQUIRED
C. SYSTEM RESPONSE IS SLUGGISH
CHECK SYSTEM
RELIEF VALVE
SETTING
LOW
ADJUST
SETTING
OK
CHECK
CONTROL
SETTING
OK
INCORRECT
ADJUST
SETTING
CHECK
CONTROL
SIGNAL
PRESSURES
OK
DEFECTIVE
CONTROL
INCORRECT
REPAIR
140
OK
INTERNAL
SYSTEM LEAKS
HIGH
LEAKAGE
REPLACE
CONTROL
(REFER TO E)
REPAIR
AS
NEEDED
22483 (01/04)
Technical Manual
A Terex Company
Troubleshooting
D. LOW PUMP OUTPUT FLOW
CHECK OIL
LEVEL IN
RESERVOIR
OK
LOW
CHECK SYSTEM
RELIEF VALVE
SETTING
OK
LOW
FILL TO
PROPER
LEVEL
ADJUST
SETTING
OK
CHECK PUMP
INLET
PRESSURE
INCORRECT
LOW
CHECK PUMP
CONTROL
SETTING
ADJUST
SETTING
OK
CHECK
INPUT
SPEED
OK
LOW
CORRECT
(REFER TO F)
CORRECT
CHECK
MAXIMUM
FLOW
ADJUSTMENT
INCORRECT
ADJUST
SETTING
E. COMPENSATOR VALVE DOES NOT OPERATE
CHECK
CONTROL
SETTING
OK
INSPECT
COMPENSATOR
SPRING
INCORRECT
WRONG
PRESSURE RANGE
ADJUST
SETTING
REPLACE
OK
INSPECT
FOR
LEAKAGE
CORRECT
141
OK
INSPECT
COMPENSATOR
SPOOL
OK
INSPECT
FLOW CONTROL
CYLINDER
DAMAGED
OR
CONTAMINATED
DAMAGED
OR
CONTAMINATED
REPAIR
OR
REPLACE
REPAIR
OR
REPLACE
22483 (01/04)
Technical Manual
A Terex Company
Troubleshooting
F. HIGH INLET VACCUM
CHECK OIL
TEMPERATURE
OK
INSPECT
INLET
FILTER
OK
CHECK
OIL
VISCOSITY
OK
INSPECT
INLET
PIPING
COLD
CLOGGED OR
TOO SMALL OF
MESH
ABOVE
150-275 SSU
AT 100 F
TOO LONG
OR SMALL
DIAMETER
ALLOW SYSTEM
TO WARM UP
REPLACE
FILTER
REPLACE
OIL
REPAIR
AFFECTED PART
PROBLEM
PROBABLE CAUSE
A. Pump is used at higher than
maximum working pressure
B. Seizure is due to lack of lubrication
Broken
Shaft
Needle bearing wear on L-15

Excessive shaft end play on L23,
L38, L50, L70 models
Wear
Seizure
A. Oil contamination
Wear
A.
B.
C.
D.
E.
Slipper Pads
Wear
B. Excessive speed
C. Excessive pressure
Bearings
Damage
A. Improper shaft alignment

B. Abnormal pressure
C. Insufficient end play on L23, L38, L50
and L70 models
Oil Seals
Damage
A. Excessive case leakage

B. Excessive case pressure
C. Improper shaft alignment
Control Cylinder
Cylinder Rod
Wear
Cylinder Block
Valve Plate
Excessive oil temperature

Cavitation
Improper case drain filling
Excessive speed
Excessive pressure
Common Causes of Wear and Part Damage
142
22483 (01/04)
Technical Manual
A Terex Company
Standard Control Adjustment

Maximum Flow Adjustment
Maximum volume or flow from the pump can be
varied to match the application requirement by turning the flow adjusting screw located on the back of
the pump.
DISPLACEMENT
COUNTERCLOCKWISE
TURNING
CLOCKWISE
TURNING
Using appropriate wrenches, loosen the locknut and

turn the adjusting screw clockwise to decrease maximum pump flow or counterclockwise to increase
maximum flow.
PRESSURE
FLOW
ADJUSTING SCREW
The flow rate will be increased or decreased by

approximately the following amount for each complete turn of the adjustment screw.
END CAP
CYLINDER ROD
CONTROL CYINDER
L15 .091 in. 3/rev. per turn
COUNTERCLOCKWISE
TURNING
CLOCKWISE
TURNING

CAP
L50 .25 in 3/rev. per turn
SWASHPLATE
Stops are provided to limit both the minium and

maximum positions of the screw within the following angle and displacement per revolution range.
PUMP
SIZE
SWASHPLATE
ANGLE
L15
2 to 15
3
3
0.135 in. /rev. to 0.913 in. /rev.
L23
5 to 17
3
3
0.378 in. /rev. to 1.41 in. /rev.
L38
7 to 18
3
3
0.9 in. /rev. to 2.3 in. /rev.
L50
0 to 18
3
0 to 3.15 in. /rev.
L70
2 to 18
DISPLACEMENT
.4 in. 3/rev. to 4.26 in. 3/rev.
Flow Adjustment
After adjustment, hold the screw in place and torque

the locknut to 12-16 ft. lbs.
Caution! Excessive torque may damage
threads and allow setting to change during
operation.
143
22483 (01/04)
Technical Manual
A Terex Company
Pressure Compensator Control (PC)

The following adjustment procedure is applicable
for the pressure compensator function on the pressure compensator control, the flow and pressure
compensator control and the remote pressure compensator control.
CLOCKWISE
TURNING
COUNTERCLOCKWISE
TURNING
DISPLACEMENT
The standard pressure compensator adjustment range

is 500 to 3000 PSI (35 BAR to 210 BAR). The
following optional ranges are available. 250-1000
PSI (15 BAR to 70 BAR) and 250-2000 PSI (15
BAR to 140 BAR)
PRESSURE
Typical Pressure Compensator Curve
LOCKNUT
P
It is necessary to refer to the machine specifications

for specific control settings and any procedures
particular to adjusting the control on each machine.
PRESSURE ADJUSTING
SPRING SCREW
1)The system relief valve should be set at

least 300 PSI (20 BAR) higher than the
desired pressure compensator setting.
2)The flow compensator function, if
present, must be disabled prior to adjusting
the pressure compensator by connecting
system pressure to the flow compensator
feedback port.
3)Using an appropriate adapter, connect a
high pressure gauge (10,000 PSI) into the
pressure line from the pump.
Warning! To set the pressure compensator
requires deadheading the pump. Take necessary precautions of securing the work function so no movement of the load occurs, and
also that the system high pressure relief
valve is properly adjusted as noted earlier.
COUNTERCLOCKWISE
TURNING
VALVE BODY
CLOCKWISE
TURNING
SPOOL
Cutaway View of Pressure Compensator Control
SYSTEM PRESSURE
CONTROL SETTING
DIRECTIONAL
VALVE IN
CLOSED
POSITION
PRESS.
COMP
PV
TO
SYSTEM
SYSTEM RELIEF VALVE

SET 300 PSI ABLVE
CONTROL SETTING
4)Start the prime mover and allow fluid to

reach normal operating temperature.
5)Note the high pressure gauge reading
which is the pressure setting of the pressure
compensator.
Refer to machine
specifications for proper pressure setting.
6)To adjust the pressure compensator
loosen the locknut. Then, using appropriate
hex wrench, turn the adjusting screw
clockwise to increase setting or
counterclockwise to decrease setting.
Typical System Schematic Using

Pressure Compensator Control
144
22483 (01/04)
Technical Manual
A Terex Company

If the pressure setting does not increase in
response to turning the adjustment screw
clockwise, the system relief valve may be
improperly adjusted.
7)Once the desired pressure setting (shown
on the pressure gauge) is obtained, hold the
adjustment screw in place and torque the
locknut to 16-20 ft. lbs.
Note: Cycle pump 2 or 3 times to insure
pressure setting is maintained.
Pressure Adjustment on the Flow Pressure Control
L50 & L70
L15, L23 & L38

3000
210
3000
PR
175
70
00
N
RI
00
I
PS
105
SP
20
70
1000
0
100
PS
R
SP
ING
30
PS
2000
COMPENSATING PRESSURE
105
140
00
140
30
COMPENSATING PRESSURE
IS
PS
PR
IS
IN
175
IN
210
2000
IN
PS
0
00
R
SP
1000
NG
PRI
100
S
PSI
35
35
0
0
PSI
BAR
PSI
BAR
PRESSURE ADJUSTING SCREW

(REVOLUTIONS)
PRESSURE ADJUSTING SCREW

(REVOLUTIONS)
145
22483 (01/04)
Technical Manual
A Terex Company
Minor Repairs
Introduction
The areas of repair indicated are classified as minor
repairs and may be performed, following the procedures in the section, without voiding the unit warranty. Although specific units are illustrated, these
procedures apply to all series and types of units in the
Series L Family.
General
Cleanliness is a primary means of insuring satisfactory pump life, on either new or repaired units.
Cleaning parts by using a solvent wash and air
drying is adequate, providing clean solvent is used.
As with any precision equipment, the internal mechanism and related items must be kept free of foreign
materials and chemicals.
Removal of a Standard Control
Protect all exposed sealing surfaces and open cavities from damage and foreign material.
It is recommended that all gaskets and o-rings be
replaced. All gasket sealing surfaces must be cleaned
prior to installing a new gasket. Lightly lubricate all
o-rings with clean petroleum jelly prior to assembly.
L15, L50, L70 Style Shown
L15, L50, L70 Models
Shaft Seal
Removal
Two types of shaft seals are used on the L Series
pumps. The L15, L50 and L70 models each utilize
a seal retainer and O-ring. The L23 and L38 models,
however, use a replaceable seal and retaining ring
only. Refer to the appropriate instruction which
follow for seal replacement. Please note: The seal
retainer on the L50 manufactured after serial number
84-50XXXX has been eliminated.
L23 and L38 Models
Using retaining ring pliers, remove the retaining ring

from the shaft end of the pump.
Caution! The retaining ring holds the shaft
in the housing on the L15 model. Do not pull
on the shaft after the retaining ring has been
removed. In the event the shaft is pulled
from the housing, do no attempt to slide it
back into the unit. The shaft aligns all
cylinder block components, which have
146
22483 (01/04)
Technical Manual
A Terex Company
Minor Repairs
probably now become misaligned. Reinstalling the
shaft by sliding it back in will damage the
cylinder block assembly. Once the shaft has
been removed, it becomes necessary to remove the end cap and cylinder block. Refer
to the major repair section of this manual.
L15, L50 and L70 Models
Install a screw into each of the two threaded holes in
the face of the seal retainer. (The screws which hold
the control onto the end cap will fit.)
Pull or pry the seal retainer from the housing. The
retainer will not come out easily as it is held in place
by a large o-ring.
Using a seal driver or similar tool, remove the seal
from the seal retainer. Discard the seal when removed.
Remove and discard the o-ring from the outside of
the seal retainer.
L23 and L38 Models
Using a punch, or some type of sharp instrument,
puncture the shaft seal and gently pry it out of the
housing. Remove the old seal from the shaft and
discard.
Installation
L15, L50 and L70 Models
Use a seal driver or similar tool to press a new seal
into the seal retainer. Make certain the seal is
bottomed on the counterbore within the retainer.
Caution! Do not use excessive force as seal
will be damaged.
Install a new o-ring on the outside of the seal retainer.
Lubricate the o-ring with oil and slide the seal
retainer over the shaft and into the housing. Press the
seal retainer into the housing until the retaining ring
groove is exposed.
Install the retaining ring with the beveled side out.
Make certain the retaining ring has snapped into the
groove completely.
Standard Control Removal
147
22483 (01/04)
Technical Manual
A Terex Company
Minor Repairs
L23 and L38 Models
Lubricate the new seal with oil and carefully slide it
over the shaft. Make sure the shaft is covered or
other measures have been taken to protect the seal
from damage by the shaft keyway.
Press the seal into place and securely install the
retaining ring in the groove within the housing.
Control
Using an internal hex wrench, remove the four
socket head screws which hold the control on the end
cap.
Remove the control and gasket from the end cap.
Remove the o-ring from the groove in the mating
surface of the control.
148
22483 (01/04)
Technical Manual
A Terex Company
Minor Repairs
It is suggested that a new o-ring be installed on the
control and a new gasket placed on the end cap
mating surface. Make certain the large hole on the
gasket will mate with the o-ring on the control when
assembled.
Place the control on the end cap and reinstall mounting screws. Tighten to 61-69 in. lbs. torque.
Note: The standard controls, which include the pressure compensator, remote
pressure compensator and flow and pressure compensator controls, for the L15,
L23 and L38 are interchangeable between
the three models. Likewise, the standard
controls are interchangeable between the
L50 and L70 models. All other controls are
not interchangeable.
Note orientation of gasket with relation to O-ring
SPRING
RETAINER
SPOOL
SPRING
ADJUSTMENT
END
PLUG
LOCKNUT
Standard Control Disassembly

If the control is not performing properly because of
a sticking or contamination, it can be further disassembled for cleaning or repair.
Using appropriate wrenches, loosen the adjustment
screw locknut and remove the adjustment screw.
The control spring and spring retainer can now be
removed from the cavity.
Using an internal hex wrench remove the threaded
plug from the opposite end of the control and remove
the control spool.
When reassembling control, be sure spool is not reversed
Remote Pressure
Compensator Control
Flow and Pressure
Compensator Control
Pressure
Compensator Control
{
{
{
Flush the control cavity with clean solvent and wash

all parts in solvent and air dry. Examine spool and
cavity surfaces for nicks or scratches and replace any
parts found to be defective.
Pressure
Compensator
Adjustment
Flow
Compensator
Adjustment
Replace spring and spring retainer in cavity from

adjustment end and reinstall adjustment screw and
locknut. Install control spool in opposite end of
control and install plug. Insure that orientation of
spool is correct.
Pressure
Compensator
Adjustment
Exploded View of Standard Control
Reinstall control on pump housing replacing o-ring

and control gasket as part of the procedure.
Refer to control adjustment procedure in this manual
and set control for maximum system pressure.
149
22483 (01/04)
Technical Manual
A Terex Company
Fastach II Generator Drive Pump

Rexroth A10VO
Max Pressure Valve
Standby Pressure
Valve
150
22483 (01/04)
Technical Manual
A Terex Company

Set-Up Procedure
Screed Generator Pump Set-Up

To properly operate the Fastach II screed electric
heating units, it is necessary to set up the screed
generator pump circuit. This hydraulic pump circuit
has three (3) valves which require adjustment, the
needle valve (located on the drive motor manifold),

and the pump standby and max pressure valves (both
located on the pump) (Figure 1).
Generator Drive Motor
Generator
Control
Box
Generator Pump
(Mounted on Tractor)
Motor Manifold
Needle Valve
Standby
Pressure
Valve
Test Port (P)
Max
Pressure
Valve
Figure 1 Screed Generator Hydraulic Pump Adjustments
Start-up After Initial Installation of Pump
5) Turn generator switch on and let run with

engine at idle approximately one (1) minute to
prime pump and purge air from lines. Generator should turn at a low speed.
1) Fill pump housing with clean oil. Do this

through the case drain port on the pump
housing.
Notice - Do not apply electrical load to

generator.
2) Loosen needle valve jam nut on screed generator drive motor manifold.
6) Turn generator switch off.

3) Turn screw clockwise until it bottoms to fully
close valve.
7) Shut off engine.
4) Start engine and run at idle.
151
22483 (01/04)
Technical Manual
A Terex Company

Set-Up Procedure
Set Pump Max Pressure
4) Re-start engine and run at 1400 rpm.
1) Start engine and run at 1400 rpm.
5) Re-check pressure to make sure standby pressure reads 400 psi. Adjust if necessary.
Notice - Make sure generator switch is turned

OFF.
6) Tighten jam nut on standby pressure adjustment

screw and reinstall cap.
2) Install 6000 psi gauge on test port (P) of generator drive motor manifold. (Figure 1)
7) Shut off engine.

Set Generator Motor Speed (Frequency)
1) Install a frequency (Hz) test meter into the 120
volt outlet on the generator control box.
(Figure 2)
3) Remove cap from standby pressure adjustment

screw and loosen jam nut.
4) Turn standby pressure adjustment screw clockwise until it bottoms to fully seat valve.

5) Note gauge pressure: Pressure will be approximately 500 - 2500 psi.
3) Turn generator switch on.
6) Remove cap from max pressure adjustment screw

and loosen jam nut.
4) Turn needle valve screw counter-clockwise until test meter reads 62 Hz.
7) Turn max pressure adjustment screw clockwise

until gauge reads 4000 psi.
5) Tighten jam nut on needle valve.

6) Shut off engine.
8) Tighten jam nut on max pressure adjustment

Set Pump Standby Pressure
1) With engine still running at 1400 rpm as described above, turn standby pressure adjustment
screw counter-clockwise until gauge reads approximately 400 psi.
Notice - Make sure generator switch is turned
OFF.
Figure 2 Setting Generator Frequency
2) Shut off engine.
Screed generator pump and hydraulics are now

ready to be put into operation.
3) Remove 6000 psi gauge and install 1000 psi

gauge.
152
22483 (01/04)
Technical Manual
A Terex Company
Stretch Electric Screed Generator Drive

Pump Set-Up Procedure
All Grayhound & Tier II Pavers
Screed Generator Pump Set-Up

Generator Pump
(Mounted on Tractor)
Generator Drive Motor
PC Cartridge Valve Pressure Adjustment

(4000 psi)
Motor Manifold
Needle Valve
Standby
Pressure
Adjustment
Screw
(400 psi)
Test Port (P)
Figure 3 Screed Generator Hydraulic Pump Assembly
To properly operate the screed electric heating units,

it is necessary to set up the screed generator pump
circuit.
drive motor manifold.

3)
This hydraulic pump circuit has three valves which

require adjustment: the needle valve (located on the
drive motor manifold), the pump standby pressure
adjustment screw and the maximum pressure valves,
both located on the pump (Figure 3).
Turn screw clockwise until it bottoms to fully

close valve.
4) Start engine and run at idle.

5) Turn generator switch on and let run with engine
at idle approximately one (1) minute to prime
pump and purge air from lines. Generator should
turn at a low speed.
Start-up After Initial Installation of Pump

1) Fill pump housing with clean oil. Do this through
the case drain port on the pump housing.
CAUTION
2) Loosen needle valve jam nut on screed generator
Do not apply electrical load to generator.

6) Turn generator switch off.
7) Shut off engine.
153
22483 (01/04)
Technical Manual
A Terex Company

Set Pump Max Pressure
NOTICE
Make sure generator switch is turned OFF or
the screed is disconnected from the tractor.
1)
Install 6000 psi gauge on test port (P) of

generator drive motor manifold (Figure 3 ).
X Port
(Not
Shown)
M2 Port
2) Remove load sensor line from X port on pump.

(Figure 4 ).
Connect M2 and X Ports With Jumper Hose
Figure 5 M2 Port - Tractor Generator Pump
5) Loosen the jam nut on the max pressure

adjustment screw.
6) Turn max pressure adjustment screw clockwise
until gauge reads 4000 psi.
7) Tighten jam nut on max pressure adjustment
screw.
8) Shut off engine.
X Port
9) Remove jumper hose and reconnect load sensor

line to the X port on pump.
Figure 4 X Port - Tractor Generator Pump
Set Pump Standby Pressure

Add a jumper hose between ports X and M2 on 1) Start engine and run at 1400 rpm as described
above. Turn standby pressure adjustment screw
pump (Figure 5 ).
counter-clockwise until gauge reads
approximately 400 psi.
3)
NOTICE
Make sure generator switch is turned OFF.
154
22483 (01/04)
Technical Manual
A Terex Company

The screed generator pump and hydraulics are now
ready to be put into operation.
2) Shut off engine.

3) Remove 6000 psi gauge and install 1000 psi
gauge.
Tractor Generator Plumbing

Adding or removing the electric screed from the
tractor will require changes to the tractor generator
pump plumbing configuration.
4) Re-start engine and run at 1400 rpm.

5) Re-check pressure to make sure standby pressure
reads 400 psi. Adjust if necessary.
CAUTION
6) Tighten jam nut on standby pressure adjustment

Make sure generator pump plumbing is

properly connected prior to operation.
7) Shut off engine.

Set Generator Motor Speed (Frequency)
Attaching Screed To Tractor Generator Pump
1) Install a frequency (Hz) test meter into the

120-volt outlet on the generator control box
(Figure 6).
When the screed is attached to the tractor, the

generator pump load sensor line is connected to the
quick connect fitting on the screeds generator drive
hydraulic motor (Figure 7).

3) Turn generator switch on.
4) Turn needle valve screw counter-clockwise until
test meter reads 62 Hz.
5) Tighten jam nut on needle valve.
6) Shut off engine.
Connect Load Sensor Line From Pump To Valve
Figure 7 Tractor Generator Pump Connection on

Screed Generator Drive Motor
Figure 6 Setting Generator Frequency

155
22483 (01/04)
Technical Manual
A Terex Company

Operating Tractor Pump Without Screed
Removing the screed from tractor requires
disconnecting the generator pump load sensor line
from the screeds generator drive motor. The line is
then rerouted to the pump by attaching it to the 1/ 4"
nipple on the rear of the tractor (Figure 8).
RH Conveyor Motor
Coupling
Figure 8 Generator Pump Connections for Detached

Screed
156
22483 (01/04)
Technical Manual
A Terex Company
Conveyor Drive Motor

Char-Lynn 6000 Series
157
22483 (01/04)
Technical Manual
A Terex Company
Lohmann & Stolterfoht

Travel Drive Unit Assembly
158
22483 (01/04)
Technical Manual
A Terex Company
Travel Drive Motor

Rexroth (Various Series)
159
22483 (01/04)
Technical Manual
A Terex Company
Travel Drive Motor Begin of Stroke

Adjustment Procedure
Description
Tire and steel track units are set by the motor

supplier and adjustment should not be necessary
unless a problem is encountered.
The begin of stroke adjustment on the travel

motors is required to assure proper automatic shift
operation when paver is in Travel Mode. It is
important that both travel motors shift from
Travel to Pave at the same pressure. Tire and
steel track units are set at 2500 psi. Rubber track
units are set at 4400 psi.
Rubber track units must be adjusted to match

the two sides. This must be done when one or
both travel motors are replaced or when a problem
is encountered.
Figure 1 Travel Motor Port Location
160
22483 (01/04)
Technical Manual
A Terex Company

Preparation for Adjustment
1) Isolate each side G ports by disconnecting
the cross-over line at left side motor
bulkhead (tire units will require removal of
tire) or, on rubber track, left side take-up
valve (400 & 500 series).
DIN Connector
2) Install 10,000 psi gauge on each side G

port at the point you disconnected above.
3) Install 10,000 psi gauge on each side M1
test port.
Figure 4 Brake Valve DIN Connector 300 Series
4) Raise hood, lock in up position, and set

brakes by removing DIN connector from
brake solenoid valve.(Figure 4 or Figure 5)
DIN Connector
Figure 5 Brake Valve DIN Connector 400/500 Series
5) Raise paver frame, lock screed in up

position, and jack up paver and block to
access the underneath side of travel motors.
Figure 2 Gauges Installed 300 Series Rubber Track

Shown
You may now proceed with the adjustment procedure.

Begin of Stroke Adjustment Procedure
1) Start and run engine at idle.
2) Travel switch in FORWARD, speed dial at
0, range switch in TRAVEL, and steering
wheel centered.
Figure 3 400/500 Rubber Track Units
161
22483 (01/04)
Technical Manual
A Terex Company

3) Slowly increase travel speed dial and note
what each G port pressure gauge reads at
the point each side begins to shift to pave
speed. (Figure 6)
Figure 7 Begin of Stroke Adjustment
6) To change the setting turn the adjustment

screw in (clockwise) to lower the begin
point setting and out (counter clockwise)
to increase the begin point setting.
Figure 6 Pressure Readings
7) Repeat steps 1 through 6 until the required

begin of stroke set point is achieved, stable,
and the same on each side.
The G port pressure should rise steadily while the

M1 port pressure will rise just a little, remain steady,
then start continuing to rise as the dial is turned.
Read G port pressure when M1 port pressure starts
rising again. This is the Begin of Stroke Point.
8) After obtaining the desired setting, lock

begin of stroke adjustment screw into place.
9) Shut down engine.
Caution - Do not allow oil to flow over

the high pressure relief valves for long
periods of time, as excessive heat can be
generated to the pump.
10) Remove individual gauges from G ports

and tee one 10,000 psi gauge in G port
cross-over line.
4) Note: The begin of stroke setting should

be 2500 psi for tire and steel track units and
4400 psi for rubber track units.
Caution - Port G may contain trapped

pressure.
5) Break off the tamper resistant cap on the

HA control valve adjustment screw and
back off the locknut while holding the
adjustment screw with a 3mm hex wrench.
The locknut requires a 10mm wrench.
(Figure 7)
162
22483 (01/04)
Technical Manual
A Terex Company

11) Repeat steps 1 through 6 again to verify
proper shifting.
12) Perform above adjustment until proper
shifting is achieved.
13) Shut down engine.
Caution - Port G may contain trapped
pressure.
14) Remove all gauges and reconnect crossover line on G ports.
Figure 8 Rubber Tire Units
The following figures show the bulkhead areas

for the rubber tire units (Figure 8) and steel track
units (Figure 9). As you may note, there are no
gauge fittings pre-installed on these units. You
must remove the hoses/lines and install gauge
fittings to perform the above mentioned
procedure.
Figure 9 Steel Track Units
163
22483 (01/04)
Technical Manual
A Terex Company
Travel Drive Motor

Self-cleaning Swivel-time Orifices
Orifice Plug " B"
Uni-Directional
Shuttle Orifice
Orifice Plug " A"
Passage 1
Passage 2
Bi-Directional
Shuttle Orifice
"M 1" Port
Motor Cap
There are two types of self-cleaning swivel-time orifices available, a uni-directional and a bi-directional. This means that one
type of shuttle orifice will control flow in one direction and will
free flow in the other. The second type of shuttle orifice will control flow in both directions. Both types of shuttle orifices are
shown above.
A swivel-time orifice kit is made up of two orifice plugs and one
shuttle orifice. This kit is inserted into the "M1" port of the motor
cap (see page 26 for "M1" port location). There is only one way
to properly insert the swivel-time kit. First, thread orifice plug "A"
into the "M1" port until it bottoms. Caution: Do not overtighten
this orifice plug. Next, insert the shuttle orifice in it's proper orientation for desired flow control. Finally, thread orifice plug "B"
into the "M1" port until it is tightly against orifice plug "A". Plug
port "M1".
The bi-directional shuttle orifice can be inserted with either

tapered end in first. It's orientation does not affect flow control.
The orientation of the uni-directional shuttle is important. With
the uni-directional shuttle assembled into the motor cap as
shown above, controlled flow will be from passage 2 to passage
1 (into the stroking piston). Free flow will occur from passage 1
to passage 2 (out of the stroking piston). To reverse flow control, rotate the uni-directional shuttle orifice 180. The orifice plug
B requires a 5mm Allen Wrench and orifice plug A requires a
6mm Allen Wrench.
Note: When using a uni-directional shuttle orifice, it will typically
be assembled to control motor swivel time from minimum to
maximum displacement. Contact Rexroth for more details.
164
22483 (01/04)
Technical Manual
A Terex Company
Travel Drive Motor

Installation, Start-up, & Troubleshooting
Installation
The AA6VM motor may be mounted in any position. When
mounting in a shaft up position, special considerations regarding
the case drain line may be required to ensure the motor bearings are always immersed in oil.
The AA6VM is usually face mounted to a final drive gear box
with the shaft engaging a mating female splined gear hub or
spline adapter. The large drive shaft bearings permit vee or
toothed belt pulleys, or gear pinions to be mounted directly to
the drive shaft. (Consult Rexroth for radial and axial force limitations.) The motor may also be used to transmit power via a
universal drive shaft. The case drain line should be connected
to the highest case drain port so that the motor always remains
full of oil.
For mobile applications, the oil reservoir capacity required (in
U.S. gallons) is generally .75 to 1 times the charge pump flow (in
U.S. gallons per minute) for a one pump, one motor transmission. The heat exchanger should be located between the pump
case drain and the reservoir, and sized to accept the full flow of
the charge pump at the maximum anticipated drive speed.
To accommodate slight shaft misalignment and to dampen
vibration, use of a flexible coupling is recommended. The motor
user should work closely with the coupling manufacturer in
selecting and applying a suitable coupling . When flexible couplings, Veebelts or toothed timing belts are to be used, the
coupling halve, gear or pulley, should be secured to the drive
shaft using a spacer between the coupling and the shoulder on
the drive shaft, and locking the coupling to the shaft by using a
set screw into the threaded hole in the end of the shaft. If this is
not possible, as when mounting the motor to a drive gearbox,
Optimoly Paste White T multipurpose lubricating paste or equivalent must be applied to the shaft to avoid fretting corrosion of
the spline.
Motor Flushing
A flushing valve is usually required when a motor will be operated for extended periods of time at high speed and/or high
pressure conditions.
Each application should be analyzed to determine the proper

method of filtration needed to maintain the required cleanliness
levels, as contaminant generation and ingression can vary
greatly,depending on the configuration and complexity of the
system. For particular system requirement, or for application
outside these parameters, a Rexroth Applications Engineer
should be consulted.
Pre-Start Procedure
This should be performed prior to start-up a new installation, or
for a system in which new or overhauled components have been
fitted.
1. Ensure that hydraulic reservoir piping and pressure hoses
are cleaned and flushed.
2. Fill the reservoir through fill pump and filter.
3. If there is any doubt regarding the absolute cleanliness of
the system, fit high pressure bi-direction filters in high pressure lines as shown in following diagram. the filters are in
addition to the installed suction and return filters.
4. Check that all filters have elements of the correct rating and
the filter housing are filled with the hydraulic fluid to be used
in the system.
5. Where possible, fill the high pressure lines.
6. Open suction line valves.
A flushing valve is available for manifold mounting on the rear

cover of an AA6VM motor. This valve provides a regulated flow
of oil from the low pressure side of the loop into the motor case.
This oil is used to cool and flush the motor bearings.
Note: Consult Rexroth application engineer to determine if a
motor flushing valve is required for your application.
7. Fill pump and motor case to the highest drain or vent port.
8. Check that all pressure connections are secure.
9. Ensure all mechanical gear boxes have the correct oil type
and are filled to the prescribed level.
10. Fully back off all high pressure relief valves and then reset
one half turn against the spring.
11. Fit 10,000 psi pressure gauges to each high pressure line.
12. Fit 500 psi pressure gauges to charge and pilot circuits.
13. Fit 100 psi pressure gauge to pump case drain port.
14. Fit vacuum gauge to the charge pump suction line, as close
as possible to suction port.
TG
EP1 and EP2 Control with Flushing Valve
Filtration
The fluid should be filtered prior to system start-up, and continuously during operation to achieve and maintain a cleanliness
level of ISO 18/15 (This corresponds approximately to NAS
1638 class 9, or SAE [1963] Class 6.) This recommendation
should be considered a minimum, as better cleanliness levels
will significantly increase component life.
165
15. Release brakes and jack up the driving wheels. Winches

should be started without the cable fitted.
16. Ensure that the fluid temp. in the reservoir is 45F or higher.
17. Ensure that the motor minimum displacement (maximum
speed) is set correctly as shown on page 23.
22483 (01/04)
Technical Manual
A Terex Company
Travel Drive Motor

Start-Up Procedure
The following procedure has been developed based on experience with most types of applications, however certain
applications may require a departure from or variation to this
procedure.
For the start-up of new or overhauled installations.
18. Check oil level and temperature.
1. If the prime mover is:

Internal combustion engine: (Diesel, gasoline or LP)Remove the coil wire, close the injector rack or leave the
gas turned off and turn the engine over until the charge
pressure reaches 50 psi or more.
Electric Motor: Jog the starting circuit until the charge pressure reaches 50 psi or more.
2. Start the prime mover, and if possible, maintain a pump
speed of approximately 750 rpm for 5 minutes. This will
allow the system to be filled.
19. Remove and inspect high pressure filter elements, if so

equipped. Replace with new elements.
20. Operate transmission under no load conditions for about 15
minutes to stabilize the temperature and remove any residual air from the fluid.
21. Again remove and inspect high pressure filter elements, if
so equipped. If clean, the high pressure, bi-direction filters
may be removed from the circuit. If contamination is still
evident, fit new elements and continue flushing until the system is clean.
3. Listen for any abnormal noises.

4. Check for oil leaks.
22. Replace the elements in the charge pump suction or pressure filter, whichever is installed.
5. Run prime mover to 1800 rpm. (Adjust to the design speed

if less than 1800 rpm.)
23. Operate the transmission under full and normal load conditions.
6. Set charge and pilot pressure as required for the application. (Refer to circuit schematic)
24. Erratic operation may indicate there is still air trapped in the
system. By working the pump control to one or both sides
the remaining air can be eliminated. The system is free of
air when all functions can be operated smoothly and when
the oil in the reservoir is no longer aerated. (Usually less
than 1 hour of operation)
7. Bleed the pilot lines by loosening the connections on the

motor X port(s) and then actuate the remote control unit in
both directions until oil seeps from the connections. Also
bleed the pilot lines to the pump (if any).
8. Retighten all connections.
9. Operate the control to work the hydrostatic transmission at
approximately 20% of maximum speed.
Note:
If, after following the Pre-Start and Start-up procedures, the
transmission does not perform correctly, refer to the relevant sections of the trouble-shooting procedures on pages
17, 18 & 19.
10. Deaerate system by venting a bleed valve or by cracking

the highest connection until fluid seeps out without bubbles.
11. Check fluid level and add fluid if necessary.
12. Continue operating transmission and gradually increase to
full speed, still with no load.
13. With controls neutralized, check for creep in neutral. If evident, center the control in accordance with the instructions
in the pump service manual.
14. Check that the controls are connected so that the transmission operates in the correct direction related to the control
input.
15. Continue to monitor all pressure gauges and correct any
irregularities.
16. Apply brakes and set high pressure relief valves (and pressure override if installed) to levels required for the
application by stroking the pump to approximately 20% of
maximum displacement.
17. Check security of high pressure connections.
166
22483 (01/04)
Technical Manual
A Terex Company
Travel Drive Motor

Troubleshooting Procedure
To aid in troubleshooting, refer also to the Hydrostatic
Transmission Pump Service Manual. Procedure assumes
gauges are installed.
This procedure was written to aid the troubleshooter in following

a logical approach to a system fault.
1. Transmission does not Drive with the Prime Mover Running

1.1 Is there oil in the reservoir?
No Fill reservoir.
Yes Proceed to step1.2.
1.2 Is engine clutch engaged?
No Engage clutch.
Yes Proceed to step 1.3.
1.3 Is the hydraulic piping in

accordance with the
hydraulic circuit?
No Correct the piping.

1.4 Is the pump direction of

rotation correct?
No Fit pump having the

correct direction of rotation.
1.5 Is there a broken pipe,

loose fitting or burst
hose?
No Proceed to step 1.6.

Yes Repair the fault.
1.6 Are the brakes released?
No Check brake release

circuit or mechanism.
1.7 Is there any charge

pressure?

1.8 Is the charge circuit at

the recommended pressure level while the
pump is running at normal operating speed?

1.9 Can the charge pressure be adjusted at the

charge pressure relief
valve?

Yes Adjust charge pressure
and proceed to step
1.19.
1.10 Is the suction line shutoff?
No Open valve
1.11 Is the charge pump suction pressure within the

recommended limits?

1.12 Is the suction filter element plugged.

Yes Replace filter element
1.13 Does the reservoir design ensure that suction

pipe is always covered
with oil.
No Correct the reservoir

design.
1.14 Is the suction pipe size

adequate for the flow?
No Run at lower speed and

return to point 1.7, or
rework suction piping.
167
1.15 Is the reservoir air

breather blocked or
undersized?

Yes Clean or Replace air
breather.
1.16 Remove charge pressure

relief
valve
cartridge and inspect.
Is it damaged?
No Refit cartridge and proceed to step 1.17.

Yes Fit a new cartridge and
return to step 1.7.
1.17 Remove and inspect

charge pump assembly.
Is it damaged?

Yes Repair or replace damaged components and
return to step 1.7.
1.18 Is the charge pump

installed for correct
direction of rotation?
No Refit charge pump.

Return to step 1.7.
Yes With proper charge
pressure, and transmission still does not
operate, proceed to
step 1.19.
1.19 Is control medium connected to pump control?

Hydraulic pilot pressure
mechanical cable or
linkage. 12 or 24 volts
dc, electrical current.
No Connect appropriate
medium and check that
control signal is actually
being applied to the
pump stroker.
1.20 Is maximum displacement selected on the

variable motors? (If not
done automatically)
No Select maximum displacement.

1.21 Actuate the control in

both directions. Does
pump stroke? Does it
go to full stroke?
No Refer to the pump service manual and then

proceed to step 1.22.
Yes Operate the transmission.
1.22 Is it possible to adust

high pressure relief
valves?
No Replace high pressure

relief valve cartridges
and return to step 1.21.
Yes Adjust high pressure
relief valves
1.23 Actuate control in both

directions. Does transmission run?
No Check if motor sizing is

adequate for application. Check for excessive motor leakage and
replace motor if defective.
Check for
mechanical faults in the
drive beyond the motor
shaft.
22483 (01/04)
Technical Manual
A Terex Company
Travel Drive Motor

2. Transmission Drive is Sluggish or Erratic
2.1 Is the control medium in
good condition? For
example: control medium is not in good
condition if: The hydraulic pilot pressure
lines have air in them,
the manual control
cable or linkage is sticking, or the electrical
control current is fluctuating. (pump and/or
motor)
No Rectify the control fault.

Bleed pilot lines.
Lubricate or free the
cable or linkage. Check
control current.
2.2 Are the brakes fully

released?
No Check brake release

circuit or mechanism.
2.3 Is the pump stroking

time correct for the
application?
No Correct pump stroking

time.
2.4 With hydraulic pilot control, is the contol curve

of remote pilot valve
correctly matched to the
motor?
No Change spring to suit.

2.5 Does the charge pressure fluctuate more

than 30 psi when
stroking the pump?
No Proceed to 2.9
2.6 If the charge pump output is used to operate

auxilary functions, do
these other functions
cause fluctuations in
charge pressure?
No Proceed to 2.8
2.7 Isolate the auxilary

function and run the
transmission. Are the
charge pressure fluctuations reduced or
eliminated?
No Proceed to 2.8
Yes Operate transmission
and return to step 2.1.
2.8 Are there system pressure fluctuations which

are syncronous with the
charge pressure flucuations?

Yes Determine the cause of
system pressure fluctuations.
2.9 Is the motor stroking

time correct for the
application?
No. Add motor stroking time

adjustment valve or orifice to the variable
motor, or modify the
control circuit to provide
desired stroking time.
3. Transmission Drives in One Direction Only

3.1 Is it possible that the
control signal to one
side of the pump does
not work properly?

Yes Refer to pump sevice
manual.
3.3 Switch releif valves.

Does the transmission
drive in the other direction only?

Yes Repair or replace releif
valve on non-driving
side.
3.2 Check flushing valve (if

installed). Is shuttle
spool stuck in one position?
No (Not installed).
Yes Remove flushing valve
and clean or replace.
3.4 Actuate control. Does

the transmission run in
both directions?
No Check for mechanical

faults in the drive
beyond the motor shaft.
4.2 To change direction at

motor:
Switch the high pressure lines at ports A

and B.
4. Transmission Drives in the Wrong Direction

4.1 To change direction at
pump:
Switch the control signal lines or linkage to

the pump control module or stroker.
168
22483 (01/04)
Technical Manual
A Terex Company
Travel Drive Motor

5. Insufficient Output Torque in One or Both Directions
5.1 Using the 010,000 psi
gauges, is the load side
of the loop required or
design pressure?
No Review steps 1.1

through 1.22.
5.2 Is the motor receiving

the hydraulic or electrical control signal on the
control spool? (HD &
EL)
No Correct problem.
5.3 Is the motor begin of

stroke set correctly? For
example, the output
torque may be low if the
begin of stroke is: HD &
EL controls-set too low.
HA-control-set too high.
No Set begin of stroke

per page 21.
5.4 With a pressure gauge

at port G, does G port
pressure match system
high pressure with
either port A or B pressurized?
No Replace faulty motor.

5.5 Is output torque sufficient in both directions?
No Check if motor sizing is

adequate for application.
Check for mechanical
faults or improper
design sizing in the
drive beyond the motor
shaft.
6.4 Is the suction pressure

at the charge pump inlet
within recomended limits?
No Return to step 1.7.

Yes Proceed to step. 6.5.
6.5 Is there air in the

hydraulic oil? This may
be indicated by foaming
or milky colored oil.

Yes Deaerate the oil and
inspect system for
cause of air induction.
6.6 Is the hydraulic motor

operating at excessive
speed?
Yes Check motor sizing in

relation to available oil
flow from the pump.
check motor minimum
displacement.
See
page 20.
6. Transmission Drives at a High Noise Level

6.1 Are the drive gearboxes
filled with correct grade
of oil?
No Fill gearbox with correct

grade of oil to the prescribed level.
6.2 Is the drive coupling

correctly installed and
aligned?
No Install coupling per

manufacturers instructions and tolerances.
6.3 Is rigid piping connected to the pump and

motor?
No Proceed to step 6.4

Yes Install short length of
hose between pressure
ports and the system
piping.
7. Transmission Operates at a Higher Than Normal Temperature

7.1 Is the operating temperature above 195F?
7.2 Does
temperature
remain above 195F
after cleaning oil
cooler?
7.3 Is the hydaulic motor
stalling intermittently?
No 195F is the upper limit.

If temp. is close to
195F the oil cooler may
need to be cleaned.
7.4 Check differential pressure across oil cooler

as compared to the
manufacturers specs at
charge pump flow. Is
P higher than it should
be?
No Proceed to 7.4.
Yes Hydraulic oil is being
heated through system
releif valves. Shut down
system and rectify
cause of the motor stall.
Note: See page 7 for

case pressure rating.
169
7.5 Disconnect pump case

drain from oil cooler and
check flow from charge
pump. Is flow normal?
No Proceed to step 7.5

Yes Check piping from oil
cooler to tank or
plugged oil cooler.
No Refer to charge pump

removed and inspection
procedure.
Yes Check oil cooler location.
22483 (01/04)
Technical Manual
A Terex Company
Travel Drive Units/Motors

The Following Pages and information are take from

Portions of Manuals, Form Numbers:
19353 GFT 25T2.1017
19376 GFT 36E.1051
19378 GFT 36E.1040
20267 GFT 56T2.1074
20410 GFT 25T2.1092
20966 GFT 44T2.1123
21020 GFT 44T2.1124
21062 GFT 36E.1060
21147 GFT 25T2.1152
21747 GFT 26T2.1026
21865 GFT 40T2.9202
21866 GFT 40T2.9228
22190 GFT 40T2.9296
22528 GFT 50T3.9311
Lohmann & Stolterfoht Drive w/Rexroth Motor
170
22483 (01/04)
Technical Manual
A Terex Company
171
22483 (01/04)
Technical Manual
A Terex Company
172
22483 (01/04)
Technical Manual
A Terex Company
173
22483 (01/04)
Technical Manual
A Terex Company
174
22483 (01/04)
Technical Manual
A Terex Company
XX
(See Attached Table)
175
22483 (01/04)
Technical Manual
A Terex Company
(See Attached Table)
176
22483 (01/04)
Technical Manual
A Terex Company
177
22483 (01/04)
Technical Manual
A Terex Company
178
22483 (01/04)
Technical Manual
A Terex Company
179
22483 (01/04)
Technical Manual
A Terex Company
Travel Drive Unit Data

CR Part No. 45080-004-75
CR Part No. 45080-004-88

Serial No.
Order No.
Year of Mfg.
Output Torque
Input Speed
Gear Ratio
Gear Lubrication Group
Serial No.
Order No.
Year of Mfg.
Output Torque
Input Speed
Gear Ratio
See Rating Plate

See Rating Plate
See Rating Plate
27,730 ft. lbs.
4500 rpm
58.3
PP 100
See Rating Plate

See Rating Plate
See Rating Plate
27,730 ft. lbs.
4500 rpm
58.3
CLP 150
It is important to quote the full drive designation,

serial and order numbers when ordering spare
parts.

parts.
Installation Drawing
with Technical Data
Spare Parts Drawing
Spare Parts List
with Technical Data
Spare Parts Drawing
Spare Parts List
2/6061/5040/1
1/6061/1040/0
4/6061/3040/0
Hydraulic Motor CR Part No. 45080-004-75-08

Rexroth
A6VE107HA2T/63W0352-PVU027A
2/6061/5051/1
4/6061/1551/0
4/6061/3051/0

Rexroth
CR Part No. 45080-004-89

CR Part No. 45080-004-85
Serial No.
Order No.
Year of Mfg.
Output Torque
Input Speed
Gear Ratio
Serial No.
Order No.
Year of Mfg.
Output Torque
Input Speed
Gear Ratio
See Rating Plate

See Rating Plate
See Rating Plate
16,336 ft. lbs.
5000 rpm
50.4
CLP 150
Approx. Capacity
See Rating Plate

See Rating Plate
See Rating Plate
31,093 ft. lbs.
4526 rpm
62
CLP 220
L&S LubeGroup LS-2
1.75 Gallons

parts.

parts.
with Technical Data
Spare Parts Drawing
Spare Parts List
with Technical Data
Spare Parts Drawing
Spare Parts List
2/6111/5017/3
4/6111/1517/0
4/6111/3017/0

Rexroth
A6VE80HA2T/61W0263-PAU027A
2/6091/5074/0
1/6091/1074/0
4/6091/2074/0

Rexroth
180
22483 (01/04)
Technical Manual
A Terex Company

CR Part No. 45080-004-98
CR Part No. 45080-006-04

Serial No.
Order No.
Year of Mfg.
Output Torque
Input Speed
Gear Ratio
Brake Holding Torque (input)
Serial No.
Order No.
Year of Mfg.
Output Torque
Input Speed
Gear Ratio
Approx. Capacity
See Rating Plate

See Rating Plate
See Rating Plate
16,336 ft. lbs.
5000 rpm
50.4
413 ft. lbs.
CLP 220
L&S LubeGroup LS-2
1 Gallon
Approx. Capacity

parts.

parts.
with Technical Data
Spare Parts Drawing
Spare Parts List
See Rating Plate

See Rating Plate
See Rating Plate
29,257 ft. lbs.
4500 rpm
58.3
CLP 220
L&S LubeGroup LS-2
1.75 Gallons
with Technical Data
Spare Parts Drawing
Spare Parts List
2/6111/5092/0
1/6111/1092/0
7/6111/2092/0
2/6108/5123/1
0/6108/1123/0
7/6108/2123/0

Rexroth

Rexroth
A6VE80HA2T/61W0263-PAL027A
CR Part No. 45080-006-03

CR Part No. 45080-006-05

Serial No.
Order No.
Year of Mfg.
Output Torque
Input Speed
Gear Ratio
Serial No.
Order No.
Year of Mfg.
Output Torque
Input Speed
Gear Ratio
Approx. Capacity
See Rating Plate

See Rating Plate
See Rating Plate
27,730 ft. lbs.
4500 rpm
58.3
CLP 220
L&S LubeGroup LS-2
1.1 Gallons
Approx. Capacity
See Rating Plate

See Rating Plate
See Rating Plate
29,257 ft. lbs.
4500 rpm
58.3
CLP 220
L&S LubeGroup LS-2
1.75 Gallons

parts.

parts.
with Technical Data
Spare Parts Drawing
Spare Parts List
with Technical Data
Spare Parts Drawing
Spare Parts List
2/6061/5060/0
0/6061/1060/0
7/6061/2060/0

Rexroth
A6VE107HA2T/61W0352-VZL027A
2/6108/5124/0
0/6108/1124/0
7/6108/2124/0

Rexroth
181
22483 (01/04)
Technical Manual
A Terex Company

CR Part No. 45080-006-08
CR Part No. 45080-006-22

Serial No.
Order No.
Year of Mfg.
Output Torque
Input Speed
Gear Ratio
Serial No.
Order No.
Year of Mfg.
Output Torque
Input Speed
Gear Ratio
Approx. Capacity
See Rating Plate

See Rating Plate
See Rating Plate
16,336 ft. lbs.
5000 rpm
50.4
413 ft. lbs.
CLP 220
L&S LubeGroup LS-2
1 Gallon
Approx. Capacity
See Rating Plate

See Rating Plate
See Rating Plate
18,710 ft. lbs.
4767 rpm
50.5
527 ft. lbs.
CLP 220
L&S LubeGroup LS-2
1 Gallon

parts.

parts.
with Technical Data
Spare Parts Drawing
Spare Parts List
with Technical Data
Spare Parts Drawing
Spare Parts List
2/6111/5152/0
1/6111/1152/0
7/6111/2152/0
1/6171/5026/0
0/6171/1026/0
7/6171/2026/0

Rexroth
A6VE80HA2T/63W0263-VAL027A

Rexroth
A6VE80HA2T/63W0263-VAL027A
CR Part No. 45080-006-20

CR Part No. 45080-006-23

Serial No.
Order No.
Year of Mfg.
Output Torque
Input Speed
Gear Ratio
Serial No.
Order No.
Year of Mfg.
Output Torque
Input Speed
Gear Ratio
Approx. Capacity
See Rating Plate

See Rating Plate
See Rating Plate
29,661 ft. lbs.
4500 rpm
59.1
590 ft. lbs.
CLP 220
L&S LubeGroup LS-2
1.1 Gallons
Approx. Capacity

parts.
with Technical Data
Spare Parts Drawing
Spare Parts List

parts.
with Technical Data
1/6167/5228/0
Spare Parts Drawing
0/6167/1228/0
Spare Parts List
7/6167/2228/0
1/6167/5202/0
0/6167/1202/1
7/6167/2202/2

(Motor Displacement Modified Per Above Print)
Rexroth
A6VE160HA2T/63W-VZL027A

Rexroth
See Rating Plate

See Rating Plate
See Rating Plate
29,485 ft. lbs.
4055 rpm
35.9
590 ft. lbs.
CLP 220
L&S LubeGroup LS-2
1.1 Gallons
182
22483 (01/04)
Technical Manual
A Terex Company

CR Part No. 45080-006-29
Serial No.
Order No.
Year of Mfg.
Output Torque
Input Speed
Gear Ratio
Approx. Capacity
See Rating Plate

See Rating Plate
See Rating Plate
29,485 ft. lbs.
4055 rpm
35.9
590 ft. lbs.
CLP 220
L&S LubeGroup LS-2
1.1 Gallons

parts.
with Technical Data
Spare Parts Drawing
Spare Parts List
1/6167/5296/0
0/6167/1296/0
16218282

Rexroth
A6VE160HA2T/63W-VZL027A
CR Part No. 45080-006-31
Serial No.
Order No.
Year of Mfg.
Output Torque
Input Speed
Gear Ratio
Approx. Capacity
See Rating Plate

See Rating Plate
See Rating Plate
36,878 ft. lbs.
3820 rpm
66.3
590 ft. lbs.
CLP 220
L&S LubeGroup LS-2
1.1 Gallon

parts.
with Technical Data
Spare Parts Drawing
Spare Parts List
1/6167/5311/0
0/6167/1311/0
16558180

Rexroth
183
22483 (01/04)
Technical Manual
A Terex Company
184
22483 (01/04)
PAVER
TECHNICAL MANUAL
Automatic Feed
& Grade Control
Section
Technical Manual
A Terex Company
Table of Contents
Automatic Feed & Grade Control Section
Description ................................................................................... Page /Form

AUTOMATIC FEED & GRADE CONTROL TROUBLESHOOTING
Grayhound 300 Series Analog Display ............................................................................... 1
Grayhound 300 Series Analog Display ............................................................................... 2
Grayhound 400 Series Digital Display ................................................................................ 3
Grayhound 400/500 Series Analog Display ........................................................................ 4
Grayhound 400/500 Series Remix Pavers ........................................................................... 7
All Grayhound Series Pavers ............................................................................................... 9
LH Conveyor Manual Mode
Grayhound Analog Display ............................................................................................... 10
RH Conveyor Manual Mode
LH Conveyor Auto Mode
RH Conveyor Auto Mode
LH Conveyor Adjustment Procedure
RH Conveyor Adjustment Procedure
Automatic Feed & Grade Control
22482 (11/01)
Technical Manual
A Terex Company
Table of Contents - Cont.

Automatic Feed & Grade Control Section
LH Automatic Screed Control
Grayhound Analog Display ........................................................................................ 16 - 17
RH Automatic Screed Control
Grayhound Analog Display ........................................................................................ 18 - 19
Generation III Sonics
1st Generation Controls
Grayhound Pavers .............................................................................................................. 20
2nd Generation Controls
Grayhound Pavers .............................................................................................................. 21
Generation III Sonics Conveyor Control
3rd Generation Controls
Grayhound Pavers 1999 & After ................................................................................ 22 - 23
Amplifier Module
Grade Systems ................................................................................................................... 24
Amplifier Module
Slope Systems .................................................................................................................... 25
Remote Slope Set .............................................................................................................. 26
Slope Sensor Checks ......................................................................................................... 27
System 4 LH Automatic Screed Control
Grayhound Pavers 1999 & Before .............................................................................. 28 - 29
System 4 RH Automatic Screed Control
Grayhound Pavers 1999 & Before .............................................................................. 32 - 33
Remix Delivery Control
All Grayhound Pavers ................................................................................................. 36 - 38
Remix Delivery Control Re-Work Kit
Wiring Diagram & Installation Instructions ............................................................... 39 - 43
AUTOMATIC FEED & GRADE CONTROL MANUALS
Generation III Sonic Feed Control .................................................................... Form 20576
Sundstrand Automatic Grade & Slope Control ................................................. Form 18121
Topcon System Four Grade & Slope Control .................................................... Form 21048
SMOOTHTRAC Sonic Averaging System (SAS) ......................................... Form 22506
ii
22482 (11/01)
Technical Manual
A Terex Company

24 23 22 21 20 19 18 17 16 15
1
2
3
4
5
6
7
8
9
12
14
13
10
11

4 ........... F/G/S breaker: 15 amp
10 ......... Key switch
11 ......... K2 relay
12 ......... K22 relay

15 ......... K3 relay
16 ......... K4 relay
17 ......... K5 relay
18 ......... K6 relay
19 ......... K15 relay
20 ......... K16 relay
21 ......... K17 relay
22 ......... K18 relay
22482 (10/01)
Technical Manual
A Terex Company

23 22 21 20 19 18 17 16 15 14
1
2
3
4
5
6
7
8
9
13
10
11
12

4 ........... F/G/S breaker: 15 amp
10 ......... Key switch
11 ......... K2 relay
12 ......... Cooler breaker: 50 amp

14 ......... Cooler relay
15 ......... K3 relay
16 ......... K4 relay
17 ......... K5 relay
18 ......... K6 relay (flasher)
19 ......... K15 relay
20 ......... K16 relay
21 ......... K17 relay
22 ......... K18 relay
23 ......... K22 relay
22482 (10/01)
Technical Manual
A Terex Company

Grayhound 400 Series Digital Display
L44
L42
L43
L40
L46
L45
L41
L47
L48
L49
L50
L54
L51
L53
L40 ....... Master key

L41 ....... Detroit governor card/feeder resistor card
L42 ....... 60 amp breaker (burner)
L43 ....... 15 amp breaker (power)
L44 ....... 15 amp breaker (control)
L45 ....... 15 amp breaker (flasher)
L46 ....... 15 amp breaker (Lights)

L51 ....... Proportional module
L52 ....... Horn relay
L53 ....... Terminal block
L54 ....... Murphy timer relay
22482 (10/01)
Technical Manual
A Terex Company

13 12 11 10
9 8
14
15
16
1 ........... Timing relay

2 ........... Engine breaker 15 amp
3 ........... Light breaker 15 amp
4 ........... Flasher breaker 15 amp
5 ........... Control breaker 15 amp
6 ........... Power breaker 30 amp
7 ........... Burner breaker 60 amp
8 ........... Spare relay
9 ........... K3 relay
10 ......... K15 relay
11 ......... K16 relay
12 ......... K17 relay
13 ......... K18 relay
16 ......... K1 relay
22482 (10/01)
Technical Manual
A Terex Company

24 23 22 21 20 19 18 17 16 15
1
2
3
4
5
6
7
8
9
12
14
13
10
11

4 ........... F/G/S breaker: 15 amp
10 ......... Key switch
11 ......... K2 relay
12 ......... K22 relay

15 ......... K3 relay
16 ......... K4 relay
17 ......... K5 relay
18 ......... K6 relay
19 ......... K15 relay
20 ......... K16 relay
21 ......... K17 relay
22 ......... K18 relay
22482 (10/01)
Technical Manual
A Terex Company

22 21 20 1918 17 16 15 14 13
1
2
3
4
5
6
7
8
9
12
10
11

13 ......... K3 relay
14 ......... K4 relay
15 ......... K5 relay
16 ......... K6 relay
17 ......... K15 relay
18 ......... K16 relay
19 ......... K17 relay
20 ......... K18 relay
21 ......... K22 relay

4 ........... F/G/S breaker: 15 amp
10 ......... Key switch
11 ......... K2 relay
22482 (10/01)
Technical Manual
A Terex Company

21 19 18 17 16
K4
20
K3
K5
AR
K6
SP
15
13
14
FEED INTERFACE
MODULE
1
2
3
4
5
6
7
8
9
10
11
12

3 ........... Console breaker: 15 amp
4 ........... F/G/S breaker: 15 amp
10 ......... Key switch
11 ......... K2 relay
12 ......... RH & LH Feed Interface Module

13 ......... Spare Feed Interface Module
14 ......... RH Remix Controller
15 ......... LH Remix Controller
16 ......... K3 relay
17 ......... K4 relay
18 ......... K5 relay
19 ......... K6 relay
20 ......... K22 relay
22482 (10/01)
Technical Manual
A Terex Company
22482 (10/01)
Technical Manual
A Terex Company

L4
L2
L1
L3
L5
L6
Front
Bulkhead
L17
L9
L12
L8
L7
L16
L11
L13
L10
Rear
Bulkhead
L14
L15

22482 (10/01)
Technical Manual
A Terex Company
LH Conveyor Manual Mode

Grayhound Analog Display
Main
Keyswitch
12 VDC
0
LH
Conveyor
Control
1
46
Auto
Off
15 A
LH Feed Control
Man
46
55
Remote
Feed
Override
46
(3)
55
(9)
84
(2)
(8) 85
52 (1)
86
Adjust (10)
Speed
3
Module (11)
(5)
'C' Stop
46
(7)
(6)
46
(12)
B CW
C
A
3
'C' 87
(4)
83
Man
Conv
Speed
1K
LH Feed
Servo
B
Stop
LH CONVEYOR DOES NOT RUN IN MANUAL MODE

LH conveyor switch to MANUAL.
55 to 3 ........ If no voltage (12 Vdc), defective LH conveyor switch.
85 to 3 ........ Voltage should vary from approximately 6.5 to 9 Vdc as conveyor speed dial is rotated.
If voltage does not vary, check conveyor speed pot for resistance:
Pin B to A .. 1000 100 ohms at all times.
Pin B to C .. Ohms should vary as speed pot is rotated.
Pin A to C .. Ohms should vary as speed pot is rotated.
83 to 3 ........ If no voltage, defective conveyor speed module. (Voltage should not read 12 Vdc.)
Voltage should vary from 0.2 to 2.2 Vdc as conveyor speed dial is rotated.
If 12 Vdc is present
87 to 3..........If no voltage, defective override/stop switch or open wiring to screed.
If 12 Vdc is present, LH feed servo is open or open wiring to servo:
Main key switch OFF.
Pins A to B should read 19.5 ohms resistance. If not, defective servo.
If 19.5 ohms, open wiring.
CONVEYOR CANNOT BE STOPPED BY OVERRIDE/STOP SWITCH
LH conveyor switch to MANUAL, LH override/stop switch to STOP.
LH conveyor should stop. If not, defective LH override/stop switch.
CONVEYOR CANNOT BE STARTED BY OVERRIDE/STOP SWITCH
LH conveyor switch to STOP, LH conveyor speed dial to MAX., LH override switch to OVERRIDE.
52 to 3 ........ If no voltage, defective override/stop switch.
If 12 Vdc, replace module.
10
22482 (10/01)
Technical Manual
A Terex Company
RH Conveyor Manual Mode

Main
Keyswitch
12 VDC
0
RH
Conveyor
Control
1
46
Auto
Off
15 A
RH Feed Control
Man
46
56
Remote
Feed
Override
46
(3)
56
(9)
94
(2)
(8) 95
54 (1)
96
Adjust (10)
Speed
3
Module (11)
(5)
'D' Stop
46
(7)
(6)
46
(12)
B CW
C
A
3
'D' 97
(4)
93
Man
Conv
Speed
1K
RH Feed
Servo
B
Stop
RH CONVEYOR DOES NOT RUN IN MANUAL MODE

RH conveyor switch to MANUAL.
56 to 3 ........ If no voltage (12 Vdc), defective LH conveyor switch.
95 to 3 ........ Voltage should vary from 6.5 to 9 Vdc as conveyor speed dial is rotated.
If voltage does not vary, check conveyor speed pot for resistance:
Pin B to A .. 1000 100 ohms at all times.
Pin B to C .. Ohms should vary as speed pot is rotated.
Pin A to C .. Ohms should vary as speed pot is rotated.
93 to 3 ........ If no voltage, defective conveyor speed module.
If 12 Vdc is present:
97 to 3 ........ If no voltage, defective override/stop switch or open wiring to screed.
If voltage (12 Vdc), RH feed servo is open or open wiring to servo:
Main key switch OFF, pins A to B on servo should read 19.5 ohms resistance. If not, defective servo.
If 19.5 ohms, open wiring.
CONVEYOR CANNOT BE STOPPED BY OVERRIDE/STOP SWITCH
RH conveyor switch to MANUAL. RH override/stop switch to STOP.
RH conveyor should stop. If not, defective RH override/stop switch.
CONVEYOR CANNOT BE STARTED BY OVERRIDE/START SWITCH
RH conveyor switch to STOP, RH conveyor speed dial to MAX, RH override switch to OVERRIDE.
54 to 3 ........ If no voltage, defective override/stop switch.
If 12 Vdc, replace module
11
22482 (10/01)
Technical Manual
A Terex Company
LH Conveyor Auto Mode

Main
Keyswitch
12 VDC
3
0
Control
46
46
Brake
Note: Closed in forward (travel control)

34
47
Engage
'A' Release
15 A
LH
Conveyor
Auto
47
Off
Man
55
46
Remote
Feed Override
'C' Stop
46
Forward L.S.
47
LH Feed Control
Feed Sensor
(C)
(E)
(D)
51
80
51
(7)
84
Man.
B CW
Conv.
85
(2)
(8)
C
Adjust.
Speed
52 (1) Speed (10) 86
A
1K
3
3
(5) Module (11)
LH Feed Servo
(6)
'C' 87
3
46
83
B
A
(4)
(12)
(3)
(9)
55
Stop
LH CONVEYOR DOES NOT RUN IN AUTO MODE

LH conveyor switch to AUTO, brakes RELEASED, travel lever(s) FORWARD.
51 to 3 ........ If no voltage (12 Vdc), defective conveyor switch.
80 to 3 ........ Voltage should vary from 6.5 to 9 Vdc as conveyor feed sensor shaft is rotated.
If voltage does not vary, check feed sensor pot for resistance:
Pin E to C... 1000 100 ohms at all times.
Pin C to D .. Ohms should vary as speed pot is rotated.
Pin D to E .. Ohms should vary as speed pot is rotated.
12
22482 (10/01)
Technical Manual
A Terex Company
RH Conveyor Auto Mode

Main
Keyswitch
12 VDC
0
Control
46
15 A
46
Brake
Note: Closed in forward (travel control)

34
47
Engage
'A' Release
RH
Conveyor
Auto
47
Off
Man
56
46
Remote
Feed Override
'D' Stop
46
Forward L.S.
47
RH Feed Control
Feed Sensor
53
(C)
(D)
(E)
90
53
(7)
94
Man.
B CW
Conv.
95
(2)
(8)
C
Adjust.
Speed
54 (1) Speed (10) 96
A
1K
3
3
(5) Module (11)
RH Feed Servo
(6)
'D' 97
3
46
B
A
(4) 93
(12)
(3)
(9)
56
Stop
RH CONVEYOR DOES NOT RUN IN AUTO MODE

RH conveyor switch to AUTO, brakes RELEASED, travel lever(s) FORWARD.
53 to 3 ........ If no voltage (12 Vdc), defective conveyor switch.
90 to 3 ........ Voltage should vary from 6.5 to 9 Vdc as conveyor feed sensor shaft is rotated.
If voltage does not vary, check feed sensor pot for resistance:
Pin E to C... 1000 100 ohms at all times.
Pin C to D .. Ohms should vary as speed pot is rotated.
Pin D to E .. Ohms should vary as speed pot is rotated.
13
22482 (10/01)
Technical Manual
A Terex Company
LH Conveyor Adjustment Procedure

52 55 51 83
R2
R1
R3
MAX
MIN
LIMIT
80 85 84 86 3 46
LH CONVEYOR SPEED ADJUSTMENT PROCEDURE

(1) Start engine and warm hydraulics to running temperature. Set engine to FULL THROTTLE.
(2) Put LH conveyor switch to MANUAL and LH conveyor speed dial to MINIMUM.
(3) Adjust minimum speed pot on LH proportional module until auger creeps, then turn
counterclockwise until auger ceases to turn.
(4) LH conveyor speed dial to MAXIMUM.
(5) Adjust limit pot on LH proportional module until auger turns at 135-150 RPM.
(6) LH conveyor speed dial to MINIMUM. Auger should stop turning just as dial hits MINIMUM.
If not, repeat step 3.
(7) If adjustment was needed in step 6, repeat steps 4 and 5.
(8) LH conveyor speed dial should be set for 8.3 Vdc from 85 to 3.
(9) Adjust MAX pot on LH proportional module until auger turns at 135-150 RPM.
(10) LH manual conveyor speed dial to MINIMUM. Conveyor should stop.
14
22482 (10/01)
Technical Manual
A Terex Company
RH Conveyor Adjustment Procedure

54 56 53 93
R2
R1
R3
MAX
MIN
LIMIT
90 95 94 96 3 46
RH CONVEYOR SPEED ADJUSTMENT PROCEDURE

(1) Start engine and warm hydraulics to running temperature. Set engine to FULL THROTTLE.
(2) RH conveyor in MANUAL and RH conveyor speed dial to MINIMUM.
(3) Adjust minimum speed pot on RH proportional module until auger creeps, then turn
counterclockwise until auger ceases to turn.
(4) RH conveyor speed dial to MAXIMUM.
(5) Adjust limit pot on RH proportional module until auger turns at 135-150 RPM.
(6) RH conveyor speed dial to MINIMUM. Auger should stop turning as dial hits MINIMUM. If
not repeat step 3.
(7) If adjustment was needed in step 6, repeat steps 4 and 5.
(8) RH conveyor speed dial should be set for 8.3 Vdc from 95 to 3.
(9) Adjust MAX pot on RH proportional module until auger turns at 135-150 RPM.
(10) RH manual conveyor speed dial to MINIMUM. Conveyor should stop.
15
22482 (10/01)
Technical Manual
A Terex Company

Main
Keyswitch
1
1
12 VDC
0
Control
46
15A
NOTE: Closed in forward (travel control)

34
47
Brake Engage
34
'A' Release
Forward L.S.

47
46
Auto
Set
Mat Thickness
152
155
157
155
157
Man
INC
150
DEC
155
157
A
B
C
D
E
F
G
3
155
157
Raise Sol.
Lower Sol.
H
I
J
AUTOMATIC SCREED CONTROL

The automatic screed control system will operate either in MANUAL or AUTOMATIC modes.
A manual/setup/auto switch is used to select the desired mode of operation. If set in MANUAL,
the pull point cylinders can be moved up or down by pressing the increase/decrease switch. If set
in SETUP, the grade or slope control will be active all the time. This position is used to set up
and NULL the sensor. If set in AUTO, the grade or slope control will only be active when the
paver is moved forward.
TOW POINT CYLINDER DOES NOT RAISE OR LOWER IN MANUAL
Manual/setup/auto switch in MANUAL.
Press the manual override buttons on the ends of the solenoid valve.
If the cylinder fails to move in both directions refer to the hydraulic troubleshooting section.
Increase/decrease switch to INCREASE
Check DIN connector for light. If on, defective solenoid.
150 to 3 ...... If no voltage, defective manual/setup/auto switch.
155 to 3 ...... If no voltage, defective increase/decrease switch.
If voltage, defective DIN connector.
Increase/decrease switch to DECREASE.
16
22482 (10/01)
Technical Manual
A Terex Company

TOW POINT CYLINDER DOES NOT RAISE OR LOWER IN AUTO MODE
Test in MANUAL. If tow point cylinder moves in both directions, the problem is not with the
solenoid or hydraulic systems. Block tires. Set the following controls:
Release BRAKES, set paver speed to 0, push travel lever FORWARD.
(Test one lever at a time on track machines)
47 to 3 ........ If no voltage, defective forward limit switch.
Manual/setup/auto switch to AUTO.
Connect the grade sensor to the left connection point of the burner control console.
If voltage, defective grade controller. Exchange controllers to confirm.
SLOPE CONTROL
The grade and slope amplifier modules are interchangeable. To isolate the cause of a problem,
try exchanging modules. Make sure the grade/slope switch on the module is set properly. (to
SLOPE if module is used in the slope box and to GRADE if module is used in grade sensor.)
The remote slope hand set is powered by a 9 volt battery. If this battery gets low, the letters LO
BAT appear in the readout window. Replace the battery. If the battery goes dead, the slope
control system will function properly; information in the window will not be available
17
22482 (10/01)
Technical Manual
A Terex Company

Main
Keyswitch
1
1
12 VDC
0
Control
46
15A
NOTE: Closed in forward (travel control)

34
47
Brake Engage
34
Release
'A'
Forward L.S.

47
46
Auto
Set
Mat Thickness
162
165
167
167
165
Man
INC
160
DEC
165
167
A
B
C
D
E
F
G
3
165
167
Raise Sol.
Lower Sol.
H
I
J
AUTOMATIC SCREED CONTROL

The automatic screed control system will operate either in MANUAL or AUTOMATIC modes.
A manual/setup/auto switch is used to select the desired mode of operation. If set in MANUAL,
the pull point cylinders can be moved up or down by pressing the increase/decrease switch. If set
in SETUP, the grade or slope control will be active all the time. This position is used to set up
and NULL the sensor. If set in AUTO, the grade or slope control will only be active when the
paver is moved forward.
Press the manual override buttons on the ends of the solenoid valve.
If the cylinder fails to move in both directions refer to the Hydraulic Troubleshooting section.
Manual/setup/auto switch in MANUAL.
Increase/decrease switch to INCREASE.
Check DIN connector for light. If ON, defective solenoid.
Increase/decrease switch to DECREASE.
18
22482 (10/01)
Technical Manual
A Terex Company

TOW POINT CYLINDER DOES NOT RAISE OR LOWER IN AUTO MODE
Test in MANUAL. If tow point cylinder moves in both directions, the problem is not with the
solenoid or hydraulic systems. Block tires and set the following controls:
Release BRAKES, set paver speed to 0, push the travel lever FORWARD.
(Test one lever at a time on track machines)
47 to 3 ........ If no voltage, defective forward limit switch.
Manual/setup/auto switch to AUTO.
Connect the grade sensor to the left connection point of the burner control console.
If voltage, defective grade controller. Exchange controllers to confirm.
SLOPE CONTROL
The grade and slope amplifier modules are interchangeable. To isolate the cause of a problem,
try exchanging modules. Make sure the grade/slope switch on the module is set properly. (to
SLOPE if module is used in the slope box and to GRADE if module is used in grade sensor.)
The remote slope hand setter is powered by a 9 volt battery. If this battery gets low, the letters
LO BAT appear in the readout window. Replace the battery. If the battery goes dead, the slope
control system will function properly; information in the window will not be available
19
22482 (10/01)
Technical Manual
A Terex Company

Grayhound Pavers
LH Conveyor - Generation III Sonics
RH Conveyor - Generation III Sonics
For Generation III Sonic troubleshooting, refer to operation manual form 20576 in this section.
20
22482 (10/01)
Technical Manual
A Terex Company

Grayhound Pavers
LH Conveyor - Generation III Sonics
RH Conveyor - Generation III Sonics
For Generation III Sonic troubleshooting, refer to operation manual form 20576 in this section.
21
22482 (10/01)
Technical Manual
A Terex Company

22
22482 (10/01)
Technical Manual
A Terex Company

GEN. III CONVEYOR CONTROL WITH SINGLE INTERFACE MODULE
There are 5 relays used with this type control:
One used for Automatic Mode
1/2 of relay for LH
1/2 of relay for RH
One used for LH Run
One used for RH Run
One used for LH Override
One used for RH Override
Use the following table to test controls.
Note: If NO 12 VDC voltage, check appropriate wiring and switches.
Conveyor
Side
Wires
Voltage
Comment
Automatic Operation Mode
LH
RH
47...3
51...3
80...3
83...3
87...3
12VDC
12VDC
0-2VDC
0-2VDC
0-2VDC
47...3
53...3
90...3
93...3
97...3
12VDC
12VDC
0-2VDC
0-2VDC
0-2VDC
Forward Direction
Console in Auto Mode
Voltage Readings for 0 to Full Speed
Manual Operation Mode
LH
RH
51...3
81...3
83...3
87...3
12VDC
0-2VDC
0-2VDC
0-2VDC
53...3
91...3
93...3
97...3
12VDC
0-2VDC
0-2VDC
0-2VDC
Forward Direction
Console in Manual Mode
Override Mode
LH
RH
51...3
52...3
83...3
87...3
12VDC
12VDC
2VDC
2VDC
53...3
54...3
93...3
97...3
12VDC
12VDC
2VDC
2VDC
Forward Direction
Switches in Override
Voltage Readings for Full Speed Only
23
22482 (10/01)
Technical Manual
A Terex Company
Amplifier Module
Grade Systems
Not used when in
grade sensor
Cable to Burner Console plugs in here
RUN
STAND BY
RUN
STAND BY
Deadband
Set Point
The same amplifier is

used in the GRADE
and SLOPE. The only
difference is the setting of the SLOPE/
GRADE toggle switch
located on the back of
the unit.
Down
Light
Up
Light
Side
View
Back
View
GRADE
Slope/Grade
Toggle Switch
SLOPE
AMPLIFIER MODULE
The same amplifier module is used in the GRADE and SLOPE units. The only difference is the
setting of the Grade/Slope toggle switch located on the back side of the amplifier module. If the
unit is to be used in the grade sensor, set the grade/slope switch to GRADE. If the unit is to be
used in the slope system, set the grade/slope switch to SLOPE.
GRADE OR SLOPE NOT WORKING
Perform all checks listed in Electrical Automation section.
Inspect all cables and connections for damage.
Set manual/setup/auto switch to SETUP, set standby/run switch to RUN.
Disconnect large cable from the amplifier. Check pins A to B on cable, voltage should be 11
Vdc or more.
If low or no voltage, refer to electrical automation for checking machine wiring.
Plug cable back in.
With the up light ON, check voltage on:
155 to 3 (for LH pull point), 165 to 3 (for RH pull point) for 12 Vdc.
With the down light ON, check voltage on:
157 top 3 (for LH pull point), 167 to 3 (for RH pull point) for 12 Vdc.
If no voltage, take an amplifier out of a unit that is known to be functioning properly and install
it in the system in question. (Make sure the slope/grade switch is set for the unit to be used in.)
If the problems disappear, defective amplifier.
24
22482 (10/01)
Technical Manual
A Terex Company
Amplifier Module
Slope Systems
Remote slope hand set
plugs in here
Clockwise
Light
RUN
Deadband
Set Point
CounterClockwise
Light
RUN
STAND BY
Side
View
STAND BY
Back
View
Cable to Burner Console plugs in here
GRADE
Slope/Grade
Toggle Switch
SLOPE
AUTOMATION NOT WORKING PROPERLY

Inspect cables and connections for damage.
Check deadband setting on amplifier. The correct deadband setting for the slope amplifier is 0.2
light to light. The correct setting for the grade is: Passing a .050 feeler gauge under the wand or
shoe will not show a light, but passing a .080 feeler gauge under the wand or shoe will show a
light. Refer to Operation Manual for procedure on setting deadband.
Check the Grade/Slope switch located on the back side of the amplifier. It must be in the
GRADE position if amplifier is used in the grade sensor and set to SLOPE if used in the slope
system.
If slope system is in question, refer to Remote Slope Hand Set.
Check pull point solenoid valve DIN connectors for light, refer to electrical Pull Point.
Take an amplifier out of a unit that is known to be functioning properly and install it in the
system in question. (Make sure the Slope/Grade switch is set for the unit to be used in.) If the
problems disappear, defective amplifier.
LIGHT BULB REPLACEMENT
Unscrew the lens cover over the light bulb. Take a piece of 516" ID rubber hose and press down
and turn bulb counterclockwise. The bulb can be purchased at most local vendors as #161 (12
Vdc) bulb.
25
22482 (10/01)
Technical Manual
A Terex Company
Remote Slope Set
9
Volt
WHEN DISPLAY
SHOWS "LOW
BAT" REPLACE 9
VOLT BATTERY
BATTERY
LOCATION
NO DISPLAY
Check harness and connectors for damage.
Check battery, replace as necessary.
Check pins A to C on the slope amplifier (the unit the remote set plugs into).
Voltage should be at least 2.1 Vdc.
If voltage is OK, defective remote slope hand set.
If no or low voltage, unplug the harness coming from the burner console to the slope
amplifier.
Check pins A to B on the socket end. Voltage should be 11 Vdc or more.
If voltage, defective amplifier.
If no or low voltage, refer to automation.
DISPLAY STAYS ON EVEN WHEN UNPLUGGED
Replace remote slope hand set unit.
SLOPE APPEARS TO BE UNSTABLE OR OSCILLATES
Check deadband setting on the slope amplifier. The proper setting is 0.2 light to light.
If deadband is OK, unplug remote hand set and check pins B to D. 1500 ohms should be
read.
If a reading shows 500 ohms, a capacitor is shorted. Replace unit.
Check pins A to C for 2500 ohms.
Then check for continuity between pins A to B and pins B to C, while rotating the dial.
The reading should vary as the dial is turned.
If another remote slope hand set unit is available, connect it in place of existing one.
If problem disappears, defective remote hand set.
26
22482 (10/01)
Technical Manual
A Terex Company
Slope Sensor Checks
SLOPE SENSOR CHECKS

Check Ohms between pins.
A to B......... 10 ohms.
C to D ........ 300 ohms.
E to F ......... 300 ohms.
No cross continuity.
27
22482 (10/01)
Technical Manual
A Terex Company

L.H. AUTOMATIC SCREED CONTROL

47
MAT THICKNESS
AUTO
SET
46
152
L.H. AUTO ISOLATION RELAY

14
LAI
13
MAN
152
INC 155B
150
DEC 157B
157B
150
46
3
155B
A
B
C
D
E
F
G
H
I
J
3
46
155A
157A
155A
157A
3
4
155A
12
157A
155
B SOL.
157
A SOL.
10 PIN RECPTACLE FOR AUTO CABLE
PROPER OPERATION
Refer to System 4 operation manual, Form 21048, in the Automatic Grade & Feed Controls section of
this manual for additional information.
Proper operation of the System 4 Control System occurs when:
Controls power-up whenever paver is in Run and Grade or Slope is selected.
Valves become "live" when Mat Thickness mode switch on LH Screed Remote box is either in Setup
or when in Auto and paver is moving Forward.
Manual Up-Down on System 4 will work only when valves are "live".
This is accomplished by modifying the tractor wiring from standard by adding Isolation Relays.
28
22482 (10/01)
Technical Manual
A Terex Company

Man-Setup-Auto switch in Manual.
Press Manual Override button on solenoid valve;
If Nonfunctional, refer to Hydraulic Troubleshooting.
If Functional, proceed below.
Check DIN connector on valve for light;
If light is ON, check for 12 VDC across solenoid coil (pin 1 to pin 2);
If no voltage, check connection of DIN connector.
If voltage, check and/or replace solenoid coil.
If No Light;
Check for 12 VDC from 155 to 3 with switch in Increase, 157 to 3 with switch in Decrease.
If no voltage, check 155B to 3 in Increase, 157B to 3 in Decrease.
If voltage, check 152 to 3. Should not have any voltage.
Replace Man-Setup-Auto switch if voltage present. Replace Isolation Relay if no voltage.
If NO voltage, check 150 to 3;
If voltage, replace Increase-Decrease switch.
If NO voltage, check/replace Man-Setup-Auto switch.
If voltage, check wiring to valves.
SYSTEM 4 CONTROL DOES NOT RAISE OR LOWER TOW POINT IN MANUAL OR AUTO
If System 4 control will NOT power up when Grade or Slope is selected;
Check for 12 VDC from 46 to 3 in Main Screed Box.
If NO voltage, check wiring from Tractor.
If voltage, check for 12 VDC from pin F to pin K at Controller power cable.
If NO voltage, check wiring from Main Screed Box.
If voltage, proceed to System 4 Troubleshooting.
If System 4 control powers up when Grade or Slope is selected but valves will not operate;
Check for 12 VDC from 155A for UP, 157A for DOWN;
If NO voltage, proceed to System 4 Troubleshooting.
If voltage, check for 12 VDC from 155 for UP, 157 for DOWN;
If NO voltage, check 152 to 3.
If voltage, check Isolation Relay by switching with RH Relay. Replace if defective.
29
22482 (10/01)
Technical Manual
A Terex Company

PROPER OPERATION
Valves become "live" when Mat Thickness mode switch on LH Screed Remote box is either in Setup
30
22482 (10/01)
Technical Manual
A Terex Company

If No Light;
If no voltage, check 155 to 3 in Increase, 157 to 3 in Decrease.
CONTROL DOES NOT RAISE OR LOWER TOW POINT IN MANUAL OR AUTO
If voltage, check Isolation Relay by switching with RH Relay. Replace if defective.
31
22482 (10/01)
Technical Manual
A Terex Company

R.H. AUTOMATIC SCREED CONTROL

47
46
MAT THICKNESS
R.H. AUTO ISOLATION
AUTO
13
14
SET 162
RAI
MAN
162
RELAY
3
INC 165B
160
160
46
DEC 167B
167 B
165B
A 3
46
4
1
B
165A
C
12
167A
165A 8
B SOL.
165
D
167A
167A
E
167
A SOL.
165A
F
5
9
G
H
I
10 PIN RECEPTACALE FOR AUTO CABLE
J
3
3
PROPER OPERATION
Valves become "live" when Mat Thickness mode switch on RH Screed Remote box is either in Setup
32
22482 (10/01)
Technical Manual
A Terex Company


If No Light;
If no voltage, check 165B to 3 in Increase, 167B to 3 in Decrease.
SYSTEM 4 CONTROL DOES NOT RAISE OR LOWER TOW POINT IN MANUAL OR AUTO
If voltage, check Isolation Relay by switching with LH Relay. Replace if defective.
33
22482 (10/01)
Technical Manual
A Terex Company

PROPER OPERATION
Valves become "live" when Mat Thickness mode switch on RH Screed Remote box is either in Setup
34
22482 (10/01)
Technical Manual
A Terex Company


If No Light;
If no voltage, check 165 to 3 in Increase, 167 to 3 in Decrease.
CONTROL DOES NOT RAISE OR LOWER TOW POINT IN MANUAL OR AUTO
If voltage, check Isolation Relay by switching with LH Relay. Replace if defective.
35
22482 (10/01)
Technical Manual
A Terex Company

1
3
FEED INTERFACE
MODULE
K3
K4
K5
SP
AR
K6
Delivery Control Components

4) Ratio Pot: Sends 0.5 - 4.5 VDC signal to
controller.
1) Controller W/Ind. Lights: Programmed to

process electrical signals coming from speed and
pressure sensors and ratio pot, then output signals
to feed interface module. Indicator lights provide
troubleshooting assistance.
5) Speed Sensor: Located on spreading auger

motor and provides pulse signal to controller to
allow AUTO operation.
2) Feed Interface Module: Provides a relay

contact between controller output and spreading
auger pump EDC coil. This relay pulls in via
AUTO-OFF-MANUAL Switch.
6) Pressure Sensor: Located on rear bulkhead in

delivery auger motor pressure circuit and provides
0.5 - 4.5 VDC to controller indicating 0 to 10,000
PSI of hydraulic pressure.
a) 0.5 VDC @ 0 PSI
b) 2.5 VDC @ 5000 PSI
c) 4.5 VDC @ 10,000 PSI
3) AUTO-OFF-MANUAL Switch: Sends 12

VDC signal to controller to select mode of
operation.
36
22482 (10/01)
Technical Manual
A Terex Company

Remix Delivery Control Operation
AUTO-OFF-MANUAL Switch in MANUAL
If replacement of a controller becomes necessary,

simply remove the old one and plug in the new
one. No adjustment is needed.
1) Ratio dial operates strictly as a speed control.

2) Operates whether spreading augers ore ON or
OFF.
Refer to the electrical schematic supplied with

your machine and the following information to
assist in troubleshooting this system. Also, the
chart below gives a guide to reading the status of
the indicator lights on the controllers.
3) Pressure sensor on delivery auger motor is

active and will limit horsepower when needed.
AUTO-OFF-MANUAL Switch in AUTO
1) Controller: Sensor power output wire 284 (LH)

and 294 (RH) should have 5 VDC. If low voltage,
check for defective sensor, ratio pot, or grounded
wiring.
1) Ratio dial setting determines the speed of the

delivery augers in relation to the spreading auger
speed. (0 - 100% of spreading auger speed range)
2) Ratio Pot: Provides range of 0.5 to 4.5 VDC to

controller.
a) 0.5 VDC at MIN
b) 2.5 VDC at 50% dial setting
c) 4.5 VDC at MAX
2) Delivery augers start and stop with spreading

augers no matter what mode the spreading augers
are operating. (MANUAL, AUTO, or
OVERRIDE)
3) Delivery auger speed is based on spreading
auger speed and ratio setting.
3) AUTO-OFF-MANUAL Switch: Provides 12

VDC to controller to select mode of operation and
supplies power to the controller eliminating need
for feed interface module on valve output.
4) Set ratio dial to maintain a uniform head of

material (one half auger level).
4) Speed Sensor: Located on spreading auger

motor, provides pulse signal to controller to allow
AUTO operation.
5) Spreading auger RPM should remain constant

with this setting.
6) Pressure sensor on delivery auger motor is
active and will limit horsepower when needed.
5) Pressure Sensor: Located on rear bulkhead in

delivery auger motor pressure circuit, provides a
range of 0.5 to 4.5 VDC to controller.
a) 0.5 VDC at 0 PSI
b) 0.7 VDC at 500 PSI
c) 0.9 VDC at 1000 PSI
d) 2.5 VDC at 5000 PSI
e) 4.5 VDC at 10,000 PSI
Remix Delivery Control Troubleshooting

The delivery augers are controlled by the remix
feed controllers mounted in the main electrical
box. (See previous page)
37
22482 (10/01)
Technical Manual
A Terex Company

INDICATOR
COLOR
LIGHT
POWER
LIGHT
STATUS
ERROR
CODE
ERROR DESCRIPTION
Power
Green
On Solid
N/A
Indicates Power to Controller
System
Green
On Solid
N/A
Indicates +5 VDC Out of

Controller
Mode
Yellow
Blinking
1 Blink / 2 Seconds
Program is Running OK
Mode
Yellow
Blinking
10 Blinks / 1 Second
Controller Needs Replaced (No Program Loaded)
SYSTEM
MODE
STATUS
Mode
Status
Program Not Running Not Blinking Light Completely Off Cycle Power Off and back On
Yellow
(If problem still exists, replace
On or Off
or On Solid
controller)
Pressure signal out of range
Red
Blinking
1110
(defective wiring or sensor)
Status
Red
Blinking
0100
Status
Red
Blinking
0110
Ratio Pot signal out of range

(defective wiring or speed pot)
Spreading Auger not running or
defective wiring or speed sensor
Status Indicator Light Code Legend: Short Blink = 0 Long Blink = 1
38
22482 (10/01)
Technical Manual
A Terex Company

Wiring Diagram 9704-417-20
LH
RH
39
22482 (10/01)
Technical Manual
A Terex Company

Installation Instructions 9704-417-21
40
22482 (10/01)
Technical Manual
A Terex Company

41
22482 (10/01)
Technical Manual
A Terex Company

42
22482 (10/01)
Technical Manual
A Terex Company

43
22482 (10/01)
Technical Manual
A Terex Company
44
22482 (10/01)
Generation III
Sonic Feeder
Control System
Operation & Maintenance Instructions
Generation III
Sonic Feeder Control System
A Terex Company
20576 (11/00)
49999-176
Operation & Maintenance Manual
A Terex Company
Introduction
To the Owner & Operator:

We have tried to provide information which will give you a clear understanding of equipment
construction, function, capabilities and requirements. This information is based on the
knowledge and experience of highly qualified people at our company and in our field
organization. Proper use of this information will promote high efficiency, maximum service
life and low maintenance costs.
We strongly recommend that all persons directly involved with this equipment be familiar
with this manual.
The information contained in this manual should not be considered all-inclusive for every
application. Questions about specific uses of this equipment should be directed to Cedarapids
Inc. Anyone who uses this equipment for any purposes other than its intended use assumes
the risk of any danger in doing so.
Respectfully,
Cedarapids Inc.
Important Notice!
Federal, state and local safety regulations must be complied with to prevent possible danger
to person(s) or property from accidents or harmful exposure. This equipment must be used
in accordance with all operation and maintenance instructions.
(1)
Read all warning, caution and instruction signs. Know what guards and protective
devices are included and see that each is used. Additional guards and protective devices
that may be required due to proximity to related equipment must be installed by the user
(owner) before operating.
(2)
Never lubricate or adjust equipment when it is operating!
(3)
Securely lock out the involved power source before doing maintenance, cleaning,
adjusting or repair. Secure the power source lockout to prevent start-up by other
persons.
(4)
Wear a protective mask whenever harmful air pollution exists.
(5)
Use ear plugs whenever noise level is above established limits.
16885 (7/91)
A Terex Company
Safety
Safety Rules
When operating this equipment, always follow the
safety rules. Cedarapids makes no guarantee either
expressed or implied that the equipment meets all
local or federal safety regulations. It is the responsibility
of the individual user to verify that all safety regulations
are complied with before starting the machine.
We strongly recommend that all persons

involved with this equipment be familiar with
this manual and all related engine manuals.
Read all Danger, Warning, Caution and
instruction decals.
Know what guards and protective devices are
included and see that each is used.
Personal Safety Rules

Cedarapids equipment is designed to operate safely
when used responsibly and as instructed in the
operation manuals. Do not attempt to change, modify
or eliminate the accident prevention devices installed
at the factory. Make sure all personnel who regularly
work or who might do work in the area of the
equipment are familiar with the safety precautions.
Operators are responsible for following safe operating
procedures. It is the responsibility of the owner to
establish a safe working environment and to train the
employees on the employers safety policies
Hazard Seriousness Level

Signal words (Danger, Warning and Caution) are
used to identify levels of hazard seriousness in this
manual and on decals located on the equipment.
Definitions for identifying hazard levels are provided
below with their respective signal words.
Danger! Immediate hazards which WILL
result in severe personal injury or death.
Warning! Hazards or unsafe practices which
COULD result in severe personal injury or
death.
Guards, covers and shields are installed around moving

parts at the factory whenever necessary to prevent
accidental injury to operators and others working on
or near the equipment. Do not remove them. In come
cases the owner may need to install additional guarding
and safety systems to protect the operator.
Caution! Hazards or unsafe practices which

COULD result in minor personal injury.
Instructional and Informational Levels
Signal words are used to identify instructional
procedures and informational suggestions or directions
for Cedarapids equipment operation and maintenance.
Warning! This manual contains important

information regarding the operation of your
machine. Carefully read the entire manual
before attempting to operate. Failure to read
this manual and follow the instructions and
warnings in it could cause severe personal
injury, death or substantial property damage.
Definitions for identifying instructional or

informational levels are provided below.
Notice: Failure to follow proper instructional
procedures could lead to serious and/or expensive
damage to the equipment.
Important: Informational suggestions or
directions regarding operational and maintenance
of equipment.
Only qualified and trained persons should

operate, repair or maintain this equipment.
Keep this manual for future reference.
Federal, state and local safety regulations must
be complied with to prevent possible danger to
person(s) or property from accidents or harmful
exposure.
This equipment must be used in accordance
with all operation and maintenance instructions.
20576 (11/00)
Generation III Feeder Controls - P/N 49999-176
A Terex Company
Safety
Warning! Failure to follow these guidelines
may result in severe personal injury or death.
Caution! Failure to follow these guidelines

may result in minor personal injury and/or
damage to the equipment.
Never attempt to install or remove any part or

assembly when the paver is running.
Wear protective mask when harmful air pollution

exists.
Do not allow personnel to walk between the

machine and truck.
Wear safety goggles, gloves and long-sleeve

shirts when in close proximity to hot asphalt
materials.
Do not refuel the machine with the engine

running. All sparks and open flames must be
kept a minimum of 50 feet away from the
machine when refueling.
Wear ear plugs if needed.

To prevent fire hazards, keep the engine area
free of oil, fuel and trash buildup .
Wear snug-fitting clothing to prevent getting

caught in moving parts. Loose-fitting clothing
should never be worn.
Mount and dismount the machine using only
the steps, handrails and walkways provided.
Do not mount or dismount the machine when it
is moving.
Keep all personnel clear of machine when
operating.
20576 (11/00)
A Terex Company
Gen-III Feeder Controls

Introduction
The Gen-III feeder control is an optional control
system that uses ultrasonic sensors or proportional
sensors to monitor and maintain the head of material
in front of the screed. As the material level changes
the auger/conveyor speed is varied proportional to
maintain the set material level.
LH ADAPTER CABLE
09704-416-25
LH PLATE
09704-416-23
Features of the Gen-III Feeder System

1) The screed mounted control unit allows for
easy setup and adjustment of the material level
without requiring the screedman to relocate the
height of the sensor to meet varying conditions.
Once the sensor has been mounted and targeted
the material level can be adjusted from the rear
of the screed.
POWER CABLE
46061-500-27
SONIC SENSOR
46061-100-20
SENSOR CABLE
46061-100-23
FEEDER CONTROL
46061-100-27
Figure 1
2) The sonic system has detachable sensor and

cable assemblies. The cable has connectors on
both ends that allow quick replacement in the
event a cable is damaged.
Plug one end the power cable into the RH rear

bulkhead of the tractor and the other end into the RH
feeder control mounted on the screed (Figure 2). This
cable can be left connected all the time. Remove the
protective cap from the RH side of the feeder control
and plug in the coiled sensor cable (Figure 2). Place
sonic sensor in the RH end-gate sonic mount and
route coiled cable to it. Plug coiled cable into sensor.
3) Standard proportional feeder controls can be

plugged into the Gen-III feeder control and
used in place of the sonic sensor.
Connecting Sonics Sensors
1) Plug one end of the power cable into the LH
rear bulkhead of the tractor and the other end
into the LH feeder control mounted on the
screed (Figure 1). This cable can be left connected
all the time.
RH ADAPTER CABLE
09704-416-24
RH PLATE
09704-416-22
2) Remove the protective cap from the LH side of

the feeder control and plug in the coiled sensor
cable (Figure 1).
3) Place sonic sensor in the LH end-gate sonic
mount and route coiled cable to it. Plug coiled
cable into sensor.
POWER CABLE
46061-500-27
SENSOR CABLE
46061-100-23
SONIC SENSOR
46061-100-20
FEEDER CONTROL
46061-100-27
Figure 2
20576 (11/00)
A Terex Company
Gen-III Feeder Controls

Connecting Proportional Sensors
1) Plug one end of the power cable into the LH
into the LH feeder control mounted on the
all the time.
RH REAR BULKHEAD
PROPORTAIONAL
SENSOR
46061-500-24
2) Place proportional sensor on outer auger bearing

support or end-gate mount.
3) Remove the protective cap from the LH side of
cable (Figure 3).
Direction of Travel
Figure 4
Wand Mounting
Loosen the control arm clamp and position the wand
so that the roll pin is at 90 in relation to control arm
(Figure 5). Tighten clamp.
Notice: The proportional feed sensor should

always be mounted with the sensor shaft facing
the direction of travel.
LH REAR BULKHEAD
CONTROL ARM
CLAMP
SENSOR SHAFT
ROLL PIN
PROPORTIONAL
SENSOR
46061-500-24
ROLL PIN 90
TO CONTROL ARM
WAND
Direction of Travel
Figure 3
Connecting Proportional Sensors

1) Plug one end of the power cable into the RH
into the RH feeder control mounted on the
all the time.
Figure 5
2) Place proportional sensor on outer auger bearing

support or end-gate mount it.
3) Remove the protective cap from the RH side of
cable (Figure 4)
Notice: The proportional feeder sensor should
always be mounted with the sensor shaft facing
the direction of travel.
20576 (11/00)
A Terex Company
Controls
Feeder Control
1) AUTO/OFF/MANUAL (Item 1, Figure 6)
switch is the primary means to control the
auger/conveyor. When placed in the OFF
position the auger/conveyor is off; when placed
in the MANUAL position the auger/conveyor
is turned on. The speed of the auger conveyor
when in MANUAL is determined by the pile
height knob setting. When placed in the AUTO
position the auger/conveyor speed is controlled
by the feed sensor. In AUTO mode the auger/
conveyor has the capability of being driven
from 0 to full speed depending on sensor output.
When proportional sensors are used with the

system the GAIN switch sets the amount of
rotation required for the sensing wand to go
from OFF to full ON. In LOW gain, the wand
will react in a 45 control range (Figure 7). In
HIGH gain, the want will react in a 22 control
range (Figure 7). Normally, the GAIN switch
should be set to HIGH when using the
proportional sensor.
1
2) The PILE HEIGHT knob performs different

functions depending on sensor used and setting
of AUTO/OFF/MANUAL switch. Its used to
set the maximum speed of the auger/conveyor
when the AUTO/OFF/MANUAL switch is in
the MANUAL mode (Item 2, Figure 6).
MODE
PILE HEIGHT
AUTO
GAIN
HIGH
OFF
MANUAL
Another usage is to set the distance from the

face of the sonic sensor to the material when the
AUTO/OFF/MANUAL switch is placed in
the AUTO mode. Turning the knob
counterclockwise lowers the material level.
Clockwise rotation of the knob increases the
material level.
LOW
HIGH
LOW
FEEDER CONTROL
46061-100-27
Figure 6
Finally, its used to set the angle at which the

proportional sensor shuts off when the AUTO/
OFF/MANUAL switch is placed in the AUTO
mode and the proportional sensor is used.
LOW GAIN (45)
3) GAIN switch must be set in the LOW position

when sonic sensors are used with the system
(Item 3, Figure 6). When GAIN switch is in
LOW, the sonic system controls the speed of
the auger/conveyor proportionally within a 5"
range. When GAIN switch is in HIGH position
the control range is reduced to 2.5". Since the
level of the mix can vary by more than 2.5"
during normal operation, the sonic control will
function like an on/off switch and will not
provide proportional control.
20576 (11/00)
HIGH GAIN (22)
Figure 7
A Terex Company
Controls
Operator Console
1) Left Auger/Conveyor (Item 1, Figure 8) is a
two position switch. When the switch is pressed
into the STOP position, the auger/conveyor is
stopped. When the switch is pressed into the
OVERRIDE position the auger/conveyor is
turned on.
Remote Handset
The Stop/Override (Figure 9) is a two position switch.
When the switch is pressed into the STOP position,
the auger/conveyor is stopped. When the switch is
pressed into the OVERRIDE position the auger
conveyor is turned on.
D
N
TE
EX
2) Right Auger/Conveyor (Item 2, Figure 8) is a

two position switch. When the switch is pressed
into the STOP position, the auger/conveyor is
stopped. When the switch is pressed into the
OVERRIDE position the auger conveyor is
turned on.
PE
O
SL
T
SE P
U
ED
FE
R
VE
O IDE
R
N
R
O
H
OFF
SCREED LIFT
RAISE
TO
AU
P
O
ST
4) Right Flow Gate switch (Item 4, Figure 8) is

used to control the amount of material that is
delivered to the auger chamber
LIGHTS
ON
T
H
G
EI
H
H P
TC U
A
M
SE
EA
R
EC
D
AN
M
3) Left Flow Gate switch (Item 3, Figure 8) is used

to control the amount of material that is delivered
to the auger chamber .
S
N
ES
W
N
O
K
D
IC
SE
TH
EA
T
R
A
C
M
IN
FLASHERS
ON
Figure 9
OFF
REAR FRAME
RAISE
LOWER
LOWER
HORN
ON
VIBRATORS
ON
OFF
OFF
BRAKE
RELEASE
ENGINE
START
ENGAGE
STOP
SCREED ASSIST
ON
ENGAGE
ONLY
WHEN
SCREED
IS ON
OFF
GROUND
Item 3
Item 4
GATES
RAISE
LH
4625-001-09
RH
LOWER
MIN
GATES
MIN
MAX
MAX
MAX PAVER SPEED

4
3
2
LH
THROTTLE
FULL
RH
CONVEYOR
OVER
RIDE
RANGE
TRAVEL
P/2
IDLE
P/4
Item 1
4600-009041
LH
HOPPER
RAISE
TRUCK HITCH
ENGAGE
1
MIN
6
7
8
9
MAX
RH
STOP
LOWER
RELEASE
Item 2
4600-009041
4418-804
Figure 8
20576 (11/00)
A Terex Company
Targeting Sonic Sensor

Targeting on Active Material
The sensor should always be targeted on the
material that is actively moving. This area is
traditionally on the forward outboard end of the auger
(Figure 12). The sensor should be targeted in the
center area of the face of material for best results.
The sensor should be mounted in a position that

targets the cone shaped field of view of the sensor on
the ACTIVE MATERIAL near the outer end of the
auger.
Sensor Distance
The sonic sensor should be no closer than 12 inches
and no further than 30 inches away from the face of
the material (Figure 10).
Correct
MAXIMUM
30 Inches
MINIMUM
12 Inches
Figure 10
Sonic Sensor Alignment

For best possible results the sensor should be targeted
perpendicular (90) to the material surface being
monitored. Misalignment decreases the amount of
return echos to the sensor. The type of material being
used determines the amount of misalignment tolerance.
Fine graded material designs, like sand mixes, have a
low reflective value and require the sensor to be
targeted perpendicular while course graded material
designs have a high reflective value and may allow up
to a 10 misalignment (Figure 11).
Incorrect Would sense shaft
Figure 12
The most common problem encountered with the use

of sonic feeder controls is improper mounting and
targeting. The system will react to the object that is
inside the view window and closest to the sensor
(Figure 12). Care must be taken in mounting and
targeting the sensors to prevent sensing objects (end
gates, augers, material retaining plates, etc.) other
than the desired material level.
90
Correct Alignment
Incorrect Alignment
Figure 11
20576 (11/00)
A Terex Company
Targeting Sonic Sensor

Setup & Use of Proportional
The following procedure will initially establish the
desired material level:
Positioning Proportional Sensor

The proportional sensor should be mounted at the
outboard end of the auger so the control arm is free to
follow the level of material without interference from
augers, material retaining plates and end gates. Best
results occur when sensing on the active material.
1) Connect the sensor cable to the feed control.

2) Place sensor at the outboard end of the auger.
3) Using the remote handset OVERRIDE/STOP
switch or the feed control AUTO/OFF/
MANUAL switch, auger out material until the
desired level is established
Correct
4) Place the feed control AUTO/OFF/MANUAL

switch in AUTO mode.
5) As the paver start moving adjust the PILE
HEIGHT knob until the auger just comes on.
6) Using the GAIN switch can effectively raise or
lower the material level. Select the mode that
produces the best result.
Figure 13
Setup & Use of Sonic

The following steps will initially establish the desired
material level.
7) Minor adjustments to the PILE HEIGHT knob

can fine tune the level of material that the auger
shuts off. Note however the pile height knob
has a limited working range (degree of rotation)
that the proportional sensor will function in. If
The pile height knob is set incorrectly the auger/
conveyor could be either on or off continually.
1) Connect the sensor cable to the sensor and to the

feed control.
2) Place sensor in endgate mount and establish
preliminary targeting.
3) Using either OVERRIDE/STOP switch or the
feed control AUTO/OFF/MANUAL switch,
auger out material until the desired level is
established
Important: The system will only operate when

the traction control lever is in forward and the
brakes are released.
4) Place the feed control AUTO/OFF/MANUAL

switch in AUTO mode.
5 ) As the paver starts moving adjust the PILE
HEIGHT knob until the desired level is
maintained.
Important: The feed system will only operate in
AUTO when the traction control lever is in
forward and the brakes are released.
20576 (11/00)
A Terex Company
Adjustments for Gen-III Systems

Maximum Speed Automatic Mode
The following procedure will adjust the maximum
speed of the auger in Override mode:
Maximum Speed Manual Override

To adjust the maximum speed of the auger in override
mode:
1) Engine at full throttle.
1) Engine at full throttle.
2) Press and hold OVERRIDE switch in either the

operator console or remote handset to override
position.
2) Travel speed dial at 0.

3) Brakes released.
4) Travel lever in forward.
3) Place a tachometer on the end of the auger shaft.

The auger should be running between 135 and
150 RPM.
5) Feed control Auto/Off/Manual switch to AUTO.

6) Hold the sonic sensor 4 to 5 feet away from and
pointed at the back of the tractor or a truck.
If the auger speed is not within this range, the

speed can be adjusted on the conveyor circuit
card found in the main electrical junction box
on the tractor (Figure 14). The circuit card has
three speed adjustments; MAX, MIN and
LIMIT. The MIN adjustment is not used with
the Gen-III systems. Rotate the MAX
adjustment clockwise to increase the auger
speed and counterclockwise to decrease the
auger speed. If the desired auger speed cannot
be reached, rotate the LIMIT adjustment
clockwise to increase the upper auger speed
limit and continue adjusting the MAX speed
adjustment to change the auger speed.
7) Using a tachometer on the end of the auger

shaft, adjust the maximum speed set point on
the feeder control card located inside the feed
control box. The normal setting is 135 to 150
RPM (Figure 15).
IMAX MAX ADJUST

Set for desired
max speed in AUTO
Warning! Failure to use caution when

working near the rotating augers could result
in serious injury or death.
MAX
C3
TF1
R9
D4
MIN
LIMIT
D3
R12
Figure 15
D2
R11
D7
RLY 1
R5
U1
R16
Q1
C4
RLY 3
MAX
MIN
R13
R3
R4
R10
D5
R1
R8
R7
RLY 2
R6
R17
R2
D6
LIMIT
D8
R14
MV1
C1
U2
J1
MIN
C2
Figure 14
20576 (11/00)
A Terex Company
20576 (11/00)
10
A Terex Company
Maintenance
Maintenance Recommendations
1) Remove sonic sensors every evening and store
in a secured location.
2) Install protective caps on all electrical connectors.
3) Handle sonic sensor with care to prevent damage
to the transducer. The transducer is made of a
ceramic material can be cracked or damaged if
impacted.
9704-452-64
Notice: If the transducer becomes damaged it will

require replacement of the complete sensor. These
are permanently sealed and can not be repaired.
46185-001-20
4) Check transducer daily for material buildup.

The transducer can be cleaned off with contact
cleaner or a parts solvent. Place cleaning fluid
on a clean rag and rub transducer gently to
remove any material. Then wipe transducer
clean and dry (Figure 16). Do not use a sharp or
solid object to scrape materials off. This could
possibly damage the sensor.
9704-452-63
Figure 17
Mounting Hardware
Theory of Operation
When cleaning and

handling sensor take
care not to damage
ceramic transducer!
SONIC SENSOR
CLEAN
TRANSDUCER
OF MATERIAL
BUILDUP
Figure 16
20576 (11/00)
11
A Terex Company

Electrical Schematic
LH Feeder System
Figure 18
20576 (11/00)
12
A Terex Company

RH Feeder System
Figure 19
20576 (11/00)
13
A Terex Company

LH Feeder System
Figure 18a
20576 (11/00)
14
A Terex Company

RH Feeder System
Figure 19a
20576 (11/00)
15
A Terex Company

20576 (11/00)
16
A Terex Company

GEN. III CONVEYOR CONTROL WITH SINGLE INTERFACE MODULE
There are 5 relays used with this type control:
One used for Automatic Mode
1/2 of relay for LH
1/2 of relay for RH
One used for LH Run
One used for RH Run
One used for LH Override
One used for RH Override
Use the following table to test controls.
Note: If NO 12 VDC voltage, check appropriate wiring and switches.
Conveyor
Side
Wires
Voltage
Comment
Automatic Operation Mode
LH
RH
47...3
51...3
80...3
83...3
87...3
12VDC
12VDC
0-2VDC
0-2VDC
0-2VDC
47...3
53...3
90...3
93...3
97...3
12VDC
12VDC
0-2VDC
0-2VDC
0-2VDC
Forward Direction
Console in Auto Mode
Manual Operation Mode
LH
RH
51...3
81...3
83...3
87...3
12VDC
0-2VDC
0-2VDC
0-2VDC
53...3
91...3
93...3
97...3
12VDC
0-2VDC
0-2VDC
0-2VDC
Forward Direction
Console in Manual Mode
Override Mode
LH
RH
20576 (11/00)
51...3
52...3
83...3
87...3
12VDC
12VDC
2VDC
2VDC
53...3
54...3
93...3
97...3
12VDC
12VDC
2VDC
2VDC
Forward Direction
Switches in Override
Voltage Readings for Full Speed Only
17
A Terex Company
Wiring Diagram
Operator Console
Figure 20
20576 (11/00)
18
A Terex Company
Wiring Diagram
Main Junction
Figure 21
20576 (11/00)
19
GND
+14V
AUTO
OUT
MAN
OUT
J1
11
2
OFF
MANUAL
AUTO
10
12
20
J2
A
B
C
D
E
LH
SENSOR
+14V
GND
+8V
SIGNAL
GND
1/2 W
56 OHM
1/2 W
56 OHM
TB1
1
+14V
GND
20576 (11/00)
GND
4
4
VALVE -
VALVE + 0-2V
+8V
INPUT
PWB ASSY
OFFSET
GAIN SW
GAIN SW
10
10
10
CW
J3
PILE
HEIGHT
GAIN
GND
SIGNAL
+8V
GND
+14V
RH
SENSOR
HIGH
LOW
1 LOW
3 HIGH
Auto Mode
6.5V @ Low
1.5V @ High
Short Dist. 1.5V - Long Dist. 8.5V

Depending on
Material Height
A Terex Company
Wiring Diagram
Control Box

82 OHM
A Terex Company
Troubleshooting
Theory of Operation
The Feed Conveyor System consists of a variable
displacement hydrostatic pump that drives a
hydrostatic motor. Output of the hydrostatic pump
can be controlled by a variable electrical signal to the
EDC (electrical displacement control) of the pump. A
0 to 2 volt dc signal changes the output speed from
zero to maximum. The electrical signal to the EDC is
affected by the following four (4) modes of operation:
Quick Troubleshooting Hints:

The system consists of two (2) identical subsystems,
Left and Right. This allows substitution of working
components from one side with suspected nonworking
components on the other side. If the problem follows
the component, replace the faulty component. If the
problem remains on the original side, further testing
must be performed.
Manual Override: Signal from the proportional

speed module mounted in main electrical junction
box triggered by a relay which is energized by the
Override switch(es). Fixed output is adjustable via
Max and/or Limit pots on conveyor circuit card
(Figure 14).
1) Sonic sensor (P/N 46061-100-20) affects

automatic operation only.
These components are:
2) Sonic sensor cable (P/N 46061-100-23) affects

3) Proportional sensor (P/N 46065-500-24) affects
Manual: Signal from the Feeder Control box at

either end of the screed. Speed adjustable via Pile
Height knob (maximum speed is non-adjustable).
4) Feeder control box (P/N 46061-100-27) affects

manual and automatic operation only.
5) Feeder control board (P/N 46061-100-22)
located inside feeder control box affects
Automatic : Signal from the Feeder Control box at

either end of the screed. Speed variable via sensor
signal which is limited by the pile height setting. This
signal goes through the auto interlock relay contact on
the conveyor circuit card in the main junction box on
the tractor. This relay activates whenever the brakes
are released and the control handle is pushed forward.
Maximum output is adjustable via IMAX pot on
feeder control board (Figure 15).
6) Proportional speed module (P/N 46065-50027) mounted in tractor main junction box affects
override and automatic operation only.
7) Override/Stop toggle switches at console and at
screed remotes affect operation in override,
manual, and automatic modes.
Stop: Either Override/Stop switch in Stop position

disconnects power from the Conveyor pump servo
coils.
20576 (11/00)
21
A Terex Company
Left Conveyor Flow Charts

Flow Chart #1
LH CONVEYOR
WILL NOT
OPERATE
FUNCTIONAL IN
ANY MODE?
OVERRIDE
MANUAL OR
AUTOMATIC?
MANUAL OVERRIDE ON
No
LH CONVEYOR PUMP
CAUSE AUGER
MOVEMENT?
No
No
Yes
0 VDC
Check VDC
from #87 to #3
No
GO TO
FLOW CHART
LH #2
0.5 - 2.0 VDC
Replace
EDC
>5 VDC
>5 VDC
Does Remote
Feed
Override
Work?
Refer to Hydraulic
Troubleshooting
Check VDC at
EDC plug
Repair or replace
wiring harness(es)
0 VDC
Yes
Does Operator
Console
Override
Work?
Yes
Does Manual
at Feed
Control
Work?
No
Check VDC at
wires #83 to #3
GO TO
FLOW CHART
LH #3
Faulty wiring or LH
remote feed switch
>5 VDC
0 VDC
No
Check VDC at
wires #81 to #3
GO TO
FLOW CHART
LH #4
>5 VDC
Faulty wiring or LH
conveyor override
switch
Yes
Does Auto at
Feed Control
Work?
20576 (11/00)
No
GO TO
FLOW CHART
LH #5
22
A Terex Company

Flow Chart #2
LH remote feed
Override does not
function
12 VDC from #52

to #3?
No
Faulty wiring or LH
remote feed switch
No
Adjust/Replace
adjustable speed module
No
Faulty wiring or LH
conveyor override switch
No
Adjust/Replace
adjustable speed
module
Yes
2 VDC from #81

to #3
Yes
Functional
Flow Chart #3
LH conveyor
override at console does
not function
12 VDC from #52

to #3?
Yes
2 VDC from #81

to #3
Yes
Functional
Flow Chart #4
LH manual feed
control does not
function
Check VDC from

#81 to #3
0 - 8 VDC
Faulty wiring or LH
0 - 8 VDC
Faulty wiring to main

junction box on tractor
0 VDC
Check VDC from
TB1-10 to TB1-6 in
feed control box
0 VDC
Repair or replace
feed control box
20576 (11/00)
23
A Terex Company

Flow Chart #5
LH auto feed
control does
not function
Check indicator
lamps (LED's) on
feed control board
Check VDC from pin
B to Pin A in 10 pin
connetctor at
feed control box
No
+12 VOLTS
light on?
Yes
0 VDC
Faulty power wiring

from main jct. box
to feed control box
0 VDC
Replace auto-man
switch or replace
feed control box
12 VDC
Check VDC from
TB1-1 to TB1-6 in
feed control box
>12 VDC
Replace feeder
control board in
feed control box
No
+8 VOLTS
light on?
6.5 to 1.5 VDC

from MIN to MAX
Yes
Check VDC from
TB1-8 to TB1-3 on
feed control board
while moving
pile height dial
No change
in VDC
Replace pile height

pot or feed control
box
1.5 - 8.5 VDC w/Sonic (6"-42")

2 - 6 VDC w/wand (stop to stop)
V OUT
light on?
No change
Check VDC from
in VDC
TB1-9 to TB1-6 in
feed control box
while moving sensor
No
Replace sensor
Yes
Check VDC from
TB1-4 to TB1-6 in
feed control box
0 VDC
Faulty wiring inside

feed control box
0 VDC
Faulty wiring from

main jct. box to
feed control box
>12 VDC
Check VDC from
#80 to #3
>12 VDC
Check VDC from
#81 to #3
0 VDC
Check VDC from

#47 to #3
>12 VDC
Replace adjustable
speed module
>12 VDC
Adjust/replace
forward limit swich
on control handle
0 VDC
Check VDC from
#34 to #3
>12 VDC
0 VDC
Faulty wiring on LH
conveyor override
switch
20576 (11/00)
24
Check and/or
replace brake switch
A Terex Company

Flow Chart #6
LH CONVEYOR
WILL NOT STOP
Does disconnecting
plug from pump
control stop
conveyor?
No
Refer to Hydraulic
Troubleshooting
No
Replace LH remote
feed switch
No
Replace LH
conveyor switch
No
Replace MODE
switch or feed
control box
No
Replace PILE
HEIGHT pot or feed
control box
No
Replace PILE
HEIGHT pot or feed
control box
Yes
Does LH remote
feed switch
stop conveyor?
Yes
Does LH conveyor
switch at console
stop conveyor?
Yes
Does MODE switch

at feed control box
stop conveyor in
STOP?
Yes
Does PILE HEIGHT
dial control conveyor
speed in MANUAL?
Yes
Does PILE HEIGHT

dial change material
depths in AUTO?
Yes
Does conveyor
speed change
relative to sensor
position in AUTO?
No
Replace sensor
Yes
Does conveyor stop
when in AUTO with
travel control handle
in neutral?
Adjust or replace
forward limit
switch(es) on
handle(s)
No
Yes
Does conveyor stop
when in AUTO with
BRAKE engaged?
20576 (11/00)
No
Replace BRAKE
switch
25
A Terex Company
Right Conveyor Flow Charts

Flow Chart #1
RH CONVEYOR
WILL NOT
OPERATE
FUNCTIONAL IN
ANY MODE?
OVERRIDE
MANUAL OR
AUTOMATIC?
MANUAL OVERRIDE ON
No
RH CONVEYOR PUMP
CAUSE AUGER
MOVEMENT?
No
No
Yes
0 VDC
Check VDC
from #97 to #3
No
GO TO
FLOW CHART
RH #2
0.5 - 2.0 VDC
Replace
EDC
>5 VDC
>5 VDC
Does Remote
Feed
Override
Work?
Refer to Hydraulic
Troubleshooting
Check VDC at
EDC plug
Repair or replace
wiring harness(es)
0 VDC
Yes
Does Operator
Console
Override
Work?
Yes
Does Manual
at Feed
Control
Work?
No
Check VDC at
wires #93 to #3
GO TO
FLOW CHART
RH #3
Faulty wiring or RH
remote feed switch
>5 VDC
0 VDC
No
Check VDC at
wires #91 to #3
GO TO
FLOW CHART
RH #4
>5 VDC
Faulty wiring or RH
conveyor override
switch
Yes
Does Auto at
Feed Control
Work?
20576 (11/00)
No
GO TO
FLOW CHART
RH #5
26
A Terex Company

Flow Chart #2
RH remote feed
override does not
function
12 VDC from #54

to #3?
No
Faulty wiring or RH
remote feed switch
No
Adjust/Replace
adjustable speed module
No
Faulty wiring orRH

No
Adjust/Replace
adjustable speed
module
Yes
2 VDC from #91

to #3
Yes
Functional
Flow Chart #3
RH conveyor
override at console does
not function
12 VDC from #54

to #3?
Yes
2 VDC from #91

to #3
Yes
Functional
Flow Chart #4
RH manual feed
control does not
function
Check VDC from

#91 to #3
0 - 8 VDC
Faulty wiring or RH
0 - 8 VDC
Faulty wiring to main

junction box on tractor
0 VDC
Check VDC from
TB1-10 to TB1-6 in
feed control box
0 VDC
Repair or replace
feed control box
20576 (11/00)
27
A Terex Company

Flow Chart #5
RH auto feed
control does
not function
Check indicator
lamps (LED's) on
feed control board
Check VDC from pin
B to Pin A in 10 pin
connetctor at
feed control box
No
+12 VOLTS
light on?
Yes
0 VDC
Faulty power wiring

from main jct. box
to feed control box
0 VDC
Replace auto-man
switch or replace
feed control box
12 VDC
Check VDC from
TB1-1 to TB1-6 in
feed control box
>12 VDC
Replace feeder
control board in
feed control box
No
+8 VOLTS
light on?
6.5 to 1.5 VDC

from MIN to MAX
Yes
Check VDC from
TB1-8 to TB1-3 on
feed control board
while moving
pile height dial
No change
in VDC
Replace pile height

pot or feed control
box
1.5 - 8.5 VDC w/Sonic (6"-42")

2 - 6 VDC w/wand (stop to stop)
V OUT
light on?
No change
Check VDC from
in VDC
TB1-9 to TB1-6 in
feed control box
while moving sensor
No
Replace sensor
Yes
Check VDC from
TB1-4 to TB1-6 in
feed control box
0 VDC
Faulty wiring inside

feed control box
0 VDC
Faulty wiring from

main jct. box to
feed control box
>12 VDC
Check VDC from
#90 to #3
>12 VDC
Check VDC from
#91 to #3
0 VDC
Check VDC from

#47 to #3
>12 VDC
Replace adjustable
speed module
>12 VDC
Adjust/replace
forward limit swich
on control handle
0 VDC
Check VDC from
#34 to #3
>12 VDC
0 VDC
Faulty wiring on RH
conveyor override
switch
20576 (11/00)
28
Check and/or
replace brake switch
A Terex Company

Flow Chart #6
RH CONVEYOR
WILL NOT STOP
Does disconnecting
plug from pump
control stop
conveyor?
No
Refer to Hydraulic
Troubleshooting
No
Replace RH remote
feed switch
No
Replace RH
conveyor switch
No
Replace MODE
switch or feed
control box
No
Replace PILE
HEIGHT pot or feed
control box
No
Replace PILE
HEIGHT pot or feed
control box
Yes
Does RH remote
feed switch
stop conveyor?
Yes
Does RH conveyor
switch at console
stop conveyor?
Yes
Does MODE switch

at feed control box
stop conveyor in
STOP?
Yes
Does PILE HEIGHT
dial control conveyor
speed in MANUAL?
Yes
Does PILE HEIGHT

dial change material
depths in AUTO?
Yes
Does conveyor
speed change
relative to sensor
position in AUTO?
No
Replace sensor
Yes
Does conveyor stop
when in AUTO with
travel control handle
in neutral?
Adjust or replace
forward limit
switch(es) on
handle(s)
No
Yes
Does conveyor stop
when in AUTO with
BRAKE engaged?
20576 (11/00)
No
Replace BRAKE
switch
29
A Terex Company
20576 (11/00)
30
Sundstrand
Automatic Grade
and Slope
Control
Sundstrand
Automatic Grade & Slope Control
A Terex Company
18121 (11/00)
A Terex Company
Introduction

with this manual.
Respectfully,
Cedarapids Inc.
Important Notice!
(1)
(2)
(3)
persons.
(4)
(5)
18121 (11/00)
A Terex Company
Table of Contents
Description ........................................................................................................................ 1
Grade Control ................................................................................................................... 1
Grade Sensor Deadband ............................................................................................................................. 2
To Set Grade Sensor Deadband: ................................................................................................................. 2
Joint Matching Skate 46061-550-06........................................................................................................... 3
Ski 46061-550-07 ....................................................................................................................................... 3
Fixed String Line ........................................................................................................................................ 4
Slope Control..................................................................................................................... 5
Slope Deadband .......................................................................................................................................... 6
To Set Slope Sensor Deadband: .................................................................................................................. 6
Building Rideability - Sensor mounted forward......................................................................................... 7
To use the slope system: ............................................................................................................................. 7
Building Profile - Sensor mounted rearward .............................................................................................. 8
To use the slope system: ............................................................................................................................. 8
Troubleshooting Sundstrand Automatic Grade & Slope System ............................... 10

Amplifier Module ..................................................................................................................................... 10
Grade or Slope Not Working .................................................................................................................... 10
Slope Function Erratic .............................................................................................................................. 10
Automation Not Working Properly........................................................................................................... 10
Light Bulb Replacement ........................................................................................................................... 11
Remote Slope Set - No Display ................................................................................................................ 11
Remote Slope Set - Display Stays On Even When Unplugged ................................................................ 11
Remote Slope Set - Slope Appears to be Unstable or Oscillates .............................................................. 11
Slope Sensor ............................................................................................................................................. 11
Sundstrand Automatic Grade & Slope Control
18121 (11/00)
A Terex Company
Table of Contents
ii
18121 (11/00)
A Terex Company
Sundstrand
Description
Automatic screed controls provide a means to
enhance a paving operation by monitoring and
controlling the screed position in relation to the
tractor and the reference plane. This eliminates the
need for a screed operator to manually introduce the
changes that would be necessary for a uniformly
smooth mat to be placed over irregular grades.
All of these reference in a plane parallel to the line of

paving.
Grade Control
The grade controller consists of a housing containing
a grade sensing module and an amplifying module
which has indicator lights and a mode operation
switch. A counter-balanced sensor arm can be
attached to either side of the grade sensor. Depending
on the application, a wand or a skate assembly is
attached to the follower. (Figure 1) A grade sensor
can control either the left or right tow point cylinder,
depending on which side of the paver it is mounted.
Dual grade sensors can also be used to control both
left and right sides of the screed.
Automatic screed controls can enhance a good or

proper paving operation by maintaining an
established line of grade and/or percentage of slope.
However, proper operation means controlling all of
the factors that can adversely affect the screed.
Refer to Quality Paving Guide Book.
If these factors are not controlled by recommended
operational techniques they can introduce a change
in the screeds position in relation to the established
line of grade and/or percentage of slope quickly
enough that the automation cannot correct for them.
The automation cannot make up for improper
operational techniques. Refer to Quality Paving
Guide Book.
CABLE
Evaluation of specifications and grade conditions on

a job is extremely important if the paver and
automation are to be configured properly to produce
the desired or required results. Failure to properly
configure the screed and automation for each phase
of the paving operation will result in producing a mat
that is unsatisfactory or will not meet specifications.
One configuration of the screed and automation will
not produce superior results for all conditions and
jobs.
SENSING
ARM
SKATE
RUNNER
STRINGLINE
FOLLOWER
SKATE
The automation system consists of two basic sensory

devices, the grade control and the slope control.
Both systems operate independently of each other to
control the screeds angle-of-attack by moving the
tow points up or down in relation to the reference
plane of each. The reference plane for a grade
sensory system can be one of three types, ski (mobile
grade reference), joint matcher, or fixed (established)
string line. The slope system uses an angular
reference plane in relation to the horizon, which is
perpendicular to the line of paving.
GRADE CONTROLLER
Figure 1
The sensor arm can be mounted on either side of the

sensor, depending on which side of the paver the
sensor is to be mounted. The sensor arm has to be
mounted so that it is trailing the sensor at 45 angle
in relation to the flat on the sensor shaft, to work
properly. (Figure 2)
18121 (11/00)
A Terex Company
Sundstrand
If the sensing arm is mounted in a position other than
45, the amount of rotation on the sensor module, in
relation to the amount of deflection of the sensing
arm, will not produce the correct amount of tow
point cylinder movement. (Figure 3)
Grade Sensor Deadband
Mounting the sensor arm at any angle other than at

45, changes the amount the sensor shaft is rotated
for a given deviation. (Figure 4)
To Set Grade Sensor Deadband:
The deadband of the grade sensor refers to the

amount the sensing arm can move without triggering
a tow point cylinder response. A given amount is
necessary to allow for normal machine vibration.
1) Assemble the grade sensor jack and
mounting hardware. Place sensor on the
jack and connect the electrical cable from
the sensor to the tow point control
connector.
2) When installing the sensor control arm, it
is extremely important to install so it is
trailing the sensor at 45 angle in relation
the the flat on the sensor shaft.
3) Place the sensor Run/Standby switch in
Standby mode.
4) Place the remote control mat thickness
Manual/Setup/Auto switch in Setup mode.
5) Adjust the sensor jack height until both
lights are out when the switch on the sensor
is in Standby mode and the remote control
material thickness switch is in the Setup
mode.
6) The deadband is correct when a dime (.050
inch) can be passed under the follower
without triggering a light, but a nickel
(.080 inch) passed under the follower will
trigger a light response.
7) If the deadband is not correct, remove the
screw located on the face of the grade
sensor. There is an adjustment located
under the face screw.
8) Use the small screw driver provided.
Clockwise rotation will increase the amount
of deadband, while counterclockwise
rotation will decrease the amount of
deadband.
Flat on sensor shaft
Mount location
45
Sensor Arm
Dead Band
Set
Point
45500- 036- 07
Complete Control
46061-550-15
Figure 2
With the sensor arm mounted at
45, a 1/4 inch deviation will rotate
the sensor shaft 3 22' 52".
1/4"
Sensor Arm Mounted Correctly
Figure 3
With the sensor arm mounted horizontally, the same 1/4 inch
deviation only rotates the sentor shaft 227'46".
Sensor Arm Mounted Incorrectly
Figure 4
18121 (11/00)
A Terex Company
Sundstrand
Joint Matching Skate 46061-550-06
Notice - Clockwise rotation of the grade

sensor jack THICKENS the mat being
placed. Counterclockwise rotation of the
grade sensor jack THINS the mat being
placed.
Matching the height of the mat being placed to an

existing mat or curb requires the screed to be very
responsive to any changes in the elevation of the
existing mat or curb. This is an application where we
are building "profile" or over-correcting the screed,
forcing it to change depth in a very short distance.
This mode is not necessarily good for rideability.
1) The grade sensor should be mounted 3/4 of
the way back from the tow point, just
ahead of the augers, and the sensor skate in
as close to the joint as possible, taking into
account the shape of the joint to be matched.
If the joint being matched is distorted, it
may be necessary to locate the sensor further
from the joint. Keep in mind that the
further the sensor is from the actual joint
being matched, the less likely that an exact
match will occur.
Standby mode and the remote control mat
thickness Manual/Setup/Auto switch in
Setup mode.
Sensor Jack
Figure 6
Ski 46061-550-07
When using automation off a ski, corrections to
deviations that occur at the sensor or the screed will
require the paver to travel approximately 5 lengths
of the tow arm before the correction is fully
completed. Deviations that occur at the tow point
due to the tractor traveling over irregular grades are
corrected for immediately. In effect, the sensor is
correcting for deviations at the tow point before they
can affect the screed's angle of attack (position). In
this application, we are building "rideability", or
averaging all required changes in depth over a longer
area.
(Centerline)
CL
The grade sensor should be mounted 1/4 of the way

back from the tow point.
Figure 5
3) Adjust the sensor jack assembly until the

lights go out.
Run mode and the remote control mat
Auto mode.
5) If mat depth needs correction, turn the
grade sensor jack slowly in the correct
direction until the mat being placed is the
correct thickness.
Sensor mounted
forward
Figure 7
3
18121 (11/00)
A Terex Company
Sundstrand
1) Pave manually using the depth cranks until
the correct depth is achieved.
Setup mode.
lights go out.
Auto mode.
correct thickness.
placed.
Sensor just
ahead of auger
(Centerline)
CL
Figure 9

the correct depth is achieved.
Setup mode.
lights go out.
Auto mode.
correct thickness.
placed.
Figure 8
Fixed String Line

When using automation off an established or fixed
string line, it requires the screed to be responsive to
any changes in elevation of the string line. This is an
application where we are building profile, or overcorrecting the screed and forcing it to change depth
in relation to the elevation of the string line.
back from the tow point, or just ahead of the augers.
Figure 10
4
18121 (11/00)
A Terex Company
Sundstrand
Slope Control
The position of the sensor, whether mounted on the

forward cross beam or on the rearward cross beam,
determines how fast the screed will react to a change
of the null point at the sensor. By positioning the
sensor, we can build profile or rideability. We need
to evaluate job specifications and grade related
conditions to determine the desired mounting position
to produce the desired results.
The slope control system consists of a hand-held

remote set unit, a slope sensor (pendulum) and an
amplifier module which has indicator lights and a
mode operation switch. On the CR351 and CR361
pavers the slope sensor and amplifier modules are
incorporated into the same mount housing. (Figure
11) All other models have the slope sensor and
amplifier modules mounted separately. (Figures 12
& 13)
The slope control system can control the left or the
right tow point cylinder and is capable of maintaining
up to 10% positive or negative slope from each side
of the paver. (Figure 14)
Slope Sensor, 400 and 500 Series Pavers
Figure 12
Slope System Components of the 300 Series Pavers
Slope Controller, 400 and 500 Series Pavers
Figure 11
Figure 13
Figure 14
18121 (11/00)
A Terex Company
Sundstrand
Slope Deadband
3) Connect the slope amplifier to tow point

control cable from the slope amplifier to
either the left or right tow point connector.
The deadband on the slope system refers to the

amount of angular change that can occur on the slope
beam without triggering a tow point cylinder
response. A given amount of deadband is necessary
to allow for normal machine vibration.
Slope running on left tow point cylinder
Cable
46061-504-07
To Set Slope Sensor Deadband:

1) Connect the sensor harness from the slope
amplifier to the slope sensor connection on
the tractor bulkhead (slope sensor mounted
forward). Or, from the slope amplifier to
the slope sensor connection on the slope
sensor (slope sensor mounted rearward).
This step is not necessary on 300 series
Grayhound pavers as the slope sensor and
amplifier are in the same module.
Burner Control
Figure 17
Slope Sensor
46061-550-02-02
Slope running on right tow point cylinder

Front
Beam
Mount
Rear Beam Mount

Cable 46061-504-10
Cable
46061-504-07
Cable
46061504-09
Burner Control
OR
Slope Amplifier
Complete
46061-550-16
Figure 18
Figure 15
2) Connect the hand held remote control.

+-
4) Place slope amplifier Run/Standby switch

in Standby mode.
5) Place the remote control mat thickness
Manual/Setup/Auto switch in Setup mode
6) Turn the slope set dial on the remote slope
control until both lights on the slope
amplifier go out.
7) Turn the remote slope control dial
clockwise until a light just comes on, then
turn counterclockwise until the light just
goes out. Note the number readout on the
LCD.
Hand Held
Remote
46061-550-11
Module
Card
46061-550-15-01
Figure 16
18121 (11/00)
A Terex Company
Sundstrand
Building Rideability - Sensor mounted
forward
8) Turn the remote slope control dial

counterclockwise until a light just comes
on, then turn clockwise until the light just
goes out. Note the number readout on the
LCD.
9) Subtract the smaller noted readout number
from the larger. Example: 2.1 - 1.7 = 0.4
The deadband is set correctly if the
differential from light to light is 0.2%
slope.
10) If the deadband is not correct, remove the
screw located on the face of the slope
amplifier. There is an adjustment located
under the face screw.
11)Use the small screw driver provided.
Clockwise rotation will increase the amount
of deadband, while counterclockwise
rotation will decrease the amount of
deadband.
When using a slope control system with the sensor

mounted on the forward cross beam, corrections to
deviations at the screed will require the paver to
travel approximately 5 lengths of the tow arm before
the correction is fully completed. Deviations that
occur at the tow point, due to tractor traveling over
irregular grades, are corrected for immediately. In
effect, the sensor is correcting for deviations at the
tow point before they can affect the screeds angle of
attack (position).
In this application we are building rideability, or
area.
Sensor forward
Figure 20
To use the slope system:

1) Connect system harnesses to control the
desired left or right tow point cylinder as in
Setting Deadband section.
the desired slope is achieved on the mat
being placed by checking with a carpenters
level.
Dead-Band
Set
Point
Figure 19
18121 (11/00)
A Terex Company
Sundstrand
Building Profile - Sensor mounted
rearward
NOTICE - With a four foot level, 1/4 rise

equals 1/2% slope and 1/2 rise equals 1%
slope.
When using a slope control system with the sensor

mounted on the rearward cross beam, requires the
screed to be very responsive to any changes in the
percentage of slope of the screed. This is an
application where we are building profile, or overcorrecting the screed, forcing to change depth in a
very short distance.
4 foot
1/4 inch = 1/2 %

(0.5 %)
Figure 21
3) Place the Run/Standby switch on the slope

amplifier to Standby and the remote mat
Setup.
4) Adjust slope hand held remote dial until
the lights go out.
5) Remove the cover cap from the number set
point potentiometer.
6) Adjust the number set point potentiometer
until the LCD readout displays the correct
percentage and fall of slope.
Sensor
rearward
Figure 23
+/- Slope
Indicator
LCD readout
% of slope
To use the slope system:

1) Connect system harnesses to control the
desired left or right tow point cylinder as in
Setting Deadband section.
the desired slope is achieved on the mat
being placed by checking with a carpenters
level.
Slope adjustment dial

is used to change the
actual percentage of
slope being placed or
is used to NULL slope
(lights out) to the current
slope of the screed.
Remote Unit requires

9 volt battery.
(Be sure battery has
adequate power.)
Display Calibration Knob

(Changes display only.
Does not change slope.)
NOTICE - With a four foot level, 1/4 rise

equals 1/2% slope and 1/2 rise equals 1%
slope.
Figure 22

amplifier to Run and the remote mat
Auto.
4 foot
1/4 inch = 1/2 %

(0.5 %)
Figure 24
18121 (11/00)
A Terex Company
Sundstrand
amplifier to Standby and the remote mat
Setup.
4) Adjust slope hand held remote dial until
the lights go out.
5) Remove the cover cap from the number set
point potentiometer.
6) Adjust the number set point potentiometer
until the LCD readout displays the correct
percentage and fall of slope.
+/- Slope
Indicator
LCD readout
% of slope
Slope adjustment dial

is used to change the
actual percentage of
slope being placed or
is used to NULL slope
(lights out) to the current
slope of the screed.
Remote Unit requires

9 volt battery.
(Be sure battery has
adequate power.)
Display Calibration Knob

(Changes display only.
Does not change slope.)
Figure 25

amplifier to Run and the remote mat
Auto.
18121 (11/00)
A Terex Company
Sundstrand
7) Plug cable back into amplifier.
8) With the UP light on, check voltage on 155
to 3 (for LH tow point) or 165 to 3 (for RH
tow point) for 12 VDC
9) With the DOWN light on, check voltage
on 157 to 3 (for LH tow point) or 167 to 3
(for RH tow point) for 12 VDC.
10) If no voltage, take amplifier out of a unit
known to be functioning properly and
install it in system in question. Make sure
slope/grade switch is set for unit to be used
in.
11) If problem disappears, defective amplifier.
Troubleshooting Sundstrand Automatic

Grade & Slope System
WARNING - Hydraulic cylinders may
activate unexpectedly during testing which
could injure someone that is not prepared
for such movement. The operator and
maintenance personnel must be constantly
aware of who is near the paver and what
mechanisms may activate during testing.
Ensure that personnel are clear of
mechanisms that may activate during
testing.
Amplifier Module
Slope Function Erratic
The same amplifier module is used in both the grade

and slope units. The only difference is the setting of
the GRADE/SLOPE switch located on the back side
of the amplifier module. If the unit is to be used as
a grade control, set the Grade/Slope switch to
GRADE. If unit is to be used as a slope control, set
the Grade/Slope switch to SLOPE.
1) Check all connections for moisture.

2) If tow point cylinder overshoots during
automatic operation, check for proper
cylinder speed.
Automation Not Working Properly
1) Perform checks on tractor base wiring and
systems to ensure they function properly.
2) Inspect all cables and connections for
damage.
3) Check the deadband setting on the
amplifier.
4) Check the Grade/Slope switch on the back
of the amplifier. It must be in GRADE if
the amplifier is used in a grade senor and in
SLOPE if the unit is used in the slope
system.
5) If slope system is in question, refer to
Remote Slope Set.
6) Check tow point solenoid valve DIN
connectors for a light. Each solenoid valve
has an LED that should light when power
is applied to the solenoid.
7) Take the amplifier out of a unit that is
known to be functioning properly and
install it in the system in question. Make
sure the slope/grade switch is set properly
for the unit used.
If problems
disappear,defective amplifier.
Grade or Slope Not Working

1) Perform checks on tractor base wiring and
systems to ensure they function properly.
2) Inspect cables and connections for damage.
3) If one side works and the other does not,
swap sides with those components and recheck. If problem moves with the
component, replace that component.
4) Set Manual/Setup/Auto switch to Manual.
Do the tow point cylinders go up and down
when selected? If they do, proceed with the
next step. If they do not, troubleshoot tractor
wiring and/or systems.
5) Set Manual/Setup/Auto switch to Setup,
set Standby/Run switch to Run.
6) Disconnect large cable from amplifier.
Check pins A to B on cable for voltage. It
should be 11 VDC or more. If low or no
voltage, troubleshoot tractor wiring and/or
systems.
10
18121 (11/00)
A Terex Company
Sundstrand
Light Bulb Replacement
Slope Sensor
Unscrew the lens cover from the bulb. Slide a piece

of 5/16 inside diameter rubber hose over the bulb.
Press down and turn bulb counterclockwise. The
bulb can be purchased at most local vendors as #161
(12 VDC) bulb.
Disconnect cable and check ohms between pins.
Remote Slope Set - No Display
No cross continuity.
A to B: 10 ohms
C to D: 300 ohms
E to F: 300 ohms
1) Check battery in backside of remote slope

hand held unit and replace if necessary. A
dead battery will cause the LCD to blank
out.
2) Check harnesses and connections for
damage.
3) Check pins A to C on the slope amplifier
(connection point that remote plugs into).
Voltage should be at least 2.1 VDC. If
voltage is OK, defective remote slope set
unit.
4) If no or low voltage, unplug the harness
coming from tow point. Check pins A to B
on the socket end. Voltage should be 11
VDC or more.
5) If voltage, defective amplifier.
6) If no or low voltage, check tractor base
wiring or systems.
Remote Slope Set - Display Stays On Even
When Unplugged
Replace remote slope set unit.
Remote Slope Set - Slope Appears to be
Unstable or Oscillates
1) Check deadband setting on amplifier.
2) If deadband is OK, unplug remote slope set
unit and check pins B to D for 1500 ohms.
3) If a reading shows 500 ohms, a capacitor is
shorted. Replace unit.
4) Check pins A to C for 2500 ohms, then
check for continuity between pins A to B
and pins B to C while rotating dial. Reading
should vary as dial is turned. If not, replace
unit.
11
18121 (11/00)
A Terex Company
Sundstrand
12
18121 (11/00)
System Four
Grade & Slope
Automation
Operation & Maintenance Instructions
System Four
Grade and Slope Automation
A Terex Company
21048 (12/95)
Part # 49999-188
A Terex Company
Introduction

with this manual.
Respectfully,
Cedarapids Inc.
Important Notice!
(1)
(2)
(3)
persons.
(4)
(5)
16885 (7/91)
A Terex Company
Table of Contents
Introduction ..................................................................................................................................................................1
About This Manual .....................................................................................................................................................1
About Cedarapids Inc. ................................................................................................................................................1
Safety .............................................................................................................................................................................2
Safety Rules ................................................................................................................................................................2
Personal Safety Rules .................................................................................................................................................2
Hazard Seriousness Level ...........................................................................................................................................2
Instructional and Informational Levels .......................................................................................................................2
System Overview ..........................................................................................................................................................4
Control Box ................................................................................................................................................................4
Sonic Tracker II ..........................................................................................................................................................4
Slope Sensor ...............................................................................................................................................................5
Junction Box ...............................................................................................................................................................5
Carrying Case .............................................................................................................................................................5
System Four Signal Routing .......................................................................................................................................6
Non-Contacting Systems ............................................................................................................................................6
Sonic Tracker II: How It Works ..................................................................................................................................6
The Working Window .................................................................................................................................................7
Slope Sensor: How It Works .......................................................................................................................................8
Slope Sensor Correction Zones ..................................................................................................................................8
Function .........................................................................................................................................................................9
Control Box ................................................................................................................................................................9
Control Box Front Panel Switches and Controls ........................................................................................................9
1) Grade Correction Display ..................................................................................................................................9
2) Auto/Manual/Survey (Cal) Switch ....................................................................................................................10
3) Jog Switch ......................................................................................................................................................... 11
4) Elevation: Power/Off/Slope: Power Switch ...................................................................................................... 11
5) Grade Adjustment Knob .................................................................................................................................... 11
6) LCD Digital/Symbol Display ............................................................................................................................ 11
Lower Control Box Components .............................................................................................................................. 12
1) Serial Number Plate ......................................................................................................................................... 12
2) 11 Pin Cable Connector ................................................................................................................................... 12
3) Audible Beeper ..................................................................................................................................................12
4) Mounting Knob .................................................................................................................................................12
Control Box Memory ................................................................................................................................................ 12
Entering Survey/Control Mode ................................................................................................................................. 12
Calibrating the Tracker or Slope Sensor (changing numbers only) ..........................................................................13
Accessing System Four Performance Settings ......................................................................................................... 13
1) Blank Screen ..................................................................................................................................................... 14
2) Gain (Elevation) ............................................................................................................................................... 14
3) Gain (Slope Control) ......................................................................................................................................... 14
4) Slope Resolution ............................................................................................................................................... 15
21048 (12/95)
A Terex Company
Table of Contents
5) Beeper ............................................................................................................................................................... 15
6) Hour Meter .......................................................................................................................................................15
7) Deadband .......................................................................................................................................................... 16
8) Valve Offset .......................................................................................................................................................16
9) Unit ...................................................................................................................................................................17
Sonic Tracker II ........................................................................................................................................................17
Sonic Tracker II Front Panel .....................................................................................................................................18
1) Grade Correction Display ................................................................................................................................18
2) Sonic Tracker II Bail LED ................................................................................................................................18
Sonic Tracker II Rear ................................................................................................................................................ 18
1) Mounting Access ............................................................................................................................................... 18
2) Serial Number Plate ......................................................................................................................................... 19
3) 11 Pin Connector .............................................................................................................................................. 19
4) Temperature Sensor .......................................................................................................................................... 19
Sonic Tracker II Bail .................................................................................................................................................19
Sonic Tracker II Bail Installation .............................................................................................................................. 19
Sonic Tracker II Components ................................................................................................................................... 20
Sonic Tracker II Transducer Replacement ................................................................................................................ 20
Slope Sensor .............................................................................................................................................................20
Junction Box .............................................................................................................................................................20
Power & Interlock (Screed Remote Controls) .......................................................................................................... 21
Burner Control Console Components ....................................................................................................................... 22
Tow Point Valves .......................................................................................................................................................22
Right Tow Point Valves .......................................................................................................................................... 22
Left Tow Point Valves ............................................................................................................................................. 22
Solenoid Valve Din Connectors ............................................................................................................................. 23
Getting Started ........................................................................................................................................................... 24
Getting an On Grade Bar: (NULLING) ....................................................................................................................24
Sonic Tracker II Control ........................................................................................................................................ 25
Slope Control ......................................................................................................................................................... 25
Setting Control Box Display (Changing Numbers ONLY): ................................................................................... 26
Sonic Tracker II Control ........................................................................................................................................ 26
Slope Sensor Calibration ......................................................................................................................................26
Getting Started Paving .............................................................................................................................................. 26
Transverse Joints ................................................................................................................................................... 28
Joint Preparation ................................................................................................................................................ 28
Nulling the Screed .................................................................................................................................................28
Line of Pull ............................................................................................................................................................ 29
Building Rideability or Profile ................................................................................................................................. 29
Evaluation of Jobs .................................................................................................................................................29
Building Profile ..................................................................................................................................................... 29
Rideablility ............................................................................................................................................................ 30
21048 (12/95)
ii
A Terex Company
Table of Contents
Sensor Positioning .................................................................................................................................................30

Effective Length of Tow Arm ................................................................................................................................. 30
Control References ................................................................................................................................................... 30
Grade Control (Joint Matching) ........................................................................................................................... 30
Grade Control (Ski) ............................................................................................................................................... 31
Averaging Ski .................................................................................................................................................... 31
Over the Screed Ski ...........................................................................................................................................31
Existing Surface .................................................................................................................................................... 32
Curb or Gutter ...................................................................................................................................................... 32
Surface Stringline ..................................................................................................................................................32
Slope Table ............................................................................................................................................................... 33
Maintenance and Parts .............................................................................................................................................. 34
Preventative Maintenance & Daily Care .................................................................................................................. 34
Illustrated Parts Guide .............................................................................................................................................. 34
Illustrated Parts Guide .............................................................................................................................................. 35
Illustrated Cable Guide ............................................................................................................................................. 36
System Four Cable Numbers ................................................................................................................................. 37
Transducer Replacement Procedure .........................................................................................................................37
Sonic Tracker II Transducer Replacement ............................................................................................................ 37
Connector and Wiring Diagram ........................................................................................................................ 38 - 39
Troubleshooting .......................................................................................................................................................... 40
System Checkout Grade ...........................................................................................................................................40
System Checkout Slope ............................................................................................................................................41
Operating Checkout Grade ....................................................................................................................................... 42
Operating Checkout Slope ........................................................................................................................................ 44
System Performance Operational Check .................................................................................................................. 45
Symptom Quick Reference ....................................................................................................................................... 47
Troubleshooting Procedures .....................................................................................................................................47
LH Electrical Automatic Screed Control .................................................................................................................. 48
Tow Point Cylinder Does Not Raise or Lower in Manual ..................................................................................... 48
Topcon Control Does not Raise or Lower Tow Point in Manual or Auto ............................................................. 48
RH Electrical Automatic Screed Control .................................................................................................................. 49
Tow Point Cylinder Does Not Raise or Lower in Manual ..................................................................................... 49
Topcon Control Does not Raise or Lower Tow Point in Manual or Auto ............................................................. 50
Tow Point Hydraulic .................................................................................................................................................50
Auxiliary System .................................................................................................................................................... 50
Tow Point Will Not Increase .................................................................................................................................. 50
Tow Point Will Not Decrease ................................................................................................................................. 51
Tow Point Cylinder Drifts Up or Down ................................................................................................................ 51
Tow Point Cylinder Timing ......................................................................................................................................51
Checking Cylinder Timing .....................................................................................................................................51
Tow Point Timing Adjustment ................................................................................................................................52
21048 (12/95)
iii
A Terex Company
Table of Contents
21048 (12/95)
iv
A Terex Company
System Four
Introduction
About This Manual
We have tried to provide information which will give you a clear understanding of equipment construction,
function capabilities and requirements. This information is based on the knowledge and experience of highly
qualified people at our company and in our field organization. Proper use of this information will promote
high efficiency, maximum service life and low maintenance.
We strongly recommend that all persons directly involved with this equipment be familiar with this manual
whether or not you have experience with previous generations of machines.
Experience has shown that it is to your advantage to have a copy of this manual on site where the operators
can consult it as needed and have a copy on file in your office so supervisors can conveniently refer to it.
Danger! This manual contains vital information essential to proper and safe operation of this
equipment. Carefully read the entire manual before attempting to operate this equipment. Failure
to follow instructions and warnings contained in this manual can cause severe personal injury or
death or substantial property damage.
Additional copies can be ordered through your local Cedarapids Distributor Representative.
On going improvement of product design may result in future changes to some parts. When ordering
replacement parts, please be exact as possible in describing the part. Use part numbers, model number and
serial number to communicate with your local Cedarapids Distributor Representative.
When you have a question about your machine or operation manual, please contact your local Cedarapids
Distributor Representative.
About Cedarapids Inc.
Cedarapids is proud to manufacture this machine for your use and profit. We also take pride in the quality
of our service and replacement parts.
Cedarapids Inc., located in Cedar Rapids, Iowa, USA, has been manufacturing heavy equipment for the
construction industry since 1923. Our friendly, helpful people are ready and able to serve your needs.
If you have a question or concern please feel free to give us a call at (319) 363-3511 Monday - Friday 7:30
am to 4:30 PM Central Time. If you have a problem and need assistance during after hours, call our
emergency service number at (319) 398- 9114. An operator will get your name and number so a service
representative can return your call (usually with in 30 minutes). If your concern can not be resolved at that
time a representative from engineering will be contacted. We are looking forward to serving you.
21048 (12/95)
A Terex Company
System Four
Safety
This equipment must be used in accordance

with all operation and maintenance instructions.
Safety Rules
When operating the equipment, always follow the
safety rules. Cedarapids makes no guarantee either
expressed or implied that the equipment meets all
local or federal safety regulations. It is the
responsibility of the individual user to verify that all
safety regulations are complied with before starting
the machine.
We strongly recommend that all persons

involved with this equipment be familiar with
this manual and all related engine manuals.
Read all Danger, Warning, Caution and
instruction decals.
Know what guards and protective devices are
included and see that each is used.
Personal Safety Rules

Cedarapids equipment is designed with the safety of
all personnel in mind. Do not attempt to change,
modify, or eliminate the accident prevention devices
installed at the factory. Make sure all personnel who
regularly work or who might do work in the area of
the equipment are familiar with the safety
precautions. Owners and operators are responsible
for safety information and following safe practices.
Hazard Seriousness Level

Signal words (Danger!, Warning! and Caution!) are
used to identify levels of hazard seriousness in this
manual and on decals located on the equipment.
Guards, covers, and shields are installed around

moving parts at the factory whenever necessary to
prevent accidental injury to operators and others
working on or near the equipment. Do not remove
them. In some cases it is the customers responsibility
to properly guard the machine before operation.
Warning! Hazards or unsafe practices which

COULD result in severe personal injury or
death.
Definitions for identifying hazard levels are provided

below with their respective signal words.
Danger! Immediate hazards which WILL
Caution! Hazards or unsafe practices which

COULD result in minor personal injury.
Instructional and Informational Levels
Signal words (Notice and Important) are used to
identify instructional procedures and informational
suggestions or directions for Cedarapids equipment
operation and maintenance
Danger! This manual contains important

information regarding the operation of your
machine. Carefully read the entire manual
before attempting to operate. Failure to read
this manual and follow the instructions and
warnings in it can cause severe personal
injury, death or substantial property damage.
Definitions for identifying instructional or

informational levels are provided below.
Notice
Notice: Failure to follow proper
instructional procedures could lead to
serious and/or expensive damage to the
equipment.
Only qualified and trained persons should

operate, repair or maintain this equipment.
Keep this manual for future reference.
Federal, state and local safety regulations must
be complied with to prevent possible danger to
person(s) or property from accidents or harmful
exposure.
21048 (12/95)
A Terex Company
System Four
Important
Important: Informational suggestions or
directions regarding operational and
maintenance of equipment.
Mount and dismount the machine using only

the steps, handrails and walkways.
Do not mount or dismount the machine when
it is moving.
Danger! Failure to avoid the following

hazards will result in severe personal injury
or death.
Keep all personnel clear of machine when

operating.
Caution! Failure to heed the following
could result in personal injury.
Never attempt to install or remove any part or

assembly when the paver is running.
Wear protective mask when harmful air

pollution exists.
Do not allow personnel to walk between the

machine and truck.
Wear safety goggles, gloves and long-sleeve

shirts when in close proximity to hot asphalt
materials.
Do not refule the machine with the engine

running. All sparks and open flames must be
kept to a minimum of 50 feet away from the
machine while refueling.
Wear ear plugs if needed.

To prevent fire hazards, keep the engine area
free of oil, fuel and trash buildup.
Warning! Failure to take action to resolve

these hazards or unsafe conditions could
Wear clothing that fits snug to prevent getting
caught in moving parts. Loose-fitting clothing
should never be worn.
21048 (12/95)
A Terex Company
System Four
System Overview
All of the controls for the System Four are on the

front panel of the Control Box. The Control Box
connects to the Junction Box on the respective side
with one cable. It attaches easily with one mounting
clamp, and at the end of the day can be quickly
removed for storage.
System Four is a complete, non-contacting control

system which combines both elevation control and
slope control into a simple, easy to use package. The
system includes two Control Boxes, two Sonic
Tracker IIs and a single Slope Sensor. The Control
Box on the right side of the machine controls the
right side for either elevation or slope. Likewise, the
left Control Box controls the left side for either
elevation or slope.
Sonic Tracker II
The Sonic Tracker II is an elevation control sensor.
It sends out pulses of high frequency sound and
measures the time it takes for the echoes reflected
from physical objects to return. Sonic Tracker II
then sends that information to the Control Box. The
Control Box then evaluates the information and
raises or lowers the towpoint cylinder to maintain
proper mat thickness.
The primary function of the System Four is to

provide screed control so that the paving material is
placed into position at the correct elevation and
slope.
Control Box
The Control Box is the operators interface to System
Four. The Control Box receives signals from the
sensors, (Sonic Tracker II, Laser Trackers and/or
Slope Sensor), and uses these signals to determine if
grade or slope correction is necessary. If a change in
grade or slope is required, the Control Box sends a
signal to the valve controlling the tow point cylinder
on the appropriate side of the machine to raise or
lower, thus maintaining correct mat thickness.
Sonic Tracker II attaches to the system through one

quick connect cable and attaches to the machine
with a single bolt. At the end of the day, Sonic
Tracker II should be removed for proper storage in
the carrying case.
AUTO
21048 (12/95)
A Terex Company
System Four
Slope Sensor
The Slope Sensor is a precision electronic sensor
which functions much like a precision carpenters
level. The Slope Sensor reads the inclination (tilt) of
the screed and sends the signal to the Control Box.
The Junction Box allows for quick and easy

attachment and removal of the system cables, and
once installed on the paving machine it is not
removed.
Carrying Case
A Carrying Case is provided with each System Four.
The Carrying Case is lined and includes pre-cut
sections for each Sonic Tracker II and Control Box.
A plastic bucket is also provided for storing coil
cords and cables.
The Slope Sensor is a sealed unit and contains no

adjustments. It is the only component of System
Four which may be selected to control either side of
the paver. It is connected to both Junction Boxes by
two cables, and is not removed from the paver once
installed.
ON
C
OP
Junction Box
The primary function of the Junction Box is to route
power and ground from the paving machine to the
Control Box, and to route correction signals from the
Sonic Tracker II or Slope Sensor to the Control Box.
It also routes valve signals from the Control Box to
the paving machine valves.
At the end of each job or at the end of the day, always

wipe down each of the components and place them
and the coil cords in the appropriate sections for
storage. This will ensure the continued integrity of
these components and will protect them from
vandalism or theft.
Notice: Keep the Carrying Case dry and
store in a dry location. Never let the Carrying
Case become wet. If the case does become
wet, remove the components and air until
dry.
21048 (12/95)
A Terex Company
System Four
System Four Signal Routing
LEFT
SOLENOID VALVE
&
TOW POINT CYL.
RIGHT
SOLENOID VALVE
&
TOW POINT CYL.
D
C
SONIC GRADE
SENSOR
JUNCTION
BOX
B
SLOPE
SENSOR
CONTROL
BOX
JUNCTION
BOX
SONIC GRADE
SENSOR
CONTROL
BOX
(A) The Sonic Tracker II measures the distance

between it and the reference plane and sends
the information to the Control Box.
principles of the Sonic (Sonic Tracker II) and the

Gravitational (Slope Sensor) devices supplied with
System Four.
(B) The Slope Sensor measures angle of the slope

beam and sends the information to the Control
Box.
Sonic Tracker II: How It Works

The Sonic Tracker II measures distances to a physical
reference (Control Reference) using sound pulses,
much like a SONAR.
(C) The Control Box determines if corrections are

required and sends correction signals to the
pavers hydraulic valve.
A Transducer, located in the bottom of the Sonic

Tracker II generates sound pulses like a speaker, and
listens for returned echoes like a microphone. When
the Transducer generates a sound pulse, it also starts
a counter that is a lot like a stopwatch.
(D) The pavers hydraulic valve responds by moving

the tow point cylinder to make the correction.
Non-Contacting Systems
Non-Contacting Grade control or Paving control
systems operate from Sonic, Laser or Gravitational
sensors that do not require physical contact with a
Control Reference to maintain a desired Elevation
or Slope. The following sections will explain the
21048 (12/95)
A Terex Company
System Four
The Working Window
Before paving is started, the operator will use the
Control Box to set (or Calibrate) a control region or
zone around the Control Reference (see Sonic Tracker
II Calibration). This process is called Nulling.
The pulse travels away from the Sonic Tracker II at

the speed of sound, gradually increasing in diameter.
Sound Pulse
When the sound pulse strikes an object (Control

Reference), a portion of the sound pulse is reflected
back up toward the Transducer. The size of the cone
determines what the Sonic Tracker II can see.
Objects within the cone reflect sound back (an
echo). Objects outside of the cone do not reflect
back sound. When the Transducer hears the
returning sound pulse (echo), the Sonic Tracker II
stops the counter. Using the elapsed time measured
by the counter and knowing the speed of sound, the
Sonic Tracker II calculates the exact distance to the
object (Control Reference). It repeats this procedure
40 times per second.
ADJUSTABLE
14" TO 55"
(35.5 TO 140 cm)
2.4"(6 cm)
2.4"(6 cm)
Solid Up Arrow
Flashing Up Arrow
On Grade
Flashing Down Arrow
Solid Down Arrow
AT 24" THE
24" SOUND PULSE
WILL BE
APPROXIMATELY
6" IN DIAMETER
No Correction
Made
Coarse Correction
(Automatic)
Fine Correction
(Automatic)
The Working Window is a zone 2.4" above and 2.4"

below the On Grade distance. When the distance
measured by Sonic Tracker II to the Control
Reference is within the Working Window, automatic
control of the screed can occur. If the distance
measured is outside of the control window, control
is switched to manual and no corrections are sent to
the control valve unless the measured distance is
returned to within the Working Window. This
prevents the system from diving should the Sonic
Tracker II be moved off of a Control Reference like
ski, stringline, or curb.
Transducer generates
a sound pulse and
starts timer.
Sound pulse
strikes control
reference
Echo returns
and stops
timer
Distance = Elapsed Time x Speed of Sound

21048 (12/95)
A Terex Company
System Four
Under automatic control, the Control Box tries to
keep the Control Reference at a constant distance
from the Sonic Tracker II (On Grade). If the Sonic
Tracker II measures the distance to the Control
Reference and the Control Box finds its not at the
desired distance (On Grade), the Control Box
determines which part of the Working Window
(Fine or Course Correction above or below On
Grade) the Control Reference is residing in. Once
this is determined, the Control Box displays the
appropriate correction symbol on its LED Display
as well as on the Sonic Tracker II LED Display, and
sends correction signals to the paver valve to adjust
the screed to bring the screed back to On Grade.
COARSE
CORRECTION
UP
SOLID
ARROW
UP
FINE
CORRECTION
UP
FLASHING
UP
ARROW
ON GRADE
ON GRADE
FINE
CORRECTION
DOWN
FLASHING
DOWN
ARROW
SystemFour
SystemFour
SystemFour
Once the desired Slope has been set at the Control

Box, the Slope Sensor measurements will be indicated
on the Control Box LCD and LED Displays. When
the paver is at the correct slope (On Grade), the
Control Box will display the On Grade Symbol.
COARSE
CORRECTION
UP
Slope Sensor Correction Zones

The Control Box receives signals from the Slope
Sensor and sets up Correction Zones regions around
the On Grade Zone. These Correction Zones are
divided into two sections. Just above and just below
On Grade to .05% is the Fine Correction Zone.
Any slope measured beyond the Fine Correction
Zones is in the Course Correction Zone. When a
slope that is more than 2.0% beyond On Grade is
encountered, a Grade Adjustment Arrow around the
Grade Adjustment Knob will illuminate.
SOLID
ARROW
DOWN
If the Control Reference is measured to be outside of

the Working Window (above, or below 2.4" of On
Grade), the LED arrows on Sonic Tracker II will
flash once every two seconds, and one of the Grade
Correction Arrows around the Grade Correction
Knob on the Control Box will flash indicating which
way to turn the knob to bring the Working Window
back around the Control Reference. The System
will also be placed under manual control.
Each of these Correction Zones also have there own

symbols. While displaying the desired control slope
of the paver on the Control Box LCD Display,
symbols will also appear on the Control Box LEDs
so the operator knows, at any time, the correction
needed for the paver to reach On Grade.
Slope Sensor: How It Works

The Slope Sensor has a precision electronic device
much like a carpenters level inside the slope sensor
that constantly measures the slope that the paver is
operating on. Using the Control Box to set (Calibrate)
the Slope Sensor (see Slope Sensor Calibration), the
operator can maintain a desired left hand or right
hand slope from +20% to -20%.
21048 (12/95)
COARSE
CORRECTION
UP
FINE
CORRECTION
UP
SOLID
ARROW
UP
FLASHING
UP
ARROW
ON GRADE
ON GRADE
FINE
CORRECTION
DOWN
COARSE
CORRECTION
UP
FLASHING
DOWN
ARROW
SOLID
ARROW
DOWN
A Terex Company
System Four
Function
1) Grade Correction Display LEDs
This chapter reviews the System Four components

and explains the function of each.
2) Auto/Manual/Survey (Cal) Switch

3) Jog Switch
Notice: When operating in rainy weather

or in wet conditions, the Control Box, Sonic
Tracker II, and cables must be thoroughly
dried BEFORE placing them in the
Carrying Case at the end of the day.
4) Elevation: Power Off Slope: Power

5) Grade Adjustment Knob
6) LCD Display
All features of the System Four can be accessed
using the switches and displays located on the front
panel of the Control Box.
Any moisture left on the Control Box, Sonic

Tracker II, and/or cables when put in the
Carrying Case will cause condensation on
the inside of the components which may
severely affect accurate operation during
the next paving operation.
The function of each is as follows:

1) Grade Correction Display
The Grade Correction Display cues you when grade
is too high, on grade or too low.
Control Box
The Control Box is the main operator control interface
for the System Four. It contains LEDs (Light
Emitting Diodes) as well as an LCD (Liquid Crystal
Display) to inform the operator of the systems
performance. The Control Boxs LEDs duplicate
the symbols being displayed on the Sonic Tracker
IIs LED display.
Control Box LEDs indicate the correction

required to return to grade.
Too High (lower tow
point to reach grade)
Flashes when within .6"
1.5 cm, of On Grade
Solid when greater than
.6" (1.5cm) but less than
2.4" (6 cm) of On Grade
The Control Box is also the brains of the System

Four. It receives information from the sensors,
processes the information, and sends out correction
signals to the pavers tow arm valves.
Off when beyond 2.4" (6

cm) of On Grade
Control Box Front Panel Switches and

Controls
On Grade
At correct grade.
1
SystemFour
(the depth of On Grade

depends on the amount of
deadband calibrated)
Auto
2
SurveyCal
TOPCON
3
21048 (12/95)
5
9
A Terex Company
System Four
Too Low (Raise tow point
to reach grade)
this chapter).
Holding the switch again for less that 2 (two)
seconds will set the Control Box to the Control
Mode (see Survey/Control Function later in
this chapter).
Flashes when within .6"

(1.5 cm) of On Grade
Solid when greater than
.6" (1.5cm) but less than
2.4" (6 cm) of On Grade
B) After the Control Box has been powered On,

continuously holding this switch down while
turning the Grade Adjustment Knob will set
the Control Box LCD to a new numerical
value. (See Calibrating the Tracker or Slope
Sensor later in this chapter).
Off when beyond 2.4" (6

cm) of On Grade
Survey Mode (Flashing)
Indicates that the system
is no longer in Control
Mode and that the LCD
Display is now showing
the actual grade or slope
of the screed.
C) Powering On the Control Box while holding

the switch down continuously will allow
selection of system Performance Settings. The
Grade Correction Arrows will flash and the
LCD will be blank. Turn the Grade Adjustment
Control Knob (while continuing to hold down
the Auto/Manual/Survey (Cal) Switch) to the
right 1 (one) click at a time. The Calibration
Modes will appear in the following order:
2) Auto/Manual/Survey (Cal) Switch

The Auto/Manual/ Survey
(Cal) Switch is used to
AUTO
select
Manual
or
M
A
Automatic control and to
N
calibrate the System Four.
1) Blank (Exit)
2) Gain (Elevation)
3) Gain (Slope)
SURVEY
(CAL)
4) Unit (Sets unit of measure: Ft/In/cm)

5) Slope Resolution (Sets to: . 1 or to: .01)
Up position sets the system to the Automatic

Mode. This is the normal operating mode.
Paver tow arms are automatically adjusted up
or down to maintain proper grade.
6) Beeper (Sets audible beep to On or Off)

7) Hour Meter (Total hours the system has been
On/Total hours system has been in the Auto
Mode)
Center position sets the system to the Manual

Mode. In this mode System Four will give
readings, but the pavers tow arms will not be
adjusted.
8) Deadband (Sets On Grade Deadband)

9) Valve Offset
(See Accessing System Four Performance
Settings later in this chapter).
Down position controls three separate

functions:
A) After the Control Box has been powered on,
holding this switch down less than 2 (two)
seconds will set the Control Box in the Survey
Mode (see Survey/Control Function later in
21048 (12/95)
10
A Terex Company
System Four
3) Jog Switch
Grade Adjustment Direction Arrows

These red arrows light up
around the Grade
Adjustment Knob to
indicate the direction the
knob should be rotated to
reach On Grade.
This switch is used to

manually move the tow
point up or down. The Jog
Switch is always active
when the Control Box is
turned on.
Up position causes the tow arm cylinder to raise.
Down position causes the tow arm cylinder to lower.
1) Rotate the knob to

the right to reach
grade.
4) Elevation: Power/Off/Slope: Power Switch

This switch sets the control
for either Elevation or
Cross Slope. It is also the
power switch for the
system.
2) Rotate the knob to

the left to reach
grade.
6) LCD Digital/Symbol Display
This display allows the operator to view a numerical
representation of the grade or slope the System Four
is currently maintaining. When setting System Four
performance settings, their individual symbols will
be displayed (See Accessing System Four
Performance Settings later in this chapter).
Up position turns power On and selects Elevation

Control.
Middle position turns power Off.
Down position turns power on and selects cross
Slope Control.
Graphic symbols indicate the type of control

that has been selected:
5) Grade Adjustment Knob

This knob is used to make measured adjustments to
the cross slope or elevation settings.
This knob is also used to access Calibration and

System Performance Settings when used in
conjunction with the Auto/Man/Survey (Cal) Switch.
(See Calibrating the Tracker or Slope Sensor or
Accessing System Four Performance Settings later
in this chapter).
Cross Slope Control

Slope down to the right
Cross Slope Control

Slope down to the left (+)
Sonic Tracker II
Control
Laser Tracker Control
Adjusts the grade height for the Sonic Tracker

II when elevation control is selected.
Adjusts the percentage slope when cross slope
control is selected.
When Cross Slope Control is selected, the

numbers on the display represent percentage
of slope.
21048 (12/95)
11
A Terex Company
System Four
When Elevation Control is selected, the
numbers on the display represent elevation
measurements in either feet, inches, or
centimeters.
attached to the Control Box and is long enough

to allow the Mounting Knob to be loosened
without being removed from the stud when
mounting the Control Box.
Control Box Memory
The Control Box automatically stores all operating
information when it is turned Off.
Auto Indicator
AUTO
This indicator illuminates

when the system is
switched to Automatic.
NOTICE: If power is interrupted to the

Control Box within 2 (two) seconds after
making an adjustment, the new setting will
not have had time to be stored and the
settings will revert to the previous (or
original) setting.
Lower Control Box Components
Entering Survey/Control Mode

The Survey Mode allows the operator to view the
actual elevation or slope of the screed. In this mode,
the LCD Display reading will change as the screed
is raised or lowered or tilted. This feature is useful
in setting up the machine or pre-surveying the job.
NOTICE: The screed cannot be controlled

in the Survey Mode.
To activate the Survey mode do the following:

3
1) Turn the System Four On by selecting either

Elevation or Slope Control.
1) Serial Number Plate - The Serial Number

Plate contains your System Fours part number
and serial number.
2) Momentarily press the Auto/Manual/Survey

(Cal) Switch down.
2) 11 Pin Cable Connector - Power and signal

communications between System Four
components travel via this connector.
The Control Box will beep one time and the Grade
Correction Display will show a flashing, circular
pattern . The LCD Display will now show the correct
elevation if Elevation Control has been selected or
the current slope if Slope Control has been selected.
3) Audible Beeper - When the power is turned

on, or calibration selections are made, the
beeper will sound. The beeper may be turned
Off or On using the Beeper Calibration Mode
(see Accessing System Four Performance
Settings later in this chapter).
To return to the Control mode:

Momentarily press the Auto/Manual/Survey
(Cal) Switch again (less than 2 seconds) then
place in Auto.
4) Mounting Knob - The Mounting Knob is

used to secure the Control Box to its mounting
bracket. The mounting stud is permanently
21048 (12/95)
The system will be returned to the normal Control

mode and grade will automatically be set to On
Grade.
12
A Terex Company
System Four
Calibrating the Tracker or Slope Sensor
(changing numbers only)
Once the Control Box is powered On by selecting
Elevation or Slope Control, pressing the Auto/
Manual/Survey (Cal) Switch down to Survey (Cal)
continuously places the unit in the Display Setting
Mode and under Manual Control.
Switch while a particular Performance Setting is

displayed will select that Setting for adjustment.
NOTICE: The recommended, or typical
values listed in some of the Performance
Settings to follow are meant to be suggested
starting points for those settings. If your
machine does not perform properly within
those recommended values, adjust that
setting accordingly until satisfactory
performance of your machine is reached.
NOTICE: Turing the Grade Adjustment

Knob with the Auto/Manual/Survey (Cal)
Switch depressed enters the display setting
mode instantly, without the 2 second wait.)
NOTICE: Because of the potential to

seriously affect System Four performance
and accuracy, three System Four
Performance Settings may be locked-out
by a Cedarapids authorized technician once
the correct values for these Settings are set
for your paver. These Settings are Units,
Deadband, and Valve Offsets. If you feel
further adjustments to these Settings are
required, contact your Cedarapids Inc.
representative.
As long as the Auto/Manual/Survey (Cal) Switch is

depressed, the arrows around the Grade Adjustment
Knob will flash. The LCD can be set to any reading
by turning the Grade Adjustment Knob.
Releasing the Auto/Manual/Survey(Cal) Switch
stores the LCD reading and sets system control to On
Grade.
To return to Automatic Control, push switch up.
If Elevation Control has been selected, the elevation
displayed is set by this process. If Cross Slope has
been selected, cross slope calibration is set.
Continue to hold the Auto/Manual/Survey (Cal)

Switch down and turn the Grade Adjustment Knob
Accessing System Four Performance

Settings
With the screed remote Man/Setup/Auto switch in
SETUP, continuously pressing the Auto/Manual/
Survey (Cal) Switch on th econtrol box down when
powering the System Four On (selecting Elevation
Control or Slope Control) allows access to the System
Performance Settings. These settings are Blank,
Gain (Elevation), Gain (Slope), Units, Slope
Resolution, Beeper, Hour Meter Deadband, Valve
Offsets and units.
AUTO
M
A
N
SURVEY
(CAL)
OR
Continuously
Holding Switch
Down
=
Turn Knob
One "Click"
to the Right
System Four
Sonic Tracker III

Gain Calibration
(first of 8 calabration modes)
While Turning
Power ON
one click at a time to access the other Performance

Settings.
Releasing the Auto/Manual/Survey (Cal) Switch
will display the current system settings. Turning the
Grade Adjustment Knob one click at a time will
change the settings.
When the Performance Setting menu is entered at

start-up, the arrows around the Grade Adjustment
Knob will flash. Rotating the Grade Adjustment
Knob clockwise scrolls the LCD display through the
System Performance Settings in the order listed
above. Releasing the Auto/Manual/Survey (Cal)
21048 (12/95)
NOTICE: The Blank Screen must be

displayed to exit and SAVE changes made
to the System Performance Settings
13
A Terex Company
System Four
1) Blank Screen
The Blank Screen will be the first setting displayed
when entering the System Performance Settings and
must be displayed to exit and save the System
Performance Settings.
to the main System Performance Settings menu.

You may now rotate the Grade Adjustment knob to
access another Performance Setting or exit the System
Four Performance Settings menu by rotating the
Grade Adjustment Knob until the Blank Screen is
displayed and releasing the Auto/Manual/Survey
(Cal) Switch.
2) Gain (Elevation)
This setting determines the speed at which System
Four will cause the Tow Point Cylinders to adjust to
a change in elevation.
3) Gain (Slope Control)

This setting determines the speed at which System
Four will cause the Tow Point Cylinders to adjust
to a change in slope.
When the Sonic Tracker II senses a change in

elevation, the Control Box takes that information
and makes a determination as to how far from On
SystemFour
SystemFour
When the Slope Sensor senses a change in slope, the

Control Box takes that information and makes a
determination as to how far from On Grade the
screed currently rests.
Grade the screed currently rests.

The Control Box will then send a signal to the paver
valve to open a pre-determined amount, returning
the screed to the desired grade at a certain speed. The
Gain (Elevation) setting allows the paver operator to
set Sonic Tracker II so that the paver valve opens a
pre-determined amount allowing the screed to react
(adjust to the change in elevation) faster or slower.
The objective is to set the Gain so the screed reacts
to the change in grade quickly, but without
overshooting the new elevation.
The Control Box will then send a signal to the paver

valve to open a predetermined amount, returning the
screed to the desired slope at a certain speed.
The Gain (Slope) setting allows the paver operator
to set System Four so that the paver valve opens a
predetermined amount allowing the screed to react
(adjust to the change in slope) faster or slower. The
objective is to set the Gain so the screed reacts to the
change in slope quickly, but without overshooting
the new slope.
When chosen, the Gain symbol along with the Sonic

Tracker II and Laser symbols are displayed until the
Auto/Manual/Survey (Cal) Switch is released. The
percentage gain, 1 % to 100%, is then displayed.
The arrows around the Grade Adjustment Knob
flash.
The Gain Symbol along with the + Slope and - Slope

symbols are displayed until the Auto/Manual/Survey
(Cal) Switch is released. The percentage gain, 1 %
to 100%, is then displayed. The arrows around the
Grade Adjustment Knob flash.
The typical Gain setting for the Tracker is 25%.
The typical gain setting for the Slope is 25%.
After the desired value is selected by turning the

Grade Adjustment Knob pressing and holding the
Auto/Manual/Survey (Cal) Switch stores the value
into the Control Box memory and returns the LCD
21048 (12/95)

Grade Adjustment Knob Pressing and holding the
14
A Terex Company
System Four
(Cal) Switch.
SystemFour
After On or Off has been selected by turning the

Grade Adjustment Knob, pressing and holding the
to the main
4) Slope Resolution
(Sets display to read in increments of .1 % or to .01
%)
System Performance Settings menu. You may now

rotate the Grade Adjustment knob to access another
Performance Setting or exit the System Four
Performance Settings menu by rotating the Grade
Adjustment Knob until the Blank Screen is displayed
and releasing the Auto/Manual/Survey (Cal) Switch.
The is displayed until the Auto/Manual/Survey (Cal)

Switch is released. The arrows around the Grade
Adjustment Knob flash and rotating the knob cycles
the display between a resolution of . 1 % and .01%.
SystemFour
6) Hour Meter
(Displays Total and Auto Hours) The Hour Meter
symbol is displayed until the Auto/Manual/Survey
(Cal) Switch is released. The arrows around the
Grade Adjustment Knob flash and rotating the knob
cycles the display between total hours System Four
has been powered On, and hours System Four has
been under automatic control. Auto hours are
represented by a colon (:) preceding the number.
Slope Resolution should be set to .1% (tenths) for

paving applications.
After the desired resolution is selected by turning the
Grade Adjustment Knob, pressing and holding the
(Cal) Switch.
SystemFour
After viewing the desired hours by turning the Grade

Adjustment Knob, pressing and holding the Auto/
Manual/Survey (Cal) Switch returns the LCD to the
main System Performance Settings menu. You may
now rotate the Grade Adjustment knob to access
another Performance Setting or exit the System Four
5) Beeper
(Sets audible beep On or Off)
The Beeper symbol is displayed until the Auto/
Manual/Survey (Cal) Switch is released. The arrows
around the Grade Adjustment Knob flash and rotating
the knob cycles the display between On and Off.
21048 (12/95)
15
A Terex Company
System Four
7) Deadband
(Sets On Grade Deadband)
8) Valve Offset
The Valve Offset setting controls the duration of the
signal sent to the paver valves from the Control Box.
If the signal is to short in duration, the operator will
hear the paver valve clicking but the cylinder will
not move. Like wise, if the signal is too long in
duration the valve will spring wide open causing
the cylinder to jump and overcorrect.
Deadband is the area of the Working Window that is

On Grade and simply means that while the reference
is within that area, the pavers valves are idle (closed).
Therefore the wider the Deadband (On Grade area),
the more a reference can move up or down without
a correction being initiated.
SystemFour
SystemFour
To set the Valve Offset release the Auto/Manual/

Survey (Cal) switch. The LED display will
momentarily display the letters CAL and then
back to OFS
When Deadband is added or taken away from the On

Grade region of the working window, it takes this
extra area from the Fine Correction region (.6"
above or below On Grade). It Does Not add this
distance to the overall working window height.
SystemFour
NOTICE: The amount of Deadband should

be carefully selected so that constant
hunting of the screed (rising up and down)
is prevented.
Press the Auto/Manual/Survey (Cal) switch to Survey
(Cal) and Release.
The Deadband symbol is displayed until the Auto/

Manual Survey (Cal) Switch is released. The arrows
around the Grade Adjustment Knob flash. Rotating
the knob cycles the display between 0 and 15. The
number displayed represents the Deadband (On
Grade area) in millimeters.
SystemFour
The typical Deadband setting is 3 mm.

Grade Adjustment pressing and holding the Auto/
Manual/Survey (Cal) Switch stores the value into
the Control Box memory and returns the LCD to the
main System Performance Settings menu. You may
now rotate the Grade Adjustment knob to access
another Performance Setting or exit the System Four
21048 (12/95)
This causes the current offset in the up direction to

be displayed and shows a UP light indicator.
Turning the Grade Adjustment Knob adjusts the rate
at which the tow point cylinder moves.
16
A Terex Company
System Four
NOTICE: The control boxes should be
marked and used on the same side of the
machine the Valve Offset was set for as
setting may vary from left to right sides.
9) Unit
(Sets display to read in feet, inches, or centimeters)
The Unit symbol is displayed until the Auto/Manual/
Survey (Cal) Switch is released. At switch release,
the current unit of measure is displayed. The arrows
around the Grade Adjustment Knob will flash and
rotating the knob cycles through the units of Feet,
Inches and Centimeters.
Adjust the Grade Knob until No cylinder movement

is noted and then adjust to the point where a slight
cylinder movement is noted.
Press the Auto/Manual/Survey (Cal) switch to Survey
(Cal) and Release.
SystemFour
SystemFour
The Units should be set to Inches or Centimeters.

(Feet settings are not used in paving applications.)
This causes the current offset in the up direction to

be displayed and shows a DOWN light indicator.
After the desired unit of measure is selected by

turning the Grade Adjustment Knob, pressing and
holding the Auto/Manual/Survey (Cal) Switch stores
the value into the Control Box memory and returns
the LCD to the main System Performance Settings
menu. You may now rotate the Grade Adjustment
knob to access another Performance Setting or exit
the System Four Performance Settings menu by
rotating the Grade Adjustment Knob until the Blank
Screen is displayed and releasing the Auto/Manual/
Survey (Cal) Switch.
Turning the Grade Adjustment Knob adjusts the rate

at which the tow point cylinder moves.
Adjust the Grade Knob until No cylinder movement

is noted and then adjust to the point where a slight
cylinder movement is noted.
Sonic Tracker II
The Sonic Tracker II measures the distance to a
Control Reference. It can be set to maintain a
specific elevation above a given control reference
(Ski, Stringline, Curb or Gutter, Existing Mat, etc.).
After the desired value have been selected Press the

Auto/Manual/Survey (Cal) switch to Survey (Cal)
and hold while turning the Grade Adjustment Knob
to the next performance setting.
21048 (12/95)
See Sonic Tracker II: How It Works.
17
A Terex Company
System Four
Sonic Tracker II Front Panel
The Sonic Tracker II- front panel contains an LED
display similar to the Control Box as well as a Bail
Sensor LED:
(6.1 cm) of On Grade. Slowly flashes when beyond

2.4" (6.1 cm) of On Grade
The Sonic Tracker II- Grade Correction LEDs and
the Control Box Grade Correction LEDs will
simultaneously display the same symbols during
operation.
2) Sonic Tracker II Bail LED

In the upper right corner of the Sonic Tracker II face
plate is a small symbol used to represent the use of
the Sonic Tracker II Bail. This LED symbol will
TOPCON
T
automatically illuminate when the Bail is attached to
the Sonic Tracker II (see Sonic Tracker II Bail- later
in this chapter).
1) Grade Correction Display
The Sonic Tracker II Grade Correction Display, like
the Control Box, cues you when the grade level is
Too High, On Grade or Too Low:
Too High (lower tow point to reach
grade). Flashes when within .6" (1.5
cm) of On Grade. Solid when greater
than .6" (1.5cm) but less than 2.4"
(6.1 cm) of On Grade. Slowly flashes
when beyond 2.4" (6.1cm) of On
Grade
Sonic Tracker II Rear
The Sonic Tracker II rear contains the areas for
mounting and System Four hook up, as well as a
temperature sensor.
On Grade - At correct grade.
1) Mounting Access - The Sonic Tracker II

Mounting Access mates to a bracket on the
paver ( Installation).
Too Low (Raise tow point to reach

grade). Flashes when within 6" (1.5
cm) of On Grade. Solid when greater
than .06" (1.5cm) but less than 2.4"
21048 (12/95)
18
A Terex Company
System Four
2) Serial Number Plate - The Serial Number
Plate contains your Sonic Tracker IIs part
number and your Sonic Tracker II serial
Number.
1) With the Sonic Tracker II laying face up on a

flat surface, gently pull outward on the Bail
forks until they just clear the lower Skirt of
the Sonic Tracker II.
3) 11 Pin Connector - Power and signal

communications between the Sonic Tracker II
and the Control Box travel via this connector.
NOTICE: Do Not pull the bail forks out far

enough to permanently bend them.
Repeated bending will weaken the bail
resulting in breakage or a bail that will not
stay affixed to the Sonic Tracker II.
4) Temperature Sensor - The Temperature

Sensor is used to compensate for air temperature
changes during non-paving operations. When
the Sonic Tracker II Bail is in place, this sensor
is overridden by the Bail.
Sonic Tracker II Bail
The Sonic Tracker II Bail is used to compensate for
the rapid air temperature changes that can occur
while paving.
2) Making sure the rubber material is all the way

to the bail fork ends, place the fork ends in the
existing holes in each side of the Sonic Tracker
II.
The Sonic Tracker II transducer sends out sound

pulses. These pulses bounce off of a physical
reference (Ski, Stringline, Curb or Gutter, Existing
Mat, etc.) and return to the transducer at the speed of
sound.
The speed at which these pulses hit the reference and
return are affected by the air temperature they travel
through, slower through cooler air, and faster through
warmer air. The Sonic Tracker II Bail provides a
constant physical reference for the Sonic Tracker II
to calibrate the speed of sound, thus avoiding effects
caused by rapid fluctuations in air temperature over
freshly laid asphalt (see Sonic Tracker II How It
Works).
3) Once the Bail fork ends are set in the existing

holes, gently squeeze the bail forks into the
securing slots. Make sure the ends have
securely snapped into place.
Sonic Tracker II Bail Installation

Mount the Bail to the Sonic Tracker II using the
following procedures:
21048 (12/95)
19
A Terex Company
System Four
Sonic Tracker II Components
the Transducer can be easily removed, and a new

Transducer installed returning the Sonic Tracker II
to its original condition.
SONIC TRACKER II
46062-551-09
Sonic Tracker II Transducer Replacement

(see: Maintenance and Parts)
O-RING PART OF KIT

46062-551-02-02
SCREW PART OF KIT
46062-551-02-02
Slope Sensor
The Slope Sensor reads slope using an internal
precision level. It works by reading the lateral
inclination (right side to left side tilt, or left side to
right side tilt) of the screed.
TRANSDUCER ASSEMBLY
PART OF KIT 46062-551-02-02
RETAINING RING
FILTER PART OF KIT

46062-551-02-02
BOX OF FILTERS
46061-551-02-03
1) Sonic Tracker II Transducer

NOTICE: If the Sonic Tracker II is
experiencing erratic or inconsistent
readings, Transducer contamination should
be considered first before assuming any
other type of failure. The most common
sign of Transducer contamination is the
ability of the Sonic Tracker II See the
ground, but not a Fixed Stringline or the
Bail.
P
O
SLOPE SENSOR
46061-551-18
The Transducer operates by generating sound pulses.

This is done by sending an electrical charge through
a very thin piece of metallic material which vibrates
rapidly creating the sound pulse. When oily or
moisture laden particles stick to this metallic material
it reduces its ability to vibrate therefore reducing the
strength of the sound pulse.
Unlike the Sonic Tracker II, the Slope Sensor is a

sealed unit and contains no adjustments or user
serviceable parts. Once the Slope Sensor is mounted
to the paver, all calibration and/ or operating displays
are represented on the Control Box. The Slope
Sensor contains no displays or adjustments and once
the Slope Sensor is mounted to the paver, it is not
removed.
NOTICE: During normal operation, the

Sonic Tracker II should always have the
small piece of Filter Foam over the
Transducer assembly. This Filter Foam
will trap most of the contaminants that can
foul the Transducer. This Filter Foam
should be replaced at least every month.
Junction Box
The primary function of the Junction Box is to route
power and ground from the paving machine to the
Control Box, and to route correction signals from the
Sonic Tracker II and Slope Sensor to the Control
Box. It also routes valve signals from the Control
Box to the paving machine.
Over an extended period, very fine particles can pass

through the Filter Foam and stick to the Transducer
slowly reducing its sound pulse. When this happens
21048 (12/95)
20
A Terex Company
System Four
CEDARAPIDS
MAT THICKNESS
EXTEND
INCREASE
2.
SLOPE
DECREASE
JUNCTION BOX
46061-551-19
MATCH HEIGHT
UP
MAN
1.
DOWN
MAT THICKNESS
SET-UP
INCREASE
DECREASE
STOP
MAN
SET-UP
STOP
FEED
STOP
The Junction Box is a sealed unit and contains no

adjustments or user serviceable parts. It allows for
quick and easy attachment and removal of the system
cables, and once installed on the paving machine it
is not removed.
OVER
RIDE
1) The MAN/SET-UP/AUTO controls the

function modes listed:
Power & Interlock (Screed Remote Controls)

Located on the left and right Screed Remote Control
boxes are two switches that provide manual operation
of the tow point cylinders or allow function of the
System Four automation. The left and right Mat
Thickness switches are independent of each other
and control only the tow point function of its
respective side.
MAN/SET-UP/AUTO switch in MAN

mode: Power is provided to the INCREASE/
DECREASE switch. The System Four
automation will not control the tow point
cylinder in this mode(isolation relay is open).
MAN/SET-UP/AUTO switch in SET-UP
mode: The System Four automation can drive
the tow point cylinder with the paver stopped
or moving (isolation relay is closed). The
INCREASE/DECREASE switch will not work
in this mode.
MAN/SET-UP/AUTO switch in AUTO
mode: Function of the System Four automation
is interlocked to the travel system. When the
paver is moving forward, the isolation relay is
closed the automation is allowed to drive the
tow point cylinder. As the travel lever (s) or the
21048 (12/95)
21
A Terex Company
System Four
CABLE Coil Cord

junction box to Burner
46061-551-21
CABLE Coil Cord

junction box to Burner
46061-551-21
LH Isolation Relay
(46325-001-52)
located inside console
RH Isolation Relay
(46325-001-52)
located inside console
Forward/Neutral/Reverse switch are placed in

neutral or the brake switch is engaged. The
isolation relay is opened, preventing the
automation from driving the tow point cylinder.
1) Solenoid Valve: Used to direct hydraulic fluid

to either the rod or base ports of the tow point
cylinder. The valve has a manual override on
each end for trouble-shooting purposes.
2) The INCREASE/DECREASE switch allows

manual positioning of the tow point cylinder
when the MAN/SET-UP/Auto switch is in the
MAN mode.
2) Dual Throttle Valve: Used to set cylinder

travel speed for both directions to 18 seconds.
3) Holding Valve: Used to hydraulically lock the
tow point cylinders.
Burner Control Console Components

The Burner Control Console has cable connection
points on the top LH & RH to connect the System
Four junction box to the respective tow point solenoid
valve.
Left Tow Point Valves
LH Front Bulkhead Valves
The isolation relays for each side are located inside

the console.
3.
Tow Point Valves

Right Tow Point Valves
2.
RH Front Bulkhead Valves
1.
cylinder. The valve has a manual override on
each end for trouble-shooting purposes.
3.

2.

1.
21048 (12/95)
22
A Terex Company
System Four
Solenoid Valve Din Connectors
Red LED (light) located
inside each connector
Din Connectors
Manual Override
Buttons
Each solenoid valve electrical connector (Din

Connector) has a red LED (light) located inside the
clear connector cap. This LED is used for troubleshooting purposes.
21048 (12/95)
23
A Terex Company
System Four
Getting Started
This chapter is designed to get the operator started
using System Four. Before starting however,
decisions have to be made as to the type of control to
be used Sonic Tracker II for longidudinal grade
elevation, or Slope Sensor for controlling transverse
slope and whether the controls should be placed to
enhance rideability or build profile, see Building
Rideability or Profile.
Place Tracker II
14" above
reference
If elevation control is to be used, a control reference

must be decided upon (Fixed Stringline, Surface
String, Existing Mat, Ski etc.). (For information on
setting control references, see Control References.
Target Sonic Tracker II

Over Target Reference
(ski, stringline, curb, or
existing mat)
Target Reference
4) Turn the Grade Adjustment Knob on the

Control Box in the direction the arrows indicate
until the On Grade Bar comes on:
Once these factors have been chosen and System

Four has been installed on the paver use the following
steps to Null and Calibrate the System Four and
begin a paving session.
Getting an On Grade Bar: (NULLING)
Sonic Tracker II Control
To set the Sonic Tracker II to On Grade or Null:
AUTO
M
A
N
OR UNTIL=
1) Set the Auto/

Manual/Survey
switch to Manual
SURVEY
(CAL)
OR:
2) Make sure that the

Power Switch is set
to Sonic Tracker
Control
a) Momentarily hold the Auto/Manual/Survey

switch down until it beeps (This will place the
Control Box in the Survey mode)
b) Momentarily hold the switch down again until
it beeps (This will place the Control Box back
to the control mode (NULL) and the On
Grade Bar will be set)
3) Place the Sonic Tracker II over the control

reference
21048 (12/95)
24
A Terex Company
System Four
AUTO
M
A
N
BEEP
&
SURVEY
(CAL)
THEN
OR UNTIL=
AUTO
M
A
N
BEEP
&
SURVEY
(CAL)
For more information on Control Box settings see

Functions.
Slope Control
To set the Slope Control to On Grade or Null:
AUTO
M
A
N
OR
A) Momentarily hold the Auto/Manual/Survey
(Cal) switch down until it beeps (This will
place the Control Box in the Survey mode)
1) Set the Auto/

Manual/Survey
(Cal) switch to
Manual
B) Momentarily hold the switch down again until

it beeps (This will place the Control Box back
to the control mode and the On Grade or
(NULL) Bar will be set)
SURVEY
(CAL)
2) Make sure that the

Power Switch is set
to Slope Control
AUTO
M
A
N
BEEP
&
SURVEY
(CAL)
THEN
AUTO
M
A
N
NOTICE: Only one side of the paver should

be in the slope mode.
Control Box in the direction the arrows indicate
until the On Grade Bar comes on:
21048 (12/95)
BEEP
&
SURVEY
(CAL)
For more information on Control Box settings

Functions.
25
A Terex Company
System Four
Setting Control Box Display (Changing
Numbers ONLY):
Sonic Tracker II Control
3) While holding the Auto/Manual/Survey (Cal)

switch down, turn the grade adjustment knob
until the slope being laid is displayed
To set the Control Box Display to a desired number:
M
A
N
1) Follow instructions listed in Getting an On

Grade Bar: (NULLING) to get the Tracker II
over the control reference and get it NULLED
(on grade bar showing).
M
A
N
4) Release the Auto/Manual/Survey (Cal) Switch.

The slope entered will remain on the display
and the On Grade symbol will be.
SURVEY
(CAL)
5) Place Auto/Manual/Survey (Cal) Switch in

Auto mode.
3) Release the Auto/Manual/Survey (Cal) Switch
NOTICE: When using slope control, never

adjust the screed using the manual hand
cranks. Adjustments using the hand cranks
will require re-calibrating the Slope Sensor.
4) The number entered will remain on the display

and the On Grade symbol will be set
5) Place Auto/Manual/Survey (Cal) Switch in
Auto mode.
Getting Started Paving
NOTICE: The number display does not

necessarily reflect mat depth being placed
and should not be used to control depth.
1) Pre-heat the screed to the temperature of the

material being delivered. A cold screed bottom
will tear and drag causing the mat depth to be
lower than desired (a depression).
NOTICE: When using grade control, never

cranks.
2) If a transverse joint is to be created the quality

and durability of the joint depends on careful
preparation of the existing mat or lane. It is
critical that any taper or defective area be
removed. The joint area has to be perfectly
flat and parallel with the line of paving! If
not, a depression or bump will be produced.
Refer to Transverse Joint in this chapter
Slope Sensor Calibration

To Calibrate the Slope Sensor (Change number
readout to reflect percentage of slope being placed):
1) Pave manually using screed depth cranks until
desired percentage of slope has been established
2) Follow instructions listed in Getting an On
Grade Bar: (NULLING) to get the slope
control NULLED (on grade bar showing).
21048 (12/95)
NOTICE: Make sure to enter a positive

slope if the grade slopes Up to the right and
a negative slope if it slopes Down to the
right
System Four
SURVEY
(CAL)
2) While holding the Auto/Manual/Survey (Cal)

Switch down, turn the grade adjustment knob
until the desired number is displayed
AUTO
System Four
AUTO
3) Set initial tow point height in relation to mat

depth. Refer to Line of Pull in this chapter.
26
A Terex Company
System Four
Line of Pull Applied Parallel
to the Line of Paving
Place Tracker II
14" above
reference
4) Nulling the screed is traditionally done with

the use of boards that equal the desired loose
mat depth. Then a given amount (18 to 14) of
nose up attitude is introduced to the screed.
The boards needed should be equal to the
thickness of the loose or unrolled mat. The
number need will depend the width the screed
is set up to pave at. Generally 2 boards at 10'
wide, 4 boards at 20' and etc. The length of
each board should be such that the screed
bottom is fully supported from front to tail
when set on the boards.
Target Reference
8) Null the Control Box (s) to get an on grade bar.

Refer to Getting an ON Grade Bar (Nulling)
in this chapter.
9) Place the Auto/Manual/Survey switch(s) in
Auto and begin paving.
After the machine has traveled at least a few feet,
measure the mat thickness. Make mat thickness
changes by making small adjustments using the
Grade Adjustment Knob.
5) Null the screed, then manually preset the angle

of attack. Refer to Nulling the Screed in this
chapter
6) Fill auger chamber to exactly 1/2 an auger
level. Hand filling outboard ends of the screed
to prevent force feeding.
Controlling Yield
Take at least 5 checks about 5 foot apart and average

the checks. DO NOT adjust the screed depth after
each check. Doing so will produce a rough riding
surface. Remember the purpose of a paver is to place
a flat mat over an irregular grade.
7) Place the Sonic Tracker II(s) 14 inches over

the control reference. Refer to Control
References in this chapter.
21048 (12/95)
Target Sonic Tracker II

Over Target Reference
(ski, stringline, curb, or
existing mat)
NOTICE: For best performance, make

only small adjustments and let the paver
move several machine lengths before
making another adjustment.
27
A Terex Company
System Four
material & material design. Once the
compaction rate has been determined and the
correct thickness of lath has been acquired,
place the lath at the edge of the joint to elevate
& support the screed to the correct starting
level.
NOTICE: When using slope control, never

cranks. Adjustments using the hand cranks
will require re-calibrating the Slope Sensor.
Once satisfactory mat thickness has been reached,
you may want to set the Control Box LCD (Elevation)
to display that mat thickness.
Place boards or lath that equal the compaction rate

of the material from thickness of the joint.
The paver will now maintain the desired mat thickness

until another change is desired or the job is completed.
Transverse Joints
Transverse joints are created when an existing mat
or lane is to be continued. The quality and durability
of the joint depends on careful preparation of the
existing mat or lane. It is critical that any taper or
defective area be removed. The joint area has to be
perfectly flat and parallel with the line of paving! If
not, a depression or bump will be produced.
2) Back the paver up over the joint and align the

screed so the face or mold board is square with
the edge of the joint. Lower the screed onto the
boards or lath and adjust the screed depth
cranks so the screed is resting flat on the
boards.
Joint Preparation
An existing mat should be checked and the tapered
area removed to produce a joint area that is flat and
parallel with the line of paving.
Null Screed
(No angle of attack)
Checking the existing mat with a good straight edge
Remove
3) Using the screed depth cranks, introduce

approx. 1/8" to 1/4" initial angle of attack.
1/8" to 1/4"
Angle of Attack
Proper joint
area after
removing taper
Nulling the Screed

1) Place boards or lath that equal the amount of
compaction in the joint area. Remember
compaction rates change due to thickness of
21048 (12/95)
28
A Terex Company
System Four
4) The auger chamber should be filled to 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.
We see above a thin mat being placed, but the initial

tow point setting is extremely high. In this condition
the towing forces are being applied at a upward
angle, increasing the lift forces applied to the screed.
To maintain a given depth, the angle of attack must
be decreased to compensate for the increased lift.
The screed is now running with a slight nose down
attitude. Only the front portion of the screed is
compacting & finishing the material being placed,
causing poor mat texture & extreme wear at the front
portion of the screed bottom. Also, when the screed
stops, it will have more of a tendency to rock or teeter
as the tractor relaxes the tension on the screed. This
could increase the amount of settling & deviations
introduced to the mat.
Building Rideability or Profile
Evaluation of Jobs
Line of Pull
The Line of Pull refers to the angle at which the
screed is being towed forward. Best results occur
when the towing force is applied relatively parallel
to the grade. To do this we set the tow point cylinders
in relation to the general depth we will be paving.
Line of Pull Applied Parallel
to the Line of Paving
Evaluation of specifications and grade conditions on

a job is extremely important if the paver and
automation are to be configured properly to produce
the desired or required results. Failure to properly
configure the screed and automation for each phase
of the paving operation, or specific conditions, will
result in producing a road that is unsatisfactory or
will not meet specifications. Just as one size of shoe
does not fit everyone, one configuration of the
screed and automation will not produce superior
results in all conditions and jobs.
Building Profile
Rule of Thumb: Thin mats will require a lower

initial tow point setting, while thicker mats will
require a higher initial tow point setting.
The screed inherently resists immediate changes in

depth or slope and averages changes over
approximately five lengths of the tow arm. Job
specifications that require an exact profile (thickness
of material and or slope) at any given point in the
grade, require the screed to react very quickly to
maintain its position in relation to the established
line of grade and or percentage of slope. Very
simply, when building profile we are over correcting
the screed to force it into changing depth very
quickly to maintain exact thickness and or slope at
Line of Pull Applied Upwards

Can cause the screed to run with a
nose-down attitude.
21048 (12/95)
29
A Terex Company
System Four
given points in the grade. Building for profile is not
necessarily building a smooth rideable surface, as
any changes will be introduced very quickly.
Effective Length of Tow Arm

Automation sensors will always move the tow point
up or down to maintain the sensors null point, in
effect the location of the sensor becomes our control
point. The tow point becomes only a point from
which we raise or lower the tow arm to reestablish
the null point at the sensor. The effective length of
tow arm becomes the distance between the control
point (sensor) and the pivot point (trailing edge of
the screed). Because the screed must travel 5 tow
arm lengths to fully react to a correction, shortening
the effective tow arm length shortens the distance
the paver must travel to complete a correction,
therefore increasing reaction time. Moving the sensor
towards the screed increases reaction time (builds
profile), while moving the sensor towards the tow
point decreases reaction time (builds rideability).
Building for profile is desirable on jobs where two or

more layers of pavement will be placed or where
exacting slopes (transitions & super elevations) have
to be built or maintained. By reestablishing or
building the desired profile of a road on the first
layer, all other layers can be built for rideability or
smoothness.
Rideability
When building for rideability, automation enhances
the screeds resistance to immediate changes,
producing a very smooth riding surface. Very simply,
when building for rideability we are taking a given
change and stretching that change over a long area to
produce a superior riding surface. Building for
rideability is desirable where job specifications place
a high emphasis on the smoothness of the finished
job. On jobs where two or more layers of pavement
will be placed, the first layer should be built for
profile to get the grade and slope to proper elevation
specifications. All other lifts should be built for
rideability, to smooth out any deviations from the
previous lift.
Profile
(Rearward)
Rideability
(Foreward)
Effective Tow Arm Length
NOTICE: Never mount Tracker II behind

the center line of the augers. This could
cause severe over-correction.
Sensor Positioning
The position of the sensor on the tow arm determines
how fast the screed will react to a change of the null
point at the sensor. By positioning the sensor, we can
build profile or rideability. We need to evaluate job
specifications and grade related conditions to
determine the desired mounting position that will
produce the required results.
Control References
Grade Control (Joint Matching)
Joint matching or matching the height of the mat
being placed to an existing mat or curb, requires the
screed to be very responsive to any changes in the
elevation of the existing mat or curb. This is an
application where we are building Profile, or
over-correcting the screed, forcing it change depth
in a very short distance.
Rule: Sensor(s) mounted 1/4 the tow arm length

back from the tow point builds RIDEABILITY.
Sensor(s) mounted inline with the augers builds
PROFILE.

back from the tow point, or just ahead of the augers.
21048 (12/95)
30
A Terex Company
System Four
conditions will not permit running a ski beside the
screed. When paving at wide widths the over the
screed ski is mounted in close to the tractor, the
reference system being close to the tractor, provides
the automation a more precise reference in relation
to tow point deviations caused by grade conditions,
by virtue of being mounted close to the tractor.
Problems of flexing mounting hardware simply do
not exist due to the close mounting position. The
Cedarapids Over the Screed Ski system provides a
true independent mounted ski reference system that
is not effected by the tractor traveling over irregular
grades and provides a very consistent reference
plane for the grade sensory system.
With the sensor mounted close to the screed, it is

very responsive to any deviation in the screeds
position, though not very responsive to deviations of
the tow point position, caused by the tractor traveling
over irregular grades. Therefore it is not anticipating
these deviations , it can only react when a deviation
of the tow point position affects the position of the
screed.
Grade Control (Ski)
When using automation off a ski, corrections to
deviations that occur at the sensor or the screed, will
require the paver to travel approximately 5 lengths
of the tow arm before the correction is fully
completed. Deviations that occur at the tow point,
due to the tractor traveling over irregular grades, are
corrected for immediately. In effect the sensor is
correcting for deviations at the tow point before they
can affect the screeds angle of attack (position). In
this application we are building Rideability, or
area.
Mount the Sonic Tracker II 14 inches above the top

wire. A piece of 1/8 tubing should be placed over
the wire to increase its reflective surface for best
results.

back from the tow point. With the sensor mounted in
the forward position, any deviation at the tow point
caused by the tractor traveling over irregular grades,
will cause the sensor to react immediately, to correct
for that deviation. Therefor maintaining the same
tow point position (angle of attack on the screed) in
relation to the reference (ski), regardless of the grade
irregularities.
14"
Ski Wire
Averaging Ski
1/8" Tubing Or Tape Wraped
Over the Screed Ski

The over the screed ski is the preferred reference
system when paving wide widths or where job
21048 (12/95)
31
A Terex Company
System Four
Existing Surface
Surface Stringline
The Sonic Tracker II can follow nearly any existing

surface. Simply place the Sonic Tracker II 14 to 24
inches above the surface. Get an On Grade Bar
(Refer to Getting an On Grade Bar Sonic Tracker II
Control earlier in this chapter), switch the Control
Box to Auto and start paving.
A Surface Stringline is stretched over a given length

of grade. It rests on the high places and bridges the
low, creating an average over a distance as long as
1500 feet. Since the Sonic Tracker II is noncontacting, it can track Surface Stringline without
deflecting it, producing an average of the surface.
Surface Stringlines can produce acceptable results
in low specification type jobs, but traditionally are
not used in very demanding or high specification
jobs.
Notice: Using automation to follow existing

surfaces is NOT RECOMMENDED as
every deviation in the existing surface will
be introduced into the mat being placed.
Once Surface Stringline is in place, all you need to

do is line up the Sonic Tracker II 14 to 18 inches
above the string, get an On Grade Bar and switch to
Auto.
Curb or Gutter
A curb or gutter that is poured before paving can be
used as a reference. Simply line the Sonic Tracker
II 14" above the curb or gutter edge and get an On
Grade Bar. Switch the Control Box to Auto and start
paving.
Notice: Curbs and gutters make a very poor
reference if smoothness of the placed mat is
of concern. This is due to the variations in
elevation along the length of the curb or
gutter.
21048 (12/95)
32
A Terex Company
System Four
Slope Conversion Table
Slope
Actual Approx.
decimal fraction
inch per inch per
ft.
ft.
Inch
per
10 ft.
Inch
per
11 ft.
Inch
per
12 ft.
Inch
per
13 ft.
Inch
per
14 ft.
Inch
per
15 ft.
Inch
per
16 ft.
Inch
per
17 ft.
Inch
per
18 ft.
Inch
per
19 ft.
Inch
per
20 ft.
0.10%
.012
1/64
1/8
1/8
5/32
5/32
5/32
3/16
3/16
7/32
7/32
7/32
1/4
0.13%
.015
1/64
5/32
5/32
3/16
3/16
7/32
7/32
1/4
1/4
9/32
9/32
5/16
0.20%
.024
1/32
1/4
1/4
9/32
5/16
11/32
3/8
3/8
13/32
7/16
15/32
15/32
0.26%
.031
1/32
5/16
11/32
3/8
13/32
7/16
15/32
1/2
17/32
9/16
19/32
5/8
0.30%
.036
3/64
3/8
13/32
7/16
15/32
1/2
17/32
9/16
5/8
21/32
11/16
23/32
0.40%
.048
3/64
1/2
17/32
9/16
5/8
11/16
23/32
25/32
13/16
7/8
29/32
31/32
0.50%
.060
1/16
19/32
21/32
23/32
25/32
27/32
29/32
31/32
1-1/32
1-3/32
1-1/8
1-3/16
0.52%
.062
1/16
5/8
11/16
3/4
13/16
7/8
15/16
1-1/16
1-1/8
1-5/16
1-1/4
0.60%
.072
5/64
23/32
25/32
7/8
15/16
1-3/32
1-5/32
1-7/32
1-9/32
1-3/8
1-7/16
0.78%
.093
3/32
15/16
1-1/32
1-1/8
1-7/32
1-5/16
1-13/32
1-1/2
1-19/32
1-11/16
1-25/32
1-7/8
0.80%
.096
3/32
31/32
1-1/16
1-5/32
1-1/4
1-11/32
1-7/16
1-17/32
1-5/8
1-23/32
1-13/16
1-29/32
1.0%
.120
1/8
1-3/16
1-5/16
1-7/16
1-9/16
1-11/16
1-13/16
1-29/32
2-1/32
2-5/32
2-9/32
2-13/32
1.5%
.180
3/16
1-13/16
1-21/32
2-5/32
2-11/32
2-17/32
2-11/16
2-7/8
3-1/16
3-1/4
3-13/32
3-19/32
2%
.240
1/4
2-7/16
2-5/8
2-7/8
3-1/8
3-3/8
3-19/32
3-27/32
4-3/32
4-5/16
4-9/16
4-13/16
3%
.360
3/8
3-5/8
3-31/32
4-5/16
4-11/16
5-1/32
5-13/32
5-3/4
6-1/8
6-15/32
6-27/32
6-3/16
4%
.480
15/32
4-13/16
5-9/16
5-3/4
6-1/4
6-23/32
7-3/16
7-11/16
8-5/32
8-5/8
9-1/8
9-19/32
5%
.600
19/32
6-19/32
7-3/16
7-13/16
8-13/32
9-19/32
10-3/16
10-13/16 11-13/32
6%
.720
23/32
7-3/16
7-29/32
8-5/8
9-3/8
10-3/32
10-13/16 11-17/32
12-1/4
12-31/32 13-11/16 14-13/32
7%
.840
27/32
8-13/32
9-1/4
10-3/32
10-29/32
11-3/4
12-19/32
13-7/16
14-9/32
15-1/8
8%
.960
32/32
9-19/32
10-9/16
11-17/32 12-15/32
13-7/16
14-13/32
15-3/8
16-5/16
17-9/32
9%
1.08
1-3/32
10-13/16
11-7/8
12-31/32
15-1/8
16-3/16
17-9/32
18-3/8
19-7/32
10%
1.20
1-3/16
12
13-3/16
14-13/32 15-19/32 16-13/16
18
19-3/16
20-13/32 21-19/32 22-13/16
11%
1.32
1-5/16
13-3/16
12%
1.44
1-7/16
14-13/32 15-27/32
14-17/32 15-27/32
17-9/32
14-1/32
17-5/32
18-15/32 19-13/16
21-1/8
22-7/16
18-23/32
20-5/32
23-1/32
24-15/32 25-29/32
21-19/32
23-3/4
All figures in feet are measured horizontally.

All figures in inches should be measured vertically and accurately to within 1/32 inch.
21048 (12/95)
33
12
15-21/32 16-13/16
18-1/4
19-3/16
20-17/32 21-19/32
24
25-3/32
26-13/32
27-3/8
28-13/16
A Terex Company
System Four
Maintenance and Parts
If the Transducer appears to be covered with

debris and performance is being affected (see
Lower Sonic Tracker II Components in
Function) replace the Transducer using the
steps listed later in this chapter.
This section contains information regarding

preventative maintenance and daily care of System
Four. Also included are:
1) An Illustrated Parts Guide
Illustrated Parts Guide

Using the chart below, match the item number of the
part located on the illustration to the item numbers
listed on the chart below. The chart is divided into
three categories: Component Assemblies, Bracket
Assemblies, and Kits. For cable part numbers see
Illustrated Cable Guide later in this chapter
2) An Illustrated Cable Guide

3) Replacement procedures for the Sonic Tracker
II Transducer
4) Wiring Diagram
Preventative Maintenance & Daily Care
A good Preventative Maintenance and Daily Care
routine will prevent many problems before they
occur. The most important part of Daily Care for
System Four is to clean it and keep it free of debris,
and to thoroughly dry removable components (Sonic
Tracker IIs, Control Boxes, and cables) before
storing them in the Carrying Case. In addition, the
following procedures will ensure trouble free
operation:
Component Assembly Part Numbers
1) Keep the Carrying Case clean and dry. Do not

leave it open and exposed to the elements.
Clean and dry all components prior to placing
them in the Carrying Case.
Part #
Part Description
Qty
46061-551-10
Control Box
46061-551-09
Sonic Tracker II
46061-551-02-01
Temperature Bail
46061-551-18
Slope Sensor
46061-551-19
4-Way Junction Box
Bracket Assembly Part Numbers
2) Be sure protective connector caps, provided

on the Junction Box, are in place when the
cables are not in use. Water accumulating on
the connectors can cause electrical shorts.
46061-551-11
Asm., Sonic Tracker II Mtg. Bracket
10
46061-511-38
Bracket, Tracker End Gat Mtg.
11
46061-551-37
Bracket, Tracker Tow Arm Mtg.
12
46061-551-27
Arm, Tracker Swing (Short)
13
46061-551-28
Arm, Tracker Swing (Long)
Kit Part Numbers
3) The components can be used in the rain or light

spraying but are not submergible. Do not
spray water or use high pressure steam cleaner
hoses directly on cables and components.
4) Check the Sonic Tracker II Transducer daily to
make sure the Filter Foam and Transducer are
clean and free of debris. If the Filter foam is
clogged with dirt, replace it (see Illustrated
Parts Guide for Filter Foam re-order part
number).
21048 (12/95)
Item
34
46061-551-02-02
Kit, Transducer Replacement
46061-551-02-03
Filter Foam, Box of 10 Transducer
46061-551-12
Kit, .75" Sonic Tracker II Mtg. Bolt
A Terex Company
21048 (12/95)
35
13
12
11
10
Illustrated Parts Guide
AUTO
11
AUTO
12
13
System Four
A Terex Company
System Four
21048 (12/95)
SONIC GRADE SENSOR
LEFT SOLENOID VALVE & TOW POINT CYL.
36
CONTROL BOX
CONTROL BOX
JUNCTION BOX
SLOPE
SENSOR
BURNER
CONTROL
BOX
MAIN
JUNCTION BOX
JUNCTION BOX
SONIC GRADE SENSOR
RIGHT SOLENOID VALVE & TOW POINT CYL.
Illustrated Cable Guide

Using the chart below, match the item number of the
cable located on the illustration to the item numbers
listed on the following page.
A Terex Company
System Four
System Four Cable Numbers
NOTICE: Always remove and discard used

O-Rings. Used O-Rings will be distorted
and may loose their elasticity due to weather
or exposure to diesel fumes.
Cable Part Numbers

Item
Part#
46061-551-21
Coil Cord, Power
46061-561-07
Coil Cord Sonic Tracker

to Junction Box
46061-551-08
Cable Control Box to

Junction Box (44")
46061-551-16
Cable Junction Box to

Slope Sensor (3')
46061-551-17

Slope Sensor (8')
46061-551-20

Slope Sensor (20')
Part Description
Qty
3) The Transducer can now be gently pulled out.

Use a SMALL pair of wire cutters to gently cut the
Ty-Wrap then remove the small wire connectors
from their tabs.
NOTICE: When cutting the Ty-Wrap, be
careful not to cut or damage the wires.
Transducer Replacement Procedure

NOTICE: If the Sonic Tracker II is
experiencing erratic or inconsistent
readings, Transducer contamination should
be considered first before assuming any
other type of failure. The most common
sign of Transducer contamination is the
ability of the Sonic Tracker II to see the
ground, but not a Stringline.
4) Place the wire connectors of the new Transducer

firmly on their tabs (the gray wire connector is
placed on the elevated tab). Place the TyWrap in the slot next to the elevated (gray
wire) tab, tighten and trim. DO NOT pinch the
wires.

The only tools needed are a Philips screwdriver and
a small pair of cutters. Replace the Transducer as
follows:
TRIM EXCESS
TY-WRAP
1) Remove and discard

the Filter foam (a
new Filter foam is
provided in the
Transducer
Replacement Kit).
CAREFULLY PLACE
WIRE CONNECTORS
ON TABS
PLACE NEW TY-WRAP

AROUND WIRES
AND TIGHTEN
5) Feed the wires back up into the Sonic Tracker

II and seat the Transducer into place (the two
wire tabs have to sit down into the extra deep
area of the recess). Place the new O-ring
around the Transducer and seat firmly between
the Transducer and the Sonic Tracker II
Transducer recess.
2) Remove the 4 screws that secure the black

Retaining Ring and remove the Retaining Ring,
(4 replacement screws are supplied in the
Transducer Replacement Kit , but it is advisable
to use the original screws and keep the 4
supplied in the kit for replacements in the
event one or more are lost). Remove and
discard the O-Ring (a new O-Ring is supplied
with the Transducer Replacement Kit).
21048 (12/95)
CAREFULLY
REMOVE WIRE
CONNECTIONS
CUT
TY-WRAP
37
A Terex Company
System Four
9) Place a NEW Filter Foam over the Transducer.
The Sonic Tracker II is now ready to return to
operation.
Connector and Wiring Diagram
The electrical diagram shows which wires and pins
are used in each components connector.
TRANSDUCER
WIRE CONNECTOR PINS
The diagram may also be used to determine the

specific part number of a cable needed to connect to
a specific paver. Simply find the cable on the
diagram, then use the Cable Specification Chart to
determine the part number for the cable to your
paver.
6) Place the black Retaining Ring over the

Transducer assembly with the beveled edges
out and the flat surface against the Sonic Tracker
II base. Lineup the holes for the mounting
screws (the mounting screw holes are set to an
irregular pattern. This ensures the retaining
ring will only line up with the mounting holes
one way).
7) Start the mounting screws into the holes and
tighten each until firm. DO NOT OVER
TIGHTEN. Use a cross (X) pattern to tighten
screws.
NOTICE: Over tightening may distort the
Transducer metallic material and may crack
the Retaining Ring. Use of the O-Ring
assures tightness while preventing vibration
from loosening the Mounting Screws.
NOTICE: DO NOT use Loctite on the
mounting screws. Loctite will attack the
plastic retaining ring.
8) Make sure no wrinkles in the metallic surface

is visible inside the Transducer. If distortion is
evident repeat Steps 5 through 8.
21048 (12/95)
38
21048 (12/95)
Connector and Wiring Diagram

COMM A
A
B
C
D
AUTO/MAN E
VBATT
F
RAISE
G
VSWITT
H
J
LOWER
K
GROUND
CONFIG
L
C
O
N
N
A
B
C
D
E
F
G
H
1 J
K
L
C
O
N
N
CONTROL
BOX
LEFT SIDE
CONTROL
BOX
RIGHT SIDE
COMM A
COMM B
AUTO/MAN
VBATT
RAISE
VSWITT
LOWER
GROUND
CONFIG
3
A BCDE F G HJ KL
CONN 3
A BCDE F G HJ KL
CONN 3
39
CONFIG
C
O
N
N
JUNCTION BOX
LEFT SIDE
A
B
C
D
E
F
G
H
COMM A
COMM B
VSWIT
GROUND
COMM A
COMM B
VSWIT
GROUND
CONFIG
CONFIG
A
B
C
D
E
F
G
H
JUNCTION BOX
RIGHT SIDE
COMM A
COMM B
VSWIT
GROUND
CONFIG
CONN 1
LKJ HG F E DCBA
CONN 1
A B C D E F G H J KL
COMM A
COMM A
A
B
C C
O D
N
N
C
O
N
N
COMM A
COMM B
853 OHMS
853 OHMS
COMM A
VSWIT
A
B
C
D
E
F
G
COMM A
COMM A
C
O
N
N
2
C
O
N
N
DUAL PORT
SLOPE SENSOR
A
B
C
D
E
F
G
GROUND
CONFIG
A
B
C
D
E
F
G
H
I
SCREED JUNCTION
BOX
C
O
N
N
SONIC
TRACKER II
RIGHT SIDE
GROUND
VBATT
RAISE
LOWER
A
B
C
D
E
F
G
H
J
K
L
A
B
C
D
E
F
G
H
I
GROUND
VBATT
RAISE
LOWER
JUNCTION BOX CONNECTOR

CONN 1 PINOUT
A
B
C
D
E
F
G
H
J
K
L
COMM A
COMM B
JOG UP
JOG DOWN
AUTO/MANUAL
VBATT
RAISE
VSWIT
LOWER
GROUND
CONFIG
A Terex Company
LEFT SIDE
A
B
C C
D O
N
N
System Four
SONIC
TRACKER II
C
O
N
N
A
B
C
D
E
F
G
H
J
K
L
COMM A
COMM B
VSWIT
GROUND
A Terex Company
System Four
Troubleshooting
System Checkout Grade
Set-Up
1) Place the screed on the ground
2) Turn off engine. Ensure all switches are in the
OFF position and the Brakes are Engaged.
Observe the following:
3) Mount all System Four components on the

machine and attach all connectors properly.
1) The Control Box should give a single audible

beep.
4) Position the Sonic Tracker II 14 inches above

the ground. Install the Temperature Bail on
both Sonic Tracker II
2) The LCD Digital/Symbol Display should come

on.
5) Start engine and let idle.
a.A digital number should appear.
6) Switch the Auto/ Manual/ Survey(Cal) switch

to Manual on both control boxes.
System Four
AUTO
M
A
N
This is a software revision number.
SURVEY
(CAL)
b. A configuration number should appear next.
SystemFour
7) Place screed remote Mat Thickness Man/Setup/
Auto switches in SETUP on both sides of the
screed.
MAT THICKNESS
NOTICE: The display should always show

c009 as the configuration. If any thing
other than this appears it is an indicator of
a bad power cable or damaged junction
box.
INCREASE
DECREASE
c. The digital display should momentarily

display an ERR.
MAN
SET-UP
System Four
STOP
8) On the right control box, switch the Elevation:

Power / Off/ Slope: Power Switch to Elevation.
21048 (12/95)
40
A Terex Company
System Four
1) Adjust the Grade Adjustment Knob on the
Control Box in the direction indicated by the
Grade Adjustment Arrows until the On Grade
symbol illuminates.
NOTICE: If ERR is displayed

continuously, the control box is not able to
communicate with the Sonic Tracker II.
Check the cable and connections.
d. The Tracker symbol in the lower right
corner of the LCD display should appear.
System Four
OR
System Four
UNTIL=
==========
OR

3) Grade Correction Display may show an UP,
DOWN, ON GRADE or no light indicators.
Also Grade Adjustment Arrows around the
Grade Adjustment Knob should appear if the
Correction Display is not showing ON
GRADE.
1) The Sonic Tracker II and Control Box, Grade

Correction Display should show On Grade.
4) Temperature Bail symbol should be displayed

on the Sonic Tracker II display.
System Checkout Slope

1) Switch the Elevation: Power / Off / Slope:
Power Switch to Slope.
TOPCON
T
NOTICE: A transducer is failing if the
Sonic Tracker II Bail indicator does nor
appear while the bail is installed.
5) The Sonic Tracker II Transducer should emit
a ticking sound.

1) The Control Box should give a single audible
beep.
2) The LCD Digital/Symbol Display should come
on.
TICK
21048 (12/95)
41
A Terex Company
System Four
a. A digital number should appear.
4) Grade Correction Display may show an UP,

DOWN, ON GRADE or no light indicators.
Also Grade Adjustment Arrows around the
Grade Adjustment Knob should appear if the
Correction Display is not showing ON
GRADE.
System Four
This is a software revision number.

b. A configuration number should appear next.
SystemFour
1) Turn the Adjustment Knob on the Control Box
in the direction indicated by the Grade
Adjustment Arrows until the On Grade symbol
illuminates.
NOTICE: The display should always show

c009 as the configuration. If any thing
other than this appears it is an indicator of
a bad power cable or damaged junction
box.
OR
c. The digital display should momentarily

display an ERR.
UNTIL=

1) The Control Box, Grade Correction Display
should show On Grade.
System Four
NOTICE: If ERR is displayed

continuously, the control box is not able to
communicate with the Sonic Tracker II.
Check the cable and connections.
Switch the right control box OFF. Repeat System
Checkout procedures for both grade and slope on the
left side of the paver.
3) LCD Digital/Symbol Display should come on

a. The (+ Slope) or (-Slope) should be on. A
digital slope number should appear and the
% symbol should appear.
System Four
SystemFour
21048 (12/95)
Operating Checkout Grade

Set-Up
OR

42
A Terex Company
System Four
UNTIL=
OR
4) Position the Sonic Tracker II 14 inches above

the ground. Install the Temperature Bail on
both Sonic Tracker II
10) Switch the Auto/Manual/Survey(Cal) Switch

to AUTO.

to Manual.
AUTO
M
A
N
AUTO
M
A
N
SURVEY
(CAL)
SURVEY
(CAL)

1) The tow point should move up

screed.
2) The Grade Correction Display should indicate

On Grade when the cylinder stops moving.
MAT THICKNESS
INCREASE
+
DECREASE
MAN
1) Switch the Auto/Manual/ Survey (Cal) Switch

to Manual
SET-UP
STOP
AUTO

Power / Off/ Slope: Power Switch to Elevation.
M
A
N
SURVEY
(CAL)
2) Adjust the Grade Correction Display for a

Down correction
9) Using the Grade Adjustment Knob, adjust the

Grade Correction Display for an Up correction.
21048 (12/95)
43
A Terex Company
System Four
OR
AUTO
UNTIL=
M
A
N
SURVEY
(CAL)
3) Switch the Auto / Manual / Survey (Cal) Switch

to Auto

screed.
AUTO
M
A
N
MAT THICKNESS
SURVEY
(CAL)
INCREASE

DECREASE
1) The tow point should move down
MAN

SET-UP
STOP

Power / Off/ Slope: Power Switch to Slope.
Operating Checkout Slope

Set-Up
8) Using the Grade Adjustment Knob, adjust the

Grade Correction Display for an Up correction.

OR
UNTIL=

to Manual.
to AUTO.
21048 (12/95)
44
A Terex Company
System Four
AUTO
1) The tow point should move down
M
A
N

SURVEY
(CAL)

1) The tow point should move up

System Performance Operational Check

to Manual on both control boxes.
AUTO
M
A
N
1) Switch the Auto/Manual/ Survey (Cal) Switch

to Manual
SURVEY
(CAL)
AUTO
M
A
N

screed.
SURVEY
(CAL)
2) Adjust the Grade Correction Display for a

Down correction
OR
MAT THICKNESS
INCREASE
UNTIL=
DECREASE
MAN
3) Switch the Auto / Manual / Survey (Cal) Switch

to Auto
SET-UP
STOP
AUTO
3) Switch the Elevation: Power / Off / Slope:

Power Switch to Slope.
M
A
N
SURVEY
(CAL)
21048 (12/95)
45
A Terex Company
System Four
OBSERVE THE FOLLOWING TOW POINT
CYLINDER REACTION
4) Adjust the Grade Adjustment Knob on the

Control Box in the direction indicated by the
Grade Adjustment Arrows until the On Grade
symbol illuminates.
OR
The tow point cylinder should move to the new

position and stop.
If the tow point cylinder does not move, the
valve offset performance setting for that
direction of cylinder movement is too slow
and needs to be increased.
UNTIL=
If the tow point cylinder jumps a large distance

and has to come back before stopping, the
direction of cylinder movement is too Fast and
needs to be decreased.

to AUTO.
AUTO
M
A
N

Control Box one click counterclockwise.
SURVEY
(CAL)

Control Box one click clockwise.
OBSERVE THE FOLLOWING TOW POINT

CYLINDER REACTION
The tow point cylinder should move to the new

position and stop.
21048 (12/95)
46
A Terex Company
System Four
Symptom 2 - Control Box LCD Digital/Symbol
Display reads ERR.
If the tow point cylinder does not move, the

direction of cylinder movement is too slow
and needs to be increased.
Probable Cause
No communication with the sensor selected.
If the tow point cylinder jumps a large distance

and has to come back before stopping, the
direction of cylinder movement is too Fast and
needs to be decreased.
1) Check that all cables are properly connected to

System Four
2) Disconnect cables and inspect them for damage
or contamination. Clean all connections with
a commercial De-Greaser /Cleaner
IF NECESSARY READJUST VALVE OFFSET

PERFORMANCE SETTING AND REPEAT
SYSTEM PERFORMANCE OPERATIONAL
CHECKS
3) If slope has been selected, check that slope had

not been selected on the other Control Box
4) If elevation has been selected, swap the Sonic
Tracker II and/or Cables with unit from opposite
side to determine if symptom continues
Symptom Quick Reference

1) Control Box LCD Digital/Symbol Display
does not come on
Symptom 3 - Cannot adjust to on grade when

elevation control is selected.
2) Control Box LCD Digital/Symbol Display

reads Err
Probable Cause
Tracker is too close to control reference.
3) Cannot adjust to On Grade when Elevation

control is selected
1) Check that the Sonic Tracker II is at least 14

inches away from the control reference
4) Tow point cylinder does not move Up or Down
2) Check for contamination on Sonic Tracker II.

Transducer. Refer to Transducer and Filter
replacement information in Maintenance and
Parts
5) Tow point cylinder moves too fast or too slow

6) Cross slope being placed is not correct
Troubleshooting Procedures
Symptom 1 - Control Box LCD Digital/Symbol
Display does not come on.
3) Swap the Tracker with the unit on the opposite

side to determine if the symptom continues
Probable Cause
Symptom 4 - Tow point cylinder does not move up

or down.
No power to Control Box.

1) Check that machine power is on and all switches
for automatic control are in the proper position
Probable Cause
Paver electrical switches are not in the proper position
or hydraulics to the cylinder are not active.
2) Check that all cables are properly connected to

System Four
1) Check that all paver electrical switches are in

the correct position for automatic control.

a commercial De-Greaser / Cleaner
2) Check hydraulic system is functioning

properly.
4) Swap Control Box with the unit from the other

side to see if the symptom continues.
21048 (12/95)
47
A Terex Company
System Four
LH Electrical Automatic Screed Control
3) Check that the Auto / Manual / Survey (Cal)

Switch is in Auto and that the Auto symbol is
illuminated on the front panel
12 VDC
12 VDC - FORWARD ONLY

a commercial De-Greaser /Cleaner
MAT THICKNESS
47
AUTO
SET
46
152
L.H.AUTO ISOLATION RELAY

14
LAI
13
MAN
152
INC 155B
150
5) Swap the Control Box with the unit on the

opposite side to determine if the symptom still
exists
DEC 157B
157B
150
46
3
155B
A
B
C
D
E
F
G
H
I
J
Symptom 5 - Tow point cylinder moves too fast or

too slow.
Probable Cause
System Performance Settings are not correct.
1) Adjust both the Gain, Deadband and Valve
Offset Performance Settings to there
recommended settings. Refer to Accessing
System Performance Settings
3
46
155A
157A
155A
157A
3
4
155A
12
157A
155
B SOL.
157
A SOL.
10 PIN RECEPTACLE FOR AUTO CABLE
Tow Point Cylinder Does Not Raise or Lower in

Manual
Man/Setup/Auto switch in Manual.
2) Tow Point valve timing set faster or slower

than 18 seconds.
Symptom 6 - Cross slope being placed is not correct.

Probable Cause
If Non-functional, refer to Hydraulic

Troubleshooting.
Calibration on Slope Sensor is incorrect.

1) Calibrate the Slope Sensor as described in

Slope Calibration in the Function section
If light is ON, check for 12VDC across solenoid

coil (pin I to pin 2);
2) Check that the Transverse Beam is mounted

properly with no looseness or damage.
3) Re-check grade using a good reference such as

a laser or level

If No Light;
4) Pavers mat thickness controls have been used.
Check for 12VDC from 155 to 3 with switch in

Increase, 157 to 3 with switch in Decrease.
If no voltage, check 155B to 3 in Increase,
157B to 3 in Decrease.
If voltage, check 152 to 3. Shouldn't have any
voltage.
Replace Man-Setup-Auto switch if voltage
present. Replace Isolation Relay if no voltage.
21048 (12/95)
48
A Terex Company
System Four
RH Electrical Automatic Screed Control
12VDC 12VDC - FORWARD ONLY
If NO voltage, check/replace Man/Setup/Auto

switch.
47
46
MAT THICKNESS
R.H. AUTO ISOLATION
AUTO
13
14
SET 162
RAI
MAN
162
RELAY
3
INC 165B
160
DEC 167B
167B
160
Topcon Control Does Not Raise or Lower Tow

Point in Manual or Auto
46
165B
A 3
46
B
165A
C
167A
D
167A
E
165A
If Topcon control will NOT power up when Grade

or Slope is selected;
Check for 12VDC from 46 to 3 in Main Screed
Box.
G
H
I
J

If voltage, check for 12VDC from pin F to pin
K at Controller power cable.
3
4
165A
167A
12
165
B SOL.
167
A SOL.
Tow Point Cylinder Does Not Raise or Lower in

Manual
If voltage, proceed to Topcon Troubleshooting.
Man/Setup/Auto switch in Manual.
If Topcon control powers up when Grade or Slope is

selected but valves will not operate;

If Non-functional, refer to Hydraulic
Troubleshooting.
Check for 12VDC from 155A for UP, 157A for

DOWN;
If NO voltage, proceed to Topcon

Troubleshooting.

If light is ON, check for 12VDC across solenoid
coil (pin I to pin 2);
If voltage, check for 12VDC from 155 for UP,

157 for DOWN;
If no voltage, check connection of DIN

connector.
If voltage, check Isolation Relay by switching

with RH Relay. Replace if defective.
If No Light;
Check for 12VDC from 165 to 3 with switch in
Increase, 167 to 3 with switch in Decrease.

switch.
If no voltage, check 165B to 3 in Increase,

167B to 3 in Decrease.
If voltage, check 162 to 3. Should not have any
voltage.
Replace Man/Setup/Auto switch if voltage
present. Replace Isolation Relay if no voltage.
21048 (12/95)
49
A Terex Company
System Four
Check other auxiliary functions for operation. (screed
raise/lower, any extend/ retract function, tow point
functions and etc.) If other functions work, this
indicates the problem is only in the effected function
and the general auxiliary system is working.

switch.
If paver is equipped with SCREED ASSIST, check

manual dump needle valve to insure it is closed. If
no other function is working, install a 3000 psi gauge
in the test port. Refer to pressure setting above for
each series of paver. If pressure can not be obtained,
check and clean suction strainer, check suction hose
Topcon Control Does Not Raise or Lower Tow

Point in Manual or Auto
If Topcon control will NOT power up when Grade
or Slope is selected;
Check for 12VDC from 46 to 3 in Main Screed Box.
Tow Point Will Not Increase
If voltage, check for 12VDC from pin F to pin

K at Controller power cable.

Tow point Increase/Decrease switch to the
INCREASE position.
If NO voltage, check wiring from Main Screed

Box.
Check for DIN connector light, if no light refer to

electrical troubleshooting.
If voltage, proceed to Topcon Troubleshooting.

If Topcon control powers up when Grade or Slope is
selected but valves will not operate;
If light is ON:
1) Refer to electrical for testing ground
connection.
Check for 12VDC from 165A for UP, 167A for

DOWN;
2) Press MANUAL OVERRIDE button on

solenoid valve.
If NO voltage, proceed to Topcon

Troubleshooting.
If tow point cylinder increases, defective solenoid.
If voltage, check for 12VDC from 165 for UP,

167 for DOWN;

1) Install a 3000 psi gauge in-line, between hose
going to rod end of cylinder and manifold
block. if full pressure reading but no cylinder
movement, plugged or defective holding valve.

If voltage, check Isolation Relay by switching
with LH Relay. Replace if defective.
2) Extend cylinder all the way, disconnect the

hose going to the ROD END of the tow point
cylinder. Carefully push the increase/decrease
switch to DECREASE. If fluid comes out of
the fitting on the cylinder, check cylinder for
blown piston packing.

switch.
Tow Point Hydraulic
Auxiliary System
21048 (12/95)
50
A Terex Company
System Four
Tow Point Cylinder Timing
Refers to the length of time it takes to extend or
retract the tow point cylinder. A dual hydraulic
throttle valve is adjusted so the extend and retract
stroke of the cylinder occurs in 18 seconds.
Tow Point Will Not Decrease

Tow point increase/decrease switch to the
DECREASE position.
Check for DIN connector light, if no light refer to
electrical troubleshooting.
Checking Cylinder Timing

1) Acquire two pieces of pipe 2 OD or greater
and 1 in length.
If light is ON:
1) Refer to electrical for testing ground
connection.
2) Place the pieces of pipe under each end of the

screed.
2) Press MANUAL OVERRIDE button on

solenoid valve.
If tow point cylinder decreases, defective solenoid.
1) Install a 3000 psi gauge in-line, between hose
going to base end of cylinder and manifold
block. If full pressure reading but no cylinder
movement, plugged or defective holding valve.
Place pipe on each

side of screed and
in center of screed
3) Center both tow point cylinders at 6 on the

number scale.
2) Retract cylinder all the way, disconnect the

hose going to the BASE END of the tow point
switch to INCREASE, If fluid comes out of the
fitting on the cylinder, check cylinder for blown
piston packing.
Center

Tow Point Cylinder Drifts Up or Down
4) Set engine at Full Throttle.
5) On the right side retract the tow point cylinder

fully.
Check DIN connectors for lights, If any light

on, electrical system is telling the cylinder to
move. If no lights are flashing on, proceed
with checks.
Retracted
Fully
Extend cylinder all the way, disconnect the

hose going to the ROD END of the tow point
switch to DECREASE, if fluid comes out of
the fitting on the cylinder, check cylinder for
blown piston packing.
6) Extend cylinder: Using a stop watch note the

amount of time it takes to fully extend the tow
point cylinder.

21048 (12/95)
51
A Terex Company
System Four
Tow Point Timing Adjustment
TO
All checks and adjustments should be

performed with Engine at FULL
THROTTLE and machine at operating
temperature.
18 Seconds
To adjust the tow point timing locate the perspective

dual throttle valve.
7) On the right side extend the tow point cylinder

fully.
Extend
Fully
RH Front Bulkhead Valves
3.
8) Retract cylinder: Using a stop watch note the
amount of time it takes to fully extend the tow
point cylinder.
2.
1.
TO
LH Front Bulkhead Valves
18 Seconds
9) Center right tow point cylinders at 6 on the

number scale.
3.
Center
2.
10) Repeat Steps 4 through 9 on the left side.
1.
If either the up or down stroke time was anything

other than 18 seconds, adjust Tow Point Timing
according to Tow Point Timing Adjustment in
this chapter.

cylinder.
21048 (12/95)
52
A Terex Company
System Four
To adjust the perspective up or down stroke time.

1) Loosen Jam Nut.
The Dual Throttle Valve adjustment points are as

follows:
2) Using a Allen Wrench (Hex Wrench) turn

adjuster a slight amount.
Adjusts Timing
for UP Stroke
Adjustor
Jam Nut
Clockwise rotation
DECREASES cylinder
speed.
Adjusts Timing
for DOWN Stroke
Adjustor
Jam Nut
Counterclockwise
rotation INCREASES
cylinder speed.
3) Tighten Jam Nut.

4) Recheck tow point timing according to
procedures listed in :Checking Tow Point
Timing and readjust if necessary.
21048 (12/95)
53
A Terex Company
System Four
21048 (12/95)
54
Topcon
System 5
&
Smoothtrac
Topcon Corporation
System 5 & Smoothtrac

Operator's Manual
7010-0341 Rev. D
(P/N 499992526004) 23021 (11/02)
2002 TOPCON Positioning Systems, Inc. All rights

reserved. No part of this manual may be reporduced in any
form or by any means without prior written permission from:
TOPCON Positioning Systems, Inc.
Warranty
Warranty
TOPCON Limited Warranty
Electronic and Mechanical Components
TOPCON warrants that the electronic components manufactured by TOPCON shall be free of defects in materials
and workmanship for a period of one year from the original
date of shipment to the dealer. TOPCON warrants that all
valves, hoses, cables and mechanical parts manufactured by
TOPCON shall be free of defects in materials and workmanship for a period of 90 days from the date of installation.
Return and Repair

During the respective warranty periods, any of the above
items found defective may be shipped to TOPCON for
repair. TOPCON will promptly repair the defective item at
no charge, and ship it back to you. Calibration of components, labor and travel expenses incurred for in-field removal and replacement of components are not covered
under this warranty policy. Damage to components due to
negligence, abuse or improper use is NOT covered under
this warranty.
Warranty Disclaimer
The above warranties are in lieu of all other warranties,
whether expressed or implied, including all warranties or
merchantability, or fitness for a particular purpose. In no
event will Topcon Positioning Systems, Inc. or its Representative be liable for lost profits or other consequential
damages arising from the purchase or use of TOPCONs
System FiveTM Paver Operator's Manual
W-1
Warranty
components or any performance hereunder or any claims of

negligence, even if TOPCON has been advised of the
possibility of such damages.
Service assistance can be provided by contacting
your local TOPCON dealer or by calling the
Corporate Service Center.
Travel charges will be applied for any on-site
service whether warranty or non-warranty in
nature.
Phone: (866) 4-TOPCON - (866-486-7866)
8 a.m. to 5 p.m. Pacific Time
Monday through Friday
FAX: (925) 460-1329
W-2
Foreword
Foreword
TOPCON Positioning Systems, Inc.TM produces
productivity enhancement tools engineered and
manufactured by professionals from the construction
industry. The efficient design and advanced technology of
TOPCON Positioning SystemsTM System FiveTM allows you
to increase production, effectively control materials, and
reduce time spent setting and checking grade.
This manual has been developed to provide the paver
operator with information necessary to operate and
maintain TOPCON System FiveTM. Proper service and use
is important to the reliable operation of the equipment. The
procedures described herein are effective methods for
performing service and operation of this system.
The sections provided in this manual include information
necessary for the correct operation care and troubleshooting
of your TOPCON System FiveTM. Also contained in this
manual is a selection of WARNINGS, CAUTIONS,
and NOTICES you should become familiar with in order
to safely operate the system.
Each symbol represents a particular level of danger:
WARNING
WARNING
Represents a procedure or operation that,

if not strictly followed, can cause serious
damage to the equipment, and/or serious
injury or death to the person performing the
operation.
F-1
Foreword
CAUTION
CAUTION
Represents a procedure or operation that,

if not followed correctly, can result in
serious damage to the equipment or
personal injury.
NOTICE
NOTICE
Represents a procedure that, if not performed

correctly, can adversely effect the performance of the
equipment.
Please study this manual carefully. The benefits this
product provides can be greatly influenced by your
applications knowledge.
All information, illustrations, and applications contained
herein are based on the latest available information at the
time of publication. TOPCON reserves the right to make
product changes at any time without notice.
Comments, suggestions, and questions about TOPCON
products are welcomed. Contact your local TOPCON
representative or a representative at our corporate facility.
TOPCON POSITIONING SYSTEM, Inc.
5758 W. Las Positas Blvd.
Pleasanton, CA 94588
925 / 460 1300
925 / 460 1315 FAX
F-2
Table of Contents
Table of Contents
Warranty ............................................................... W-1
Limited Warranty ............................................................. W-1
Electronic and Mechanical Components ................... W-1
Return and Repair ..................................................... W-1
Warranty Disclaimer .................................................. W-1
Foreword ................................................................ F-1
Table of Contents .............................................. TOC-1
Safety Information .................................................. S-1
General Precautions ......................................................... S-1
Chapter 1: System Overview .................................. 1-1
Paver Illustration ................................................................ 1-2
Control Box ........................................................................ 1-3
LCD
....................................................................... 2-3
Light Sensor for LCD ................................................... 2-3
Power Switch .............................................................. 2-3
Grade Adjustment Knob .............................................. 2-4
Grade Adjustment Arrows ........................................... 2-5
Grade Adjustment LED ............................................... 2-6
Set/Menu Button ......................................................... 2-7
Slope/Elevation Button ................................................ 2-8
Survey/Indicate Button ................................................ 2-9
Auto/Manual Button ................................................... 2-10
Jog Switch ................................................................. 2-11
Sonic Tracker IITM ........................................................................................................ 1-4
Slope Sensor ..................................................................... 1-5
Smoothtrac Sonic Averaging System (SAS) ................... 1-6
Laser Tracker & Trackerjack ............................................. 1-7
Carrying Case .................................................................... 1-8
TOC-1
Table of Contents
Chapter 2: Operation .............................................. 2-1
Control Box ........................................................................ 2-1
Control Box Frt Pnl Switches and Controls ................. 2-2
Other Control Box Components ................................ 2-12
Sonic Tracker II ......................................................... 2-13
Working Window ................................................. 2-15
Slope Control ............................................................ 2-27
Performance Menu ................................................. 3-1
Control Box Memory .......................................................... 3-1
Accessing Menu Settings ..................................... 3-1
Gain (Elevation) ............................................. 3-5
Gain (Slope Control) ...................................... 3-7
Valve Offset .................................................... 3-9
Averaging ..................................................... 3-12
Deadband Elevation ..................................... 3-14
Deadband Slope .......................................... 3-16
Beeper Alarm ............................................... 3-18
Unit ............................................................... 3-19
Test .............................................................. 3-21
Principles of Paving ................................................ 4-1
Paver Components ............................................................ 4-1
How a Screed Works ......................................................... 4-2
Tow Point Force ................................................................ 4-6
Truck Exchange .......................................................... 4-7
"M" Head of Material .......................................................... 4-8
"R" Reaction of Material Under Screed ........................... 4-10
Mix Characteristics .......................................................... 4-11
Gradation .................................................................. 4-11
Mix Temperature ............................................................. 4-13
"W" Weight of Screed ...................................................... 4-14
Quality of Base Being Paved ........................................... 4-15
Rolling Techniques .......................................................... 4-16
Controlling Mat Quality .................................................... 4-16
TOC-2
Table of Contents
Getting Ready to Pave ........................................... 5-1
Machine Setup ................................................................... 5-2
Sonic Tracker Setup .......................................................... 5-5
Control Box Setup - Elevation ........................................... 5-6
Control Box Setup - Cross Slope ..................................... 5-11
Tracker Placement ................................................. 6-1
Stringline ................................................................ 7-1
Setting Surface Stringline .................................................. 7-1
Setting Elevated Stringline ................................................ 7-5
Making a Grade Verification Lath .............................. 7-13
Verifying Grade ......................................................... 7-14
Smoothtrac (SAS) Set Up ..................................... 8-1
Positioning the SAS ........................................................... 8-5
Placement of Sonic Averaging System ............................. 8-9
Applications ............................................................ 9-1
Paving City Streets with Sonics ......................................... 9-1
Paving City Streets with Cross Slope ................................ 8-9
Paving Streets Through Intersections ............................... 9-7
Method 1 ..................................................................... 9-7
Method 2 ................................................................... 9-10
Paving Intersections with Cross Slope ............................ 9-11
Maitenance ........................................................... 10-1
Preventative Maintenance & Daily Care .......................... 10-1
Transducer Cleaning ....................................................... 10-3
Transducer Replacement Procedure ............................... 10-4
Troubleshooting ................................................... 11-1
Control Box Symptoms .................................................... 11-1
Tracker Symptoms ........................................................ 11-13
Slope Sensor Symptoms ............................................... 11-17
SAS Symptoms ............................................................. 11-21
Appendix ............................................................................ A-1
TOC-3
Table of Contents
Notes
TOC-4
Safety Information
Safety Information
It is your responsibility to be completely familiar with the
cautions described in this System FiveTM Manual. These
messages advise against the use of specific methods or
procedures which can result in personal injury, damage to
the equipment, or unsafe operating conditions. Remember,
most accidents are caused by failure to observe basic safety
precautions.
General Precautions
1.
Read and become familiar with the paver

manufacturers operations manual, including
safety information before installing or using
your TOPCON System FiveTM.
2.
Use extreme caution on the jobsite. Working

around heavy construction equipment can be
dangerous.
3.
System Five is externally mounted on the

paving machine. DO NOT install the system
while the paver is running.
4.
DO NOT allow any System FiveTM component

to limit the visibility of the operator or protrude
into traffic.
5.
Use Ty-Wraps supplied with System FiveTM to

keep hoses and wires secured and away
from possible wear or pinch points.
S-1
Safety Information
6.
Use eye protection when welding, cutting or

grinding is being done on the machine.
7.
Protect yourself at all times and wear protective clothing when working on or near hydraulic lines. Hydraulic lines can be under
extreme pressure even when the machine is
turned off.
WARNING
WARNING
Relieve all pressure in the hydraulic lines

before disconnecting or removing any lines,
fittings or related components. If injury
does occur, seek medical assistance immediately.
8.
CAUTION
Avoid direct exposure to your eyes when

using laser control.
CAUTION
DO NOT stare into the laser beam or view

the beam directly with optical equipment.
9.
Use appropriate welding precautions and

practices when welding.
After welding, all affected areas should be
painted with a rust inhibitor.
NOTICE
NOTICE
Disconnect all TOPCON system electrical cables prior

to welding on the machine.
S-2
Safety Information
WARNING
WARNING
Do not weld near hydraulic lines or on any

equipment when in operation.
NOTICE
NOTICE
All mounting bracket welds must be secure and

strong to prevent the sensor equipment from vibrating
excessively or from becoming detached at the weld
during operation.
NOTICE
NOTICE
Keep the Carrying Case dry at all times. DO NOT

allow moisture to get inside the case. Moisture
trapped in the case can adversely affect components.
If moisture does enter the Carrying Case, leave it
open and allow it to thoroughly dry before storing any
components.
10. To prevent vandalism or theft, do not leave
the removable TOPCON components
(Control Boxes, Sonic Tracker IIsTM and
cables) on the machine at night. Remove the
components each evening and store
appropriately in the Carrying Case.
S-3
Safety Information
Notes
S-4
Chapter 1: System Overview
System Overview
System FiveTM is a complete, non-contacting control system
which combines both elevation control and slope control
into a simple, easy to use package. A standard system
includes two (2) Control Boxes, two (2) Sonic Tracker
IITM's and a single (1) Slope Sensor. The Control Box on
the right side of the machine controls the right side for
either elevation or slope. Likewise, the left Control Box
controls the left side for either elevation or slope.
The primary function of System FiveTM is to provide screed
control so that the paving material is placed into position at
the correct elevation and slope.
1-1
Figure 1.01
1-2
Control Box
The Control Box is the operators interface to System FiveTM.
The Control Box receives signals from the sensors, (Sonic
Tracker IITM, Laser Tracker and/or Slope Sensor), and uses
these signals to determine if grade or slope corrections are
necessary. If a change in grade or slope is required, the
Control Box sends a signal to the valve controlling the tow
point cylinder on the appropriate side of the machine to raise
or lower, thus maintaining correct mat thickness.
The Control Box easily attaches to its mounting bracket with
one clamp, and at the end of the day should be removed for
storage. The Control Box connects to the Sonic Tracker IITM,
the Slope Sensor, and to the paver through electrical cables.
1-3
Figure 1.03
Sonic Tracker IITM

The Sonic Tracker IITM measures and controls the elevations of the screed. A transducer, located in the bottom of
the Sonic Tracker IITM, generates sound pulses like a
speaker and listens for returned echoes like a microphone.
The Tracker measures the distance, and controls grade from
a physical grade reference, such as a curb, stringline, or
existing road surface. A bail is used to compensate for
rapid air temperature changes. In paving applications a bail
should always be used.
The Sonic Tracker IITM attaches to the system through one
quick connect cable and attaches to the machine with a
single bolt. At the end of the day, Sonic Tracker IITM
should be removed for proper storage in the carrying case.
1-4
Figure 1.04
Slope Sensor
The Slope Sensor is a precision electronic sensor which
functions much like a precision carpenter's level. The
Slope Sensor reads the inclination (tilt) of the screed and
sends the signal to the Control Box.
The Slope Sensor will measure slopes from +20% to -20%.
The Slope Sensor is a sealed unit and contains no adjustments. It is the only component of System FiveTM which
may be selected to control either side of the paver. It is
connected to each Control Box through an electrical cable.
The Slope Sensor is a sealed component and once attached
to the paver should not be removed.
Figure 1.05
1-5
Smoothtrac Sonic Averaging

System (SAS)
The Smoothtrac is an elevation control system that combines
multiple Sonic Tracker II's together to calculate an average
of the physical reference. Each tracker sends its distance
measurement to the Control Box which then averages all of
those measurements and sends a correction signal to the tow
point cylinder. The Smoothtrac replaces the mechanical ski
that drags on the ground. The Smoothtrac connects to the
Control Box through the tracker cable.
1-6
Figure 1.06
Laser Tracker & Trackerjack

The Laser Tracker is an elevation control sensor. It measures and controls the elevation of the screed. It works by
receiving a signal from a rotating laser and sending a signal
to the Control Box.
The Trackerjack attaches to the laser receiver and then
mounts onto a vibration pole. Use the same cable from the
Sonic Tracker IITM to power up the Laser Tracker/Trackerjack System.
The Laser Trackerjack should be removed at the end of
each day and stored in its carrying case.
Figure 1.07
1-7
Carrying Case
A Carrying Case is provided with each System FiveTM. The
Carrying Case is lined and includes pre-cut sections for
each Sonic Tracker IITM and the Control Boxes. A cut-out
section is also provided for storing coil cords.
At the end of the day, always wipe down each of the components and place them and the coil cords in the appropriate sections for storage. This will ensure the continued
integrity of these components and will protect them from
vandalism or theft.
Figure 1.08
NOTICE
1-8
Keep the Carrying Case dry and store in a dry location. Never let the interior of the Carrying Case become wet. If the case does become wet, remove the
components and dry it out.
Chapter 2: Operation
Operation
NOTICE
When operating in rainy weather or in wet conditions,
the Control Box, Sonic Tracker IITM, and cables must
be thoroughly dried BEFORE placing them in the
Carrying Case at the end of the day.
Any moisture in the Carrying Case will cause condensation on the inside of the components which may
severely affect accurate operation during the next
paving operation.
Control Box
The Control Box is the main operator control interface for
System FiveTM. The Control Box receives signals from the
sensors and uses these signals to determine if a grade or
slope correction is necessary. If a correction is necessary
the Control Box sends a signal to the valve controlling the
tow point cylinder on the appropriate side of the paver to
raise or lower, thus maintaining correct mat thickness.
2-1
Control Box Front Panel

Switches, Buttons and Controls
The operator can control and monitor the slope and thickness
of the mat using the buttons and displays located on the front
panel of the Control Box. The function of each is as follows:
Figure 2.0
2-2
1 The LCD (Liquid Crystal Display)

The LCD allows the operator to view text and graphic
symbols that represent elevation or slope settings that
System FiveTM is currently maintaining for the paver.
Figure 2.01
2 Light Sensor for LED Display

Automatically adjusts the brightness of the LED display
for better visability.
3 Power Switch
The Power Switch for System FiveTM.
Press "|" on the switch to turn the Box on.
Press "O" on the switch to turn the Box off.
Figure 2.02
2-3
4 Grade Adjustment Knob

This knob is used to make measured adjustments to the
Cross Slope or Elevation settings and allows the
operator to cycle through the menu options.
Knob adjusts the grade height for when Elevation

Control is selected.
Figure 2.03a
Knob adjusts the percentage of slope when Cross

Slope Control is selected.
2-4
Figure 2.03b
Grade Adjustment Direction Arrows

These red arrows light up around the Grade Adjustment
Knob to indicate the direction the knob should be
rotated to reach On Grade.
A
Rotate the knob counterclockwise to reach grade.
Rotate the knob clock

wise to reach grade.
Figure 2.03c
2-5
2-6
6 Set/Menu Button
The Set/Menu button has two functions.
Set Mode
Set is used to change the reference number
viewed on the display to a desired value.
Press and hold the Set/Menu button and dial in
desired value using the Grade Adjustment Knob.
Both the Grade Correction Indictor Lights and the
Double Arrows will be lit.
Release the Set/Menu Button and the value will
be saved.
NOTICE
Using Set will not change the existing mat thickness, it

only changes the reference number viewed on the
display.
Menu Mode
(See Accessing System FiveTM Performance
Settings)
2-7
Figure 2.05
7 Slope/Elevation Button
The Slope/Elevation button is used to select
System FiveTM for slope or elevation control.
Slope Mode
Press the button and the yellow LED next to the
Cross Slope Symbol will illuminate.
Elevation Mode
Press the button again and green LED next to the
Elevation Symbol will illuminate.
Figure 2.06
2-8
8 Survey/Indicate Button
Survey
Survey is used to quickly "Null Out", or set the
sensor to On-grade.
Push button for 1 second until box beeps and green
On-Grade Correction Display bar is illuminated.
Indicate
Indicate Mode allows the operator to continuously monitor the grade or slope setting on
the LCD.
Continue pressing on the button until there is a
second beep. "IND" will be shown in the LCD
display. There will be no Grade lights. To exit
out of Indicate Mode push either the Survey
button or the Auto Button.
NOTICE
By entering Indicate Function, System FiveTM will be

taken out of Automatic Mode.
2-9
Figure 2.07
9 Auto/Manual Button
Automatic Mode
The tow point cylinders are automatically
adjusted up or down to maintain proper grade.
Press the red button. The red LED will light up
showing that the Control Box is in Auto Mode.
Manual Mode
System FiveTM will display grade corrections
but the tow point cylinders will not be adjusted.
Press in the Red Button. The red LED will NOT be
lit, showing that the Box is in Manual Mode.
Figure 2.08
2-10
10
Jog Switch
Manually moves the tow point up or down. The Jog
Switch is always active when the Control Box is
turned on.
To raise tow arm cylinder, push switch up.

To lower tow arm cylinder, push switch down.
Figure 2.09
2-11
Other Control Box Components
Figure 2.10
1 Mounting Knob
Secures Control Box to its mounting bracket. The
bracket has a jaw that matches up with the jaw located
on the side of the Box.
2 Serial Number Plate
Contains System FiveTM part and serial number.
2-12
3 Audible Beeper
When the power is turned on, or calibration selections
are made, the beeper will sound. The beeper may be
turned Off or On for certain functions by using the
Beeper Alarm Mode (see Accessing System FiveTM
Performance Settings section in this booklet).
Sonic Tracker II
The Sonic Tracker IITM measures and controls the elevation
of the screed. A transducer, located in the bottom of the
Tracker, generates sound pulses like a speaker and listens
for returned echoes like a microphone. The Tracker measures the distance, and controls grade from any physical
grade reference, such as a curb, stringline, or existing road
surface.
Figure 2.11a
2-13
The Sonic Tracker IITM measures the distance to a physical

reference by sending out sound pulses 39 times per second.
As soon as the Tracker sends out a sound wave it starts a
stop watch. The sound waves go down, bounce off of any
physical reference, and are reflected back to the Tracker.
The Tracker measures the time it takes for the sound wave
to return to the Tracker. Knowing the speed of sound, the
Tracker accurately calculates the exact distance to the
grade reference. The Tracker can use any physical grade
reference, such as a stringline, curb, or existing surface.
2-14
Figure 2.11b
Working Window
Since the Sonic Tracker IITM is mounted to the tow arm
or screed extension, as they raise or lower, the tracker
measures exactly how far above or below the desired
grade reference it is. Built into the Tracker is an
operational zone, or Working Window, 2.4 inches
above and below the grade reference. The grade lights
on the Sonic Tracker and Control Box continuously
display this grade information to the screed operator.
2-15
Figure 2.12a
On the paver the Sonic Tracker II will be positioned

above the grade reference. Its job is to maintain the
exact distance from the tracker to the reference, keeping
the Tracker On Grade. If the Tracker is On Grade, the
mat being laid will be at the desired depth.
Figure 2.12b
2-16
If the screed and the Tracker IITM start to raise, the

watch will be stopped at a longer time. The Tracker
and Control Box will indicate a down correction arrow,
and lower hydraulic valve corrections will be applied to
bring the Tracker back to On Grade.
Figure 2.12c
2-17
If the screed and Tracker IITM are lowered the watch

will be stopped at a shorter time. The Tracker and
Control Box will indicate a raise correction arrow, and
raise hydraulic valve corrections will be applied to
bring the Tracker back to On Grade.
Figure 2.12d
2-18
If the Tracker IITM is side shifted off a stringline, the

sound waves reflect off the ground and the Tracker's
stopwatch will indicate a long time for the sound waves
to return. The Tracker is out of the Working Window,
and no On Grade correction signals will be applied.
Figure 2.12e
2-19
If the Tracker sees an obstruction closer than the reference signal, such as a grade pin, the sound waves do not
take as long to come back and the stop watch is stopped
much sooner. The Tracker is out of the Working
Window, and no On Grade correction signals will be
applied.
Figure 2.12f
2-20
Temperature will change the speed of sound. The

tracker has a built in temperature sensor for applications
with gradual temperature changes such as on graders or
dozers. In paving applications you can get a more
dramatic and rapid change in air temperature. To
compensate for these variations a temperature bail is
positioned 9 inches below the tracker. When the sound
wave is emitted, the tracker records the time to the bail
and continues to listen for the grade reference. If a
temperature variation occurs, such as heat off a freshly
paved mat, a difference in time to the temperature bail
is recorded. The correction for the speed of sound is
then applied to the grade reference signal, preventing a
change in mat depth. The tracker corrects for temperature variations with every sound wave, 39 times per
second.
2-21
Figure 2.12g
In the upper right hand corner of the Sonic Tracker IITM

faceplate is a small symbol used to represent the use of
the temperature bail. The LED symbol will automatically illuminate when the bail is connected to the
tracker. The tracker is casted with holes on each side
for the bail to snap and lock into place.
2-22
Figure 2.12h
When setting up the Tracker over a grade reference, the

size of the Sonic Cone or the "footprint" needs to be
considered. As an example, at about 2 feet from the
tracker, you will have a footprint or cone of about 6
inches.
As the Tracker is positioned closer to the grade reference the working footprint decreases in size. As the
Tracker is moving farther away from the grade reference the sonic footprint or cone will increase in size.
Figure 2.12i
2-23
For Laser Control a laser transmitter is used to produce

a plane of light which becomes the grade control reference for the job site. The laser receiver will control the
screed to lay a mat parallel to the laser beam reference.
When the laser beam is in the center of the receiver, it
indicates an On-Grade signal.
Figure 2.12j
2-24
As the screed is raised, the beam of light hits the Laser

Receiver below the center and a lower signal is indicated.
Figure 2.12k
2-25
As screed is lowered the beam of light hits the Laser

Receiver above the center a raise signal is indicated.
Figure 2.12l
2-26
Slope Control
System Five uses a slope sensor mounted to the
transducer beam on the paver to measure and control
the slope of the mat being laid. The sensor contains an
electronic level vial, that acts as a "precision
carpenter's level". Slope control with this electric level
vial is very accurate and repeatable.
Figure 2.12m
2-27
If the required slope changes, the screed man dials the

new slope in the System Five Box. The tow point
cylinder on the slope side will raise or lower until the
slope sensor measures the new slope.
Figure 2.12n
2-28
Chapter 3: Performance Menu
Performance Menu
Control Box Memory
The Control Box automatically stores all operating information when it is turned off.
NOTICE
If power is interrupted to the Control Box within 2
seconds after making an adjustment, the new setting
will not have had time to be stored and the settings
will revert to the previous (or original) settings.
Accessing System Five TM Performance Menu Settings
System FiveTM Performance Menu Settings are a series of
features that allow System FiveTM to be modified for operator
ease-of-use reasons, or performance enhancement reasons.
Performance Menu Settings Chart
3-1
Figure 3.0
NOTICE
Some of the Menu selections may not be available for
the operator to select or change. Please contact
dealer/distributor with any questions.
NOTICE
The factory settings are preset values that will run
most pavers. If your machine does not perform properly within those preset values, then adjust the setting
accordingly until you have satisfactory machine performance.
1. Turn power off. While holding down the Set/
Menu button turn the box back on. The Auto LED
light and Grade Adjustment Direction Arrows
will flash.
Figure 3.01a
3-2
2. Rotate the Grade Adjustment Knob to scroll

through the Performance Menu selections located
on the LCD.
Figure 3.01b
3. Select a menu item by pressing the Auto button.
Figure 3.01c
3-3
4. Turn the Grade Adjustment Knob to view the

options available for the Menu selection.
Figure 3.01d
5. Press the Auto button again to store value.
Figure 3.01e
6. To access other Menu settings just turn the Grade

Adjustment Knob. To exit Performance Menu press
the Set/Menu button.
3-4
Gain (Elevation)
This setting determines the speed at which System FiveTM
allows the Tow Point Cylinders to adjust to a change in
elevation. For faster hydraulic response, increase the gain
value. For slower hydraulic response, decrease the gain
value. The objective is to set the gain so the screed reacts
to the change in grade quickly but without "overshooting"
the new elevation.
Gain Elevation Value Range: 1-100

Factory Preset: 25
NOTICE
Before setting the Gain, make sure the machine's

hydraulic flow controls valves are adjusted for proper
cylinder speed according to the manufacturer's recommendations. Typical cylinder speed is 15-20
seconds for full up or down cylinder travel.
1. Press the Auto button to select Gain (Elevation).
Figure 3.02a
3-5
2. Turn the Grade Adjustment Knob to select the

desired value - typically 25 for most paving
applications.
Figure 3.02b
3. Press the Auto button again to store value.

4. Rotate the Grade Adjustment Knob to access
another choice in the Performance Menu or press
the Menu button to exit.
3-6
Gain (Slope Control)

This setting determines the speed at which System FiveTM
allows the Tow Point Cylinders to adjust to a change in
slope. For faster hydraulic response, increase the gain
value. For slower hydraulic response, decrease the gain
value. The objective is to set the gain so the screed reacts to
the change in grade quickly but without "overshooting" OnGrade. Slope gain should not be set at a higher value than
the elevation gain on the other side of the paver.
Gain Elevation Value Range: 1-100

Factory Preset: 25
NOTICE
Before setting the Gain, make sure the machine's

hydraulic flow controls valves are adjusted for proper
cylinder speed according to the manufacturer's recommendations. Typical cylinder speed is 15-20 seconds
for full up or down cylinder travel.
1. Press the Auto button to select Gain (Slope Control).
Figure 3.03a
3-7

desired value - typically 20% to 25%.
Figure 3.03b
3. Press the Auto button again to store the value.

NOTICE
Do not set slope gain at a higher value than the elevation gain on the other side of the paver. A higher
value may cause the slope to be over reactive.
3-8
Valve Offset
The valve offset is the minimum amount of electrical signals
sent to the valve which causes the hydraulic cylinder to move. If
the valve offset is too small, the sensor will not reach On-Grade.
Likewise, if the valve offset value is too large, the sensor will
move too much and overshoot On-Grade. Valve offsets should
be set before adjusting elevation and slope gains and averaging.
Valve Offset Value Range: 1-700

Solenoid: 135
Proportional: 350
Factory Preset: 135
NOTICE
Valve offsets should be the first performance menu

function completed. The paver should be run until the
hydraulic oil is at normal operating temperature before
the value offset functions preformed. Once they are
set, valve offsets should not need to be adjusted
unless the Control Box has been moved to a new
paver, or the hydraulic performance has changed.
1. Press the Auto button to select Valve Offset. This
will automatically activate the value screen for
Raise Offsets. The Raise Grade Correction Display
Arrow will illuminate, and the Control Box will
begin sending a raise correction signal to the valve.
3-9
Figure 3.04a
2. Turn the Grade Adjustment Knob counterclockwise,

decreasing the Valve Offset value until the
hydraulic cylinder is not moving.
Then slowly rotate the Grade Adjustment Knob
clockwise until the hydraulic cylinder just begins to
move up.
Figure 3.04b
3. Press the Auto button to store the Raise Offset

Value. Pressing the Auto button also switches the
box to Lower Offset. The Lower Grade Correction
Display Arrow will illuminate and the Control Box
will begin sending a lower correction signal to
the value.
3-10
Figure 3.04c
4. Turn the Grade Adjustment Knob counterclockwise, decreasing the Valve Offset value until
the hydraulic cylinder is not moving.
Then slowly rotate the Grade Adjustment Knob
clockwise until the hydraulic cylinder just begins to
move down.
Figure 3.04d
5. Press the Auto button to store the Lower Offset

Value. Pressing the Auto button will also return
you to the Performance Menus.
another choice in the Performance Menu or
press the Set/Menu button to exit.
3-11
Averaging
This setting changes the amount of dampening, or filtering,
applied to sonic tracker and laser receiver measurements.
It can be thought of as the time period over which a running
average of the elevation measurement is calculated. A
lower value will average fewer elevation measurements,
allowing the system to react more quickly to smaller grade
changes. This will make it more susceptible to fluctuations
in temperature or small obstructions.
A larger value will average more elevation measurements,
preventing the system from reacting to undesirable items
close to the reference. This will also make it less susceptible to fluctuations in temperature or small obstructions.
Averaging Value Range: 1-100

Factory Preset: 50
1. Press the Auto button to select Averaging.
Figure 3.05a
3-12

desired value.
Figure 3.05b

3-13
Deadband Elevation
Deadband is the area of the Working Window that is OnGrade. While the reference is within that area, the pavers
valves are idle (closed). Therefore the wider the Deadband
(On-Grade area), the more a reference can move up or
down without a correction being initiated. Once the signal
from the reference is out of the deadband, System FiveTM
will drive the hydraulics to place the reference back in the
CENTER of the deadband.
Deadband Elevation Value Range : 1-30 mm

Factory Preset : 3mm (.01', or 1/8")
1. Press Auto Button to select Elevation Deadband.
Figure 3.06a
3-14

desired value - typically 3mm (0.01').
Figure 3.06b

the Set/Menu button to exit.
NOTICE
The amount of Deadband should be carefully selected. Too small of a Deadband will cause the tow
point cylinder to constantly hunt up and down while
the sensor tries to find On-Grade. Too large of a
deadband will not allow the sensor to send grade
corrections to the valves, causing unwanted variations
in the mat thickness.
3-15
Deadband Slope
Deadband is the area of the Working Window that is OnGrade. While the reference is within that area, the pavers
valves are idle (closed). Therefore the wider the Deadband
(On-Grade area), the more a reference can move up or
down without a correction being initiated. Once the signal
from the reference is out of the deadband, System FiveTM
will drive the hydraulics to place the reference back in the
CENTER of the deadband.
When the Deadband is changed it adds or takes away from
the fine correction region (1% above or below On-Grade)
of the slope sensor. It does not add this distance to the
overall working range.
Deadband Slope Value Range : 025 - 750%

Factory Preset : 075
1. Press the Auto button to select Slope Deadband.
Figure 3.07a
3-16

desired value typically 075.
Figure 3.07b

NOTICE
The amount of Deadband should be carefully selected. Too small of a Deadband will cause the tow
point cylinder to constantly hunt up and down while
the sensor tries to find On-Grade. Too large of a
deadband will not allow the sensor to send grade
corrections to the values, causing unwanted variations in the mat thickness.
3-17
Beeper Alarm
When System FiveTM is in Automatic Mode and the Sonic
Tracker gets a reference signal that is out of the Working
Window (more than 2.0" from grade) a single audible beep
will be heard.
1. Press the Auto button to select Beeper.
Figure 3.08a
2. Turn the Grade Adjustment Knob to turn the beeper

ON or OFF.
Figure 3.08b
3. Press the Auto button again to store the choice.

3-18

Unit
Set display to read in feet, inches, or centimeters.
1. Press Auto Button to select Units.
Figure 3.09a
2. Rotate the Grade Adjustment Knob to select a

measuring unit (either feet, inches or centimeters).
Figure 3.09b
3-19
Figure 3.09c

NOTICE
If the Unit is changed, the working window of the
Sonic Tracker will have to be reset to grade.
3-20
Test
This tests the valves for shorts and disconnected valves. It
test the Raise Valve first and then the Lower Valve.
1. Press the Auto button to select Test Mode.
Figure 3.10a
2. Display will read "Pass" if the raise valves test out

OK. If there is a problem the display will read
"Open" or "Short".
3. Press the Auto Button to test lower valves. The
display will read "Pass" if the lower valves test out
OK. If there is a problem the display will read
"Open" or "Short".
Good Valve
Valve NOT connected
Valve wires are electronically

shorted
Figure 3.10b
3-21
4. Press the Auto button once more to return to the

Menu selections.
5. Rotate the Grade Adjustment knob to access another
choice in the performance menu or press the Set/
Menu button to exit.
3-22
Chapter 4: Principles of Paving
Principles of Paving
Figure 4.0
Paver Components
Modern pavers consist of two major units: The Tractor and
the Screed.
The primary function of the tractor is to propel the truck or
paver feeding device, to convey and distribute the paving
material and to tow the screed. The function of the screed is
to strike off the material in preparation for further compaction.
The screed is mounted to the tow arms at the screed pivot
points and is attached to the paver at the tow points.
4-1
How a Screed Works
Figure 4.01a
The screed on all modern pavers is of the "floating, self

leveling" type. As the paver tows the screed unit forward,
paving material flows under the screed. This causes the screed
to float on the mat of material, thus establishing mat thickness.
Since the screed is mounted to the paver only at the tow points,
the screed is completely free to float up or down. The screed
will always seek it's own "Planing Angle", or angle of attack,
dependent on the combination of forces acting upon the
screed.
4-2
Figure 4.01b
If the screed angle of attack is increased the screed

rises increasing the mat thickness.
If the angle of attack is decreased, the screed will settle
providing a thinner mat surface.
Figure 4.01c
Because the screed floats, it will not immediately react to a

change in the tow point. It needs a certain amount of time or
distance to make a correction in the mat thickness. If the tow
point is changed by a unit of one, the paver must move one tow
arm length before the screed will correct 63% of the elevation.
After 2 tow arm lengths 83% of the correction is made and 3
tow arm lengths would account for 95%. It takes 6 tow arm
lengths to achieve 100% of the elevation change. Considering
that 95% of the change takes place after 3 tow arm lengths, this
can be used in practical applications to qualify for full correction.
4-3
Figure 4.01d
The same is true when making elevation changes with the

manual thickness cranks.
Figure 4.01e
It is very important to check mat depth in several locations

before making any elevation corrections. The surface being
paved may have wheel ruts, dips and ridges that will give an
untrue indication of overall mat depth. Check several spots to
get an average. If an elevation change is made, wait 3 tow arm
lengths for full correction. Too much cranking and stabbing
will cause raise and lower changes that will produce an uneven
mat surface.
4-4
Figure 4.01f
There are four main forces acting on the screed at all times.
These forces occur whether you are paving in manual or with
automatics. A change in any one of the forces will cause the
screed to rise or fall, changing the mat depth. The key to
smoother paving is to keep these forces as constant as
possible. Let's review each of the forces and what factors will
have an effect.
Figure 4.01g
4-5
Tow Point Force

The tow point force (P) is the resistance to forward travel. The
P force will remain constant if the paver is kept moving at a
consistent speed at all times. If the paver is allowed to stop,
the screed will settle in the fresh mat and leave a mark. The
mark cannot be fully smoothed out by the roller and a bump
will end up in the mat. This will show up in the profilograph
readings and reduce your chance for any bonuses. Changing
the speed of the paver will also cause the screed to rise and fall,
affecting the mat thickness. The optimum paving speed is
determined by the depth and width being paved and the rate at
which material can be delivered to the job. Calculate the tons/
hour into feet per minute. Do not start and stop the paver.
Figure 4.02
4-6
Truck Exchange is another tow point force.

It is very important that truck exchanges be carried out as
smoothly as possible to avoid disturbing the smooth, uninterrupted forward motion of the paver. The following lists some
steps to take to avoid disturbance of the paving operation by
trucks.
1. Stop the mix delivery truck close, but not too short of
the paver. Always allow the paver to pickup trucks on
the run.
2. Never allow the truck to bump the paver. Allowing
trucks to bump the paver when backing up, can drive
the screed into the mat and produces bumps and ridges
which may not roll out.
3. Trucks applying and holding their brakes excessively
while dumping their load may cause the paver to slow,
which in turn will cause the screed to rise. The truck
driver should apply only light pressure on the brakes,
sufficient to maintain contact with the paver.
4. Dumping of material in front of the paver as the truck
pulls away after emptying its load into the hopper, can
cause the paver to ride over the pile of material with
subsequent adverse effects on mat quality. Avoid
trucks pulling away prior to completely dumping all
material. Use a dump person to monitor and regulate
truck movements in front of the paver.
4-7
"M" Head of Material

As described before, one of the primary functions of the paver
tractor is to convey and distribute paving material onto the
ground in front of the entire width of the screed. This material,
once deposited in front of the screed is the head of material
over which the screed will pass.
One of the keys to smooth paving is to maintain this head of
material as constant as is possible. The resistance to forward
motion exerted by the head of material (M) is one of the major
component of resistance to forward motion. Control of this
force is a basic and necessary function of any paving operation.
The volume and consistency of the head of material determines how much paving material flows under the screed and
influences mat thickness and surface texture.
Figure 4.03a
4-8
The most common factor affecting force "M", the head of

material, is the following:
Incorrectly Adjusted Automatic Feeder Controls:
These systems, whether they are of the "hanging
paddle" type or the sonic sensors should be adjusted to
operate the auger/conveyor assemblies 95 to 100% of
the time.
On/off operation of the auger system will cause fluctuation in the head of material.
The highest quality mat will generally result when a
constant head of material is maintained across the
entire width of the screed and the material almost
covers the auger shaft. If the volume of paving
material is too high, there is resistance to the travel of
the screed. This causes the screed to rise and can result
in ripples, auger shadows and long waves. It also
results in increased auger wear.
4-9
Figure 4.03b
"R" Reaction of Material Under Screed

Ideally, every truck load of material delivered to the paver
would be exactly like every other load with no variation.
However, as a practical matter, changes in mix characteristics
such as mix temperature, density, gradation, A.C. Content,
segregation, etc., will affect the internal stresses developed
within the mix, which in turn affects the resistance of the mix
to flow under the screed. The key element to bear in mind is
that the screed passing over the paving material will compact
the material to a certain degree. Variable in the resistance of
the material to compactive forces will cause changes in the
screed's angle of attack, which in turn will affect mat thickness
and therefore mat smoothness.
Figure 4.04
4-10
Mix Characteristics
Gradation
This aspect of the paving material will vary according to the
intended use of the material as abase course, binder course or
the final wearing surface. Normally, maximum aggregate
size, ratio of aggregates, fines content and most importantly,
asphaltic binder content, is specified by the contracting agency.
Adherence to mix design specifications is usually the responsibility of the material supplier.
Segregation is a material deficiency caused by a separation of
the larger aggregate sizes from the bulk of the paving material.
This condition is encountered especially in mixes with relatively large maximum size aggregate (example: 1" and larger,
the so called "large-particle" mixes). When paving material is
deposited in piles, as in an asphalt plant silo, a haul truck, a
paver hopper, on the ground in front of the paver in a windrow,
or on the ground in the auger chamber, segregation can and
does frequently occur.
NOTICE
The areas listed above where segregation can occur
are all areas that the material may encounter before
being laid down as a mat. Therefore, these areas of
segregation must be addressed prior to any paving.
The screed cannot rectify segregation during the
paving process.
4-11
Segregation can also be the result of improper hopper dumping:

Duration normal operation, the vibration of the pavers hopper
will cause segregation. Therefore, dumping the hopper after
each truck should be avoided because material that has rolled
to the outside of the hopper (the large aggregate) will fill the
conveyors and auger chamber and result in a segregated area
behind the paver with a noticeable difference in surface
texture.
If It Doesn't Look Right, It Isn't Right:
Surface and texture irregularities indicate that the homogeneous characteristics of the material in the mat have been
interrupted, which usually results in bumpiness and premature failure of the pavement in those areas.
Segregation can also be the result of excessively worn augers:
"Center Streak" segregation can be caused by worn "Kicker
Paddles" at the center chain cause or near the outside auger
bearings. In fact center streak segregation is frequently
caused by incorrect arrangement of the auger segments adjacent to the auger chain case. (Consult the Manufacturers
Manual).
"Center Streak" segregation is also caused by feeder gates
being set to tow. Adjust as necessary to provide sufficient
uniform material at the center of the paver.
NOTICE
"Center Streak" segregation can be limited and even
eliminated by slowing paving speed.
4-12
Mix Temperature
A common paving problem is inconsistent temperatures in the
asphalt mix. As the material cools it loses its viscosity making
it more difficult to compact. If the resistance to compaction
increases, the screed will naturally increase its angle of attack
and begin to float up. This will change the mat depth, resulting
in bumps in the surface. If the mix and or screed temperature
are too low, the screed may no longer slide smoothly over the
material and a tearing of the mat will occur.
Some simple steps to take to control temperature variations:
A. Ensure that haul trucks take the shortest, most
practical route to the paver. Make certain that all
trucks take the same route to the paver.
B. Make sure that the trucks arrive at the same order in
which they were loaded at the asphalt plant.
C. Ensure that no bunching of trucks occurs at the paver,
with several trucks waiting to dump their loads.
D. Match lay-down rate to material delivery rate.
NOTICE
Temperature problems may occur will before the time
the material is loaded into the trucks, or during the trip
to the paver. They can be the result of temperature
variations at the plant. If this is not addressed prior to
delivery of material to the paver, waviness in the he
mat will be the result.
4-13
"W" Weight of Screed

For weight of screed force "W" to remain constant, the weight
of the screed or the downward pressure exerted by the screed
on the paving material should not change. The weight of the
screed is measured in pounds per square inch.
Figure 4.05a
Members of the paving crew climbing on and off the screed

will have some affect on the weight of screed force.
The primary factor affecting this force is changing the width
of the screed. Extendible screeds weigh the same whether
they are fully retracted or fully extended. The difference is the
wider the extension of the screed the greater the surface area
of paving material to support. An extended screed has fewer
psi, which means less compaction, causing the screed to raise.
4-14
Figure 4.05b
Quality of Base Being Paved

There are factors other than the four main forces that can have
an effect on the quality of the mat. An important one is the
quality of the base to be paved. It makes more sense to build
smoothness from the base up, than to try to smooth a road in
the last lift of paving. However, on overlay paving jobs we
have to work with what we have.
Remember that a mat which appears smooth immediately
behind the paver, may actually contain areas of considerably
varying thickness of material as a result of undulations in the
base being paved. Due to the principle of "Differential
Compaction" high spots will not compact as much as the low,
therefore allowing some of the irregularities to be rolled back
onto the mat. To minimize this problem, lay a leveling course
in the low spots or pave multiple lifts to average out the
irregularities.
Figure 4.06
4-15
Rolling Techniques
A well laid mat can end up with a poor ride quality if proper
rolling methods are not followed. Consult your compaction
equipment manufacture's manuals and handbooks on compaction techniques.
Controlling Mat Quality

The primary purpose of the asphalt paver is to place a smooth
mat of material. The primary function of System Five is to
control the vertical position of the screed in relation to the
surface being paved. Automatic grade and slope control
systems can help tremendously in controlling mat smoothness but mat quality is also dependent on the following
factors:
A.
B.
C.
D.
E.
Non-Stop, Continuous Operation of Paver

Constant Speed of Paver
Truck Exchange
Head of Material
Mix Characteristics
1. Gradation
2. Segregation
3. Mix Temperature
F. Screed Compaction
G. Quality of Base Being Paved
H. Rolling Techniques
NOTICE
4-16
Changes in any of these factors will cause a change

in mat thickness, density, surface appearance and
mat quality. If changes must be made, make them as
gradually as possible. Abrupt changes in any of the
above factors will produce rapid changes in mat
thickness, adversely affecting mat quality.
Chapter 5 : Getting Ready to Pave
Getting Ready to Pave
Figure 5.0
This chapter is designed to get the paving crew started using

System FiveTM. The job application and the desired results will
determine what type of non-contacting controls should be
used; i.e. sonic, slope, laser and SAS. The components should
be mounted on the paver and then the paver itself must be
properly set up.
5-1
Chapter 5: Getting Ready to Pave
Connect the cables into the Control Box:
Figure 5.01
NOTICE
Due to different types of machine configuration, your
cable connections may vary.
Machine Setup
To start paving with System FiveTM, set up the paver just as you
would under manual control. Place the screed on blocks or
lath set for the desired paving thickness. Make sure you
account for material compaction.
5-2
Figure 5.02a
Center the tow point cylinders to maximize travel in raise or

lower directions. You can use the jog switch on the System
FiveTM Box (Power must be on) or the switch provided with the
paver.
5-3
Figure 5.02b
Using the manual thickness adjustment cranks or hand cranks

on the paver, null the screed and set the proper angle of attack.
Next, turn on the auger feeder controls to place the asphalt in
front of the screed.
Figure 5.02c
5-4
Sonic Tracker Setup

When installing and positioning the Sonic Tracker IITM, first
connect the coil cord to the Tracker. Then bolt the Tracker to
the bracket, and visually check to get the Sonic Tracker
plumb.
Make one wrap of the coil cord around the "L"-Bar. This will
act as a strain relief for the connector on the Tracker. Be sure
the coil cord snap hook is in place and secure.
Figure 5.03
5-5
Control Box Setup - Elevation

Once the Sonic Tracker has been positioned over the reference, the Control Box can now set the Tracker On-Grade. Flip
the power switch to the on position press and hold the survey
button for 1 second until the box beeps and the green OnGrade Bar is displayed.
Figure 5.04a
Next, make the display read the same number as depth of mat
to be laid. Press and hold the "Set" button with one hand. With
your other hand, turn the grade adjustment knob to change the
display to the height of the blocks under the screed. Release
the "Set" Button and the value will be saved.
5-6
Figure 5.04b
Using Set will not change the existing mat thickness, it only
changes the reference number viewed on the display.
Figure 5.04c
Press the Red Button and the Red LED will light up. You are
now in automatic mode and can begin paving.
5-7
After you begin paving it is important to check the mat depth

to insure the desired thickness is being laid. The blocks
initally placed under the screed may cause the mat to be too
thick or thin. Check the mat several times to get an average
before making any corrections.
Figure 5.04d
5-8
If a 2.50 inch mat is required, but a 3.0 inch mat is being laid,
then an adjustment is necessary. You must first get the box to
display the same number as the mat depth. Press and hold the
"Set" button with one hand. With other hand turn grade
adjustment knob to read 3.0 inches. Press the red auto button
to put the system back in automatic control.
Figure 5.04e
5-9
With the paver moving and in auto, slowly dial the display
from 3 inches down to 2.5 inches. How fast you turn the knob
depends on how smooth you want the transition to take place.
Highways require gradual changes, parking lot require quick
changes. The display should now read the depth of the mat
being laid.
Figure 5.04f
5-10
Control Box Setup - Cross Slope

The slope sensor should already be mounted on the transverse
beam of the paver. The sensor can talk to both control boxes,
but only one at a time. The sensor communicates to the
Control Box through the cable.
Figure 5.05a
To pave using cross slope you must first calibrate the slope
sensor, to the screed. Find a smooth area where the screed can
rest evenly across its entire surface. Using a laser, a Smart
Level, or a slope board, that itself has been calibrated, check
the cross slope and direction of fall of the ground.
5-11
Figure 5.05b
Now place the screed on the ground and null it out. Flip the
power switch to the On position and push the Slope Mode
Button. The yellow LED next to the cross slope symbol will
illuminate.
Figure 5.05c
To find out the slope and direction of fall the slope sensor
thinks the screed is resting on, push the survey button for 1
second to lock sensor On-Grade. If the box is displaying and
On-Grade bar and a slope value that is identical to the laser or
Smart Level then you can begin paving. Make sure to push the
Auto Button.
5-12
Figure 5.05d
If the slope displayed in the box does not match the surface,
then the sensor must be calibrated. Press and hold the "Set"
button with one hand. With your other hand, turn the grade
adjustment knob to change the display to match the slope of
surface. Release the "Set" button and the value will be saved.
Figure 5.05e
NOTICE
Using Set will not change the slope, it only changes
the slope value viewed on the display.
Press the Red Button and the Red LED will light up.
You are now in Automatic Mode and can begin paving.
5-13
Once the slope sensor is calibrated and you are ready to

begin paving, you may find the existing surface does not
have the same slope as the finish design. In order to produce a smooth transition, begin paving at the existing slope
and slowly turn the grade adjustment knob to change the
cross slope to the correct percentage.
Figure 5.05f
If a smooth transition is not required, then dial in the desired

slope and begin paving.
5-14
Chapter 6: Tracker Placement
Tracker Placement
Raise or lower the tracker bracket to position the tracker at
the proper height above the grade reference. The tracker
has a total working range of 14 to 55 inches. For paving
applications the recommended working height would be
from 14 to 24 inches. At 55 inches the sonic footprint
would be very large and the tracker may pick up an undesired reference. The tracker also compensates for temperature changes only within the bail range. Placing the
tracker too far from the reference may not allow for accurate temperature compensation.
6-1
Figure 6.0
Position the "L"-Bar horizontally so the tracker will be over

the reference. For example, when tracking a curb and gutter,
place the screed or extension flush with the edge of gutter and
slide the "L"-Bar so the Tracker is over the lip of the gutter.
6-2
Figure 6.01a
The "L"-Bar can also be mounted to a bracket on the screed

extension. This would work well in applications where the
reference will not be a constant width and requires the extension to be moved in and out. Mounting to the extension will
make it easier to keep the tracker over the reference.
6-3
Figure 6.01b
When tracking a curb and gutter, keep the tracker 14 to 24

inches above the lip of gutter. If the tracker is placed too high,
the sonic cone may pick up an unwanted surface, such as the
face of the curb.
Figure 6.01c
For joint matching and tracking sub-grade or most surfaces

keep the tracker between 14 to 24 inches. A good rule of
thumb is to set the tracker about 18 inches from the reference.
6-4
Figure 6.01d
Temperature and atmospheric conditions will have an effect

on the speed of sound. In paving applications you can get a
dramatic and rapid change in air temperature. A temperature
bail is attached to the tracker to compensate for these variations. If you are on a job where there are high winds and/or
large temperature fluctuations, lower the tracker closer to the
reference.
Figure 6.01e
6-5
If a mechanical ski with an elevated string or wire is being

used, make sure the string/wire reference is a minimum of 4
inches above the ski. When paving with a mechanical ski
through super elevations the ski will tend to pull away from the
paver and may even tip to one side. Elevating the string at least
4" will insure the ski stays out of the working window.
It is also important to place the tracker in the center of the ski
to maximize the averaging length. If you are using a 30' ski,
then the sensor should be placed 15' from the end of the ski.
For every 1' positioning error from the center of the ski, you
lose 2' effectivity of the ski. An example of this would be if
the sensor is moved foreword or backward 2 1/2 ' (12 1/2' from
the end) you are using a 25' ski.
Figure 6.01f
6-6
Some jobs may require the mat be laid to a specified elevation.

In an application like this an elevated stringline or wire may
be set up. As was mentioned in the operation section, the sonic
tracker has a built in working window that will prevent the
screed from diving if the tracker loses the stringline reference.
Position the tracker over the stringline and set the distance
between 18 and 24 inches.
Figure 6.01g
6-7
Sometimes the surface to be paved contains pot holes or the

surface is too broken up to use as a joint match reference.
Setting an elevated stringline is too time consuming especially
for small, divided up projects. In these applications, surface
stringline would be a good alternative. (See section on Setting
Surface Stringline).
Figure 6.01h
6-8
We've discussed how far a tracker should be positioned from

the reference, now we need to look at where the tracker should
be placed in relation to the screed. As a tracker is moved closer
to or further away from the screed, the response of the screed
to an elevation correction changes. A rule of thumb is to place
the tracker about 1/3 to 2/3 the length of the tow arm forward
of the screed pivot point.
Figure 6.01i
If the tracker is not placed between these points then incorrect

screed responses could result. Let's look at a couple of
examples. If the tracker is placed directly at the screed pivot
point, you can see exactly where the screed is relative to the
grade reference. This is good, but the problem is we have no
feedback from the tow point cylinder, which is what we are
using to make the grade control changes.
6-9
Figure 6.01j
If the tracker gets closer to the reference, it sends a raise

correction signal to the valve and the tow point cylinder begins
to move up. Because the screed floats it does not react
immediately to the tow point movement so the tracker continues to send raise correct signals to the valve. By the time the
screed gets to grade, (approximately 3 tow arm lengths) the
tow point cylinder has moved too far causing the screed to
continue raising. The tracker senses this over correction and
sends a lower signal to the tow point cylinder, repeating the
whole process in the other direction. Therefore, with the
tracker mounted at the screed pivot point, long waves in the
mat will be produced because there is no feedback from the
tow point cylinder to the screed.
Figure 6.01k
6-10
To compensate for no tow point feedback let's place the

tracker directly at the tow point where we are making the grade
corrections. At this point we can keep the sonic tracker an
exact distance from the grade reference. Any tracker elevation changes will cause the tow point cylinder to move right
away.
The problem with the tracker placed here is we have no
feedback from the screed.
Figure 6.01l
If any of the forces acting on the screed change then the screed
will rise or fall without the tracker sensing the movement. For
example if the amount of material in front of the screed was
decreased, the head of material force "M" also decreases and
the screed would begin to fall. The sonic tracker would keep
the tow point cylinder on grade, but not the screed since there
is no feedback.
6-11
Figure 6.01m
The best place for the tracker is in the 1/3 to 2/3 zone, but
where do we position the tracker within that area? That
depends on what end result of paving you are trying to
achieve. As the tracker is moved further back towards the
screed it becomes more reactive. At the 1/3 point a 1/4
inch correction at the tracker will cause a 3/4 inch correction at the tow point. Another way to look at it is the "Net
Tow Arm Length".
A paver with a 9 foot tow arm and no sonic tracker will
take 27 feet (9 feet x 3 tow arm lengths) to see 96% of the
elevation change. If a tracker is placed at the 1/3 point or 3
feet in front of the screed pivot point then the paver must
only move 9 feet (3 feet x 3 tow arm lengths) for 96% of
the elevation change. The tracker is measuring the distance
to the reference so its position along the tow arm becomes
the net tow arm length. A more reactive screed would be
beneficial for applications where it is important to match
the reference such as tracking a curb and gutter or matching
a joint.
6-12
Figure 6.01n
As the tracker is moved further forward the screed becomes

less reactive. A tracker placed at the 2/3 point and looking
for a 1/4 inch correction will only cause the tow point to
move 3/8 inch. The net tow arm length is now 18 feet
(6 feet x 3 tow arm lengths). This would be a better tracker
position for applications where smoothness is desired such
as mainline paving or when using a mechanical or noncontacting (SAS) ski.
Figure 6.01o
6-13
Notes
6-14
Chapter 7: Stringline
Stringline
Setting Surface Stringline
Surface Stringline is a great replacement for a contacting
averaging ski, or where no reference is available or practical. The purpose of a ski is to average out the irregularities
of the surface being paved. Although a good idea in principle, averaging skis seldom work well in practice. They
are bulky, complex, cumbersome and get broken easily.
When they are working they still only average over their
length.
Surface Stringline is better. As a Surface Stringline is
stretched over the ground it levels out the high places and
bridges the low, creating a very natural average over a
distance as long as 500 feet. Since the Sonic Tracker IITM is
non-contacting, it can track Surface Stringline without
deflecting it, producing an extremely smooth surface.
Additionally, the smoothness of the surface you will get
from Surface Stringline is verifiable before you begin
paving. Just sight down the string and you can see how
good the job will be. If there will be problem areas, mark
the spots and either fix them ahead of time or use the marks
as a "I told you so" for future reference. You can also use
the same Sonic Stringline as a steering guide.
7-1
Figure 7.0
Position the tracker 14 to 18 inches above the stringline.
Figure 7.01a
NOTICE
It is important to use a stringline with a diameter at
least 1/8" thick. The sonic tracker can detect a
smaller diameter stringline, but when stretched on the
surface to be paved the surface below the stringline
will be within the working window so you want to
make sure you have a strong return signal.
7-2
To setup surface string, simply drive a concrete nail into the

existing surface to be overlaid and tie the stringline to the
concrete nail.
Figure 7.01b
7-3
Roll out the stringline to the desired length. Pull tight and
secure to another nail at the opposite end.
The tightened stringline will rest right on top of the existing
surface.
When the sonic tracker sends out a sound wave, the first thing
the tracker sees will be the reference stringline.
Figure 7.01c
Since the stringline has been pulled tight, any small variables
in the existing surface will be bridged. You now have 500 ft.
ski.
Figure 7.01d
The operator may use the surface stringline for steering and
grade control.
Trucks and other traffic can drive right over the top of the
surface string with out causing any grade control problems or
damage to the reference
7-4
The surface stringline is a verifiable grade reference, what you

see is what you get. Any potential problems can be pointed out
to the inspector before you pave. Try it, it really works!
Setting Elevated Stringline

On some projects the asphalt must be laid to a specified
elevation. For this application an elevated stringline
must be set. The stringline will usually be set up at a 1'
or 2' "hike up" from finished grade. The stringline is set
referencing hubs or lath placed by the surveyor.
Figure 7.02a
Sonic Stringline provides an inexpensive, easy to set up,

continuous reference that takes the best advantage of the
non-contacting feature of the Sonic Tracker IITM. By taking
a few minutes to set up a stringline the Tracker can transfer
grade to the paver 39 times per second! The stringline also
becomes a great visual reference for the job. Any mistakes
in a hub elevation can be quickly spotted by just sighting
down the string.
7-5
Figure 7.02b
NOTICE
Although Topcons Sonic Tracker will work with many
sizes and types of stringline, for best results werecommend an 1/8 inch diameter nylon stringline. Using
steel wire or a plastic coated stringline with a smooth
surface is not recommended. If the Tracker will track
the ground, but will not track a 1/8 inch diameter
stringline, clean or replace the transducer.
1. Place the Sonic Grade Clips on stakes and drive

the stakes approximately 6 to 8 inches away
from, but in line with, the hubs (Do Not disturb the
hubs).
7-6
Figure 7.02c
2. Using an anchor pin at each end, roll out the Sonic

Stringline the length of the working area and pull
the stringline tight.
3. After the stringline has been pulled tight, place it
into the fingers of each Sonic Grade Clip.
Figure 7.02d
4. Decide what the Sonic Stringline hike-up (the

distance from Finished Grade to the Sonic
Stringline) should be: in this case, 2 feet.
Make a cut/fill lath using a lath and a Topcon
Cut/Fill Decal.
7-7
Measure, from the bottom of the lath, the desired

hike-up and make a mark at that point. Place the
Cut/Fill Decal on the lath with 0 on the point
you marked.
Figure 7.02e
5. Next, set the cut/fill lath on the hub and read the
cut or fill from the grade stake next to the hub.
Adjust the clip up or down until the stringline
crosses the cut/fill lath at that point.
A cut of .25 feet
7-8
Figure 7.02f
The stringline is now set to 2 feet above

finished grade.
Figure 7.02g
Repeat this process at each station before

starting to pave.
Figure 7.02h
7-9
Setting Stringline to Projected Slope

Jobs with slope transitions or super-elevations
must have the stringline set to the projected
slope. Failure to do this will produce an elevation
error at the edge of the road as the slope is
changed. To set the stringline to the projected
slope, first set up the string at the desired hike up
as shown in the previous pages. Next, raise or
lower the stringline to compensate for the % slope
and the distance from edge of the road to the
stringline. [RISE = (RUN)(%)]. If the road is rising
away from the stringline, the stringline will need to
be lowered. If the road is sloping down from the
stringline, the stringline will need to be raised.
This adjustment is needed at each station.
Example: 2.0% Cross Slope with 2 feet offset.
Figure 7.02i
7-10
Example: 3.0% Cross Slope with 2 feet offset.
Figure 7.02j
On some jobs, it may be more practical to secure the

stringline directly to the grade stake next to the hub.
First, mark the lath with a 2 or 3 feet hike up or boot
above grade, just as you would to check grade with
an eye level or pulling a string across the street.
7-11
Figure 7.02k
Secure an anchor pin at each end of the stringline

and pull the stringline tight. At each station, staple or
ty-rap the stringline directly to the witness lath so the
stringline is at the desired hike-up.
Figure 7.02l
Due to the height of some stakes the Tracker may

need to be raised or the tops of those stakes may
need to be cut off.
7-12
Making a Grade Verification Lath

Verifying grade requires measuring the distance
from the asphalt to the Sonic Stringline. Because
the hubs are offset from the edge of road and the
Sonic Stringline is a predetermined hike-up
above Finished Grade, a simple tool called a
Grade Checking Lath can be constructed. This
can be easily done using lath, a level bubble and
simple hand tools.
In this example assume that the hub offset from
the edge of road is 1.5 feet and that the hike-up
is 2.0 feet. Construct a Grade Checking Lath as
shown below.
7-13
Figure 7.02m
Verifying Grade
To verify grade, set the Grade Checking Lath on the
newly laid mat edge so that the level bubble
extends over the Sonic Stringline shown below.
Figure 7.02n
7-14
Tilt the Grade Checking Lath until the level bubble is

centered. Finished Grade is correct when the level
just touches the Sonic Stringline.
Chapter 8: Smoothtrac (SAS) Set Up
Smoothtrac (SAS) Set Up

Topcon's Smoothtrac is a non-contacting averaging system
that uses multiple sonic trackers to smooth out the bumps and
dips in a mat surface. The non-contacting design allows full
maneuverability of the paver when turning around, backing
up or passing over obstacles without lifting or removing the
beam. The screed man can adjust mat thickness on the
control box while standing on the screed. The Smoothtrac
is mounted to the tow arm of the paver, and connects to
System FiveTM with the same coil cord used for the Sonic
Tracker.
Figure 8.0
8-1
When mounting the SAS to the paver there are a few

simple steps to follow First, if the ski is not in one piece,
connect both halves together.
Figure 8.01a
Next, mount the "L" bars to the brackets on the tow arm.
The outside "L" bar can be attached so it points up or
down. The position will depend on how tall the tow arm is
off the ground. For pavers with a tall tow arm, mount the
"L" bar in the downward position. For shorter tow arms,
mount in the upward position. Place locking collars on
bars and adjust so they are parallel with one another before
tightening with an Allen wrench. This will allow the ski to
move freely when adjustments need to be made without
falling off.
8-2
Bend "L" bars so they are aligned in the same position and
fold inwards so they are close to the paver. Make sure
clamp handles are loose so bars can move.
Figure 8.01b
Lift ski and slide over "L" bars. Adjust the ski so it is
approximately 2 1/2 feet off the ground. Slide the locking
collar up to the ski and lock in place. Helpful hint, the ski
will be easier to mount if the end beams are folded in.
Bend "L" bars so they are aligned in the same position and
fold inwards so they are close to the paver. Make sure
clamp handles are loose enough so bars can move.
8-3
Lower each of the Tracker hangers on the SAS and mount a

Sonic Tracker using the "L" handle bolt. An extra washer
may need to be added so the "L" handle does not block the
cable connection.
Figure 8.01c
Connect the SAS coil cable to each tracker to the Sonic

Tracker coil cord. Make sure to loop the coil cable through
the "U" hangers to keep it from getting damaged. Don't
forget to install temp bails before paving!
8-4
Figure 8.01d
Positioning the SAS

The SAS should be positioned so the Sonic Trackers are 14
to 24 inches from the grade reference. As with single
tracker operation, the "lower the better" is a good rule of
thumb for paving applications. This will help minimize the
variable temperature conditions that can cause erratic
signals. The beam does not have to be perfectly level
because each tracker averages the distance to the reference
individually.
Figure 8.02a
With SAS be careful when the screed is raised, that the

front tracker does not hit the ground. If needed the tracker
bracket can be folded back when raising the screed to keep
the tracker from hitting obstructions.
8-5
The trackers can be placed so all four are over the reference, or the back tracker can be set over the freshly laid
mat. The best method is the one you are presently using or
the one in which you are most comfortable.
8-6
Figure 8.02b
In some applications the grade reference outside the screed

extension may not be in satisfactory condition, such as the
shoulder of a road or the broken and warped edge of pavement. Traditionally the screedman would manually adjust
mat thickness on that side of the paver. The non-contacting
SAS can be set up over the screed so full automation can be
used. The first three trackers will reference the existing
grade and the back tracker will reference the mat just laid.
Figure 8.02c
8-7
When paving with the screed extensions out, there may be

a large "head of material: which could be picked up by the
Sonic Tracker. If this happens determine how far forward
the tracker must be placed on the beam to not pickup the
mix and drill a new mounting hold for the tracker hanger.
The SAS coil cable will easily reach the tracker.
Figure 8.02d
8-8
Placement of Sonic Averaging System

The center connection point of the SAS is the balance
point. The position of the balance point to the tow arm is
very critical. By moving the balance point, the performance of the system is greatly affected. The balance point
of the beam should be located 1/3 to 2/3 the distance from
the pivot point of the screed to the tow point cylinder.
Placing the balance point closer to the 2/3 point (near the
tow point cylinder), will cause the system to have a slower
reaction time. This would be good for smoothness or for
mainline paving. Placing the balance point near the back
1/3 (closer to screed) will cause the system to have a faster
reaction time. This would be good for a combination of
smoothness and joint matching.
To determine where to position the SAS on the paver, start
by measuring the length of the tow arm. Divide the total
length by three. This will give you the placement of the
balance point of the SAS on your machine.
8-9
Figure 8.03a
Once the SAS has been installed, the System Five control
box will automatically configure for SAS when powered
on. The box will check to see how many trackers are
connected and average over that amount.
Getting the System Five Box ready to pave is the same as
with one tracker.
1. Block screed for required mat thickness
2. Center hydraulic rams
3. Null screed and turn on augers to place material in front
of the screed
4. Place trackers over reference
5. Push survey button on Box to lock trackers On-Grade.
6. Push and hold set button while dialing in mat depth.
7. Put Control Box in Auto and begin paving.
Figure 8.03b
NOTICE
8-10
It is not necessary to start paving in manual as is

traditionally done when using a mechanical ski. If the
setup procedures are followed correctly, paving with
the SAS can and should start in automatic.
The SAS system has been designed to discontinue operating

when one of the Trackers fails. When a failure occurs, the
control box will flash "ERR" followed by a number from 1 to
4. The number represents the Tracker which failed, making
troubleshooting easy and fast.
To reset the control box once a new tracker has been installed, or if the tracker has been removed and only three
trackers will be used, turn the power off then on. The control
box will reconfigure to the number of trackers. Changing the
number of trackers may change the average distance. Resurvey the Control Box to lock SAS On-Grade.
Once one of the Trackers has been eliminated from the
averaging, the balance point of the beam will have changed.
If the faulty Tracker is not replaced the beam will need to be
repositioned to adjust for the new balance point. It is strongly
recommended, if the first or last Tracker fails, to replace it
with one of the Trackers from the middle of the beam. This
will insure that the balance point is not outside of the 1/3 to
2/3 rule.
NOTICE
A number reading of "1" could mean the first or last
Tracker has failed depending on which side of the paver
the beam has been mounted. The SAS cable is labeled
with numbers at each connector for easy identification.
8-11
Figure 8.03c
8-12
Chapter 9: Applications
Applications
What type of controls you should use for paving depends on
what result is required for the finish product. Some projects
are looking for smoothness and improved rideability. Others
are concerned with mat thickness and some require the new
asphalt to match curb and gutter or existing grades. Topcon's
System Five is very versatile and can be used in all these
applications. The following are a few examples of what
controls might be used and how to set them up.
Paving City Streets with Sonics

When paving city streets the general requirement is to lay a
mat that is so many inches above the base at the centerline
and to match curb and gutter. For this application sonic
control will be used on both sides.
Figure 9.01a
NOTICE
Before paving make sure the machine is properly
setup, cross slope is calibrated and trackers are set in
the correct position. (See Chapters - Getting Ready
to Pave & Tracker Placement.)
9-1
Position right Tracker over lip of gutter and left Tracker

past the centerline on the base material.
Figure 9.01b
Turn Boxes on, then "Survey" and "Set" the displays to

read the depth of asphalt to be laid.
Figure 9.01c
Put boxes in Automatic and begin paving. Check depth of

mat at centerline and verify joint is matching at lip of
gutter. After compaction make necessary adjustments on
the Control Box.
NOTICE
If the road width varies, it will be easier to keep the
Tracker over the gutter if the Tracker is mounted to
the extension on the paver.
9-2
To pave the other side of the road, position the left Tracker
over the lip of the gutter and place the right Tracker over
the new mat.
Figure 9.01d
"Survey" boxes On-Grade and "Set" the displays to read the

depth of asphalt to be laid. Put boxes in Automatic and
begin paving. Check to make sure joints are matching after
compaction.
9-3
Paving City Streets with Cross Slope

Another option is to pave the street using cross slope and
sonic control. The Tracker is positioned over the lip of
gutter on one side and cross slope is dialed in for the crown
on the other. This method may have to be modified due to
the fact that in many cases the curbs may be poured at
different elevations across the street. Even though the curb
was poured out of tolerance, it may have passed inspection
and the asphalt needs to match the curb and gutter. If the
curbs are at different elevations, it is impossible to pave a
typical design slope on both sides of the street.
A cross section design of a 36 feet wide street with a 2.0%
slope will produce a .36 feet rise at centerline.
Figure 9.02a
9-4
If the curbs are at different elevations, a .36 feet rise at

centerline will produce incorrect slopes.
Figure 9.02b
When System FiveTM is used to pave a true 2.0% slope, the

crown of the street will not be at the centerline.
Figure 9.02c
9-5
To pave from uneven curbs using slope control choose the

side of the road with the highest curb and position the
tracker over the curb. Set the other side for the desired
cross slope and begin paving.
Figure 9.02d
To keep the centerline in the middle of the road, the second

pass will have to be set up with Sonic Control on each side
of the paver. The left Tracker will match the lip of the curb
and the right side Tracker will follow the new mat. The
cross will not be consistent on this side of the roadway, but
the joints will match.
9-6
Figure 9.02e
The curb elevations can be easily spot checked using a fast

leveling RL-HB rotating laser. Set the laser at the lip of
one curb, then use the detector and a folding rule to take a
reading on the other curb. Spot check every 25-50 feet by
just moving the laser.
Figure 9.02f
Paving Streets Through Intersections

As you pave city streets you will come upon an intersection
where the curb will not continue. There are a couple of
methods for controlling grade through the intersection.
Method 1
For this method the base of intersecting road will be used
as the reference.
With both sides in Elevation Control, pave to the
intersection.
9-7
Figure 9.03a
Just before the right Tracker reaches the end of the curb,
put the Control Box in Manual Mode by pushing the Red
Auto Button.
Figure 9.03b
Without stopping, continue paving until the Tracker is

on the base material of the intersecting road. "Survey"
the Tracker On-Grade on the new reference and put
back into Automatic Control.
Figure 9.03c
9-8
Pave through the intersection and just before the

Tracker reaches the curb on the other side, put the
Control Box in Manual mode.
Figure 9.03d
Without stopping, continue paving until the Tracker is

back on the lip of the curb. "Survey" the Tracker OnGrade and put back into Automatic Control.
Figure 9.03e
9-9
NOTICE
You may find after surveying the Tracker on the curb
that the number has changed slightly from the curb on
the other side of the intersection. This is due to the
different depth of the base below lip of curbs. While
paving, slowly dial the display back to the previous
number.
Method 2
Sometimes the base of the intersecting road is too rough
to use as a reference. A great alternative is to use a
simple piece of stringline. Take a section of 1/8"
diameter string and nail or secure it to the curb. Pull
the string tight through the intersection and nail or
secure it to the other curb. If the intersecting road has a
crown, hike the stringline up in the middle of the road
to place the string at the proper height. A hub or a stake
with a piece of wire to hold the stringline works fine.
9-10
Figure 9.03f
This constant reference will give you complete control

through the intersection and will also insure that you tie
in perfectly to both curbs.
Paving Intersections with Cross Slope

When paving with slope, intersections do not require any
adjustments if the "mainline" cross slope does not change.
If the slope does change, then a combination of slope and
Tracker should be used.
Figure 9.04a
9-11
Put the slope side of System Five Box in Manual just

before the slope of the intersection begins to change.
Switch from slope to elevation control on the box and
"survey" the Tracker On-Grade.
Figure 9.04b
Figure 9.04c
9-12
Pave through the intersection with the Sonic Tracker in

Automatic. Upon reaching the end of the intersection put
the System Five Box back in Manual and change to slope
control and survey the slope to get an On-grade signal.
Figure 9.04d
9-13
Figure 9.04e
Figure 9.04f
NOTICE
You may find after surveying the slope that the number displayed is not the same as the desired cross
slope. This will occur if the surface being paved is not
also at the desired slope. To get back to the correct
slope continue paving in automatic and slowly dial the
display to the desired slope. Failing to survey when
changing back to slope control could result in a bump
in the mat.
9-14
Chapter 10: Maintenance
Maintenance
This section contains information regarding preventative maintenance
and daily care of System FiveTM. Also included are:
1. Cleaning procedures for the Sonic Tracker IITM

Transducer.
2. Replacement procedures for the Sonic Tracker IITM
Transducer.
Preventative Maintenance &

Daily Care
A good preventative maintenance and daily care routine
will prevent many problems before they occur. The most
important part of daily care for System FiveTM is to clean it
and keep it free of debris, and to thoroughly dry removable
components (Sonic Tracker IITM, the Control Box, and
cables) before storing them in the Carrying Case. In addition, the following procedures will ensure trouble free
operation:
1. Keep the Carrying Case clean and dry. Do not
leave it open and exposed to the elements. Clean
and dry all components prior to placing them into
the Carrying Case.
2. Be sure cables left on the paver are attached to
protective connector caps, not in use. Water accumulating on the connectors can cause electrical
shorts.
10-1
3. Do not use high pressure spray water steam cleaner

hoses directly on cables and components. The
components can be used in the rain or light
spraying.
4. Check the Sonic Tracker IITM Transducer daily to
make sure the Filter Foam and Transducer are clean
and free of debris. If the Filter Foam is clogged
with dirt, replace it. If the Transducer appears to be
covered with debris and performance is being
affected (see Sonic Tracker IITM in Chapter 2:
Operation) clean or replace Sonic Tracker IITM
Transducer using the steps listed later in
this chapter.
10-2
Transducer Cleaning
(Sonic Tracker II)
NOTICE
This procedure is not meant to be a regular maintenance procedure. Cleaning of the Transducer should
only be performed when Transducer contamination is
suspected or evident.
Over cleaning of the transducer will result in shortened Transducer life and/or water damage to the
Sonic Tracker.
1. Hold the Sonic Tracker IITM in an UPRIGHT
position (this will prevent moisture from inadvertently entering the Sonic Tracker).
2. Mix a mild detergent with water and place the
mixture in a spray bottle (use Simple Green where
available.)
3. With the Sonic Tracker IITM upright, thoroughly
spray the Transducer with the detergent solution.
4. Once the Transducer has been sprayed with the
detergent, fill the spray bottle with clean water and
rinse any residual detergent off of the Transducer.
5. Allow to thoroughly dry.
If the ability of the Sonic Tracker IITM to "see" a sonic
stringline continues to be impaired, the transducer may be
damaged and needs replaced.
10-3
Transducer Replacement
Procedure (Sonic Tracker II)
NOTICE
If the Sonic Tracker II is experiencing erratic or inconsistent readings, Transducer contamination should be
considered first before assuming any other type of
failure.
The most common sign of Transducer contamination
is the ability of the Sonic Tracker IITM to see the
ground, but not a Sonic Stringline.

1. Remove and discard the
Filter Foam (a new Filter
Foam is provided in the
Transducer
Replacement Kit).
Figure 10.01a
10-4
2. Remove the four screws and the black Retaining

Ring. There are four replacement screws supplied
in the Transducer Replacement Kit, but it is
advisable to use the original screws and keep the
four supplied in the kit for
replacements in the event
one or more are lost).
Remove and discard the
O-Ring (a new O-Ring
is supplied with the Transducer Replacement kit).
Figure 10.01b
NOTICE
Always remove and discard used O-Rings. Used
O-Rings will be distorted and may loose there elasticity due to weather or exposure to diesel fumes.
3. The Transducer can now be gently pulled out. Use
a SMALL pair of dikes to gently cut the Ty-Wrap
then remove the small wire connectors from their
tabs.
NOTICE
When cutting the Ty-Wrap, be careful not to cut or
damage the wires.
Figure 10.01c
10-5
4. Place the wire connectors of the new Transducer

firmly on their tabs (the gray wire connector is
placed on the elevated tab). Place the Ty-Wrap in
the slot next to the elevated (gray wire) tab, tighten
and trim. DO NOT pinch the wires.
Figure 10.01d
5. "Feed" the wires back up into the Sonic Tracker IITM

and seat the Transducer into place (the two wire
tabs have to sit down into the extra deep area of the
recess). Place the new O-ring around the
Transducer and seat firmly between the Transducer
and the Sonic Tracker IITM Transducer recess.
Figure 10.01e
10-6
6. Place the black Retaining Ring over the Transducer

assembly with the beveled edges out and the flat
surface against the Sonic Tracker IITM base. Line up
the holes for the mounting screws (the mounting
screw holes are set to an irregular pattern. This
ensures the retaining ring will only lineup with the
mounting holes one way).
7. Start the mounting screws into the holes and tighten
each until firm. DO NOT OVER TIGHTEN. Use a
cross (X) pattern to tighten screws.
Figure 10.01f
NOTICE
Over tightening may distort the Transducer metallic
material and may crack the Retaining Ring. Use of
the O-Ring assures tightness while preventing
vibration from loosening the Mounting Screws.
10-7
NOTICE
DO NOT use Loctite on the mounting screws.
Loctite will attack the plastic retaining ring.
8. Make sure there are no visible wrinkles in the
metallic surface inside the Transducer. If distortion
is evident, repeat Steps 5 through 8.
9. Place a NEW Filter Foam over the Transducer. The
Sonic Tracker IITM is now ready to return to
operation.
10-8
Chapter 11: Troubleshooting
Troubleshooting
Control Box Symptoms
1.
Control Box LCD does not Display
2.
Control Box LCD displays "Error"
3.
Cannot adjust to On-Grade when Elevation

Control is selected.
4.
Tow point cylinder does not move Up or Down
5.
Tow point cylinder moves in the

wrong direction
6.
Tow point cylinder moves too fast or too slow.
7.
System intermittently drives the cylinder all the

way up or down when tracking a mechanical ski.
8.
Control Box displays Error and a number

from 1 to 4
9.
Grade lights flash high and low and will not

stay On-Grade.
10. The valve is driving the hydraulic cylinder

too far overshooting grade.
11. The valve will not drive hydraulic cylinder far
enough to get sensor On-Grade.
12. The Control Box displays "No Signal" when
indicate is selected in elevation mode.
13. The Auto light on the Control Box intermittently
flashes on and off.
11-1
Control Box Symptom 1
"The Control Box LCD does not display."
Probable Cause
No power to the Control Box.
1. Check that the machine power is on and all
switches for automatic control on the paver
are in the proper position.
2. Check that all cables are properly and
securely connected to the System Five
Box and the paver. Make sure cables are
not still connected to Control Box bracket.
3. Disconnect cables and inspect them for
damage or contamination. Clean all
connections with an electrical contact
cleaner.
NOTICE
Do not use electrical contact cleaner to clean
the Tracker's transducer.
4. Swap Control Boxes from left to right side.
5. For System Four bypass Junction Box by
plugging coil cord from paver to J-Box
directly into Control Box.
11-2
"Control Box LCD shows 'Error '"
Figure 11.0
Probable Cause
No communication with the sensor selected.
1. Check that all cables are properly
connected to System Five Control Box
and sensors.
cleaner.
NOTICE
Do not use electrical contact cleaner to clean
the Tracker's Transducer.
3. If elevation has been selected, one at a
time, swap the Sonic Tracker II and
cables from the opposite side to locate the
error.
11-3
4. Refer to Tracker Symptom #1.

5. If slope has been selected, check that slope
has not been selected on the other Control
Box. Only one box at a time can have
slope turned on.
6. Swap slope cable from opposite side.
7. Disconnect cable at slope sensor and
connect to other side of sensor to check
slope sensor pins.
"Cannot adjust to On-Grade when elevation

control is selected."
Probable Cause
Tracker is too close to control reference.
1. Check that the Sonic Tracker II is at least
14 inches away from the control reference.
2. Check for unwanted objects within the sonic
footprint.
3. Make sure tracker is not positioned in front
of a gusty heat source, such as the engine
fan exhaust.
11-4
4. Stop the paver, make sure the screed is on

the ground and turn the vibrators off. Press
Survey and hold for 2 seconds. "IND" will
display on the faceplate and a number will
be displayed on the LCD. The number
should stay constant, or change up and
down by a few numbers. If the numbers
fluctuate significantly then the Transducer is
probably weak or damaged.
5. Check for contamination on the Sonic

Tracker II Transducer or foam filter.
Refer to Transducer and Filter Cleaning and
replacement information in the Maintenance
and Parts section of this manual.
6. Swap the Tracker with the unit on the
opposite side.
7. Averaging may be set too low if tracking an
uneven reference. Factory setting is 50.
"The tow point cylinder doesn't move up or down."
Probable Cause
Machine electrical switches are not in the
proper position, or hydraulics to the cylinder
are not active.
1. Check that all locking pins have been
removed and that all hydraulic blocking
valves are in the open and correct position
for automatic control. Refer to the paver
manufacturer's manual.
2. Check that all machine electrical switches and in motion circuits are in the correct
position for automatic control. Refer to the
paver manufacturers manual. Press the jog
switch up and down on the Control Box to
make sure there is a current going to the
valve. Cylinder should move in the same
direction the jog switch is pressed.
3. Check that the Auto Switch is in "Auto" and
that the Auto Symbol is illuminated on the
front panel.
11-5

cleaner.
5. Swap the Control Box with the unit on the
opposite side.
6. If a Control Box is replaced make sure the
configuration and performance settings are
correct.
7. If a cable is replaced make sure it is the
right part number. A cable with the incorrect
resistor could set the Control Box to have the
wrong configuration.

"The tow point cylinder is moving in the
wrong direction."
Probable Cause
Machine is incorrectly wired or

hydraulically connected.
1. Check that the machine is properly wired
and hydraulically connected to the valve.
A raised jog switch should make the
cylinder go up, lowering the jog switch
should make the cylinder go down.
2. Check that the proper cables have been
supplied for your machine.
3. For System Four, if "OIN" setting is in the
performance menu, make sure it is in the
off position.
11-6
4. Make sure the screed lift cylinders are in the

float position and not supporting the screed.

"The tow point cylinder is moving 'too
fast' or 'too slow."
Probable Cause
The paving machine's hydraulic flow
adjustment is incorrect, or the control

box Valve Offsets or Gain Adjustments
are not correct.
1. Refer to paver manufacturers recommended
flow adjustment setting for the time it takes
the hydraulic cylinder to complete a full stroke
of travel. Typically between 12 to
15 seconds.
2. Adjust Gain Performance Settings. Factory
setting is 25.
3. Adjust Valve Offsets. Refer to Valve Offset
section in the Performance Section within this
Manual.

"System intermittently drives the cylinder all the
way up or down when tracking a mechanical ski."
Probable Cause
Tracker is intermittently picking up signals
from the ski.
1. Verify string is at least 4 inches above the
surface of the ski. Ski will pull away from the
paver and can get in Tracker's Working
Window if string is too close. Ski will also
tilt to one side when traveling through
a super elevation or slope transition.
11-7
2. For a multi-foot ski, make sure "foot spring

pin" is not within the sonic footprint as the ski
surges back and forth.

"Control Box displays Error and a number from 1-4"
Probable Cause
Defective Sonic Tracker or SAS cable.
1. Check SAS cable connections at each tracker.
2. Turn Control Box off and swap tracker showing
the error number (1-4) with another tracker on
the SAS. (Tracker number is on the cable at
the tracker connector). Turn Control Box on to
reset SAS. If the error number (1-4) has
changed, the problem is the tracker. If the
error number remains the same, the problem is
the SAS cable.
3. If more than one error number is shown, check
trackers individually by plugging sonic trackers
directly into the single tracker coil cord to determine if trackers or SAS cable is source of error.
4. The defective tracker or SAS cable
should be repaired, but SAS can still be
operated without all four. Remember balance
point will change if a tracker is removed.
11-8

"Grade lights flash high and low and will not stay
on grade."
Probable Cause
If problem is only in automatic mode, then
hydraulic Performance Settings are incorrect.
1. Verify paving machines hydraulic flow adjustments (time for hydraulic cylinder to travel full
stroke) are set to manufactures recommendations.
2. Check that the Valve Offsets are set correctly.
3. Check that the Gain setting is too high.
Factory setting is 25.
If problem is in manual mode, then
1. Verify that temperature bails are clean and

securely attached.
2. Verify temperature bail symbol "T" is displayed on face of Tracker. If not clean or
replace transducer.
3. Check that Trackers are between 14 and 24
inches from reference.
4. If there are gusty winds, lower Tracker
closer to reference. Approximately 14 to 16
inches.
5. Move Tracker away from gusty heat source,
such as engine fan exhaust.
6. Verify Tracker is not picking up erroneous
signals from undesired reference.
Example: Head of material, end gate,
shoulder grade or material spillage
from hopper.
11-9
7. If using Stringline, verify line is not bouncing.

8. Check to see if Averaging in Performance
Menu is set too low. Factory setting is 50.
9. Check Deadband in Performance Menu is not
less than 3mm.

"The valve is driving the hydraulic cylinder too far,
overshooting grade."
Probable Cause
Valve Offset in Control Box are set too high.
1. Lower the Valve Offset value till the sensor
no longer overshoots grade. Refer to
"Setting Valve Offsets" section in this manual.
2. For Servo and solenoid valves lower the
value by 2 to 5 numbers, then check the
hydraulic performance.
3. For Proportional valves, lower the value by
10 to 15 numbers, then check hydraulic
performances.

"The valve will not drive hydraulic cylinder far
enough to get sensor On-Grade."
Probable Cause
Valve offsets in Control Box are set too low.
1. Raise the Valve Offset Value till the sensor
is driven to grade. Refer to "Setting Valve
Offsets" section in this Manual.
11-10
2. For Servo and Solenoid valves raise the

value by 2 to 5 numbers, then check
hydraulic performance.
3. For Proportional valves raise the value by
10 to 15 numbers, then check hydraulic
performance.

"The Control Box displays 'No Signal' when
indicate is selected in elevation mode."
Probable Cause
Sonic Tracker is reporting no echo.
1. Verify that the Sonic Tracker is ticking.
2. Make sure tracker is pointing at a target with
the working range, recommended 14 to 24
inches.
3. Transducer may be dirty or damaged. Refer
to the Transducer and Filter section within
this manual.
4. Power or ground connection at transducer
may be loose. Remove transducer and check
wires.
11-11

"The Auto light on the Control Box intermittently
flashes on and off."
Probable Cause
Sonic Tracker is too far from reference for
current atmospheric conditions, or Temperature
Cutout is too low.
1. Verify that the Sonic Tracker is positioned 14
to 24 inches from the reference. If there are
gusty winds lower the Tracker to 14 to 16
inches from the reference.
3. Temperature Cutout is set too low. Factory
setting is 7. Refer to Technicians manual.
11-12
Tracker Symptoms
1.
Sonic Tracker will not power on.
2.
Sonic Tracker is ticking, but will not adjust to Grade
3.
Tracker grade lights flash high and low and will

not stay On-Grade.
4.
Sonic Tracker is not matching joint or curb.
5.
The Sonic Tracker will pick up the ground, but

will not pick up a stringline.
Tracker Symptom 1
"Sonic Tracker will not power on"
Probable Cause
Defective cable or tracker.
1. Check coil cord is plugged in correctly and
securely.
2. Inspect Coil cord for any physical damage.
3. Turn Control Box on and watch the tracker
lights to make sure they go through the
power up sequence. All the lights on the
tracker should flash at once followed by a
flash of an arrow pointing to the left. The
"T" symbol should also be displayed in the
upper right hand corner of the tracker
faceplate when a Temperature Bail is
attached. If the tracker does not go through
this sequence then the tracker is not getting
power or is defective.
4. One at a time, swap tracker and then coil
cord from opposite side to determine the
problem.
11-13
Tracker Symptom 2
"Sonic Tracker is ticking, but will not adjust to
grade."
Probable Cause
Tracker is too close to reference, minimum
working distance is 14 inches.
1. Tracker is too close to reference point.
Position tracker 14 to 24 inches from grade
reference.
2. Connect tracker to other side of paver to
determine if problem stays with tracker.
3. If problem stays with tracker, clean or
replace transducer or foam filter. Refer to
the Transducer and filter cleaning and
replacement information in the
"Maintenance and Parts" section of this
manual.
4. If problem does not move with tracker,
inspect coil cord for damage and swap with
cord from other side.
Tracker Symptom 3
"Tracker grade lights flash high and low and will
not stay On-Grade."
Probable Cause
If problem is only in Automatic Mode, then
Hydraulic Performance Settings are incorrect.
11-14
1. Verify paving machines hydraulic flow

adjustments, time for hydraulic cylinder to
travel full stroke, are set to manufacturers
recommendations. Typically 12 to 15
seconds.
2. Check Valve Offsets are set correctly. Refer

to setting valve offsets.
3. Make sure Gain Setting is not too high.
If problem exists in manual mode, then

Tracker is setup incorrectly or Performance
Settings are incorrect.

securely attached.
2. Verify temperature bail symbol "T" is dis
played on face of Tracker. If not, clean or
replace transducer.
4. If there are gusty winds, lower Tracker
closer to reference. Approximately 14 to 16
inches.
6. Verify Tracker is not picking up erroneous
signals from undesired reference.
Example: Head of material, end gate,
shoulder grade or material spillage
from hopper.
7. If using Stringline, verify line is not bouncing.
11-15
9. Check that Deadband, in Performance

Menu, is not less than 3mm.
Tracker Symptom 4
"The Sonic Tracker is not matching joint or curb."
Probable Cause
Tracker is too far forward on the tow arm.
1. Position the Tracker at 1/3rd the tow arm
length (just in front of auger).
2. Gain for tracker may be set too low. Adjust
Gain to a minimum of 25.
3. Brackets and L-Bars have not been securely
tightened. Also, check for excessive
play or slop where tracker is attached to the
paver. (Tow arm or end gate.)
Tracker Symptom 5
"The Sonic Tracker will pick up the ground, but will
not pick up a stringline."
Probable Cause
Tracker is too close to a reference or transducer
is weak.
1. Verify that tracker is at least 14" from the
stringline.
2. Smooth, steel wire is not recommended.
Use minimum 1/16" diameter string for
elevated stringline or averaging ski. Use
1/8" string for Surface Stringline.
11-16
Slope Sensor Symptoms

1. Cross Slope reads "Error"
2. Cross slope drives cylinder in the wrong direction
3. Slope lights flash between raise and lower and
will not stay On-Grade.
4. Cross slope will not lock On-Grade.
5. Cross slope being laid is not correct.
Slope Sensor Symptom 1

"Cross Slope reads 'Error."
Probable Cause
Both Control Boxes are selected for slope or
have a defective cable.
1. Cross slope operates one side at a time.
Verify only one Control Box has been
selected for slope.
2. Verify that the slope cable is connected
securely and properly.
3. Swap slope cable from other side to check
cable.
11-17

"Cross Slope drives cylinder in the wrong
direction."
Probable Cause
Slope sensor installed incorrectly.
1. Verify the slope sensor is positioned
correctly on the transverse beam. "Slope
Forward" Decal must be in direction of travel.
2. Check that the machine is properly wired
and hydraulically connected to the valve.
Raised jog switch should make the cylinder
go up, lower jog switch should make the
cylinder go down. Refer to the paver
manufacturers manual.

"Slope lights flash between raise and lower and will
not stay On-Grade."
Probable Cause
Incorrect Performance Setting adjustments or a
loose transverse beam.
1. Check Valve Offset for proper operation.
Refer to "Setting Valve Offsets" section in this
manual.
2. Check gain setting. Factory setting is 25.
3. Slope deadband set too low. Increase Slope
Deadband. Factory Setting is .075%
4. Check for excess vibration in the Transverse
Beam due to poor connection at Tow Arm.
11-18
5. Make sure slope sensor is mounted directly to

the Transverse Beam and is not elevated or
supported by additional brackets.

"Cross Slope will not lock On-Grade."
Probable Cause
Loose Transverse Beam or incorrect
Performance Setting adjustments.
1. Verify that the Slope Sensor is not moving
or vibrating when trying to survey slope on
grade.
2. Slope deadband setting is too low, factory
setting is .075%.
3. Stop the paver, make sure the screed is on
the ground and turn the vibrators off. Press
Survey and hold for 2 seconds. IND will
display on the faceplate and a slope value
will appear in the LCD. The number should
stay constant or change up or down by a
few counts. If the numbers fluctuate
significantly then the slope sensor is
probably the problem.

"The Cross Slope being laid is not correct."
Probable Cause
Calibration in Slope Sensor is incorrect.
1. Calibrate the Slope Sensor as described in
Daily Cross Slope Calibration in the
Function and Operations section.
2. Check that the Transverse Beam is
mounted according to the manufacturers
instructions and that it is not loose
or damaged.
11-19
3. Recheck slope using a good reference such

as a laser or level. Make sure to wait at
least 3 tow arm lengths before checking the
slope after a change has been made.
4. If the paver's mat thickness controls have
been used then the slope calibration may
have to be changed. This can occur after
"buying back" cylinder.
11-20
SAS Symptoms
1. When the SAS is connected, control Box displays
"Error" and a number.
2. 1 Tracker stops working
3. SAS will not lock On-Grade
4. SAS is not producing smooth surface
5. Tracker picking up head of material
SAS Symptom 1
"When the SAS is connected, the Control Box
displays 'Error' and a number."
Probable Cause
Defective tracker or cable, tracker with
incorrect code.
1. Verify that all trackers are correctly and
securely plugged into the SAS cable.
2. Turn Control Box off and move the Tracker
to a different position on the SAS cable.
Turn the Control Box on to reconfigure
SAS. If error number moved positions with
the swapped tracker, then the tracker is the
problem. Replace transducer if necessary.
Refer to transducer and filter cleaning and
replacement information in the
"Maintenance and Parts" section of
this manual.
11-21
3. Check to see if a Tracker without SAS code

is attached to the cable. Verify that the
tracker has a SAS compatible decal near
the S/N label.
Figure 11.01a
4. Tracker can also be checked by verifying

code revision. Turn box off and back on.
Watch the temperature bail symbol in the
top right portion of the tracker. The "T"
symbol will flash a certain number of times,
pause and flash again to indicate the
revision of its code.
Figure 11.01b
11-22
Example: Flash twice, pause flash twice

means the code in the Tracker is
2.2. SAS requires trackers with
code of 2.2 or higher.
SAS Symptom 2
"A Tracker stops working."
Probable Cause
Defective Tracker.
1. Check SAS cable connections at each
tracker.
2. Turn off Control Box and swap tracker
showing error with another tracker on the
SAS. (Tracker number is on the cable at
the tracker connector). Turn the Control
Box back on to reset SAS. If error number
moved positions with the swapped tracker,
then the tracker is the problem. Replace
transducer if necessary. Refer to
Transducer and Filter Cleaning and
Replacement information in the
"Maintenance and Parts" section of this
manual.
3. If error continues to display for the same
position even after trackers have been
swapped, the tracker connector or SAS
cable is the problem.
4. The defective tracker or SAS cable should
be repaired, but SAS can still be operated
without all four trackers operating.
Remember balance point will change if a
tracker is removed.
11-23
SAS Symptom 3
"SAS will not lock on grade."
Probable Cause
Tracker too close to reference or defective
transducer in Tracker.
1. Verify that all cable connections are
properly and securely connected.
2. Check that all trackers are sending out
sound waves (transducer is making ticking
sound) and grade lights are flashing.
3. If tracker is not working, check that
transducer and foam filter are clean and
free from damage. Replace transducer if
necessary. Refer to transducer and filter
cleaning and replacement information in the
"Maintenance and Parts" section of
this manual.
4. SAS beam and trackers may be too close to
reference. Bottom of tracker must be
minimum of 14 inches from reference.
5. Non-SAS compatible tracker attached to cable.
Verify tracker has SAS compatible decal near
S/N label.
11-24
Figure 11.02
SAS Symptom 4
"SAS is not producing smooth surface."
Probable Cause
Improper setup or Performance Menu Settings.
securely attached.
2. Verify temperature bail symbol "T" is
displayed on face of Tracker. If not clean or
replace transducer. Refer to transducer
and filter cleaning and replacement
information in the "Maintenance and Parts"
section of this manual.
4. If there are gusty winds, lower SAS to get
Trackers closer to reference.
5. Move the Tracker away from gusty heat
source, such as engine fan exhaust.
6. Verify that the Trackers are not picking up
erroneous signals from undesired reference.
Example:
Head of material, end gate

shoulder grade or material
spillage from hopper.
7. Verify that the center of the SAS beam is

between the midpoint and the forward 2/3
point of the tow arm.
9. Check that Deadband in Performance
Menu is not less than 3mm.
11-25
10. Check that Valve Offsets are set properly.

11. Check that the Gain setting in the
Performance Menu is not set too high.
SAS Symptom 5
"Tracker picking up head of material."
Probable Cause
Improper placement of Tracker
1. Move tracker forward of the material. Rotate Tracker to front of bracket or drill a hole
in the beam far enough forward to move
tracker away from material.
2. Check balance point. Balance point will shift
when moving a tracker.
11-26
Appendix
Appendix
A
Aggregate
Various hard, inert materials such as sand, gravel,

pebbles, etc. used as the bulk material in asphaltic
mixes.
Angle of Attack
The angle that exists between the bottom of the screed

and the grade over which the screed is traveling.
Auger
The broad, spiral flange on a screed which rotates and

spreads paving material evenly in front of the screed.
Auger Shadows
The dark and light areas along the length of a mat surface
caused by the compaction of materials having different
densities and textures.
Automatic Feed Controls
The dual feed system on a paving machine used to

maintain a constant head of material in front of the
screed.
Automatic Grade and Slope Controls
Sensing equipment used on paving machines to set and

maintain proper elevations and percent slope. Paver
Control System FiveTM provides paver operators with
automatic grade and slope control.
A-1
Appendix
B
Bitumen
A thick, viscous, petroleum-based substance used as a

bonding agent in asphaltic mixes.
Bail
A wire frame added to the Tracker that acts as a fixed

target to compensate for rapid air temperature changes.
C
Calibration
Setting the elevation reading or Slope Sensor reading to

match the actual position of the screed.
Compaction
To press tightly, thereby increasing the density of

paving material.
Cone
Pattern of distribution of the Sonic Tracker IITM sound

waves. The sound waves leave the Tracker in a circular
pattern that gets wider as it gets further from the
Tracker.
Conveyor
The assembly used to move paving material from the

hopper to the auger.
Cross Slope
The angle of slope required to produce a desired surface

slope. Cross slope is measured in percent.
Cross Slope
A-2
The angle of slope required to produce a desired surface

slope. Cross slope is measured in percent.
Appendix
Crown
1. The transverse contour of a finished mat.

2. The contour of the screed plate.
3. The transition line between 2 different slopes (i.e.
between lanes or between lanes and shoulders).
Lead Crown
The contour or profile from side to side of the

leading edge of the screed.
Tail (Road) Crown
The contour of the trailing edge of the screed.

Negative Crown
Contour which is higher at the edges than at the

center of a mat.
Positive Crown
Contour which is higher at the center than at the

edges of a mat.
Cut-off Shoe
A detachable plate used to reduce the paving width of a

screed.
D
Density
Compactness of paving material.
E
Edger Plate
A vertical plate at each end of the screed used to con

fine the head of material.
Elevation
The vertical height or depth of the surface being laid.

Elevation is measured in centimeters, inches, or feet.
A-3
Appendix
F
Feeders
The auger-conveyors on the right and left hand sides of

a paving machine.
G
Grade
1. The base surface (road bed) over which paving is

being laid.
2. The elevation of a fresh mat in relation to the base.
3. The incline of a paving surface in the direction of
travel, expressed by stating the rise or fall as a
percent age of horizontal distance
(i.e., 6% grade = 6' of elevation change in 100' of
horizontal longitudinal run).
Grade Control
A means of controlling the elevation of a mat as it is

being laid.
Grade Sensor
An electric device which detects positive and negative

changes in elevation from a grade reference (i.e.,
surface string, floating beam, mat reference, adjacent
mat or curb surface).
H
Head of Material
The volume of paving material directly in front of and

across the entire length of the screed.
Hopper
A-4
The area at the front of the paving machine which

receives the paving material.
Appendix
Hydraulic
Liquid in motion under pressure, the flow of which

causes work to be accomplished.
Hydrostatic Transmission
Power transmitted by a positive displacement pump

through a liquid under pressure to a positive displacement motor.
I
Inclinometer
See Slope Sensor
J
Joint Matcher
See Automatic Level Control
L
LCD
Liquid crystal display. LCD is used in the display

window on the Control Box and Sonic Tracker IITM to
show numbers and symbols for Paver Control System
FiveTM functions.
LED
Light Emitting Diode. These are the red lights seen on

the faces of the Control Box, Sonic Tracker IITM and
Laser Tracker.
Line of Shear
The lateral line of contact in the paving material at the

leading edge of the screed pre-strike-off where material
divides to pass beneath the screed plate or moves
upward along the face of the screed into the augured
material for later placement.
A-5
Appendix
M
Mat
The material being placed by a paver/finisher
N
Null
A condition which exists when components are at rest.

"Null" Screed
A screed resting flat on the mat and having no angle

of attack.
O
On Grade
When a surface is at the desired elevation or slope, it is

referred to as being on grade.
Overlay
Paving over an existing mat.
P
Paddle Box
The sensing device used with automatic feed control to

measure and control the head of material.
Percent (%) Slope
The unit of measure used for cross slope.

Pull Points
See Tow Points

A-6
Appendix
Push Roller
Rollers mounted at the front of the paver to control the

contact area between he paver and the asphalt truck
tires.
Q
Quarter Points
Points on the screed midway between the center and the

ends.
R
Ripples
Short frequent changes in the elevation of a mat sur

face.
S
Screed
The assembly behind the tractor. The screed strikes off,

smooths and compacts the paving material into a semifinished mat.
Screed Extensions
Attachments for increasing screed width

Screed Heaters (Burners)
Devices which preheat the screed plate to a temperature

approximately that of the material to be laid.
Screed Plate
The bottom plate of the screed
A-7
Appendix
Slope
The incline of a paving surface perpendicular to the

direction of travel expressed by stating the rise or fall of
a percentage of horizontal distance (i.e. 2% slope = 2"
of elevation change in 100" of lateral run).
Slope Control
A means for controlling the transverse elevation of the

fresh laid mat in relation to the grade.
Slope
The incline of a paving surface perpendicular to the

direction of travel expressed by stating the rise or fall of
a percentage of horizontal distance (i.e. 2% slope = 2"
of elevation change in 100" of lateral run).
Slope Control
A means for controlling the transverse elevation of the

fresh laid mat in relation to the grade.
Q
Slope Sensor
An electrical device which detects positive and negative

change in lateral elevation using the grade controlled
side of the machine as a reference.
Survey
Function used to show the current elevation when in

CAL mode. Also used in Laser Tracker operations in
conjunction with he Enter Button to move the Tracker
receiver up and down.
T
Thickness Control Screws
A-8
The adjusting crank located at the rear of each side arm,

used to control the angle of attack of the screed.
Appendix
Tow Points (Pull Points)
The points where the side arms of the screed are

attached to the Tractor unit.
Transverse Beam
A steel bar connected to the side arms of a screed for

mounting the Slope Sensor.
Temperature BailTM
A wire frame added to the Tracker that acts as a fixed

target to compensate for rapid air temperature changes..
V
Vibrators
A rotating shaft and eccentric weight assembly

mounted on the screed that produces vibration.
W
Wave
Long repeating changes in the elevation of the mat

surface.
Working Window
Adjustable region of measurement used by the Sonic

Tracker IITM to determine if elevation correction is
required.
A-9
PAVER
TECHNICAL MANUAL
Schematics
Section
Table of Contents
Schematics Section
REFERENCE FORMS
Electrical & Hydraulic Schematics Cross Reference ............................................... Form 22767
Electrical Test Plug (used for operating paver feed sys. w/o screed) ....................... Form 22204
Standard Graphical Symbols ................................................................................. Form 21707
SCHEMATICS
CR551 - Electrical .................................................................................................. 4418-547
CR561 - Electrical .................................................................................................. 4418-585
CR451 - Electrical .................................................................................................. 4418-631
CR461 - Electrcial .................................................................................................. 4418-632
Stretch 20 Screed - Hydraulic .................................................................................. 4418-638
Fastach 10' Std. Screed - Hydraulic ......................................................................... 4418-639
CR461 - Hydraulic .................................................................................................. 4418-642
CR451 - Hydraulic .................................................................................................. 4418-643
CR451 - Electrical ................................................................................................... 4418-663
CR461 - Electrical ................................................................................................... 4418-664
CR351 - Hydraulic .................................................................................................. 4418-671
CR361 - Hydraulic .................................................................................................. 4418-672
CR351 - Electrical ................................................................................................... 4418-682
CR361 - Electrical ................................................................................................... 4418-683
CR551 - Hydraulic .................................................................................................. 4418-687
CR561 - Hydraulic .................................................................................................. 4418-688
Fastach 10' Screed - Hydraulic ................................................................................ 4418-698
Fastach 8' Screed - Hydraulic .................................................................................. 4418-703
CR461 - Electrical ................................................................................................... 4418-724
CR451 - Electrical ................................................................................................... 4418-725
CR451 - Hydraulic .................................................................................................. 4418-727
CR461 - Hydraulic .................................................................................................. 4418-728
Fastach 10' Screed with EZ Screed II - Hydraulic .................................................... 4418-748
CR451 w/ Steer Assist - Electrical ........................................................................... 4418-771
MS-1, MS-2, MS-3 - Electrical .............................................................................. 4418-772
Fastach 8' Screed with EZ Screed II - Hydraulic ...................................................... 4418-773
CR411 - Hydraulic .................................................................................................. 4418-793
CR361 - Electrical ................................................................................................... 4418-798
Schematics
22484 (12/04)
Table of Contents
Schematics Section
SCHEMATICS - CONT
CR351/411 - Electrical ............................................................................................
CR451/551 w/Servo - Hydraulic .............................................................................
CR461/561 - Hydraulic ...........................................................................................
Stretch 18 Screed - Hydraulic ..................................................................................
CR461/561 - Electrical ............................................................................................
CR551 w/ Servo - Electrical ....................................................................................
Stretch 16 Screed - Hydraulic ..................................................................................
MS-1 & MS-2 - Hydraulic ......................................................................................
MS-3 - Hydraulic ....................................................................................................
CR461/561 - Hydraulic ...........................................................................................
CR361/461/561 Slat - Electrical ..............................................................................
CR351/411/451/551 Slat - Electrical .......................................................................
Fastach 8 w/Vibratory Strike-Off - Hydraulic ...........................................................
Grayhound Pavers - Electrical ..................................................................................
CR351/451/551 Slat - Electrical (Current Production) .............................................
CR361/461/561 Slat - Electrical (Current Production) .............................................
CR351 - Hydraulic (Current Production) .................................................................
CR361 - Hydraulic (Current Production) .................................................................
CR451/551 Slat - Hydraulic (Current Production) ....................................................
CR461/561 Slat - Hydraulic (Current Production) ....................................................
CR461/561 Slat, Rubber Track - Hydraulic .............................................................
CR361 Rubber Track - Hydraulic ............................................................................
CR351/451/551 Gen III Standard - Electrical ..........................................................
CR361/461/561 Gen III Standard - Electrical ..........................................................
CR351/451/551 Remix - Electrical ..........................................................................
CR361/461/561 Remix - Electrical ..........................................................................
CR351 Gen III Standard - Electrical ........................................................................
CR361 Gen III Standard - Electrical ........................................................................
Rubber Tire Paver - Convert to Slat from Remix - Electrical .....................................
CR361/461/561 w/Dual Joysticks, Gen III Standard - Electrical ..............................
CR451/551 Slat, Rubber Tire - Hydraulic ................................................................
CR461/561 Slat, Steel Track - Hydraulic .................................................................
CR461/561 Slat, Rubber Track - Hydraulic ............................................................
Schematics
ii
4418-799
4418-808
4418-809
4418-810
4418-815
4418-816
4418-818
4418-831
4418-832
4418-861
4418-864
4418-865
4418-867
4418-923
4418-937
4418-938
4418-944
4418-945
4418-946
4418-947
4418-952
4418-956
4418-959
4418-960
4418-963
4418-964
4418-973
4418-974
4418-978
4418-994
4418-995
4418-996
4418-997
22484 (12/04)
Table of Contents
Schematics Section
SCHEMATICS - CONT
352 Slat Pavers - Tier II - Electrical .................................................................... 4494-105-19
362 Slat Pavers - Tier II - Electrical .................................................................... 4494-105-20
452/552 Slat Pavers - Tier II - Electrical ............................................................ 4494-105-21
462/562 Slat Pavers - Tier II - Electrical ............................................................. 4494-105-22
452/552 Remix Pavers - Tier II - Electrical ........................................................ 4494-105-23
462/562 Remix Pavers - Tier II - Electrical ......................................................... 4494-105-24
452/552 Remix Pavers - Tier II - Electrical (2004 update) ................................... 4494-105-29
462/562 Remix Pavers - Tier II - Electrical (2004 update) ................................... 4494-105-30
CR451/551 Remix Pavers - Hydraulic ..................................................................... 4495-001
CR461/561 Remix Pavers - Hydraulic ..................................................................... 4495-002
CR461/561 Remix Pavers, Rubber Track - Hydraulic .............................................. 4495-003
Stretch Screeds - Hydraulic ..................................................................................... 4495-004
Fixed Screeds - Hydraulic ....................................................................................... 4495-005
MS-4 - Hydraulic & Electrical ................................................................................. 4494-006
Stretch Electric Screeds - Hydraulic & Electrical ...................................................... 4495-007
400 & 500 Series Slat Pavers - Tier II - Hydraulic ................................................... 4495-008
400 & 500 Series Remix Pavers - Tier II - Hydraulic ............................................... 4495-009
Fastach II Screeds - Hydraulic & Electric (20kW Generator) .................................... 4495-011
300 Series Slat Pavers - Tier II - Hydraulic .............................................................. 4495-012
Fastach II Screeds - Hydraulic & Electric (34kW, 3PH Generator) ......................... 4495-013
400 & 500 Series Remix Pavers - Tier II - Hydraulic ............................................... 4495-014
Schematics
iii
22484 (12/04)
Schematics
iv
22484 (12/04)
Electrical Schematic Cross Reference

Paver Tractors
Control Panel - Digital Gauges
Control Panel - Analog Gauges

(Early Version)

(Version until late 1999)

(Version 1999 - Current)
DIGITAL GAUGES
CR551 Digital Gauge --------------------------------------------------------CR561 Digital Gauge --------------------------------------------------------CR451 Digital Gauge --------------------------------------------------------CR461 Digital Gauge --------------------------------------------------------CR451 Digital Gauge Murphy Shutdown -------------------------------CR461 Digital Gauge Murphy Shutdown -------------------------------CR351 Digital Gauge Murphy Shutdown -------------------------------CR361 Digital Gauge Murphy Shutdown --------------------------------
ANALOG GAUGES - SLAT

CR451/551 Analog Gauge, Murphy Shutdown
Dual Headlights ----------------------------------------------------------------CR461/561 Analog Gauge, Murphy Shutdown
Dual Headlights ----------------------------------------------------------------CR361 Analog Gauge, Murphy Shutdown -----------------------------CR351/411 Analog Gauge, Murphy Shutdown -----------------------Track Pavers with Steering Wheel,
Permissive Start, No-Flow Lights -----------------------------------------Rubber Tired Pavers with Permissive Start,
No-Flow Lights -----------------------------------------------------------------Track Pavers with Dual Sticks, Permissive Start,
No-Flow Lights -----------------------------------------------------------------Rubber Tired Pavers with Permissive Start,
No-Flow Lights, Elite Engine, Breakers and
Main Switch in End of Main Box ------------------------------------------Track Pavers with Steering Wheel,
Permissive Start, No-Flow Lights, Elite Engine,
Breakers and Main Switch in End of Main Box -----------------------Rubber Tire Pavers, GEN III Standard ----------------------------------Track Pavers, GEN III Standard ------------------------------------------CR351, GEN III Standard ---------------------------------------------------CR361, GEN III Standard ---------------------------------------------------Rubber Tire Pavers, Convert to Slat from Remix --------------------Track Pavers w/Dual Joysticks, GEN III Standard -------------------CR361 Digital Gauge Murphy Shutdown ------------------------------352 Slat Pavers - Tier II -----------------------------------------------------362 Slat Pavers - Tier II -----------------------------------------------------452 & 552 Slat Pavers - Tier II --------------------------------------------462 & 562 Slat Pavers - Tier II ---------------------------------------------
ANALOG GAUGES - REMIX

Rubber Tire Remix Pavers ------------------------------------------------Track Remix Pavers ---------------------------------------------------------452 & 552 Remix Pavers - Tier II ----------------------------------------462 & 562 Remix Pavers - Tier II ----------------------------------------452 & 552 Remix Pavers - Tier II (05/04) -----------------------------462 & 562 Remix Pavers - Tier II (05/04) ------------------------------
Schematics
4418-547
4418-585
4418-631
4418-632
4418-663
4418-664
4418-682
4418-683
4418-724
4418-725
4418-798
4418-799
4418-864
4418-865
4418-923
4418-937
4418-938
4418-959
4418-960
4418-973
4418-974
4418-978
4418-994
4418-683
4494-105-19
4494-105-20
4494-105-21
4494-105-22
4418-963
4418-964
4494-105-23
4494-105-24
4494-105-29
4494-105-30
22767 (12/04)
Hydraulic Schematic Cross Reference

Paver Tractors
PAVERS
CR351 W/O FUME RECOVERY ----------------------------------------------------------------------------------------------------------------------------------- 4418-671
CR351 W/FUME RECOVERY --------------------------------------------------------------------------------------------------------------------------------------- 4418-944
CR361 STEEL TRACK, W/O FRAME RAISE ------------------------------------------------------------------------------------------------------------------- 4418-672
CR361 STEEL TRACK, W/FRAME RAISE, W/O FUME RECOVERY ----------------------------------------------------------------------------------- 9704-660-98
CR361 STEEL TRACK, W/FRAME RAISE, W/FUME RECOVERY -------------------------------------------------------------------------------------- 4418-945
CR361 RUBBER TRACK --------------------------------------------------------------------------------------------------------------------------------------------- 4418-956
300 SERIES SLAT PAVERS - TIER II ---------------------------------------------------------------------------------------------------------------------------- 4495-012
CR411 ---------------------------------------------------------------------------------------------------------------------------------------------------------------------- 4418-793
CR451 SLAT, SINGLE RESERVOIR ------------------------------------------------------------------------------------------------------------------------------ 4418-643
CR451 SLAT, DOUBLE RESERVOIR, W/O FUME RECOVERY ----------------------------------------------------------------------------------------- 4418-643
CR451 SLAT, DOUBLE RESERVOIR, W/FUME RECOVERY ------------------------------------------------------------------------------------------- 4418-946
CR461
CR461
CR461
CR461
CR461
SLAT, STEEL TRACK, SINGLE RESERVOIR ------------------------------------------------------------------------------------------------------- 4418-642

SLAT, STEEL TRACK, DOUBLE RESERVOIR, W/O FRAME RAISE ------------------------------------------------------------------------ 4418-728
SLAT, STEEL TRACK, DOUBLE RESERVOIR, W/FRAME RAISE, W/O FUME RECOVERY ----------------------------------------- 4418-728
SLAT, STEEL TRACK, DOUBLE RESERVOIR, W/FRAME RAISE, W/FUME RECOVERY ------------------------------------------- 4418-947
SLAT, RUBBER TRACK ----------------------------------------------------------------------------------------------------------------------------------- 4418-952
CR551
CR551
CR551
CR551
SLAT, HYD. TRAVEL CONTROL, W/O HYD. BRAKE PEDALS -------------------------------------------------------------------------------- 4418-687
SLAT, HYD. TRAVEL CONTROL, W/HYD. BRAKE PEDALS ----------------------------------------------------------------------------------- 9704-656-97
SLAT, ELEC. TRAVEL CONTROL, W/O FUME RECOVERY ----------------------------------------------------------------------------------- 4418-727
SLAT, ELEC. TRAVEL CONTROL, W/FUME RECOVERY ------------------------------------------------------------------------------------- 4418-946
CR561
CR561
CR561
CR561
CR561
SLAT, STEEL TRACK, HYD. TRAVEL CONTROL ------------------------------------------------------------------------------------------------- 4418-688

SLAT, STEEL TRACK, ELEC. TRAVEL CONTROL, W/O FRAME RAISE ------------------------------------------------------------------- 4418-728
SLAT, STEEL TRACK, ELEC. TRAVEL CONTROL, W/O FRAME RAISE, 8.2 ENGINE, SUNDSTRAND PUMPS -------------- 9704-659-45
SLAT, STEEL TRACK, ELEC. TRAVEL CONTROL, W/FRAME RAISE, W/O FUME RECOVERY ----------------------------------- 4418-861
SLAT, STEEL TRACK, ELEC. TRAVEL CONTROL, W/FRAME RAISE, W/FUME RECOVERY -------------------------------------- 4418-947
CR561 SLAT, RUBBER TRACK ----------------------------------------------------------------------------------------------------------------------------------- 4418-952

CR451/CR551 SLAT CONVEYOR, RUBBER TIRE PAVERS --------------------------------------------------------------------------------------------- 4418-995
CR451/CR551 SLAT CONVEYOR, STEEL TRACK PAVERS --------------------------------------------------------------------------------------------- 4418-996
CR451/CR551 SLAT CONVEYOR, RUBBER TRACK PAVERS ------------------------------------------------------------------------------------------ 4418-997
CR451/CR551 REMIX PAVERS ------------------------------------------------------------------------------------------------------------------------------------ 4495-001
CR461/CR561 REMIX, STEEL TRACK PAVERS ------------------------------------------------------------------------------------------------------------- 4495-002
CR461/CR561 REMIX, RUBBER TRACK PAVERS ---------------------------------------------------------------------------------------------------------- 4495-003
400 & 500 SERIES SLAT PAVERS - TIER II ------------------------------------------------------------------------------------------------------------------- 4495-008
400 & 500 SERIES REMIX PAVERS - TIER II ----------------------------------------------------------------------------------------------------------------- 4495-009
400 & 500 SERIES REMIX PAVERS - TIER II ----------------------------------------------------------------------------------------------------------------- 4495-014
Schematics
22767 (12/04)
Hydraulic & Electric Schematic

Cross Reference
Screeds
SCREEDS
8' FASTACH W/O SLOPING STRIKE-OFF -------------------------------------------------------------------------------------------------------------------- 9704-658-78
8' FASTACH W/SLOPING STRIKE-OFF, W/O EZ-II -------------------------------------------------------------------------------------------------------- 4418-703
8' FASTACH W/SLOPING STRIKE-OFF, W/EZ-II ----------------------------------------------------------------------------------------------------------- 4418-867
10' FASTACH W/O EZ-II --------------------------------------------------------------------------------------------------------------------------------------------- 9704-657-40
10' FASTACH W/EZ-II ------------------------------------------------------------------------------------------------------------------------------------------------- 9704-658-80
STD. STRETCH 16 W/O SCREED ASSIST -------------------------------------------------------------------------------------------------------------------- 4418-818
STD. STRETCH 18 W/O SCREED ASSIST --------------------------------------------------------------------------------------------------------------------- 4418-810
STRETCH 16 & 18 W/SCREED ASSIST ------------------------------------------------------------------------------------------------------------------------- 9704-660-72
STRETCH 20 W/O SCREED ASSIST ---------------------------------------------------------------------------------------------------------------------------- 9704-657-41
10' EZ SCREED II ------------------------------------------------------------------------------------------------------------------------------------------------------ 4418-748
ALL STRETCH SCREEDS (Hydraulic Schematic) ----------------------------------------------------------------------------------------------------------- 4495-004
ALL FIXED SCREEDS (Hydraulic Schematic) ----------------------------------------------------------------------------------------------------------------- 4495-005
STRETCH ELECTRIC SCREEDS (Electric Schematic - used with 4495-004) ---------------------------------------------------------------------- 4495-007
FASTACH II SCREEDS, 20kW GENERATOR (Electric & Hydraulic Schematics) ----------------------------------------------------------------- 4495-011
FASTACH II SCREEDS, 34kW, 3PH GENERATOR (Electric & Hydraulic Schematics) ---------------------------------------------------------- 4495-013
Schematics
22767 (12/04)
Hydraulic & Electric Schematic

Cross Reference
MS Machines
MS MACHINES
MS-1, MS-2, MS-3 (Electric Schematic) ------------------------------------------------------------------------------------------------------------------------- 4418-772
MS-1 & MS-2 (Hydraulic Schematic) ----------------------------------------------------------------------------------------------------------------------------- 4418-831
MS-3 (Hydraulic Schematic) ---------------------------------------------------------------------------------------------------------------------------------------- 9702-050-43
MS-4 (Electric & Hydraulic Schematic) -------------------------------------------------------------------------------------------------------------------------- 4495-006
Schematics
22767 (12/04)
Technical Manual
Operating Paver Feed System Without

Screed Attached &Electrical Test Plug
To Operate Feed System on Tractor Without Screed Attached:
Disconnect screed electrical cable from connector and install test plug
P/N 9704-615-98 (shown below).
Or...
Disconnect screed electrical cable from connector.
Open main electrical box (shown below) and install jumper wires at terminals as follows:
................... Wire 83 to 87
................... Wire 93 to 97
Jumper Wires
Schematics
22484 (22204) (12/04)
Technical Manual
Schematics
22484 (22204) (12/04)
Standard Graphical Symbols

T H E S Y M B O L S S H O W N C O N F O R M TO T H E A M E R I C A N N AT I O N A L S TA N D A R D S I N S T I T U T E ( A N S I )
SPECIFICATIONS. BASIC SYMBOLS CAN BE COMBINED IN ANY COMBINATION. NO ATTEMPT IS MADE
TO SHOW ALL COMBINATIONS.
LINES AND LINE FUNCTIONS
PUMPS
LINE, WORKING
PUMP, SINGLE
FIXED DISPLACEMENT
LINE, PILOT (L>20W)
LINE, DRAIN (L<5W)

PUMP, SINGLE
VARIABLE DISPLACEMENT
CONNECTOR
LINE, FLEXIBLE
MOTORS AND CYLINDERS
LINE, JOINING
MOTOR, ROTARY,
FIXED DISPLACEMENT
LINE, PASSING
MOTOR, ROTARY,
VARIABLE DISPLACEMENT
DIRECTION OF FLOW,
HYDRAULIC
PNEUMATIC
MOTOR, OSCILLATING
LINE TO RESERVOIR
ABOVE FLUID LEVEL
BELOW FLUID LEVEL
CYLINDER, SINGLE ACTING
LINE TO VENTED MANIFOLD
CYLINDER, DOUBLE ACTING
PLUG OR PLUGGED
CONNECTION
CYLINDER,
DIFFERENTIAL ROD
RESTRICTION, FIXED
CYLINDER,
DOUBLE END ROD
RESTRICTION, VARIABLE
CYLINDER,
CUSHIONS BOTH ENDS
Schematics
22484 (21707) (12/04)
MISCELLANEOUS UNITS
BASIC VALVE SYMBOLS (CONT.)
DIRECTION OF ROTATION
(ARROW IN FRONT OF SHAFT)
VALVE, SINGLE FLOW

PATH, NORMALLY OPEN
COMPONENT ENCLOSURE
VALVE, MAXIMUM
PRESSURE (RELIEF)
RESERVOIR, VENTED
BASIC VALVE SYMBOL,

MULTIPLE FLOW PATHS
RESERVOIR, PRESSURIZED
FLOW PATHS BLOCKED

IN CENTER POSITION
PRESSURE GAUGE
MULTIPLE FLOW PATHS

(ARROW SHOWS FLOW
DIRECTION)
TEMPERATURE GAUGE
VALVE EXAMPLES
UNLOADING VALVE,
INTERNAL DRAIN,
REMOTELY OPERATED
FLOW METER (FLOW RATE)
ELECTRIC MOTOR
DECELERATION VALVE,
NORMALLY OPEN
ACCUMULATOR,
SPRING LOADED
SEQUENCE VALVE,
DIRECTLY OPERATED,
EXTERNALLY DRAINED
ACCUMULATOR,
GAS CHARGED
PRESSURE REDUCING VALVE
FILTER OR STRAINER
COUNTER BALANCE VALVE
WITH INTEGRAL CHECK
HEATER
COOLER
TEMPERATURE AND
PRESSURE COMPENSATED
FLOW CONTROL WITH
INTEGRAL CHECK
TEMPERATURE CONTROLLER
INTENSIFIER
PRESSURE SWITCH
DIRECTIONAL VALVE, TWO

POSITION, THREE
CONNECTION
BASIC VALVE SYMBOLS

CHECK VALVE
DIRECTIONAL VALVE,
THREE POSITION,
FOUR CONNECTION
MANUAL SHUT OFF VALVE

BASIC VALVE ENVELOPE
VALVE, INFINITE POSITIONING

(INDICATED BY HORIZONTAL
BARS)
VALVE, SINGLE FLOW PATH,

NORMALLY CLOSED
Schematics
22484 (21707) (12/04)
METHODS OF OPERATION
METHODS OF OPERATION
PRESSURE COMPENSATOR
LEVER
DETENT
PILOT PRESSURE
MANUAL
SOLENOID
MECHANICAL
SOLENOID CONTROLLED,
PILOT PRESSURE OPERATED
PEDAL OR TREADLE
SPRING
PUSH BUTTON
SERVO
Schematics
22484 (21707) (12/04)
Schematics
22484 (21707) (12/04)
(N.O.)
(N.C.)
(H.O.)
(H.C.)
(T.O.)
(T.C.)
NOTE:
2 POLE
NORMALLY OPEN
NORMALLY CLOSED
HELD OPEN
HELD CLOSED
TIMED OPEN
TIMED CLOSED
COIL
(NUMBER)
CONNECTOR
MATING
CIRCUIT BREAKERS
SINGLE POLE
CAPACITOR
BATTERY
ALWAYS POSITIVE
ARMATURE
W/BRUSHES
AC VOLTAGE
SOURCE
AC MOTOR
3 POLE
AC
GROUND
FUSE
BRIDGE
DIODES
DC
LIGHT
(COLOR)
JUMPER
INDUCTIVE
FIELD
HORN
HEATING ELEMENT
SIMPLE
DC
AC
N.C.
N.O.
CONTACTS
S.C.R.
FREQ
N.O.
N.O.
PUSHBUTTONS
OVERLOAD
HEATER
OUTLET
(HOUSE TYPE)
VOLT
METERS
DPST
SWITCHES
SOLENOID COIL
SHIELDED CABLE
SPDT
GENERAL
VARIABLE
RESISTORS
AMP
N.C.
H.O.
DIRECT ACTUATED
H.C.
TIMER CONTACTS
T.C.
T.O.
ENERGIZED
T.O.
T.C.
DE-ENERGIZED
GENERAL
IRON CORE
TRANSFORMER
PNP
NPN
TRANSISTORS
UNSHIELDED
SHIELDED
THERMOCOUPLE
SWITCHES
N.O.
N.O.
VACUUM & PRESSURE ACTUATED
N.C.
N.O.
TEMPERATURE ACTUATED
N.O.
LIMIT SW
N.C.
N.O.
FLOW ACTUATED
A Terex Company
4418-547
10/94
Page 1 of 2
CR551 Pavers
9704-415-20b
9704-415-22a 9704-415-29a
Cedarapids Inc.
A Terex Company
4418-547
10/94
Page 2 of 2
A Terex Company
4418-585
10/94
Page 1 of 2
CR561 Paver
9704-415-21b
9704-415-24a 9704-415-29a
Cedarapids Inc.
A Terex Company
4418-585
10/94
Page 2 of 2
A Terex Company
4418-631
10/94
Page 1 of 2
CR451 Paver
9704-415-33c
9704-415-37b 9704-415-40b
Cedarapids Inc.
A Terex Company
4418-631
10/94
Page 2 of 2
A Terex Company
4418-632
10/94
Page 1 of 2
CR461 Paver
9704-415-34c
9704-415-38b 9704-415-40b
Cedarapids Inc.
A Terex Company
4418-632
10/94
Page 2 of 2
A Terex Company
4418-638
8/88
Page 1 of 1
Stretch 20 Screed
Hydraulic Schematic
9704-657-41a
Cedarapids Inc.
A Terex Company
4418-639
12/99
10' Fastach Std. Screed

Hydraulic Schematic
4418-639a
Cedarapids Inc.
A Terex Company
4418-642
2/90
Page 1 of 2
CR461 Paver (Track)
Hydraulic Schematic
9704-657-05e
Cedarapids Inc.
A Terex Company
4418-642
2/90
Page 2 of 2
A Terex Company
4418-643
2/90
Page 1 of 2
CR451 Paver (Rubber Tire)
Hydraulic Schematic
9704-657-06f
Cedarapids Inc.
A Terex Company
4418-643
2/90
Page 2 of 2
A Terex Company
4418-663
4/89
Page 1 of 2
CR451 Pavers
9704-415-58c
9704-415-37b 9704-415-59b
Cedarapids Inc.
A Terex Company
4418-663
4/89
Page 2 of 2
A Terex Company
4418-664
4/89
Page 1 of 2
CR461 Electrical Schematic
9704-415-60a
9704-415-38b 9704-415-58c
Cedarapids Inc.
A Terex Company
4418-664
4/89
Page 2 of 2
A Terex Company
4418-671
2/90
Page 1 of 2
CR351 Hydraulic Schematic
9704-658-32c
Cedarapids Inc.
A Terex Company
4418-671
2/90
Page 2 of 2
A Terex Company
4418-672
2/90
Page 1 of 2
CR361 Pavers
Hydraulic Schematic
9704-658-33c
Cedarapids Inc.
A Terex Company
4418-672
2/90
Page 2 of 2
A Terex Company
4418-682
2/90
Page 1 of 2
CR351 Paver (Rubber Tire)
9704-415-67c
9704-415-71 9704-415-75d
Cedarapids Inc.
A Terex Company
4418-682
2/90
Page 2 of 2
A Terex Company
4418-683
2/90
CR361 Paver (Track)

Electrical
9704-415-68c
9704-415-72 9704-415-75d
Cedarapids Inc.
A Terex Company
4418-683
2/90
Page 2 of 2
A Terex Company
4418-687
5/89
Page 1 of 2
CR551 Hydraulic Schematic
9704-658-48a
Cedarapids Inc.
A Terex Company
4418-687
5/89
Page 2 of 2
A Terex Company
4418-688
2/90
Page 1 of 2
CR551 Paver (Track)
Hydraulic Schematic
9704-658-49a
Cedarapids Inc.
A Terex Company
4418-688
2/90
Page 2 of 2
A Terex Company
4418-698
6/90
10' Fastach Screed

Hydraulic Schematic
9704-658-80a
Cedarapids Inc.
A Terex Company
4418-703
3/90
8' Standard Screed

Hydraulic Schematic
9704-658-85
Cedarapids Inc.
A Terex Company
4418-724
Sheet 1 of 4
8/94
CR461 & CR561 Pavers

9704-416-02f
9704-416-06c 9704-416-08c
Cedarapids Inc.
A Terex Company
4418-724
Sheet 2 of 4
8/94

9704-416-02f
9704-416-06c 9704-416-08c
Cedarapids Inc.
A Terex Company
4418-724
Sheet 3 of 4
8/94

9704-416-02f
9704-416-06c 9704-416-08c
Cedarapids Inc.
A Terex Company
4418-724
Sheet 4 of 4
8/94

9704-416-02f
9704-416-06c 9704-416-08c
Cedarapids Inc.
A Terex Company
4418-725
Sheet 1 of 4
8/94
CR451 and CR551 Pavers

9704-416-01f
9704-416-05d 9704-416-08c
Cedarapids Inc.
A Terex Company
4418-725
Sheet 2 of 4
8/94

9704-416-01f
9704-416-05d 9704-416-08c
Cedarapids Inc.
A Terex Company
4418-725
Sheet 3 of 4
8/94

9704-416-01f
9704-416-05d 9704-416-08c
Cedarapids Inc.
A Terex Company
4418-725
Sheet 4 of 4
8/94

9704-416-01f
9704-416-05d 9704-416-08c
Cedarapids Inc.
A Terex Company
4418-727
3/91
Page 1 of 2
Hydraulic Schematic
9704-659-14b
Cedarapids Inc.
A Terex Company
4418-727
3/91
Page 2 of 2
A Terex Company
4418-728
3/91
Page 1 of 2
Hydraulic Schematic
9704-659-15
Cedarapids Inc.
A Terex Company
4418-728
3/91
Page 2 of 2
A Terex Company
4418-748
11/91
10-Foot Screed with

EZ Screed II
Hydraulic Schematic
Cedarapids Inc.
4418-771
451 Paver
with Steer Assist
9704-416-11a
Cedarapids Inc.
11/04
A Terex Company
4418-772
3/92
MS-1, MS-2, & MS-3

Mat Smoothness Machines
Electric Schematic
Cedarapids Inc.
A Terex Company
4418-773
6/92
Page 1 of 1
8' Screed w/EZ Screed II
Hydraulic Schematic
04418-773
Cedarapids Inc.
A Terex Company
4418-793
5/93
Page 1 of 2
CR411 Pavers
Hydraulic Schematic
9704-660-38a
Cedarapids Inc.
A Terex Company
4418-793
5/93
Page 2 of 2
A Terex Company
4418-798
Sheet 1 of 4
8/94
CR361 w/Analog Display

9704-416-14d
9704-416-16a 9704-416-20
Cedarapids Inc.
A Terex Company
4418-798
Sheet 2 of 4
8/94

9704-416-14d
9704-416-16a 9704-416-20
Cedarapids Inc.
A Terex Company
4418-798
Sheet 3 of 4
8/94

9704-416-14d
9704-416-16a 9704-416-20
Cedarapids Inc.
A Terex Company
4418-798
Sheet 4 of 4
8/94

9704-416-14d
9704-416-16a 9704-416-20
Cedarapids Inc.
A Terex Company
4418-799
Sheet 1 of 4
8/94

9704-416-13e
9704-416-15b 9704-416-20
Cedarapids Inc.
A Terex Company
4418-799
Sheet 2 of 4
8/94

9704-416-13e
9704-416-15b 9704-416-20
Cedarapids Inc.
A Terex Company
4418-799
Sheet 3 of 4
8/94

9704-416-13e
9704-416-15b 9704-416-20
Cedarapids Inc.
A Terex Company
4418-799
Sheet 4 of 4
8/94

9704-416-13e
9704-416-15b 9704-416-20
Cedarapids Inc.
A Terex Company
B
TO STRAINER
PAGE 2
200 MESH
STRAINER
5000 PSI
49 CID
CID
3.35
.86
CID
2500
RPM
36.3 GPM MAX
9.3 GPM
5
2
25 PSI
BY-PASS
5000 PSI
350
PSI
LH TRACTION PUMP
COOLER
PARKING
B RAKE
FRONT WHEEL ASSIST

(OPTIONAL)
TRACTION DRIVE
.078" DIA.
ORIFICES
TO AUXILIARY FILTER
PAGE 2
TRACTION DRIVE
RANGE
SHIFT
TO RH CONVEYOR
CHARGE PUMP
PAGE 2
RH TRACTION PUMP
350 PSI
COOLER
5000 PSI
2500 RPM
3.35
CID
9.3 GPM
.86
CID
5
2
25 PSI
BY-PASS
49 CID
5000 PSI
A
TO STRAINER
PAGE 2
4418-808
4/94
200 MESH
STRAINER
CR451-CR551
Hydraulic Schematic w/Servo
9704-660-53 Pages 1 & 2
Cedarapids Inc.
A Terex Company
TRUCK HOOK
(OPTIONAL)
LH PULL
POINT
RH PULL
POINT
HOPPER WINGS
175 PSI NITROGEN

PRECHARGE
SCREED ASSIST
(SUPPLED WITH STRETCH 20)
OPTIONAL
REAR WHEEL
SUSPENSION
SCREED LIFT
SCREED LIFT
STEERING
REPHASE PORT
AT EACH END OF
CYLINDER STROKE
V
A
D
STEERING
VALVE
900
PSI
I
SCREED EXTENSIONS
(OPTIONAL)
FLOW TO
SCREED VALVES
FLOW FROM
SCREED VALVES
FULL
TO FRONT WHEEL
DRIVE PAGE 1
IDLE
SCREED VIBRATORS
THROTTLE
FLOW FROM
SCREED VIBRATORS
5
2
RH CONVEYOR
C
LH CONVEYOR
REPHASE PORT CROSS SECTION
5
2
9.9 GPM MAX
5
2
1500 PSI
TO PARKING BRAKE
AND RANGE SHIFT
PAGE 1
FLOW TO
SCREED VIBRATORS
HOOD RAISING SYSTEM
.85
CID
.913
CID
AUXILIARY PUMP
2.8 CID
2500
RPM
2500 PSI
2.8 CID
220 PSI
2.8 CID
3800 PSI
2.8 CID
2500
RPM
2500 RPM
MAX
9.2 GPM
30.3 GPM MAX
2500 RPM
MAX
3800 PSI
.85
CID
2500
RPM
220 PSI
1.2
CID
9.2 GPM
13 GPM
30.3 GPM MAX
900 PSI
(2.1 GPM MAX)
12
VDC
TO TRACTION PUMP
PAGE 1
B
200 MESH
STRAINERS
TO TRACTION PUMP
PAGE 1
12 VDC
4418-808
Page 2
A Terex Company
B
TO STRAINER
PAGE 2
200 MESH
STRAINER
5000 PSI
TRACK TENSIONING
2500 RPM
36.3 GPM MAX
5
2
25 PSI
BY-PASS
0.86
CID
3.35
CID
2050 PSI
9.3 GPM
5000 PSI
350
PSI
LH TRACTION PUMP
COOLER
PARKING BRAKE
TRACTION DRIVE
TRACTION DRIVE
RANGE SHIFT
TRACK TENSIONING
TO RH CONVEYOR
CHARGE PUMP
PAGE 2
RH TRACTION PUMP
2050 PSI
350 PSI
COOLER
36.3 GPM MAX
5000 PSI
2500 RPM
3.35
CID
5
2
25 PSI
BY-PASS
.86
CID
5000 PSI
A
TO STRAINER
PAGE 2
200 MESH
STRAINER
4418-809
4/94

Hydraulic Schematic
9704-660-54 Pages 1 & 2
Cedarapids Inc.
A Terex Company
LH PULL POINT
TRUCK HOOK
(OPTIONAL)
RH PULL POINT
SCREED ASSIST
(SUPPLED WITH STRETCH 20)
HOPPER WINGS
HOOD RAISING SYSTEM
E
SCREED LIFT
175 PSI NITROGEN
PRECHARGE
V
A
900
PSI
SCREED EXTENSIONS
(OPTIONAL)
900 PSI
T
I
12.1 GPM MAX
FLOW TO SCREED
VALVES
FLOW FROM SCREED
VALVES
12 VDC
SCREED VIBRATORS
IDLE
FULL
THROTTLE
FLOW FROM SCREED

VIBRATORS
LH CONVEYOR
5
2
2.8 CID
TO TRACTION PUMP
PAGE 1
9.2 GPM
2.8 CID
.85
CID
2500
RPM
.913
CID
AUXILIARY PUMP
2.8 CID
220 PSI
2.8 CID
2500 RPM
MAX.
3800 PSI
2500 RPM
MAX.
3800 PSI
1.2
CID
30.3 GPM MAX
2500
RPM
220 PSI
1.2
CID
30.3 GPM MAX
9.2 GPM
13 GPM
FLOW TO SCREED
VIBRATORS
2500 PSI
RH CONVEYOR
12 VDC
19.9 GPM MAX
5
2
1500 PSI
6
8
TO PARKING BRAKE
AND RANGE SHIFT
PAGE 1
C
TO TRACTION PUMP
PAGE 1
B
A
200 MESH
STRAINERS
4418-809
4/94

Hydraulic Schematic
9704-660-54 Pages 1 & 2
Cedarapids Inc.
A Terex Company
4418-810
Stretch 18
Hydraulic Schematic
9704-660-56
Cedarapids Inc.
4/94
30A.
POWER
15A.
LIGHTS
K1
15A.
ENGINE
60A.
15A.
CONTROL
BURNER
15A.
FLASHERS
46
20
113
109
4418-815
46
46
46
46
46
46
46
46
46
115
115
115
115
115
115
115
115
115
109
21
HIGH
OFF
110
148
146
138
136
128
126
118
116
VM
FUEL
OT
OP
WT
K1
114
105
101
REL
110
112
HI/LO
BEAM
HEAD
LGTS.
111
105
YEL
101
YEL
14
LT.
TD
RED
106
RED
102
128
126
138
136
148
146
RT. EXT. BURNER (NO.4)
GLOW PLUG NO.4
TRAVEL
PAVE
DECREASE
42
190
189
186
42
48
B SOL.
A SOL.
B SOL.
RANGE SOL.
THROTTLE SOL.
CR461 and CR561

9704-416-32
9704-416-06c 9704-416-08
Cedarapids Inc.
A SOL.
185
UP
DOWN
B SOL.
176
DOWN
A SOL.
175
W
R
UP
A SOL.
B SOL.
A SOL.
B SOL.
A SOL.
B SOL.
A SOL.
GLOW PLUG NO.4
FAN MOTOR NO.4
GLOW PLUG NO.3
FAN MOTOR NO.3
GLOW PLUG NO.2
FAN MOTOR NO.2
GLOW PLUG NO.1
FAN MOTOR NO.1
FUEL PUMP MOTOR
110
WORK
LGTS.
HI
BEAM
HEAD
LGTS.
111
HORN
R.H. GATE
MOTOR
HORN SW.
19
K18
K16
L.H. GATE
MOTOR
K2
~)
B SOL.
183
174
173
182
181
172
171
W
R
106
102
15
STARTER RELAY
FUEL SOL.
TEMP. (223
184
INCREASE
FULL
118
116
LT. EXT. BURNER (NO.3)
GLOW PLUG NO.3
RT.
23
OIL PRESS (5#)
SENSOR
SENSOR
SENSOR
OUT
IN
OUT
IN
DECREASE
INCREASE
DECREASE
117
RT. MAIN BURNER (NO.2)
GLOW PLUG NO.2
16
(NC)
10
SENSOR
STARTER MOTOR
OVERHEAD STROBE
18
K17
K18
K15
K16
LT. MAIN BURNER (NO.1)
GLOW PLUG NO.1
(S)
(NO)
CLOSED IN NEUTRAL
(TRAVEL CONTROLS)
CR
OPTIONAL SCREED CONTROLS

INCREASE
FASTACH SCREED BURNER CONTROL
112
IDLE
RANGE
ON
OFF
ON
OFF
ON
OFF
ON
117
LOW
110
OFF
CROWN
MAIN
HEIGHT
RH
MATCH
MATCH
HEIGHT
LH
RH
EXTEND
EXTEND
LH
RH
SLOPE
SLOPE
LH
FAN NO.4
FAN NO.3
FAN NO.2
FAN NO.1
10A.
FUEL PUMP
K17
K15
'A'
ENG
FU-1
SFE-14
(B)
MURPHY RELAY #758-A-NG
18
K3
HORN RELAY
H/T
POWER RELAY
11
STARTER SOL.
ENGINE SAFETY SHUTDOWN
22
VOLTMETER
FUEL LEVEL
OIL TEMP.
GND
OIL PRESS.
WATER TEMP.
100
OFF
ON
D+
B+
19
K3
K2
HOUR/TACHOMETER
ALTERNATOR
BRAKE
13
22
22
22
22
22
22
22
22
12 V.D.C.
100
100
100
100
100
START
RUN
STOP
START
RUN
STOP
PRESS. SW.
ENGINE
THROTTLE
21
22
22
LIGHTS
MAIN
KEYSWITCH
MAIN
KEYSWITCH
46
46
46
46
46
46
46
46
46
46
46
46
46
46
46
46
46
ENGAGE
47
47
RH
GATE
GATE
LH
WINGS
HOPPER
SCREED
LIFT
165A
167A
167A
165A
46
160
162
MAN
SET
AUTO
51
78
77
34
(12)
(6)
(5)
(1)
(2)
(3)
(7)
ADJUST.
SPEED
MODULE
80
(D)
FEED SENSOR
46
54
56
53
(7)
ADJUST.
SPEED
MODULE
90
(D)
FEED SENSOR
(12)
(6)
(5)
(1)
(2)
(3)
(E)
(E)
(9)
(8)
(4)
(11)
(10)
(8)
(9)
(C)
(4)
(11)
(10)
R.H. FEED CONTROL
46
52
55
(C)
150
LAI
157
155
155
157
DEC
INC
157
155
LT. AUTO ISOLATION RELAY
157
155
RAI
167
165
INC
165
167
DEC
165
167
ENGAGE
LOWER
RAISE
LOWER
RAISE
LOWER
RAISE
LOWER
RAISE
RELEASE
ASSIST
64
33
108
107
104
103
66
65
ON
OFF
64
63
62
61
160
RT. AUTO ISOLATION RELAY
'D'
'A' SOL.
'B' SOL.
'A' SOL.
'B' SOL.
AREA
68 Q
2W.
'A' SOL.
'B' SOL.
RH
RH
97
K18
K17
K16
K15
POINT
REVISION
RT. PULL
POINT
SERVO
SERVO
1K Q
SPEED
MAN.
CONV.
MAN.
CONV.
SPEED
1K Q
LT. PULL
SERVO
R.H. FEED
CW
STOP
L.H. FEED
SERVO
87
STOP
B
CW
VIBRATOR SOL.
COIL
REVERSE
COIL
VIBRATOR SOL.
'C'
68 Q
2W.
93
96
95
94
83
86
85
84
50
50
LH
FORWARD
COIL
SPEED
1K Q
MAX
PAVER
78
77
LH
COIL
REVERSE
SPEED
1K Q
MAX
PAVER
ASSIST SOL.(OPT)
SYM.
167
165
162
CW
74
3
74
73
FORWARD
BRAKE RELEASE SOL.
73
34
152
MAT THICKNESS
157A
155A
157A
155A
46
150
152
MAN
SET
AUTO
53
51
ON
AUTO
L.H. FEED CONTROL
OFF
47
VIBRATORS
ON
OFF
VIBRATORS
34
34
STOP
56
47
47
47
MAT THICKNESS
'D'
OVERRIDE
REMOTE
FEED
MAN
OFF
AUTO
55
STOP
R.H.
CONVEYOR
'C'
OVERRIDE
REMOTE
FEED
MAN
OFF
SPEED
TRAVEL
CONTROLLER
AUTO
L.H.
CONVEYOR
RT. FORWARD L.S.
LT. FORWARD L.S.
(TRAVEL CONTROL)
34
CONTROLLER
SPEED
TRAVEL
RELEASE
CLOSED IN FORWARD
NOTE:
OPTIONAL
TRUCK
HITCH
47
47
34
34
34
34
'A'
BRAKE
VIBRATOR WIRING
OPTIONAL EZ SCREED
STANDARD SCREED
VIBRATOR WIRING
11/04
23
NC
NO
22
758A-NG
TIMING
RELAY
C
22
9
10
9
10
11
VIEW C-C
11
15
15
18
18
19
19
RELAY WIRING
20
21
27
33
33
34
34
46
MODULE
OPTIONAL
20
22
23
27
46
LEFT
15
ENGINE
3
46
109
80
85
84
86
52
55
51
83
25
LIGHTS
47
48
48
50
50
RIGHT
15
FLASHERS
OPTIONAL
113
T1
52
53
53
54
54
55
55
56
56
61
62
62
63
63
64
64
65
65
66
66
70
70
71
71
73
73
74
74
77
77
78
78
46
90
95
94
96
3
46
54
56
53
93
15
CONTROL
51
52
61
R.H.
PROPORTIONAL
MODULE
42
46
46
47
51
T1
21
22
23
42
L.H.
PROPORTIONAL
20
30
POWER
80
80
83
83
84
84
85
85
86
86
87
87
90
90
93
93
94
94
100
60
BURNER
95
95
96
96
97
115
100
100
100
100
100
100
100
101
A
SPARE
101
102
102
103
103
104
104
105
106
105
106
107
107
108
108
109
109
110
K3
97
100
111
110
111
112
112
113
113
114
114
117
117
K15
VIEW A-A
155
155
157
157
165
165
167
167
115
115
C.B. WIRING
K16
K17
K18
100
3
108
107
106
K18
104
19
3
105
K17
100
100
100
3
103
102
K16
K15
100
101
100
18
K3
SPARE
VIEW B-B
4418-815
11/04
30A.
POWER
15A.
LIGHTS
K1
15A.
ENGINE
60A.
15A.
CONTROL
BURNER
15A.
FLASHERS
46
20
113
109
4418-816
46
46
46
46
46
46
46
115
115
115
115
115
115
115
115
115
109
21
22
22
21
ON
OFF
ON
OFF
ON
OFF
ON
OFF
ON
148
146
138
136
128
126
118
116
117
LOW
110
110
OFF
CROWN
MAIN
HEIGHT
RH
MATCH
HEIGHT
LH
MATCH
RH
EXTEND
LH
EXTEND
RH
SLOPE
SLOPE
LH
FAN NO.4
FAN NO.3
FAN NO.2
FAN NO.1
10A
FUEL PUMP
HIGH
OFF
K3
K1
UP
OUT
IN
OUT
IN
110
112
HI/LO
BEAM
HEAD
LGTS.
111
105
YEL
101
YEL
14
RED
106
RED
102
117
118
116
138
GLOW PLUG NO.4

148
146
RT. EXT. BURNER (NO.4)
GLOW PLUG NO.3
136
LT. EXT. BURNER (NO.3)
128
126
RT. MAIN BURNER (NO.2)
GLOW PLUG NO.2
K18
K16
DECREASE
190
B SOL.
CR551 Pavers w/Servo

9704-416-31
9704-416-05d 9704-416-08c
Cedarapids Inc.
A SOL.
189
INCREASE
W
R
A SOL.
B SOL.
A SOL.
B SOL.
A SOL.
B SOL.
A SOL.
B SOL.
A SOL.
B SOL.
A SOL.
GLOW PLUG NO.4
FAN MOTOR NO.4
GLOW PLUG NO.3
FAN MOTOR NO.3
GLOW PLUG NO.2
FAN MOTOR NO.2
GLOW PLUG NO.1
FAN MOTOR NO.1
FUEL PUMP MOTOR
110
WORK
LGTS.
LGTS.
~)
B SOL.
HORN
R.H. GATE
MOTOR
HI
BEAM
HEAD
111
K2
L.H. GATE
MOTOR
HORN SW.
19
FUEL SOL.
TEMP. (223
STARTER RELAY
OIL PRESS (5#)
SENSOR
SENSOR
SENSOR
186
185
176
175
184
183
174
173
182
181
172
171
W
R
106
102
15
23
OVERHEAD STROBE
18
K17
K18
K15
K16
LT. MAIN BURNER (NO.1)
GLOW PLUG NO.1
(NC)
10
CLOSED IN NEUTRAL
(TRAVEL CONTROL)
L.S.3
(S)
(NO)
SENSOR
STARTER MOTOR
DOWN
UP
DOWN
DECREASE
INCREASE
DECREASE
S
G
TD
OPTIONAL SCREED CONTROLS

INCREASE
FASTACH SCREED BURNER CONTROL
112
105
101
REL
114
18
K17
K15
'A'
ENG
FU-1
SFE-14
CR
MURPHY RELAY #758-A-NG
(B)
100
HORN RELAY
VM
FUEL
OT
OP
WT
H/T
POWER RELAY
11
STARTER SOL.
ENGINE SAFETY SHUTDOWN
22
VOLTMETER
FUEL LEVEL
OIL TEMP.
GND
OIL PRESS.
19
K3
D+
B+
WATER TEMP.
BRAKE
13
22
22
22
22
22
22
22
22
K2
ALTERNATOR
HOUR/TACHOMETER
12 V.D.C.
100
100
100
100
100
START
RUN
STOP
START
RUN
STOP
PRESS. SW.
ENGINE
LIGHTS
MAIN
KEYSWITCH
MAIN
KEYSWITCH
46
46
46
46
46
46
46
46
46
46
46
46
46
46
46
46
46
46
46
46
ENGAGE
THROTTLE
GATE
RH
GATE
LH
REAR
FRAME
WINGS
HOPPER
SCREED
LIFT
165A
167A
167A
165A
46
160
162
MAN
SET
AUTO
CW
ON
51
(12)
(6)
(5)
(1)
(2)
(3)
(7)
ADJUST.
SPEED
MODULE
80
(D)
FEED SENSOR
53
46
54
56
(7)
ADJUST.
SPEED
MODULE
90
(D)
FEED SENSOR
(12)
(6)
(5)
(1)
(2)
(3)
(E)
(E)
(9)
(8)
(4)
(11)
(10)
(8)
(9)
(C)
(4)
(11)
(10)
R.H. FEED CONTROL
46
52
55
(C)
150
LAI
157
155
155
157
DEC
INC
157
155
LT. AUTO ISOLATION RELAY
157
155
RAI
167
165
165
167
DEC
INC
167
165
LOWER
RAISE
LOWER
RAISE
LOWER
RAISE
LOWER
RAISE
LOWER
FULL
IDLE
RAISE
RELEASE
ENGAGE
64
ASSIST
33
64
108
107
104
103
71
70
66
65
ON
OFF
63
62
61
160
RT. AUTO ISOLATION RELAY
48
'D'
AREA
'A'
SOL.
'B' SOL.
'A' SOL.
'B' SOL.
68 Q
2W.
87
B SOL.
A SOL.
'A' SOL.
'B' SOL.
LH
LH
97
B
MAN.
CONV.
SPEED
1K Q
SPEED
1K Q
REVISION
RT. PULL
POINT
SERVO
POINT
SERVO
LT. PULL
THROTTLE SOL.
K18
K17
K16
K15
MAN.
CONV.
RH
R.H. FEED
SERVO
CW
STOP
L.H. FEED
SERVO
CW
STOP
RH
FORWARD
COILS
VIBRATOR SOL.
'C'
68 Q
2W.
93
96
95
94
83
86
85
84
50
78
A
REVERSE
COILS
VIBRATOR SOL.
ASSIST SOL.(OPT)
SYM.
167
165
162
50
MAX
PAVER
SPEED
1K Q
74
74
73
77
BRAKE RELEASE SOL.
RANGE SOL.
FWD SOL.
73
AUTO VIBRATORS
152
MAT THICKNESS
157A
155A
157A
155A
46
150
152
MAN
SET
AUTO
53
51
C
B
34
L.H. FEED CONTROL
OFF
47
ON
OFF
VIBRATORS
34
34
42
27
STOP
56
46
47
47
MAT THICKNESS
'D'
OVERRIDE
REMOTE
FEED
MAN
OFF
AUTO
CONVEYOR
R.H.
'C'
55
STOP
OVERRIDE
FEED
REMOTE
MAN
OFF
SPEED
TRAVEL
34
42
27
CONTROLLER
34
RELEASE
AUTO
L.H.
CONVEYOR
FORWARD L.S.
OPTIONAL
TRUCK
HITCH
47
47
47
47
34
P/2
P/4
TRAVEL
NOTE:
CLOSED IN FORWARD
(TRAVEL CONTROL)
'A'
BRAKE
RANGE
OPTIONAL EZ SCREED
VIBRATOR WIRING
STANDARD SCREED
VIBRATOR WIRING
11/04
VIEW C-C
RELAY WIRING
VIEW A-A
CB WIRING
4418-816
11/04
CR551 Pavers w/Servo

9704-416-31
9704-416-05d 9704-416-08c
Cedarapids Inc.
A Terex Company
4418-818
Stretch 16 Screed
Hydraulic Schematic
9704-660-55
Cedarapids Inc.
4/94
A Terex Company
.063"
300-310 PSI
MACHINE RAISE
2.8
"B"
CID
"A"
CONVEYOR PUMP
400 PSI
52.8 GPM MAX

50:1 RATIO
N.S. SWITCH
2400 PSI
2000 RPM
5
6.1
CID
50:1 RATIO
"A"
2.8
"B"
FORWARD
3600 PSI
1.2
CID
10.1 GPM
1.2
CID
1940 RPM
1000 PSI
"A"
REVERSE
10.4 GPM
AUX. PUMP
"B"
CID
4418-831
300-310 PSI
.063"
MS1 & MS2

Hydraulic Schematic
9702-050-42
Cedarapids Inc.
4/94
A Terex Company
HOPPER GATE
MACHINE RAISE
PUSH BEAM
HOPPER RAISE
TRUCK HOOK
(OPTIONAL)
.063"
300-310 PSI
200 PSI PRECHARGE

1 PINT EACH
2.8
"B"
CID
"A"
CONVEYOR PUMP
50:1 RATIO
400 PSI
52.8 GPM MAX
N.S. SWITCH
2000 RPM
CID
"B"
FORWARD
B
A
B
A
2400 PSI
6.1
50:1 RATIO
B
A
1.2
CID
1000 PSI
"A"
REVERSE
B
A
10.4 GPM
5
2
10.1 GPM
1.2
CID
3600 PSI
AUX. PUMP
1940 RPM
"A"
2.8
"B"
CID
4418-832
300-310 PSI
.063"
MS3
Hydraulic Schematic
9702-050-43
Cedarapids Inc.
4/94
A Terex Company
4418-861
12/94
Page 1 of 2
with Frame Raise
Hydraulic Schematic
9704-660-90
A Terex Company
4418-861
12/94
Page 2 of 2
A Terex Company
4418-864
2/95
Page 1 of 4
9704-416-54b, 9704-416-56c,
9704-416-57a, 9704-416-59a
Cedarapids Inc.
A Terex Company
4418-864
2/95
Page 2 of 4
A Terex Company
4418-864
2/95
Page 3 of 4
A Terex Company
300 Only
400 & 500 Only
300 Only
4418-864
2/95
Page 4 of 4
A Terex Company
4418-865
2/95
Page 1 of 4
Rubber Tire Pavers
9704-416-53b, 9704-416-55b,
9704-416-57a, 9704-416-59a
Cedarapids Inc.
A Terex Company
4418-865
2/95
Page 2 of 4
A Terex Company
4418-865
2/95
Page 3 of 4
A Terex Company
300 & 411 Only
400 & 500 Only
300 & 411 Only
4418-865
2/95
Page 4 of 4
A Terex Company
4418-867
3/95
Page 1 of 1
Fastach 8 Screed
with Vibratory Strike-off
Hydraulic Schematic
Cedarapids Inc.
A Terex Company
4418-923
12/96
Page 1 of 4
Grayhound Pavers
9704-416-80
9704-416-81
9704-416-57a
9704-416-59a
Cedarapids Inc.
A Terex Company
4418-923
12/96
Page 2 of 4
A Terex Company
300 & 411 Only
400 & 500 Only
300 & 411 Only
4418-923
12/96
Page 3 of 4
A Terex Company
4418-923
12/96
Page 4 of 4
A Terex Company
4418-937
12/97
Page 1 of 4
Rubber Tire Pavers
ROC/Elite
9704-416-88
9704-416-55b 9704-416-86a
A Terex Company
4418-937
12/97
Page 2 of 4
A Terex Company
4418-937
12/97
Page 3 of 4
A Terex Company
4418-937
12/97
Page 4 of 4
A Terex Company
4418-938
12/97
Page 1 of 4
Track Pavers
ROC/Elite
9704-416-89
9704-416-92 9704-416-86a
A Terex Company
4418-938
12/97
Page 2 of 4
A Terex Company
4418-938
12/97
Page 3 of 4
A Terex Company
4418-938
12/97
Page 4 of 4
4418-944
11/04
Page 1 of 2
CR351 Pavers
Hydraulic Schematic
9704-661-58c
Cedarapids Inc.
4418-944
11/04
Page 2 of 2
4418-945
11/04
Page 1 of 2
CR361 Pavers
Hydraulic Schematic
9704-661-59c
Cedarapids Inc.
4418-945
11/04
Page 2 of 2
A Terex Company
4418-946
10/98
Page 1 of 2
CR451/CR551
Hydraulic Schematic
9704-661-38b
Cedarapids Inc.
A Terex Company
4418-946
10/98
Page 2 of 2
A Terex Company
4418-947
10/98
Page 1 of 2
CR461/CR561
Hydraulic Schematic
9704-661-39b
Cedarapids Inc.
A Terex Company
4418-947
10/98
Page 2 of 2
A Terex Company
4418-952
10/98
Page 1 of 2
CR461 and CR561 Slat Pavers
Rubber Track
Hydraulic Schematic
9704-661-68
A Terex Company
4418-952
10/98
Page 2 of 2
4418-956
11/04
Page 1 of 2
CR361R Pavers
Hydraulic Schematic
9704-661-78a
Cedarapids Inc.
4418-956
11/04
Page 2 of 2
4418-959
11/04
Page 1 of 4
Rubber Tire Pavers
Gen 3 Std. Electrical Schematic
9704-417-01c 9704-417-03d
9704-417-05a
Cedarapids Inc.
4418-959
11/04
Page 2 of 4
4418-959
11/04
Page 3 of 4
4418-959
11/04
Page 4 of 4
4418-960
11/04
Page 1 of 4
Track Pavers
Gen 3 Std.
9704-417-02d 9704-417-04d
9704-417-05a
4418-960
11/04
Page 2 of 4
4418-960
11/04
Page 3 of 4
4418-960
11/04
Page 4 of 4
4418-963
11/04
Page 1 of 4
Rubber Tire Pavers
Remix
9704-417-06c 9704-417-07d
9704-417-09a
4418-963
11/04
Page 2 of 4
4418-963
11/04
Page 3 of 4
4418-963
11/04
Page 4 of 4
A Terex Company
4418-964
05/01
Page 1 of 4
Track Pavers
Remix
9704-417-06c 9704-417-08c
9704-417-10c
A Terex Company
4418-964
05/01
Page 2 of 4
A Terex Company
4418-964
05/01
Page 3 of 4
A Terex Company
4418-964
05/01
Page 4 of 4
4418-973
11/04
Page 1 of 4
CR351 Pavers
Gen 3 Electrical Schematic
9704-417-03d 9704-417-12c
9704-417-15c
Cedarapids Inc.
4418-973
11/04
Page 2 of 4
4418-973
11/04
Page 3 of 4
4418-973
11/04
Page 4 of 4
4418-974
11/04
Page 1 of 4
CR361 Pavers
Gen 3 Electrical Schematic
9704-417-04d 9704-417-12c
9704-417-14c
Cedarapids Inc.
4418-974
11/04
Page 2 of 4
4418-974
11/04
Page 3 of 4
4418-974
11/04
Page 4 of 4
4418-978
11/04
Page 1 of 4
Rubber Tire Pavers
Slat From Remix
9704-417-17
9704-417-16a 9704-417-18
Cedarapids Inc.
4418-978
11/04
Page 2 of 4
4418-978
11/04
Page 3 of 4
4418-978
11/04
Page 4 of 4
4418-994
11/04
Page 1 of 4
Track Pavers w/Dual Joysticks
Gen 3 Std.
9704-417-22c 9704-417-23b
9704-417-05a
4418-994
11/04
Page 2 of 4
4418-994
11/04
Page 3 of 4
4418-994
11/04
Page 4 of 4
4418-995
11/04
Page 1 of 2
CR451/CR551
Hydraulic Schematic
9704-662-09a
4418-995
11/04
Page 2 of 2
4418-996
11/04
Page 1 of 2
CR461/CR561
Hydraulic Schematic
9704-662-10a
4418-996
11/04
Page 2 of 2
A Terex Company
4418-997
10/00
Page 1 of 2
CR461R/CR561R
Rubber Track
Hydraulic Schematic
9704-662-11
A Terex Company
4418-997
10/00
Page 2 of 2
4494-105-19b
Page 1 of 4
12/03
352 Paver
9704-417-33b, 9704-417-34b, 9704-417-35d
4494-105-19b
Page 2 of 4
12/03
352 Paver
9704-417-33b, 9704-417-34b, 9704-417-35d
4494-105-19b
Page 3 of 4
12/03
352 Paver
9704-417-33b, 9704-417-34b, 9704-417-35d
4494-105-19b
Page 4 of 4
12/03
352 Paver
9704-417-33b, 9704-417-34b, 9704-417-35d
4494-105-20
Page 1 of 4
11/04
362 Paver
9704-417-46b, 9704-417-47c, 9704-417-35d
4494-105-20
Page 2 of 4
11/04
362 Paver
9704-417-46b, 9704-417-47c, 9704-417-35d
4494-105-20
Page 3 of 4
11/04
362 Paver
9704-417-46b, 9704-417-47c, 9704-417-35d
4494-105-20
Page 4 of 4
11/04
362 Paver
9704-417-46b, 9704-417-47c, 9704-417-35d
NOTE:
SEE SHEET 2 OF 2 FOR ADDITIONAL CONTROLS
4494-105-21
Page 1 of 4
11/04
452/552 Paver
9704-417-36, 9704-417-55a, 9704-417-54a
1
K1
B50
15A.
46
MAINTENANCE
RUN
START
WARNING
STOP
17
STOP
START
RUN
STOP
ENGINE
17
TWISTED
OPTION
J1939
TO
ENGINE
45
ON
GENERATOR
OFF
FULL
THROTTLE
22
22
22
22
22
22
22
22
22
22
22
5A
S
G
24
25
OT
OP
WT
S
G
S
G
S
G
H/T
ON
125A FUSE
BATTERY + 1
125A FUSE
BATTERY + 1
BATTERY +
J1939 SH
J1939 -
POWER RELAY
K1
25
10R
10L
GRID
TWIN
6 AWG
6 AWG
DIAGNOSTIC
ENGINE BLOCK
GROUND
UNIT
REMIX
ONLY
46
46
46
46
46
46
46
47
15
14
25A.
LIGHTS
4
15A.
FLASHERS
RH
GATE
LH
GATE
REAR
FRAME
HOPPER
WINGS
47
SCREED
LIFT
SCREED
LIFT
RED
79
K6
K5
LOWER
RAISE
LOWER
RAISE
LOWER
RAISE
LOWER
RAISE
89C
LOWER
RAISE
LOWER
RAISE
RELEASE
114
110
64
63
62
61
ON
114
HEAD
LGTS.
110
108
107
104
103
71
70
66
65
ON
OFF
ALARM
64
74A
73A
34
CW
OFF
78
77
74
73
74A
73A
50
49
34
WORK
LGTS.
110
K18
K17
K16
K15
78
77
74
73
STROBE
CRFA
89B
89A
ON
VIBRATORS
47
MAX
PAVER
SPEED
1K Q
OFF
33
ASSIST
47
F
ENGAGE
113A
47
49
WHT
F
GRN
RED
BLK
RED
BLK
74A
73A
76
75
STEER
ASSIST
MODULE
46065-500-34
74A
73A
42
27
TRAVEL
CONTROL
HANDLE
79
WHT
34
76
75
ON
TRAVEL
SPEED
CONTROL
MODULE
RELEASE
109A
WHT
RED
'A'
46A
46A
ENGAGE
BRAKE
OFF
STEER ASSIST
46A
DIFF. LOCK
P/4
P/2
TRAVEL
RANGE
OPTIONAL
TRUCK
HITCH
47
TO
STARTING
CIRCUIT
46
46
46
CONTINUED TO PAGE 2 OF SCHEMATIC
FLASHER RELAY
3
K6
HEATER
113
109
RH
TANK
LIGHTS RELAY
3
K5
VOLTMETER
24
OIL TEMP.
9
LH
TANK
OIL PRESS.
8
COOLING
FAN
1
2
HYD DUMP
VENT
VALVE
J1587 PUBLIC DATA LINK(-)
WATER TEMP.
7
23 PIN
(LOCATED IN
FUEL FILTER)
J1587 PUBLIC DATA LINK(+)
J1939 +
17
K2
STARTER RELAY
15
STARTER
HOUR/TACHOMETER
WIF SENSOR
ON
OFF
FLASHER
VM
10
OFF
LIGHTS
RH
11
FUEL LEVEL
10A
10A
7.5A
7.5A
7.5A
FUEL
LH
L.S.3
CLOSED IN NEUTRAL
(TRAVEL CONTROL)
5A
FUEL
I
REL
14
GRID HTR RELAYS
21A
DECREMENT
INCREMENT
ON
OFF
DIAGNOSTIC
WATER IN FUEL
13
K2
ENG
BRAKE
100
12 V.D.C.
12 V.D.C.
WAIT TO START
HYD VENT
5A
21B
48
36
35
37
29
28
30
IDLE
E-STOP
21
CONSOLE
B49
B31
B41
B40
B47
1400 RPM
B36
B35
B37
B2
B11
B4
B3
B1
QSB
B28
FAULT
CODE
ALTERNATOR
MAIN
KEYSWITCH
2200 RPM
15A.
20
100
ENGINE
100
MAIN
KEYSWITCH
'LOWER' SOL.
'RAISE' SOL.
'LOWER' SOL.
'RAISE' SOL.
NO MATERIAL FLOW
AUDIBLE ALARM
ASSIST SOL.(OPT)
'LOWER' SOL.
'RAISE' SOL.
'RELEASE' SOL.
'ENGAGE' SOL.
VIBRATOR SOL.
BACKUP ALARM
(OPTIONAL)
BRAKE RELEASE SOL.
RH
TRACTION
EDC
LH
TRACTION
EDC
LOCK SOL.
RANGE SOL.
FWD SOL.
100
NOTE:
SEE SHEET 1 OF 2 FOR REMAINDER OF SCHEMATIC
4494-105-21
Page 2 of 4
11/04
452/552 Paver
9704-417-36, 9704-417-55a, 9704-417-54a
15A.
4
50A.
BURNER
15A.
45
245
SCREED
15A.
F/G/S
30A.
GATES
NOTE:
WIRE 45
SAME AS
46 ON
SCREED
ONLY!
SPRAYDOWN
47
117A
115
115
115
115
115
115
115
115
115
45
45
45
45
47
(C)
(C)
150
165A
167A
167A
165A
45
106
K18
K16
98
89
88
157A
5
155A 4
150
LAI
DEC
INC
157
155
157
155
LH AUTO ISOLATION RELAY
167A
165A
160
RAI
DEC
INC
167
165
167
165
RH CONVEYOR CONTROL
162
RH AUTO ISOLATION RELAY
117
ON
FUEL PUMP
OFF
ON
FAN NO.4
OFF
ON
FAN NO.3
OFF
ON
FAN NO.2
OFF
ON
FAN NO.1
OFF
ON
148
146
138
136
128
126
118
116
117
148
GLOW PLUG NO.4
146
RH EXT. BURNER (NO.4)
138
GLOW PLUG NO.3
136
LH EXT. BURNER (NO.3)
128
GLOW PLUG NO.2
126
RH MAIN BURNER (NO.2)
118
GLOW PLUG NO.1
116
LH MAIN BURNER (NO.1)
117
DEC. SOL.
INC. SOL.
DEC. SOL.
INC. SOL.
RH NO FLOW
CRFA
LH NO FLOW
R.H. GATE
MOTOR
L.H. GATE
MOTOR
FUEL PUMP MOTOR
GLOW PLUG NO.4
FAN MOTOR NO.4
GLOW PLUG NO.3
FAN MOTOR NO.3
GLOW PLUG NO.2
FAN MOTOR NO.2
GLOW PLUG NO.1
FAN MOTOR NO.1
FUEL PUMP MOTOR
STANDARD FUEL OIL BURNER CONTROL

FUEL PUMP
OFF
117
OPTIONAL FOR NON-FUEL OIL HEATING
MAN
SET
160
RED
106
102
RH AUTOMATIC SCREED CONTROL

AUTO
162
K17
K18
K15
RED
152
MAT THICKNESS
(TOWPOINT)
157A
155A
157A
155A
45
MAN
SET
AUTO
MAT THICKNESS
(TOWPOINT)
105
YEL
101
YEL
102
HORN
HORN SW.
LH AUTOMATIC SCREED CONTROL
OPENS WITH
MATERIAL
PRESENT
152
(B) 98
RH FLOW
SWITCH
(A)
105
101
K16
18
19
MATERIAL FLOW INDICATORS

AND FLOW ALARM RELAY
K17
K15
18
19
(B) 88
OPENS WITH
MATERIAL
PRESENT
(A)
LH FLOW
SWITCH
100
100
100
100
JUMPER
K3
K3
HORN RELAY
100
100
45
45
45
45
45
45
45
45
47
45
46
46
46
46
46
47
46
46
46
RH
SLOPE
LH
SLOPE
5 PIN
46
MAIN
CROWN
RH
MATCH
HEIGHT
LH
MATCH
HEIGHT
RH EXT
(CONSOLE)
RH
EXTEND
LH EXT.
(CONSOLE)
12
11
10
9
8
7
6
5
4
3
2
1
GND
+8V
SIG.
GND
C
D
E
DECREASE
INCREASE
DECREASE
INCREASE
DECREASE
INCREASE
DOWN
UP
DOWN
UP
OUT
IN
OUT
IN
OUT
IN
OUT
IN
51
91
90
81
80
+8V
SIG.
GND
GND
+14V
81 80
FEEDER
CONTROL
FEEDER
CONTROL`
46
53
54
93
91
90
47
80
81
83
52
46
GND
SIG.
+8V
GND
+14V
184
183
174
173
190
189
186
185
176
175
184
183
174
173
182
181
172
171
SCREED CONTROLS
GENERATION III
+14V
53
54
54
51
10 PIN
5 PIN
AUTO
OFF
OVERRIDE
STOP
RH FEED
OVERRIDE
REMOTE
FEED
LH
EXTEND
47
AUTO
OFF
FEED
INTERFACE
MODULE
46
46
OVERRIDE
STOP
LH FEED
REMOTE
FEED
1KQ
1/2W.
C
A
B
WAND
52
52
GENERATION III
LH CONVEYOR CONTROL
OVERRIDE
SONIC
CONTINUED FROM PAGE 1 OF SCHEMATIC
93
WAND
SONIC
1KQ
1/2W.
DEC. SOL.
INC. SOL.
DOWN SOL.
UP SOL.
DOWN SOL.
UP SOL.
OUT SOL.
IN SOL.
OUT SOL.
IN SOL.
DEC. SOL.
INC. SOL.
DEC. SOL.
INC. SOL.
STOP
97
STOP
87
5 PIN
5 PIN
10 PIN
83
+8V
SIG.
GND
GND
+14V
RH
FEED
EDC
LH
FEED
EDC
4494-105-21
Page 3 of 4
11/04
452/552 Paver
9704-417-36, 9704-417-55a, 9704-417-54a
ENGINE
113A
103
K15
100
3
3
101
K16
100
3
3
102
107
K17
100
3
3
105
108
K18
100
3
3
106
K15
10
7.5
10
7.5
10
7.5
FEED INTERFACE
MODULE
K16
K17
K2
K1
K18
15
SPARE
17
291
292
294
295
296
297
331
332
245
TO BATTERY
POSITIVE
20
1
4
#21
TO T.B.
#1 TO
STARTER
VIEW B-B
115
A
D
STARTER
B
C
OFF
291
292
294
295
296
297
331
332
245
ON
281
282
284
285
286
287
115
100
VIEW C-C
281
282
284
285
286
287
BATTERY
VIEW E-E
K6
51
52
83
81
80
3
47
90
91
93
54
53
VIEW A-A
SCREED
104
K5
OFF
G
J
F A B
C
E
D
REAR
K3
PUSH ON - PULL OFF
115
114
CIRCUIT BREAKERS
POWER
ON
100
50
BURNER
113A
K6
30
GATES
RIGHT
113
15
FLASHERS
109A
110
109A
15
LIGHTS
117A
18
15
SPRAYDOWN
46
K5
15
F/G/S
245
109
15
CONSOLE
45
100
15
SCREED
LEFT
19
15
ENGINE
FRONT
K3
ENGINE
100
GRID
HEAT
MEGA
125A
3A
3C
5
6
7
8
9
10
11
15
17
18
19
21
21A
21B
22
24
25
27
28
29
30
33
34
35
36
37
42
45
46
46
46
46
47
48
49
50
51
52
53
54
61
62
63
64
65
66
70
71
73
74
77
78
79
80
81
83
87
88
90
91
93
97
98
101
102
103
104
105
106
107
108
109
110
110
113
114
117
117A
155
157
165
167
173
174
183
184
20
3A
3C
5
6
7
8
9
10
11
15
17
18
19
21
21A
21B
22
24
25
27
28
29
30
33
34
35
36
37
42
45
46
46
46
46
47
48
49
50
51
52
53
54
61
62
63
64
65
66
70
71
73
74
77
78
79
80
81
83
87
88
90
91
93
97
98
101
102
103
104
105
106
107
108
109
110
110
113
114
117
117A
155
157
165
167
173
174
183
184
MEGA
125A
VIEW D-D
4494-105-21
Page 4 of 4
11/04
452/552 Paver
9704-417-36, 9704-417-55a, 9704-417-54a
4494-105-22
Page 1 of 4
11/04
462/562 Paver
9704-417-39b, 9704-417-56a, 9704-417-54a
100
NOTE:
SEE SHEET 1 OF 2 FOR REMAINDER OF SCHEMATIC
4494-105-22
Page 2 of 4
11/04
462/562 Paver
9704-417-39b, 9704-417-56a, 9704-417-54a
NOTE:
WIRE 45
SAME AS
46 ON
SCREED
ONLY!
15A.
4
50A.
BURNER
15A.
45
45
45
45
115
115
115
115
115
115
115
115
115
117A
45
245
SCREED
15A.
F/G/S
30A.
SPRAYDOWN
GATES
(C)
(C)
150
ON
FAN NO.4
OFF
ON
FAN NO.3
OFF
ON
FAN NO.2
OFF
ON
FAN NO.1
OFF
ON
148
146
138
136
128
126
118
116
117
117
165A
167A
167A
165A
45
RED
106
K18
98
89
88
157A
155A
150
LAI
DEC
INC
157
155
157
155
LH AUTO ISOLATION RELAY
167A
165A
160
RAI
DEC
INC
167
165
167
165
RH AUTO ISOLATION RELAY
162
ON
FUEL PUMP
OFF
148
GLOW PLUG NO.4
146
RH EXT. BURNER (NO.4)
138
GLOW PLUG NO.3
136
LH EXT. BURNER (NO.3)
128
GLOW PLUG NO.2
126
RH MAIN BURNER (NO.2)
118
GLOW PLUG NO.1
116
LH MAIN BURNER (NO.1)
117
DEC. SOL.
INC. SOL.
DEC. SOL.
INC. SOL.
RH NO FLOW
CRFA
LH NO FLOW
R.H. GATE
MOTOR
L.H. GATE
MOTOR
FUEL PUMP MOTOR
GLOW PLUG NO.4
FAN MOTOR NO.4
GLOW PLUG NO.3
FAN MOTOR NO.3
GLOW PLUG NO.2
FAN MOTOR NO.2
GLOW PLUG NO.1
FAN MOTOR NO.1
FUEL PUMP MOTOR
STANDARD FUEL OIL BURNER CONTROL
117
OPTIONAL FOR NON-FUEL OIL HEATING
MAN
SET
160
K17
106
102
RH AUTOMATIC SCREED CONTROL

AUTO
162
K15
K18
RED
K16
152
MAT THICKNESS
(TOWPOINT)
157A
155A
157A
155A
45
MAN
SET
AUTO
MAT THICKNESS
(TOWPOINT)
105
YEL
101
YEL
102
HORN
HORN SW.
LH AUTOMATIC SCREED CONTROL
OPENS WITH
MATERIAL
PRESENT
152
(B) 98
RH FLOW
SWITCH
(A)
105
101
K16
18
19
MATERIAL FLOW INDICATORS

AND FLOW ALARM RELAY
K17
K15
18
19
(B) 88
OPENS WITH
MATERIAL
PRESENT
(A)
LH FLOW
SWITCH
100
100
100
100
FUEL PUMP
OFF
JUMPER
47
47
K3
HORN RELAY
100
100
K3
45
45
45
45
45
45
45
45
45
46
46
46
46
46
46
46
STOP
5 PIN
46
RH EXT
(CONSOLE)
RH
EXTEND
LH EXT
(CONSOLE)
LH
EXTEND
RH
SLOPE
MAIN
CROWN
RH
MATCH
HEIGHT
12
11
10
9
8
7
6
5
4
3
2
1
GND
+8V
SIG.
GND
C
D
E
51
91
90
81
80
+8V
SIG.
GND
GND
+14V
81 80
FEEDER
CONTROL
FEEDER
CONTROL`
46
53
54
93
91
90
47
80
81
83
52
46
GND
SIG.
+8V
GND
+14V
DECREASE
INCREASE
DOWN
UP
DOWN
UP
OUT
IN
OUT
IN
OUT
IN
OUT
IN
DECREASE
INCREASE
DECREASE
INCREASE
184
183
174
173
190
189
186
185
176
175
184
183
174
173
182
181
172
171
SCREED CONTROLS
93
WAND
SONIC
1KQ
1/2W.
DEC. SOL.
INC. SOL.
DOWN SOL.
UP SOL.
DOWN SOL.
UP SOL.
OUT SOL.
IN SOL.
OUT SOL.
IN SOL.
DEC. SOL.
INC. SOL.
DEC. SOL.
INC. SOL.
STOP
97
STOP
87
5 PIN
5 PIN
10 PIN
83
+8V
SIG.
GND
GND
+14V
GENERATION III
RH CONVEYOR CONTROL
+14V
53
54
54
51
52
52
10 PIN
5 PIN
AUTO
OFF
OVERRIDE
STOP
RH FEED
OVERRIDE
REMOTE
FEED
FEED
INTERFACE
MODULE
46
AUTO
OFF
OVERRIDE
LH FEED
46
LH
SLOPE
47
OVERRIDE
GENERATION III
LH CONVEYOR CONTROL
A
REMOTE
FEED
1KQ
1/2W.
WAND
SONIC
LH
MATCH
HEIGHT
47
CONTINUED FROM PAGE 1 OF SCHEMATIC
RH
FEED
EDC
LH
FEED
EDC
4494-105-22
Page 3 of 4
11/04
462/562 Paver
9704-417-39b, 9704-417-56a, 9704-417-54a
ENGINE
K5
113A
103
K15
100
3
3
101
K16
100
3
3
102
107
K17
100
3
3
105
108
K18
100
3
3
106
7.5
10
7.5
10
7.5
FEED INTERFACE
MODULE
K16
K17
K2
K1
K18
15
SPARE
17
291
292
294
295
296
297
331
332
245
TO BATTERY
POSITIVE
20
1
4
#21
TO T.B.
#1 TO
STARTER
VIEW B-B
115
A
D
STARTER
B
C
OFF
291
292
294
295
296
297
331
332
245
OFF
H
G
J
F A B
C
E
D
ON
281
282
284
285
286
287
115
100
VIEW C-C
281
282
284
285
286
287
BATTERY
VIEW E-E
K15
10
SCREED
104
K6
51
52
83
81
80
3
47
90
91
93
54
53
PUSH ON - PULL OFF
115
K3
POWER
ON
VIEW A-A
REAR
114
CIRCUIT BREAKERS
100
50
BURNER
113A
K6
30
GATES
RIGHT
113
15
FLASHERS
109A
110
109A
15
LIGHTS
117A
18
15
SPRAYDOWN
245
K5
15
F/G/S
46
109
15
CONSOLE
45
19
100
15
SCREED
LEFT
15
ENGINE
FRONT
K3
ENGINE
100
GRID
HEAT
MEGA
125A
3A
3C
5
6
7
8
9
10
11
15
17
18
19
21
21A
21B
22
24
25
27
28
29
30
33
34
35
36
37
42
45
46
46
46
46
47
48
49
50
51
52
53
54
61
62
63
64
65
66
70
71
73
74
77
78
79
80
81
83
87
88
90
91
93
97
98
101
102
103
104
105
106
107
108
109
110
110
113
114
117
117A
155
157
165
167
173
174
183
184
20
3A
3C
5
6
7
8
9
10
11
15
17
18
19
21
21A
21B
22
24
25
27
28
29
30
33
34
35
36
37
42
45
46
46
46
46
47
48
49
50
51
52
53
54
61
62
63
64
65
66
70
71
73
74
77
78
79
80
81
83
87
88
90
91
93
97
98
101
102
103
104
105
106
107
108
109
110
110
113
114
117
117A
155
157
165
167
173
174
183
184
MEGA
125A
VIEW D-D
4494-105-22
Page 4 of 4
11/04
462/562 Paver
9704-417-39b, 9704-417-56a, 9704-417-54a
4494-105-23
Page 1 of 4
11/04
452/552 Remix Paver

9704-417-41, 9704-417-43b, 9704-417-45d
4494-105-23
Page 2 of 4
11/04
452/552 Remix Paver

9704-417-41, 9704-417-43b, 9704-417-45d
4494-105-23
Page 3 of 4
11/04
452/552 Remix Paver

9704-417-41, 9704-417-43b, 9704-417-45d
LEFT HAND
RIGHT HAND
4494-105-23
Page 4 of 4
11/04
452/552 Remix Paver

9704-417-41, 9704-417-43b, 9704-417-45d
4494-105-24
Page 1 of 4
11/04
462/562 Remix Paver

9704-417-42a, 9704-417-44a, 9704-417-45d
4494-105-24
Page 2 of 4
11/04
462/562 Remix Paver

9704-417-42a, 9704-417-44a, 9704-417-45d
4494-105-24
Page 3 of 4
11/04
462/562 Remix Paver

9704-417-42a, 9704-417-44a, 9704-417-45d
LEFT HAND
RIGHT HAND
4494-105-24
Page 4 of 4
11/04
462/562 Remix Paver

9704-417-42a, 9704-417-44a, 9704-417-45d
4494-105-29
Page 1 of 4
11/04
452/552 Remix Paver

9704-417-59a, 9704-417-43b, 9704-417-45d
4494-105-29
Page 2 of 4
11/04
452/552 Remix Paver

9704-417-59a, 9704-417-43b, 9704-417-45d
4494-105-29
Page 3 of 4
11/04
452/552 Remix Paver

9704-417-59a, 9704-417-43b, 9704-417-45d
LEFT HAND
RIGHT HAND
4494-105-29
Page 4 of 4
11/04
452/552 Remix Paver

9704-417-59a, 9704-417-43b, 9704-417-45d
4494-105-30
Page 1 of 4
5/04
462/562 Remix Paver

9704-417-60a, 9704-417-44a, 9704-417-45d
4494-105-30
Page 2 of 4
5/04
462/562 Remix Paver

9704-417-60a, 9704-417-44a, 9704-417-45d
4494-105-30
Page 3 of 4
5/04
462/562 Remix Paver

9704-417-60a, 9704-417-44a, 9704-417-45d
LEFT HAND
RIGHT HAND
4494-105-30
Page 4 of 4
5/04
462/562 Remix Paver

9704-417-60a, 9704-417-44a, 9704-417-45d
A Terex Company
4495-001
12/00
Page 1 of 3
CR451/CR551 Remix Pavers
Hydraulic Schematic
9704-662-33
Cedarapids Inc.
A Terex Company
4495-001
12/00
Page2 of 3
A Terex Company
4495-001
12/00
Page3 of 3
A Terex Company
4495-002
12/00
Page 1 of 3
CR461/CR561 Remix Pavers
Hydraulic Schematic
9704-662-34
Cedarapids Inc.
A Terex Company
4495-002
12/00
Page2 of 3
A Terex Company
4495-002
12/00
Page3 of 3
A Terex Company
4495-003
12/00
Page 1 of 3
CR461R/CR561R Remix Pavers
Hydraulic Schematic
9704-662-35
Cedarapids Inc.
A Terex Company
4495-003
12/00
Page2 of 3
A Terex Company
4495-003
12/00
Page3 of 3
A Terex Company
4495-004
11/00
Page 1 of 1
Stretch Screeds
Hydraulic Schematic
9704-662-36
Cedarapids Inc.
A Terex Company
4495-005
11/00
Page 1 of 1
Fixed Screeds
Hydraulic Schematic
9704-662-37
Cedarapids Inc.
4495-006
11/04
Page 1 of 2
MS-4 Electrical Schematic
9702-200-09d
& MS-4 Hydraulic Schematic
9702-050-46b
Cedarapids Inc.
4495-006
11/04
Page2 of 2
V1
U1
V2
U2
GROUND BAR
W1
W2
34 KVA GENERATOR
208Y/120V-3PH-60HZ
208V (L-L)
120V (L-N)
L3
L2
L1
V-F-A
GND
METER
(1)
(4)
GND
GND
GND
100
100
100
100
100
100
100
100
100
V2
T2
30
T3
AMP
L2
L3
T2
30 T3
AMP
L2
L3
T2
30 T3
AMP
L2
L3
30 T3
AMP
L3
T3
T2
5L1
5L3
5L2
5L1
4L3
4L2
4L1
3L3
3L2
3L1
2L3
2L2
2L1
1L3
1L2
1L1
113
112
111
123
122
121
133
132
131
MAN
OFF
AUTO
143
142
141
CT5
HEATER POWER
LED
1 L1
C1
2 T1
10AWG/4c
1H1
BLACK
C4
GREEN
BLACK
LOAD
WHITE
143
OT2 OT1
IN
+ - + - + 7 6 5 4 3 2 1
PWR
8
133
OT2 OT1
IN
+ - + - + 7 6 5 4 3 2 1
PWR
8
123
OT2 OT1
IN
+ - + - + 7 6 5 4 3 2 1
PWR
8
113
OT2 OT1
IN
+ - + - + 7 6 5 4 3 2 1
PWR
8
BLACK
A1
A1
A1
A1
C4
C3
C2
C1
LOAD
LINE
BLACK
A2
TEMP SENSOR
100 ohm RTD
A2
TEMP SENSOR
100 ohm RTD
A2
TEMP SENSOR
100 ohm RTD
A2
TEMP SENSOR
100 ohm RTD
WHITE
GREEN
LOAD
LINE
WHITE
GREEN
GFCI OUTLET
120V-20A GND
GND
RED
WHITE
BLACK
GREEN
RED
WHITE
BLACK
5L2
10AWG/4c
4H3
4H2
4H1
GND
3H3
3H2
3H1
GREEN
RED
WHITE
BLACK
GREEN
RED
GFCI OUTLET
120V-20A GND
GREEN
RH EXT. HEAT CONTROL
4 T2
2 T1
10AWG/4c
10AWG/4c
GND
2H3
2H2
2H1
GND
1H3
5L2
LINE
RH MAIN HEAT CONTROL
4 T2
2 T1
6 T3
37 AMP
LH MAIN HEAT CONTROL
C3
6 T3
37 AMP
LH EXT. HEAT CONTROL
4 T2
2 T1
6 T3
37 AMP
C2
6 T3
37 AMP
4 T2
WHITE
GFCI OUTLET
120V-20A GND
5 L3
3 L2
1 L1
5 L3
3 L2
1 L1
5 L3
3 L2
1 L1
5 L3
3 L2
1H2
5L3
10 AWG MTW
TEMPERATURE
CONTROLLER
MAN
OFF
AUTO
CT4
HEATER POWER
LED
10 AWG MTW
TEMPERATURE
CONTROLLER
MAN
OFF
AUTO
CT3
HEATER POWER
LED
10 AWG MTW
TEMPERATURE
CONTROLLER
MAN
OFF
AUTO
CT2
10 AWG MTW
TEMPERATURE
CONTROLLER
3A
CONTROL
L3 20A
CB7
L2 20A
CB6
L1 20A
T1
T2
L2
CB5
T1
L1
CB4
T1
L1
CB3
T1
L1
CB2
T1
L1
CB1
HEATER POWER
LED
U2
POWER LUGS
W2
U1
V1
W1
BLK
GND
1L3
1L2
1L1
GND
1L3
1L2
1L1
BLK
GRN
RED
WHT
BLK
GRN
RED
WHT
HD30-18-8
GRN
RED
WHT
BLK
GRN
RED
WHT
BLK
GND
1L3
1L2
1L1
GND
1L3
1L2
1L1
GND
1L3
1L2
1L1
GND
1L3
1L2
1L1
HD30-18-8
GRN
RED
WHT
BLK
GRN
RED
L3
L2
L1
WHT
L3
1
2
GND
L2
CT1
100:5
L1
20 KVA GENERATOR
208Y/120V-3PH-60 HZ
208V (L-L)
120V (L-N)
1L3
1L1
RH EXTENDER
1L1
RH MAIN
1L1
LH MAIN
1L1
LH EXTENDER
1L1
1L1
1L2
1L3
1L2
1L3
1L2
1L3
1L2
1L3
1L2
1L3
1L2
1L3
OPTIONAL EXTENSION
1L2
1L3
1L2
1L3
1L2
1L3
1L2
1L3
1L2
1L3
1L2
OPTIONAL EXTENSION
1L2
1L1
1L2
1L1
1L2
1L1
1L2
1L1
1L2
1L1
1L2
1L1
EXTENSION
ELEMENTS
(2) 450W 208V ON 14"
(2) 900W 208V ON 26"
(2) 1350W 208V ON 38"
RH EXTENDER
ELEMENTS
(2) 2.25KW 208V ON S20
(2) 1.8KW 208V ON S16
RH MAIN SCREED
ELEMENTS
(2) 2.25KW 208V ON S20
(2) 1.8KW 208V ON S16
LH MAIN SCREED
ELEMENTS
(2) 2.25KW 208V ON S20
(2) 1.8KW 208V ON S16
LH EXTENDER
ELEMENTS
(2) 2.25KW 208V ON S20
(2) 1.8KW 208V ON S16
EXTENSION
ELEMENTS
(2) 450W 208V ON 14"
(2) 900W 208V ON 26"
(2) 1350W 208V ON 38"
A Terex Company
4495-007
Page 1 of 2
Stretch Electric Screed
Electrical Schematic 9704-611-55
& Stretch Electric Screed
Hydraulic Schematics
9704-662-58 Stretch 16
9704-662-56 Stretch 20
Cedarapids Inc.
7/02
A Terex Company
TRACTOR
SCREED
MOTOR
2.14 CID
X
S S S
13/64"
17 GPM
1800 RPM
Stretch 16
400 PSI
STANDBY
5000 PSI
4000 PSI
COMPENSATOR
T
VALVE BLOCK
ADJUST NEEDLE VALVE

TO ACHIEVE DESIRED
MOTOR SPEED
PUMP
2.75 CID
FILTER
PUT JUMPER HOSE BETWEEN PORTS

M2 AND X ON PUMP
TRACTOR
SCREED
1800 RPM
P
22 GPM
S S S
13/64"
P
X
.063"
Stretch 20
B
5000 PSI
300 PSI
400 PSI
T
VALVE BLOCK
M2
ADJUST NEEDLE VALVE

TO ACHIEVE DESIRED
MOTOR SPEED
T
MOTOR
2.8 CID
4500 PSI
M4
PUMP
3.48 CID
L1,L2
STRAINER
4495-007
7/02
Page 2 of 2
4495-008
Page 1 of 2
452/552 and 462/562 Paver
Hydraulic Schematic
9704-662-63c
11/04
4495-008
Page 2 of 2
452/552 and 462/562 Paver
Hydraulic Schematic
9704-662-63c
11/04
4495-009
Page 1 of 3
452/552 and 462/562 Remix Paver

Hydraulic Schematic
9704-662-64
11/04
4495-009
Page 2 of 3

Hydraulic Schematic
9704-662-64
11/04
4495-009
Page 3 of 3

Hydraulic Schematic
9704-662-64
11/04
4495-011
Page 1 of 2
7/03
Fastach II - Electrical & Hydraulic Schematics

9704-611-46b, 9704-662-58, 9704-662-97
TRACTOR
SCREED
MOTOR
2.14 CID
X
13/64"
17 GPM
B
S S S
1800 RPM
400 PSI
STANDBY
5000 PSI
4000 PSI
COMPENSATOR
Generator Drive
Hydraulics
9704-662-58
T
VALVE BLOCK
ADJUST NEEDLE VALVE

TO ACHIEVE DESIRED
MOTOR SPEED
PUMP
2.75 CID
FILTER
Screed
Hydraulics
9704-662-97
4495-011
Page 2 of 2
7/03

9704-611-46b, 9704-662-58, 9704-662-97
RH TRACTION
RH CONVEYOR
33.6 GPM MAX
33.6 GPM MAX
50.4 RATIO
230 RPM
MAX.
390 PSI
29.9
2500 RPM
48.0
CID
2.8
CID
2.8
CID
4.88
CID
1.4
CID
1.61 CID
MINIMUM
CID
4WD VALVE
10
.078" DIA.
ORIFICES
m
2
FILTER
PARKING BRAKE
IDLE
DIFFERENTIAL
LOCK VALVE
RANGE SHIFT
OPTIONAL
FRONT WHEEL ASSIST
TIRE PAVERS ONLY
TIRE PAVERS ONLY
FULL
4WD PILOT
VALVE
RH TRACTION DRIVE
LH TRACTION DRIVE
THROTTLE
CYLINDER
CHARGE PRESSURE
THROTTLE
VALVE
LH TRACTION
LH CONVEYOR
33.6 GPM MAX
230 RPM
MAX.
B
390 PSI
29.9
2500 RPM
CID
4WD VALVE
4.88
CID
2.8
2.8
CID
1.61 CID
MINIMUM
CID
1.4
CID
48.0
CID
50.4 RATIO
10
m
2
FILTER
33.6 GPM MAX
4495-012
Page 1 of 2
352 and 362 Paver
Hydraulic Schematic
9704-663-02
9/03
HOPPER WINGS
TRUCK HOOK
(OPTIONAL)
LH GRADE
(OPTIONAL)
175 PSI NITROGEN

PRECHARGE
RH GRADE
(OPTIONAL)
OPTIONAL
SCREED ASSIST
(SUPPLIED WITH
EXTENDABLE)SCREED)
UP
SCREED LIFT
FRAME RAISE
STEERING
UP
TIRE PAVERS ONLY
REPHASE PORT
AT EACH END OF
CYLINDER STROKE
V
A
STEERING
VALVE
900
PSI
T
I
TO SCREED
VALVES
P
8.1 GPM MAX
FROM SCREED
VALVES
AUXILIARY PUMP
SUPERCHARGE FILTER
2050
RPM
SCREED VIBRATORS
FLOW FROM SCREED
VIBRATORS
REPHASE PORT CROSS SECTION
2250 PSI
PRECHARGE
.913
CID
LH
1500 PSI
5
2500 PSI
b2
FLOW TO SCREED
VIBRATORS
15 PSI
2250 PSI
PRECHARGE
FUME
FAN
.659
CID
RH
HOOD RAISING SYSTEM
4550
RPM
TRACK TENSIONING
TRACK PAVERS ONLY
2800
PSI
COOLING FAN VALVE

10.7 GPM
12VDC
2
2130
RPM
1.16
CID
2.1 GPM MAX

COOLER
23.5 GPM
900 PSI
COOLING FAN
2800 RPM MAX
2400 ACTUAL
3000 PSI
MAX
1.94
CID
2.55
CID
3
12VDC
10
m
2
FILTER
4495-012
Page 2 of 2
352 and 362 Paver
Hydraulic Schematic
9704-663-02
9/03
4495-013
Page 1 of 2
10/04

9704-611-80, 9704-662-56, 9704-663-24
Generator Drive
Hydraulics
9704-662-56
Screed
Hydraulics
9704-663-24
4495-013
Page 2 of 2
10/04

9704-611-80, 9704-662-56, 9704-663-24
4495-014
Page 1 of 3

Hydraulic Schematic
9704-663-31
12/04
4495-014
Page 2 of 3

Hydraulic Schematic
9704-663-31
12/04
4495-014
Page 3 of 3

Hydraulic Schematic
9704-663-31
12/04
24 Hour Service Number

(800) 821-5600

Asphalt Paver Technical Manual

Caricato da

Informazioni sul documento

Copyright

Formati disponibili

Condividi questo documento

Condividi o incorpora il documento

Opzioni di condivisione

Hai trovato utile questo documento?

Questo contenuto è inappropriato?

Copyright:

Formati disponibili

Asphalt Paver Technical Manual

Caricato da

Copyright:

Formati disponibili

PAVER

24 Hour Service Number

Serial Number/Date Record

Coding System for Re-useable End Type

HOSE TYPE CODE

HOSE SIZE CODE

9- Hose Sizes Not Listed Such As 7/16 I.D.

Hose Coding (22483)

Coding System for Re-useable End Type

HOSE END CLAMP

HOSE ASSEMBLY VARIATIONS

Hose Coding (22483)

Coding System for Re-useable End Type

Hose Coding (22483)

Coding System for Crimped Type

CODE NUMBER ASSIGNMENTS

SAE100R4 Suction Hose

SAE100R5 Single wire braid-cotton braid cover

SAE100R1 Single Wire Braid/ Abrasion Resistant Synthetic Cover

SAE100R2 Two Wire Braid/ Abrasion Resistant Synthetic Cover

Very High Pressure

SAE100R9 Four Wire Spiral/ Abrasion Resistant Synthetic Cover

Extremely High Pres. Hose Rated Greater Than SAE100R9

All Hose Types Not Assigned

HOSE SIZE CODE

Hose Sizes Not Listed (Such As 7/16 I.D.)

Hose Coding (22483)

Coding System for Crimped Type

Hose Coding (22483)

Coding System for Crimped Type

Hose Coding (22483)

Rubber Track Operating Hints

Rubber Track Operating Hints

Do Not Allow Asphalt Build-up on Track

The following are some specific considerations for

During paving, asphalt sometimes flows down to

Oil in the asphalt will cause the rubber in the

Aggregate will abrade the rubber in the track

Asphalt material build-up in the undercarriage

Inner Rubber Wear

Figure 1 Asphalt on Track & Wear

Rubber Track Operating Hints

Rubber Track Operating Hints

Before paving begins, loosen nuts, slide plate out

Rubber Track Operating Hints

Rubber Track Operating Hints

Rubber Track Operating Hints

Rubber Track Operating Hints

Do not turn on or near hot asphalt. Move to

Do not park on hot asphalt. High

Rubber Track Operating Hints

Rubber Track Operating Hints

Caution - If a turn is attempted on an

Uneven terrain such as curbs, concrete ridges or

Figure 6 Steps in Elevation & Uneven Surfaces

Do not turn on or near sharp edges of

Do not approach a step in elevation at a

Do not park on a step in elevation. When

Rubber Track Operating Hints

Figure 7 Damage From Steps in Elevation & Uneven Surfaces

Rubber Track Operating Hints

Rubber Track Operating Hints

To maintain and preserve the life of the rubber

Do not use solvents to wash the rubber