Introduction and General Information Highway Class Paver/Finishers

TABLE OF CONTENTS
TASK PAGE NO.

Introduction ........................................................................................................................2
Safety Practices for the Shop ............................................................................................2
General Safety ...................................................................................................................2
Maintenance Safety ............................................................................................................4
Using This Manual ..............................................................................................................5
General Specifications .......................................................................................................6
Lubricants ...........................................................................................................................8
Sealants.............................................................................................................................10
Cap Screw and Nut Standard Torque Valves ...................................................................11
SAE Boss Style O-Ring Fitting Service Recommendations ............................................13
ORS Face O-Ring Seal Fitting Service Recommendations .............................................14
Hydraulic Four-Bolt Flange Fitting Service Recommendations .......................................15
Hydraulic Lines and Fittings .............................................................................................16
Hydraulic Flared Fitting Service Recommendations ........................................................17
Cleaning and Preparation for Service ..............................................................................18
First Aid for Molten Asphalt Cement Burns .....................................................................19
Welding ............................................................................................................................20
Painting ............................................................................................................................22

1
Highway Class Paver/Finishers
INTRODUCTION
This Blaw-Knox paver/finisher has been carefully
designed and manufactured to provide the utmost in
dependable service. To obtain the best results and
keep it operating efficiently, read and follow the
instructions in this Service Manual.
This service manual has been developed to aid the
trained service technician in the repair of Blaw-Knox
Highway Class Paver/Finishers.
Every effort has been made to make this manual
accurate. In the even that your machine is configured
differently from that shown within, you may contact
Blaw-Knox Product Support for additional guidance at
(217) 234-8811.
If a procedure, method, tool or part is not specifically
recommended, you must satisfy yourself that it is safe
for you and others, and that the paver will not be
damaged or made unsafe as a result of your decision.
SAFETY PRACTICES FOR
THE SHOP
This section is devoted to general safety practices. In
addition, specific safety precautions can be found
where appropriate throughout the manual.
The following symbols and signal words identify
safety related information.
The Safety Alert Symbol means ATTENTION!
BECOME ALERT! YOUR SAFETY IS INVOLVED!
When you see this symbol, carefully read the
message that follows.
WARNING
This symbol and signal word indicate a poten-
tially hazardous situation which, if not avoid-
ed, COULD result in death or serious injury.
CAUTION
This symbol and signal word indicate a poten-
tially hazardous situation which, if not avoid-
ed, COULD result in minor or moderate injury.
This symbol may also be used to alert
against unsafe practices.
CAUTION
This signal word indicates a situation which if
not avoided, MAY result in product or property
damage.
2
Introduction and General Information
IMPORTANT
This signal word indicates important informa-
tion which MUST be followed for successful
completion of the task.
NOTE
This signal word indicates useful supplemen-
tal information pertaining to the procedure or
equipment.
The precautions listed in this manual and on the
paver are not all-inclusive. If a procedure, method,
tool or part is not specifically recommended, you must
satisfy yourself that it is safe for you and others, and
that the paver will not be damaged or made unsafe
as a result of your decision. REMEMBER – ALWAYS
USE COMMON SENSE WHEN SERVICING YOUR
PAVER.
GENERAL SAFETY
There is no more important safety precaution
than being thoroughly familiar with the service
procedure at hand. You must review the proce-
dure completely before starting. Be comfortable
with what is required and have the necessary
equipment and tools ready.
Read and understand all instructions contained in
the operator’s manual, the engine manual and all
optional equipment manuals before attempting to
service the paver.
Tag and lock-out equipment before servicing.
Accidental start-ups have caused many serious
injuries.
Never attempt to service a machine while it is
running.
Never attempt to lift or remove parts and compo-
nents without suitable lifting equipment. This
manual makes an attempt to identify the weight of
major components; the use of appropriate lifting
equipment is recommended to avoid personal
injury.
Be sure lifting equipment is in good working order
and rated for the anticipated load. Do not use
worn slings or non-hardened, non-welded lifting
eyes. Chains and hoists must be inspected
regularly for compliance with OSHA regulations.
Wear the appropriate safety protection for the
situation. Safety glasses are a must at all times.
Do not wear loose fitting clothing, jewelry and
make sure long hair is pulled back and fastened
so that it cannot catch in moving parts.
Introduction and General Information
Before attempting to service, attach or remove
any part or assembly on the paver, make certain
that:
• All controls and switches are in the OFF or
NEUTRAL position.
• Hopper wings are lowered.
• Screed is lowered or secured in the raised
position with the safety latches provided.
• Engine is shut off, unless otherwise
instructed.
Always mount and dismount paver from the rear,
using walkways, steps and handrails provided.
Never jump off the paver.
Escaping fluid under pressure can have sufficient
force to penetrate the skin, causing serious injury.
Before disconnecting fluid lines, be sure to relieve
all pressure. Before applying pressure to a
system, be sure all connections are tight and that
lines, tubes and hoses are not damaged. Fluid
escaping from a very small hole can be almost
invisible. Use a piece of cardboard or wood,
rather than your hands, to search for suspected
leaks.
Highway Class Paver/Finishers
If injured by escaping fluid, see a doctor at once.
Serious infection or reaction can develop if
proper medical treatment is not administered
immediately.
Batteries produce explosive gases. Keep all
sparks and open flames away from batteries. If a
battery needs recharging, avoid sparks by turning
off the charger before making connections or
disconnections.
Sulfuric acid in batteries is a poison and could
cause severe burns. Avoid contact with skin, eyes
and clothing. When working around batteries, pro-
tect eyes and face from battery fluid and possible
explosion by wearing a face shield.
Before starting the engine, be sure there is plenty
of ventilation. If it is necessary to operate the
engine in side an enclosed service area, be sure
exhaust is properly vented. Carbon monoxide
gas, while odorless, is extremely deadly.
Make sure everyone is clear of the paver before
starting so they cannot be struck or caught in
moving parts.
3
Highway Class Paver/Finishers
MAINTENANCE SAFETY
The following suggestions apply to all maintenance
procedures. Use caution whenever working on con-
struction equipment.
CAUTION
Decals and plates provide operating instruc-
tions and safety information. To help prevent
accidents or personal injury, clean or replace
any decal that cannot be easily read. Refer to
the appropriate Parts Catalog for identification
and correct mounting locations for decals and
plates.
CAUTION
ALL MOVING PARTS – To prevent possible
serious injury, avoid contact with rotating fans
and belts.
CAUTION
Never grease, oil or perform any mainte-
nance with the engine running unless so
instructed by the Operator’s Manual or
Service Manual. If the screed must be raised
in order to perform the operation, secure it in
the raised position with the safety latches pro-
vided.
CAUTION
Before attempting to remove any major com-
ponent, check the approximate weight of that
component and make adequate provision for
attaching and lifting. Use a hoist or crane
capable of supporting the weight.
CAUTION
Use proper lifting equipment. Lifting heavy
components incorrectly can cause severe
personal injury or machine damage.
CAUTION
Dispose of fluids properly. Improperly dispos-
ing of fluids can harm the environment and
may be against the law. Before draining any
fluids, find out from your supervisor the prop-
er way to dispose of waste. Never pour oil
into a stream, pond or lake. Observe relevant
environmental protection regulations when
disposing of oil, fuel, coolant, brake fluid, fil-
ters, batteries and other harmful waste.
4
Introduction and General Information
CAUTION
Inspect all lifting and blocking equipment
before use and make sure equipment is rated
for the load. Chains must be welded and
tagged for capacity. Slings should not be
frayed. Lifting eyes should be welded and
hardened. Blocking must be hardwood.
CAUTION
Support machine properly. Do not support the
machine on cinder blocks or props that may
crush or crumble under continuous load. Do
not work under a machine that is supported
solely by a jack.
IMPORTANT
Inspect the machine for loose, worn or dam-
aged parts. Report unsafe conditions or dam-
aged parts to your supervisor immediately.
IMPORTANT
Clean the machine before servicing. You may
remove large pieces of asphalt by chiseling. It
is recommended that cleaning solution be
allowed to soak overnight and removed with a
high pressure washer.
IMPORTANT
Clean rubber parts by washing in clean dena-
tured alcohol. DO NOT use mineral-base
cleaning solvents such as acetone or paint
thinner on any rubber parts. If a mineral-base
solvent is used, the rubber will start to deteri-
orate and continue to deteriorate after the
part is put back into service. The continued
deterioration of the rubber could cause the
part to fail.
IMPORTANT
Work in a clean area. Before starting a job
clean the work area and machine. Make sure
you have all necessary tools to complete your
job. Have the right parts on hand. Read all
instructions thoroughly; DO NOT attempt
shortcuts.
IMPORTANT
Use tools properly. Use tools appropriate to
the work. Makeshift tools, parts and proce-
dures will not make good repairs and could
put you and the machine at risk for injury or
damage. Use pneumatic and electric tools
only to loosen threaded parts and fasteners.
Never use such tools to tighten fasteners,
especially on light alloy parts. Use only Blaw-
Knox approved replacement parts.
Introduction and General Information Highway Class Paver/Finishers

USING THIS MANUAL service, general testing and troubleshooting as

applicable.

This manual contains information pertaining to the
service of the PF-3172, PF-3180, PF-3200, PF-5500
and PF-5510 highway class paver/finishers. The
manual is divided into sections. Each section con-
tains the information for removal, disassembly, spe-
cial testing, inspection/specifications, assembly, com-
ponent test, adjustments, installation and equipment
preparation, as applicable, for each system.
Each section is divided into service tasks. At the
beginning of each section, there is a task summary
that lists what the section covers (example: Removal,
Disassembly, Assembly, Installation, Equipment
Preparation). The summary also lists what needs to
be done to set up the machine for the task and
which, if any, special or fabricated tools are needed
for the task.

At the front of the manual is a general Table of
Contents. Each section also contains a Table of
Contents for that specific module. An alphabetical
index is found at the front of each section for quick
reference to a specific task.
The service tasks in each section are arranged so
that the main steps are highlighted in bold for the
experienced service technician. Detailed, step-by-
step procedures follow for the inexperienced service
technician (see example below.)

Each section covers specific system safety precau-

tions, system theory of operation, maintenance and

MAIN STEP
Step 9:
Remove the hydraulic pumps from the transmis-
sion box (pumps weigh approx. 120 lbs. each).

a. Keep hoist or crane attached to transmission

DETAILED box assembly with enough surface tension to
STEPS provide stability on the work surface.

b. Strap a sling around each pump as it is

removed. Attach sling to a hoist to remove
each pump from transmission box.

c. Remove four bolts from each pump and lift

clear of the transmission box assembly.

5
Highway Class Paver/Finishers Introduction and General Information

GENERAL SPECIFICATIONS

DIMENSIONS PF-3172 PF-3180 PF-3200 PF-5500 PF-5510

Width (Hopper Up) 10'0" 10'0" 10'0" 10'0" 10'0"

3.05 m 3.05 m 3.05 m 3.05 m 3.05 m

Width (Hopper Down) 10'4" 10'4" 10'4" 10'4" 10'4"

3.15 m 3.15 m 3.15 m 3.15 m 3.15 m

Length (Wedge-Lock Screed) 18'9" 20'10" 20'10" 19'6" 19'6"

5.72 m 6.35 m 6.35 m 5.94 m 5.94 m

Length (Omni Screed II) 18'9" 20'10" 20'10" 19'6" 19'6"

5.72 m 6.35 m 6.35 m 5.94 m 5.94 m

Length (Omni Screed III) 19'8" 21'9" 21'9" 20'5" 20'5"

5.99 m 6.63 m 6.63 m 6.09 m 6.09 m

WEIGHTS
Total – With Wedge-Lock Screed 29,870 lbs. 33,800 lbs. 34,000 lbs. 33,990 lbs. 32,010 lbs.
13,550 kg 15,322 kg 15,422 kg 15,418 kg 14,520 kg

Total – With Omni Screed II 31,530 lbs. 35,460 lbs. 35,660 lbs. 35,650 lbs. 33,670 lbs.
14,302 kg 16,085 kg 16,175 kg 16,171 kg 15,273 kg

Total – With Omni Screed III 32,390 lbs. 36,320 lbs. 36,520 lbs. 36,510 lbs. 34,530 lbs.
14,692 kg 16,475 kg 16,565 kg 16,561 kg 15,663 kg

SPEEDS
Trans. Motor

LO LO 0-160 fpm 0-170 fpm 0-170 fpm ––––– 0-156 fpm

Eng. @ 2100 RPM 0-48.8 m/min. 0-51.8 m/min. 0-51.8 m/min. 0-45 m/min.

LO HI 0-254 fpm 0-270 fpm 0-270 fpm 0-300 fpm 0-230 fpm
Eng. @ 2100 RPM 0-77.4 m/min. 0-82.3 m/min. 0-82.3 m/min. 0-91.4 m/min. 0-76 m/min.

HI LO 0-6.3 mph 0-6.7 mph 0-6.7 mph 0-4.3 mph 0-6.2 mph
Eng. @ 2100 RPM 0-10.1 km/hr 0-10.8 km/hr 0-10.8 km/hr 0-6.9 km/hr 0-9.3 km/hr

HI HI 0-10 mph 0-10.7 mph 0-10.7 mph ––––– 0-9.1 mph

Eng. @ 2100 RPM 0-16.1 km/hr 0-17.2 km/hr 0-17.2 km/hr 0-16.1 km/hr

Reverse –––– Full reverse in all speed ranges.

Weights are approximate on the maximum side depending on model series and how machine is option equipped.

6
Introduction and General Information Highway Class Paver/Finishers

Drain and Refill Capacities

ENGINE SYSTEMS PF-3172 PF-3180 PF-3200 PF-5500 PF-5510

Fuel Tank 42 gal. 54 gal. 54 gal. 54 gal. 54 gal.

159 L 204 L 204 L 204 L 204 L

Engine Coolant (Cummins) 24 qts. 25 qts. 25 qts. 25 qts. 25 qts.

159 L 189 L 189 L 189 L 189 L

Engine Oil With Filter (Cummins) 17.3 qts. 17.3 qts. 17.3 qts. 17.3 qts. 17.3 qts.
16.4 L 16.4 L 16.4 L 16.4 L 16.4 L

HYDRAULIC SYSTEM
WITHOUT OPTIONS
Hydraulic Reservoir 42 gal. 50 gal. 50 gal. 50 gal. 50 gal.
159 L 189 L 189 L 189 L 189 L

Pump Drive Transmission 3 qts. 3 qts. 3 qts. 3 qts. 3 qts.

2.8 L 2.8 L 2.8 L 2.8 L 2.8 L

Traction Drive Planetary 197 oz. 197 oz. 197 oz. 197 oz. 197 oz.
Transmission 5L 5L 5L 5L 5L

Auger/Conveyor Drive Chain Box 4-5 lbs. 4-5 lbs. 4-5 lbs. 4-5 lbs. 4-5 lbs.
1.8-2.3 kg 1.8-2.3 kg 1.8-2.3 kg 1.8-2.3 kg 1.8-2.3 kg

Auger/Conveyor Planetary 30 oz. 30 oz. 30 oz. 30 oz. 30 oz.

Transmissions .9 L .9 L .9 L .9 L .9 L

7
Highway Class Paver/Finishers Introduction and General Information

Filters

Blaw-Knox Part Number Description Machines Served

00164-821-00 Oil Filter Element PF-5510, beginning serial #551017-01

00164-816-00 Primary Fuel Filter PF-5500, beginning serial #550004-01
00164-822-00 Fuel Strainer PF-3200, beginning serial #320017-01
PF-3180, beginning serial #318008-01
PF-3172, beginning serial #317210-01

90140-001-00 Oil Filter Element PF-5510, before serial #551017-01

90140-002-00 Primary Fuel Filter PF-5500, before serial #550004-01
90140-003-00 Secondary Fuel Filter PF-3200, before serial #320017-01
PF-3180, before serial #318008-01
PF-3172, before serial #317210-01

00164-809-01 Filter Element, Air all machines

00112-216-01 Filter Element, Hydraulic all machines
00112-414-00 Filter Element, Screed Heater and
Wash Down System all machines
00164-658-00 Gasket for AMF Filter above all machines
00112-323-01 Filter, Pump Control Fluid all machines

LUBRICANTS
This section contains a list of recommended lubri-
cants for all major components except the engine. It
is important to ensure that the part being lubricated,
the lubrication equipment and the lubricant itself are
all free from dirt, grit or other contaminants.
Use quality lubricants furnished by reliable manufac-
turers as specified in the chart. Use the proper lubri-
cant in each application as specified. Do not mix
lubricants.
Most bearings on the Paver/Finisher are permanently
sealed and require no greasing. For those bearings
which do require hand greasing, Blaw-Knox recom-
mends the use of a hand grease gun since hand
grease guns do not force a large amount of lube into
the bearings instantly. Escaping grease should not be
visible around the bearings or felt washers.
IMPORTANT
Power grease guns can blow out and perma-
nently damage bearing seals. If power grease
guns must be used, use power guns for very
short bursts of one second or less with five
second delays between bursts to allow
grease to escape slowly.
Keep lubricants in clean, covered containers. Make
certain that funnels, grease guns and other lubrication
equipment is clean before and after use. Clean fit-
tings, plug openings and other lubrication points
before servicing. Inspect and clean plugs and other
detachable fittings before reinstalling.

8
Introduction and General Information Highway Class Paver/Finishers

Filters

Component Lube Type

Bearings Multipurpose Grease
Hydraulics Hydraulic Fluid
Engine See Engine Manual
Slides and Rollers Multipurpose Grease
Pins and Spindles Multipurpose Grease
Pump Drive Transmission Transmission Lubricant
Drive Shafts Multipurpose Grease
PTO and Clutch Multipurpose Grease
Auger Drive Planetary Transmission Lubricant
Conveyor Drive Planetary Transmission Lubricant
Drive Chain Multipurpose Grease

Recommended Lubricants

Transmission Hydraulic Multipurpose Brake

Lubricants Fluids Grease Fluids
(Pump drive trans., (Hydraulic tanks) (Grease fittings and
traction drive and auger/con. drive chains)
auger/con. planetaries)

Mobil Mobil Mobil Any DOT 4

HD 85W-140 300 523 or Lith 22
Valvoline Valvoline Valvoline
200G, 85W-140 Unitrac 300G Val-Plex EP
Amoco Amoco Amoco
Multi Gear Lube 85W-140 1000 RYKONEP 2
Exxon Exxon Exxon
GX 85W-140 Nuto-H-68 RONEX MP
Sunoco Sunfleet Sunoco Sunvis
GL5 85W-140 868WR
Mobil Gear Lube
629 or 630*

* Fill track roller housing only.

9
Highway Class Paver/Finishers Introduction and General Information

SEALANTS Hydraulic Fittings

Surface Preparation
1. Thoroughly clean parts with solvent and allow to
dry. Parts must be free of oil, dirt, grime and
other contaminants.
1. Thoroughly clean fittings with solvent and allow
to dry. Fittings must be free of traces of hydraulic
fluid, dirt, grime, etc.
2. Attach fitting and torque to specifications.

2. a. With thread sealants, apply one drop of

sealant for every 3 threads. Do not over
apply.
b. Surface sealants should be applied in a
continuous 1/16” bead, run on the center of
the surface when possible, inside of the
holes. Do not over apply.

3. Assemble parts and torque to specifications with-

in 20 minutes.

BK-6.1

Surface Sealant Bead

Sealant Application Chart

Application B-K Part Number Locktite Equivalent

Hydraulic Fitting Sealant 00147-012-00 242

Pipe Sealant – Teflon 00147-013-00 92-31

Surface Sealant – 00225-018-00 N/A

Form-a-Gasket (12 oz.)

Bonding & Retaining 00147-025-00 RC/680 Green

10
Introduction and General Information Highway Class Paver/Finishers

CAP SCREW AND NUT

STANDARD TORQUE VALUES
CAUTION
Use only the proper tools (inch or metric) on GRADE 5 CAP SCREW
hardware. Other tools may not fit properly.
They may slip and cause injury.

Fasteners should be replaced with the same or higher

grade (except shear bolts, which MUST be replaced
with the identical grade). If higher grade fasteners are GRADE 8 CAP SCREW
used, these should only be tightened to the strength
of the original.

8.8
Do no use these values if a different torque value or 8.8 8.8
tightening procedure is listed for a specific applica-
tion. Torque values listed are for general use only. All
values are suggested maximum with dry, plated hard-
ware. Reduce torque by 25% for lubricated hardware. GRADE 8.8 CAP SCREW

Make sure fastener threads are clean and you prop-

erly start thread engagement. This will prevent them

10.9
from failing when tightened. 10.9 10.9

CLASS 10.9 CAP SCREW

BK-1

Recommended Torque Values (Maximum)*

Grade 5 Grade 8
Course Thread Fine Thread Course Thread Fine Thread
Size lb-ft N•m lb-ft N•m lb-ft N•m lb-ft N•m
1/4 6 8 7 9.5 9 12 10 13.5
5/16 13 17/5 14 19 18 24 20 27
3/8 23 31 30 41 35 47 35 37
7/16 35 47 40 54 55 75 60 81
1/2 55 75 65 88 80 108 90 122
9/16 80 108 90 122 110 149 130 176
5/8 110 149 130 176 170 230 180 244
3/4 200 271 220 298 280 380 320 434
7/8 300 407 320 434 460 624 500 678
1 440 597 480 651 680 922 740 1005
* Tighten plastic insert or crimped steel-type lock nuts to approximately 50 percent of amount shown in chart. Tighten
toothed or serrated-type lock nuts to full torque value.

11
Highway Class Paver/Finishers Introduction and General Information

Metric Recommended Torque Values (+/- 10%)*

Class 8.8 Class 10.9

Dry Lubricated Dry Lubricated
Size lb-ft N•m lb-ft N•m lb-ft N•m lb-ft N•m
3 1 1.4 .09 1.1 1.5 2.1 1.2 1.7
4 2.4 3.3 1.9 2.6 3.6 4.8 2.9 3.9
5 4.9 6.7 3.9 5.3 7.2 9.8 5.8 7.8
6 8.4 11.3 6.7 9.1 12.3 16.6 9.8 13.3
8 20 28 16 22 30 40 24 32
12 70 95 56 76 103 140 82 112
14 110 150 90 120 165 220 130 180
16 175 235 140 190 255 350 205 275
20 350 475 280 380 500 675 400 540
24 605 825 480 650 860 1170 690 935
30 1200 1630 960 1300 1710 2320 1370 1850
36 2100 2850 1680 2280 3009 4060 2400 3250

* Tighten plastic insert or crimped steel-type lock nuts to approximately 50 percent of amount shown in chart. Tighten
toothed or serrated-type lock nuts to full torque value.

12
Introduction and General Information Highway Class Paver/Finishers

SAE BOSS STYLE O-RING 6. Hold fitting end (C) with wrench. Tighten lock nut
(A) to torque value shown on chart.
FITTING SERVICE
NOTE
RECOMMENDATIONS Do not allow hoses to twist when tightening
fittings.
Straight Fitting
1. Inspect O-ring boss seat (1) for dirt or defects. 2
2. Lubricate O-ring (2) with B-K #260-24 lubricant.
Place electrical tape over threads to protect the 1
O-ring. Slide O-ring over tape and into O-ring
groove of fitting. Remove tape.
3. Tighten fitting to torque value shown on chart.

Angle Fitting
1. Inspect O-ring boss seat (3) for dirt or defects.
2. Lubricate O-ring with B-K #260-24 lubricant.
Place electrical tape over threads to protect the 6
3
O-ring. Slide O-ring over tape and into O-ring
groove (4) of fitting (5). Remove tape. 7 4
3. Back lock nut (6) and back-up washer (7) to head
end of fitting.
4. Turn fitting into threaded boss (8) until washer 5
contacts face of boss.
5. Turn fitting head end (C) counterclockwise to
properly index (maximum of one turn).
6

7
8

BK-2

SAE Boss Style O-Ring Seal Fitting Torque Chart (+/- 10%)

Nominal Tube O.D.

SAE Thread
Dash Size Size In. mm lb-ft N•m
-4 3/8 - 24 UNF 1/4 6.35 6 8
-6 7/16 - 20 UNF 3/8 9.53 9 12
-8 1/2 - 20 UNF 1/2 12.70 12 16
-10 9/16 - 18 UNF 5/8 15.88 18 24
-12 3/4 - 16 UNF 3/4 19.05 34 46
-16 7/8 - 14 UNF 1 25.40 46 62
-20 1-1/16 - 12 UNF 1-1/4 31.75 75 102

13
Highway Class Paver/Finishers Introduction and General Information

ORS FACE O-RING SEAL

FITTING SERVICE
RECOMMENDATIONS

1. Inspect the fitting sealing surfaces. They must be

free of dirt or defects.
2. Inspect the O-ring. It must be free of damage or
defects.
3. Lubricate the fitting groove seat (1) ONLY using
B-K #260-24 lubricant.
4. Push O-ring into the groove seat.
5. Index angle fittings and tighten by hand pressing 6. Tighten fitting or nut to torque shown on the chart
joint together to insure O-ring remains in place. per dash size stamped on the fitting.

NOTE
Do not allow hoses to twist when tightening
fittings.

ORS Flat Face O-Ring Seal Fitting Torque Chart (+/- 15 - 20%)

Nominal Tube O.D. Swivel Nut Bulkhead Nut

ORS Thread
Dash Size Size In. mm lb-ft N•m lb-ft N•m
-4 9/16 - 18 1/4 6.35 18 24 3.5 4.7
-6 11/16 - 16 3/8 9.52 30 41 6.5 8.8
-8 13/16 - 16 1/2 12.70 52 70 12.5 17.0
-10 1- 14 5/8 15.88 75 102 12.5 17.0
-12 1-3/16 - 12 3/4 19.05 105 142 12.5 17.0
-16 1-7/16 - 12 1 25.4 150 203 12.5 17.0

14
Introduction and General Information Highway Class Paver/Finishers

HYDRAULIC FOUR BOLT b. Single piece flange: Place hydraulic line in

FLANGE FITTING SERVICE
RECOMMENDATIONS
1. Clean and inspect sealing surfaces (1). Scratches
cause leaks. Roughness causes seal wear. Out-
of-flat causes seat extrusion. If defects cannot be
polished out, replace component.
2. Install O-ring (and back-up washer if required)
into groove using B-K #260-24 lubricant.
3. a. Split flange: Loosely assemble split flange (2)
halves. Make sure split is centrally located
and perpendicular to port. Hand tighten cap
screws to hold parts in place. Do not pinch
O-ring.
center of flange and install cap screws.
Flange must be centrally located on port.
Hand tighten cap screws to hold flange in
place. Do not pinch O-ring.
4. Tighten one cap screw, then tighten the diagonal-
ly opposite cap screw. Tighten two remaining cap
screws. Tighten all cap screws as specified in the
chart below.
NOTE
DO NOT use air wrenches. DO NOT tighten
one cap screw fully before tightening the
others. DO NOT overtighten.

2
2

1
3
BK-4

SAE Four Bolt Flange Torque Chart*

lb-ft N•m
Nominal Cap Screw
Flange Size Size Min Max Min Max

1/2 5/16 - 18 UNC 15 23 20 31

3/4 3/8 - 16 UNC 21 40 28 54
1 3/8 - 16 UNC 27 40 37 54
1-1/4 7/16 - 14 UNC 35 63 47 85
1-1/2 1/2 - 13 UNC 46 97 62 131
2 1/2 - 13 UNC 54 97 73 131
2-1/2 1/2 - 13 UNC 79 97 107 131
3 5/8 - 11 UNC 117 195 158 264
3-1/2 5/8 - 11 UNC 117 195 158 264
4 5/8 - 11 UNC 117 195 158 264
5 5/8 - 11 UNC 117 195 158 264
* Tolerance +/- 10%. The torques given are enough for the given size connection with the recommended working pressure.
Torques can be increased to the maximum shown for each cap screw size if desired. Increasing cap screw torque beyond
this maximum will result in flange and cap screw bonding and connection failures.

15
Highway Class Paver/Finishers Introduction and General Information

Metric Four Bolt Flange Torque Chart*

Thread N•m lb-ft

M6 12 9
M8 30 22
M10 57 42
M12 95 70
M14 157 116
M16 217 160
M18 334 246
M20 421 318
* Tolerance +/- 10%. The torques given are enough for the given size connection with the recommended working pressure.
Increasing cap screw torque beyond this maximum will result in flange and cap screw bonding and connection failures.
** Metric standard thread.

HYDRAULIC LINES AND
FITTINGS
Blaw-Knox machines use two different O-ring sealed
hydraulic fittings: the SAE Boss style and the ORS
Face style. Hydraulic fittings are supplied with O-rings
installed; tubes and hoses do not come with O-rings.
NOTE
All O-rings furnished by Blaw-Knox are 90
Durometer.

ORS Face Style O-Ring Identification Table

ORS Dash Size Tube Size I.D. by Crossection BK Part Number

-4 ARP-11-1/4” .301 x .07 00121-098-00
-6 ARP-12 - 3/8” .364 x .07 00121-099-00
-8 ARP-14 - 1/2” .489 x .07 00121-100-00
-10 ––– ––– N/A
-12 ARP-18 - 3/4” .739 x .07 00121-101-00
-14 ––– ––– N/A
-16 ARP-21 - 1” .926 x .07 00121-104-00
SAE Boss Style O-Ring Identification Table

ORS Dash Size Nominal Tube Size I.D. by Crossection BK Part Number
-4 1/4” .351 x .072 00236-210-00
-6 3/8” .468 x .078 00236-212-00
-8 1/2” .644 x .087 00136-421-00
-10 5/8” .755 x .097 00136-697-00
-12 3/4” .924 x .116 00136-427-00
-16 1” 1.171 x .116 00136-845-00
-20 1-1/4” 1.475 x .118 00136-890-00

16
Introduction and General Information Highway Class Paver/Finishers

HYDRAULIC FLARED-FITTING 2
3
SERVICE RECOMMENDATIONS
1. Clean and inspect flare and flare seat (1). They
must be free of dirt or obvious defects. 1

NOTE
Defects in the tube flare cannot be repaired.
Overtightening a defective flared fitting will
not stop leaks.
THREE PIECE TUBE
ASSEMBLY
2. Lubricate fitting threads (2) with system fluid or
B-K #260-24 lubricant. 2
3. Align the tube (3) with the fitting before attempting 3
to start the nut (4).
4. Index angle fittings and tighten by hand.
5. Tighten fitting or nut to torque value shown on the
chart below. Do not allow hoses to twist when
tightening fittings. 1

NOTE
If female thread is cast iron (control valves,
brake valves, motors, etc.), torque MUST be
reduced approximately 10%. TWO PIECE TUBE
ASSEMBLY BK-9

Flared Fitting Torque Chart (+/- 10%)

Straight Threads Tapered Threads

FITTING THREAD SIZE lb-ft N•m lb-ft N•m
1/8 11 15
1/4 15 20 33 45
3/8 21 29 51 69
1/2 36 49 69 93
3/4 51 69 130 176

17
Highway Class Paver/Finishers Introduction and General Information

CLEANING AND PREPARATION Step 2:

FOR SERVICE
Before servicing the Blaw-Knox paver/finisher, thor-
oughly clean all areas to be serviced. One suggestion
for cleaning the paver is the use of “OPTION” or
Orange-Solv.” These two solvents are made with an
oil called d-Limonene. These products are non-toxic,
water soluble, and non-abrasive. Blaw-Knox recom-
mends the use of this alternative to hazardous chemi-
cals and solvents to clean the paver.
Step 1:
Perform clean up and wash down procedures.
a. Drive the paver to the wash down area.
b. Be sure everyone is clear of the machine.
c. Lower hopper sides.
d. Secure screed in the raised position.
CAUTION
Secure screed in the raised position with the
safety latches provided.
e. Make sure all functions are shut off.
Make sure all paving materials are removed from
all paver surfaces to be serviced.
a. Use a scraping device to help remove accu-
mulated material. A long handled scraping
device may be necessary to reach limited
access areas.
b. Start at the front of the machine and work
rearward to avoid missing any areas.
WARNING
• Do not enter hopper while conveyors are oper-
ating or hopper sides are raised.
• Do not run conveyors while using scraper to
remove paving material.
• Do not stand in the auger trough area.
• Do not run augers while using scraper to
remove paving material.
• Do not disassemble or assemble edger plate
assemblies on the machine while augers are
running.
c. Remove all paving material on the deck areas
and then carefully remove solvent residue so
walking surfaces do not remain slippery.

WARNING
When cleaning:
• Never smoke or allow other persons who are
smoking into the area during wash down. This
could result in fire or explosion.
• Run the conveyors and augers only when
required to gain access to all surfaces and
only after personnel are out of the material
handling areas.
• Never stand in the hopper, on augers, auger
tunnels, auger guards or edger plate assem-
blies while the auger conveyor system is oper-
ating.
• Diesel fuel is both flammable and slippery, so
extreme caution must be exercised during the
clean up and wash down procedure to avoid
fire or personal injury.

18
Introduction and General Information
FIRST AID FOR MOLTEN
ASPHALT CEMENT BURNS
In the event of a MOLTEN ASPHALT CEMENT
BURN:
COOL the asphalt cement and affected parts of the
body immediately.
Methods of cooling (in order of preference):
1. Completely submerge affected area in ice water;
2. Completely submerge affected area in tap water;
3. Place affected area under running water.
BK-10
DO NOT DELAY
Use any available water, cooler than body tempera-
ture, while arranging for better cooling.
CAUTION
DO NOT apply ice directly to affected area.
LEAVE cooled asphalt cement on affected area.
Proceed with the following:
Minor Asphalt Cement Burns – at first opportuni-
ty, get victim to physician.
Includes:
• Injury to small areas of fairly insensitive flesh
involving a small quantity of asphalt cement.
Highway Class Paver/Finishers
Serious Asphalt Cement Burns – as soon as
possible, get victim to
Hospital __________________________________
Clinic ____________________________________
Physician’s Office _________________________
Includes:
• Injury to the head, face or extremities;
• Injury when large amounts of asphalt cement are
involved;
• Evidence of nausea or faintness.
BK-12
Treatment for Shock
In the event shock occurs, do the following:
1. Keep victim laying down and quiet.
2. Keep victim covered with a blanket or something
similar to keep body temperature at normal (98ºF;
37ºC).
3. Keep victim’s head lower than feet to promote
blood supply to head and chest.
DO NOT attempt to remove the asphalt cement
with products containing solvents or ammonia.
Natural separation will occur in about 48–72 hours. If
necessary, for early removal, soak bandage in miner-
al oil and place over affected area for 2 to 3 hours
before attempting to remove asphalt cement from
affected area.
19
Highway Class Paver/Finishers
WELDING
General Welding Practices
Preweld preparations are necessary to obtain a good
quality weld. Operations that may need to be done
before the welding is started are items such as
preparing the weld joint, cleaning the nozzle of the
welding gun, fixturing the weldment, setting the vari-
ables and in some cases preheating. The amount of
the preweld preparation depends upon the size of the
weld and weldment, type of base metal, the ease of
fit-up, the quality requirements, the governing code or
specification and the welder.
The surface of parts to be welded shall be free of
rust, scale, point, grease or other foreign matter. Very
dirty workpieces are usually cleaned by using solvent
cleaners followed by vapor degreasing. Simple
degreasing is often used for cleaning metals that
have oxide-free surfaces. Acid pickling is generally
used for cleaning metals that have a light oxide coat-
ing. The heavier oxide coatings are generally
removed mechanically by grinding and abrasive blast-
ing.
Weld penetration shall be such as to provide transfer-
ence of maximum design stress through the base
metal juncture. Fillet welds shall be provided when
necessary to reduce stress concentration. All welds
will be chipped to remove slag, ground smooth where
accessible and primed. Welds identifiable after final
painting are acceptable in areas inaccessible for
grinding. Welds at seams will conform to original
configuration.
Machine Precautions
The tractor and screed frames, decks and hopper of
Blaw-Knox pavers are primarily manufactured with
mild steel. Material handling surfaces of the convey-
ors, augers and screed are special hardened materi-
als to produce long service life. Be sure to use the
correct filler material to product a quality weld.
The following precautions will help prevent damage to
the machine when welding:
• Disconnect the battery before the welding ground
cable is connected to the frame.
• The welding ground cable must be connected as
close to the point of work as possible and must
never allow current to travel through bearings,
bushings or gaskets.
20
Introduction and General Information
Safety
Safety is an important consideration when welding.
Technicians who fail to follow adequate safety precau-
tions when welding can cause physical injury to
themselves and others as well as damage to property.
There are a number of hazards associated with
welding. These hazards are:
• Electrical shock
• Arc radiation
• Air contamination
• Compressed gasses
• Fire and explosion
• Weld cleaning and other hazards
Keep these hazards in mind when welding any com-
ponents of the paver.
Summary of Safety Precautions
• Make sure the welding equipment is installed
properly, grounded and is in good working condi-
tion.
• Make sure that compressed gas cylinders are
secured to the wall or to other structural supports.
• The welding arc is intense and visibly bright. Its
radiation can damage eyes, penetrate lightweight
clothing and burn the skin and eyes.
• Wear flameproof welding gloves, heavy long
sleeve shirt, cuffless trousers, high topped shoes,
an approved welding helmet and cap to protect
eyes, hair and skin from hot sparks, hot metal
and arc rays. Sleeves and collars should be kept
buttoned and pockets eliminated from the front.
• Do not use gloves or other clothing which contain
oil or grease due to their combustible nature.
• Bystanders should also wear approved face
masks and should be protected with suitable
screens or spark shields.
• Exposed hot conductors or other bare metal in
the welding circuit, or in ungrounded electrically
hot equipment, can fatally shock a person whose
body becomes a conductor. Do not stand, sit, lie,
lean on or touch a wet surface when welding.
• Do not perform any welding while standing,
kneeling or lying directly in contact with the
grounded work to prevent electrical shock.
Introduction and General Information
• Keep work area clean and free of hazards.
Cluttered areas and benches invite accidents.
make sure that no flammable, volatile or explo-
sive materials are in or near the work area.
• Do not weld in a confined space without extra
special precautions.
• Do not weld in areas close to chlorinated hydro-
carbon vapors coming from degreasing or spray-
ing operations. The heat or arc rays can react
with solvent vapors to form phosgene, a highly
toxic gas, and other instant gases.
• Do not weld or perform other hot work on used
barrels, drums, tanks or other containers until
they have been completely cleaned so that there
are no substances in the container which might
produce explosive, flammable or toxic vapors.
• If combustibles are in the area, do not weld. If
practical, move the work to an area free of
combustibles. Avoid paint spray rooms, dip tanks,
storage areas and ventilators. If the work cannot
be moved, move combustibles at least 35 feet
away, out of reach of sparks and heat, or protect
against ignition with suitable and snug-fitting fire
resistant covers or shields.
• Do not weld on sealed containers or compart-
ments without providing vents and taking special
precautions.
• When it is necessary to weld in a damp or wet
area, wear rubber boots and stand on a dry
insulated platform.
Highway Class Paver/Finishers
• Welding fumes, particularly in confined spaces,
can cause discomfort and physical harm if
breathed over an extended period of time.
Provide adequate ventilation in the welding area
at all times. Adequate local exhaust ventilation
must be used or each person in the area as well
as the operator must wear an air-supplied respi-
rator. Never ventilate with oxygen.
• If you develop momentary eye, nose or throat
irritation during welding, it is an indication that
ventilation is not adequate. Stop work and take
necessary steps to improve ventilation in the
welding area. Do not continue to weld if physical
discomfort persists.
• Frequently inspect cables for wear, cracks and
damage. Immediately replace cables with
extensively worn or damaged insulation to avoid
a possibly lethal shock from bared cable.
• Keep cables dry and free of oil and grease.
• Electrode wire becomes electrically hot when the
power switch is on and welding gun trigger is
pressed. Keep hands and body clear of wire and
other hot parts.
• When the welding gun is in not in use, DO NOT
hang it on a compressed gas cylinder.
• When leaving welding equipment unattended,
always shut off and disconnect all power to the
equipment.
21
Highway Class Paver/Finishers Introduction and General Information

PAINTING Step 3:
Perform any needed chemical etching.

The paint surface provides the best type of protection Step 4:

from rust. To keep equipment in good condition, we Apply a primer coat of paint to all bare metal.
recommend painting new parts and touching up
scratches. Use Blaw-Knox Part No. 00260-021-00 Step 5:
primer and Part No. 00260-022-05 finish coat, in one Apply the finish coat.
gallon containers. Finish coat is also available in one a. The finish coat should be reasonably smooth,
pint cans. (Order Part No. 00260-011-06.) A 16-oz. free of runs and sags and present a good
spray can of touch-up finish coat is also available. appearance.
(Order Part No. 00260-023-00.) b. Apply safety and instruction decals on the
painted tractor where necessary.
Step 1:
Clean area to be painted.
a. Steam clean to remove all grease, oil, dirt and
foreign material.
b. Make sure areas to be painted are dry.

Step 2:
Prepare surface to be painted.
a. Remove all loose paint, corrosion and excess
weld material.
b. Mask all areas not to be painted, such as
cylinder rods, lights, door handles, warning
and instruction plates, etc.

22