TM 5-3895-385-10

TECHNICAL MANUAL OPERATORS MANUAL FOR

BITUMINOUS MATERIAL PAVING MACHINE (BMPM) (MODEL 8816M) (NSN 3895-01-577-2425) (EIC 6IO)

DISTRIBUTION STATEMENT A. - Approved for public release; distribution is unlimited.

HEADQUARTERS, DEPARTMENT OF THE ARMY 28 NOVEMBER 2011

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WARNING SUMMARY
This warning summary contains general safety warnings and hazardous material warnings that must be understood and applied during operation and maintenance of Bituminous Material Paving Machine (BMPM). Failure to observe these warnings could cause serious injury or death to personnel. Also included are explanations of safety and hazardous materials icons used within the Technical Manual (TM).

For First Aid information, refer to Field Manual (FM) 4-25.11.

GENERAL SAFETY INSTRUCTIONS Prior to starting any Work Package (WP) procedure, the warnings included in the WP must be reviewed and understood.
Also review the Materials/Parts listed in the INITIAL SETUP table of the WP for hazardous materials used during maintenance of the equipment. Then, refer to the detailed warnings for hazardous materials listed separately in this WARNING SUMMARY. This manual describes physical and chemical processes that may require the use of chemicals, solvents, paints, or other commercially-available material. Users of the manual should obtain the Material Safety Data Sheets (MSDS) (Occupational Safety and Health Act (OSHA) Form 20 or equivalent) from the manufacturers or suppliers of materials to be used. Users must be completely familiar with manufacturer/supplier information and adhere to their procedures, recommendations, warnings, and cautions for safe use, handling, storage, and disposal of these materials.

WARNINGS, CAUTIONS, AND NOTES WARNINGs and CAUTIONs are used in this TM to highlight operating or maintenance procedures, practices, conditions, or statements that are considered essential to protection of personnel (WARNING) or equipment (CAUTION). WARNINGs and CAUTIONs immediately precede the step or procedure to which they apply. WARNINGs and CAUTIONs consist of four parts: 1. Heading (the word WARNING, CAUTION, or an icon) 2. A statement of the hazard 3. Minimum precautions 4. Possible result, if disregarded NOTEs are used in this manual to highlight operating or maintenance procedures, practices, conditions, or statements that are not essential to protection of personnel or equipment but are helpful for operation or maintenance. NOTEs may precede or follow the step or procedure to which they relate, depending on the information to be highlighted.

WARNING
Warnings highlight an essential operating or maintenance procedure, practice, condition, statement, etc., which, if not strictly observed, could result in injury or death to personnel or longterm health problems.

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WARNINGS, CAUTIONS, AND NOTES CONTINUED.

CAUTION
Cautions highlight an essential operating or maintenance procedure, practice, condition, statement, etc., which, if not strictly observed, could result in damage to, or destruction of, equipment or loss of mission effectiveness.

NOTE
Notes highlight an essential operating or maintenance procedure, condition, or statement. WARNING ICONS CHEMICAL Drops of liquid on hand shows that the material will cause burns or irritation to human skin or tissue.

CRYOGENIC Hand in block of ice shows that material is extremely cold and can injure human skin or tissue.

EAR PROTECTION Headphones over ears shows that noise level will harm ears.

ELECTRICAL Electrical wire to arm with electricity symbol running through human body shows that life-threatening shock hazard is present.

ELECTRICAL Electrical wire to hand with electricity symbol running through hand shows that shock hazard is present.

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WARNING ICONS CONTINUED. EXPLOSION Rapidly expanding symbol shows that the material may explode if subjected to high temperatures, source of ignition, or high pressure.

EYE PROTECTION Person with goggles shows that the material will injure the eyes.

FIRE Flame shows that a material may ignite and cause burns.

FLYING PARTICLES Objects striking person shows that the material presents a danger to life or health.

HEAVY OBJECT Human figure stooping over heavy object shows physical injury potential from improper lifting technique.

HEAVY PARTS Heavy object on human figure shows that heavy parts present a danger to life or limb.

HEAVY PARTS Heavy object pinning human figure against wall shows that heavy, moving parts present a danger to life or limb.

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WARNING ICONS CONTINUED. HEAVY PARTS Hand with heavy object on top shows that heavy parts can crush and harm.

HEAVY PARTS Foot with heavy object on top shows that heavy parts can crush and harm them.

HIGH PRESSURE Human hand being penetrated by high pressure shows system pressures present a danger to life or limb.

HOT AREA Hand over object radiating heat shows that equipment is hot and can burn.

MOVING PARTS Human figure with an arm caught between the gears shows that the larger moving parts of the equipment present a danger to life or limb.

MOVING PARTS Hand with fingers caught between gears shows that the smaller moving parts of the equipment present a danger to life or limb.

POISON Skull and crossbones shows that a material is poisonous or is a danger to health or life.

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WARNING ICONS CONTINUED. SHARP OBJECT Pointed object in hand shows that a sharp object presents a danger to life or limb.

SHARP OBJECT Human hand being punctured shows equipment presents a danger to life or limb.

VAPOR Human figure in a cloud shows that material vapors present a danger to health or life.

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WARNING DESCRIPTIONS

WARNING

General Operation and maintenance of the BMPM contains many possibilities for injury or death to personnel. Be sure to be familiar with general first aid procedures as referenced in FM 425.11, First Aid. Failure to comply may cause injury or death to personnel. Metal jewelry can become entangled in equipment components. Remove all jewelry and do not wear loose clothing when working on equipment. Failure to comply may cause injury or death to personnel. Operating the BMPM exposes personnel to a high noise level. While operating or working within 37 feet (ft) (11 meters (m)) of a running BMPM wear hearing protection. Failure to comply may cause hearing loss. When running, BMPM engine has hot metal surfaces that will burn flesh on contact. Shut down engine and allow sufficient cooling before checks, services, or maintenance. Wear gloves and additional protective clothing as required. Failure to comply may cause injury or death to personnel. Be sure area surrounding BMPM is clear of personnel and objects before moving the unit, opening hopper wings, lowering screed, or deploying screed extensions. Sound unit horn before moving unit from stopped position. Turn on beacon when unit is in motion. Failure to comply may cause injury or death to personnel or damage to equipment. DO NOT disengage EMERGENCY STOP switch prior to clearing malfunctions and faults. If there was a malfunction with the machine that required the activation of the EMERGENCY STOP switch, the malfunction must be repaired before proceeding. Failure to comply may cause injury or death to personnel. Use screed locking pins when inspecting screed wear plates. Do not crawl under screed unless screed is supported properly by the screed locking pins. Failure to comply may cause injury or death to personnel.

WARNING

Cleaning Screed electric heat box must be completely shut down prior to spraydown. Fire is possible if screed electric heat box is running during washing operations. Failure to comply may cause injury or death to personnel and damage to equipment. Cleaning solvent is combustible and toxic to eyes, skin, and respiratory tract. Skin and eye protection is required. Avoid repeated or prolonged contact. Work in ventilated area only. Failure to comply may cause injury or death to personnel. f

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WARNING DESCRIPTIONS CONTINUED.

WARNING

Cold Weather Operation Exposed skin can stick to metal in extreme cold weather. Avoid contacting metal items with bare skin in extreme cold weather. Failure to comply may cause injury or death to personnel.

WARNING

Cooling System Engine cooling system operates at high temperature and pressure. Contact with highpressure steam and/or liquids can cause burns and scalding. Shut down BMPM engine and allow it to cool before performing checks, services, or maintenance. Wear gloves, protective clothing, and goggles as required. Failure to comply may cause injury or death to personnel. Engine cooling system operates at high temperature and pressure. Contact with highpressure steam and/or liquids can cause burns and scalding. Do not open radiator cap unless coolant temperature is below 100 degrees Fahrenheit (F) (38 degrees Celsius (C)). Failure to comply may cause injury or death to personnel. Engine cooling fan has sharp blades. Use caution when inspecting engine compartment. Failure to comply may cause injury or death to personnel.

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WARNING DESCRIPTIONS CONTINUED.

WARNING

Electrical Ensure equipment/vehicles being used to jump-start the BMPM set are not touching. Touching of metal surfaces can cause improper grounding and electric shock hazard. Do not allow the cable ends to touch each other or any part of the equipment other than the North Atlantic Treaty Organization (NATO) slave receptacle. Failure to comply may cause injury or death to personnel and damage to the equipment. Direct Current (DC) voltages are present at BMPM electrical components even when the unit is shut down. Avoid shorting any positive with ground/negative. Do not ground yourself in standing water. Failure to comply may cause injury or death to personnel and damage to equipment. The screed electric heat box contains high voltage. Box should be opened only when repair is needed and only by a trained and authorized technician or field maintainer. Failure to comply may cause injury or death to personnel. NATO slave receptacle is electrically live at all times and is not protected by a fuse. Turning BATTERY DISCONNECT switch to the OFF position does not ensure the circuit is dead. This circuit is only dead when the batteries are fully disconnected. Notify field maintainer to disconnect or connect batteries. Failure to comply may cause injury or death to personnel. Ensure batteries are properly connected by field maintenance personnel before attempting to use the NATO slave receptacle. Damage to batteries and cable or serious injury to personnel may result if slave starting the Bituminous Material Paving Machine (BMPM) with improperly connected batteries. Notify field maintainer if batteries are improperly connected. Failure to comply may cause injury or death to personnel.

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WARNING DESCRIPTIONS CONTINUED.

WARNING

Eye Protection Flying debris or material may enter eyes or strike the face. Wear appropriate eye/face protection while performing maintenance tasks. Failure to comply may cause injury or death to personnel. Eye protection is required when working with compressed air. Do not use compressed air to clean skin. Do not aim at personnel. Compressed air can propel particles at high velocity and injure eyes. Failure to comply may cause injury or death to personnel. Cleaner solution may enter eyes or strike the face during BMPM spraydown. Wear appropriate eye/face protection while performing system spraydown. Failure to comply may cause injury or death to personnel. Engine coolant may enter eyes or strike the face during cooling system maintenance. Wear appropriate eye/face protection while performing cooling system tasks. Failure to comply may cause injury or death to personnel. Particles blown by compressed air are hazardous. Ensure air stream is directed away from user and any personnel in the area. Use a maximum of 30 pounds per square inch (psi) (2.0 bar) when compressed air is used to clean parts. Always wear safety glasses when using compressed air. Failure to comply may result in injury or death to personnel.

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WARNING DESCRIPTIONS CONTINUED.

WARNING

Fuel Fuels used in the BMPM are combustible. Do not fill fuel tank while engine is running. Fire and possible explosion may result. Failure to comply may cause injury or death to personnel and damage to equipment.

WARNING

Heat Hot exhaust gases can ignite combustible materials. Allow room for safe discharge of hot gases. Failure to comply may cause injury or death to personnel. Components can become very hot. Shut down BMPM and allow it to cool sufficiently before performing checks, services, or maintenance. Wear gloves and additional protective clothing as required. Failure to comply may cause injury or death to personnel. Allow 30 minutes of cool down time before touching machine components. Failure to comply may cause injury or death to personnel.

WARNING

Hot Weather Operation Exposed skin can burn on metal in extreme hot weather. Avoid contacting metal items with bare skin in extreme hot weather. Failure to comply may cause injury or death to personnel.

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WARNING DESCRIPTIONS CONTINUED.

WARNING

Lifting Any component being lifted that weighs 44 pounds (lb) (20 kilograms (kg)) or less requires one personnel or a suitable lifting device to be utilized as necessary to lift component. Failure to comply may cause injury or death to personnel. Any component being lifted that weighs 45 to 88 lb (20.4 to 39.9 kg) requires two personnel or a suitable lifting device to be utilized as necessary to lift component. Failure to comply may cause injury or death to personnel. Any component being lifted that weighs 89 to 132 lb (40.4 to 59.9 kg) requires three personnel or a suitable lifting device to be utilized as necessary to lift component. Failure to comply may cause injury or death to personnel. Any component being lifted that weighs 133 to 176 lb (60.3 to 79.8 kg) requires four personnel or a suitable lifting device to be utilized as necessary to lift component. Failure to comply may cause injury or death to personnel. Any component being lifted that weighs 177 to 220 lb (80.3 to 99.8 kg) requires five personnel or a suitable lifting device to be utilized as necessary to lift component. Failure to comply may cause injury or death to personnel. Any component being lifted that weighs 221 to 264 lb (100.2 to 119.8 kg) requires six personnel or a suitable lifting device to be utilized as necessary to lift component. Failure to comply may cause injury or death to personnel. Lifting heavy components can cause back strain. Use proper lifting techniques when lifting heavy components. Many components of the BMPM are extremely heavy and require an assistant and a lifting device with sufficient capacity. Failure to comply may cause injury or death to personnel. Engine cover is heavy. Support access panel carefully when opening or closing. Open access panel completely when accessing or working on engine. Failure to comply may cause injury or death to personnel.

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WARNING DESCRIPTIONS CONTINUED.

WARNING

Moving Parts and Pinch Points There are many points on the BMPM where personnel could be injured by moving parts. Care should be taken to avoid any pinch points when performing maintenance. Failure to comply may cause injury or death to personnel. Installation of auger sections creates numerous pinch points. Keep hands clear of these pinch points when assembling augers. Failure to comply may cause injury to personnel.

WARNING

Starting Starting engine when unit is partially disassembled is dangerous. Run engine in this condition only as long as required to test operation. Keep away from unprotected moving engine parts during operation. Failure to comply may cause injury or death to personnel.

WARNING

Transport Always use a ground guide when operating machine up or down ramps. Failure to comply may cause injury or death to personnel or damage to equipment. Drive with extreme caution, at low idle, and at low speed. Failure to comply may cause injury or death to personnel or damage to equipment.

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HAZARDOUS MATERIALS ICONS CHEMICAL Drops of liquid on hand shows that the material will cause burns or irritation to human skin or tissue.

EXPLOSION Rapidly expanding symbol shows that the material may explode if subjected to high temperatures, source of ignition, or high pressure.

EYE PROTECTION Person with goggles shows that the material will injure the eyes.

FIRE Flame shows that a material may ignite and cause burns.

HIGH PRESSURE Human hand being penetrated by high pressure shows system pressures present a danger to life or limb.

POISON Skull and crossbones shows that a material is poisonous or is a danger to life.

VAPOR Human figure in a cloud shows that material vapors present a danger to life or health.

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HAZARDOUS MATERIALS DESCRIPTION

WARNING

General Exhaust discharge contains deadly gases, including carbon monoxide. Do not operate BMPM in an enclosed area unless exhaust discharge is properly vented. Failure to comply may cause injury or death to personnel.

WARNING

Battery Batteries give off combustible gas. Do not smoke or use open flame when working around or near battery. Failure to comply may cause injury or death to personnel and damage to equipment. Battery acid can cause burns to unprotected skin. Wear safety goggles and chemical gloves and avoid acid splash while working on the batteries. Failure to comply may cause injury or death to personnel. Do not damage batteries. Storage batteries are filled with a liquid acid that can leak from sealed battery when case is broken. Contact with battery acid can burn skin and eyes. Wear safety goggles and chemical gloves and avoid acid splash while handling damaged batteries. Do not lift or move batteries by using terminals. Failure to comply may cause injury or death to personnel or damage to equipment.

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HAZARDOUS MATERIALS DESCRIPTION CONTINUED.

WARNING

Cleaning Cleaning solvent is combustible and toxic to eyes, skin, and respiratory tract. Skin and eye protection is required. Avoid repeated or prolonged contact. Work in ventilated area only. Failure to comply may cause injury or death to personnel.

WARNING

Cooling System Engine coolant is toxic to eyes and poisonous if ingested. Eye protection is required when working with engine coolant. Avoid repeated or prolonged contact. Failure to comply may cause injury or death to personnel.

WARNING

Ether Do not use ether as a starting aid for the engine. Engine has an intake air pre-heater. Using ether may cause a fire or explosion. Failure to comply may cause injury or death to personnel.

WARNING

Engine Oil Engine oil pressure is hig h enough to penetrate skin. Keep hands and body away from any pressurized leak. Use cardboard or paper to check for leaks. Failure to comply may cause injury or death to personnel.

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HAZARDOUS MATERIALS DESCRIPTION CONTINUED.

WARNING

Fuel Do not operate BMPM if fuel leaks are present. Fuel is combustible. Always perform Preventive Maintenance Checks and Services (PMCS) before operation. Failure to comply may cause injury or death to personnel. Never inject fuel near a fire source. Atomized fuel is highly combustible. Fuel pressure is high enough to penetrate skin. Ensure spray from the injector nozzle is directed away from all personnel. Direct contact with spray can cause skin cell destruction and blood poisoning. Skin and eye protection are required when working in contact with fuel. Failure to comply may cause injury or death to personnel and damage to equipment. Fuels used in the BMPM are combustible and toxic to eyes, skin, and respiratory tract. Skin and eye protection are required when working in contact with fuel. Avoid repeated or prolonged contact. Provide adequate ventilation. Operators are to wash exposed skin and change soaked clothing promptly if exposed to fuel. Failure to comply may cause injury or death to personnel. Fuels used in the BMPM are combustible. Ensure fuel source grounding strap is connected to unit fuel fill grounding stud (static grounding). When filling the fuel tank, maintain metal-tometal contact between filler nozzle and fuel tank opening to eliminate Electrostatic Discharge (ESD). Failure to comply may cause injury or death to personnel. Fuels used in the BMPM are combustible. Do not smoke or use open flame when performing maintenance. Fire and possible explosion may result. Failure to comply may cause injury or death to personnel and damage to equipment.

WARNING

Hydraulic Fluid Hydraulic fluid pressure is high enough to penetrate skin. Keep hands and body away from any pressurized leak. Use cardboard or paper to check for leaks. If fluid is injected into skin, seek medical attention immediately. Failure to comply may result in serious injury or death to personnel. Hydraulic fluid may be absorbed through the skin. Wear long sleeves, gloves, and goggles or face shield when handling hydraulic fluid. If hydraulic fluid gets into the eyes, flush eyes immediately with water and seek medical attention. If hydraulic fluid gets on the skin, wash thoroughly with soap and water. Failure to comply may result in serious injury or death to personnel.

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LIST OF EFFECTIVE PAGES/WPs

NOTE: Zero in the Change No. column indicates an original page or WP. Date of issue for the original manual is: Original 28 NOVEMBER 2011 TOTAL NUMBER OF PAGES FOR FRONT MATTER AND REAR MATTER IS 46 AND T OTAL NUMBER OF WPs IS 33, CONSISTING OF THE FOLLOWING: Page/WP No. Front Cover ap i xiv Chp 1 title page WP 0001 (6 pgs) WP 0002 (12 pgs) WP 0003 (12 pgs) Chp 2 title page WP 0004 (44 pgs) WP 0005 (4 pgs) WP 0006 (46 pgs) WP 0007 (2 pgs) WP 0008 (10 pgs) WP 0009 (16 pgs) Chp 3 title page WP 0010 (4 pgs) WP 0011 (34 pgs) Chp 4 title page WP 0012 (4 pgs) WP 0013 (46 pgs) WP 0014 (6 pgs) WP 0015 (14 pgs) WP 0016 (4 pgs) WP 0017 (8 pgs) WP 0018 (10 pgs) WP 0019 (8 pgs) Change No. 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 Page/WP No. WP 0020 (4 pgs) WP 0021 (6 pgs) WP 0022 (4 pgs) WP 0023 (14 pgs) WP 0024 (4 pgs) Chp 5 title page WP 0025 (8 pgs) WP 0026 (8 pgs) WP 0027 (6 pgs) WP 0028 (6 pgs) WP 0029 (6 pgs) Chp 6 title page WP 0030 (2 pgs) WP 0031 (10 pgs) WP 0032 (2 pgs) WP 0033 (4 pgs) Change No. 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

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HEADQUARTERS DEPARTMENT OF THE ARMY WASHINGTON, D.C., 28 NOVEMBER 2011 TECHNICAL MANUAL OPERATORS MANUAL FOR BITUMINOUS MATERIAL PAVING MACHINE (BMPM) (MODEL 8816M) (NSN 3895-01-577-2425) (EIC 6IO) REPORTING ERRORS AND RECOMMENDING IMPROVEMENTS You can help improve this publication. If you find any errors, or if you would like to recommend any improvements to the procedures in this publication, please let us know. The preferred method is to submit your DA Form 2028 (Recommended Changes to Publications and Blank Forms) through the Internet on the TACOM Unique Logistics Support Applications (TULSA) Web site. The Internet address is https://tulsa.tacom.army.mil. Access to all applications requires CAC authentication, and you must complete the Access Request form the first time you use it. The DA Form 2028 is located under the TULSA Applications on the left-hand navigation bar. Fill out the form and click on SUBMIT. Using this form on the TULSA Web site will enable us to respond more quickly to your comments and to better manage the DA Form 2028 program. You may also mail, e-mail, or fax your comments or DA Form 2028 directly to the U.S. Army TACOM Life Cycle Management Command. The postal mail address is U.S. Army TACOM Life Cycle Management Command, ATTN: AMSTA-LCL-MPP/ TECH PUBS, MS 727, 6501 E. 11 Mile Road, Warren, MI 48397-5000. The e-mail address is tacomlcmc.daform2028@us.army.mil. The fax number is DSN 786-1856 or Commercial (586) 282-1856. A reply will be furnished to you.

DISTRIBUTION STATEMENT A. - Approved for public release; distribution is unlimited.

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TABLE OF CONTENTS
WP Sequence No. Page No. HOW TO USE THIS MANUAL................................................................................. xii CHAPTER 1 GENERAL INFORMATION, DESCRIPTION, AND THEORY OF OPERATION GENERAL INFORMATION ...................................................................................................WP 0001 Scope ....................................................................................................................... 0001-1 Maintenance Forms, Records, and Reports.................................. .......................... 0001-1 Reporting Equipment Improvement Recommendation (EIR) .................................. 0001-1 Corrosion Prevention and Control (CPC)....................................... ......................... 0001-1 Destruction of Army Materiel to Prevent Enemy Use ................ ............................. 0001-1 Preparation for Storage or Shipment............................................. .......................... 0001-2 Warranty Information................................................................................................ 0001-2 Nomenclature Cross-Reference List........................................................................ 0001-2 Table 1. Nomenclature Cross-Reference List.......................................................... 0001-2 List of Abbreviations/Acronyms................................................................................ 0001-2 Table 2. List of Abbreviations and Acronyms........................................................... 0001-2 Safety, Care, and, Handling ..................................................................................... 0001-5 Emergency Procedures............................................................................................ 0001-5 EQUIPMENT DESCRIPTION AND DATA ............................................................................WP 0002 Characteristics, Capabilities, and Features ............................................................. 0002-1 Location and Description of Major Components ...................................................... 0002-2 Figure 1. BMPM Components Right-Front View ................................................. 0002-2 Table 1. BMPM Components Right-Front View .................................................. 0002-3 Figure 2. BMPM Components Right-Rear View.................................................. 0002-4 Table 2. BMPM Components Right-Rear View ................................................... 0002-5 Figure 3. BMPM Components Left-Rear View .................................................... 0002-6 Table 3. BMPM Components Left-Rear View ..................................................... 0002-7 Figure 4. BMPM Components Left-Front View.................................................... 0002-8 Table 4. BMPM Components Left-Front View..................................................... 0002-9 Equipment Data ....................................................................................................... 0002-10 Table 5. Equipment Data ......................................................................................... 0002-10 THEORY OF OPERATION ...................................................................................................WP 0003 Scope ....................................................................................................................... 0003-1 Technical Principles of Operation ............................................................................ 0003-2 Screed ...................................................................................................................... 0003-2 Figure 1. BMPM Screed Left Side (Extended) .................................................... 0003-2 Sonic Auger Sensors ............................................................................................... 0003-3 Figure 2. Sonic Auger Sensors ................................................................................ 0003-3 Hopper Assembly..................................................................................................... 0003-4 Figure 3. Hopper Assembly...................................................................................... 0003-4 Hydraulic Systems ................................................................................................... 0003-5 Engine Starting......................................................................................................... 0003-5 Electrical System...................................................................................................... 0003-5 Work Lights .............................................................................................................. 0003-5 Backup Alarm........................................................................................................... 0003-5 ii

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WP Sequence No. Page No. Independently-Controlled Augers ............................................................................ 0003-6 Figure 4. Auger With Cutoff Opened........................................................................ 0003-6 Truck Hitch ............................................................................................................... 0003-7 Figure 5. Hydraulic Truck Hitch................................................................................ 0003-7 Track Tension .......................................................................................................... 0003-8 Figure 6. Self-Tensioning Drive Track ..................................................................... 0003-8 Hydrostatic Drive System......................................................................................... 0003-9 Figure 7. Hydrostatic Drive Torque Hub .................................................................. 0003-9 Braking System ........................................................................................................ 0003-10 Screed Bolt-On Extensions ...................................................................................... 0003-10 Figure 8. Bolt-On Screed Extension ........................................................................ 0003-10 Diagnostics............................................................................................................... 0003-11 Paving Preparation................................................................................................... 0003-11 Paving Operations.................................................................................................... 0003-11 Paving Completion ................................................................................................... 0003-12 CHAPTER 2 OPERATOR INSTRUCTIONS DESCRIPTIONS AND USE OF OPERATOR CONTROLS AND INDICATORS ..................WP 0004 Introduction .............................................................................................................. 0004-1 Engine and Travel Speed......................................................................................... 0004-2 Figure 1. Left Control Pedestal Joysticks, EMERGENCY STOP, Run/Stop .................................................................................................................. 0004-2 Table 1. Left Control Pedestal Joysticks, EMERGENCY STOP, Run/Stop .................................................................................................................. 0004-3 Figure 2. Right Control Pedestal Joysticks, EMERGENCY STOP, Run/Stop .................................................................................................................. 0004-4 Table 2. Right Control Pedestal Joysticks, EMERGENCY STOP, Run/Stop .................................................................................................................. 0004-4 Keyless Engine Switch............................................................................................. 0004-5 Figure 3. Keyless Engine Switch ............................................................................. 0004-5 Table 3. Keyless Engine Switch............................................................................... 0004-5 Control Pedestal Beacon Keypad ............................................................................ 0004-6 Figure 4. Left or Right Control Pedestal Beacon Keypad ........................................ 0004-6 Table 4. Left or Right Control Pedestal Beacon Keypad ......................................... 0004-6 Left Control Pedestal Horn Keypad ......................................................................... 0004-8 Figure 5. Left Control Pedestal Horn Keypad .......................................................... 0004-8 Table 5. Left Control Pedestal Horn Keypad ........................................................... 0004-9 Right Control Pedestal Horn Keypad ....................................................................... 0004-10 Figure 6. Right Control Pedestal Horn Keypad........................................................ 0004-10 Table 6. Right Control Pedestal Horn Keypad......................................................... 0004-10 Left Control Pedestal Lights Keypad........................................................................ 0004-12 Figure 7. Left Control Pedestal Lights Keypad ........................................................ 0004-12 Table 7. Left Control Pedestal Lights Keypad ......................................................... 0004-12 Right Control Pedestal Lights Keypad ..................................................................... 0004-14 Figure 8. Right Control Pedestal Lights Keypad...................................................... 0004-14 Table 8. Right Control Pedestal Lights Keypad ....................................................... 0004-14 Engine Screen.......................................................................................................... 0004-16 Figure 9. Engine Screen Buttons ............................................................................. 0004-16 Table 9. Engine Screen Buttons .............................................................................. 0004-16 Figure 10. Engine Screen Indicators........................................................................ 0004-17 Table 10. Engine Screen Indicators......................................................................... 0004-17 Fault Light Cluster .................................................................................................... 0004-18 Figure 11. Fault Light Cluster................................................................................... 0004-18 iii

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WP Sequence No. Page No. Table 11. Fault Light Cluster .................................................................................... 0004-19 Pavers Screen.......................................................................................................... 0004-20 Figure 12. Pavers Screen Buttons ........................................................................... 0004-20 Table 12. Pavers Screen Buttons ............................................................................ 0004-21 Figure 13. Pavers Screen Indicators........................................................................ 0004-22 Table 13. Pavers Screen Indicators......................................................................... 0004-22 Password Screen ..................................................................................................... 0004-24 Figure 14. Password Screen Buttons ...................................................................... 0004-24 Table 14. Password Screen Buttons........................................................................ 0004-24 Time Adjust Screen.................................................................................................. 0004-25 Figure 15. Time Adjust Screen Buttons ................................................................... 0004-25 Table 15. Time Adjust Screen Buttons .................................................................... 0004-25 Fault Screen 1, 2, or 3.............................................................................................. 0004-26 Figure 16. Fault Screen 1, 2, or 3 ............................................................................ 0004-26 Table 16. Fault Screen Buttons and Indicators........................................................ 0004-26 Active Engine Faults Screen .................................................................................... 0004-27 Figure 17. Active Engine Fault Screen 1, 2, or 3 ..................................................... 0004-27 Table 17. Active Engine Fault Buttons and Indicators ............................................. 0004-27 Inactive Engine Faults Screen ................................................................................. 0004-28 Figure 18. Inactive Engine Fault Screen 1, 2, or 3 .................................................. 0004-28 Table 18. Inactive Engine Fault Screen Buttons and Indicators .............................. 0004-29 Left Screed Control Auger/Conveyor Controls......................................................... 0004-30 Figure 19. Left Screed Control Auger/Conveyor Keypad ........................................ 0004-30 Table 19. Left Screed Control Auger/Conveyor Keypad.......................................... 0004-30 Right Screed Control Auger/Conveyor Controls ...................................................... 0004-32 Figure 20. Right Screed Control Auger/Conveyor Keypad ...................................... 0004-32 Table 20. Right Screed Control Auger/Conveyor Keypad ....................................... 0004-32 Left Screed Control Horn Keypad ............................................................................ 0004-34 Figure 21. Left Screed Control Horn Keypad........................................................... 0004-34 Table 21. Left Screed Control Horn Keypad ............................................................ 0004-34 Right Screed Control Horn Keypad.......................................................................... 0004-36 Figure 22. Right Screed Control Horn Keypad ........................................................ 0004-36 Table 22. Right Screed Control Horn Keypad.......................................................... 0004-36 Screed Electric Heat Box ......................................................................................... 0004-38 Figure 23. Screed Electric Heat Box........................................................................ 0004-38 Table 23. Screed Electric Heat Box ......................................................................... 0004-38 Hydraulic Fluid Reservoir Temperature and Liquid Sight Indicator ......................... 0004-39 Figure 24. Hydraulic Fluid Reservoir Temperature and Liquid Sight Indicator ........ 0004-39 Table 24. Hydraulic Fluid Reservoir Temperature and Liquid Sight Indicator ......... 0004-39 BATTERY DISCONNECT Switch ............................................................................ 0004-40 Figure 25. BATTERY DISCONNECT Switch........................................................... 0004-40 Table 25. BATTERY DISCONNECT Switch ............................................................ 0004-40 Screed Crown Gauge............................................................................................... 0004-41 Figure 26. Screen Crown Gauge ............................................................................. 0004-41 Table 26. Screen Crown Gauge .............................................................................. 0004-41 Vibration Control Knob ............................................................................................. 0004-42 Figure 37. Vibration Control Knob............................................................................ 0004-42 Table 27. Vibration Control Knob............................................................................. 0004-42 Flight Screw Controls ............................................................................................... 0004-43 Figure 28. Flight Screw ............................................................................................ 0004-43 Table 28. Flight Screw ............................................................................................. 0004-43 PREPARATION FOR USE....................................................................................................WP 0005 Preparation For Use Paving Area 6 to 7 Feet Wide ................................................ 0005-1 Preparation For Use Paving Area 8 to 16 Feet Wide .............................................. 0005-2 iv

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WP Sequence No. Page No. Preparation For Use Paving Area 17 to 20 Feet Wide ............................................ 0005-3 OPERATION UNDER USUAL CONDITIONS.......................................................................WP 0006 Operation Under Usual Conditions .......................................................................... 0006-1 Starting the Engine................................................................................................... 0006-2 Figure 1. Control Pedestal Starting the Engine................................................... 0006-2 Stopping the Engine................................................................................................. 0006-4 Figure 2. Control Pedestal Stopping the Engine ................................................. 0006-4 Raising and Lowering Screed .................................................................................. 0006-6 Figure 3. Raise and Lower Screed .......................................................................... 0006-6 Figure 4. Control Pedestal Raise and Lower Screed .......................................... 0006-6 Adjusting Auger Height ............................................................................................ 0006-8 Figure 5. Auger Raise and Lower ............................................................................ 0006-8 Figure 6. Control Pedestal Auger Height ........................................................... 0006-9 Operating Hydraulic Cutoff Gates ............................................................................ 0006-10 Figure 7. Cutoffs Open and Closed ......................................................................... 0006-10 Figure 8. Screed Control Cutoff Adjust................................................................ 0006-11 Extending Screed Extension.................................................................................... 0006-12 Figure 9. Screed Extensions.................................................................................... 0006-12 Figure 10. Screed Control Screed Extension...................................................... 0006-13 Driving the BMPM .................................................................................................... 0006-14 Figure 11. Control Pedestal Driving the BMPM .................................................. 0006-14 Installing Sonic Auger Sensor.................................................................................. 0006-16 Figure 12. Sonic Auger Sensor Mount..................................................................... 0006-16 Removing Sonic Auger Sensor................................................................................ 0006-17 Using Screed Heat Electric Box............................................................................... 0006-18 Figure 13. Screed Heat Electric Box........................................................................ 0006-18 Attaching to Truck Using Truck Hitch Attachment ................................................... 0006-20 Figure 14. Truck Hitch Attachment .......................................................................... 0006-20 Disengaging BMPM from Truck Using Truck Hitch Attachment .............................. 0006-21 Figure 15. Control Pedestal Truck Hitch ............................................................. 0006-21 Operating Hopper..................................................................................................... 0006-22 Figure 16. Hopper Wings ......................................................................................... 0006-22 Figure 17. Control Pedestal Hopper.................................................................... 0006-22 Adjust Pile Height Using Automatic Auger/Conveyor Setting (Requires Sonic Auger Sensors) ............................................................................. 0006-24 Figure 18. Screed Control Automatic Pile Height................................................ 0006-24 Adjust Material Thickness Using Flight Screw......................................................... 0006-25 Figure 19. Flight Screw ............................................................................................ 0006-25 Adjust Auger/Conveyor Speed Using Manual Auger/Conveyor Setting .................. 0006-26 Figure 20. Screed Control Manual Pile Height.................................................... 0006-26 Adjust Conveyor Speed Independent of Auger Speed ............................................ 0006-27 Figure 21. Screed Control Conveyor Speed ....................................................... 0006-27 Material Thickness Adjustment Using Tow Point Hydraulic Cylinder/Manual Grade Control........................................................................................................... 0006-28 Figure 22. Screed Control Tow Point Hydraulic Cylinder.................................... 0006-28 Figure 23. Tow Point Hydraulic Cylinder Gauge...................................................... 0006-29 Adjust Screed Extension Height .............................................................................. 0006-30 Figure 24. Vertical Adjustment Screws .................................................................... 0006-30 Adjust Screed Extension Attack Angle..................................................................... 0006-31 Figure 25. Attack Angle Adjustment Screw.............................................................. 0006-31 Adjust Screed Extension Slope................................................................................ 0006-32 Figure 26. Screed Extension Slope ......................................................................... 0006-32 Figure 27. Screed Control Slope Adjust .............................................................. 0006-33 Adjust Screed End Gates......................................................................................... 0006-34 v

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WP Sequence No. Page No. Figure 28. End Gate................................................................................................. 0006-34 Adjust Screed Crown and Valley ............................................................................. 0006-35 Figure 29. Material Crown and Valley...................................................................... 0006-35 Figure 30. Screed Crown Top Bar Bolts .................................................................. 0006-36 Figure 31. Screed Control Crown Adjust............................................................. 0006-37 Figure 32. Screed Crown Gauge ............................................................................. 0006-38 Adjust Seat Slide Assembly ..................................................................................... 0006-39 Figure 33. Seat Slide Assembly............................................................................... 0006-39 Figure 34. Seat Slide Assembly............................................................................... 0006-40 Screed Locking Pin .................................................................................................. 0006-41 Figure 35. Screed Locking Pin ................................................................................. 0006-41 Spraydown Procedures............................................................................................ 0006-42 Figure 36. Control Pedestal Spraydown.............................................................. 0006-42 Figure 37. Spraydown Hose .................................................................................... 0006-43 Figure 38. Spraydown Areas ................................................................................... 0006-44 OPERATION UNDER UNUSUAL CONDITIONS..................................................................WP 0007 Unusual Environment/Weather ................................................................................ 0007-1 Operation in Extreme Heat (Above 120 degrees Fahrenheit (F) (49 degrees Celsius (C))) ....................................................................................... 0007-1 Operation in Dusty or Sandy Areas ......................................................................... 0007-1 Interim Chemical, Biological, Radiological, and Nuclear (CBRN) Decontamination Procedures................................................................................... 0007-2 Operation in Contaminated Areas............................................................................ 0007-2 EMERGENCY PROCEDURES .............................................................................................WP 0008 North Atlantic Treaty Organization (NATO) Slave Receptacle Start Operation....... 0008-1 Figure 1. NATO Slave Receptacle........................................................................... 0008-2 Emergency Stopping................................................................................................ 0008-4 Figure 2. EMERGENCY STOP Switch .................................................................... 0008-4 Offloading Residual Paving Material........................................................................ 0008-5 Priming Fuel ............................................................................................................. 0008-6 Figure 3. Fuel Priming.............................................................................................. 0008-6 Engaging Track Brake Override............................................................................... 0008-7 Figure 4. Track Brake Override................................................................................ 0008-7 Disengaging Track Brake Override.......................................................................... 0008-8 Fuse Replacement ................................................................................................... 0008-8 Figure 5. Fuse Location....................................................................................... 0008-8 Table 1. Fuse Amperage Rating .............................................................................. 0008-9 Figure 6. Fuse .......................................................................................................... 0008-10 STOWAGE AND DATA PLATE/DECAL LOCATION ............................................................WP 0009 Introdu ction .............................................................................................................. 0009-1 Figure 1. Data and Instruction Plates, Right Side .................................................... 0009-2 Table 1. Data and Instruction Plates, Right Side ..................................................... 0009-2 Figure 2. Data and Instructions Plates, Left Side .................................................... 0009-3 Table 2. Data and Instructions Plates, Left Side...................................................... 0009-3 Figure 3. IUID Plates, Left Side ............................................................................... 0009-4 Table 3. IUID Plates, Left Side................................................................................. 0009-4 Figure 4. IUID Plates, Bottom Side .......................................................................... 0009-5 Table 4. IUID Plates, Bottom Side ........................................................................... 0009-5 Figure 5. IUID Plates, Engine................................................................................... 0009-6 Table 5. IUID Plates, Engine.................................................................................... 0009-6 Figure 6. Lift and Tie Down Decals.......................................................................... 0009-7 Table 6. Lift and Tie Down Decals ........................................................................... 0009-7 Figure 7. Screed Extension Decals.......................................................................... 0009-8 Figure 7. Screed Extension Decals.......................................................................... 0009-8 vi

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WP Sequence No. Page No. Figure 8. Measurement Decals................................................................................ 0009-9 Table 8. Measurement Decals ................................................................................. 0009-9 Figure 9. Screed Decals........................................................................................... 0009-10 Table 9. Screed Decals............................................................................................ 0009-10 Figure 10. Operator Platform Decals, Left Side ....................................................... 0009-11 Table 10. Operator Platform Decals, Left Side ........................................................ 0009-11 Figure 11. Operator Platform Decals, Right Side .................................................... 0009-12 Table 11. Operator Platform Decals, Right Side...................................................... 0009-12 Figure 12. Bolt-On Screed Extensions..................................................................... 0009-13 Table 12. Bolt-On Screed Extensions...................................................................... 0009-13 Figure 13. Auger Extensions Labels ........................................................................ 0009-14 Figure 14. Retaining Plates Stamps ........................................................................ 0009-15 Figure 15. Cutoff Shoes Stamps.............................................................................. 0009-15 CHAPTER 3 TROUBLESHOOTING PROCEDURES TROUBLESHOOTING INDEX .............................................................................................WP 0010 General Troubleshooting Information .................................................................0010-1 Malfunction/Symptom Index..................................................................................... 0010-1 Indications from Manual Troubleshooting Techniques ............................................ 0010-1 After Corrective Action ............................................................................................. 0010-1 Specific Troubleshooting Procedures ...................................................................... 0010-1 TROUBLESHOOTING PROCEDURES ...............................................................................WP 0011 Troubleshooting Procedures.................................................................................... 0011-1 Table 1. Bituminous Material Paving Machine (BMPM) Troubleshooting Procedures............................................................................................................... 0011-1 CHAPTER 4 OPERATOR MAINTENANCE INSTRUCTIONS PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) INTRODUCTION......WP 0012 Introduction .............................................................................................................. 0012-1 General .................................................................................................................... 0012-1 Corrosion Definition.................................................................................................. 0012-1 Rust Definition.......................................................................................................... 0012-1 Deterioration Definition............................................................................................. 0012-1 Cracking Definition ................................................................................................... 0012-1 Inspection................................................................................................................. 0012-1 Cleaning and Lubrication ......................................................................................... 0012-2 Oil Filters .................................................................................................................. 0012-2 Army Oil Analysis Program (AOAP) Sampling ........................................................ 0012-2 Lubrication................................................................................................................ 0012-3 Fluid Leakage........................................................................................................... 0012-3 Explanation of the Columns Found in the Preventive PMCS Table ........................ 0012-3 PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS)...................................WP 0013 Table 1. Preventive Maintenance Checks and Services (PMCS) Instructions ........ 0013-2 Figure 1. Bituminous Material Paving Machine (BMPM) Fluid Leaks...................... 0013-2 Figure 2. Operator Platform ..................................................................................... 0013-3 Figure 3. Screed....................................................................................................... 0013-5 Figure 4. Left End Gate............................................................................................ 0013-7 Figure 5. Left Auger and Cutoff................................................................................ 0013-8 Figure 6. Left Spraydown and Side Left Plate ......................................................... 0013-9 Figure 7. Left Track Wear ........................................................................................ 0013-10 Figure 8. Left Track .................................................................................................. 0013-11 Figure 9. Conveyor Chains ...................................................................................... 0013-12 vii

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WP Sequence No. Page No. Figure 10. Engine Compartment.............................................................................. 0013-13 Figure 11. Right Track Wear .................................................................................... 0013-14 Figure 12. Right Track.............................................................................................. 0013-15 Figure 13. Side Right Plate and Spraydown Hose .................................................. 0013-16 Figure 14. Right Cutoff and Auger ........................................................................... 0013-17 Figure 15. Right End Gate ....................................................................................... 0013-18 Figure 16. Wear Plates ............................................................................................ 0013-26 Figure 17. Operator Platform ................................................................................... 0013-28 Figure 18. Screed..................................................................................................... 0013-30 Figure 19. Left End Gate.......................................................................................... 0013-32 Figure 20. Left Auger and Cutoff.............................................................................. 0013-33 Figure 21. Left Spraydown and Side Left Plate ....................................................... 0013-34 Figure 22. Left Track Wear ...................................................................................... 0013-35 Figure 23. Left Track ................................................................................................ 0013-36 Figure 24. Conveyor Chains .................................................................................... 0013-37 Figure 25. Engine Compartment.............................................................................. 0013-38 Figure 26. Right Track Wear .................................................................................... 0013-39 Figure 27. Right Track.............................................................................................. 0013-40 Figure 28. Side Right Plate and Spraydown Hose .................................................. 0013-41 Figure 29. Right Cutoff and Auger ........................................................................... 0013-42 Figure 30. Right End Gate ....................................................................................... 0013-43 END GATE REMOVAL AND INSTALLATION ......................................................................WP 0014 End Gate Removal................................................................................................... 0014-2 Figure 1. End Gate................................................................................................... 0014-2 Figure 2 Screed Extension....................................................................................... 0014-3 End Gate Installation................................................................................................ 0014-4 Figure 3. Screed Extension...................................................................................... 0014-4 Figure 4. End Gate................................................................................................... 0014-5 BOLT-ON SCREED EXTENSION KIT REMOVAL AND INSTALLATION ............................WP 0015 Bolt-On Screed Extension Kit Removal ................................................................... 0015-2 Figure 1. Retaining Plate Extension Removal..................................................... 0015-2 Figure 2. Bolt-On Auger Extension Removal ...................................................... 0015-4 Figure 3. Bolt-On Screed Extension Removal..................................................... 0015-6 Bolt-On Screed Extension Kit Installation ................................................................ 0015-8 Figure 4. Bolt-On Screed Extension Installation ................................................. 0015-8 Figure 5. Bolt-On Auger Extension Installation ................................................... 0015-10 Figure 6. Retaining Plate Extension Installation.................................................. 0015-12 CUTOFF SHOE REMOVAL AND INSTALLATION...............................................................WP 0016 Cutoff Shoes Removal ............................................................................................. 0016-2 Figure 1. Cutoff Shoe ............................................................................................... 0016-2 Cutoff Shoes Installation .......................................................................................... 0016-3 FUELING SYSTEM SERVICE ..............................................................................................WP 0017 Check Fuel Level from Initial Startup Screen........................................................... 0017-2 Figure 1. Engine Screen .......................................................................................... 0017-2 Fill Fuel Tank............................................................................................................ 0017-4 Figure 2. Fuel Tank Cap Removal ...................................................................... 0017-4 Service Fuel Filter .................................................................................................... 0017-6 Figure 3. Fuel Filter .................................................................................................. 0017-6 ENGINE SERVICE ......................................................................................................... WP 0018 Check Engine Lubricating Oil Level ......................................................................... 0018-1 Figure 1. Engine....................................................................................................... 0018-2 Figure 2. Engine Oil Dipstick.................................................................................... 0018-3 Add Engine Lubricating Oil....................................................................................... 0018-4 Figure 3. Engine Lubricating Oil Fill ......................................................................... 0018-4 viii

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WP Sequence No. Page No. Figure 4. Engine Oil Dipstick.................................................................................... 0018-6 Figure 5. Engine Lubricating Oil Fill ......................................................................... 0018-7 Check Double Hydraulic Pump Drive Lubricating Oil Level..................................... 0018-8 Figure 6. Double Hydraulic Pump Drive Dipstick..................................................... 0018-9 Figure 7. Double Hydraulic Pump Drive Dipstick..................................................... 0018-10 HYDRAULIC SYSTEM SERVICE .........................................................................................WP 0019 Check Hydraulic Fuel Level ..................................................................................... 0019-2 Figure 1. Temperature and Liquid Sight Indicator ................................................... 0019-2 Fill Hydraulic Fluid Reservoir ................................................................................... 0019-4 Figure 2. Access Plate ............................................................................................. 0019-4 Figure 3. Hydraulic Fluid Reservoir Cap, Spring, and Filter Element ...................... 0019-5 Figure 4. Temperature and Liquid Sight Indicator ................................................... 0019-6 Figure 5. Hydraulic Fluid Reservoir Cap, Spring, and Filter Element ...................... 0019-7 Figure 6. Hydraulic Reservoir Cap Access Panel.................................................... 0019-8 CLEANER SYSTEM SERVICE .............................................................................................WP 0020 Add Cleaner Solution ............................................................................................... 0020-2 Figure 1. Cleaner Solution Fill Port .......................................................................... 0020-2 AIR FILTER PRIMARY ELEMENT REMOVAL, SERVICE, AND INSTALLATION...............WP 0021 Air Filter Primary Element Removal......................................................................... 0021-2 Figure 1. Left Side Cover Vent................................................................................. 0021-2 Figure 2. Air Cleaner Assembly ............................................................................... 0021-3 Air Filter Primary Element Service ........................................................................... 0021-4 Air Filter Primary Element Installation...................................................................... 0021-4 Figure 3. Left Side Cover Vent................................................................................. 0021-5 COOLING SYSTEM SERVICE .............................................................................................WP 0022 Add Engine Coolant to Coolant Reservoir ............................................................... 0022-2 Figure 1. Cooling System Service ....................................................................... 0022-2 Add Engine Coolant to Radiator .............................................................................. 0022-3 PACKAGING .........................................................................................................................WP 0023 Unpacking Bolt-On Screed Extension Kit, Cutoff Shoes, and End Gates ............... 0023-2 Figure 1. Screed Extension Kit Panels Removal ................................................ 0023-2 Figure 2. Bolt-On Screed Extension Removal .................................................... 0023-4 Figure 3. End Gates Removal ............................................................................. 0023-6 Figure 4. End Gates Installation .......................................................................... 0023-8 Packing Bolt-On Screed Extension Kit, Cutoff Shoes, and End Gates ................... 0023-9 Figure 5. Bolt-On Screed Extension Installation ................................................. 0023-11 Figure 6. Screed Extension Kit Panels Installation ............................................. 0023-13 PREPARATION FOR STORAGE OR SHIPMENT ...............................................................WP 0024 Level A Preparation.................................................................................................. 0024-1 Level A Remove From Storage................................................................................ 0024-2 Level B Preparation.................................................................................................. 0024-2 Level B Remove From Storage................................................................................ 0024-3 CHAPTER 5 TRANSPORT PROCEDURES PREPARATION FOR TRANSPORT INTRODUCTION .......................................................WP 0025 Introduction .............................................................................................................. 0025-1 Open Front Lifting Point Access Covers .................................................................. 0025-2 Figure 1. Front Lifting Point Access Covers............................................................. 0025-2 Close Front Lifting Point Access Covers.................................................................. 0025-3 BMPM Lifting Points................................................................................................. 0025-4 Figure 2. BMPM Lifting Points ................................................................................. 0025-4 BMPM Tie Down Points ........................................................................................... 0025-5 Figure 3. BMPM Tie Down Points............................................................................ 0025-5 ix

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WP Sequence No. Page No. Lowering Fume Vent ................................................................................................ 0025-6 Figure 4. Fume Vent ................................................................................................ 0025-6 Raising Fume Vent................................................................................................... 0025-7 HIGHWAY TRANSPORT .....................................................................................................WP 0026 Introduction .............................................................................................................. 0026-1 Loading BMPM onto Trailer ..................................................................................... 0026-2 Figure 1. Hopper Wing Strap Points ........................................................................ 0026-3 Figure 2. BMPM Ramp Loading............................................................................... 0026-4 Unloading BMPM from Trailer.................................................................................. 0026-5 Figure 3. BMPM Ramp Unloading ........................................................................... 0026-6 Figure 4. Hopper Wing Strap Points ........................................................................ 0026-7 RAIL TRANSPORT ...............................................................................................................WP 0027 Introduction .............................................................................................................. 0027-1 Loading BMPM onto Flatcar..................................................................................... 0027-2 Figure 1. Hopper Wing Strap Points ........................................................................ 0027-3 Figure 2. BMPM Ramp Loading/Unloading ............................................................. 0027-4 Unloading BMPM from Flatcar................................................................................. 0027-5 Figure 3. Hopper Wing Strap Points ........................................................................ 0027-6 MARINE TRANSPORT (ROLL-ON/ROLL-OFF (RO/RO) PROCEDURES) ........................WP 0028 Introduction .............................................................................................................. 0028-1 RO/RO Regulations ................................................................................................. 0028-2 Loading BMPM onto Ship ........................................................................................ 0028-2 Figure 1. Hopper Wing Strap Points ........................................................................ 0028-3 Figure 2. BMPM Ramp Loading/Unloading ............................................................. 0028-4 Unloading BMPM from Ship..................................................................................... 0028-5 Figure 3. Hopper Wing Strap Points ........................................................................ 0028-6 AIR TRANSPORT PROCEDURES .......................................................................................WP 0029 Loading Bituminous Material Paving Machine (BMPM)........................................... 0029-1 Figure 1. Hopper Wing Strap Points ........................................................................ 0029-2 Figure 2. BMPM Ramp Loading............................................................................... 0029-3 Unloading BMPM ..................................................................................................... 0029-4 Figure 3. BMPM Ramp Unloading ........................................................................... 0029-5 Figure 4. Hopper Wing Strap Points ........................................................................ 0029-6 CHAPTER 6 SUPPORTING INFORMATION REFERENCES .....................................................................................................................WP 0030 Introduction .............................................................................................................. 0030-1 Scope ....................................................................................................................... 0030-1 Forms ....................................................................................................................... 0030-1 Publications.............................................................................................................. 0030-1 Technical Manuals ................................................................................................... 0030-1 COMPONENTS OF END ITEM (COEI) AND BASIC ISSUE ITEMS (BII) LISTS .................WP 0031 Introduction .............................................................................................................. 0031-1 Scope ....................................................................................................................... 0031-1 General..................................................................................................................... 0031-1 Explanation of Columns in the COEI List and BII List.............................................. 0031-1 Table 1. COEI List.................................................................................................... 0031-2 Table 2. BII List ........................................................................................................ 0031-4 ADDITIONAL AUTHORIZATION LIST (AAL)........................................................................WP 0032 Introduction .............................................................................................................. 0032-1 Scope ....................................................................................................................... 0032-1 General..................................................................................................................... 0032-1 Explanation of Columns in the Additional Authorization List (AAL) ......................... 0032-1 x

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WP Sequence No. Page No. Table 1. AAL ............................................................................................................ 0032-1 EXPENDABLE AND DURABLE ITEMS LIST .......................................................................WP 0033 Introduction .............................................................................................................. 0033-1 Scope ....................................................................................................................... 0033-1 Explanation of Columns in the Expendable/Durable Items List............................... 0033-1 Table 1. Expendable and Durable Items List........................................................... 0033-1 REPORTING ERRORS AND RECOMMENDING IMPROVEMENTS, DA FORM 2028 AUTHENTICATION PAGE METRIC CONVERSION CHART

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HOW TO USE THIS MANUAL

This manual contains operator instructions for the Bituminous Material Paving Machine (BMPM) 8816M. A Lubrication Order (LO) (LO-5-3895-385-13) exists to act as a complement for the Preventive Maintenance Checks and Services (PMCS) section (WP 0013) of this Operators Manual. In addition, a Field Maintainers Manual (TM 5-3895-385-23), Field and Sustainment Maintenance Repair Parts and Special Tools List (RPSTL) (TM 5-3895-385-24P), and Warranty Technical Bulletin (TB) (TB 5-3895-385-14) are included as part of this family of manuals for the BMPM. This Operators Manual provides operating procedures, troubleshooting, maintenance, transport procedures, and supporting information required to operate and maintain the BMPM. Listed below are some of the features included in this Technical Manual (TM) to help locate and use the provided information. WORK PACKAGES (WP) This TM has been organized using the WP concept. Each chapter contains a series of WPs rather than sections and paragraphs. Each WP is designed to stand alone as a complete information module; if the user keeps the section(s) of this TM in a loose-leaf binder, the user will be able to remove just the WP needed to complete a specific task. Here are some WP features that the user should be aware of in order to help the user understand the organization of this TM: Each WP is numbered sequentially throughout each chapter using a four-digit number. The WP number is located at the top right of each page. It is also located at the bottom of the page with the WP page number included (0001-1 would be page 1 of the General Information WP (WP 0001). Each WP starts on a right-hand page. This is done so the user can remove a single WP from the paper TM if needed for a particular task. Blank pages are assigned a number that appears on the preceding or following page. For example, if page 0001-10 of a WP is blank, page 0001-9 will have the number 0001-9/10 blank; or if page 0001-1 of a WP is blank, page 0001-2 will have the number 0001-1 blank/2. Each WP containing step-by-step maintenance procedures will end with the words END OF TASK, and each WP ends with the statement END OF WORK PACKAGE. Think of each WP as a small, stand-alone TM. References to equipment data and description plates (WP 0009) are printed as they appear on the equipment whenever possible. Warnings, cautions, notes, chapter titles, and paragraph headings are printed in bold type. Icons related to warnings are shown directly above the warning text. TM CONTENT A Table of Contents is provided for a quick reference to the chapters and WPs. It is recommended that the user become familiar with it in order to quickly locate the information needed. This TM is divided into the following chapters: CHAPTER 1 provides the user with the general information including characteristics, capabilities, features, and theory of operation for the BMPM and its major components. The General Information WP (WP 0001) contains a list of abbreviations and acronyms used in this TM. CHAPTER 2 provides the detailed instructions for safe operation of the BMPM. It includes description and use of BMPM controls (WP 0004) as well as operations under usual (WP 0006) and unusual conditions (WP 0007). Emergency procedures (WP 0008) can also be found in this chapter along with stowage and data plate/decal location information (WP 0009). CHAPTER 3 provides an operator troubleshooting malfunction/symptom index (WP 0010) and troubleshooting procedures (WP 0011) for the BMPM.

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CHAPTER 4 provides operator PMCS (WP 0013) procedures necessary for the operator to service and maintain the BMPM. Operator maintenance tasks are also provided as well as packaging (WP 0023) and preparation for storage (WP 0024) procedures. CHAPTER 5 provides transport information for the BMPM including lifting and tie down points (WP 0025) and highway (WP 0026), rail (WP 0027), marine (WP 0028), and air (WP 0029) transport procedures. CHAPTER 6 provides supporting information for the BMPM, which includes a list all field manuals, forms, TMs, and miscellaneous publications referenced in the TM (WP 0030). Other items found in this chapter include Components of End Item (COEI) and Basic Issue Items (BII) lists (WP 0031) to help the user inventory items for safe and efficient operation of the BMPM. It also contains a list of additional items the users are authorized for the support of BMPM (WP 0032) and a list of expendable and durable items (WP 0033) that the user will need to operate and maintain the BMPM. Rear Matter includes Department of the Army (DA) Form 2028, Recommended Changes to Publications and Blank Forms. The DA Form 2028 is the document to be submitted by the user to correct errors found in the manual or to make recommended changes that will improve the manual.

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CHAPTER 1
GENERAL INFORMATION, DESCRIPTION, AND THEORY OF OPERATION FOR BITUMINOUS MATERIAL PAVING MACHINE (BMPM)

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0001

OPERATOR MAINTENANCE BITUMINOUS MATERIAL PAVING MACHINE (BMPM) GENERAL INFORMATION SCOPE This Operator Technical Manual (TM) contains instructions for operating, troubleshooting, and maintaining the Bituminous Material Paving Machine (BMPM), Department of Defense (DoD) Model 8816M, National Stock Number 3895-01-577-2425. The BMPM is a self-propelled, crawler-mounted, turbocharged diesel enginepowered paving machine used for laying, compacting, and finishing bituminous material strips that are 4 20 feet (ft) (1.2 6.1 meters (m)) wide at a rate of 120 tons (109 metric tons (t)) per hour. MAINTENANCE FORMS, RECORDS, AND REPORTS Department of the Army (DA) forms and procedures used for equipment maintenance will be those prescribed by (as applicable) DA Pamphlet (PAM) 750-8, The Army Maintenance Management System (TAMMS) Users Manual or AR 700-138, Army Logistics Readiness and Sustainability. REPORTING EQUIPMENT IMPROVEMENT RECOMMENDATIONS (EIR) If your BMPM needs improvement, let us know. Send us an EIR. You, the user, are the only one who can tell us what you don't like about your equipment. Let us know why you don't like the design or performance. If you have Internet access, the easiest and fastest way to report problems or suggestions is to go to https://aeps.ria.army.mil/aepspublic.cfm (scroll down and choose the Submit Quality Deficiency Report bar). The Internet form lets you choose to submit an EIR, a Product Quality Deficiency Report (PQDR), or a Warranty Claim Action (WCA). You may also submit your information using an SF 368, Product Quality Deficiency Report. You can send your SF 368 via e-mail, regular mail, or facsimile using the addresses/facsimile numbers specified in DA PAM 750-8, The Army Maintenance Management System (TAMMS) Users Manual. We will send you a reply. CORROSION PREVENTION AND CONTROL (CPC) CPC of Army materiel is a continuing concern. It is important that any corrosion problems with this item be reported so that the problem can be corrected and improvements can be made to prevent the problem in future items. Corrosion specifically occurs with metals. It is an electrochemical process that causes the degradation of metals. It is commonly caused by exposure to moisture, acids, bases, or salts. An example is the rusting of iron. Corrosion damage in metals can be seen, depending on the metal, as tarnishing, pitting, fogging, surface residue, and/or cracking. Plastics, composites, and rubbers can also degrade. Degradation is caused by thermal (heat), oxidation (oxygen), solvation (solvents), or photolytic (light, typically Ultraviolet (UV)) processes. The most common exposures are excessive heat or light. Damage from these processes will appear as cracking, softening, swelling, and/or breaking. SF 368, Product Quality Deficiency Report should be submitted to the address specified in DA PAM 750-8, The Army Maintenance Management System (TAMMS) Users Manual. DESTRUCTION OF ARMY MATERIEL TO PREVENT ENEMY USE For destruction of Army materiel to prevent enemy use, refer to TM 750-244-3, Procedures for Destruction of Equipment to Prevent Enemy Use (Mobility Equipment Command).

0001-1

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0001

PREPARATION FOR STORAGE OR SHIPMENT Preparation for shipment procedures and packaging procedures are located in WP 0024. WARRANTY INFORMATION Warranty information can be found in TB 5-3895-385-14. NOMENCLATURE CROSS-REFERENCE LIST A nomenclature cross-reference list is provided in Table 1 to identify the common names used in place of official nomenclature. Table 1. Nomenclature Cross-Reference List. Common Name Cleaner Solution Fill Cap Fuel Tank Cap Material Retaining Plate Screed Operator Platform Citrus Cover Cap, Filler Opening Auger Extension Walkboard, Long Official Nomenclature

LIST OF ABBREVIATIONS/ACRONYMS Table 2. List of Abbreviations and Acronyms. Abbreviation/ Acronym C F A AAL AAR AOAP AWS BII BMPM CAGEC CAN degrees Celsius degrees Fahrenheit amperes Additional Authorization List Association of American Railroads Army Oil Analysis Program American Welding Society Basic Issue Item Bituminous Material Paving Machine Cage Code Controller Area Network Term

0001-2

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0001

Table 2. List of Abbreviations and Acronyms Continued. Abbreviation/ Acronym CBRN CCA COEI CONUS CPC CTA DA dB DC DoD EIR ESD FOV ft ft/min gal GIC hp HPCR IAW ID in IUID JTA Term Chemical, Biological, Radiological, and Nuclear Cold Cranking Amperes Components of End Item Continental United States Corrosion Prevention and Control Common Table of Allowances Department of the Army decibel Direct Current Department of Defense Equipment Improvement Recommendation Electrostatic Discharge Field of View feet feet per minute gallon Gabarit International de Chargement (International Loading Gauge) horsepower High Pressure Common Rail In Accordance With Identification inch Item Unique Identification Device Joint Table of Allowances 0001-3

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0001

Table 2. List of Abbreviations and Acronyms Continued. Abbreviation/ Acronym kg kW L lb LED LO m m/min mm MSDS MTOE NATO NSN OCONUS OSHA oz PAM P/N PMCS PQDR psi qt RO/RO RPSTL SAE kilogram kilowatt liter pound Light Emitting Diode Lubrication Order meter meters per minute millimeter Material Safety Data Sheets Modified Table of Organization and Equipment North Atlantic Treaty Organization National Stock Number Outside Continental United States Occupational Safety and Health Act ounces Pamphlet Part Number Preventive Maintenance Checks and Services Product Quality Deficiency Report pounds per square inch quart Roll-On/Roll-Off Repair Parts and Special Tools List Society of Automotive Engineers 0001-4 Term

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Table 2. List of Abbreviations and Acronyms Continued. Abbreviation/ Acronym SDDC SOP t TAMMS TB TDA TM TOE U/I UL UV V VDC VPM WCA WP Term Surface Deployment and Distribution Command Standard Operating Procedure metric ton The Army Maintenance Management System Technical Bulletin Tables of Distribution and Allowances Technical Manual Table of Organization and Equipment Unit of Issue Underwriters Laboratory Ultraviolet volt Volts Direct Current Vibrations Per Minute Warranty Claim Action Work Package

SAFETY, CARE, AND HANDLING Follow all warnings and cautions in the individual Work Packages (WP) when handling components. The BMPM contains no radioactive components or parts or radioactive material requiring special handling or consideration. The BMPM contains no electronic modules or components requiring special handling to protect them from Electrostatic Discharge (ESD). EMERGENCY PROCEDURES In an emergency situation, press the EMERGENCY STOP switch. See WP 0004 for the location of the EMERGENCY STOP switch. See WP 0008 for detailed emergency procedures. END OF WORK PACKAGE

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OPERATOR MAINTENANCE BITUMINOUS MATERIAL PAVING MACHINE (BMPM) EQUIPMENT DESCRIPTION AND DATA EQUIPMENT CHARACTERISTICS, CAPABILITIES, AND FEATURES Characteristics, Capabilities, and Features The model 8816M BMPM is a self-propelled, crawler-mounted, turbocharged, diesel engine-powered paving machine. The BMPM consists of a 10-ton (9.07-metric ton (t)) receiving hopper, dual extendable auger material spreaders, equally-divided conveyors, a hydraulic-mechanical compaction unit with cutoff shoes, and an electrically-heated screed, all powered by a QSB 4.5, Tier 3 turbocharged electronic diesel engine. The 10-ton (9.07-t) hopper payload enables the BMPM to lay 120 tons (108.8 t) of material per hour while giving operators infinite control of fine adjustments and the flexibility required on material paving projects. The BMPM has a gross weight of 25,000 pounds (lb) (11,350 kilograms (kg)) and stands 8 feet (ft) 7 inches (in) (2.62 meters (m)) tall, 19 ft (5.79 m) long, and 8 ft 6 in (2.9 m) wide when hopper wings and screed extensions are fully retracted. The BMPM is capable of a wide range of paving tasks including but not limited to distributing, compacting, and finishing bituminous material strips from 4 20 ft (1.2 6.1 m) wide at a rate of 120 tons (108.8 t) per hour. The BMPM can receive material from the M917 truck or equivalent truck and pave a 16 ft (4.9 m) wide strip at a rate of up to 30 feet per minute (ft/min) (9.1 meters per minute (m/min)) while pushing a fully-loaded 71,000-lb (32,234kg) truck up a minimum 5% grade.

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LOCATION AND DESCRIPTION OF MAJOR COMPONENTS

Figure 1. BMPM Components Right-Front View.

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LOCATION AND DESCRIPTION OF MAJOR COMPONENTS CONTINUED. Table 1. BMPM Components Right-Front View. Key 1 2 Muffler Left seat slide assembly Component Description Sound absorption device to reduce external engine noise. Operation station for paving control from left side. Includes pedestal assembly and seat. Extends 1 ft for maximum Field of View (FOV). Fume escape to reduce fumes travelling to screed operator. Slat-style feed mechanism to deliver material to left auger. Docking mechanism for material dump truck unloading. Prevents paving material from spilling from front of BMPM. Retractable panel used to guide paving material to conveyor. Drive hub and secondary braking mechanism for BMPM track. Operation station for BMPM control from right side. Includes pedestal assembly and seat. Extends 1 ft for maximum FOV.

3 4 5 6 7 8 9

Fume vent Left conveyor Truck hitch Hopper flashing Hopper wing Hydrostatic drive torque hub Right seat slide assembly

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LOCATION AND DESCRIPTION OF MAJOR COMPONENTS CONTINUED.

Figure 2. BMPM Components Right-Rear View.

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LOCATION AND DESCRIPTION OF MAJOR COMPONENTS CONTINUED. Table 2. BMPM Components Right-Rear View. Key 1 2 3 4 5 6 7 Component Left spraydown hose Air intake Radiator fill port Hopper wing sight gauges Screed arm End gate Fire extinguisher Description Used to lubricate left areas of BMPM to keep material from hardening on surfaces. Access pathway for incoming air to engine. Access opening to maintain or refill engine coolant. Used as a visual reference point for the operator driving the BMPM. Attaches screed to drive unit of BMPM. Controls and forms edge on the finished paving surface being laid. An Underwriters Laboratory (UL)-certified fire extinguisher with a minimum rating of 10 B:C, designed to cover diesel fuel, oil, and electrical fires that may occur on a BMPM, is securely mounted on a bracket found on the stairway. Screed operator(s) station during paving operations. Used to store operator tools and Basic Issue Items (BII) (WP 0031).

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Screed operator platform Toolbox

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LOCATION AND DESCRIPTION OF MAJOR COMPONENTS CONTINUED.

Figure 3. BMPM Components Left-Rear View.

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LOCATION AND DESCRIPTION OF MAJOR COMPONENTS CONTINUED. Table 3. BMPM Components Left-Rear View. Key 1 2 3 4 5 6 7 8 Component Right spraydown hose Right screed control panel Right flight screw Screed electric heat box Left flight screw Screed extension Bolt-on screed extension Left screed control panel Description Used to lubricate right areas of BMPM to keep material from hardening on surfaces. Controls for right auger, conveyor, and extension. Used for manual adjustment of material depth on right side. Provides power and timing of screed heater. Used for manual adjustment of material depth on left side. Provides additional paving width, heat, and compaction. Manually-attached extension providing a 2-ft increase in paving width. Includes compaction vibration and heat. Controls for left auger, conveyor, and extension.

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LOCATION AND DESCRIPTION OF MAJOR COMPONENTS CONTINUED.

Figure 4. BMPM Components Left-Front View.

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LOCATION AND DESCRIPTION OF MAJOR COMPONENTS CONTINUED. Table 4. BMPM Components Left-Front View. Key 1 2 3 4 Engine Sonic auger sensor Track Right conveyor Component Description QSB 4.5 Tier3 130 horsepower (hp) electronic diesel with High Pressure Common Rail (HPCR) fuel system. Sound wave device to control depth of paving material during automatic paving operations. Self-cleaning, self-tensioning, independently-controlled rubber crawler. Slat-type feed mechanism inside hopper to deliver paving material to right auger.

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EQUIPMENT DATA Table 5. Equipment Data. ENGINE: Model and Manufacturer Type Number of cylinders Bore & Stroke Capacity ENGINE COOLING SYSTEM: Type ENGINE FUEL: Type Used Fuel Capacity BATTERY: Number Per Machine Ampere Hour Rating Voltage ALTERNATOR: Voltage Output Amperage Fan Belt Tension STARTER: Manufacturer Voltage and Type Rating DIMENSIONS: Overall Length Overall Height Overall Width (hopper wings in) Overall Width (hopper wings out) Weight SPEED: Travel Paving EFFECTIVE COVERAGE: Standard Screed Width Minimum Screed Width Maximum Screed Width SYSTEM CAPACITIES: Fuel Engine Lubrication Oil (with oil filter) Hydraulic Oil Reservoir Torque Hubs Cleaner Coolant 130 hp (97 kilowatt (kW)) QSB 4.5 Tier3 4 cycle diesel Four 4.02 in (102 mm) x 4.72 in (120 mm) 275 cubic inches (in3) (4.5 liters (L)) Water cooled JP8 or Diesel Fuel 60 gal (227.1 L) Two, maintenance free 670 Cold Cranking Amperes (CCA) 12 volts (V) each (24 V total) 24 V, negative ground 70 amperes (A) Belt tension mechanism keeps serpentine belt under constant tension (See Engine Starter plate) 24 V, negative ground 4.5 kW 19 ft (5.79 m) 8 ft 7 in (2. 62 m) 8 ft 9 in (2.67 m) 10 ft (3.05 m) 26,420 lbs (11,984 kg) 0 360 ft/min (0 109 m/min) 0 140 ft/min (0 42.7 m/min) 8 ft (2.44 m) 6 ft (1.8 m) 15 ft 6 in (4.75 m) (20 ft (6.1 m) with bolt-on screed extensions) 60 gal (227.1 L) 12 qt (11.35 L) 50 gal (189 L) Royco 770 Type 1, specification MIL-PRF-46170 32 ounces (oz) (0.355 L) each 10 gal (37.8 L) 3 gal (11.4 L)

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EQUIPMENT DATA CONTINUED. Table 5. Equipment Data Continued. SCREED: Heat Extensions Vibration Crown/Invert SPRAYDOWN SYSTEM: Components HYDRAULIC SYSTEM: Drives and Conveyor/Auger Fumes and Vibrator All other Hydraulic Functions Hydraulic Oil Reservoir w/ oil cooler MACHINE HYDRAULIC PRESSURES: Drive Conveyers/Auger Cylinders Vibrator/Blower Track Tension Track Tension (Relieving) Charge Pressure END OF WORK PACKAGE Electric, powered by hydraulically-driven 10 kW generator Two 45-in (1.14-m) hydraulically-operated extensions Two 24-in (0.6-m) bolt-on extensions Four hydraulic vibrators producing up to 3,500 VPM Adjustable; at least 2-in crown and 1 1/2-in valley Electric pump and two hose reels, each with a 15 ft (4.6 m) x 5/16 in (7.9 mm) hose and wand. Variable volume hydraulic with proportional pump for each Constant volume pump Pressure compensation pump 50 gal (189 L) 5000 pounds per square inch (psi) (344.7 bar) 4000 psi (275.8 bar) 1800 psi (124 bar) 1800 psi (124 bar) 900 psi (62 bar) 1200 psi (83 bar) 200/250 psi (14/17 bar)

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OPERATOR MAINTENANCE BITUMINOUS MATERIAL PAVING MACHINE (BMPM) THEORY OF OPERATION SCOPE The Bituminous Material Paving Machine (BMPM) is a self-propelled, crawler-mounted, turbocharged diesel engine-powered paving machine. The BMPM consists of a 10-ton (9.07-metric ton (t)) receiving hopper, dual conveyor system, extendable auger-type spreaders, a hydraulic-mechanical compaction unit with cut-off shoes, and an electrically-heated screed. The BMPM is fully capable of a wide range of paving tasks including laying, compacting, and finishing bituminous material strips that can be from 4 20 feet (ft) (1.2 6.1 meters (m)) wide. The unit is driven by a QSB 4.5 turbocharged Tier 3 electronic diesel engine that produces 130 horsepower (hp). It combines electronics and a High Pressure Common Rail (HPCR) fuel system, making it capable of operating safely on fuel with high sulfur content, such as JP8. The BMPM has significant features and capabilities specifically designed for the best possible performance, focusing on areas such as reliability, maintainability, power-to-fuel consumption ratio, horsepower-to-weight ratio, and overall unit dimensions.

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TECHNICAL PRINCIPLES OF OPERATION Screed

Figure 1. BMPM Screed Left Side (Extended). The BMPM contains an electrically-heated floating screed (Figure 1, Item 1) that is a self-contained, attachable unit incorporating hydraulics for raising and lowering the unit and an electric heating system powered by an onboard generator. The screed has two 45-inch (in) (1.14-m) hydraulically-operated screed extensions, which, when deployed, allow paving a strip of paving material up to 15.5 ft (4.7 m) in width and up to 8 in (203-millimeters (mm)) in depth. It is equipped with a variable crown system that can create crowns and valleys on the paving material being distributed. Four hydraulic-mechanical activated vibrators operate at 500 3,500 Vibrations Per Minute (VPM) each and can compact paving material to an 8-in (0.2-m) depth. Normal compaction density yields 88 90% as measured directly behind the screed. The vibrator motors are located on each side of the main screed unit. The screed can be raised, lowered, and locked in the raised position for travel and is delivered with an anti-skid operator platform containing ergonomically-designed and -located controls for paving thickness, crowning, slope, and grade.

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Screed Continued. The screed uses an electric heat system powered by an on-board generator. Electric heat provides a safety measure over propane in wartime and during operations in other hazardous environments. The hydraulicallycontrolled screed extends to 16 ft (4.9 m) and bolt-on extension boxes (one on each side) further extend the screed width to 20 ft (6.1 m). While the majority of BMPM controls are available to the main operator, screed functions can be manually adjusted by screed control operators stationed on the screed platform at the rear of the BMPM. Sonic Auger Sensors

Figure 2. Sonic Auger Sensors. The BMPM uses sonic auger sensors (Figure 2, Item 1) to control the amount of paving material flowing to the screed and screed extensions when operating in automatic mode. Each auger and conveyor is independently controlled for maximum material management on any given job requirement. The screed control operator has the capability to switch the augers from automatic to manual at any time during the paving operation.

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Hopper Assembly

Figure 3. Hopper Assembly. The BMPM 10-ton receiving hopper is equipped with hopper wings (Figure 3, Item 1) that can be raised upward (closed) hydraulically to ensure complete and even distribution and full utilization of the paving material in the hopper. The hopper has an anti-spillage barrier (Figure 3, Item 2) to prevent spillage from the front end.

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Hydraulic Systems The BMPM on-board QSB 4.5 turbocharged Tier 3 electronic diesel engine drives hydraulic pumps and gear drives to provide propulsion and power to hydraulic subsystems on the BMPM.The BMPM hydraulic system drives numerous BMPM functions. Propulsion is hydraulically transmitted through a torque hub and is independent of other hydraulic systems to prevent drive power loss during operation of other hydraulic functions. Screed raise, lower, and extension tasks use hydraulics, as do hopper wing opening and closing. The dump truck hitch, screed, and extensions, as well as the generator used to heat the screed, are all hydraulically powered. The BMPM has an air-cooled reservoir that maintains a hydraulic tank oil temperature below 200 degrees Fahrenheit (F) (93.3 degrees Celsius (C)), with an ambient temperature of 120F (49C) while under sustained operations. The hydraulic systems each have gravity-fed drains in locations that provide easy access for quick service of engine and transmissions or fluid replenishment of hydraulic systems. On-board diagnostics are programmed to monitor and display all engine and hydraulic subsystems simultaneously and provide alerts for any given element that exceeds preset thresholds. Engine Starting The engine is started by means of a keyless engine switch found on the left pedestal assembly control. The starting system consists of two 12-volt (V) batteries connected in series to produce 24 V of electric power, a starter, a 24-V battery-charging alternator, a magnetic pickup for sensing engine speed, and related switches and relays required to control the starting system. For engine cranking, battery power is supplied to the starter motor through the starter solenoid, which in turn is controlled by the cranking relay. The starter then engages the engine flywheel, causing the engine to turn over. While the engine runs, the batteries are continually being recharged by the battery-charging alternator. The BATTERY DISCONNECT switch must be in the ON position to start the BMPM. Electrical System The BMPM electrical system (engine included) is designed on a 24-Volts Direct Current (VDC) platform with alternator, providing power to all onboard systems simultaneously. A single keyless engine switch is located on the left control pedestal, and a North Atlantic Treaty Organization (NATO) STANAGA-4074 Type 1 slave receptacle is included. Work Lights Six circuit breaker-protected work lights controlled by a weatherproof switch are installed on the BMPM. Two of the lights are directed into the receiving hopper and feeders, two are directed into the area behind the compacting unit, and two are directed into the auger area. Backup Alarm The BMPM has a backup alarm that produces a sound level of 107 decibels (dB) as measured within 10 ft (3 m) of the operator platform control pedestal. This is 10 dB louder than the background noise of the operating vehicle. Additionally, a manually-controlled rotating yellow light can be used to help identify to surrounding personnel that the vehicle is in motion.

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Independently-Controlled Augers

Figure 4. Auger With Cutoff Opened. The BMPM is equipped with dual 14-in (355-mm) independently-controlled feed augers (Figure 4, Item 2) and cutoff shoes (Figure 4, Item 1) to evenly distribute paving material. The augers can distribute paving material evenly to the entire width of the compacting unit or across either half of the compacting unit as independent operations. The augers are individually controlled and can be set to function automatically or in manual mode. The bolt-on cutoff shoes reduce paving width down to 6 ft (1.8 m).

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Truck Hitch

Figure 5. Hydraulic Truck Hitch. The retractable hydraulic-controlled dump truck hitch (Figure 5, Item 1) locks the BMPM and the M917 dump truck together while the dump truck is unloading and BMPM operations are ongoing. The hitch rollers fit inside the wheel rims and contact the wheel hubs of the M917 dump truck and similar vehicles while unloading material into the BMPM hopper. The hitch is integral to the BMPM push bar, located underneath the steel rollers used to move the truck forward as paving progresses.

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Track Tension

Figure 6. Self-Tensioning Drive Track. The self-tensioning track hydraulic cylinder operates between 250 1,500 pounds per square inch (psi) (113.5 681 kilograms (kg) per square inch) using a pressure-compensating pump. A pressure-reducing valve is installed in the track tension manifold to maintain pressure at the recommended 900 psi (408.6 kg per square inch). The continuous rubber tracks are independently controlled by joysticks located on the control pedestal. The rubber track (Figure 6, Item 1) is mounted on a structural steel frame and undercarriage. All structural components within the undercarriage and steel frame are inspected and measured for square and perpendicular trueness to ensure optimum rubber track life. The floating bogie assembly allows uneven terrain to be absorbed into the track system (controlled flexing) while maintaining continuous track tension. The track system also has one of the lowest ground pressures for this class of BMPM.

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Hydrostatic Drive System

Figure 7. Hydrostatic Drive Torque Hub. The BMPM has a hydrostatic propulsion system that drives each track independently using a torque hub (Figure 7, Item 1). The propulsion system can generate paving speeds from 0 140 feet per minute (ft/min) (0 42.7 meters per minute (m/min)) with infinitely variable control of each track speed for precision paving accuracy. Forward or reverse propulsion is controlled by two joysticks. Moving the joysticks forward achieves forward motion, and moving the joysticks backward achieves reverse motion. Turning is accomplished by moving one joystick further forward than the other joystick. Travel speeds from 0 360 ft/min (0 110 m/min) are standard on the BMPM. The hydrostatic drive is a separate subsystem, not connected to any other hydraulic subsystems. The drive system circuit is isolated from all other hydraulic circuits. No power losses are experienced by the hydrostatic drive when other hydraulic subsystems are activated. 0003-9

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Braking System The BMPM braking system, one of the hydraulic systems, is a torque-lock system designed to meet the Society of Automotive Engineers (SAE) J2118 specifications for braking performance on BMPM-type equipment. It has a braking capacity of 3.2 times the machine mass and contains a service brake, a secondary brake, and a parking brake with gear interlock. The service brake is a function of the joystick control lever. When propulsion (forward or reverse) is required, the hydraulic system releases the gear drive to allow components to rotate. Returning the joystick to the neutral position will stop all motion within the torque hubs. The secondary brake is derived from the mechanical locking of the gear components within the torque hubs. Hydraulic pressure must be relieved in order to release the mechanical locks and allow internal motion. The failsafe parking brake is set by engaging the EMERGENCY STOP switch on either operator platform control pedestal. This action releases hydraulic pressure from the drive system, allowing mechanical locking of the gear components within the torque hubs, and shuts off the engine. This same mechanical locking is also set to occur in the event of engine and/or electrical power loss. Screed Bolt-On Extensions

Figure 8. Bolt-On Screed Extension. The BMPM is equipped with two bolt-on screed extensions (Figure 8, Item 1) that can be attached to each side of the screed, extending paving width to a total of 20 ft (6.1 m). Each extension contains heaters that are identical to those on the main screed, allowing for heating across the entire 20-ft (6.1-m) paving span. 0003-10

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Diagnostics The BMPM uses a commercially-available Controller Area Network (CAN) bus platform that operates from 5 35 V and will perform all designed functionality within this range. On-board diagnostics are programmed to monitor and display all hydraulic subsystems simultaneously and provide alerts for any element that exceeds preset thresholds. The diagnostics program performs self checks and continuous monitoring of all subsystems. The diagnostic program displays all faults on the control pedestal displays. Paving Preparation Several steps are required before beginning a paving operation. First the on-board spraydown system is used to thoroughly wash all BMPM parts that come into contact with hot paving material. This helps prevent material accumulations that could cause future maintenance problems. Lubrication and Before PMCS are done prior to paving operations. Refer to WP 0013 and LO 5-3895-385-13. The BMPM engine and screed electric heat box are started and allowed to warm up to normal operating temperature before beginning paving operations. After the screed electric heat box runs for 30 minutes warming the screed and hot paving material loaded into the hopper, the screed electric heat box can be turned off. While paving continues, restarting the screed electric heat box is necessary only when paving conditions require more heat than the hot paving material can provide or when the BMPM has been idle long enough for the screed to cool. Paving Operations Paving with the BMPM is typically a two- to three-person operation. One main operator controls the forward movement of the BMPM and many of the paving functions from the control pedestal. The screed control operator(s), stationed on the screed platform, can control the amount, slope, and crown (if any) of the paving material distributed during the paving operation. Paving an 8-ft (2.4-m) or wider strip of material requires two screed control operators, one at each of the screed controls located at either side of the screed platform. When the BMPM and screed have reached operating temperature, paving material is transferred from a dump truck into the hopper on the front of the BMPM to begin paving operations. This transfer of material can be easily managed by using the retractable hydraulic-controlled truck hitch attached to the front of the BMPM. This device locks small rollers inside the rear wheels of the dump truck containing the paving material, and large rollers on the truck hitch push the truck forward as the BMPM moves forward. At the same time, the paving material is being loaded into the hopper, and it can be immediately conveyed to the augers and distributed to create the paved surface. The 10-ton (9.07-t) hopper payload enables the BMPM to lay 120 tons (108.8 t) of paving material per hour while giving the operators infinite control of fine adjustments and the flexibility required on material paving projects. The BMPM is designed to distribute material up to a thickness of 8 in (203 mm) and is equipped with both automatic and manual thickness controls. Paving material is fed from the hopper to the augers by means of a dual-conveyer system. From the augers, the material is distributed over the surface being paved. Conveyor speed, auger speed, the position of the auger cutoffs, and screed height all help to determine the amount of paving material distributed. Screed height is controlled either manually or by use of the sonic auger sensor. To improve operator comfort during paving operations, fumes from the hot paving material on the conveyor are vented through the engine compartment to the outside. Should an emergency situation arise while paving is in progress, the main operator can instantly shut down the BMPM engine and all paving operations by pressing the red EMERGENCY STOP switch located on either control pedestal.

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Paving Operations Continued. During paving operations, the During PMCS operations are performed. Refer to WP 0013. The amount of paving material distributed by the BMPM can be controlled automatically or manually. In automatic mode, the sonic auger sensors keep the height of distributed paving material constant, regardless of the forward speed of the BMPM. Sound waves are used to measure material height and adjust the speed of the conveyer and augers to maintain this constant paving height. When running under manual control, the height of the paving material can be controlled in several ways: by adjusting the position of the auger cut-off shoes, by adjusting the speed of the conveyor, by adjusting the speed of the augers, by adjusting the material thickness using the flight screws, or by adjusting the forward movement of the BMPM. Paving Completion When a paving operation is complete, daily lubrication and After PMCS operations are performed. Refer to WP 0013 and LO 5-3895-385-13. END OF WORK PACKAGE

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CHAPTER 2
OPERATOR INSTRUCTIONS FOR BITUMINOUS MATERIAL PAVING MACHINE (BMPM)

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OPERATOR MAINTENANCE BITUMINOUS MATERIAL PAVING MACHINE (BMPM) DESCRIPTION AND USE OF OPERATOR CONTROLS AND INDICATORS INTRODUCTION The following tables and illustrations provide the description and use of the controls and indicators pertaining to the operator platform displays and keypads, screed control keypads, screed electric heat box, hydraulic fluid reservoir temperature and liquid sight indicator, BATTERY DISCONNECT switch, screed crown gauge, vibration control knob, and flight screws.

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Engine and Travel Speed

Figure 1. Left Control Pedestal Joysticks, EMERGENCY STOP, Run/Stop.

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Engine and Travel Speed Continued. Table 1. Left Control Pedestal Joysticks, EMERGENCY STOP, Run/Stop. KEY 1 2 3 4 5 6 CONTROL/INDICATOR Work Lights Horn Left Track Joystick Right Track Joystick EMERGENCY STOP Run/Stop Toggle Switch FUNCTION Pressing switch forward will turn on work lights. Pressing switch back will turn off work lights. Pressing button will sound the horn. Controls the forward and reverse movement of the left track. Controls the forward and reverse movement of the right track. Pressing the EMERGENCY STOP switch will disable all function of the BMPM and shut down the engine. Moving this toggle switch to the RUN position will activate control pedestal (left or right). Moving this toggle switch to the STOP position will deactivate control pedestal (left or right). Only one (left or right) control pedestal can be active at one time. The operator should ensure the opposite control pedestal (left or right) run/stop toggle switch is set to STOP before attempting to activate desired control pedestal.

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Engine and Travel Speed Continued.

Figure 2. Right Control Pedestal Joysticks, EMERGENCY STOP, Run/Stop. Table 2. Right Control Pedestal Joysticks, EMERGENCY STOP, Run/Stop. KEY 1 2 3 CONTROL/INDICATOR Left Track Joystick Right Track Joystick EMERGENCY STOP FUNCTION Controls the forward and reverse movement of the left track. Controls the forward and reverse movement of the right track. Pressing the EMERGENCY STOP switch will disable all function of the BMPM and shut down the engine. Moving this toggle switch to the RUN position will activate control pedestal (left or right). Moving this toggle switch to the STOP position will deactivate control pedestal (left or right). Only one (left or right) control pedestal can be active at one time. The operator should ensure the opposite control pedestal (left or right) run/stop toggle switch is set to STOP before attempting to activate desired control pedestal.

Run/Stop Switch

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Keyless Engine Switch

Figure 3. Keyless Engine Switch. Table 3. Keyless Engine Switch. KEY 1 CONTROL/INDICATOR Keyless Engine Switch FUNCTION When switch is turned fully counterclockwise, the BMPM is in the OFF position. When switch is in the center position, the BMPM is in the AUX position. When switch is turned fully clockwise, the BMPM is in the IGN position. This will engage the engine starter. This is a momentary switch and will release back to the AUX position when released.

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Control Pedestal Beacon Keypad

Figure 4. Left or Right Control Pedestal Beacon Keypad. Table 4. Left or Right Control Pedestal Beacon Keypad. KEY 1 CONTROL/INDICATOR Beacon Off/On FUNCTION Pressing key will toggle beacon on and off. Light Emitting Diode (LED) will be illuminated when beacon is on. 2 Vibrator Function Pressing key will activate vibrator function. This function will only be active when BMPM is moving forward. Vibrator will stop when forward motion stops and will resume when forward motion resumes. LED will be illuminated when vibrator function is on. 3 Right Tow Up Pressing and holding key will cause right tow point hydraulic cylinder to raise screed angle at right side of screed. This button is not active when grade control is in automatic. LED will be illuminated when function is active.

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Control Pedestal Beacon Keypad Continued. Table 4. Left or Right Control Pedestal Beacon Keypad Continued. KEY 4 CONTROL/INDICATOR Right Tow Down FUNCTION Pressing and holding key will cause right tow point hydraulic cylinder to lower screed angle at right side of screed. This button is not active when grade control is in automatic. LED will be illuminated when function is active. 5 Reverse Conveyor/Augers Pressing and holding key while conveyors and augers are moving forward will cause both right and left conveyors and augers to reverse slowly. LED will be illuminated when function is active. 6 Spraydown Off/On Pressing key will turn on spraydown pump. Pressing key again will turn off pump. LED will be illuminated when pump is on. 7 Two Speed Pressing key will activate high gear. Pressing key again will return to low gear. LED will be illuminated when in high gear. High gear should never be used while paving. 8 Auger Bypass Pressing key will turn off augers. LED will be illuminated when auger bypass is active (augers will be off). Pressing key again will turn off bypass and turn off LED (augers will resume function). 9 Left Tow Down Pressing and holding key will cause left tow point hydraulic cylinder to lower screed angle at left side of screed. This button is not active when grade control is in automatic. LED will be illuminated when function is active. 10 Left Tow Up Pressing and holding key will cause left tow point hydraulic cylinder to raise screed angle at left side of screed. This button is not active when grade control is in automatic. LED will be illuminated when function is active. 11 Grade Control (Auto/Man) Pressing key will toggle grade control between automatic and manual. When in automatic, top LED will be illuminated (should not be used). When in manual, bottom LED will be illuminated. In manual mode, the left and right tow point hydraulic cylinder functions will be controlled from keypad. 0004-7

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Left Control Pedestal Horn Keypad

Figure 5. Left Control Pedestal Horn Keypad.

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Left Control Pedestal Horn Keypad Continued. Table 5. Left Control Pedestal Horn Keypad. KEY 1 CONTROL/INDICATOR Truck Hitch Out FUNCTION Pressing and holding key will cause both left and right truck hitch arms to extend (release truck). LED will be illuminated when function is active. 2 Truck Hitch In Pressing and holding key will cause both left and right truck hitch arms to retract (hold truck). LED will be illuminated when function is active. 3 Screed Up Pressing and holding key will cause the screed to raise. Releasing key will hold screed in position. LED will be illuminated when function is active. LED will blink when screed is in hold position (used when forward motion is stopped while screed is in float). 4 Left Conveyor Speed Up Pressing and holding key will increase left conveyor speed. LED will be illuminated when key is pressed. 5 Right Conveyor Speed Up Pressing and holding key will increase right conveyor speed. LED will be illuminated when key is pressed. 6 Right Conveyor Speed Down Pressing and holding key will decrease right conveyor speed. LED will be illuminated when key is pressed. 7 Left Conveyor Speed Down Pressing and holding key will decrease left conveyor speed. LED will be illuminated when key is pressed. 8 Screed Down Pressing key will cause screed to float. Screed will lower until it reaches the ground or until screed up key is pressed. LED will be illuminated when screed is in float. 9 Left Screed Extension Retract Pressing and holding key will cause left screed extension to retract. Releasing key will cause left extension to maintain position. LED will be illuminated when function is active. 10 Left Screed Extension Extend Pressing and holding key will cause left screed extension to extend. Releasing key will cause left screed extension to maintain position. LED will be illuminated when function is active. 11 Horn Pressing and holding key will cause horn to sound. LED will be illuminated when function is active.

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Right Control Pedestal Horn Keypad

Figure 6. Right Control Pedestal Horn Keypad. Table 6. Right Control Pedestal Horn Keypad. KEY 1 CONTROL/INDICATOR Truck Hitch In FUNCTION Pressing and holding key will cause both left and right truck hitch arms to retract (hold truck). Top LED will be illuminated when function is active. 2 Truck Hitch Out Pressing and holding key will cause both left and right truck hitch arms to extend (release truck). Top LED will be illuminated when function is active. 3 Screed Up Pressing and holding key will cause the screed to raise. Releasing key will hold screed in position. LED will be illuminated when function is active. LED will blink when screed is in hold position (used when forward motion is stopped while screed is in float).

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Right Control Pedestal Horn Keypad Continued. Table 6. Right Control Pedestal Horn Keypad Continued. KEY 4 CONTROL/INDICATOR Left Conveyor Speed Up FUNCTION Pressing and holding key will increase left conveyor speed. LED will be illuminated when key is pressed. 5 Right Conveyor Speed Up Pressing and holding key will increase right conveyor speed. LED will be illuminated when key is pressed. 6 Right Conveyor Speed Down Pressing and holding key will decrease right conveyor speed. LED will be illuminated when key is pressed. 7 Left Conveyor Speed Down Pressing and holding key will decrease left conveyor speed. LED will be illuminated when key is pressed. 8 Screed Down Pressing key will cause screed to float. Screed will lower until it reaches the ground or until screed up key is pressed. LED will be illuminated when screed is in float. 9 Left Screed Extension Retract Pressing and holding key will cause left screed extension to retract. Releasing key will cause left extension to maintain position. LED will be illuminated when function is active. 10 Left Screed Extension Extend Pressing and holding key will cause left screed extension to extend. Releasing key will cause left extension to maintain position. LED will be illuminated when function is active. 11 Horn Pressing and holding key will cause horn to sound. LED will be illuminated when function is active.

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Left Control Pedestal Lights Keypad

Figure 7. Left Control Pedestal Lights Keypad. Table 7. Left Control Pedestal Lights Keypad. KEY 1 CONTROL/INDICATOR Augers Up FUNCTION Pressing and holding key will cause the augers to raise. Releasing the key will hold augers in position. LED will be illuminated when function is active. 2 Throttle Up Pressing and holding key will increase engine speed. Releasing key will maintain speed. LED will be illuminated when key is pressed. 3 Throttle Down Pressing and holding key will decrease engine speed. Releasing key will maintain speed. LED will be illuminated when key is pressed.

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Left Control Pedestal Lights Keypad Continued. Table 7. Left Control Pedestal Lights Keypad Continued. KEY 4 CONTROL/INDICATOR Left Auger/Conveyor Auto/Off/Man FUNCTION Pressing key will toggle between left conveyor automatic, off, and manual function. Left LED will be illuminated when in automatic mode (sonic auger sensors are required for this function). Middle LED will be illuminated when left conveyors and augers are off. Right LED will be illuminated when in manual mode. 5 Right Auger/Conveyor Auto/Off/Man Pressing key will toggle between right conveyor automatic, off, and manual function. Left LED will be illuminated when in automatic mode (sonic auger sensors are required for this function). Middle LED will be illuminated when right conveyors and augers are off. Right LED will be illuminated when in manual mode. 6 Right Extension Extend Pressing and holding key will cause right screed extension to extend. Releasing key will cause right extension to maintain position. LED will be illuminated when function is active. 7 Right Extension Retract Pressing and holding key will cause right screed extension to retract. Releasing key will cause right extension to maintain position. LED will be illuminated when function is active. 8 Hopper In Pressing and holding key will cause hopper wings to close. Releasing key will maintain hopper wing position. LED will be illuminated when function is active. 9 Hopper Out Pressing and holding key will cause hopper wings to open. Releasing key will maintain hopper wing position. LED will be illuminated when function is active. 10 Augers Down Pressing and holding key will cause the augers to lower. Releasing key will hold augers in position. LED will be illuminated when function is active. 11 Work Lights Off/On Pressing key will toggle work lights on and off. LED will be illuminated when work lights are on.

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Right Control Pedestal Lights Keypad

Figure 8. Right Control Pedestal Lights Keypad. Table 8. Right Control Pedestal Lights Keypad. KEY 1 CONTROL/INDICATOR Augers Up FUNCTION Pressing and holding key will cause augers to raise. Releasing the key will hold augers in position. LED will be illuminated when function is active. 2 Throttle Up Pressing and holding key will increase engine speed. Releasing key will maintain speed. LED will be illuminated when key is pressed. 3 Throttle Down Pressing and holding key will decrease engine speed. Releasing key will maintain speed. LED will be illuminated when key is pressed.

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Right Control Pedestal Lights Keypad Continued. Table 8. Right Control Pedestal Lights Keypad Continued. KEY 4 CONTROL/INDICATOR Left Auger/Conveyor Auto/Off/Man FUNCTION Pressing key will toggle between left conveyor automatic, off, and manual function. Left LED will be illuminated when in automatic mode (sonic auger sensors are required for this function). Middle LED will be illuminated when left conveyors and augers are off. Right LED will be illuminated when in manual mode. 5 Right Auger/Conveyor Auto/Off/Man Pressing key will toggle between right conveyor automatic, off, and manual function. Left LED will be illuminated when in automatic mode (sonic auger sensors are required for this function). Middle LED will be illuminated when right conveyors and augers are off. Right LED will be illuminated when in manual mode. 6 Right Extension Extend Pressing and holding key will cause right screed extension to extend. Releasing key will cause right extension to maintain position. LED will be illuminated when function is active. 7 Right Extension Retract Pressing and holding key will cause right screed extension to retract. Releasing key will cause right extension to maintain position. LED will be illuminated when function is active. 8 Hopper Out Pressing and holding key will cause hopper wings to open. Releasing key will maintain hopper wing position. LED will be illuminated when key is pressed. 9 Hopper In Pressing and holding key will cause hopper wings to close. Releasing key will maintain hopper wing position. LED will be illuminated when key is pressed. 10 Augers Down Pressing and holding key will cause the augers to lower. Releasing key will hold augers in position. LED will be illuminated when function is active. 11 Work Lights Off/On Pressing key will toggle work lights on and off. LED will be illuminated when work lights are on.

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Engine Screen

Figure 9. Engine Screen Buttons. Table 9. Engine Screen Buttons. KEY 1 2 3 4 CONTROL/INDICATOR Pavers Screen Button 1 System Faults Screen Button 2 Engine Faults Screen Button 3 Password Screen Button 4 (used to enter time adjust screen) FUNCTION Pressing button will switch to pavers screen. Pressing button will switch to system faults screen. Pressing button will switch to engine faults screen. Pressing button will switch to password screen where the time adjust screen is accessed. Operator should not attempt to enter password. Password is for maintainer use only. .

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Engine Screen Continued.

Figure 10. Engine Screen Indicators. Table 10. Engine Screen Indicators. KEY 1 2 3 4 5 6 7 CONTROL/INDICATOR Fuel Gauge Tachometer Engine Hour Meter Hydraulic Oil Temperature Oil Pressure Gauge Water Temperature Gauge Voltmeter FUNCTION Indicates the amount of fuel in the fuel tank. E at the bottom of the fuel gauge indicates empty, and F at the top of the fuel gauge indicates full. Indicates engine speed. Indicates the amount of time the engine has run. Indicates hydraulic system oil temperature. Indicates engine oil pressure. Indicates engine coolant temperature. Indicates battery voltage; 32 indicates 32 Volts Direct Current (VDC), and 0 indicates 0 VDC.

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Fault Light Cluster

Figure 11. Fault Light Cluster.

CAUTION
The BMPM should not be operated if the low battery, high coolant temp, high hydraulic oil temp, or low engine oil psi fault lights are present during operation. Failure to comply may result in damage to equipment.

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Fault Light Cluster Continued. Table 11. Fault Light Cluster. KEY 1 2 3 CONTROL/INDICATOR Low Fuel Low Battery High Coolant Temp FUNCTION Indicates fuel level below 15% of capacity. Indicates battery voltage below 22 VDC. Indicates engine coolant temperature over 220 degrees Fahrenheit (F) (104 degrees Celsius (C)). Indicates hydraulic oil temperature over 200F (93C). Indicates engine oil pressure is below 10 pounds per square inch (psi). Indicates the beacon light is on. Indicates electric screed heater generator is on. Indicates the work lights are on. Indicates torque hub brake is applied. This is done automatically whenever the BMPM joysticks are in the neutral position.

4 5 6 7 8 9

High Hydraulic Oil Temp Low Engine Oil psi Beacon On Generator On Lights On Park Brake On

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Pavers Screen

Figure 12. Pavers Screen Buttons.

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Pavers Screen Continued. Table 12. Pavers Screen Buttons. KEY 1 2 3 4 CONTROL/INDICATOR Engine Screen Button 1 Max Ground Speed Up Button Max Ground Speed Down Button Password Screen Button 4 (used to enter time adjust screen) 5 6 Engine Faults Screen Button 3 System Faults Screen Button 2 FUNCTION Pressing button will switch to engine screen. Pressing button will raise the maximum ground speed of BMPM. Pressing button will lower the maximum ground speed of BMPM. Pressing button will switch to password screen where the time adjust screen is accessed. Operator should not attempt to enter password. Password is for maintainer use only. . Pressing button will switch to engine faults screen. Pressing button will switch to system faults screen.

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Pavers Screen Continued.

Figure 13. Pavers Screen Indicators. Table 13. Pavers Screen Indicators. KEY 1 2 3 4 CONTROL/INDICATOR BMPM Speedometer BMPM Max Speed Setpoint BMPM Speed Setting Indicator Grade Control Indicator FUNCTION Indicates ground speed of BMPM (in percentage of capability). Indicates what level the max ground speed of BMPM is set to. Indicates low (1) or high (2) speed setting of the BMPM. Manual indicates the grade control is done manually by the operator. Automatic indicates the grade control is done through the System V control panel (requires installation of System V).

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Pavers Screen Continued. Table 13. Pavers Screen Indicators Continued. KEY 5 CONTROL/INDICATOR Right Auger/Conveyor Mode Indicator FUNCTION Indicates the selected mode of the right auger/conveyor. Off indicates right auger/conveyor function is off. Manual indicates auger/conveyor speeds are manually controlled. Automatic indicates auger/conveyor speeds are being determined using the sonic auger sensors (requires installation of sonic auger sensors). 6 Right Sonic Auger Sensor Setpoint/Actual "Setpoint indicates the target pile height as adjusted by pile height plus and minus keys on the right screed control auger/conveyor keypad. Actual indicates what the pile height currently is, according to the sonic auger sensors. Pile height is measured in inches. 7 8 9 10 11 12 13 Right Auger Speed Indicator Right Conveyor Speed Indicator Vibrator Indicator Console Active/Inactive Left Conveyor Speed Indicator Left Auger Speed Indicator Left Sonic Auger Sensor Setpoint/Actual Indicates the speed, in percentage, of the right auger. Indicates the speed, in percentage, of the right conveyor. Indicates whether the vibrator function of the screed is set to on or off. Indicates whether console is active or inactive. Indicates the speed, in percentage, of the left conveyor. Indicates the speed, in percentage, of the left auger. "Setpoint indicates the target pile height as adjusted by pile height plus and minus keys on the left screed control auger/conveyor keypad. Actual indicates what the pile height currently is, according to the sonic auger sensors. Pile height is measured in inches. 14 Left Auger/Conveyor Mode Indicator Indicates the selected mode of the left auger/conveyor. Off indicates left auger/conveyor function is off. Manual indicates auger/conveyor speeds are manually controlled. Automatic indicates auger/conveyor speeds are being determined using the sonic auger sensors. (Requires installation of sonic auger sensors.) 15 Clock Indicates time of day.

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Password Screen

Figure 14. Password Screen Buttons. Table 14. Password Screen Buttons. KEY 1 2 CONTROL/INDICATOR ESC Button Time Adjust Button 2 FUNCTION Pressing button will return to previous screen. Pressing button will enter the time adjust screen.

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Time Adjust Screen

Figure 15. Time Adjust Screen Buttons. Table 15. Time Adjust Screen Buttons. KEY 1 2 3 4 5 6 CONTROL/INDICATOR Hour Increase Button 2 Minute Increase Button 6 Minute Decrease Button 7 Exit Screen Button 8 ESC Button Hour Decrease Button 3 FUNCTION Pressing button will increase clock by 1 hour. Pressing button will increase clock by 1 minute. Pressing button will decrease clock by 1 minute. Pressing button will return to previous screen. Pressing button will return to previous screen. Pressing button will decrease clock by 1 hour.

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Fault Screen 1, 2, or 3

Figure 16. Fault Screen 1, 2, or 3. Table 16. Fault Screen Buttons and Indicators. KEY 1 2 3 4 5 6 CONTROL/INDICATOR Fault Indicator Fault Description Exit Screen Button 8 Next Page Right Button Previous Page Left Button ESC Button FUNCTION Red box next to fault description indicates an active fault. Description of possible fault. These are active faults only with the presence of a red box next to the description (fault indicator). Pressing button will return to pavers screen. Pressing button will advance to next fault screen page. Pressing button will return to previous fault screen page. Pressing button will return to pavers screen.

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Active Engine Faults Screen

Figure 17. Active Engine Fault Screen. Table 17. Active Engine Fault Screen Buttons and Indicators. KEY 1 2 3 4 5 6 CONTROL/INDICATOR Active Engine Faults Inactive Screen Button 5 Exit Screen Button 8 Next Page Right Button Previous Page Left Button ESC Button FUNCTION Active engine fault information will be displayed here. Pressing button will advance to the inactive engine faults screen page. Pressing button will return to pavers screen. Pressing button will advance to next fault screen page. Pressing button will return to previous fault screen page. Pressing button will return to pavers screen.

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Inactive Engine Faults Screen

Figure 18. Inactive Engine Fault Screen.

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Inactive Engine Faults Screen Continued. Table 18. Inactive Engine Fault Screen Buttons and Indicators. KEY 1 2 3 4 5 6 CONTROL/INDICATOR Inactive Engine Faults Inactive Screen Button 5 Exit Screen Button 8 Next Page Right Button Previous Page Left Button ESC Button FUNCTION Inactive engine fault information will be displayed here. Pressing button will advance to the inactive engine faults screen page. Pressing button will return to pavers screen. Pressing button will advance to next fault screen page. Pressing button will return to previous fault screen page. Pressing button will return to pavers screen.

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Left Screed Control Auger/Conveyor Controls

Figure 19. Left Screed Control Auger/Conveyor Keypad. Table 19. Left Screed Control Auger/Conveyor Keypad. KEY 1 CONTROL/INDICATOR Master Left Auger/Conveyor Stop/Start FUNCTION Pressing key will turn left auger and conveyor functions on. Pressing key again will turn left auger and conveyor functions off. Top LED will be illuminated when function is on. 2 Left Auger/Conveyor Auto/Man Pressing key will toggle between left auger/conveyor automatic and manual function. Bottom LED will be illuminated when in automatic mode (sonic auger sensors are required for this function).Top LED will be illuminated when in manual mode. 3 Left Material Pile Height Auger/Conveyor Speed plus (+) When left auger/conveyor manual mode is selected, pressing and holding this key increases the speed of the auger and conveyor. When left auger/conveyor automatic mode is selected, pressing and holding this key increases the material pile height controlled with the use of the sonic auger sensors. LEDs not used. Refer to right material height/auger speed minus (-) key.

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Left Screed Control Auger/Conveyor Controls Continued. Table 19. Left Screed Control Auger/Conveyor Keypad Continued. KEY 4 CONTROL/INDICATOR Left Conveyor Speed Up FUNCTION Pressing and holding key will cause left conveyor to increase in speed. LEDs are used in conjunction with left conveyor speed down key LEDs (Figure 19, Item 5). The number of total illuminated LEDs across both keys indicates speed (more LEDs illuminated indicates higher speed). 5 Left Conveyor Speed Down Pressing and holding key will cause left conveyor to decrease in speed. LEDs are used in conjunction with left conveyor speed up key LEDs (Figure 19, Item 4). The number of total illuminated LEDs across both keys indicates speed (more LEDs illuminated indicates higher speed). 6 Left Extension Retract Pressing and holding key will cause left screed extension to retract. Releasing key will maintain extension position. Top LED will be illuminated when function is active. 7 Left Extension Extend Pressing and holding key will cause left screed extension to extend. Releasing key will maintain extension position. Top LED will be illuminated when function is active. 8 Left Screed Extension Slope Down Pressing and holding key will lower left screed extension to slope down (more angle). Releasing key will hold extension in position. Top LED will be illuminated when function is active. 9 Left Screed Extension Slope Up Pressing and holding key will raise left screed extension to slope back toward level (less angle). Releasing key will hold extension in position. Top LED will be illuminated when function is active. 10 Left Material Pile Height Auger/Conveyor Speed minus (-) When left auger/conveyor manual mode is selected, pressing and holding this key reduces the speed of the left auger and conveyor. When left auger/conveyor automatic mode is selected, pressing and holding this key decreases the left material pile height controlled with the use of the sonic auger sensors. Number of illuminated LEDs and frequency of flashing indicates pile height in automatic or auger/conveyor speed in manual. (More LEDs illuminated and/or faster flashing indicates higher value.) 11 Left Conveyor Bypass Pressing key will turn off left conveyor. Top LED will be illuminated when left conveyor bypass is active (left conveyor will be off). Pressing key again will turn off bypass and turn off LED (conveyor will resume function). 0004-31

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Right Screed Control Auger/Conveyor Controls

Figure 20. Right Screed Control Auger/Conveyor Keypad. Table 20. Right Screed Control Auger/Conveyor Keypad. KEY 1 CONTROL/INDICATOR Master Right Auger/Conveyor Stop/Start FUNCTION Pressing key will turn right auger and conveyor functions on. Pressing key again will turn right auger and conveyor functions off. LED on indicates function is on. Pressing key will toggle between right auger/conveyor automatic and manual function. Bottom LED will be illuminated when in automatic mode (sonic auger sensors are required for this function). Top LED will be illuminated when in manual mode. 3 Right Material Pile Height Auger/Conveyor Speed plus (+) When right auger/conveyor manual mode is selected, pressing and holding key increases the speed of the auger and conveyor. When right auger/conveyor automatic mode is selected, pressing and holding key increases the material pile height controlled with the use of the sonic auger sensors. LEDs not used. Refer to Figure 20, Item 10 to indicate pile height or auger/conveyor speed.

Right Auger/Conveyor Auto/Man

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Right Screed Control Auger/Conveyor Controls Continued. Table 20. Right Screed Control Auger/Conveyor Keypad Continued. KEY 4 CONTROL/INDICATOR Right Conveyor Speed Up FUNCTION Pressing and holding key will cause right conveyor speed to increase. LEDs are used in conjunction with right conveyor speed down key LEDs (Figure 20, Item 5). The number of illuminated LEDs across both keys indicates speed (more LEDs illuminated indicates higher speed). 5 Right Conveyor Speed Down Pressing and holding key will cause right conveyor speed to decrease. LEDs are used in conjunction with right conveyor speed up key LEDs (Figure 20, Item 4). The number of illuminated LEDs across both keys indicates speed (more LEDs illuminated indicates higher speed). 6 Reverse Auger/Conveyor Pressing and holding key will cause both right and left conveyors and augers to reverse slowly (unless auger bypass function is engaged, then only conveyors will reverse). Top LED will be illuminated when function is active. 7 Auger Bypass Pressing key will turn off augers. Top LED will illuminate when auger bypass is active (augers will be off). Pressing key again will turn off function and turn off LED (augers will resume function). 8 Right Screed Extension Slope Down Pressing and holding key will lower right screed extension to slope down (more angle). Releasing key will hold extension in position. Top LED will be illuminated when function is active. 9 Right Screed Extension Slope Up Pressing and holding key will raise right screed extension to slope back toward level (less angle). Releasing key will hold extension in position. Top LED will be illuminated when function is active. 10 Right Material Pile Height Auger/Conveyor Speed minus (-) When right auger/conveyor manual mode is selected, pressing and holding this key reduces the speed of the right auger and conveyor. When right auger/conveyor automatic mode is selected, pressing and holding this key decreases the right material pile height controlled with the use of the sonic auger sensors. Number of illuminated LEDs and frequency of flashing indicates pile height in automatic or auger/conveyor speed in manual. (More LEDs illuminated and/or faster flashing indicates higher value.) 11 Right Conveyor Bypass Pressing key will turn off right conveyor. Top LED will be illuminated when right conveyor bypass is active (right conveyor will be off). Pressing key again will turn off bypass and turn off LED (conveyor will resume function). 0004-33

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Left Screed Control Horn Keypad

Figure 21. Left Screed Control Horn Keypad. Table 21. Left Screed Control Horn Keypad. KEY 1 CONTROL/INDICATOR Horn FUNCTION Pressing and holding key will cause horn to sound. Top LED will be illuminated when function is active. 2 Left Tow Up Pressing and holding key will cause left tow point hydraulic cylinder to raise screed angle at left side of screed. This button is not active when grade control is in automatic. Top LED will be illuminated when function is active. 3 Left Tow Up Pressing and holding key will cause left tow point hydraulic cylinder to lower screed angle at left side of screed. This button is not active when grade control is in automatic. Top LED will be illuminated when function is active.

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Left Screed Control Horn Keypad Continued. Table 21. Left Screed Control Horn Keypad Continued. KEY 4 CONTROL/INDICATOR Left Cutoff Open FUNCTION Pressing and holding key will cause left cutoff to open (raise). Releasing key will hold cutoff position. Top LED will be illuminated when function is active. 5 Left Cutoff Closed Pressing and holding key will cause left cutoff to close (lower). Releasing key will hold cutoff position. Top LED will be illuminated when function is active. 6 Reverse Auger/Conveyor Pressing and holding key will cause both right and left conveyors and augers to reverse slowly (unless auger bypass function is engaged, then only conveyors will reverse). Top LED will be illuminated when function is active. 7 Auger Bypass Pressing key will turn off augers. Top LED will be illuminated when auger bypass is active (augers will be off). Pressing key again will turn off function and turn off LED (augers will resume function). 8 Power Crown Down (Valley) Pressing and holding key will lower screed power crown (valley). Releasing key will maintain power crown position. Top LED will be illuminated when function is active. Two screed top bar bolts should be loosened whenever using this function. 9 Power Crown Up Pressing and holding key will raise screed power crown. Releasing key will maintain power crown position. Top LED will be illuminated when function is active. Two screed top bar bolts should be loosened whenever using this function. 10 Auger Down Pressing and holding key will cause the augers to lower. Releasing the key will hold augers in position. Top LED will be illuminated when function is active. 11 Auger Up Pressing and holding key will cause the augers to raise. Releasing the key will hold augers in position. Top LED will be illuminated when function is active.

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Right Screed Control Horn Keypad

Figure 22. Right Screed Control Horn Keypad. Table 22. Right Screed Control Horn Keypad. KEY 1 CONTROL/INDICATOR Horn FUNCTION Pressing and holding key will cause horn to sound. Top LED will be illuminated when function is active. 2 Right Tow Up Pressing and holding key will cause right tow point hydraulic cylinder to raise screed angle at right side of screed. This button is not active when grade control is in automatic. Top LED will be illuminated when function is active. 3 Right Tow Down Pressing and holding key will cause right tow point hydraulic cylinder to lower screed angle at right side of screed. This button is not active when grade control is in automatic. Top LED will be illuminated when function is active.

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Right Screed Control Horn Keypad Continued. Table 22. Right Screed Control Horn Keypad Continued. KEY 4 CONTROL/INDICATOR Right Cutoff Open FUNCTION Pressing and holding key will cause right cutoff to open (raise). Releasing key will hold cutoff position. Top LED will be illuminated when function is active. 5 Right Cutoff Closed Pressing and holding key will cause right cutoff to close (lower). Releasing key will hold cutoff position. Top LED will be illuminated when function is active. 6 Right Extension Retract Pressing and holding key will cause right screed extension to retract. Releasing key will maintain extension position. Top LED will be illuminated when function is active. 7 Right Extension Extend Pressing and holding key will cause right screed extension to extend. Releasing key will maintain extension position. Top LED will be illuminated when function is active. 8 Power Crown Down (Valley) Pressing and holding key will cause screed power crown to lower (valley). Releasing key will maintain power crown position. Top LED will be illuminated when function is active. Two screed top bar bolts should be loosened whenever using this function. 9 Power Crown Up Pressing and holding key will raise screed power crown. Releasing key will maintain power crown position. Top LED will be illuminated when function is active. Two screed top bar bolts should be loosened whenever using this function. 10 Auger Down Pressing and holding key will cause the augers to lower. Releasing the key will hold augers in position. Top LED will be illuminated when function is active. 11 Auger Up Pressing and holding key will cause the augers to raise. Releasing the key will hold augers in position. Top LED will be illuminated when function is active.

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Screed Electric Heat Box

Figure 23. Screed Electric Heat Box. Table 23. Screed Electric Heat Box. KEY 1 2 CONTROL/INDICATOR Screed Electric Heat On Indicator Start Heat Button FUNCTION When illuminated, this indicates screed is actively being heated. Pressing start heat button (when screed electric heat boxs power toggle switch is in the up position) will start a 25-minute screed-heating cycle. Toggling switch up enables use of the start heat button, making screed electric heating possible. Toggling switch down disables use of the start heat button, making screed electric heating impossible.

Screed Electric Heat Box Power Toggle Switch

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Hydraulic Fluid Reservoir Temperature and Liquid Sight Indicator

Figure 24. Hydraulic Fluid Reservoir Temperature and Liquid Sight Indicator. Table 24. Hydraulic Fluid Reservoir Temperature and Liquid Sight Indicator. KEY 1 CONTROL/INDICATOR Hydraulic Fluid Reservoir Temperature and Liquid Sight Indicator Hydraulic Fluid High Level Mark Hydraulic Fluid Low Level Mark FUNCTION Contains a thermometer and both high and low level marks for the hydraulic fluid. Indicates the highest level the hydraulic fluid should reach in the reservoir. Indicates the lowest level the hydraulic fluid should reach in the reservoir.

2 3

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BATTERY DISCONNECT Switch

Figure 25. BATTERY DISCONNECT Switch. Table 25. BATTERY DISCONNECT Switch. KEY 1 CONTROL/INDICATOR BATTERY DISCONNECT Switch FUNCTION When switch is turned counterclockwise to the OFF position, the battery is cut off from the rest of the BMPM and no power will be applied to the BMPM. Power will still be applied to the NATO slave receptacle. . When switch is turned clockwise to the ON position, the battery is connected to the BMPM.

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Screed Crown Gauge

Figure 26. Screed Crown Gauge. Table 26. Screed Crown Gauge. KEY 1 CONTROL/INDICATOR Screed Crown Gauge FUNCTION When the edge of the post (Figure 26, Item 2) is left of center mark on the gauge (Figure 26, Item 1), there is crown applied to the screed. When the edge of the post (Figure 26, Item 2) is centered on the gauge (Figure 26, Item 1), the screed is flat. When the edge of the post (Figure 26, Item 2) is right of center mark on the gauge (Figure 26, Item 1), there is valley applied to the screed.

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Vibration Control Knob

Figure 27. Vibration Control Knob. Table 27. Vibration Control Knob. KEY 1 CONTROL/INDICATOR Vibration Control Knob FUNCTION Turning the vibration control knob counterclockwise decreases the amount of vibration applied to the screed. Turning the vibration control knob clockwise increases the amount of vibration applied to the screed.

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Flight Screw Controls

Figure 28. Flight Screw. Table 28. Flight Screw. KEY 1 2 CONTROL/INDICATOR Locking Tab Flight Screw FUNCTION Used to hold the flight screw in place when adjustments are not being made. Used to manage the depth of paving material being laid. Turning the flight screw clockwise increases the material depth. Turning the flight screw counterclockwise decreases the material depth. 3 Flight Screw Gauge Used as a reference point for adjustments

END OF WORK PACKAGE

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0005

OPERATOR MAINTENANCE BITUMINOUS MATERIAL PAVING MACHINE (BMPM) PREPARATION FOR USE

INITIAL SETUP: Personnel Required 12V (1) References WP 0006 WP 0013 WP 0014 WP 0015 WP 0016 WP 0023 PREPARATION FOR USE PAVING AREA 6 TO 7 FEET WIDE 1. Unpack cutoff shoes and end gates (WP 0023). 2. Install cutoff shoes (WP 0016). 3. Install end gates (WP 0014). 4. Perform Before PMCS (WP 0013). 5. Install sonic auger sensors (if required for mission) (WP 0006). 6. Raise screed fully (WP 0006). 7. Drive BMPM into position (WP 0006). 8. Turn on electric screed heater and allow screed to heat for approximately 15 minutes (WP 0006). 9. Extend screed extension to appropriate width (WP 0006). 10. Place starter blocks under screed and lower screed onto starter blocks. 11. Adjust tow point cylinders to zero (WP 0006). 12. Adjust flight screw to the null position then turn one complete turn counterclockwise (thicker) (WP 0006). 13. Adjust screed crown to appropriate level (WP 0006). 14. Open cutoffs fully (WP 0006). 15. Attach truck to BMPM using truck hitch (WP 0006). 16. Turn on augers/conveyors and select manual or automatic setting (sonic augers are required for automatic setting) (WP 0006). 17. Adjust pile height (for automatic auger/conveyor settings) or auger/conveyor speed (for manual auger/conveyor settings) to appropriate settings (WP 0006). END OF TASK

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0005

PREPARATION FOR USE PAVING AREA 8 TO 16 FEET WIDE 1. Unpack end gates (WP 0023). 2. Install end gates (WP 0014). 3. Perform Before PMCS (WP 0013). 4. Install sonic auger sensors (if required for mission) (WP 0006). 5. Raise screed fully (WP 0006). 6. Drive BMPM into position (WP 0006). 7. Turn on electric screed heater and allow screed to heat for approximately 15 minutes (WP 0006). 8. Extend screed extension to appropriate width (WP 0006). 9. Place starter blocks under screed and lower screed onto starter blocks. 10. Adjust tow point cylinders to zero (WP 0006). 11. Adjust flight screw to the null position then turn one complete turn counterclockwise (thicker) (WP 0006). 12. Adjust screed crown to appropriate level (WP 0006). 13. Open cutoffs fully (WP 0006). 14. Attach truck to BMPM using truck hitch (WP 0006). 15. Turn on augers/conveyors and select manual or automatic setting (sonic augers are required for automatic setting) (WP 0006). 16. Adjust pile height (for automatic auger/conveyor settings) or auger/conveyor speed (for manual auger/conveyor settings) to appropriate settings (WP 0006). END OF TASK

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PREPARATION FOR USE PAVING AREA 17 TO 20 FEET WIDE 1. Unpack bolt-on screed extension kit and end gates (WP 0023). 2. Install bolt-on screed extension kit (WP 0015). 3. Install end gates (WP 0014). 4. Perform Before PMCS (WP 0013). 5. Install sonic auger sensors (if required for mission) (WP 0006). 6. Raise screed fully (WP 0006). 7. Drive BMPM into position (WP 0006). 8. Turn on electric screed heater and allow screed to heat for approximately 15 minutes (WP 0006). 9. Extend screed extension to appropriate width (WP 0006). 10. Place starter blocks under screed and lower screed onto starter blocks. 11. Adjust tow point cylinders to zero (WP 0006). 12. Adjust flight screw to the null position then turn one complete turn counterclockwise (thicker) (WP 0006). 13. Adjust screed crown to appropriate level (WP 0006). 14. Open cutoffs fully (WP 0006). 15. Attach truck to BMPM using truck hitch (WP 0006). 16. Turn on augers/conveyors and select manual or automatic setting (sonic augers are required for automatic setting) (WP 0006). 17. Adjust pile height (for automatic auger/conveyor settings) or auger/conveyor speed (for manual auger/conveyor settings) to appropriate settings (WP 0006). END OF TASK END OF WORK PACKAGE

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OPERATOR MAINTENANCE BITUMINOUS MATERIAL PAVING MACHINE (BMPM) OPERATION UNDER USUAL CONDITIONS

INITIAL SETUP: Tools and Special Tools 15/16 in socket wrench socket (WP 0031, Item 11) 15/16 inch combination wrench (WP 0031, Item 18) Socket wrench handle (WP 0031, Item 5) Personnel Required 12V (1) References FM 4-25.11 FM 21-60 WP 0002 WP 0004 Equipment Conditions Before PMCS completed (WP 0013)

OPERATION UNDER USUAL CONDITIONS

WARNING

Operation and maintenance of the Bituminous Material Paving Machine (BMPM) contains many possibilities for injury or death to personnel. Make sure to be familiar with general first aid procedures as referenced in FM 4-25.11, First Aid. Failure to comply may cause injury or death to personnel. Operating the BMPM exposes personnel to a high noise level. While operating or working within 37 feet (ft) (11 meters (m)) of a running BMPM wear hearing protection. Failure to comply may cause hearing loss. When running, BMPM engine has hot metal surfaces that will burn flesh on contact. Shut down engine and allow sufficient cooling before checks, services, or maintenance. Wear gloves and additional protective clothing as required. Failure to comply may cause injury or death to personnel. Exhaust discharge contains deadly gases, including carbon monoxide. Do not operate BMPM in an enclosed area unless the exhaust discharge is properly vented. Failure to comply may cause injury or death to personnel. Be sure area surrounding BMPM is clear of personnel and objects before moving the unit, opening hopper wings, lowering screed, or deploying screed extensions. Sound unit horn before moving unit from stopped position. Turn on beacon when unit is in motion. Failure to comply may cause injury or death to personnel or damage to equipment.

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0006

OPERATION UNDER USUAL CONDITIONS CONTINUED.

NOTE
Pressing the red EMERGENCY STOP switch on either of the control pedestals will stop all BMPM movement and operations immediately. Prior to operation of BMPM, become familiar with controls and indicators (WP 0004).

STARTING THE ENGINE

Figure 1. Control Pedestal Starting the Engine. 1. Ensure EMERGENCY STOP switch (Figure 1, Item 1) on each control pedestal is off. 2. Ensure the joysticks (Figure 1, Items 4 and 5) on left and right control pedestals are in neutral position. 3. Ensure the run/stop toggle switches (Figure 1, Item 3) on both left and right control pedestals are set to the STOP position. 4. Set BATTERY DISCONNECT switch to ON (WP 0004). 5. Set one (left or right) run/stop toggle switches (Figure 1, Item 3) to the RUN position.

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STARTING THE ENGINE CONTINUED.

WARNING

Do not use ether as a starting aid for the engine. Engine has an intake air pre-heater. Using ether may cause a fire or explosion. Failure to comply may cause injury or death to personnel.

CAUTION
Do not use ether as a starting aid for the engine. Engine has an intake air pre-heater. Using ether may cause a fire or explosion. Failure to comply may cause damage to equipment. 6. Turn keyless engine switch (Figure 1, Item 2) clockwise to the AUX position.

CAUTION
Do not operate starter longer than 10 15 seconds. If the engine does not start, release keyless engine switch to AUX position, and allow starter to cool 2 3 minutes. Failure to comply may cause damage to equipment. 7. Turn keyless engine switch (Figure 1, Item 2) clockwise to the IGN position to engage the starter. 8. Release keyless engine switch (Figure 1, Item 2) back to the AUX position when engine starts.

NOTE
Engine warm up will give the hydraulic oil time to warm, providing for more efficient operation. 9. Allow engine to warm for approximately 10 minutes before moving BMPM. END OF TASK

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STOPPING THE ENGINE

Figure 2. Control Pedestal Stopping the Engine.

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STOPPING THE ENGINE CONTINUED. 1. Ensure the joysticks (Figure 2, Item 1) are in the neutral position. 2. Allow BMPM to come to a complete stop. 3. Ensure the run/stop toggle switches (Figure 2, Item 2) on both left and right control pedestal are switched to the STOP position.

CAUTION
Engine is equipped with a turbocharger. Turbocharger generates heat during operation and must cool prior to shutting the engine off. Failure to comply may cause damage to equipment. 4. Allow engine to idle for approximately 5 minutes to allow turbocharger to cool. 5. Turn keyless engine switch (Figure 2, Item 3) to the OFF position. 6. Set BATTERY DISCONNECT switch to OFF (WP 0004). END OF TASK FOLLOW-ON TASK Perform After PMCS (WP 0013). END OF TASK

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0006

RAISING AND LOWERING SCREED

Figure 3. Raise and Lower Screed.

Figure 4. Control Pedestal Raise and Lower Screed. 0006-6

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0006

RAISING AND LOWERING SCREED CONTINUED.

NOTE
Raising screed using screed raise key will raise the screed and lock screed into position. This is useful for performing maintenance, transporting BMPM while not paving, and loading and unloading from trailer. This is not used to adjust material height while paving, as this does not allow screed to float. Raising screed using screed raise key should not be done to adjust material height. Use the flight screw and/or tow hydraulic cylinder raise and lower keys. 1. Press and hold screed raise key (Figure 4, Item 1) until desired screed height is reached (Figure 3, Item 2), and then release key.

NOTE
When screed lower/float key is pressed, the screed is placed in a float setting. The screed will lower to the ground unless the screed raise key is pressed. The screed should normally be placed in a float setting whenever paving is performed. The screed lower/float key is not used to adjust material height while paving. After moving forward while screed is in the float setting, the BMPM will initiate a hold screed setting whenever the BMPM is not moving forward. This is to ensure the screed does not settle further into material when BMPM is stopped. The screed will resume float when forward motion is resumed.

2. Press screed lower/float key (Figure 4, Item 2) to lower screed to the ground and place screed into float setting (Figure 3, Item 1). END OF TASK

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ADJUSTING AUGER HEIGHT

Figure 5. Auger Raise and Lower.

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ADJUSTING AUGER HEIGHT CONTINUED.

Figure 6. Control Pedestal Auger Height.

CAUTION
When driving BMPM up or down ramp or running over curbs or manholes, always make sure augers are all the way up. Failure to comply may cause damage to equipment.

NOTE
Left and right auger height adjustment is done simultaneously. Independent auger height adjustment is not possible. Normally augers are adjusted all the way down while paving and all the way up for transport or driving over curbs, manholes, or other obstacles. 1. Press and hold auger raise key (Figure 6, Item 1) to raise auger height (Figure 5, Item 2) until desired level is reached, and then release key. 2. Press and hold auger lower key (Figure 6, Item 2) to lower auger height (Figure 5, Item 1) until desired level is reached, and then release key. END OF TASK

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OPERATING HYDRAULIC CUTOFF GATES

Figure 7. Cutoffs Open and Closed.

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OPERATING HYDRAULIC CUTOFF GATES CONTINUED.

Figure 8. Screed Control Cutoff Adjust.

CAUTION
When driving BMPM up or down ramp or running over curbs or manholes, always make sure cutoffs are all the way open (up). Failure to comply may cause damage to equipment. 1. Press and hold the right cutoff open key (Figure 8, Item 1) to increase the material flow through the right cutoff to the screed (Figure 7, Item 2). 2. Press and hold the left cutoff open key (Figure 8, Item 1) to increase the material flow through the left cutoff to the screed (Figure 7, Item 2). 3. Press and hold the right cutoff close key (Figure 8, Item 2) to decrease the material flow through the right cutoff to the screed (Figure 7, Item 1). 4. Press and hold the left cutoff close key (Figure 8, Item 2) to decrease the material flow through the left cutoff to the screed (Figure 7, Item 1). END OF TASK

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EXTENDING SCREED EXTENSION

Figure 9. Screed Extensions.

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EXTENDING SCREED EXTENSION CONTINUED.

Figure 10. Screed Control Screed Extension.

WARNING

Be sure area surrounding BMPM is clear of personnel and objects before moving the unit, opening hopper wings, lowering screed, or deploying screed extensions. Sound unit horn before moving unit from stopped position. Turn on beacon when unit is in motion. Failure to comply may cause injury or death to personnel or damage to equipment. 1. Press and hold desired screed extension in key (Figure 10, Item 2) until desired extension (Figure 9, Item 1) is achieved, and then release key. 2. Press and hold desired screed extension out key (Figure 10, Item 1) until desired extension (Figure 9, Item 2) is achieved, and then release key. END OF TASK

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DRIVING THE BMPM

Figure 11. Control Pedestal Driving the BMPM.

WARNING

Be sure area surrounding BMPM is clear of personnel and objects before moving the unit. Sound unit horn before moving unit from stopped position. Turn on beacon when unit is in motion. Failure to comply may cause injury or death to personnel or damage to equipment.

CAUTION
The high-speed setting on BMPM should only be used when not paving. Never use highspeed setting while paving. Always lock screed using locking pins when driving in high speed setting. Failure to comply may cause damage to equipment. When backing the BMPM with load, maintain at least a one-half throttle setting. Failure to do so may cause improper track tension, resulting in poor performance and damage to equipment. Allow engine to warm for 10 minutes before moving BMPM. Failure to do so may cause poor performance and damage to equipment.

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DRIVING THE BMPM CONTINUED.

NOTE
Illuminated Light Emitting Diode (LED) indicates high-speed setting is selected. The BMPM will only move if one control pedestal is set to the RUN position. If both control pedestals are set to the RUN position, the joysticks will not be active.

1. Fasten seat belt. 2. Turn beacon light on (Figure 11, Item 1). 3. Turn the run/stop toggle switch (Figure 11, Item 3) on the desired (left or right) control pedestal to the RUN position. 4. Select high or low gear using two speed key (Figure 11, Item 6). 5. Set the desired max speed using pavers screen and up and down arrow buttons (Figure 11, Item 2) (WP 0004).

CAUTION
Turns should not be made while the BMPM is attached to a truck using truck hitch arms. Failure to comply may cause damage to equipment. Vehicle can be turned 360 degrees on its axis by moving one track forward and the other track backward (counter rotation). This should never be done with a full load of material or when two-speed setting is set to high. Failure to comply may cause damage to equipment.

NOTE
Turning is done by moving one joystick (left or right) further than the other joystick. This will increase speed of one track, causing the vehicle to veer left or right. 6. Use one hand to move the joysticks (Figure 11, Items 4 and 5) on the active (left or right) control pedestal in the desired direction (forward or reverse) to reach the desired speed. END OF TASK

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INSTALLING SONIC AUGER SENSOR

Figure 12. Sonic Auger Sensor Mount.

NOTE
Sonic auger sensors are used to control conveyor and auger speed when set to automatic. These sensors will need to be installed by the operator before use. The procedure for installation and removal of the sonic auger sensor is the same whether being performed on the left side or right side. Left side shown.

1. Obtain sonic auger sensor from BMPM toolbox. 2. Insert thin end of sonic auger sensor (Figure 12, Item 1) into sonic auger sensor mount (Figure 12, Item 2) on end gate (Figure 12, Item 7). 3. Ensure corded side of sonic auger sensor (Figure 12, Item 1) is facing front (toward the hopper). 4. Tighten wing screw (Figure 12, Item 3) to secure sonic auger sensor (Figure 12, Item 1) into sonic auger sensor mount (Figure 12, Item 2). 5. Remove cap (Figure 12, Item 5) from socket (Figure 12, Item 6) on BMPM. 6. Remove cap (Figure 12, Item 7) from sonic auger connector (Figure 12, Item 4) on sonic auger sensor. 7. Install sonic auger connector (Figure 12, Item 4) into socket (Figure 12, Item 6). END OF TASK 0006-16

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0006

REMOVING SONIC AUGER SENSOR 1. Remove sonic auger connector (Figure 12, Item 4) from socket (Figure 12, Item 6). 2. Install cap (Figure 12, Item 7) onto sonic auger connector (Figure 12, Item 4) on sonic auger sensor. 3. Install cap (Figure 12, Item 5) onto socket (Figure 12, Item 6) on BMPM. 4. Loosen wing screw (Figure 12, Item 3), and remove sonic auger sensor (Figure 12, Item 1) from sonic auger sensor mount (Figure 12, Item 2). 5. Store sonic auger sensor in BMPM toolbox (WP 0002). END OF TASK

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USING SCREED ELECTRIC HEAT BOX

Figure 13. Screed Electric Heat Box.

WARNING

Do not touch the screed wear plate when the screed electric heat box is on. Contact with the screed wear plate when screed electric heat box is on can cause burns and scalding. Paving material and screed wear plate temperatures can exceed 400F (204C). When screed electric heat box is on and/or working with material, the BMPM has hot metal surfaces that can burn flesh on contact. Failure to comply may cause injury or death to personnel.

NOTE
The screeds electric heat box is used to raise the temperature of the screed to approximately 300F (149C). This will help to ensure smooth texture of the material. Moving screed electric heat box power toggle switch to the on (up) position will not apply heat to the screed. This only enables use of the start heat button.

1. Start BMPM engine (perform Starting the Engine task). 2. Raise screed fully (WP 0006). 3. Move screed electric heat box power toggle switch (Figure 13, Item 3) to the on (up) position. Engine speed will automatically rise to 1500 revolutions per minute (rpm). 0006-18

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USING SCREED ELECTRIC HEAT BOX CONTINUED.

NOTE
The screeds electric heat box will apply heat for approximately 25 minutes after the start heat button is pressed. During normal operation, the temperature of the material will keep the screed at a sufficiently high temperature. If more heating is necessary, the start heat button (Figure 13, Item 2) can be pressed again to start another 25-minute cycle. The screed electric heat box on indicator will illuminate when the screed is actively being heated.

4. Press start heat button (Figure 13, Item 2), verify screed electric heat box on indicator (Figure 13, Item 1) is illuminated, and allow screed to heat for approximately 15 minutes. 5. Move screed electric heat box power toggle switch (Figure 13, Item 3) to the off (down) position when done using screed electric heat box. END OF TASK

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ATTACHING TO TRUCK USING TRUCK HITCH ATTACHMENT

Figure 14. Truck Hitch Attachment.

WARNING

Always use a ground guide when attaching BMPM to truck using truck hitch arms (FM 21-60). Failure to comply may cause injury or death to personnel or damage to equipment. Drive with extreme caution, at low speed. Be sure area surrounding BMPM is clear of personnel and objects before moving the unit or extending truck hitch arms. Sound unit horn before moving unit from stopped position. Turn on beacon when unit is in motion. Failure to comply may cause injury or death to personnel or damage to equipment.

NOTE
The truck hitch attachment is used to attach dump truck to BMPM. This allows for consistent contact between truck and BMPM without manual braking of truck, ensuring smooth forward motion of BMPM and reduced material spillage between truck and BMPM hopper. 1. Extend the truck hitch arms (Figure 14, Item 2) by pressing and holding the truck hitch out key (Figure 15, Item 1) until truck hitch arms (Figure 14, Item 2) are fully extended. 2. Ensure rear tires of the truck make even contact with rollers on BMPM hitch rollers.(Figure 14, Item 1). 3. Retract the truck hitch arm (Figure 14, Item 2) by pressing and holding the truck hitch in key (Figure 15, Item 2) until both guide rollers are fully locked into truck wheel rims (Figure 14, Item 3). END OF TASK

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DISENGAGING BMPM FROM TRUCK USING TRUCK HITCH ATTACHMENT

Figure 15. Control Pedestal Truck Hitch.

WARNING

Always use a ground guide when attaching BMPM to truck using truck hitch arms (FM 21-60). Failure to comply may cause injury or death to personnel or damage to equipment. Drive with extreme caution, at low speed. Be sure area surrounding BMPM is clear of personnel and objects before moving the unit or extending truck hitch arms. Sound unit horn before moving unit from stopped position. Turn on beacon when unit is in motion. Failure to comply may cause injury or death to personnel or damage to equipment.

Extend the truck hitch arms (Figure 14, Item 2) by pressing and holding the truck hitch out key (Figure 15, Item 1) until hitch arms (Figure 14, Item 2) are fully extended. END OF TASK

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OPERATING HOPPER

Figure 16. Hopper Wings.

Figure 17. Control Pedestal Hopper.

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OPERATING HOPPER CONTINUED.

CAUTION
Before opening the hopper wings, ensure ratchet straps have been removed and hopper wings have clearance available, as they will extend further than the body of the BMPM when fully opened. Failure to comply may cause damage to equipment.

NOTE
Opening hopper wings will allow room for dump truck to transfer material from truck bed to BMPM. Closing hopper wings allows for more clearance of BMPM while not paving. Closing hopper wings while paving (provided there is room for hopper wing movement) will bring material from outer edges of hopper to the center of hopper where the conveyors can bring material back to the augers. 1. Start BMPM engine (perform Starting the Engine task). 2. Press and hold hopper out (open) key (Figure 17, Item 1) to open hopper wings to desired position (Figure 16, Item 1), and then release hopper out (open) key to hold hopper position.

CAUTION
Always ensure nothing will impede the movement of the hopper wings. Do not close hopper wings while BMPM is attached or too close to dump truck. Failure to comply may cause damage to equipment. 3. Press and hold hopper in (close) key (Figure 17, Item 2) to close hopper wings to desired position (Figure 16, Item 2), and release hopper in (close) key to hold hopper position. END OF TASK

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ADJUST PILE HEIGHT USING AUTOMATIC AUGER/CONVEYOR SETTING (REQUIRES SONIC AUGER SENSORS)

Figure 18. Screed Control Automatic Pile Height.

NOTE
Sonic auger sensors must be installed for automatic pile height function to operate. 1. Press and release desired (left or right) auger/conveyor ON/OFF key (Figure 18, Item 1) until LED indicates ON is selected. Engine speed will automatically raise to 1500 rpm. 2. Press and release desired (left or right) auger/conveyor auto/man key (Figure 18, Item 2) until LED indicates automatic is selected. 3. Press and hold desired (left or right) material height auger/conveyor speed plus (+) key (Figure 18, Item 3) to increase pile height to desired level, and then release key. 4. Press and hold desired (left or right) material height auger/conveyor speed minus (-) key (Figure 18, Item 4) to reduce pile height to desired level, and then release key. 5. Press and release desired (left or right) auger/conveyor ON/OFF key (Figure 18, Item 1) until LED indicates OFF is selected to turn off augers and conveyors. END OF TASK

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ADJUST MATERIAL THICKNESS USING FLIGHT SCREW

Figure 19. Flight Screw.

NOTE
This procedure can be done starting with either the left or the right side of the screed. It is recommended that only one-half turn of flight screw per 10 ft of paving is performed while actively paving to allow screed to settle into adjustment. The amount of flight screw adjustment needed to achieve a sufficient change in material depth will vary with terrain, material temperature, material thickness, and speed of BMPM. The screed angle gauge is used as a reference point only. This number does not directly reflect a measurement of material depth.

1. Unlock (Figure 19, Item 5) flight screw locking tab (Figure 19, Item 1). 2. Turn flight screw using flight screw handle (Figure 19, Item 2) until desired material thickness is reached. 3. Lock (Figure 19, Item 4) flight screw locking tab (Figure 19, Item 1). 4. Note screed angle gauge (Figure 19, Item 3), and adjust opposite side of screed to the same angle by repeating steps 1 3. END OF TASK

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ADJUST AUGER/CONVEYOR SPEED USING MANUAL AUGER/CONVEYOR SETTING

Figure 20. Screed Control Manual Pile Height. 1. Press and release desired (left or right) auger/conveyor ON/OFF key (Figure 20, Item 1) until LED indicates ON is selected. Engine speed will automatically raise to 1500 rpm. 2. Press and release desired (left or right) auger/conveyor auto/man key (Figure 20, Item 2) until Light Emitting Diode (LED) indicates manual is selected. 3. Press and hold desired (left or right) material height auger/conveyor speed minus (-) key (Figure 20, Item 4) to slow the speed of the auger and conveyor until desired speed is reached, and then release key. 4. Press and hold desired (left or right) material height auger/conveyor speed plus (+) key (Figure 20, Item 3) to increase the speed of the auger and conveyor until desired speed is reached, and then release key. 5. Press and release desired (left or right) auger/conveyor ON/OFF key (Figure 20, Item 1) until LED indicates OFF is selected to turn off augers and conveyors. END OF TASK

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ADJUST CONVEYOR SPEED INDEPENDENT OF AUGER SPEED

Figure 21. Screed Control Conveyor Speed.

NOTE
Auger/conveyor function must be on before attempting to adjust conveyor speed. 1. Press and hold desired (left or right) conveyor speed down key (Figure 21, Item 2) to slow the speed of conveyor until desired speed is reached, and then release key. 2. Press and hold desired (left or right) conveyor speed up key (Figure 21, Item 1) to increase the speed of conveyor until desired speed is reached, and then release key. END OF TASK

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MATERIAL THICKNESS ADJUSTMENT USING TOW POINT HYDRAULIC CYLINDER/MANUAL GRADE CONTROL

Figure 22. Screed Control Tow Point Hydraulic Cylinder.

NOTE
It is recommended that the operator continues paving for 10 ft after performing adjustment to allow screed to settle into adjustment. 1. Press and hold desired (left or right) tow point hydraulic cylinder UP or DOWN key (Figure 22, Items 1 and 2) to reach desired material height, and then release key.

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MATERIAL THICKNESS ADJUSTMENT USING TOW POINT HYDRAULIC CYLINDER/MANUAL GRADE CONTROL CONTINUED.

Figure 23. Tow Point Hydraulic Cylinder Gauge. 2. Refer to tow point hydraulic cylinder gauge (Figure 23, Item 1) to adjust opposite side tow point hydraulic cylinder to the same level by repeating step 1. END OF TASK

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ADJUST SCREED EXTENSION HEIGHT

Figure 24. Vertical Adjustment Screws.

NOTE
Turning outer screed extension vertical adjustment screw clockwise will raise screed extension. Turning outer screed extension vertical adjustment screw counterclockwise will lower screed extension. 1. Turn outer screed extension vertical adjustment screw (Figure 24, Item 2) on desired screed extension (left or right) to reach desired height, taking note of direction of turn and how many turns of screw are being made. 2. Turn the inner screed extension vertical adjustment screw (Figure 24, Item 1) on the same screed extension in the same direction and the same number of turns as the outer screed extension vertical adjustment screw (Figure 24, Item 2) was turned. END OF TASK

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ADJUST SCREED EXTENSION ATTACK ANGLE

Figure 25. Attack Angle Adjustment Screw.

NOTE
Turning screed extension attack angle screw counterclockwise will increase angle of screed extension. Turning screed extension attack angle screw clockwise will decrease angle of screed extension. Turn the screed extension attack angle screw (Figure 25, Item 1) on desired screed extension (left or right) to reach desired angle. END OF TASK

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ADJUST SCREED EXTENSION SLOPE

Figure 26. Screed Extension Slope.

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ADJUST SCREED EXTENSION SLOPE CONTINUED.

Figure 27. Screed Control Slope Adjust. 1. Press and hold desired (left or right) screed extension slope down key (Figure 27, Item 2) to lower outer edge of screed extension until desired extension slope is achieved (Figure 26, Item 1), and then release key. 2. Press and hold desired (left or right) screed extension slope up key (Figure 27, Item 1) to raise outer edge of screed extension back toward level (Figure 26, Item 2), and then release key. END OF TASK

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ADJUST SCREED END GATES

Figure 28. End Gate. 1. Use end gate height gauge (Figure 28, Item 3) to identify current level. 2. Release locking tab (Figure 28, Item 2).

NOTE
Turning end gate depth screw clockwise lowers end gate, and turning end gate depth screw counterclockwise raises end gate. 3. Turn end gate depth screw (Figure 28, Item 1) to set end gate to desired depth. 4. Secure end gate depth screw (Figure 28, Item 1) with locking tab (Figure 28, Item 2). 5. Turn end gate tilt control bolt (Figure 28, Item 4) to set end gate to desired tilt. END OF TASK

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ADJUST SCREED CROWN AND VALLEY

Figure 29. Material Crown and Valley.

NOTE
This adjustment is used to set the desired crown or valley of material being laid (Figure 29). This adjustment will bend the screed to achieve desired crown or valley.

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ADJUST SCREED CROWN AND VALLEY CONTINUED.

Figure 30. Screed Crown Top Bar Bolts. 1. Loosen two screed crown top bar bolts (Figure 30, Item 1) on right side of screed finger-tight to allow screed top bar to slide while adjusting crown.

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0006

ADJUST SCREED CROWN AND VALLEY CONTINUED.

Figure 31. Screed Control Crown Adjust.

0006-37

TM 5-3895-385-10

0006

ADJUST SCREED CROWN AND VALLEY CONTINUED.

Figure 32. Screed Crown Gauge. 2. Press and hold crown up key (Figure 31, Item 1) to raise screed crown until desired level is reached (refer to screed crown adjustment gauge (Figure 32, Item 1)), and then release key. 3. Press and hold crown down (valley) key (Figure 31, Item 2) to lower screed crown until desired level is reached (refer to screed crown adjustment gauge (Figure 32, Item 1)), and then release key. 4. Tighten two screed crown top bar bolts (Figure 30, Item 1) on right side of screed. END OF TASK

0006-38

TM 5-3895-385-10

0006

ADJUST SEAT SLIDE ASSEMBLY

Figure 33. Seat Slide Assembly.

NOTE
The operator can extend the seat slide assembly to better view the paving area. Seat slide assembly will not lock in the out position as it does when pushed completely in.

1. Grasp the seat slide assembly handle (Figure 33, Item 2), and pull firmly to extend seat slide assembly (Figure 33, Item 1). 2. Push seat slide assembly handle (Figure 33, Item 2) firmly to retract seat slide assembly (Figure 33, Item 1).

0006-39

TM 5-3895-385-10

0006

Figure 34. Seat Slide Assembly. 3. Push the seat adjustment handle (Figure 34, Item 2) in, slide seat (Figure 34, Item 1) forward or backward, and then release seat adjustment handle. END OF TASK

0006-40

TM 5-3895-385-10

0006

SCREED LOCKING PIN

Figure 35. Screed Locking Pin. 1. Raise screed fully (perform step 1 of Raising and Lowering Screed task). 2. Loosen wing screw (Figure 35, Item 4). 3. Slide screed locking pin (Figure 35, Item 2) out from housing (Figure 35, Item 1) to lock screed up (Figure 35, Item 3), or slide screed locking pin in to release screed. 4. Tighten wing screw (Figure 35, Item 4). END OF TASK

0006-41

TM 5-3895-385-10

0006

SPRAYDOWN PROCEDURES

Figure 36. Control Pedestal Spraydown.

WARNING

Cleaner solution is toxic to eyes, skin, and respiratory tract. Skin and eye protection are required when working in contact with cleaner solution. Avoid repeated or prolonged contact. Provide adequate ventilation. Operators are to wash exposed skin and change soaked clothing promptly if exposed to cleaner solution. Failure to comply may cause injury or death to personnel.

NOTE
Hopper wings should be empty and all excess paving material should be manually removed from the BMPM before performing spraydown procedure. The spraydown key LED will be illuminated when spraydown pump is on.

1. Turn keyless engine switch to the AUX position (WP 0004). 2. Press the spraydown key (Figure 36, Item 1) to turn on spraydown. 3. Remove wand handle (Figure 37, Item 1) from storage bracket (Figure 37, Item 4). 4. Unroll the amount of spraydown hose (Figure 37, Item 3) needed from hose reel (Figure 37, Item 2).

0006-42

TM 5-3895-385-10

0006

SPRAYDOWN PROCEDURES CONTINUED.

Figure 37. Spraydown Hose.

WARNING

Screed electric heat box must be completely shut down prior to spraydown. Fire is possible if screed electric heat box is running during washing operations. Failure to comply may cause injury or death to personnel and damage to equipment.

NOTE
The spraydown hose is used to thoroughly spray a light coat of cleaner solution on any component of the BMPM that comes in contact with material before operation and at the end of the days operation. Cleaner solution keeps material from hardening on BMPM. Use enough cleaner solution to dissolve hardened paving material. This is not used as a pressure washer to clean material from BMPM. 5. Squeeze the wand handle (Figure 37, Item 1) to spray all areas that come in contact with paving material with a light coat of cleaner solution, paying close attention to conveyor chains (Figure 38, Item 3), idler pulleys (Figure 38, Item 1), hopper wings (Figure 38, Item 2), augers (Figure 38, Item 8), cutoffs (Figure 38, Item 7), screed (Figure 38, Item 6), screed extensions (Figure 38, Item 5), and end gates (Figure 38, Item 4), and release wand handle when done spraying.

0006-43

TM 5-3895-385-10

0006

SPRAYDOWN PROCEDURES CONTINUED.

Figure 38. Spraydown Areas.

0006-44

TM 5-3895-385-10

0006

SPRAYDOWN PROCEDURES CONTINUED. 6. Turn on BMPM engine (perform Starting the Engine task). 7. Turn on augers and conveyors (perform steps 1 and 3 of Adjust Auger/Conveyor Speed Using Manual Speed Auger/Conveyor Setting).

WARNING

There are m any points o n the BMPM whe re personnel could b e injured by moving pa rts. Care should be ta ken to avoid any pinch p oints when performing spraydown pro cedure. Failure to comply may cause injury or death to personnel.

CAUTION
Do not allow spraydown wand to touch any movi ng parts of the BMPM. Failure to compl y will result in damage to equipment. 8. Squeeze the wand handle (Figure 37, Item 1) to spray conveyor chains (Figure 38, Item 3), idler pulleys (Figure 38, Item 1), and augers (Figure 38, Item 8), and release wand handle when done spraying. 9. Turn off augers and conveyors (perform steps 1 and 3 of Adjust Auger/Conveyor Speed Using Manual Speed Auger/Conveyor Setting). 10. Press the spraydown key (Figure 36, Item 1) to turn off spraydown pump. 11. Turn keyless engine switch to the OFF position (WP 0004). 12. Retract spraydown hose (Figure 37, Item 3) using hose reel (Figure 37, Item 2). 13. Return wand handle (Figure 37, Item 1) to storage bracket (Figure 37, Item 4). END OF TASK END OF WORK PACKAGE

0006-45/46 blank

TM 5-3895-385-10

0007

OPERATOR MAINTENANCE BITUMINOUS MATERIAL PAVING MACHINE (BMPM) OPERATION UNDER UNUSUAL CONDITIONS

INITIAL SETUP: Materials/Parts Wiping rag (WP 0033, Item 15) Personnel Required 12V (1) References FM 3.11.5 LO 5-3895-385-13 UNUSUAL ENVIRONMENT/WEATHER Operation in Extreme Heat (Above 120 degrees Fahrenheit (F) (49 degrees Celsius (C))) References Continued WP 0004 WP 0013 WP 0021

WARNING

Exposed skin can burn on metal in extreme hot weather. Avoid contacting metal items with bare skin in extreme hot weather. Failure to comply may cause injury or death to personnel. 1. Remove any obstructions from Bituminous Material Paving Machine (BMPM) ventilation openings (WP 0013). 2. Check water temperature gauge on engine screen frequently for any indication of overheating (WP 0004). END OF TASK Operation in Dusty or Sandy Areas

CAUTION
Do not allow sand or dust to contaminate any fluids on the BMPM. Failure to comply may cause damage to equipment. 1. Do not fill fluids in dusty or sandy areas. 2. Perform daily lubrication tasks before beginning each work day (LO 5-3895-385-13). 3. Clean exterior BMPM surfaces prior to operation with a damp wiping rag while unit is completely shut down paying close attention to grease fittings, hydraulic cylinders, flight screws, seat assembly slides, fuel fill cap, cleaner fill cap, and any moving parts where dust and sand could collect. 4. Service air cleaner assembly (WP 0021) daily to compensate for intake of additional dust or sand. END OF TASK

0007-1

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0007

INTERIM CHEMICAL, BIOLOGICAL, RADIOLOGICAL, AND NUCLEAR (CBRN) DECONTAMINATION PROCEDURES Operation in Contaminated Areas The BMPM is capable of being operated by personnel wearing CBRN protective clothing without special tools or supporting equipment. Refer to FM 3.11.5, CBRNE Decontamination for information on decontamination procedures. END OF TASK END OF WORK PACKAGE

0007-2

TM 5-3895-385-10

0008

OPERATOR MAINTENANCE BITUMINOUS MATERIAL PAVING MACHINE (BMPM) EMERGENCY PROCEDURES

INITIAL SETUP: Tools and Special Tools 7/16 inch combination wrench (WP 0031, Item 14) Materials/Parts NATO slave cable Fully-charged 24-VDC system Personnel Required 12V (1) NORTH ATLANTIC TREATY ORGANIZATION (NATO) SLAVE RECEPTACLE START OPERATION References WP 0006 WP 0013

WARNING

NATO slave receptacle is electrically live at all times and is not protected by a fuse. Turning BATTERY DISCONNECT switch to the OFF position does not ensure the circuit is dead. This circuit is only dead when the batteries are fully disconnected. Disconnect both batteries before performing maintenance on the NATO slave receptacle. Failure to comply may cause injury or death to personnel. Ensure batteries are properly connected before attempting to use the NATO slave receptacle. Damage to batteries and cable or serious injury to personnel may result if slave starting the Bituminous Material Paving Machine (BMPM) with improperly connected batteries. Failure to comply may cause injury or death to personnel.

0008-1

TM 5-3895-385-10

0008

NORTH ATLANTIC TREATY ORGANIZATION (NATO) SLAVE RECEPTACLE START OPERATION CONTINUED.

Figure 1. NATO Slave Receptacle.

0008-2

TM 5-3895-385-10

0008

NORTH ATLANTIC TREATY ORGANIZATION (NATO) SLAVE RECEPTACLE START OPERATION CONTINUED. 1. Open engine cover (Figure 1, Item 2). 2. Ensure battery cables (Figure 1, Item 1) are properly connected to battery terminals. Notify field maintenance if not connected properly. 3. Close engine cover (Figure 1, Item 2). 4. Ensure 24-Volts Direct Current (VDC) power source system is fully charged. 5. Remove protective cover (Figure 1, Item 4) from NATO slave receptacle (Figure 1, Item 3). 6. Connect one end of NATO slave cable to fully-charged 24-VDC system and other end to BMPM NATO slave receptacle (Figure 1, Item 3).

NOTE
The NATO slave receptacle can be used to start BMPM set when batteries are discharged. 7. Start fully-charged 24-VDC system. 8. Start BMPM (WP 0006). 9. Remove NATO slave cable after BMPM engine starts. 10. Install protective cover (Figure 1, Item 4) onto NATO slave receptacle (Figure 1, Item 3). END OF TASK

0008-3

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0008

EMERGENCY STOPPING

Figure 2. EMERGENCY STOP Switch. 1. Push EMERGENCY STOP switch (Figure 2, Item 1) in the event of an urgent need to stop the BMPM instantly. 2. Twist EMERGENCY STOP switch (Figure 2, Item 1) clockwise to release the EMERGENCY STOP switch and enable BMPM functions.

0008-4

TM 5-3895-385-10

0008

OFFLOADING RESIDUAL PAVING MATERIAL

NOTE
In an emergency situation in which a fully-loaded hopper must be emptied immediately, use the following procedures to empty all paving material from the hopper. 1. Retract screed extensions fully (WP 0006). 2. Raise screed fully (WP 0006). 3. Drive BMPM forward (WP 0006). 4. Adjust auger/conveyor settings to maximum pile height (WP 0006). 5. Close hopper wings fully (WP 0006). 6. Continue to drive BMPM forward until hopper is empty. 7. Stop BMPM (WP 0006). 8. Perform all PMCS After procedures (WP 0013). END OF TASK

0008-5

TM 5-3895-385-10

0008

PRIMING FUEL

NOTE
The procedure may be necessary if the BMPM has been allowed to run out of fuel then refilled.

Figure 3. Fuel Priming. 1. Push fuel primer (Figure 3, Item 1), and turn counterclockwise to release fuel primer lock. 2. Pump fuel primer (Figure 3, Item 1) until fuel is primed. 3. Push fuel primer (Figure 3, Item 1) and turn clockwise to lock fuel primer. END OF TASK

0008-6

TM 5-3895-385-10

0008

ENGAGING TRACK BRAKE OVERRIDE

Figure 4. Track Brake Override.

NOTE
This procedure will allow the BMPM to be towed by releasing the brakes internal to the track drive torque hubs. Do not tow the BMPM, this is used only to load onto recovery vehicle. The procedure is the same for both the left and right side. Left side shown. The procedure must be performed on both sides for towing to be possible.

1. Remove two bolts (Figure 4, Item1) and the brake override bracket (Figure 4, Item 2) from torque hub (Figure 4, Item 3). 2. Install two bolts (Figure 4, Item1) and the brake override bracket (Figure 4, Item 2) into the torque hub (Figure 4, Item 3) with the indented portion of the brake override bracket facing toward the torque hub. END OF TASK

0008-7

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0008

DISENGAGING TRACK BRAKE OVERRIDE

NOTE
The procedure will return the BMPM to normal operation. The procedure is the same for both the left and right side. Left side shown.

1. Remove two bolts (Figure 4, Item1) and the brake override bracket (Figure 4, Item 2) from torque hub (Figure 4, Item 3). 2. Install two bolts (Figure 4, Item1) and the brake override bracket (Figure 4, Item 2) into the torque hub (Figure 4, Item 3) with the indented portion of the brake override bracket facing away the torque hub. END OF TASK FUSE REPLACEMENT

Figure 5. Fuse Location.

0008-8

TM 5-3895-385-10

0008

FUSE REPLACEMENT CONTINUED. Table 1. Fuse Amperage Rating. Fuse Amperage 20 20 20 20 5 20 20 5 20 5 5 5 20 20 20 20 Generator System 5 Sonic Augers Heat Box Right Display Screed Controller Screed Output Module Left Display Propel Controller Screed Keypads Left Key Pads Right Key Pads Horn Light Beacon Spraydown Pump Fuse Name

WARNING

Ensure BATTERY DISCONNECT switch is in the O FF position before opening fuse box. Failure to comply may cause injury or death to personnel. 1. Locate and remove fuse to be checked (Figure 5) and identify amperage rating (Table 1).

0008-9

TM 5-3895-385-10

0008

FUSE REPLACEMENT CONTINUED.

Figure 6. Fuse. 2. Inspect fuse for blown state (Figure 6, Item 1).

CAUTION
Replace fuses with same type and amperage rating. Failure to comply may cause damage to equipment. 3. Install new fuse if blown (Figure 6, Item 1) or install existing fuse if found to be good (Figure 6, Item 2). END OF TASK END OF WORK PACKAGE

0008-10

TM 5-3895-385-10

0009

OPERATOR MAINTENANCE BITUMINOUS MATERIAL PAVING MACHINE (BMPM) STOWAGE AND DATA PLATE/DECAL LOCATION INTRODUCTION Identification and instruction plates are mounted on the Bituminous Material Paving Machine (BMPM). Figure 1 through Figure 14 show the location and contents of each plate on the BMPM as well as other stamps and markings.

0009-1

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0009

Figure 1. Data and Instruction Plates, Right Side. Table 1. Data and Instruction Plates, Right Side. ITEM NUMBER 1 2 3 NAME Warranty Data Plate Hearing Protection Required Plate Lubrication Points

0009-2

TM 5-3895-385-10

0009

Figure 2. Data and Instruction Plates, Left Side. Table 2. Data and Instruction Plates, Left Side. ITEM NUMBER 1 2 3 4 5 NAME Screed Electric Plate BMPM Serial Number Plate North Atlantic Treaty Organization (NATO) Slave Plate Lift and Tie Down Shipping Data Plate Military Load Class Plate

0009-3

TM 5-3895-385-10

0009

Figure 3. IUID Plates, Left Side. Table 3. IUID Plates, Left Side. ITEM NUMBER 1 2 NAME Screed Item Unique Identification Device (IUID) Track IUID

0009-4

TM 5-3895-385-10

0009

Figure 4. IUID Plates, Bottom Side.

NOTE
Each torque hub has an IUID. Location point i s the same for each side. Left side l ocation shown. Each hydraulic drive motor has an IUID. Location point is the same for each side. Right side location shown. Table 4. IUID Plates, Bottom Side. ITEM NUMBER 1 2 3 4 5 NAME Conveyor Assembly IUID Torque Hub IUID, Left Side Torque Hub IUID, Right Side Hydraulic Drive Motor IUID, Right Side Hydraulic Drive Motor IUID, Left Side

0009-5

TM 5-3895-385-10

0009

Figure 5. IUID Plates, Engine. Table 5. IUID Plates, Engine. ITEM NUMBER 1 2 3 NAME Engine IUID Propulsion Pump IUID Variable Auger, Conveyor Pump IUID

0009-6

TM 5-3895-385-10

0009

Figure 6. Lift and Tie Down Decals. Table 6. Lift and Tie Down Decals. ITEM NUMBER 1 2 3 Screed Only Lift Points Lifting Points Tie Down Points NAME

0009-7

TM 5-3895-385-10

0009

Figure 7. Screed Extension Decals. Table 7. Screed Extension Decals. ITEM NUMBER 1 2 3 4 NAME Sonic Auger Caution Vertical Adjustment Indicator Attack Angle Indicator Pinch Point

0009-8

TM 5-3895-385-10

0009

Figure 8. Measurement Decals. Table 8. Measurement Decals. ITEM NUMBER 1 2 3 4 5 6 7 NAME Tow Point Measurement Lift Stick Measurement Screed Slope Measurement Screed Crown Measurement Flight Screw Measurement Screed Extension Measurement End Gate Measurement

0009-9

TM 5-3895-385-10

0009

Figure 9. Screed Decals. Table 9. Screed Decals. ITEM NUMBER 1 2 3 4 5 6 7 8 Pinch Point Top Bar Bolts Screed Electric Heater Vibrator Step Warning Flight Screw Thicker Flight Screw Thinner Toolbox NAME

0009-10

TM 5-3895-385-10

0009

Figure 10. Operator Platform Decals, Left Side. Table 10. Operator Platform Decals, Left Side. ITEM NUMBER 1 2 3 4 5 6 Left Pedestal Top Right Pedestal Top Entanglement Hazard Fuse Box Grease Daily Hydraulic Oil Warning NAME

0009-11

TM 5-3895-385-10

0009

Figure 11. Operator Platform Decals, Right Side. Table 11. Operator Platform Decals, Right Side. ITEM NUMBER 1 2 3 4 5 6 7 8 Electric Generator Battery Engine Oil Drain Grease Daily Battery Disconnect Fuel Warning Cleaning Agent Keyless Engine Switch 0009-12 NAME

TM 5-3895-385-10

0009

Figure 12. Bolt-On Screed Extensions. Table 12. Bolt-On Screed Extensions. ITEM NUMBER 1 2 3 Vertical Adjustment Lift Warning Rougher Smoother NAME

0009-13

TM 5-3895-385-10

0009

Figure 13. Auger Extensions Labels.

0009-14

TM 5-3895-385-10

0009

Figure 14. Retaining Plates Stamps.

Figure 15. Cutoff Shoes Stamps. END OF WORK PACKAGE 0009-15/16 blank

TM 5-3895-385-10

CHAPTER 3
TROUBLESHOOTING PROCEDURES FOR BITUMINOUS MATERIAL PAVING MACHINE (BMPM)

TM 5-3895-385-10

0010

OPERATOR MAINTENANCE BITUMINOUS MATERIAL PAVING MACHINE (BMPM) TROUBLESHOOTING INDEX GENERAL TROUBLESHOOTING INFORMATION The operator troubleshooting procedures Work Package (WP) is designed to give general instruction for resolving the most common problems associated with the Bituminous Materials Paving Machine (BMPM). Troubleshooting procedures list the symptoms, malfunctions, and corrective actions required to correct BMPM problems and system faults and warnings. Perform all steps in the order they appear in the WP. Troubleshooting procedures are listed according to symptom, followed by the malfunction, and then any corrective action(s). All necessary references to procedures/instructions can be found within the troubleshooting WP (WP 0011).
Do not begin a task until you understand the task.

MALFUNCTION/SYMPTOM INDEX The malfunction/symptom index is a quick reference for locating troubleshooting procedures. Troubleshooting procedures are arranged based upon probability of occurrence and sequence in which it was encountered. Indications from Manual Troubleshooting Techniques Field maintenance is responsible for performing manual troubleshooting techniques, including continuity tests and voltage checks, maintenance actions that require the use of tools, and activities other than routine operator adjustments. After Corrective Action After the corrective action is completed, the equipment must be tested to verify that a fault or warning has been corrected. Locate the malfunction in the troubleshooting procedures and perform the test or inspection. If the correct response is not obtained, ensure that the corrective action was properly performed and then proceed to the next malfunction. Proceed to next malfunction is stated when the operator is to proceed to the malfunction immediately following the one they are currently troubleshooting. When proceed to malfunction is stated with a numerical value, the operator is to skip over any malfunctions between the one they are currently troubleshooting and the one they have been instructed to proceed to. Specific Troubleshooting Procedures This Technical Manual (TM) cannot list all malfunctions that may occur or all tests or inspections and corrective actions. If a malfunction is not listed or is not corrected by the listed corrective action, notify Field Maintenance.

0010-1

TM 5-3895-385-10

0010

Malfunction/Symptom 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36.

(WP/Page No.)

Screed fails to raise or lower......................................................................................................... WP 0011-1 Left screed extension fails to extend or retract ....................................................................................0011-2 Right screed extension fails to extend or retract..................................................................................0011-3 Left screed extension fails to lower or raise slope ...............................................................................0011-4 Right screed extension fails to lower or raise slope.............................................................................0011-5 Vibrator function fails to operate ..........................................................................................................0011-6 Screed crown fails to operate. .............................................................................................................0011-7 Left tow hydraulic cylinder fails to raise or lower. ................................................................................0011-8 Right tow hydraulic cylinder fails to raise or lower ...............................................................................0011-9 Electric screed heat box malfunction. ................................................................................................0011-10 Hopper wings fail to open or close.....................................................................................................0011-10 Display fails to show engine screen...................................................................................................0011-11 Reverse Alarm fault indicated on fault screen ...................................................................................0011-12 Horn fails to sound. ............................................................................................................................0011-12 EMERGENCY STOP switch fails to shut down BMPM. ....................................................................0011-12 Work lights fail to operate...................................................................................................................0011-13 Beacon light fails to operate...............................................................................................................0011-13 Spraydown fails to operate. ...............................................................................................................0011-14 Left Console Beacon Key Pad fault indicated on fault screen ...........................................................0011-14 Left Console Horn Key Pad fault indicated on fault screen ...............................................................0011-15 Left Console Lights Key Pad fault indicated on fault screen..............................................................0011-15 Right Console Beacon Key Pad fault indicated on fault screen.........................................................0011-15 Right Console Horn Key Pad fault indicated on fault screen .............................................................0011-15 Right Console Lights Key Pad fault indicated on fault screen ...........................................................0011-15 Left Screed Aug/Conv Key Pad fault indicated on fault screen .........................................................0011-15 Right Screed Aug/Conv Key Pad fault indicated on fault screen.......................................................0011-15 Right Console Left Joy fault indicated on fault screen.......................................................................0011-16 Right Console Right Joy fault indicated on fault screen ....................................................................0011-16 Right Console Left Joy Cal fault indicated on fault screen ................................................................0011-16 Right Console Right Joy Cal fault indicated on fault screen ..............................................................0011-16 Left Console Left Joy fault indicated on fault screen .........................................................................0011-16 Left Console Right Joy fault indicated on fault screen.......................................................................0011-16 Left Console Left Joy Cal fault indicated on fault screen...................................................................0011-17 Left Console Right Joy Cal fault indicated on fault screen ................................................................0011-17 High hydraulic oil temperature indicator lit. ........................................................................................0011-17 HYD Temp Sensor fault indicated on fault screen.............................................................................0011-17 0010-2

TM 5-3895-385-10

0010

Malfunction/Symptom....................................................................................................................... (WP/Page No.) 37. 38. 39. 40. 41. 42. 43. 44. 45. 46. 47. 48. 49. 50. 51. 52. 53. 54. 55. 56. 57. 58. 59. 60. 61. 62. 63. 64. 65. 66. 67. 68. Engine fails to crank or cranks slowly. ...............................................................................................0011-17 Engine cranks normally but fails to start ............................................................................................0011-18 Engine smokes excessively after normal warm-up............................................................................0011-19 Low fuel indicator lit............................................................................................................................0011-19 High coolant temperature indicator lit. ...............................................................................................0011-19 Low engine oil psi indicator lit. ...........................................................................................................0011-19 Fuel Level Sensor fault indicated on fault screen ..............................................................................0011-19 Engine Enable Relay fault indicated on fault screen .........................................................................0011-20 Engine J1939 Offline fault indicated on fault screen..........................................................................0011-20 Any fault indicated on engine fault screen. ........................................................................................0011-20 Low battery indicator lit. .....................................................................................................................0011-20 Propel Controller Offline fault indicated on fault screen.....................................................................0011-20 Screed Controller Offline fault indicated on fault screen....................................................................0011-20 Output Module Offline fault indicated on fault screen ........................................................................0011-20 Right Sonic Sensor fault indicated on fault screen ............................................................................0011-20 Left Sonic Sensor fault indicated on fault screen...............................................................................0011-21 Left Auger Reverse EDC fault indicated on fault screen ...................................................................0011-21 Left Auger Forward EDC fault indicated on fault screen....................................................................0011-21 Left auger fails to turn. .......................................................................................................................0011-21 Right auger fails to turn. .....................................................................................................................0011-22 Left or right augers fail to reverse. .....................................................................................................0011-23 Augers fail to raise or lower. ..............................................................................................................0011-24 Left or right cutoff fails to open or close. ............................................................................................0011-25 Truck hitch arms fail to extend or retract............................................................................................0011-26 Left conveyor fails to turn...................................................................................................................0011-27 Right conveyor fails to turn. ...............................................................................................................0011-28 Conveyors fail to reverse. ..................................................................................................................0011-29 Left track fails to move forward or reverse.........................................................................................0011-30 Right track fails to move forward or reverse ......................................................................................0011-31 Track tension loose. ...........................................................................................................................0011-33 Speed 2 Coil fault indicated on fault screen ......................................................................................0011-33 Brake Valve fault indicated on fault screen........................................................................................0011-33

END OF WORK PACKAGE

0010-3/4 blank

TM 5-3895-385-10

0011

OPERATOR MAINTENANCE BITUMINOUS MATERIAL PAVING MACHINE (BMPM) TROUBLESHOOTING PROCEDURES

INITIAL SETUP: Personnel Required 12V (1) References WP 0004 WP 0008 WP 0013 WP 0017 WP 0018 TROUBLESHOOTING PROCEDURES Table 1. Bituminous Material Paving Machine (BMPM) Troubleshooting Procedures. MALFUNCTION 1. Screed fails to raise or lower. TEST OR INSPECTION 1. Check for Screed Up fault or Screed Down fault indicated on fault screen (WP 0004). CORRECTIVE ACTION 1. If no fault is found, proceed to next test. 2. If fault is found, notify field maintenance. 1. Ensure engine is on (WP 0006). 2. If conditions are met, proceed to next test. References Continued WP 0019 WP 0020 WP 0021 WP 0022 Equipment Conditions Engine on (WP 0006)

2. Check for proper BMPM setup (WP 0006).

WARNING

The screed down button will lower the screed even if the engine is off if the keyless engine switch is in the AUX position. Ensure area around screed is clear any time the screed down button is pressed. Failure to comply may cause injury or death to personnel or damage to equipment. 3. Check fuse box for blown fuse (WP 0008). 1. If blown fuse is found, replace fuse (WP 0008). 2. If blown fuse is not found, proceed to next test.

0011-1

TM 5-3895-385-10

0011

Table 1. Bituminous Material Paving Machine (BMPM) Troubleshooting Procedures Continued. MALFUNCTION TEST OR INSPECTION 4. Attempt operation with opposite (left or right) horn keypad (WP 0004). CORRECTIVE ACTION 1. If opposite horn keypad accomplishes operation, notify field maintenance. 2. If opposite keypad does not accomplish operation, turn keyless engine switch to the OFF position (WP 0006), and proceed to next test.

WARNING

There are many points on the BMPM where personnel could be injured by moving parts. Turn BMPM off before performing maintenance. Care should be taken to avoid any pinch points when performing maintenance. Failure to comply may cause injury or death to personnel. 5. Check for obstructed movement. 1. Remove any obstructions around screed and hydraulic cylinders. 2. If no obstructions are found, proceed to next test. 6. Check for proper hydraulic oil level. 1. Ensure hydraulic oil is at proper level and temperature, and fill as necessary (WP 0019). 2. Notify field maintenance if problem persists. 2. Left screed extension fails to extend or retract. 1. Check for Left Extension Out fault or Left Extension In fault indicated on fault screen (WP 0004). 2. Check for proper BMPM setup (WP 0006). 1. If no fault is found, proceed to next test. 2. If fault is found, notify field maintenance. 1. Ensure engine is on (WP 0006). 2. If conditions are met, proceed to next test. 1. If blown fuse is found, replace fuse (WP 0008). 2. If blown fuse is not found, proceed to next test.

3. Check fuse box for blown fuse (WP 0008).

0011-2

TM 5-3895-385-10

0011

Table 1. Bituminous Material Paving Machine (BMPM) Troubleshooting Procedures Continued. MALFUNCTION TEST OR INSPECTION 4. Attempt operation with opposite (left or right) horn keypad (WP 0004). CORRECTIVE ACTION 1. If opposite horn keypad accomplishes operation, notify field maintenance. 2. If opposite keypad does not accomplish operation, turn keyless engine switch to the OFF position (WP 0006), and proceed to next test.

WARNING

There are many points on the BMPM where personnel could be injured by moving parts. Turn BMPM off before performing maintenance. Care should be taken to avoid any pinch points when performing maintenance. Failure to comply may cause injury or death to personnel. 5. Check for obstructed movement. 1. Remove any obstructions around screed extension, extension slide, and hydraulic cylinders. 2. If no obstructions are found, proceed to next test. 6. Check for hydraulic level. 1. Ensure hydraulic oil is at proper level and temperature, and fill as necessary (WP 0019). 2. Notify field maintenance if problem persists. 3. Right screed extension fails to extend or retract. 1. Check for Right Extension Out fault or Right Extension In fault indicated on fault screen (WP 0004). 2. Check for proper BMPM setup (WP 0006). 1. If no fault is found, proceed to next test. 2. If fault is found, notify field maintenance. 1. Ensure engine is on (WP 0006). 2. If conditions are met, proceed to next test. 1. If blown fuse is found, replace fuse (WP 0008). 2. If blown fuse is not found, proceed to next test.

3. Check fuse box for blown fuse (WP 0008).

0011-3

TM 5-3895-385-10

0011

Table 1. Bituminous Material Paving Machine (BMPM) Troubleshooting Procedures Continued. MALFUNCTION TEST OR INSPECTION 4. Attempt operation with opposite (left or right) lights keypad (WP 0004). CORRECTIVE ACTION 1. If opposite lights keypad accomplishes operation, notify field maintenance. 2. If opposite keypad does not accomplish operation, turn keyless engine switch to the OFF position (WP 0006), and proceed to next test.

WARNING

There are many points on the BMPM where personnel could be injured by moving parts. Turn BMPM off before performing maintenance. Care should be taken to avoid any pinch points when performing maintenance. Failure to comply may cause injury or death to personnel. 5. Check for obstructed movement. 1. Remove any obstructions around screed extension, extension slide, and hydraulic cylinders. 2. If no obstructions are found, proceed to next test. 6. Check for proper hydraulic oil level. 1. Ensure hydraulic oil is at proper level and temperature, and fill as necessary (WP 0019). 2. Notify field maintenance if problem persists. 4. Left screed extension fails to lower or raise slope. 1. Check for Left Slope Down fault or Left Slope Up fault indicated on fault screen (WP 0004). 1. If no fault is found, proceed to next test. 2. If fault is found, notify field maintenance. 1. Ensure engine is on (WP 0006). 2. If conditions are met, proceed to next test. 1. If blown fuse is found, replace fuse (WP 0008). 2. If blown fuse is not found, proceed to next test. 0011-4

2. Check for proper BMPM setup (WP 0006).

3. Check fuse box for blown fuse (WP 0008).

TM 5-3895-385-10

0011

Table 1. Bituminous Material Paving Machine (BMPM) Troubleshooting Procedures Continued. MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION

WARNING

There are many points on the BMPM where personnel could be injured by moving parts. Turn BMPM off before performing maintenance. Care should be taken to avoid any pinch points when performing maintenance. Failure to comply may cause injury or death to personnel. 4. Check for obstructed movement. 1. Remove any obstructions around and under screed. 2. If no obstructions are found, proceed to next test. 5. Check for proper hydraulic oil level. 1. Ensure hydraulic oil is at proper level and temperature, and fill as necessary (WP 0019). 2. Notify field maintenance if problem persists. 5. Right screed extension fails to lower or raise slope. 1. Check for Right Slope Down fault or Right Slope Up fault indicated on fault screen (WP 0004). 2. Check BMPM engine status. 3. Check fuse box for blown fuse (WP 0008). 1. If no fault is found, proceed to next test. 2. If fault is found, notify field maintenance. Ensure engine is on (WP 0006). 1. If blown fuse is found, replace fuse (WP 0008). 2. If blown fuse is not found, proceed to next test.

0011-5

TM 5-3895-385-10

0011

Table 1. Bituminous Material Paving Machine (BMPM) Troubleshooting Procedures Continued. MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION

WARNING

There are many points on the BMPM where personnel could be injured by moving parts. Turn BMPM off before performing maintenance. Care should be taken to avoid any pinch points when performing maintenance. Failure to comply may cause injury or death to personnel. 4. Check for obstructed movement. 1. Remove any obstructions around and under screed. 2. If no obstructions are found, proceed to next test. 5. Check for proper hydraulic oil level. 1. Ensure hydraulic oil is at proper level and temperature, and fill as necessary (WP 0019). 2. Notify field maintenance if problem persists. 6. Vibrator function fails to operate. 1. Check for Vibrator Relay fault indicated on fault screen (WP 0004). 1. If no fault is found, proceed to next test. 2. If fault is found, notify field maintenance. 1. Ensure engine is on (WP 0006). 2. Ensure screed is in a float setting (WP 0004). 1. If blown fuse is found, replace fuse (WP 0008). 2. If blown fuse is not found, proceed to next test.

2. Check for proper BMPM setup (WP 0006).

3. Check fuse box for blown fuse (WP 0008).

0011-6

TM 5-3895-385-10

0011

Table 1. Bituminous Material Paving Machine (BMPM) Troubleshooting Procedures Continued. MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION

NOTE
Screed will not vibrate unless BMPM is moving forward. 3. Ensure BMPM is moving forward (WP 0004). 4. Ensure vibration control knob is set properly (WP 0004). 5. If conditions are met, proceed to next test. 4. Attempt operation with opposite (left or right) beacon keypad (WP 0004). 1. If opposite beacon keypad accomplishes operation, notify field maintenance. 2. If opposite keypad does not accomplish operation, turn keyless engine switch to the OFF position (WP 0006), and proceed to next test. 5. Check for proper hydraulic oil level. 1. Ensure hydraulic oil is at proper level and temperature, and fill as necessary (WP 0019). 2. Notify field maintenance if problem persists. 7. Screed crown fails to operate. 1. Check for Crown Down fault or Crown Up fault indicated on fault screen (WP 0004). 1. If no fault is found, proceed to next test. 2. If fault is found, notify field maintenance. 1. Ensure screed crown top bar bolts are finger-tight (WP 0006). 2. If conditions are met, proceed to next test. 3. Check fuse box for blown fuse (WP 0008). 1. If blown fuse is found, replace fuse (WP 0008). 2. If blown fuse is not found, proceed to next test.

2. Check for proper BMPM setup (WP 0006).

0011-7

TM 5-3895-385-10

0011

Table 1. Bituminous Material Paving Machine (BMPM) Troubleshooting Procedures Continued. MALFUNCTION TEST OR INSPECTION 4. Attempt operation with opposite (left or right) horn keypad (WP 0004). CORRECTIVE ACTION 1. If opposite horn keypad accomplishes operation, notify field maintenance. 2. If opposite keypad does not accomplish operation, turn keyless engine switch to the OFF position (WP 0006), and proceed to next test.

WARNING

There are m any points o n the BMPM where perso nnel could be injured by moving part s. Turn BMPM off before performing maintenance. Care should be taken to avoid any pinch points when performing maintenance. Failure to comply may cause injury or death to personnel. 5. Check for obstructed movement. 1. Remove any obstructions around screed crown chains. 2. If no obstructions are found, proceed to next test. 6. Check for proper hydraulic oil level. 1. Ensure hydraulic oil is at proper level and temperature, and fill as necessary (WP 0019). 2. Notify field maintenance if problem persists. 8. Left tow hydraulic cylinder fails to raise or lower. 1. Check for Left Tow Up fault or Left Tow Down fault indicated on fault screen (WP 0004). 1. If no fault is found, proceed to next test. 2. If fault is found, notify field maintenance. 1. Ensure engine is on (WP 0006). 2. If conditions are met, proceed to next test. 1. If blown fuse is found, replace fuse (WP 0008). 2. If blown fuse is not found, proceed to next test.

2. Check for proper BMPM setup (WP 0006).

3. Check fuse box for blown fuse (WP 0008).

0011-8

TM 5-3895-385-10

0011

Table 1. Bituminous Material Paving Machine (BMPM) Troubleshooting Procedures Continued. MALFUNCTION TEST OR INSPECTION 4. Attempt operation with opposite (left or right) beacon keypad (WP 0004). CORRECTIVE ACTION 1. If opposite beacon keypad accomplishes operation, notify field maintenance. 2. If opposite keypad does not accomplish operation, turn keyless engine switch to the OFF position (WP 0006), and proceed to next test.

WARNING

There are m any points o n the BMPM where perso nnel could be injured by moving part s. Turn BMPM off before performing maintenance. Care should be taken to avoid any pinch points when performing maintenance. Failure to comply may cause injury or death to personnel. 5. Check for obstructed movement. 1. Remove any obstructions around screed, screed raise cylinder, and tow point hydraulic cylinder. 2. If no obstructions are found, proceed to next test. 6. Check for proper hydraulic oil level. 1. Ensure hydraulic oil is at proper level and temperature, and fill as necessary (WP 0019). 2. Notify field maintenance if problem persists. 9. Right tow hydraulic cylinder fails to raise or lower. 1. Check for Right Tow Up fault or Right Tow Down fault indicated on fault screen (WP 0004). 1. If no fault is found, proceed to next test. 2. If fault is found, notify field maintenance. 1. Ensure engine is on (WP 0006). 2. If conditions are met, proceed to next test. 1. If blown fuse is found, replace fuse (WP 0008). 2. If blown fuse is not found, proceed to next test.

2. Check for proper BMPM setup (WP 0006).

3. Check fuse box for blown fuse (WP 0008).

0011-9

TM 5-3895-385-10

0011

Table 1. Bituminous Material Paving Machine (BMPM) Troubleshooting Procedures Continued. MALFUNCTION TEST OR INSPECTION 4. Attempt operation with opposite (left or right) beacon keypad (WP 0004). CORRECTIVE ACTION 1. If opposite beacon keypad accomplishes operation, notify field maintenance. 2. If opposite keypad does not accomplish operation, turn keyless engine switch to the OFF position (WP 0006), and proceed to next test.

WARNING

There are m any points o n the BMPM where perso nnel could be injured by moving part s. Turn BMPM off before performing maintenance. Care should be taken to avoid any pinch points when performing maintenance. Failure to comply may cause injury or death to personnel. 5. Check for obstructed movement. 1. Remove any obstructions around screed, screed raise cylinder, and tow point hydraulic cylinder. 2. If no obstructions are found, proceed to next test. 6. Check for proper hydraulic oil level. 1. Ensure hydraulic oil is at proper level and temperature, and fill as necessary (WP 0019). 2. Notify field maintenance if problem persists. 10. Electric screed heat box malfunction. 11. Hopper wings fail to open or close. Note status of screed electric heat box on indicator (WP 0006). 1. Check for Hopper Out fault or Hopper In fault indicated on fault screen (WP 0004). Notify field maintenance. 1. If no fault is found, proceed to next test. 2. If fault is found, notify field maintenance. 1. Ensure engine is on (WP 0006). 2. If conditions are met, proceed to next test.

2. Check for proper BMPM setup (WP 0006).

0011-10

TM 5-3895-385-10

0011

Table 1. Bituminous Material Paving Machine (BMPM) Troubleshooting Procedures Continued. MALFUNCTION TEST OR INSPECTION 3. Check fuse box for blown fuse (WP 0008). CORRECTIVE ACTION 1. If blown fuse is found, replace fuse (WP 0008). 2. If blown fuse is not found, proceed to next test. 4. Attempt operation with opposite (left or right) lights keypad (WP 0004). 1. If opposite lights keypad accomplishes operation, notify field maintenance. 2. If opposite keypad does not accomplish operation, turn keyless engine switch to the OFF position (WP 0006), and proceed to next test.

WARNING

There are m any points o n the BMPM where perso nnel could be injured by moving part s. Turn BMPM off before performing maintenance. Care should be taken to avoid any pinch points when performing maintenance. Failure to comply may cause injury or death to personnel. 5. Check for obstructed movement. 1. Remove any obstructions around hopper wings. 2. If no obstructions are found, proceed to next test. 6. Check for proper hydraulic oil level. 1. Ensure hydraulic oil is at proper level and temperature, and fill as necessary (WP 0019). 2. Notify field maintenance if problem persists. 12. Display fails to show engine screen. 1. Check that BATTERY DISCONNECT switch is set to ON position. 1. Ensure BATTERY DISCONNECT switch is set to ON position (WP 0004). 2. If condition is met, proceed to next test. 2. Check that battery is connected properly. 1. Inspect battery connectors and cables for damage or corrosion (WP 0013). 2. If problem persists, notify field maintenance. 0011-11

TM 5-3895-385-10

0011

Table 1. Bituminous Material Paving Machine (BMPM) Troubleshooting Procedures Continued. MALFUNCTION TEST OR INSPECTION 3. Check fuse box for blown fuse (WP 0008). CORRECTIVE ACTION 1. If blown fuse is found, replace fuse (WP 0008). 2. If blown fuse is not found, proceed to next test. 13. Reverse Alarm fault indicated on fault screen (WP 0004). 14. Horn fails to sound. Note fault indicated. 1. Check for Horn Relay fault indicated on fault screen (WP 0004). Notify field maintenance. 1. If no fault is found, proceed to next test. 2. If fault is found, notify field maintenance. 1. Ensure BATTERY DISCONNECT switch is set to the ON position (WP 0004). 2. Ensure BMPM keyless engine switch is set to AUX position (WP 0004). 3. If conditions are met, proceed to next test. 3. Check fuse box for blown fuse (WP 0008). 1. If blown fuse is found, replace fuse (WP 0008). 2. If blown fuse is not found, proceed to next test. 4. Attempt operation with opposite (left or right) horn keypad (WP 0004). 1. If opposite horn keypad accomplishes operation, notify field maintenance.

2. Check for proper BMPM setup (WP 0006).

WARNING

Do not operate BMPM if EMERGENCY STOP switch fails to shut down BMPM. Failure to comply may cause injury or death to personnel or damage to equipment. 15. EMERGENCY STOP switch fails to shut down BMPM. Note malfunctioning EMERGENCY STOP switch. 1. Turn keyless engine switch to the OFF position (WP 0006). 2. Notify field maintenance.

0011-12

TM 5-3895-385-10

0011

Table 1. Bituminous Material Paving Machine (BMPM) Troubleshooting Procedures Continued. MALFUNCTION 16. Work lights fail to operate. TEST OR INSPECTION 1. Check for Light Relay fault indicated on fault screen (WP 0004). CORRECTIVE ACTION 1. If no fault is found, proceed to next test. 2. If fault is found, notify field maintenance. 1. Ensure BATTERY DISCONNECT switch is set to ON position (WP 0004). 2. Ensure BMPM keyless engine switch is set to AUX position (WP 0004). 3. If conditions are met, proceed to next test. 3. Check fuse box for blown fuse (WP 0008). 1. If blown fuse is found, replace fuse (WP 0008). 2. If blown fuse is not found, proceed to next test. 4. Attempt operation with opposite (left or right) lights keypad (WP 0004). 17. Beacon light fails to operate. 1. Check for Beacon Relay fault indicated on fault screen (WP 0004). 1. If opposite lights keypad accomplishes operation, notify field maintenance. 1. If no fault is found, proceed to next test. 2. If fault is found, notify field maintenance. 1. Ensure BATTERY DISCONNECT switch is set to ON position (WP 0004). 2. Ensure BMPM keyless engine switch is set to AUX position (WP 0004). 3. If conditions are met, proceed to next test. 3. Check fuse box for blown fuse (WP 0008). 1. If blown fuse is found, replace fuse (WP 0008). 2. If blown fuse is not found, proceed to next test. 4. Attempt operation with opposite (left or right) beacon keypad (WP 0004). If opposite beacon keypad accomplishes operation, notify field maintenance.

2. Check for proper BMPM setup (WP 0006).

2. Check for proper BMPM setup (WP 0006).

0011-13

TM 5-3895-385-10

0011

Table 1. Bituminous Material Paving Machine (BMPM) Troubleshooting Procedures Continued. MALFUNCTION 18. Spraydown fails to operate. TEST OR INSPECTION 1. Check for Spray Pump fault indicated on fault screen (WP 0004). CORRECTIVE ACTION 1. If no fault is found, proceed to next test. 2. If fault is found, notify field maintenance.

WARNING

Cleaning solvent is combustible and toxic to eyes, skin, and respiratory tract. Skin and eye protection is required. Avoid repeated or prolonged contact. Work in ventilated area only. Failure to comply may cause injury or death to personnel. 2. Check for proper BMPM setup (WP 0006). 1. Ensure cleaner solution tank is properly filled (WP 0020). 2. Ensure BATTERY DISCONNECT switch is set to ON position (WP 0004). 3. Ensure BMPM keyless engine switch is set to AUX position (WP 0004). 4. Ensure spraydown pump shutoff valve is in the open position (WP 0013). 5. If conditions are met, proceed to next test. 3. Check fuse box for blown fuse (WP 0008). 1. If blown fuse is found, replace fuse (WP 0008). 2. If blown fuse is not found, proceed to next test. 4. Attempt operation with opposite (left or right) beacon keypad (WP 0004). 19. Left Console Beacon Key Pad fault indicated on fault screen (WP 0004). 1. Check fuse box for blown fuse (WP 0008). If opposite beacon keypad accomplishes operation, notify field maintenance. 1. If blown fuse is found, replace fuse (WP 0008). 2. If blown fuse is not found, proceed to next test. 2. Note fault indicated. Notify field maintenance.

0011-14

TM 5-3895-385-10

0011

Table 1. Bituminous Material Paving Machine (BMPM) Troubleshooting Procedures Continued. MALFUNCTION 20. Left Console Horn Key Pad fault indicated on fault screen (WP 0004). TEST OR INSPECTION 1. Check fuse box for blown fuse (WP 0008). CORRECTIVE ACTION 1. If blown fuse is found, replace fuse (WP 0008). 2. If blown fuse is not found, proceed to next test. 2. Note fault indicated. 21. Left Console Lights Key Pad fault indicated on fault screen (WP 0004). 1. Check fuse box for blown fuse (WP 0008). Notify field maintenance. 1. If blown fuse is found, replace fuse (WP 0008). 2. If blown fuse is not found, proceed to next test. 2. Note fault indicated. 22. Right Console Beacon Key Pad fault indicated on fault screen (WP 0004). 1. Check fuse box for blown fuse (WP 0008). Notify field maintenance. 1. If blown fuse is found, replace fuse (WP 0008). 2. If blown fuse is not found, proceed to next test. 2. Note fault indicated. 23. Right Console Horn Key Pad fault indicated on fault screen (WP 0004). 1. Check fuse box for blown fuse (WP 0008). Notify field maintenance. 1. If blown fuse is found, replace fuse (WP 0008). 2. If blown fuse is not found, proceed to next test. 2. Note fault indicated. 24. Right Console Lights Key Pad fault indicated on fault screen (WP 0004). 1. Check fuse box for blown fuse (WP 0008). Notify field maintenance. 1. If blown fuse is found, replace fuse (WP 0008). 2. If blown fuse is not found, proceed to next test. 2. Note fault indicated. 25. Left Screed Aug/Conv Key Pad fault indicated on fault screen (WP 0004). 1. Check fuse box for blown fuse (WP 0008). Notify field maintenance. 1. If blown fuse is found, replace fuse (WP 0008). 2. If blown fuse is not found, proceed to next test. 2. Note fault indicated. 26. Right Screed Aug/Conv Key Pad fault indicated on fault screen (WP 0004). 1. Check fuse box for blown fuse (WP 0008). Notify field maintenance. 1. If blown fuse is found, replace fuse (WP 0008). 2. If blown fuse is not found, proceed to next test. 0011-15

TM 5-3895-385-10

0011

Table 1. Bituminous Material Paving Machine (BMPM) Troubleshooting Procedures Continued. MALFUNCTION TEST OR INSPECTION 2. Note fault indicated. 27. Right Console Left Joy fault indicated on fault screen (WP 0004). 1. Check fuse box for blown fuse (WP 0008). CORRECTIVE ACTION Notify field maintenance. 1. If blown fuse is found, replace fuse (WP 0008). 2. If blown fuse is not found, proceed to next test. 2. Note fault indicated. 28. Right Console Right Joy fault indicated on fault screen (WP 0004). 1. Check fuse box for blown fuse (WP 0008). Notify field maintenance. 1. If blown fuse is found, replace fuse (WP 0008). 2. If blown fuse is not found, proceed to next test. 2. Note fault indicated. 29. Right Console Left Joy Cal fault indicated on fault screen (WP 0004). 1. Check fuse box for blown fuse (WP 0008). Notify field maintenance. 1. If blown fuse is found, replace fuse (WP 0008). 2. If blown fuse is not found, proceed to next test. 2. Note fault indicated. 30. Right Console Right Joy Cal fault indicated on fault screen (WP 0004). 1. Check fuse box for blown fuse (WP 0008). Notify field maintenance. 1. If blown fuse is found, replace fuse (WP 0008). 2. If blown fuse is not found, proceed to next test. 2. Note fault indicated. 31. Left Console Left Joy fault indicated on fault screen (WP 0004). 1. Check fuse box for blown fuse (WP 0008). Notify field maintenance. 1. If blown fuse is found, replace fuse (WP 0008). 2. If blown fuse is not found, proceed to next test. 2. Note fault indicated. 32. Left Console Right Joy fault indicated on fault screen (WP 0004). 1. Check fuse box for blown fuse (WP 0008). Notify field maintenance. 1. If blown fuse is found, replace fuse (WP 0008). 2. If blown fuse is not found, proceed to next test. 2. Note fault indicated. Notify field maintenance.

0011-16

TM 5-3895-385-10

0011

Table 1. Bituminous Material Paving Machine (BMPM) Troubleshooting Procedures Continued. MALFUNCTION 33. Left Console Left Joy Cal fault indicated on fault screen (WP 0004). TEST OR INSPECTION 1. Check fuse box for blown fuse (WP 0008). CORRECTIVE ACTION 1. If blown fuse is found, replace fuse (WP 0008). 2. If blown fuse is not found, proceed to next test. 2. Note fault indicated. 34. Left Console Right Joy Cal fault indicated on fault screen (WP 0004). 1. Check fuse box for blown fuse (WP 0008). Notify field maintenance. 1. If blown fuse is found, replace fuse (WP 0008). 2. If blown fuse is not found, proceed to next test. 2. Note fault indicated. 35. High hydraulic oil temperature indicator lit. Check hydraulic oil temperature. Notify field maintenance. 1. Shut down BMPM (WP 0006). 2. Check hydraulic oil temperature at gauge (WP 0019). 3. Notify field maintenance. 36. HYD Temp Sensor fault indicated on fault screen (WP 0004). 37. Engine fails to crank or cranks slowly. Note fault indicated. Notify field maintenance.

1. Check that BATTERY DISCONNECT switch is set to ON position (WP 0004).

1. Set BATTERY DISCONNECT switch to ON position. 2. If conditions are met, proceed to next test. 1. Ensure BATTERY DISCONNECT switch is set to ON (WP 0004). 2. Ensure desired (left or right) control pedestal is set to RUN position and the other control pedestal is set to STOP position (WP 0004). 3. Ensure all joysticks are in the neutral position (WP 0004). 4. If conditions are met, proceed to next test.

2. Check for proper BMPM setup (WP 0006).

0011-17

TM 5-3895-385-10

0011

Table 1. Bituminous Material Paving Machine (BMPM) Troubleshooting Procedures Continued. MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION

WARNING

DO NOT disengage EMERGENCY STOP switch prior to clearing malfunctions and faults. If there was a malfunction with the machine that required the activation of the EMERGENCY STOP switch, the malfunction must be repaired before proceeding. Failure to comply may cause injury or death to personnel. 3. Check that EMERGENCY STOP switch is not pushed in (WP 0004). 1. If EMERGENCY STOP switch was pushed intentionally, determine cause. 2. If EMERGENCY STOP switch was not pushed intentionally, pull EMERGENCY STOP switch out to extended position. 3. If conditions are met, proceed to next test. 4. Check fuse box for blown fuse (WP 0008). 1. If blown fuse is found, replace fuse (WP 0008). 2. If blown fuse is not found, proceed to next test. 5. Check for loose battery connection(s). 1. Inspect battery connectors and cables for damage or corrosion (WP 0013). 2. If damage is found, notify field maintenance. 3. If no damage is found, proceed to next test. 6. Check for corroded battery terminals or connections. 1. Clean corrosion from battery terminals and cable connections. 2. Notify field maintenance if problem persists. 38. Engine cranks normally but fails to start. 1. Check for engine fault on engine faults screen (WP 0004). 1. If no fault is found, proceed to next test. 2. If fault is found, notify field maintenance.

0011-18

TM 5-3895-385-10

0011

Table 1. Bituminous Material Paving Machine (BMPM) Troubleshooting Procedures Continued. MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION

WARNING

There are many points on the BMPM where personnel could be injured by moving parts. Turn BMPM off before performing maintenance. Care should be taken to avoid any pinch points when performing maintenance. Failure to comply may cause injury or death to personnel. 2. Check fuel level. 1. Check fuel level, and fill as necessary (WP 0017). 2. If conditions are met, proceed to next test. 3. Check air filter for blockage. 1. Remove blockage if found (WP 0021). 2. If conditions are met, proceed to next test. 4. Service fuel filter. 1. Remove water from fuel filter (WP 0017). 2. Notify field maintenance if problem persists. 39. Engine smokes excessively after normal warm-up. 1. Visually inspect exhaust smoke for black, grey, blue, or white color, and check air filter for blockage. 1. Remove blockage if found (WP 0021). 2. Clean or replace air filter if found to be blocked (WP 0021). 3. Notify field maintenance if problem persists. 40. Low fuel indicator lit. 41. High coolant temperature indicator lit. 42. Low engine oil psi indicator lit. 43. Fuel Level Sensor fault indicated on fault screen (WP 0004). Check fuel level, and fill as necessary (WP 0017). Check coolant level, and fill as necessary (WP 0022). Check engine oil level, and fill as necessary (WP 0018). Note fault indicated. Notify field maintenance if problem persists. Notify field maintenance if problem persists. Notify field maintenance if problem persists. Notify field maintenance.

0011-19

TM 5-3895-385-10

0011

Table 1. Bituminous Material Paving Machine (BMPM) Troubleshooting Procedures Continued. MALFUNCTION 44. Engine Enable Relay fault indicated on fault screen (WP 0004). 45. Engine J1939 Offline fault indicated on fault screen (WP 0004). 46. Any fault indicated on engine fault screen. TEST OR INSPECTION Note fault indicated. CORRECTIVE ACTION Notify field maintenance.

Note fault indicated.

Notify field maintenance.

1. Check fuse box for blown fuse (WP 0008).

1. If blown fuse is found, replace fuse (WP 0008). 2. If blown fuse is not found, proceed to next test.

2. Note fault code on display screen. 47. Low battery indicator lit. Inspect battery connectors and cables for damage or corrosion (WP 0013). 1. Check fuse box for blown fuse (WP 0008).

Notify field maintenance. Notify field maintenance if problem persists. 1. If blown fuse is found, replace fuse (WP 0008). 2. If blown fuse is not found, proceed to next test.

48. Propel Controller Offline fault indicated on fault screen (WP 0004).

2. Note fault code on display screen. 49. Screed Controller Offline fault indicated on fault screen (WP 0004). 1. Check fuse box for blown fuse (WP 0008).

Notify field maintenance. 1. If blown fuse is found, replace fuse (WP 0008). 2. If blown fuse is not found, proceed to next test.

2. Note fault code on display screen. 50. Output Module Offline fault indicated on fault screen (WP 0004). 1. Check fuse box for blown fuse (WP 0008).

Notify field maintenance. 1. If blown fuse is found, replace fuse (WP 0008). 2. If blown fuse is not found, proceed to next test.

2. Note fault code on display screen. 51. Right Sonic Sensor fault indicated on fault screen (WP 0004). 1. Check fuse box for blown fuse (WP 0008).

Notify field maintenance. 1. If blown fuse is found, replace fuse (WP 0008). 2. If blown fuse is not found, proceed to next test.

0011-20

TM 5-3895-385-10

0011

Table 1. Bituminous Material Paving Machine (BMPM) Troubleshooting Procedures Continued. MALFUNCTION TEST OR INSPECTION 2. Ensure sonic auger sensor is connected properly (WP 0006). 52. Left Sonic Sensor fault indicated on fault screen (WP 0004). 1. Check fuse box for blown fuse (WP 0008). CORRECTIVE ACTION Notify field maintenance if problem persists. 1. If blown fuse is found, replace fuse (WP 0008). 2. If blown fuse is not found, proceed to next test. 2. Ensure sonic auger sensor is connected properly (WP 0006). 53. Left Auger Reverse EDC fault indicated on fault screen (WP 0004). 54. Left Auger Forward EDC fault indicated on fault screen (WP 0004). 55. Left auger fails to turn. Note fault indicated. Notify field maintenance if problem persists. Notify field maintenance.

Note fault indicated.

Notify field maintenance.

1. Check for Left Auger Reverse EDC fault or Left Auger Forward EDC fault indicated on fault screen (WP 0004). 2. Check for proper BMPM setup (WP 0006).

1. If no fault is found, proceed to next test. 2. If fault is found, notify field maintenance. 1. Ensure engine is on (WP 0006). 2. Ensure auger/conveyor bypass is off (WP 0004). 3. If conditions are met, proceed to next test.

3. Check fuse box for blown fuse (WP 0008).

1. If blown fuse is found, replace fuse (WP 0008). 2. If blown fuse is not found, proceed to next test.

0011-21

TM 5-3895-385-10

0011

Table 1. Bituminous Material Paving Machine (BMPM) Troubleshooting Procedures Continued. MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION

WARNING

There are m any points o n the BMPM where perso nnel could be injured by moving part s. Turn BMPM off before performing maintenance. Care should be taken to avoid any pinch points when performing maintenance. Failure to comply may cause injury or death to personnel. 4. Check for obstructed movement. 1. Remove any obstructions around auger. 2. If no obstructions are found, proceed to next test. 5. Ensure sonic auger sensors are connected properly. 1. Ensure sonic auger sensors are installed properly (WP 0006). 2. Ensure pile height setting is properly adjusted (WP 0006). 6. Check for proper hydraulic oil level. 1. Ensure hydraulic oil is at proper level and temperature, and fill as necessary (WP 0019). 2. Notify field maintenance if problem persists. 56. Right auger fails to turn. 1. Check for Right Auger Reverse EDC fault or Right Auger Forward EDC fault indicated on fault screen (WP 0004). 2. Check for proper BMPM setup (WP 0006). 1. If no fault is found, proceed to next test. 2. If fault is found, notify field maintenance. 1. Ensure engine is on (WP 0006). 2. Ensure auger/conveyor bypass is off (WP 0004). 3. If conditions are met, proceed to next test. 3. Check fuse box for blown fuse (WP 0008). 1. If blown fuse is found, replace fuse (WP 0008). 2. If blown fuse is not found, proceed to next test.

0011-22

TM 5-3895-385-10

0011

Table 1. Bituminous Material Paving Machine (BMPM) Troubleshooting Procedures Continued. MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION

WARNING

There are many points on the BMPM where personnel could be injured by moving parts. Turn BMPM off before performing maintenance. Care should be taken to avoid any pinch points when performing maintenance. Failure to comply may cause injury or death to personnel. 4. Check for obstructed movement. 1. Remove any obstructions around auger. 2. If no obstructions are found, proceed to next test. 5. Ensure sonic auger sensors are connected properly. 1. Ensure sonic auger sensors are installed properly (WP 0006). 2. Ensure pile height setting is properly adjusted (WP 0004). 3. If conditions are met, proceed to next test. 6. Check for proper hydraulic oil level. 1. Ensure hydraulic oil is at proper level and temperature, and fill as necessary (WP 0019). 2. Notify field maintenance if problem persists. 57. Left or right augers fail to reverse. 1. Check for Right Auger Reverse EDC fault, Left Auger Reverse EDC fault, Left Auger Bypass fault, or Right Auger Bypass fault indicated on fault screen (WP 0004). 2. Check for proper BMPM setup (WP 0006). 1. If no fault is found, proceed to next test. 2. If fault is found, notify field maintenance.

1. Ensure engine is on (WP 0006). 2. Ensure auger/conveyor bypass is off (WP 0004). 3. If conditions are met, proceed to next test.

3. Check fuse box for blown fuse (WP 0008).

1. If blown fuse is found, replace fuse (WP 0008). 2. If blown fuse is not found, proceed to next test.

0011-23

TM 5-3895-385-10

0011

Table 1. Bituminous Material Paving Machine (BMPM) Troubleshooting Procedures Continued. MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION

WARNING

There are many points on the BMPM where personnel could be injured by moving parts. Turn BMPM off before performing maintenance. Care should be taken to avoid any pinch points when performing maintenance. Failure to comply may cause injury or death to personnel. 4. Check for obstructed movement. 1. Remove any obstructions around auger. 2. If no obstructions are found, proceed to next test. 5. Check for proper hydraulic oil level. 1. Ensure hydraulic oil is at proper level and temperature, and fill as necessary (WP 0019). 2. Notify field maintenance if problem persists. 58. Augers fail to raise or lower. 1. Check for Auger Up fault or Auger Down fault indicated on fault screen (WP 0004). 1. If no fault is found, proceed to next test. 2. If fault is found, notify field maintenance. 1. Ensure engine is on (WP 0006). 2. If conditions are met, proceed to next test. 1. If blown fuse is found, replace fuse (WP 0008). 2. If blown fuse is not found, proceed to next test. 4. Attempt operation with opposite (left or right) lights keypad (WP 0004). 1. If opposite lights keypad accomplishes operation, notify field maintenance. 2. If opposite keypad does not accomplish operation, turn keyless engine switch to the OFF position (WP 0006), and proceed to next test.

2. Check for proper BMPM setup (WP 0006).

3. Check fuse box for blown fuse (WP 0008).

0011-24

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0011

Table 1. Bituminous Material Paving Machine (BMPM) Troubleshooting Procedures Continued. MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION

WARNING

There are many points on the BMPM where personnel could be injured by moving parts. Turn BMPM off before performing maintenance. Care should be taken to avoid any pinch points when performing maintenance. Failure to comply may cause injury or death to personnel. 5. Check for obstructed movement. 1. Remove any obstructions around auger or auger raise and lower slide. 2. If no obstructions are found, proceed to next test. 6. Check for proper hydraulic oil level. 1. Ensure hydraulic oil is at proper level and temperature, and fill as necessary (WP 0019). 2. Notify field maintenance if problem persists. 59. Left or right cutoff fails to open or close. 1. Check for Right Cutoff Open fault, Right Cutoff Close fault, Left Cutoff Open fault, or Left Cutoff Close fault indicated on fault screen (WP 0004). 2. Check for proper BMPM setup (WP 0006). 1. If no fault is found, proceed to next test. 2. If fault is found, notify field maintenance. 1. Ensure engine is on (WP 0006). 2. If conditions are met, proceed to next test. 1. If blown fuse is found, replace fuse (WP 0008). 2. If blown fuse is not found, proceed to next test.

3. Check fuse box for blown fuse (WP 0008).

0011-25

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0011

Table 1. Bituminous Material Paving Machine (BMPM) Troubleshooting Procedures Continued. MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION

WARNING

There are many points on the BMPM where personnel could be injured by moving parts. Turn BMPM off before performing maintenance. Care should be taken to avoid any pinch points when performing maintenance. Failure to comply may cause injury or death to personnel. 4. Check for obstructed movement. 1. Remove any obstructions around cutoffs. 2. If no obstructions are found, proceed to next test. 5. Check for proper hydraulic oil level. 1. Ensure hydraulic oil is at proper level and temperature, and fill as necessary (WP 0019). 2. Notify field maintenance if problem persists. 60. Truck hitch arms fail to extend or retract. 1. Check for Truck Hitch Out fault or Truck Hitch In fault indicated on fault screen (WP 0004). 1. If no fault is found, proceed to next test. 2. If fault is found, notify field maintenance. 1. Ensure engine is on (WP 0006). 2. If conditions are met, proceed to next test. 1. If blown fuse is found, replace fuse (WP 0008). 2. If blown fuse is not found, proceed to next test. 4. Attempt operation with opposite (left or right) horn keypad (WP 0004). 1. If opposite horn keypad accomplishes operation, notify field maintenance. 2. If opposite keypad does not accomplish operation, turn keyless engine switch to the OFF position (WP 0006), and proceed to next test.

2. Check for proper BMPM setup (WP 0006).

3. Check fuse box for blown fuse (WP 0008).

0011-26

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0011

Table 1. Bituminous Material Paving Machine (BMPM) Troubleshooting Procedures Continued. MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION

WARNING

There are many points on the BMPM where personnel could be injured by moving parts. Turn BMPM off before performing maintenance. Care should be taken to avoid any pinch points when performing maintenance. Failure to comply may cause injury or death to personnel. 5. Check for obstructed movement. 1. Remove any obstructions around truck hitch arms. 2. If no obstructions are found, proceed to next test. 6. Check for proper hydraulic oil level. 1. Ensure hydraulic oil is at proper level and temperature, and fill as necessary (WP 0019). 2. Notify field maintenance if problem persists. 61. Left conveyor fails to turn. 1. Check for Left Conveyor Speed Coil fault indicated on fault screen (WP 0004). 1. If no fault is found, proceed to next test. 2. If fault is found, notify field maintenance. 1. Ensure engine is on (WP 0006). 2. Ensure auger/conveyor bypass is off. 3. If conditions are met, proceed to next test. 3. Check fuse box for blown fuse (WP 0008). 1. If blown fuse is found, replace fuse (WP 0008). 2. If blown fuse is not found, proceed to next test.

2. Check for proper BMPM setup (WP 0006).

0011-27

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0011

Table 1. Bituminous Material Paving Machine (BMPM) Troubleshooting Procedures Continued. MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION

WARNING

There are m any points o n the BMPM where perso nnel could be injured by moving part s. Turn BMPM off before performing maintenance. Care should be taken to avoid any pinch points when performing maintenance. Failure to comply may cause injury or death to personnel. 4. Check for obstructed movement. 1. Remove any obstructions around conveyors. 2. If no obstructions are found, proceed to next test. 5. Ensure sonic auger sensors are connected properly. 1. Ensure sonic auger sensors are clean and installed properly (WP 0006). 2. Ensure pile height setting is properly adjusted (WP 0004). 3. If conditions are met, proceed to next test. 6. Check for proper hydraulic oil level. 1. Ensure hydraulic oil is at proper level and temperature, and fill as necessary (WP 0019). 2. Notify field maintenance if problem persists. 62. Right conveyor fails to turn. 1. Check for Right Conveyor Speed Coil fault indicated on fault screen (WP 0004). 1. If no fault is found, proceed to next test. 2. If fault is found, notify field maintenance. 1. Ensure engine is on (WP 0006). 2. Ensure auger/conveyor bypass is off. 3. If conditions are met, proceed to next test. 3. Check fuse box for blown fuse (WP 0008). 1. If blown fuse is found, replace fuse (WP 0008). 2. If blown fuse is not found, proceed to next test.

2. Check for proper BMPM setup (WP 0006).

0011-28

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0011

Table 1. Bituminous Material Paving Machine (BMPM) Troubleshooting Procedures Continued. MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION

WARNING

There are many points on the BMPM where personnel could be injured by moving parts. Turn BMPM off before performing maintenance. Care should be taken to avoid any pinch points when performing maintenance. Failure to comply may cause injury or death to personnel. 4. Check for obstructed movement. 1. Remove any obstructions around conveyors. 2. If no obstructions are found, proceed to next test. 5. Ensure sonic auger sensors are connected properly. 1. Ensure sonic auger sensors are clean and installed properly (WP 0006). 2. Ensure pile height setting is properly adjusted (WP 0004). 3. If conditions are met, proceed to next test. 6. Check for proper hydraulic oil level. 1. Ensure hydraulic oil is at proper level and temperature, and fill as necessary (WP 0019). 2. Notify field maintenance if problem persists. 63. Conveyors fail to reverse. 1. Check for proper BMPM setup (WP 0006). 1. Ensure engine is on (WP 0006). 2. Ensure auger/conveyor bypass is off (WP 0004). 3. If conditions are met, proceed to next test. 2. Check fuse box for blown fuse (WP 0008). 1. If blown fuse is found, replace fuse (WP 0008). 2. If blown fuse is not found, proceed to next test.

0011-29

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0011

Table 1. Bituminous Material Paving Machine (BMPM) Troubleshooting Procedures Continued. MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION

WARNING

There are many points on the BMPM where personnel could be injured by moving parts. Turn BMPM off before performing maintenance. Care should be taken to avoid any pinch points when performing maintenance. Failure to comply may cause injury or death to personnel. 3. Check for obstructed movement. 1. Remove any obstructions around conveyors. 2. If no obstructions are found, proceed to next test. 4. Check for proper hydraulic oil level. 1. Ensure hydraulic oil is at proper level and temperature, and fill as necessary (WP 0019). 2. Notify field maintenance if problem persists. 64. Left track fails to move forward or reverse. 1. Check for Left Track Forward EDC fault or Left Track Reverse EDC fault indicated on fault screen (WP 0004). 2. Check for proper BMPM setup (WP 0006). 1. If no fault is found, proceed to next test. 2. If fault is found, notify field maintenance. 1. Ensure engine is on (WP 0006). 2. Ensure desired (left or right) control pedestal is set to RUN position and the other control pedestal is set to STOP position (WP 0004). 3. Ensure max speed setting is set above zero (WP 0004). 4. Ensure joysticks are not set to counter rotate while the BMPM is set to the high-speed setting (WP 0004). 5. If conditions are met, proceed to next test. 3. Check fuse box for blown fuse (WP 0008). 1. If blown fuse is found, replace fuse (WP 0008). 2. If blown fuse is not found, proceed to next test. 0011-30

TM 5-3895-385-10

0011

Table 1. Bituminous Material Paving Machine (BMPM) Troubleshooting Procedures Continued. MALFUNCTION TEST OR INSPECTION 4. Attempt operation with opposite (left or right) control pedestal joysticks. CORRECTIVE ACTION 1. If opposite joysticks accomplish operation, notify field maintenance. 2. If opposite joysticks do not accomplish operation, turn keyless engine switch to the OFF position (WP 0006), and proceed to next test.

WARNING

There are many points on the BMPM where personnel could be injured by moving parts. Turn BMPM off before performing maintenance. Care should be taken to avoid any pinch points when performing maintenance. Failure to comply may cause injury or death to personnel. 5. Check for obstructed movement. 1. Remove any obstructions around BMPM. 2. Remove any obstructions in and around tracks, bogies, pulleys, and torque hub. 3. If no obstructions are found, proceed to next test. 6. Check for proper hydraulic oil level. 1. Ensure hydraulic oil is at proper level and temperature, and fill as necessary (WP 0019). 2. Notify field maintenance if problem persists. 65. Right track fails to move forward or reverse. 1. Check for Right Track Forward EDC fault or Right Track Reverse EDC fault indicated on fault screen (WP 0004). 1. If no fault is found, proceed to next test. 2. If fault is found, notify field maintenance.

0011-31

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0011

Table 1. Bituminous Material Paving Machine (BMPM) Troubleshooting Procedures Continued. MALFUNCTION TEST OR INSPECTION 2. Check for proper BMPM setup (WP 0006). CORRECTIVE ACTION 1. Ensure engine is on (WP 0006). 2. Ensure desired (left or right) control pedestal is set to RUN position and the other control pedestal is set to STOP position (WP 0004). 3. Ensure max speed setting is set above zero (WP 0004). 4. Ensure joysticks are not set to counter rotate while the BMPM is set to the high-speed setting (WP 0004). 5. If conditions are met, proceed to next test. 3. Check fuse box for blown fuse (WP 0008). 1. If blown fuse is found, replace fuse (WP 0008). 2. If blown fuse is not found, proceed to next test. 4. Attempt operation with opposite (left or right) control pedestal joysticks. 1. If opposite joysticks accomplish operation, notify field maintenance. 2. If opposite joysticks do not accomplish operation, turn keyless engine switch to the OFF position (WP 0006), and proceed to next test.

WARNING

There are many points on the BMPM where personnel could be injured by moving parts. Turn BMPM off before performing maintenance. Care should be taken to avoid any pinch points when performing maintenance. Failure to comply may cause injury or death to personnel. 5. Check for obstructed movement. 1. Remove any obstructions around BMPM. 2. Remove any obstructions in and around tracks, bogies, pulleys, and torque hub. 3. If no obstructions are found, proceed to next test. 0011-32

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0011

Table 1. Bituminous Material Paving Machine (BMPM) Troubleshooting Procedures Continued. MALFUNCTION TEST OR INSPECTION 6. Check for proper hydraulic oil level. CORRECTIVE ACTION 1. Ensure hydraulic oil is at proper level and temperature, and fill as necessary (WP 0019). 2. Notify field maintenance if problem persists. 66. Track tension loose. Check for proper BMPM setup (WP 0006). 1. Ensure engine is on (WP 0006).

2. If conditions are met, notify field maintenance. 67. Speed 2 Coil fault indicated on fault screen (WP 0004). 68. Brake Valve fault indicated on fault screen (WP 0004). END OF TASK END OF WORK PACKAGE Note fault indicated. Note fault indicated. Notify field maintenance. Notify field maintenance.

0011-33/34 blank

TM 5-3895-385-10

CHAPTER 4
OPERATOR MAINTENANCE INSTRUCTIONS FOR BITUMINOUS MATERIAL PAVING MACHINE (BMPM)

TM 5-3895-385-10

0012

OPERATOR MAINTENANCE BITUMINOUS MATERIAL PAVING MACHINE (BMPM) PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) INTRODUCTION INTRODUCTION This section contains information needed to perform operator Preventive Maintenance Checks and Services (PMCS). Illustrated steps are included to help perform these procedures easily and quickly. PMCS consists of scheduled maintenance items used to make sure the Bituminous Material Paving Machine (BMPM) is ready for operation at all times. Inspect the system regularly and carefully to find any defects and correct or prevent them. General PMCS is performed to keep the equipment in operating condition. The checks are used to find, correct, or report problems. Pay attention to WARNING and CAUTION statements. A WARNING indicates the possibility of injury or death to personnel. A CAUTION means the equipment could be damaged. Before operation, perform Before PMCS. During operation, perform During PMCS. After operation, perform After PMCS.

Corrosion Definition Component damage is caused when material has been dissolved or eaten away, especially by chemical action. Rust Definition Any various scaly or powdery reddish-brown or reddish-yellow materials that form on iron and iron-coated materials in the presence of moisture, deteriorating as a result of disuse or neglect. Deterioration Definition Any condition that causes material to be impaired or lessens the quality or value of the material. Cracking Definition When material is found to be split or broken, either completely or partially. Inspection Always look for signs of problems or trouble. Most easily-fixed problems can be detected by feel, smell, or sound. Be alert when around the BMPM. Inspect to ensure all components are in good condition. Are they correctly assembled, stowed, or secured? Are any components worn, corroded, or rusty? Correct any problems found or notify immediate supervisor. There are common items that should be checked. These include the following: Bolts, clamps, screws, and nuts: Continuously inspect for looseness. Inspect for chipped paint, bare metal, rust, or corrosion around bolt and screw heads and nuts. Replace as necessary. Tighten hardware as required and if tools are not available, notify immediate supervisor. Inspect welds: Some components of the BMPM set are welded. To inspect welds, look for chipped paint, rust, corrosion, or gaps. When these conditions are noted, notify immediate supervisor. 0012-1

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0012

Inspection Continued.

WARNING

High voltage is used in the operation of this equipment. When working with the electrical system, care must be exercised. Remove rings, bracelets, wristwatches, neck chains, Identification (ID) tags, and any other jewelry. Jewelry may catch on equipment or short across an electrical circuit or battery terminal. Failure to comply may result in injury or death to personnel. Operating the BMPM exposes personnel to a high noise level. While operating or working within 37 feet (ft) (11 meters (m)) of a running BMPM wear hearing protection. Failure to comply may cause hearing loss. When running, BMPM engine has hot metal surfaces that will burn flesh on contact. Shut down engine and allow sufficient cooling before checks, services, or maintenance. Wear gloves and additional protective clothing as required. Failure to comply may cause injury or death to personnel. Electrical wires, connectors, and harnesses: Tighten loose connections. Inspect for cracked or broken insulation, bare wires, and broken connectors. If any are noted, notify immediate supervisor. Hoses and fluid lines: Inspect for wear, damage, and leaks. Ensure clamps and fittings are tight. Wet spots indicate a leak. A stain by a fitting or connector can also mean a leak. When this is noted, notify immediate supervisor.

CLEANING AND LUBRICATION Proper cleaning and lubrication can aid in avoiding possible problems or trouble. Make it a habit to do the following:

CAUTION
Follow all cleaning and lubrication instructions carefully. Failure to do so could result in damage to the equipment. Under harsh environmental conditions, PMCS should be conducted more frequently. Use only the recommended cleaning solutions and lubricants listed in the Expendable and Durable Items List (WP 0033). Oil Filters Oil filters shall be serviced/cleaned/changed, as applicable: When they are known to be contaminated or clogged At prescribed hardtime intervals

Army Oil Analysis Program (AOAP) Sampling This BMPM is not enrolled in the AOAP. Hardtime intervals apply. For equipment under manufacturer's warranty, hardtime oil service intervals shall be followed. Intervals shall be shortened if lubricants are known to be contaminated or if operation is under adverse conditions (such as longerthan-usual operating hours, extended idling periods, extreme dust).

0012-2

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0012

Lubrication Refer to LO 5-3895-385-13 for all lubrication procedures and intervals. FLUID LEAKAGE It is necessary to know how fluid leakage affects the status of the BMPM. The following are types/classes of leakage needed to determine the status of the BMPM. Learn these leakage definitions and rememberwhen in doubt, notify immediate supervisor. Equipment operation is allowed with minor leakage (Class I or II). Consideration must be given to fluid capacity in the item/system being checked/inspected. When in doubt, notify immediate supervisor. When operating with Class I or II leaks, continue to check fluid levels as required in the PMCS. If there is a Class I or II fuel leak, leak should be reported immediately to immediate supervisor. Class III leaks should be reported immediately to immediate supervisor. (1) Class I - Seepage of fluid (as indicated by wetness or discoloration) not great enough to form drops. (2) Class II - Leakage of fluid great enough to form drops but not enough to cause drops to drip from item being checked/inspected. (3) Class III - Leakage of fluid great enough to form drops that fall from item being checked/inspected. EXPLANATION OF THE COLUMNS FOUND IN THE PMCS TABLE Item No. The item number lists the checks and services in the order they are to be performed. This column will be used as a source of item for the TM Number Column on DA Form 2404 or Form 5988E (electronic version), Equipment Inspection and Maintenance Worksheet, in recording the result of the PMCS. Interval. References when the PMCS should be performed. Application/Explanation Before an operation During an operation After an operation Weekly Item to be Checked or Serviced. Identifies the portion of the system to be inspected. Procedures. Provides the procedures for performing the checks. Equipment not Ready/Available If. Contains the criteria that will render the system incapable of performing its primary mission. If system does not perform as required, refer to Chapter 3, Operator Troubleshooting Procedures. If anything looks wrong and cannot be fixed, immediately report it to immediate supervisor and report it on DA Form 2404 or 5988E (electronic version). END OF WORK PACKAGE

0012-3/4 blank

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OPERATOR MAINTENANCE BITUMINOUS MATERIAL PAVING MACHINE (BMPM) PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS)

INITIAL SETUP: Tools and Special Tools Hand lubricating gun (WP 0031, Item 7) Materials/Parts Wiping rag (WP 0033, Item 15) Personnel Required 12V (1) References LO 5-3895-385-13 WP 0007 WP 0009 WP 0017 WP 0018 References Continued. WP 0019 WP 0020 WP 0021 WP 0022 WP 0023 Equipment Conditions Keyless engine switch OFF (WP 0004) Screed fully lowered (WP 0006) Screed extensions fully extended (WP 0006) Cutoffs fully closed (WP 0006) BMPM cool (Before procedures only)

0013-1

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0013

Table 1. Preventive Maintenance Checks and Services (PMCS) Instructions. ITEM TO BE CHECKED OR SERVICED

ITEM NO.

INTERVAL

PROCEDURE

EQUIPMENT NOT READY/AVAILABLE IF:

Figure 1. Bituminous Material Paving Machine (BMPM) Fluid Leaks. 1 Before Overall View Check BMPM for fluid leaks or major damage that would impair operation (Figure 1). Check safety decals and data plates for damage and legibility (WP 0009). Damage that would impair operation or class III leaks are evident.

Before

Safety Decals and Data Plates

0013-2

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Table 1. Preventive Maintenance Checks and Services (PMCS) Instructions Continued. ITEM NO. ITEM TO BE CHECKED OR SERVICED EQUIPMENT NOT READY/AVAILABLE IF:

INTERVAL

PROCEDURE

Figure 2. Operator Platform. 3 4 Before Before Left Control Pedestal Left Operator Seat Slide Assembly Cleaner Solution Level Right Control Pedestal Check left control pedestal (Figure 2, Item 12) for damage. Check left operator seat slide assembly, seat, and seat belt (Figure 2, Item 11) for damage. Check cleaner solution level (Figure 2, Item 10). Fill as necessary. Check right control pedestal (Figure 2, Item 5) for damage. 0013-3 Controls are damaged or missing. Seat belt missing, damaged, or inoperable. Cap is missing or damaged. Controls are damaged or missing.

Before

Before

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0013

Table 1. Preventive Maintenance Checks and Services (PMCS) Instructions Continued. ITEM NO. 7 ITEM TO BE CHECKED OR SERVICED Right Operator Seat Slide Assembly Air Intake EQUIPMENT NOT READY/AVAILABLE IF: Seat belt missing, damaged, or inoperable. Damage or blockage that would impair operation is evident. Damage that would impair operation is evident. Damage or blockage that would impair operation is evident.

INTERVAL Before

PROCEDURE Check right operator seat slide assembly, seat, and seat belt (Figure 2, Item 6) for damage. Check external air cleaner assembly components (Figure 2, Item 13) for damage or blockage. Remove blockage. Check beacon light assembly (Figure 2, Item 2) for cracks or damage. Check fume exhaust (Figure 2, Item 1) for damage or blockage. Remove blockage.

Before

Before

Beacon

10

Before

Fume Exhaust

WARNING

When operating, muffler has hot metal surfaces that will burn flesh on contact. Shut down BMPM and allow to cool before performing maintenance. Wear gloves and additional protective clothing as required. Failure to comply may cause injury or death to personnel. 11 Before Muffler Check external muffler (Figure 2, Item 3) for damage, rust, or blockage. Remove blockage. Check radiator cap (Figure 2, Item 4) for damage. Check fuel cap (Figure 2, Item 7) for damage. Ensure spraydown pump shutoff valve (Figure 2, Item 9) is in the open position. Ensure coolant (Figure 2, Item 8) is filled to proper level. Fill as necessary (WP 0022). Damage or blockage that would impair operation is evident. Radiator cap is missing or damaged. Fuel cap is missing or damaged or any leak is evident. Class III leaks are evident. Class III leaks are evident.

12 13

Before Before

Radiator Cap Fuel Cap

14

Before

Spraydown Pump Shutoff Valve Coolant Reservoir

15

Before

0013-4

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0013

Table 1. Preventive Maintenance Checks and Services (PMCS) Instructions Continued. ITEM NO. ITEM TO BE CHECKED OR SERVICED EQUIPMENT NOT READY/AVAILABLE IF:

INTERVAL

PROCEDURE

Figure 3. Screed. 16 Before Rear Work Lights Check work lights (Figure 3, Item 2) for damage. Work lights are missing or damage that would impair operation is evident.

0013-5

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0013

Table 1. Preventive Maintenance Checks and Services (PMCS) Instructions Continued. ITEM NO. 17 18 ITEM TO BE CHECKED OR SERVICED Rifle Mounts Left Screed Control Left Flight Screw EQUIPMENT NOT READY/AVAILABLE IF: Rifle mounts missing. Keypads are missing or damage that would impair operation is evident. Damage that would impair operation is evident. Keypads are missing or damage that would impair operation is evident. Damage that would impair operation is evident. Damage that would impair operation is evident. Damage that would impair operation is evident. Low level is found.

INTERVAL Before Before

PROCEDURE Check rifle mounts (Figure 3, Item 1) for missing parts or damage. Check left screed control (Figure 3, Item 9) for damage. Check left flight screw (Figure 3, Item 8) for damage. Check right screed control (Figure 3, Item 3) for damage. Check right flight screw (Figure 3, Item 4) for damage. Check screed electric heat box (Figure 3, Item 6) for damage. Check screed crown chains (Figure 3, Item 7) and related hardware for damage. a. Check fire extinguisher (Figure 3, Item 5) for proper fill level; ensure needle is in the green portion of the gauge. b. Check fire extinguisher (Figure 3, Item 5) for current service date.

19

Before

20

Before

Right Screed Control Right Flight Screw Screed Electric Heat Box Screed Crown Chains Fire Extinguisher

21

Before

22

Before

23

Before

24

Before

Missing tag or expired date is found.

0013-6

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Table 1. Preventive Maintenance Checks and Services (PMCS) Instructions Continued. ITEM NO. ITEM TO BE CHECKED OR SERVICED EQUIPMENT NOT READY/AVAILABLE IF:

INTERVAL

PROCEDURE

Figure 4. Left End Gate. 25 Before Left End Gate Check left end gate components (Figure 4, Item 2) for damage and obstructions. Ensure sonic sensor mount wing screw (Figure 4, Item 1) is present. Damage that would impair operation is evident. Wing screw is missing.

26

Before

Sonic Sensor Mount

0013-7

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0013

Table 1. Preventive Maintenance Checks and Services (PMCS) Instructions Continued. ITEM NO. ITEM TO BE CHECKED OR SERVICED EQUIPMENT NOT READY/AVAILABLE IF:

INTERVAL

PROCEDURE

Figure 5. Left Auger and Cutoff. 27 Before Left Auger and Cutoff Check auger (Figure 5, Item 3), cutoff (Figure 5, Item2), and hydraulic cylinder and hoses (Figure 5 Item 1) for damage or leaks. Damage that would impair operation or class III leaks are evident.

0013-8

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Table 1. Preventive Maintenance Checks and Services (PMCS) Instructions Continued. ITEM NO. ITEM TO BE CHECKED OR SERVICED EQUIPMENT NOT READY/AVAILABLE IF:

INTERVAL

PROCEDURE

Figure 6. Left Spraydown and Side Left Plate. 28 Before Left Spraydown Wand and Hose Check spraydown hose, fittings, and reel (Figure 6, Item 3) for damage. Visually inspect hydraulic manifold (Figure 6, Item 1) for damage or leaks. Check hydraulic fluid level (Figure 6, Item 4). Fill hydraulic fluid as necessary (WP 0019). Visually inspect NATO slave receptacle (Figure 6, Item 5) for damage. Damage that would impair operation or frayed or cracked hoses are evident. Damage that would impair operation or class III leaks are evident. Contaminants in hydraulic fluid detected. Damage that would impair operation is evident.

29

Before

Hydraulic Manifold Hydraulic Fluid

30

Before

31

Before

North Atlantic Treaty Organization (NATO) Slave Receptacle

0013-9

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Table 1. Preventive Maintenance Checks and Services (PMCS) Instructions Continued. ITEM NO. 32 ITEM TO BE CHECKED OR SERVICED Sonic Auger Connectors EQUIPMENT NOT READY/AVAILABLE IF: Damage that would impair operation is evident and sonic augers are required for mission.

INTERVAL Before

PROCEDURE Check sonic auger connectors (Figure 6, Item 2) for damage.

Figure 7. Left Track Wear. 33 Before Left Track a. Check rubber track (Figure 7, Item 3) for separation of upper ply from lower ply. Separation of upper ply from lower ply larger than the width of the track tread and deep enough to see the steel belt. Tread is worn flat with inner portion of track (Figure 7, Item 2).

b. Check track for proper treading (Figure 7, Item 1).

0013-10

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Table 1. Preventive Maintenance Checks and Services (PMCS) Instructions Continued. ITEM NO. ITEM TO BE CHECKED OR SERVICED EQUIPMENT NOT READY/AVAILABLE IF:

INTERVAL

PROCEDURE

Figure 8. Left Track. 34 Before Bogies Check bogies (Figure 8, Item 1) for damage or obstructions. Check front idler assembly pulley (Figure 8, Item 3) for damage or obstructions. Check torque hub (Figure 8, Item 2) for damage and leaks. Damage that would impair operation is evident. Damage that would impair operation is evident. Damage that would impair operation or class III leaks are evident.

35

Before

Front Idler Assembly Pulley Torque Hub

36

Before

0013-11

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Table 1. Preventive Maintenance Checks and Services (PMCS) Instructions Continued. ITEM NO. ITEM TO BE CHECKED OR SERVICED EQUIPMENT NOT READY/AVAILABLE IF:

INTERVAL

PROCEDURE

Figure 9. Conveyor Chains. 37 Before Conveyors Check conveyor chains (Figure 9, Item 1) for damage or obstructions. Check work lights (Figure 9, Item 2) for cracks and damage. Damage that would impair operation is evident. Damage that would impair operation is evident.

38

Before

Front Work Lights

0013-12

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Table 1. Preventive Maintenance Checks and Services (PMCS) Instructions Continued. ITEM NO. ITEM TO BE CHECKED OR SERVICED EQUIPMENT NOT READY/AVAILABLE IF:

INTERVAL

PROCEDURE

Figure 10. Engine Compartment. 39 Before Engine Compartment Components Engine Oil Check engine components (Figure 10, Item 2) for leaks and damage. Check engine oil dipstick (Figure 10, Item 1) for proper level, and check for contaminants (WP 0018). Add engine oil as necessary (WP 0018). Check double hydraulic pump drive dipstick (Figure 10, Item 3) for proper level, and check for contaminants (WP 0018). Add fluid as necessary (WP 0018). Damage that would impair operation or class III leak is evident. Contaminants are detected or engine oil dipstick is broken or missing. Contaminants are detected or dipstick is broken or missing.

40

Before

41

Before

Double Hydraulic Pump Drive

0013-13

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0013

Table 1. Preventive Maintenance Checks and Services (PMCS) Instructions Continued. ITEM NO. 42 ITEM TO BE CHECKED OR SERVICED Batteries EQUIPMENT NOT READY/AVAILABLE IF: Batteries, cables, or terminals broken or damaged.

INTERVAL Before

PROCEDURE Visually inspect batteries (Figure 10, Item 4) for corrosion and broken or damaged terminals.

Figure 11. Right Track Wear. 43 Before Right Track a. Check rubber track (Figure 11, Item 2) for separation of upper ply from lower ply. Separation of upper ply from lower ply larger than the width of the track tread and deep enough to see the steel belt. Tread is worn flat with inner portion of track (Figure 11, Item 3).

b. Check track for proper treading (Figure 11, Item 1).

0013-14

TM 5-3895-385-10

0013

Table 1. Preventive Maintenance Checks and Services (PMCS) Instructions Continued. ITEM NO. ITEM TO BE CHECKED OR SERVICED EQUIPMENT NOT READY/AVAILABLE IF:

INTERVAL

PROCEDURE

Figure 12. Right Track. 44 Before Bogies Check bogies (Figure 12, Item 1) for damage or obstructions. Check front idler assembly pulley (Figure 12, Item 2) for damage or obstructions. Check torque hub (Figure 12, Item 3) for damage and leaks. Damage that would impair operation is evident. Damage that would impair operation is evident. Damage that would impair operation or class III leaks are evident.

45

Before

Front Idler Assembly Pulley Torque Hub

46

Before

0013-15

TM 5-3895-385-10

0013

Table 1. Preventive Maintenance Checks and Services (PMCS) Instructions Continued. ITEM NO. ITEM TO BE CHECKED OR SERVICED EQUIPMENT NOT READY/AVAILABLE IF:

INTERVAL

PROCEDURE

Figure 13. Side Right Plate and Spraydown Hose. 47 Before Radiator Cover Vent Sonic Auger Connectors Inspect radiator cover vent (Figure 13, Item 1) for clogging. Check sonic auger connectors (Figure 13, Item 2) for damage. Damage that would impair operation is evident. Damage that would impair operation is evident and sonic augers are required for mission. Damage that would impair operation or frayed or cracked hoses are evident.

48

Before

49

Before

Right Spraydown Wand and Hose

Check spraydown hose, fittings, and reel (Figure 13, Item 3) for damage.

0013-16

TM 5-3895-385-10

0013

Table 1. Preventive Maintenance Checks and Services (PMCS) Instructions Continued. ITEM NO. ITEM TO BE CHECKED OR SERVICED EQUIPMENT NOT READY/AVAILABLE IF:

INTERVAL

PROCEDURE

Figure 14. Right Cutoff and Auger. 50 Before Right Auger and Cutoff Check auger (Figure 14, Item 1), cutoff (Figure 14, Item3), and hydraulic cylinder and hoses (Figure 14 Item 2) for damage or leaks. Damage that would impair operation or class III leaks are evident.

0013-17

TM 5-3895-385-10

0013

Table 1. Preventive Maintenance Checks and Services (PMCS) Instructions Continued. ITEM NO. ITEM TO BE CHECKED OR SERVICED EQUIPMENT NOT READY/AVAILABLE IF:

INTERVAL

PROCEDURE

Figure 15. Right End Gate. 51 Before Right End Gate Check right end gate components (Figure 15, Item 2) for damage and obstructions. Ensure sonic sensor mount wing screw (Figure 15, Item 1) is present. Damage that would impair operation is evident. Wing screw is missing.

52

Before

Sonic Sensor Mount

0013-18

TM 5-3895-385-10

0013

Table 1. Preventive Maintenance Checks and Services (PMCS) Instructions Continued. ITEM NO. ITEM TO BE CHECKED OR SERVICED EQUIPMENT NOT READY/AVAILABLE IF:

INTERVAL

PROCEDURE

WARNING

Chain lube may enter eyes or strike the face during lubrication. Wear appropriate eye/face protection while performing PMCS. Failure to comply may cause injury or death to personnel. 53 54 55 56 Before Before Before Before Screed Crown Chains Conveyor Drive Chain Auger Chain BMPM Lubricate chains (LO 5-3895-38513). Lubricate chain (LO 5-3895-38513). Lubricate chain (LO 5-3895-38513). Lubricate at lube fittings (LO 53895-385-13).

WARNING

Exhaust discharge contains deadly gases, including carbon monoxide. Do not operate BMPM in an enclosed area unless exhaust discharge is properly vented. Failure to comply may cause injury or death to personnel. Be sure area surrounding BMPM is clear of personnel and objects before moving the unit, opening hopper wings, lowering screed, or deploying screed extensions. Sound unit horn before moving unit from stopped position. Turn on beacon when unit is in motion. Failure to comply may cause injury or death to personnel or damage to equipment. Before Display Screen Indicators a. Turn on BMPM (WP 0006). b. Check fuel gauge to ensure fuel is at least 25% filled (WP 0004). Gauge is below 25%.

57

0013-19

TM 5-3895-385-10

0013

Table 1. Preventive Maintenance Checks and Services (PMCS) Instructions Continued. ITEM NO. ITEM TO BE CHECKED OR SERVICED c. EQUIPMENT NOT READY/AVAILABLE IF: Gauge is above normal range.

INTERVAL

PROCEDURE Ensure hydraulic oil temperature gauge and water temperature gauge do not exceed normal range (WP 0004).

d. Ensure voltmeter and oil pressure gauge is not above or below normal range (WP 0004). 58 Before Screed Extension Kit Left Control Pedestal Ensure all pieces are accounted for and are not visibly damaged (WP 0023). a. Verify proper operation of EMERGENCY STOP switch.

Gauge is above or below normal range.

Damage that would impair operation is evident. BMPM and engine do not shut down.

59

Before

WARNING

Ensure area around BMPM (especially around the screed) is clea r before performing PMCS tests. Failure to comply may cause injury or death to personnel. b. Ensure left and right tow point hydraulic cylinders raise and lower properly (WP 0004). c. Ensure left and right screed extensions extend and retract properly (WP 0004). Tow point hydraulic cylinders fail to raise and lower. Screed extensions fail to extend and retract. Screed fails to raise and lower. Truck hitch arms fail to extend and retract. Augers fail to raise and lower. Hopper wings fail to open and close.

d. Ensure screed raises and lowers properly (WP 0004). e. Ensure truck hitch arms extend and retract properly (WP 0004). f. Ensure augers raise and lower properly (WP 0004).

g. Ensure hopper wings open and close properly (WP 0004). 0013-20

TM 5-3895-385-10

0013

Table 1. Preventive Maintenance Checks and Services (PMCS) Instructions Continued. ITEM NO. ITEM TO BE CHECKED OR SERVICED EQUIPMENT NOT READY/AVAILABLE IF: Beacon fails to operate. Work lights fail to operate. Horn fails to operate. Back up alarm fails to operate. BMPM and engine do not shut down.

INTERVAL

PROCEDURE h. Ensure beacon functions properly (WP 0004). i. j. k. Ensure work lights function properly (WP 0004). Ensure horn functions properly (WP 0004). Ensure back up alarm functions properly (WP 0004).

60

Before

Right Control Pedestal

a. Verify proper operation of EMERGENCY STOP switch.

WARNING

Ensure area around BMPM (especially around the screed) is clear before performing PMCS tests. Failure to comply may cause injury or death to personnel. b. Ensure left and right tow point hydraulic cylinders raise and lower properly (WP 0004). c. Ensure left and right screed extensions extend and retract properly (WP 0004). Tow point hydraulic cylinders fail to raise and lower. Screed extensions fail to extend and retract. Screed fails to raise and lower. Truck hitch arms fail to extend and retract. Augers fail to raise and lower. Hopper wings fail to open and close.

d. Ensure screed raises and lowers properly (WP 0004). e. Ensure truck hitch arms extend and retract properly (WP 0004). f. Ensure augers raise and lower properly (WP 0004)..

g. Ensure hopper wings open and close properly (WP 0004).

0013-21

TM 5-3895-385-10

0013

Table 1. Preventive Maintenance Checks and Services (PMCS) Instructions Continued. ITEM NO. ITEM TO BE CHECKED OR SERVICED EQUIPMENT NOT READY/AVAILABLE IF: Work lights fail to operate. Beacon fails to operate. Horn fails to operate. Back up alarm fails to operate.

INTERVAL

PROCEDURE h. Ensure work lights function properly (WP 0004). i. j. k. Ensure beacon functions properly (WP 0004). Ensure horn functions properly (WP 0004). Ensure back up alarm functions properly (WP 0004).

WARNING

Ensure area around BMPM is clear (especially around the screed) before performing PMCS tests. Failure to comply may cause injury or death to personnel. 61 Before Left Screed Control a. Ensure left slope lowers and raises (WP 0004). b. Ensure augers raise and lower (WP 0004). c. Ensure left tow point hydraulic cylinder raises and lowers (WP 0004). Slope fails to raise and lower. Augers fail to raise and lower. Tow point hydraulic cylinders fail to raise and lower.. Cutoff fails to raise and lower. Horn fails to operate.

d. Ensure left cutoff raises and lowers (WP 0004). e. Ensure horn functions properly (WP 0004).

WARNING

Ensure area around BMPM is clear (especially around the screed) before performing PMCS tests. Failure to comply may cause injury or death to personnel.

0013-22

TM 5-3895-385-10

0013

Table 1. Preventive Maintenance Checks and Services (PMCS) Instructions Continued. ITEM NO. 62 ITEM TO BE CHECKED OR SERVICED Right Screed Control EQUIPMENT NOT READY/AVAILABLE IF: Slope fails to raise and lower. Augers fail to raise and lower. Tow point hydraulic cylinders fail to raise and lower. Cutoff fails to raise and lower. Horn fails to operate. Gauge is below 25%.

INTERVAL Before

PROCEDURE a. Ensure right slope lowers and raises (WP 0004). b. Ensure augers raise and lower (WP 0004). c. Ensure right tow point hydraulic cylinder raises and lowers (WP 0004).

d. Ensure right cutoff raises and lowers (WP 0004). e. Ensure horn functions properly (WP 0004). 63 During Display Screen Indicators a. Check fuel gauge to ensure fuel is at least 25% filled (WP 0004). b. Ensure low battery, high coolant temp, high hydraulic oil temp, and low engine oil psi fault lights are not on (WP 0004). c. Ensure voltmeter and oil pressure gauge is not above or below normal range (WP 0004).

Low battery, high coolant temp, high hydraulic oil temp, or low engine oil psi fault lights are on. Gauge is above or below normal range.

WARNING

Hydraulic system operates at high temperature and pressure. Contact with high-pressure liquids can cause burns and scalding. Shut down BMPM and allow system to cool before performing services and maintenance. Wear gloves, additional protective clothing, and goggles as required. Failure to comply may cause injury or death to personnel. 64 During Hydraulic Oil a. Periodically check hydraulic oil level and temperature. Fill oil as necessary (WP 0019). Hydraulic oil temperature exceeds prescribed level.

0013-23

TM 5-3895-385-10

0013

Table 1. Preventive Maintenance Checks and Services (PMCS) Instructions Continued. ITEM NO. ITEM TO BE CHECKED OR SERVICED EQUIPMENT NOT READY/AVAILABLE IF:

INTERVAL

PROCEDURE b. Shut down BMPM if hydraulic oil temperature exceeds 160 degrees Fahrenheit (F) (71 degrees Celsius (C)).

WARNING

Cooling system operates at high temperature and pressure. Contact with high-pressure steam and/or liquids can cause burns and scalding. Shut down BMPM and allow system to cool before performing checks, services, and maintenance. Wear gloves, additional protective clothing, and goggles as required. Contact with high-pressure steam and/or liquids can cause burns and scalding. Failure to comply may cause injury or death to personnel. 65 During Coolant Reservoir Periodically check coolant reservoir to ensure coolant is filled to proper level. Fill as necessary (WP 0022). Be alert to unusual noises, odors, and visual indicators to problems with engine or hydraulic system. a. Turn on BMPM (WP 0006). b. Check fuel gauge to ensure fuel is at least 25% filled (WP 0004). c. Ensure hydraulic oil temperature gauge and water temperature gauge do not exceed normal range (WP 0004). Gauge is below 25%. Damage that would impair operation is evident.

66

During

Unusual Noise

67

After

Display Screen Indicators

Gauge is above normal range.

d. Ensure voltmeter and oil pressure gauge is not above or below normal range (WP 0004).

Gauge is above or below normal range.

0013-24

TM 5-3895-385-10

0013

Table 1. Preventive Maintenance Checks and Services (PMCS) Instructions Continued. ITEM NO. 68 ITEM TO BE CHECKED OR SERVICED BMPM EQUIPMENT NOT READY/AVAILABLE IF:

INTERVAL After

PROCEDURE a. Raise the screed fully up, extend screed locking pins, extend the screed extensions fully out, close the cutoffs, and turn on augers and conveyors (WP 0006).

CAUTION
Avoid spraying electrical components and rubber tracks with cleaner solution whenever possible. Failure to comply will result in damage to equipment. b. Spray all areas of BMPM that come in contact with material, except for the tracks, with spraydown cleaner solution (WP 0006). c. Spray inside of auger chain housing (WP 0006).

0013-25

TM 5-3895-385-10

0013

Table 1. Preventive Maintenance Checks and Services (PMCS) Instructions Continued. ITEM NO. ITEM TO BE CHECKED OR SERVICED EQUIPMENT NOT READY/AVAILABLE IF:

INTERVAL

PROCEDURE

Figure 16. Wear Plates.

0013-26

TM 5-3895-385-10

0013

Table 1. Preventive Maintenance Checks and Services (PMCS) Instructions Continued. ITEM NO. ITEM TO BE CHECKED OR SERVICED EQUIPMENT NOT READY/AVAILABLE IF:

INTERVAL

PROCEDURE

WARNING

Use screed locking pins when inspecting screed wear plates. Do not crawl under screed unless screed is supported properly by the screed locking pins. Failure to comply may cause injury or death to personnel. d. Check main screed wear plate (Figure 16, Item 3) for excessive wear. e. Check left and right screed extension wear plate (Figure 16, Items 2 and 4) for excessive wear. f. Check left and right end gate bottom bars (Figure 16, Items 1 and 5) for excessive wear. Metal is worn away at any spot. Metal is worn away at any spot.

Metal is worn away at any spot.

69

After

Cleaner Tank

Fill cleaner tank to appropriate level (WP 0020).

WARNING

Fuel is combustible and toxic to eyes, skin, and respiratory tract. Skin and eye protection are required when working in contact with fuel. Avoid repeated or prolonged contact. Provide adequate ventilation. Operators are to wash exposed skin and change soaked clothing promptly if exposed to fuel. Failure to comply may cause injury or death to personnel. 70 After Fuel Fill a. Clean fuel fill area of dirt and debris. b. Fill fuel to appropriate level (WP 0017).

0013-27

TM 5-3895-385-10

0013

Table 1. Preventive Maintenance Checks and Services (PMCS) Instructions Continued. ITEM NO. ITEM TO BE CHECKED OR SERVICED EQUIPMENT NOT READY/AVAILABLE IF:

INTERVAL

PROCEDURE

Figure 17. Operator Platform. 71 72 After After Left Control Pedestal Left Operator Seat Slide Assembly Cleaner Solution Level Right Control Pedestal Right Operator Seat Slide Assembly Check left control pedestal (Figure 17, Item 11) for damage. Check left operator seat slide assembly, seat, and seat belt (Figure 17, Item 10) for damage. Check cleaner solution level (Figure 17, Item 9). Fill as necessary. Check right control pedestal (Figure 17, Item 5) for damage. Check right operator seat slide assembly, seat, and seat belt (Figure 17, Item 6) for damage. Controls are damaged or missing. Seat belt missing, damaged, or inoperable. Cap is missing or damaged. Controls are damaged or missing. Seat belt missing, damaged, or inoperable.

73

After

74 75

After After

0013-28

TM 5-3895-385-10

0013

Table 1. Preventive Maintenance Checks and Services (PMCS) Instructions Continued. ITEM NO. 76 ITEM TO BE CHECKED OR SERVICED Air Intake EQUIPMENT NOT READY/AVAILABLE IF: Damage or blockage that would impair operation is evident. Damage that would impair operation is evident. Damage or blockage that would impair operation is evident.

INTERVAL After

PROCEDURE Check external air cleaner assembly components (Figure 17, Item 12) for damage or blockage. Remove blockage. Check beacon light assembly (Figure 17, Item 2) for cracks or damage. Check fume exhaust (Figure 17, Item 1) for damage or blockage. Remove blockage.

77

After

Beacon

78

After

Fume Exhaust

WARNING

When operating, muffler has hot metal surfaces that will burn flesh on contact. Shut down BMPM and allow to cool before performing maintenance. Wear gloves and additional protective clothing as required. Failure to comply may cause injury or death to personnel. 79 After Muffler Check external muffler (Figure 17, Item 3) for damage, rust, or blockage. Remove blockage. Check radiator cap (Figure 17, Item 4) for damage Check fuel cap (Figure 17, Item 7) for damage. Ensure coolant (Figure 17, Item 8) is filled to proper level. Fill as necessary (WP 0022). Damage or blockage that would impair operation is evident. Radiator cap is missing or damaged. Fuel cap is missing or damaged or any leak is evident. Class III leaks are evident.

80 81

After After

Radiator Cap Fuel Cap

82

After

Coolant Reservoir

0013-29

TM 5-3895-385-10

0013

Table 1. Preventive Maintenance Checks and Services (PMCS) Instructions Continued. ITEM NO. ITEM TO BE CHECKED OR SERVICED EQUIPMENT NOT READY/AVAILABLE IF:

INTERVAL

PROCEDURE

Figure 18. Screed. 83 After Rear Work Lights Check work lights (Figure 18, Item 2) for damage. Work lights are missing or damage that would impair operation is evident.

0013-30

TM 5-3895-385-10

0013

Table 1. Preventive Maintenance Checks and Services (PMCS) Instructions Continued. ITEM NO. 84 ITEM TO BE CHECKED OR SERVICED Rifle Mounts EQUIPMENT NOT READY/AVAILABLE IF: Rifle mounts missing.

INTERVAL After

PROCEDURE Check rifle mounts (Figure 18, Item 1) for missing parts or damage. Check left screed control (Figure 18, Item 9) for damage. Check left flight screw (Figure 18, Item 8) for damage. Check right screed control (Figure 18, Item 3) for damage. Check right flight screw (Figure 18, Item 4) for damage. Check screed electric heat box (Figure 18, Item 6) for damage. Check screed crown chains (Figure 18, Item 7) and related hardware for damage. a. Check fire extinguisher (Figure 18, Item 5) for proper fill level; ensure needle is in the green portion of the gauge. b. Check fire extinguisher (Figure 18, Item 5) for current service date.

85

After

Left Screed Control Left Flight Screw

Keypads are missing or damage that would impair operation is evident. Damage that would impair operation is evident. Keypads are missing or damage that would impair operation is evident. Damage that would impair operation is evident. Damage that would impair operation is evident. Damage that would impair operation is evident. Low level is found.

86

After

87

After

Right Screed Control Right Flight Screw Screed Electric Heat Box Screed Crown Chains Fire Extinguisher

88

After

89

After

90

After

91

After

Missing tag or expired date is found.

0013-31

TM 5-3895-385-10

0013

Table 1. Preventive Maintenance Checks and Services (PMCS) Instructions Continued. ITEM NO. ITEM TO BE CHECKED OR SERVICED EQUIPMENT NOT READY/AVAILABLE IF:

INTERVAL

PROCEDURE

Figure 19. Left End Gate. 92 After Left End Gate Check left end gate components (Figure 19, Item 2) for damage and obstructions. Ensure sonic sensor mount wing screw (Figure 19, Item 1) is present. Damage that would impair operation is evident. Wing screw is missing.

93

After

Sonic Sensor Mount

0013-32

TM 5-3895-385-10

0013

Table 1. Preventive Maintenance Checks and Services (PMCS) Instructions Continued. ITEM NO. ITEM TO BE CHECKED OR SERVICED EQUIPMENT NOT READY/AVAILABLE IF:

INTERVAL

PROCEDURE

Figure 20. Left Auger and Cutoff. 94 After Left Auger and Cutoff Check auger (Figure 20, Item 3), cutoff (Figure 20, Item2), and hydraulic cylinder and hoses (Figure 20 Item 1) for damage or leaks. Damage that would impair operation or class III leaks are evident.

0013-33

TM 5-3895-385-10

0013

Table 1. Preventive Maintenance Checks and Services (PMCS) Instructions Continued. ITEM NO. ITEM TO BE CHECKED OR SERVICED EQUIPMENT NOT READY/AVAILABLE IF:

INTERVAL

PROCEDURE

Figure 21. Left Spraydown and Side Left Plate. 95 After Left Spraydown Wand and Hose Check spraydown hose, fittings, and reel (Figure 21, Item 3) for damage. Visually inspect hydraulic manifold (Figure 21, Item 1) for damage or leaks. Check hydraulic fluid level (Figure 21, Item 4). Fill hydraulic fluid as necessary (WP 0019). Visually inspect NATO slave receptacle (Figure 21, Item 5) for damage. Damage that would impair operation or frayed or cracked hoses are evident. Damage that would impair operation or class III leaks are evident. Contaminants in hydraulic fluid detected. Damage that would impair operation is evident.

96

After

Hydraulic Manifold Hydraulic Fluid

97

After

98

After

NATO Slave Receptacle.

0013-34

TM 5-3895-385-10

0013

Table 1. Preventive Maintenance Checks and Services (PMCS) Instructions Continued. ITEM NO. 99 ITEM TO BE CHECKED OR SERVICED Sonic Auger Connectors EQUIPMENT NOT READY/AVAILABLE IF: Damage that would impair operation is evident and sonic augers are required for mission.

INTERVAL After

PROCEDURE Check sonic auger connectors (Figure 21, Item 2) for damage.

Figure 22. Left Track Wear. 100 After Left Track a. Check rubber track (Figure 22, Item 3) for separation of upper ply from lower ply. Separation of upper ply from lower ply larger than the width of the track tread and deep enough to see the steel belt. Tread is worn flat with inner portion of track (Figure 22, Item 2).

b. Check track for proper treading (Figure 22, Item 1).

0013-35

TM 5-3895-385-10

0013

Table 1. Preventive Maintenance Checks and Services (PMCS) Instructions Continued. ITEM NO. ITEM TO BE CHECKED OR SERVICED EQUIPMENT NOT READY/AVAILABLE IF:

INTERVAL

PROCEDURE

Figure 23. Left Track. 101 After Bogies Check bogies (Figure 23, Item 1) for damage or obstructions. Check front idler assembly pulley (Figure 23, Item 3) for damage or obstructions. Check torque hub (Figure 23, Item 2) for damage and leaks. Damage that would impair operation is evident. Damage that would impair operation is evident. Damage that would impair operation or class III leaks are evident.

102

After

Front Idler Assembly Pulley Torque Hub

103

After

0013-36

TM 5-3895-385-10

0013

Table 1. Preventive Maintenance Checks and Services (PMCS) Instructions Continued. ITEM NO. ITEM TO BE CHECKED OR SERVICED EQUIPMENT NOT READY/AVAILABLE IF:

INTERVAL

PROCEDURE

Figure 24. Conveyor Chains. 104 After Conveyors Check conveyor chains (Figure 24, Item 1) for damage or obstructions. Check work lights (Figure 24, Item 2) for cracks and damage. Damage that would impair operation is evident. Damage that would impair operation is evident.

105

After

Front Work Lights

0013-37

TM 5-3895-385-10

0013

Table 1. Preventive Maintenance Checks and Services (PMCS) Instructions Continued. ITEM NO. ITEM TO BE CHECKED OR SERVICED EQUIPMENT NOT READY/AVAILABLE IF:

INTERVAL

PROCEDURE

Figure 25. Engine Compartment. 106 After Engine Compartment Components Engine Oil Check engine components (Figure 25, Item 2) for leaks and damage. Check engine oil dipstick (Figure 25, Item 1) for proper level, and check for contaminants (WP 0018). Add engine oil as necessary (WP 0018). Check double hydraulic pump drive dipstick (Figure 25, Item 3) for proper level, and check for contaminants (WP 0018). Add fluid as necessary (WP 0018). Damage that would impair operation or class III leak is evident. Contaminants are detected or engine oil dipstick is broken or missing. Contaminants are detected or dipstick is broken or missing.

107

After

108

After

Double Hydraulic Pump Drive

0013-38

TM 5-3895-385-10

0013

Table 1. Preventive Maintenance Checks and Services (PMCS) Instructions Continued. ITEM NO. 109 ITEM TO BE CHECKED OR SERVICED Batteries EQUIPMENT NOT READY/AVAILABLE IF: Batteries, cables, or terminals broken or damaged.

INTERVAL After

PROCEDURE Visually inspect batteries (Figure 25, Item 4) for corrosion and broken or damaged terminals.

Figure 26. Right Track Wear. 110 After Right Track a. Check rubber track (Figure 26, Item 2) for separation of upper ply from lower ply. Separation of upper ply from lower ply larger than the width of the track tread and deep enough to see the steel belt. Tread is worn flat with inner portion of track (Figure 26, Item 3).

b. Check track for proper treading (Figure 26, Item 1).

0013-39

TM 5-3895-385-10

0013

Table 1. Preventive Maintenance Checks and Services (PMCS) Instructions Continued. ITEM NO. ITEM TO BE CHECKED OR SERVICED EQUIPMENT NOT READY/AVAILABLE IF:

INTERVAL

PROCEDURE

Figure 27. Right Track. 111 After Bogies Check bogies (Figure 27, Item 1) for damage or obstructions. Check front idler assembly pulley (Figure 27, Item 2) for damage or obstructions. Check torque hub (Figure 27, Item 3) for damage and leaks. Damage that would impair operation is evident. Damage that would impair operation is evident. Damage that would impair operation or class III leaks are evident.

112

After

Front Idler Assembly Pulley Torque Hub

113

After

0013-40

TM 5-3895-385-10

0013

Table 1. Preventive Maintenance Checks and Services (PMCS) Instructions Continued. ITEM NO. ITEM TO BE CHECKED OR SERVICED EQUIPMENT NOT READY/AVAILABLE IF:

INTERVAL

PROCEDURE

Figure 28. Side Right Plate and Spraydown Hose. 114 After Radiator Cover Vent Sonic Auger Connectors Inspect radiator cover vent (Figure 28, Item 1) for clogging. Check sonic auger connectors (Figure 28, Item 2) for damage. Damage that would impair operation is evident. Damage that would impair operation is evident and sonic augers are required for mission. Damage that would impair operation or frayed or cracked hoses are evident.

115

After

116

After

Right Spraydown Wand and Hose

Check spraydown hose, fittings, and reel (Figure 28, Item 3) for damage.

0013-41

TM 5-3895-385-10

0013

Table 1. Preventive Maintenance Checks and Services (PMCS) Instructions Continued. ITEM NO. ITEM TO BE CHECKED OR SERVICED EQUIPMENT NOT READY/AVAILABLE IF:

INTERVAL

PROCEDURE

Figure 29. Right Cutoff and Auger. 117 After Right Auger and Cutoff Check auger (Figure 29, Item 1), cutoff (Figure 29, Item3), and hydraulic cylinder and hoses (Figure 29 Item 2) for damage or leaks. Damage that would impair operation or class III leaks are evident.

0013-42

TM 5-3895-385-10

0013

Table 1. Preventive Maintenance Checks and Services (PMCS) Instructions Continued. ITEM NO. ITEM TO BE CHECKED OR SERVICED EQUIPMENT NOT READY/AVAILABLE IF:

INTERVAL

PROCEDURE

Figure 30. Right End Gate. 118 After Right End Gate Check right end gate components (Figure 30, Item 2) for damage and obstructions. Ensure sonic sensor mount wing screw (Figure 30, Item 1) is present. Damage that would impair operation is evident. Wing screw is missing.

119

After

Sonic Sensor Mount

0013-43

TM 5-3895-385-10

0013

Table 1. Preventive Maintenance Checks and Services (PMCS) Instructions Continued. ITEM NO. ITEM TO BE CHECKED OR SERVICED EQUIPMENT NOT READY/AVAILABLE IF:

INTERVAL

PROCEDURE

WARNING

Chain lube may enter eyes or strike the face during lubrication. Wear appropriate eye/face protection while performing PMCS. Failure to comply may cause injury or death to personnel. 120 121 122 123 After After After After Screed Crown Chains Conveyor Drive Chain Auger Chain BMPM Lubricate chains (LO 5-3895-38513). Lubricate chain (LO 5-3895-38513). Lubricate chain (LO 5-3895-38513). Lubricate at lube fittings (LO 53895-385-13).

WARNING

Exhaust discharge contains deadly gases, including carbon monoxide. Do not operate BMPM in an enclosed area unless exhaust discharge is properly vented. Failure to comply may cause injury or death to personnel. Be sure area surrounding BMPM is clear of personnel and objects before moving the unit, opening hopper wings, lowering screed, or deploying screed extensions. Sound unit horn before moving unit from stopped position. Turn on beacon when unit is in motion. Failure to comply may cause injury or death to personnel or damage to equipment. After Display Screen Indicators a. Turn on BMPM (WP 0006). b. Check fuel gauge to ensure fuel is at least 25% filled (WP 0004). Gauge is below 25%.

124

0013-44

TM 5-3895-385-10

0013

Table 1. Preventive Maintenance Checks and Services (PMCS) Instructions Continued. ITEM NO. ITEM TO BE CHECKED OR SERVICED c. EQUIPMENT NOT READY/AVAILABLE IF: Gauge is above normal range.

INTERVAL

PROCEDURE Ensure hydraulic oil temperature gauge and water temperature gauge do not exceed normal range (WP 0004).

d. Ensure voltmeter and oil pressure gauge is not above or below normal range (WP 0004). 125 After Screed Extension Kit Ensure all pieces are accounted for and are not visibly damaged (WP 0023).

Gauge is above or below normal range.

Damage that would impair operation is evident.

NOTE
Clean and inspect air filter daily if working in dusty or sandy environment. 126 Weekly Primary Air Filter Clean primary air filter element (WP 0021). Damage that would impair operation is evident.

END OF WORK PACKAGE

0013-45/46 blank

TM 5-3895-385-10

0014

OPERATOR MAINTENANCE BITUMINOUS MATERIAL PAVING MACHINE (BMPM) END GATE REMOVAL AND INSTALLATION

INITIAL SETUP: Tools and Special Tools 9/16 inch combination wrench (WP 0031, Item 16) 1 1/4 inch combination wrench (WP 0031, Item 19) Materials/Parts Lock nut (WP 0033, Item 14) Lock washer (WP 0033, Item 18) Personnel Required 12V (4) References WP 0013 WP 0023 Equipment Conditions Screed extensions fully extended (WP 0006) Screed fully lowered (WP 0006) Engine off (WP 0006) BATTERY DISCONNECT switch OFF (WP 0004) Time Required 0.5 hr END GATE REMOVAL AND INSTALLATION

NOTE
The procedure for installation and removal of the end gate is the same whether being performed on the screed extension or bolt-on screed extension. The procedure for installation and removal of the end gate is the same whether being performed on the left side or right side. Left side shown.

0014-1

TM 5-3895-385-10

0014

END GATE REMOVAL

Figure 1. End Gate. 1. Remove two bolts (Figure 1, Item 6), lock washers (Figure 1, Item 7), and screed end gate bracket mount bar (Figure 1, Item 8) from screed extension (Figure 1, Item 2), and discard lock washers. 2. Remove lock nut (Figure 1, Item 5) from screed extension bolt (Figure 1, Item 3) and end gate depth screw bracket (Figure 1, Item 4), and discard lock nut.

WARNING

The end gate weighs 168 pounds (lb) (76 kilograms (kg)). Four personnel are required to lift component. Failure to comply may cause injury or death to personnel.

CAUTION
Properly support the item being lifted. Failure to comply may cause damage to equipment.

NOTE
It may be necessary to raise screed slightly in order to slide end gate on or off screed extension. 3. Remove end gate (Figure 1, Item 1) from screed extension (Figure 1, Item 2) with assistance. 0014-2

TM 5-3895-385-10

0014

END GATE REMOVAL CONTINUED.

Figure 2. Screed Extension. 4. Install two bolts (Figure 2, Item 5), new lock washers (Figure 2, Item 6), and screed end gate bracket mount bar (Figure 2, Item 1) onto screed extension (Figure 2, Item 2). 5. Install new lock nut (Figure 2, Item 4) onto screed extension bolt (Figure 2, Item 3). 6. Pack end gate (WP 0023). END OF TASK

0014-3

TM 5-3895-385-10

0014

END GATE INSTALLATION

Figure 3. Screed Extension.

NOTE
The Bituminous Material Paving Machine (BMPM) is shipped without end gates attached. The end gates must be installed prior to use. End gates must also be removed and installed when installing or removing bolt-on extensions. The procedure for installation and removal of the end gate is the same whether being performed on the screed extension or bolt-on screed extension. The procedure for installation and removal of the end gate is the same whether being performed on the left side or right side. Left side shown.

1. Unpack end gate (WP 0023). 2. Remove two bolts (Figure 3, Item 5), lock washers (Figure 3, Item 6), and screed end gate bracket mount bar (Figure 3, Item 1) from screed extension (Figure 3, Item 2), and discard lock washers. 3. Remove lock nut (Figure 3, Item 4) from screed extension bolt (Figure 3, Item 3), and discard lock nut.

0014-4

TM 5-3895-385-10

0014

END GATE INSTALLATION CONTINUED.

Figure 4. End Gate.

WARNING

The end gate weighs 168 lb (76 kg). Four personnel are required to lift component. Failure to comply may cause injury or death to personnel.

CAUTION
Properly support the item being lifted. Failure to comply may cause damage to equipment.

NOTE
It may be necessary to raise screed slightly in order to slide end gate on or off screed extension. It may be necessary to adjust the end gate tilt screw post for proper alignment.

4. Install the end gate (Figure 4, Item 1) onto screed extension (Figure 4, Item 2) with assistance.

0014-5

TM 5-3895-385-10

0014

END GATE INSTALLATION CONTINUED. 5. Install two bolts (Figure 4, Item 6), new lock washers (Figure 4, Item 7), and screed end gate bracket mount bar (Figure 4, Item 8) onto screed extension (Figure 4, Item 2).

CAUTION
To ensure proper operation, do not over tighten the nut on screed extension bolt. There should be just enough space to allow the end gate to tilt. Approximately three threads of the screed extension bolt will be showing. Failure to comply will cause degraded operation. 6. Install new lock nut (Figure 4, Item 5) onto screed extension bolt (Figure 4, Item 3) until lock nut just touches the end gate depth screw bracket (Figure 4, Item 4). END OF TASK FOLLOW-ON TASK 1. Perform Before PMCS (WP 0013). 2. Turn BATTERY DISCONNECT switch ON (WP 0004) END OF TASK END OF WORK PACKAGE

0014-6

TM 5-3895-385-10

0015

OPERATOR MAINTENANCE BITUMINOUS MATERIAL PAVING MACHINE (BMPM) BOLT-ON SCREED EXTENSION KIT REMOVAL AND INSTALLATION

INITIAL SETUP: Tools and Special Tools 14 mm screwdriver attachment (WP 0031, Item 8) 9/16 inch combination wrench (WP 0031, Item 16) 15/16 inch combination wrench (WP 0031, Item 18) 1 1/4 inch combination wrench (WP 0031, Item 19) Socket wrench handle (WP 0031, Item 5) Materials/Parts Lock nut (WP 0033, Item 14) Lock washer (WP 0033, Item 18) Personnel Required 12V (6) References WP 0002 WP 0009 WP 0023 Equipment Conditions End gates removed (WP 0014) Screed extensions fully extended (WP 0006) Screed fully lowered (WP 0006) Cutoffs fully closed (WP 0006) Engine off (WP 0006) BATTERY DISCONNECT switch OFF (WP 0004) Time Required 1.0 hr

0015-1

TM 5-3895-385-10

0015

BOLT-ON SCREED EXTENSION KIT REMOVAL AND INSTALLATION BOLT-ON SCREED EXTENSION KIT REMOVAL

Figure 1. Retaining Plate Extension Removal.

0015-2

TM 5-3895-385-10

0015

BOLT-ON SCREED EXTENSION KIT REMOVAL CONTINUED.

WARNING

Allow 30 minutes of cool down time before touching machine components. Failure to comply may cause injury or death to personnel.

CAUTION
Care should be taken when retracting screed extension with bolt-on screed extensions installed. If screed extensions are retracted too far, the end gates will collide with the auger extensions. Failure to comply may cause damage to equipment.

NOTE
The Bituminous Material Paving Machine (BMPM) is equipped with screed extensions that will enable the operator to pave up to a 20-foot (ft) (6.1-meter (m)) width. This requires the installation of screed extensions and auger extensions. The procedure for installation and removal of material retaining plate extensions is the same whether being performed on the left side or right side. Left side shown.

1. Remove wing screw (Figure 1, Item 4) from 4-ft bolt-on extension material retaining plate L or R (Figure 1, Item 1). 2. Remove 2-ft bolt-on extension material retaining plate L or R (Figure 1, Item 5) from 4-ft bolt-on extension material retaining plate L or R (Figure 1, Item 1). 3. Install wing screw (Figure 1, Item 4) on 4-ft bolt-on extension material retaining plate L or R (Figure 1, Item 1). 4. Remove wing screw (Figure 1, Item 3) from BMPM (Figure 1, Item 2). 5. Remove 4-ft bolt-on extension material retaining plate L or R (Figure 1, Item 1) from BMPM (Figure 1, Item 2) with assistance. 6. Install wing screw (Figure 1, Item 3) onto BMPM (Figure 1, Item 2).

0015-3

TM 5-3895-385-10

0015

BOLT-ON SCREED EXTENSION KIT REMOVAL CONTINUED.

Figure 2. Bolt-On Auger Extension Removal.

0015-4

TM 5-3895-385-10

0015

BOLT-ON SCREED EXTENSION KIT REMOVAL CONTINUED. 7. Remove bolt (Figure 2, Item 3), nut (Figure 2, Item 10), and auger shaft cap (Figure 2, Item 1) from 2-ft auger extension L or R (Figure 2, Item 2). 8. Install bolt (Figure 2, Item 3) and nut (Figure 2, Item 10) onto 2-ft auger extension L or R (Figure 2, Item 2) for storage. 9. Remove bolt (Figure 2, Item 4) and nut (Figure 2, Item 9) from 4-ft auger extension L or R (Figure 2, Item 5).

WARNING

The 2-ft auger extension weighs 89 pounds (lb) (40 kilograms (kg)). Two personnel are required to lift component. Failure to comply may cause injury or death to personnel.

CAUTION
Do not drop item being lifted. Failure to comply may cause damage to equipment. 10. Remove 2-ft auger extension L or R (Figure 2, Item 2) from 4-ft auger extension L or R (Figure 2, Item 5) with assistance. 11. Install bolt (Figure 2, Item 4) and nut (Figure 2, Item 9) onto 2-ft auger extension L or R (Figure 2, Item 2) for storage. 12. Remove bolt (Figure 2, Item 7) and nut (Figure 2, Item 8) from auger (Figure 2, Item 6).

WARNING

The 4-ft auger extension weighs 170 lb (77 kg). Four personnel are required to lift component. Failure to comply may cause injury or death to personnel.

CAUTION
Do not drop item being lifted. Failure to comply may cause damage to equipment. 13. Remove 4-ft auger extension L or R (Figure 2, Item 5) from auger (Figure 2, Item 6) with assistance. 14. Install auger shaft cap (Figure 2, Item 1), bolt (Figure 2, Item 7), and nut (Figure 2, Item 8) onto auger (Figure 2, Item 6).

0015-5

TM 5-3895-385-10

0015

BOLT-ON SCREED EXTENSION KIT REMOVAL CONTINUED.

Figure 3. Bolt-On Screed Extension Removal. 15. Disconnect screed electric heat box element cable (Figure 3, Item 11) from bolt-on extension screed electric heat box element cable (Figure 3, Item 10). 16. Obtain screed electric heat box element cable cap (Figure 3, Item 9) from toolbox (WP 0002), and install screed electric heat box element cable cap onto screed electric heat box element cable (Figure 3, Item 11). 17. Remove lock nut (Figure 3, Item 14) from screed extension bolt (Figure 3, Item 13), and discard lock nut. 18. Remove two bolts (Figure 3, Item 16), lock washers (Figure 3, Item 17), and screed end gate bracket mount bar (Figure 3, Item 18) from screed extension (Figure 3, Item 8), and discard lock washers. 19. Remove bolt (Figure 3, Item 2), lock washer (Figure 3, Item 3), and nut (Figure 3, Item 4) from screed extension multiple angle bracket (Figure 3, Item 1), and discard lock washer. 20. Remove bolt (Figure 3, Item 19), flat washer (Figure 3, Item 5), lock washer (Figure 3, Item 6), and nut (Figure 3, Item 7) from screed extension multiple angle bracket (Figure 3, Item 1), and discard lock washer.

0015-6

TM 5-3895-385-10

0015

BOLT-ON SCREED EXTENSION KIT REMOVAL CONTINUED.

WARNING

The bolt-on screed extension weighs 236 lb (107 kg). Six personnel are required to lift component. Failure to comply may cause injury or death to personnel.

CAUTION
Do not drop item being lifted. Failure to comply may cause damage to equipment. 21. Remove bolt-on screed extension (Figure 3, Item 15) from BMPM screed extension (Figure 3, Item 8) with assistance. 22. Install bolt (Figure 3, Item 2), lock washer (Figure 3, Item 3), and nut (Figure 3, Item 4) onto screed extension multiple angle bracket (Figure 3, Item 1) for storage. 23. Install bolt (Figure 3, Item 19), flat washer (Figure 3, Item 5), lock washer (Figure 3, Item 6), and nut (Figure 3, Item 7) onto screed extension multiple angle bracket (Figure 3, Item 1) for storage. 24. Install two bolts (Figure 3, Item 16), lock washers (Figure 3, Item 17), and screed end gate bracket mount bar (Figure 3, Item 18) onto screed extension (Figure 3, Item 8) for storage. 25. Pack bolt-on screed extension kit (WP 0023). END OF TASK

0015-7

TM 5-3895-385-10

0015

BOLT-ON SCREED EXTENSION KIT INSTALLATION

Figure 4. Bolt-On Screed Extension Installation.

0015-8

TM 5-3895-385-10

0015

BOLT-ON SCREED EXTENSION KIT INSTALLATION CONTINUED.

WARNING

The bolt-on screed extension weighs 236 lb (107 kg). Six personnel are required to lift component. Failure to comply may cause injury or death to personnel.

CAUTION
Do not drop item being lifted. Failure to comply may cause damage to equipment.

NOTE
Bolt-on screed extensions, auger extensions, and material retaining plates are labeled for left and right sides of the BMPM (WP 0009). Be sure to install the correct parts on each side of the machine. 1. Unpack bolt-on screed extension kit (WP 0023). 2. Remove bolt (Figure 4, Item 2), lock washer (Figure 4, Item 3), and nut (Figure 4, Item 4) from screed extension multiple angle bracket (Figure 4, Item 1). 3. Remove bolt (Figure 4, Item 19), flat washer (Figure 4, Item 5), lock washer (Figure 4, Item 6), and nut (Figure 4, Item 7) from screed extension multiple angle bracket (Figure 4, Item 1). 4. Remove two bolts (Figure 4, Item 16), lock washers (Figure 4, Item 17), and screed end gate bracket mount bar (Figure 4, Item 18) from mounting holes (Figure 4, Item 12). 5. Install bolt-on screed extension (Figure 4, Item 15) onto screed extension (Figure 4, Item 8) with assistance. 6. Install bolt (Figure 4, Item 2), new lock washer (Figure 4, Item 3), and nut (Figure 4, Item 4) onto screed extension multiple angle bracket (Figure 4, Item 1). 7. Install bolt (Figure 4, Item 19), washer (Figure 4, Item 5), new lock washer (Figure 4, Item 6), and nut (Figure 4, Item 7) onto screed extension multiple angle bracket (Figure 4, Item 1). 8. Install screed end gate bracket mount bar (Figure 4, Item 18), two bolts (Figure 4, Item 16), and new lock washers (Figure 4, Item 17) to mounting holes (Figure 4, Item 12). 9. Install new lock nut (Figure 4, Item 14) onto screed extension bolt (Figure 4, Item 13). 10. Remove screed electric heat box element cable cap (Figure 4, Item 9) from screed electric heat box element cable (Figure 4, Item 11), and store in BMPM toolbox (WP 0002). 11. Connect bolt-on extension screed electric heat box element cable (Figure 4, Item 10) to screed electric heat box element cable (Figure 4, Item 11).

0015-9

TM 5-3895-385-10

0015

BOLT-ON SCREED EXTENSION KIT INSTALLATION CONTINUED.

Figure 5. Bolt-On Auger Extension Installation.

0015-10

TM 5-3895-385-10

0015

BOLT-ON SCREED EXTENSION KIT INSTALLATION CONTINUED.

NOTE
Auger extensions and material retaining plate extensions are labeled L and R (WP 0009). Pieces labeled L should be installed on the left side of the BMPM; pieces labeled R should be installed on the right side of the BMPM. The procedure for installation and removal of the auger extensions is the same whether being performed on the left side or right side. Left side shown.

12. Remove bolt (Figure 5, Item 7), nut (Figure 5, Item 8), and auger shaft cap (Figure 5, Item 1) from auger (Figure 5, Item 6).

WARNING

The 4-ft auger extension weighs 170 lb (77 kg). Four personnel are required to lift component. Failure to comply may cause injury or death to personnel.

CAUTION
Do not drop item being lifted. Failure to comply may cause damage to equipment. 13. Install 4-ft auger extension (Figure 5, Item 5), bolt (Figure 5, Item 7), and nut (Figure 5, Item 8) onto auger (Figure 5, Item 6) with assistance. 14. Remove bolt (Figure 5, Item 4) and nut (Figure 5, Item 9) from 4-ft auger extension (Figure 5, Item 5). 15. Remove bolt (Figure 5, Item 3) and nut (Figure 5, Item 10) from 2-ft auger extension L or R (Figure 5, Item 2).

WARNING

The 2-ft auger extension weighs 89 pounds (lb) (40 kilograms (kg)). Two personnel are required to lift component. Failure to comply may cause injury or death to personnel.

CAUTION
Do not drop item being lifted. Failure to comply may cause damage to equipment. 16. Install 2-ft auger extension L or R (Figure 5, Item 2), bolt (Figure 5, Item 4), and nut (Figure 5, Item 9) onto auger (Figure 5, Item 6) with assistance. 17. Install auger shaft cap (Figure 5, Item 1), bolt (Figure 5, Item 3), and nut (Figure 5, Item 10) onto 2-ft auger extension L or R (Figure 5, Item 2).

0015-11

TM 5-3895-385-10

0015

BOLT-ON SCREED EXTENSION KIT INSTALLATION CONTINUED.

Figure 6. Retaining Plate Extension Installation.

0015-12

TM 5-3895-385-10

0015

BOLT-ON SCREED EXTENSION KIT INSTALLATION CONTINUED.

NOTE
Auger extensions and material retaining plate extensions are labeled L and R (WP 0009). Pieces labeled L should be installed on the left side of the BMPM; pieces labeled R should be installed on the right side of the BMPM. The procedure for installation and removal of material retaining plate extensions is the same whether being performed on the left side or right side. Left side shown.

18. Remove wing screw (Figure 6, Item 3) from BMPM (Figure 6, Item 2). 19. Install 4-ft bolt-on extension material retaining plate L or R (Figure 6, Item 1) into BMPM (Figure 6, Item 2) with assistance. 20. Install wing screw (Figure 6, Item 3) onto BMPM (Figure 6, Item 2). 21. Remove wing screw (Figure 6, Item 4) from 4-ft bolt-on extension material retaining plate L or R (Figure 6, Item 1). 22. Install 2-ft bolt-on extension material retaining plate L or R (Figure 6, Item 5) into 4-ft bolt-on extension material retaining plate L or R (Figure 6, Item 1). 23. Install wing screw (Figure 6, Item 3) on 4-ft bolt-on extension material retaining plate L or R (Figure 6, Item 1). END OF TASK FOLLOW-ON TASK Install end gates (WP 0014) END OF TASK END OF WORK PACKAGE

0015-13/14 blank

TM 5-3895-385-10

0016

OPERATOR MAINTENANCE BITUMINOUS MATERIAL PAVING MACHINE (BMPM) CUTOFF SHOE REMOVAL AND INSTALLATION

INITIAL SETUP: Tools and Special Tools 9/16 inch combination wrench (WP 0031, Item 16) 9/16 socket (WP 0031, Item 10) Socket wrench handle (WP 0031, Item 5) Materials/Parts Lock washer (8) (WP 0033, Item 18) Personnel Required 12V (1) References WP 0009 WP 0023 CUTOFF SHOES REMOVAL AND INSTALLATION Equipment Conditions Screed extensions fully extended (WP 0006) Screed fully lowered (WP 0006) Cutoffs fully raised (WP 0006) Engine off (WP 0006) BATTERY DISCONNECT switch OFF (WP 0004) Time Required 0.5 hr

CAUTION
The Bituminous Material Paving Machine (BMPM) cutoffs cannot be lowered when the cutoff shoes are installed. Failure to comply may cause damage to equipment.

NOTE
The BMPM is equipped with cutoff shoes that will enable the operator to pave an area that is only 6 feet (ft) wide. The procedure for installation and removal of the cutoff shoes is the same whether being performed on the left side or right side. Left side shown.

0016-1

TM 5-3895-385-10

0016

CUTOFF SHOES REMOVAL

Figure 1. Cutoff Shoe.

0016-2

TM 5-3895-385-10

0016

CUTOFF SHOES REMOVAL CONTINUED.

WARNING

Allow 30 minutes of cool down time before touching machine components. Failure to comply may cause injury or death to personnel.

NOTE
Inner cutoff shoes are labeled as L (left) and R (right) by a stamp on the cutoff shoe (WP 0009). Out cutoff shows are interchangeable. 1. Remove two bolts (Figure 1, Item 9), lock washers (Figure 1, Item 14), nuts (Figure 1, Item 13), and outer cutoff shoe (Figure 1, Item 10) from BMPM (Figure 1, Item 1). 2. Remove two bolts (Figure 1, Item 3), lock washers (Figure 1, Item 11), nuts (Figure 1, Item 12), and inner cutoff shoe (Figure 1, Item 2) along with cutoff shoe plate (Figure 1, Item 4) from BMPM (Figure 1, Item 1). 3. Remove three bolts (Figure 1, Item 5), flat washers (Figure 1, Item 6), lock washers (Figure 1, Item 7), nuts (Figure 1, Item 8), and cutoff shoe plate (Figure 1, Item 4) from inner cutoff shoe (Figure 1, Item 2). 4. Install three bolts (Figure 1, Item 5), flat washers (Figure 1, Item 6), lock washers (Figure 1, Item 7), nuts (Figure 1, Item 8) into inner cutoff shoe (Figure 1, Item 2) for storage. 5. Install two bolts (Figure 1, Item 3), lock washers (Figure 1, Item 11), and nuts (Figure 1, Item 12) into inner cutoff shoe (Figure 1, Item 2) for storage. 6. Install two bolts (Figure 1, Item 9), lock washers (Figure 1, Item 14), and nuts (Figure 1, Item 13) into outer cutoff shoe (Figure 1, Item 10) for storage. 7. Pack cutoff shoes (WP 0023). END OF TASK CUTOFF SHOES INSTALLATION 1. Unpack cutoff shoes (WP 0023). 2. Remove two bolts (Figure 1, Item 9), lock washers (Figure 1, Item 14), and nuts (Figure 1, Item 13) from outer cutoff shoe (Figure 1, Item 10), and discard lock washers. 3. Remove three bolts (Figure 1, Item 5), flat washers (Figure 1, Item 6), lock washers (Figure 1, Item 7), nuts (Figure 1, Item 8) from inner cutoff shoe (Figure 1, Item 2), and discard lock washers. 4. Remove two bolts (Figure 1, Item 3), lock washers (Figure 1, Item 11), and nuts (Figure 1, Item 12) from inner cutoff shoe (Figure 1, Item 2), and discard lock washers.

0016-3

TM 5-3895-385-10

0016

CUTOFF SHOES INSTALLATION CONTINUED.

NOTE
Inner cutoff shoes are labeled as L (left) and R (right) by a stamp on the cutoff shoe (WP 0009). Outer cutoff shoes are interchangeable. Ensure cutoff shoes are inside of both the BMPM plate and the BMPM cutoff.

5. Install cutoff shoe plate (Figure 1, Item 4), three bolts (Figure 1, Item 5), flat washers (Figure 1, Item 6), new lock washers (Figure 1, Item 7), and nuts (Figure 1, Item 8) onto inner cutoff shoe (Figure 1, Item 2). 6. Install inner cutoff shoe (Figure 1, Item 2), two bolts (Figure 1, Item 3), new lock washers (Figure 1, Item 11), and nuts (Figure 1, Item 12) along with cutoff shoe plate (Figure 1, Item 4) onto BMPM (Figure 1, Item 1). 7. Install outer cutoff shoe (Figure 1, Item 10), two bolts (Figure 1, Item 9), new lock washers (Figure 1, Item 14), and nuts (Figure 1, Item 13) onto BMPM (Figure 1, Item 1). END OF TASK END OF WORK PACKAGE

0016-4

TM 5-3895-385-10

0017

OPERATOR MAINTENANCE BITUMINOUS MATERIAL PAVING MACHINE (BMPM) FUELING SYSTEM SERVICE

INITIAL SETUP: Materials/Parts JP 8 (WP 0033, Item 17) Wiping rag (WP 0033, Item 15) Personnel Required 12V (1) References WP 0006 WP 0013 Equipment Conditions Seat slide assembly out (WP 0006). BATTERY DISCONNECT switch ON (WP 0004) Time Required 0.5 hr

0017-1

TM 5-3895-385-10

0017

FUELING SYSTEM SERVICE Check Fuel Level from Initial Startup Screen

Figure 1. Engine Screen.

0017-2

TM 5-3895-385-10

0017

Check Fuel Level from Initial Startup Screen Continued. 1. Turn keyless engine switch to AUX (WP 0004).

NOTE
Press button 1 (Figure 1, Item 1) to enter engine screen if on a different screen. 2. Observe fuel level on fuel gauge (Figure 1, Item 2) on engine screen (WP 0004).

NOTE
E at the bottom of the fuel gauge indicates empty, and F at the top of the fuel gauge indicates full. 3. Turn keyless engine switch to the OFF position (WP 0006). 4. Perform Fill Fuel Tank task if fuel level is low. END OF TASK

0017-3

TM 5-3895-385-10

0017

Fill Fuel Tank

Figure 2. Fuel Tank Cap Removal. 1. Extend right operator seat (WP 0006).

WARNING

Fuel is combustible and toxic to eyes, skin, and respiratory tract. Skin and eye protection are required when working in contact with fuel. Avoid repeated or prolonged contact. Provide adequate ventilation. Operators are to wash exposed skin and change soaked clothing promptly if exposed to fuel. Failure to comply may cause injury or death to personnel. 2. Remove any dirt or debris from the fuel tank cap area (Figure 2).

NOTE
If a lock is placed on the fuel tank cap latch, remove lock before proceeding. 3. Pull up fuel tank cap latch (Figure 2, Item 2). 4. Turn fuel tank cap latch (Figure 2, Item 2) counterclockwise. 5. Remove fuel tank cap (Figure 2, Item 1). 6. Set aside fuel tank cap (Figure 2, Item 1) on clean surface for installation.

0017-4

TM 5-3895-385-10

0017

Fill Fuel Tank Continued.

WARNING

Hot engine surfaces are possible sources of ignition. When refueling during unit operation with JP8, avoid fuel splash and fuel spill. Do not smoke or use open flame when performing refueling. Remember Preventive Maintenance Checks and Services (PMCS) are still required (WP 0013). Flames and possible explosion may result. Failure to comply may cause injury or death to personnel. Metal jewelry can conduct electricity and become entangled in BMPM components. Remove all jewelry and do not wear loose clothing when working on equipment. Failure to comply may cause injury or death to personnel. Flying debris or material may enter eyes or strike the face. Wear appropriate eye/face protection. Failure to comply may cause injury or death to personnel.

7. Add approved fuel until the level of fuel is right below inner lip of fuel tank. Do not overfill past inner lip of fuel tank. 8. Clean any spilled fuel and dispose of In Accordance With (IAW) local Standard Operating Procedure (SOP). 9. Ensure fuel tank cap latch is turned counterclockwise while installing fuel tank cap (Figure 2, Item 1) onto fuel tank. Pressure relief valve (Figure 2, Item 3) should be positioned toward rear of vehicle. 10. Turn fuel tank cap latch (Figure 2, Item 2) clockwise, and press down on fuel tank cap latch to secure. END OF TASK

0017-5

TM 5-3895-385-10

0017

Service Fuel Filter

Figure 3. Fuel Filter.

0017-6

TM 5-3895-385-10

0017

Service Fuel Filter Continued.

WARNING

Fuel is combustible and toxic to eyes, skin, and respiratory tract. Skin and eye protection are required when working in contact with fuel. Avoid repeated or prolonged contact. Provide adequate ventilation. Operators are to wash exposed skin and change soaked clothing promptly if exposed to fuel. Failure to comply may cause injury or death to personnel.

NOTE
If the filter requires daily draining of water, notify Field Maintenance. Capture all spilled fuel IAW local SOP.

1. Turn BATTERY DISCONNECT switch to the OFF position (WP 0004). 2. Open drain tap (Figure 3, Item 1), and drain off any water from the fuel filter (Figure 3, Item 2) into suitable container. 3. Close drain tap (Figure 3, Item 1) fully. 4. Push seat slide assembly in (WP 0006). FOLLOW-ON TASK Dispose of captured fluids and soiled rags IAW local SOP. END OF TASK END OF WORK PACKAGE

0017-7/8 blank

TM 5-3895-385-10

0018

OPERATOR MAINTENANCE BITUMINOUS MATERIAL PAVING MACHINE (BMPM) ENGINE SERVICE

INITIAL SETUP: Materials/Parts Engine lubricating oil (WP 0033, Item 10) Wiping rags (WP 0033, Item 15) Personnel Required 12V (1) Equipment Conditions Engine off (WP 0006) BATTERY DISCONNECT switch OFF (WP 0004) Engine cool Time Required 0.5 hr

ENGINE SERVICE Check Engine Lubricating Oil Level

WARNING

Hot oil can be thrown when engine is running. Stop engine before checking engine lubricating oil level. Failure to comply may cause injury or death to personnel. Engine oil pressure is high enough to penetrate skin. Keep hands and body away from any pressurized leak. Use cardboard or paper to check for leaks. Failure to comply may cause injury or death to personnel. When running, Bituminous Material Paving Machine (BMPM) engine has hot metal surfaces that will burn flesh on contact. Shut down engine and allow sufficient cooling before checks, services, or maintenance. Wear gloves and additional protective clothing as required. Failure to comply may cause injury or death to personnel. Metal jewelry can become entangled in equipment components. Remove all jewelry and do not wear loose clothing when working on equipment. Failure to comply may cause injury or death to personnel.

NOTE
Engine lubricating oil level should be checked using the engine oil dipstick while the engine is turned off and before beginning any paving operation. Capture and dispose of spilled engine lubricating oil In Accordance With (IAW) local Standard Operating Procedure (SOP).

0018-1

TM 5-3895-385-10

0018

Check Engine Lubricating Oil Level Continued.

Figure 1. Engine.

WARNING

BMPM engine cover is heavy. Support engine cover carefully when opening or closing. Open engine cover completely when accessing or working on engine. Failure to comply may cause injury or death to personnel. 1. Press buttons on three engine cover latches (Figure 1, Item 1) on front of engine cover (Figure 1, Item 2) to release latches. 2. Raise BMPM engine cover (Figure 1, Item 2) fully.

CAUTION
Do not allow contaminants to enter the oil system. Failure to comply may cause damage to equipment. 3. Remove dirt and debris from area surrounding engine oil dipstick (Figure 1, Item 4). 4. Remove engine oil dipstick (Figure 1, Item 4) from dipstick housing (Figure 1, Item 3), and wipe oil residue from engine oil dipstick with clean wiping rag.

0018-2

TM 5-3895-385-10

0018

Check Engine Lubricating Oil Level Continued.

CAUTION
Inserting the engine oil dipstick into the dipstick housing may require extra force at several points during the insertion process. Use firm but gentle pressure to avoid bending or damaging the engine oil dipstick. Failure to comply may cause damage to equipment. 5. Return engine oil dipstick (Figure 1, Item 4) to dipstick housing (Figure 1, Item 3).

Figure 2. Engine Oil Dipstick. 6. Remove engine oil dipstick (Figure 1, Item 4), and ensure oil level on engine oil dipstick (Figure 2, Item 3) is between the FULL (Figure 2, Item 1) and ADD 6 QT (Figure 2, Item 2) marks.

0018-3

TM 5-3895-385-10

0018

Check Engine Lubricating Oil Level Continued.

NOTE
If the oil level on the engine oil dipstick is not between the FULL and ADD 6 QT marks, oil must be added to the engine (perform steps 5 9 of Add Engine Lubricating Oil task). If oil level on engine oil dipstick covers the engine oil dipstick markings past the FULL line, oil must be removed from engine. Notify field maintenance.

7. Return engine oil dipstick (Figure 1, Item 4) to dipstick housing (Figure 1, Item 3). 8. Close BMPM engine cover. 9. Press three latches against engine cover to secure latches and engine cover. END OF TASK Add Engine Lubricating Oil

Figure 3. Engine Lubricating Oil Fill.

0018-4

TM 5-3895-385-10

0018

Add Engine Lubricating Oil Continued.

WARNING

When running, BMPM engine has hot metal surfaces that will burn flesh on contact. Shut down engine and allow sufficient cooling before checks, services, or maintenance. Wear gloves and additional protective clothing as required. Failure to comply may cause injury or death to personnel. BMPM engine cover is heavy. Support engine cover carefully when opening or closing. Open engine cover completely when accessing or working on engine. Failure to comply may cause injury or death to personnel.

CAUTION
When engine lubricating oil covers the engine oil dipstick up to the FULL line during an oil level measurement (see steps 3 7 of Check Engine Lubricating Oil Level task), no additional oil is needed. Never add engine lubricating oil when the oil level on the engine oil dipstick is at the FULL line. Failure to comply may cause damage to equipment.

NOTE
Capture and dispose of all spilled engine lubrication oil IAW local SOP. 1. Press buttons on three engine cover latches (Figure 3, Item 1) on front of engine cover (Figure 3, Item 4) to release latches. 2. Raise BMPM engine cover (Figure 3, Item 4) fully. 3. Remove dirt and debris from area surrounding engine lubricating oil fill port (Figure 3, Item 3).

WARNING

Hot oil can be thrown if engine lubricating oil filler cap is off when engine is running. Stop engine before removing oil cap or checking engine lubricating oil level. Failure to comply may cause injury or death to personnel. 4. Remove engine lubricating oil filler cap (Figure 3, Item 2), and set aside on clean surface for reuse.

0018-5

TM 5-3895-385-10

0018

Add Engine Lubricating Oil Continued.

Figure 4. Engine Oil Dipstick.

NOTE
When adding engine lubricating oil, the oil level must be checked periodically during filling process to prevent over-filling of the lubrication system. When adding engine lubricating oil, allow 1 minute for new oil to drain down into oil pan before taking a new oil measurement. Do not overfill engine lubricating oil.

5. Perform the Check Engine Oil task, and add engine lubricating oil as needed to bring oil level to just below the FULL line (Figure 4, Item 1) on engine oil dipstick (Figure 4, Item 2).

NOTE
If the oil level on the engine oil dipstick is not between the FULL and ADD 6 QT marks, oil must be added to the engine (perform steps 5 9 of Add Engine Lubricating Oil task). If oil level on engine oil dipstick covers the engine oil dipstick markings past the FULL line, oil must be removed from engine. Notify field maintenance.

0018-6

TM 5-3895-385-10

0018

Add Engine Lubricating Oil Continued.

Figure 5. Engine Lubricating Oil Fill. 6. Install engine lubricating oil filler cap (Figure 5, Item 2) onto engine lubricating oil fill port (Figure 5, Item 3).

WARNING

Engine cover is heavy. Support engine cover carefully when opening or closing. Open engine cover completely when accessing or working on engine. Failure to comply may cause injury or death to personnel. 7. Close BMPM engine cover (Figure 5, Item 4). 8. Press three latches (Figure 5, Item 1) against engine cover (Figure 5, Item 4) to secure latches and engine cover. END OF TASK

0018-7

TM 5-3895-385-10

0018

Check Double Hydraulic Pump Drive Lubricating Oil Level

WARNING

Hot oil can be thrown when engine is running. Stop engine before checking lubricating oil level. Failure to comply may cause injury or death to personnel. When running, BMPM engine has hot metal surfaces that will burn flesh on contact. Shut down engine and allow sufficient cooling before checks, services, or maintenance. Wear gloves and additional protective clothing as required. Failure to comply may cause injury or death to personnel. Metal jewelry can become entangled in equipment components. Remove all jewelry and do not wear loose clothing when working on equipment. Failure to comply may cause injury or death to personnel.

NOTE
Double hydraulic pump drive lubricating oil level should be checked using the dipstick while the engine is turned off and before beginning any paving operation. Capture and dispose of spilled lubricating oil IAW local SOP. Access to a key will be needed if the engine cover latches are locked.

1. Press buttons on three engine cover latches (Figure 5, Item 1) on front of engine cover (Figure 5, Item 4) to release latches.

WARNING

BMPM engine cover is heavy. Support engine cover carefully when opening or closing. Open engine cover completely when accessing or working on engine. Failure to comply may cause injury or death to personnel. 2. Raise BMPM engine cover (Figure 5, Item 4).

0018-8

TM 5-3895-385-10

0018

Check Double Hydraulic Pump Drive Lubricating Oil Level Continued.

Figure 6. Double Hydraulic Pump Drive Dipstick.

CAUTION
Do not allow contaminants to enter the double hydraulic pump drive. Failure to comply may cause damage to equipment. 3. Remove dirt and debris from area surrounding double hydraulic pump drive dipstick (Figure 6, Item 1). 4. Remove double hydraulic pump drive dipstick (Figure 6, Item 1) fully from dipstick housing (Figure 6, Item 2), and wipe oil residue from dipstick with clean wiping rag.

CAUTION
Inserting the double hydraulic pump drive dipstick into the dipstick housing may require extra force at several points during the insertion process. Use firm but gentle pressure to avoid bending or damaging the engine oil dipstick. Failure to comply may cause damage to equipment. 5. Return double hydraulic pump drive dipstick (Figure 6, Item 1) to dipstick housing (Figure 6, Item 2). 0018-9

TM 5-3895-385-10

0018

Check Double Hydraulic Pump Drive Lubricating Oil Level Continued.

Figure 7. Double Hydraulic Pump Drive Dipstick. 6. Remove double hydraulic pump drive dipstick (Figure 7, Item 1), and ensure oil level on double hydraulic pump drive dipstick is between the FULL (Figure 7, Item 3) and LOW (Figure 7, Item 2) indicators.

NOTE
If oil level on double hydraulic pump drive dipstick is not between the FULL and LOW indicators, notify field maintenance. 7. Return double hydraulic pump drive dipstick (Figure 6, Item 1) to dipstick housing (Figure 6, Item 2). 8. Close BMPM engine cover (Figure 5, Item 4). 9. Press three latches (Figure 5, Item 1) against engine cover (Figure 5, Item 4) to secure latches and engine cover. END OF TASK FOLLOW-ON TASK Dispose of captured fluids and soiled rags IAW local SOP. END OF TASK END OF WORK PACKAGE

0018-10

TM 5-3895-385-10

0019

OPERATOR MAINTENANCE BITUMINOUS MATERIAL PAVING MACHINE (BMPM) HYDRAULIC SYSTEM SERVICE

INITIAL SETUP: Materials/Parts Fire resistant hydraulic fluid (WP 0033, Item 9) Wiping rags (WP 0033, Item 15) Personnel Required 12V (2) References WP 0004 Equipment Conditions Engine off (WP 0006) Time Required 0.2 hr

0019-1

TM 5-3895-385-10

0019

HYDRAULIC SYSTEM SERVICE Check Hydraulic Fluid Level

Figure 1. Temperature and Liquid Sight Indicator.

WARNING

When running, Bituminous Material Paving Machine (BMPM) engine has hot metal surfaces that will burn flesh on contact. Shut down engine and allow sufficient cooling time before checks, services, or maintenance. Wear gloves and additional protective clothing as required. Failure to comply may cause injury or death to personnel.

NOTE
Verify fluid level from temperature and liquid sight indicator on left side of BMPM while engine is running and hydraulic fluid is at operating temperature. 1. Start BMPM engine (WP 0006), and allow engine to warm up for at least 10 minutes. 2. Verify temperature of hydraulic fluid is at least 100 degrees Fahrenheit (F) (38 degrees Celsius (C)) using temperature and liquid sight indicator (Figure 1, Item 1). 3. Verify hydraulic fluid level is between 176F and the maximum indicator (black line) (Figure 1, Item 2) on temperature and liquid sight indicator (Figure 1, Item 1). 4. Turn keyless engine switch to the OFF position (WP 0004).

0019-2

TM 5-3895-385-10

0019

Check Hydraulic Fluid Level Continued.

WARNING

When running, the BMPM engine has hot metal surfaces that will burn flesh on contact. Shut down engine and allow sufficient cooling before checks, services, or maintenance. Wear gloves and additional protective clothing as required. Failure to comply may cause injury or death to personnel. 5. Add hydraulic fluid to hydraulic fluid reservoir as needed to bring level to near maximum indicator (black line) (Figure 1, Item 2) on temperature and liquid sight indicator (Figure 1, Item 1). If fluid is low, perform Fill Hydraulic Fluid Reservoir task. END OF TASK

0019-3

TM 5-3895-385-10

0019

Fill Hydraulic Fluid Reservoir

Figure 2. Access Plate. 1. Extend left seat slide assembly (Figure 2, Item 1) fully (WP 0006). 2. Open access plate (Figure 2, Item 2), and locate reservoir cap (Figure 3, Item 1).

0019-4

TM 5-3895-385-10

0019

Fill Hydraulic Fluid Reservoir Continued.

Figure 3. Hydraulic Fluid Reservoir Cap, Spring, and Filter Element.

WARNING

Do not loosen or remove the reservoir cap when the hydraulic fluid is hot. Failure to comply may cause injury or death to personnel.

CAUTION
Reservoir cap is under spring pressure. Use care when removing reservoir cap not to lose components. Failure to comply may cause damage to equipment. Do not allow contaminants to enter hydraulic system. Area around reservoir cap must be cleaned before removing reservoir cap. Failure to comply may cause damage to equipment.

3. Apply firm downward pressure to top of reservoir cap (Figure 3, Item 1), and remove three wing nuts (Figure 3, Item 2), flat washers (Figure 3, Item 3), and reservoir cap from threaded studs (Figure 3, Item 6). 4. Remove spring (Figure 3, Item 5) and O-ring (Figure 3, Item 4) from filler neck (Figure 3, Item 7).

0019-5

TM 5-3895-385-10

0019

Fill Hydraulic Fluid Reservoir Continued.

Figure 4. Temperature and Liquid Sight Indicator.

CAUTION
Do not over fill the hydraulic fluid reservoir. Hydraulic fluid expands slightly when it warms, and air space in the reservoir is critical. Failure to comply may cause damage to equipment.

NOTE
An assistant may be required to monitor fluid level on temperature and liquid sight indicator while adding hydraulic fluid to reservoir. Capture all spilled fuel In Accordance With (IAW) local Standard Operating Procedure (SOP).

0019-6

TM 5-3895-385-10

0019

Fill Hydraulic Fluid Reservoir Continued. 5. Add hydraulic fluid into reservoir fill neck (Figure 5, Item 7) until fluid level is between 176F and the maximum indicator (black line) (Figure 4, Item 2) on temperature and liquid sight indicator (Figure 4, Item 1).

Figure 5. Hydraulic Fluid Reservoir Cap, Spring, and Filter Element. 6. Install spring (Figure 5, Item 5) and O-ring (Figure 5, Item 4) onto filler neck (Figure 5, Item 7).

CAUTION
Maintain even pressure on reservoir cap when installing flat washers and wing nuts. Tighten wing nuts in sequence around the cap to keep cap level during installation. Failure to comply may cause damage to equipment. 7. Install reservoir cap (Figure 5, Item 1), three flat washers (Figure 5, Item 3), and wing nuts (Figure 5, Item 2) onto threaded studs (Figure 5, Item 6), turning wing nuts in alternating sequence until reservoir cap is secure.

0019-7

TM 5-3895-385-10

0019

Fill Hydraulic Fluid Reservoir Continued.

Figure 6. Hydraulic Reservoir Cap Access Panel. 8. Close reservoir cap access panel (Figure 6, Item 2) 9. Return left seat slide assembly (Figure 6, Item 1) to original position (WP 0006). END OF TASK FOLLOW-ON TASK 1. Verify proper operation, and check for fluid leaks. 2. Dispose of captured fluids and soiled rags IAW local SOP. END OF TASK END OF WORK PACKAGE

0019-8

TM 5-3895-385-10

0020

OPERATOR MAINTENANCE BITUMINOUS MATERIAL PAVING MACHINE (BMPM) CLEANER SYSTEM SERVICE

INITIAL SETUP: Materials/Parts Solvent-detergent cleaning compound (WP 0033, Item 3) Wiping rag (WP 0033, Item 15) Personnel Required 12V (1) Equipment Conditions Engine off (WP 0006) Time Required 0.2 hr

0020-1

TM 5-3895-385-10

0020

CLEANER SYSTEM SERVICE Add Cleaner Solution

Figure 1. Cleaner Solution Fill Port. 1. Extend left seat slide assembly fully (WP 0006) to access cleaner solution fill cap (Figure 1, Item 2).

NOTE
Removal of the cleaner solution fill cap may require removal of a lock from the fill cap locking tab.

2. Pull locking tab (Figure 1, Item 1) away from cleaner solution fill cap (Figure 1, Item 2), remove cleaner solution fill cap, and set aside on clean surface for reuse.

0020-2

TM 5-3895-385-10

0020

Add Cleaner Solution Continued.

NOTE
Cleaner tank holds a maximum of 10 gallons (gal) (37.85 liters (L)). Capture and dispose of all spilled cleaner solution In Accordance With (IAW) local Standard Operating Procedure (SOP).

3. Pour cleaner solution into cleaner solution fill port (Figure 1, Item 3) until tank appears full. 4. Install cleaner solution fill cap (Figure 1, Item 2), and push locking tab (Figure 1, Item 1) into cleaner solution fill cap.

NOTE
Install lock to fill cap locking tab as needed. 5. Return left seat slide assembly to original position (WP 0006). END OF TASK FOLLOW-ON TASK Dispose of soiled rags IAW local SOP. END OF WORK PACKAGE

0020-3/4 blank

TM 5-3895-385-10

0021

OPERATOR MAINTENANCE BITUMINOUS MATERIAL PAVING MACHINE (BMPM) AIR FILTER PRIMARY ELEMENT REMOVAL, SERVICE, AND INSTALLATION

INITIAL SETUP: Tools and Special Tools 1/2 inch combination wrench (WP 0031, Item 15) Materials/Parts Air filter primary element (WP 0033, Item 7) Lock washer (WP 0033, Item 19) Personnel Required 12V (1) Equipment Conditions Engine off (WP 0006) BATTERY DISCONNECT switch OFF (WP 0004) Engine cool Time Required 0.5 hr

0021-1

TM 5-3895-385-10

0021

AIR FILTER PRIMARY ELEMENT REMOVAL, SERVICE, AND INSTALLATION Air Filter Primary Element Removal

Figure 1. Left Side Cover Vent.

0021-2

TM 5-3895-385-10

0021

Air Filter Primary Element Removal Continued.

Figure 2. Air Cleaner Assembly. 1. Remove 14 bolts (Figure 1, Item 2), flat washers (Figure 1, Item 4), lock washers (Figure 1, Item 3), and left side cover vent (Figure 1, Item 1) from side left plate (Figure 1, Item 5), and discard lock washers. 2. Release three latches (Figure 2, Item 3) on air cleaner housing cap (Figure 2, Item 4), and remove air cleaner housing cap from air cleaner assembly housing (Figure 2, Item 1).

CAUTION
Rough handling of air cleaner primary element will damage element. Failure to comply may cause damage to equipment. 3. Remove air filter primary element (Figure 2, Item 2) from air cleaner assembly housing (Figure 2, Item 1). 4. Visually inspect secondary air filter element (Figure 2, Item 6) for damage and debris. Notify field maintenance if damage or debris is found. END OF TASK

0021-3

TM 5-3895-385-10

0021

Air Filter Primary Element Service 1. Perform Air Filter Primary Element Removal task. 2. Contact field maintenance to obtain compressed air for cleaning air filter primary element (Figure 2, Item 2).

WARNING

Particles blown by compressed air are hazardous. Ensure air stream is directed away from user and any personnel in the area. Use a maximum of 30 pounds per square inch (psi) (2.0 bar) when compressed air is used to clean parts. Always wear safety glasses when using compressed air. Failure to comply may result in injury or death to personnel.

CAUTION
Rough handling of air cleaner primary element will damage element. 3. Direct compressed air, from inside out, into air filter primary element (Figure 2, Item 2) while turning air filter primary element. If dust and dirt does not come out easily, tap air filter primary element gently to dislodge solid material. 4. Remove dirt and debris from air cleaner assembly housing (Figure 2, Item 1), air cleaner housing cap (Figure 2, Item 4), and dust ejection valve (Figure 2, Item 5) using compressed air. 5. Perform Air Filter Primary Element Installation task. END OF TASK Air Filter Primary Element Installation

CAUTION
Rough handling of air cleaner primary element will damage element. Failure to comply may cause damage to equipment. 1. Install air filter primary element (Figure 2, Item 2) over air filter secondary element (Figure 2, Item 6), and press firmly to seat air filter primary element. 2. Install air cleaner housing cap (Figure 2, Item 4) to air cleaner assembly housing (Figure 2, Item 1) with dust ejection valve (Figure 2, Item 5) pointing downward. 3. Close three latches (Figure 2, Item 3) to secure air cleaner housing cap (Figure 2, Item 4) to air cleaner assembly housing (Figure 2, Item 1).

NOTE
Install all bolts finger-tight before tightening any bolts. 4. Install left side cover vent (Figure 3, Item 1), 14 new lock washers (Figure 3, Item 3), flat washers (Figure 3, Item 4), and bolts (Figure 3, Item 2) to side left plate (Figure 3, Item 5).

0021-4

TM 5-3895-385-10

0021

Air Filter Primary Element Installation Continued.

Figure 3. Left Side Cover Vent. END OF TASK FOLLOW-ON TASK 1. Set BATTERY DISCONNECT switch to ON (WP 0004). 2. Verify proper operation. END OF TASK END OF WORK PACKAGE

0021-5/6 blank

TM 5-3895-385-10

0022

FIELD MAINTENANCE BITUMINOUS MATERIAL PAVING MACHINE (BMPM) COOLING SYSTEM SERVICE

INITIAL SETUP: Materials/Parts Antifreeze (WP 0033, Item 1) Distilled water (WP 0033, Item 6) Wiping rag (WP 0033, Item 15) Personnel Required 12V (1) Equipment Conditions Engine off (WP 0006) BATTERY DISCONNECT switch OFF (WP 0004) Right seat slide assembly fully extended (WP 0006) Engine cool Time Required 0.2 hr

COOLING SYSTEM SERVICE

WARNING

Contact with high-pressure steam and/or liquids can cause burns and scalding. Allow coolant to cool before maintaining cooling system. Wear gloves, additional protective clothing, and goggles. Failure to comply may cause injury or death to personnel. Engine coolant is toxic to eyes and poisonous if ingested. Eye protection is required when working with engine coolant. Avoid repeated or prolonged contact. Failure to comply may cause injury or death to personnel.

0022-1

TM 5-3895-385-10

0022

Add Engine Coolant to Coolant Reservoir

Figure 1. Cooling System Service. 1. Open right floorboard door (Figure 1, Item 1) to access coolant reservoir (Figure 1, Item 7). 2. Remove cap (Figure 1, Item 6) from coolant reservoir (Figure 1, Item 7).

0022-2

TM 5-3895-385-10

0022

Add Engine Coolant to Coolant Reservoir Continued

CAUTION
Never use water alone for coolant. Corrosion can result from using water alone. Failure to comply will cause damage to equipment. 3. Prepare a coolant solution of 50% engine coolant and 50% distilled water. 4. Fill coolant reservoir (Figure 1, Item 7) with diluted coolant mixture up to COLD line (Figure 1, Item 8). 5. Install cap (Figure 1, Item 6) to top of coolant reservoir (Figure 1, Item 7). 6. Close right floorboard door (Figure 1, Item 1). END OF TASK Add Engine Coolant to Radiator 1. Remove two thumb screws (Figure 1, Item 2) and access cover (Figure 1, Item 3) from BMPM. 2. Remove radiator cap (Figure 1, Item 4).

CAUTION
Never use water alo ne for coolant. Corrosion can result fro m using water al one. Failure to comply will cause damage to equipment. Adding coolant to a hot e ngine can damage engine castings. Allow e ngine to cool before adding coolant. Failure to comply may cause damage to equipment.

3. Prepare coolant solution of 50% engine coolant and 50% distilled water. 4. Fill radiator cooler (Figure 1, Item 5) with coolant solution. 5. Wait 2 3 minutes for air to vent from cooling system, and then add more coolant solution as needed.

CAUTION
Be sure to in stall radiator cap properly to avoid coolant leakage. Engine may overheat if cap is not installed properly. Failure to comply may cause damage to equipment. 6. Install radiator cap (Figure 1, Item 4). 7. Install access cover (Figure 1, Item 3) and two thumb screws (Figure 1, Item 2) onto BMPM. END OF TASK FOLLOW-ON TASK 1. Verify proper operation, and check for fluid leaks. 2. Dispose of soiled rags IAW local SOP. END OF TASK END OF WORK PACKAGE

0022-3/4 blank

TM 5-3895-385-10

0023

OPERATOR MAINTENANCE BITUMINOUS MATERIAL PAVING MACHINE (BMPM) PACKAGING

INITIAL SETUP: Personnel Required 12V (6) Equipment Conditions End gates removed (WP 0014) Cutoff shoes removed (WP 0016) Bolt-on screed extension kit removed (WP 0015)

0023-1

TM 5-3895-385-10

0023

UNPACKING BOLT-ON SCREED EXTENSION KIT, CUTOFF SHOES, AND END GATES

Figure 1. Screed Extension Kit Panels Removal.

0023-2

TM 5-3895-385-10

0023

UNPACKING BOLT-ON SCREED EXTENSION KIT, CUTOFF SHOES, AND END GATES CONTINUED. 1. Remove 22 bolts (Figure 1, Item 2) and flat washers (Figure 1, Item 3) securing top panel (Figure 1, Item 1) to screed extension kit box (Figure 1, Item 4).

WARNING

The front panel weighs 55 lb (25 kg). Two personnel are required to lift component. Failure to comply may cause injury or death to personnel.

CAUTION
Properly support the item being lifted. Failure to comply may cause damage to equipment. 2. Remove 13 bolts (Figure 1, Item 6), flat washers (Figure 1, Item 5), and front panel (Figure 1, Item 7) from screed extension kit box (Figure 1, Item 4) with assistance.

WARNING

The top panel weighs 142 lb (64 kg). Four personnel are required to lift component. Failure to comply may cause injury or death to personnel.

CAUTION
Properly support the item being lifted. Failure to comply may cause damage to equipment. 3. Remove top panel (Figure 1, Item 1) from screed extension kit box (Figure 1, Item 4) with assistance.

0023-3

TM 5-3895-385-10

0023

UNPACKING BOLT-ON SCREED EXTENSION KIT, CUTOFF SHOES, AND END GATES CONTINUED.

Figure 2. Bolt-On Screed Extension Removal.

0023-4

TM 5-3895-385-10

0023

UNPACKING BOLT-ON SCREED EXTENSION KIT, CUTOFF SHOES, AND END GATES CONTINUED.

WARNING

Each bolt-on screed extension weighs 236 pounds (lb) (107 kilograms (kg)). Six personnel are required to lift component. Failure to comply may cause injury or death to personnel.

CAUTION
Properly support the item being lifted. Failure to comply may cause damage to equipment. 4. Remove bolt-on screed extensions (Figure 2, Items 14 and 15) from the front side of screed extension kit box (Figure 2, Item 13) with assistance. 5. Remove two outer cutoff shoes (Figure 2, Items 3 and 4), screed extension multiple angle bracket (Figure 2, Item 6), inner cutoff shoe (Figure 2, Item 5), cardboard sleeve (Figure 2, Item 1), cutoff shoe plate (Figure 2, Item 2), and 4-ft bolt-on extension material retaining plate (Figure 2, Item 17) from left side of screed extension kit box (Figure 2, Item 16). 6. Remove inner cutoff shoe (Figure 2, Item 9), screed extension multiple angle bracket (Figure 2, Item 10), cardboard sleeve (Figure 2, Item 8), cutoff shoe plate (Figure 2, Item 7), and 4-ft bolt-on extension material retaining plate (Figure 2, Item 11) from right side of screed extension kit box (Figure 2, Item 12).

0023-5

TM 5-3895-385-10

0023

UNPACKING BOLT-ON SCREED EXTENSION KIT, CUTOFF SHOES, AND END GATES CONTINUED.

Figure 3. End Gates Removal. 0023-6

TM 5-3895-385-10

0023

UNPACKING BOLT-ON SCREED EXTENSION KIT, CUTOFF SHOES, AND END GATES CONTINUED. 7. Remove the vertical divider (Figure 3, Item 10) from the screed extension kit box (Figure 3, Item 9).

WARNING

The end gate weighs 168 lb (76 kg). Four personnel are required to lift component. Failure to comply may cause injury or death to personnel.

CAUTION
Properly support the item being lifted. Failure to comply may cause damage to equipment. 8. Remove end gate (Figure 3, Item 1), 2-ft bolt-on extension material retaining plate (Figure 3, Item 3), and level 2 vertical support (Figure 3, Item 2) from the screed extension kit box (Figure 3, Item 9) with assistance. 9. Remove the level 3 horizontal divider (Figure 3, Item 15) from the screed extension kit box (Figure 3, Item 9).

WARNING

The end gate weighs 168 lb (76 kg). Four personnel are required to lift component. Failure to comply may cause injury or death to personnel.

CAUTION
Properly support the item being lifted. Failure to comply may cause damage to equipment. 10. Remove end gate (Figure 3, Item 13), 2-ft bolt-on extension material retaining plate (Figure 3, Item 6), and three level 3 vertical supports (Figure 3, Items 4, 5, and 14) from the screed extension kit box (Figure 3, Item 9) with assistance. 11. Remove the level 2 horizontal divider (Figure 3, Item 12) from the screed extension kit box (Figure 3, Item 9).

WARNING

Each 2-ft auger extension weighs 89 lb (40 kg). Two personnel are required to lift component. Failure to comply may cause injury or death to personnel.

CAUTION
Properly support the item being lifted. Failure to comply may cause damage to equipment. 12. Remove 2-ft auger extensions (Figure 3, Item 11) from the screed extension kit box (Figure 3, Item 9) with assistance.

0023-7

TM 5-3895-385-10

0023

UNPACKING BOLT-ON SCREED EXTENSION KIT, CUTOFF SHOES, AND END GATES CONTINUED.

Figure 4. End Gates Installation.

0023-8

TM 5-3895-385-10

0023

UNPACKING BOLT-ON SCREED EXTENSION KIT, CUTOFF SHOES, AND END GATES CONTINUED.

WARNING

Each 4-ft auger extension weighs 170 lb (77 kg). Four personnel are required to lift component. Failure to comply may cause injury or death to personnel.

CAUTION
Properly support the item being lifted. Failure to comply may cause damage to equipment. 13. Remove two 4-ft auger extensions (Figure 3, Items 7 and 8) from the screed extension kit box (Figure 3, Item 9) with assistance. END OF TASK PACKING BOLT-ON SCREED EXTENSION KIT, CUTOFF SHOES, AND END GATES

WARNING

Each 4-ft auger extension weighs 170 lb (77 kg). Four personnel are required to lift component. Failure to comply may cause injury or death to personnel.

CAUTION
Properly support the item being lifted. Failure to comply may cause damage to equipment. 1. Install two 4-ft auger extensions (Figure 4, Items 7 and 8) into the screed extension kit box (Figure 4, Item 9) with assistance.

WARNING

Each 2-ft auger extension weighs 89 lb (40 kg). Two personnel are required to lift component. Failure to comply may cause injury or death to personnel.

CAUTION
Properly support the item being lifted. Failure to comply may cause damage to equipment. 2. Install 2-ft auger extensions (Figure 4, Item 11) into the screed extension kit box (Figure 4, Item 9) with assistance. 3. Install the level 2 horizontal divider (Figure 4, Item 12) into the screed extension kit box (Figure 4, Item 9).

0023-9

TM 5-3895-385-10

0023

PACKING BOLT-ON SCREED EXTENSION KIT, CUTOFF SHOES, AND END GATES CONTINUED.

WARNING

The end gate weighs 168 lb (76 kg). Four personnel are required to lift component. Failure to comply may cause injury or death to personnel.

CAUTION
Properly support the item being lifted. Failure to comply may cause damage to equipment. 4. Install end gate (Figure 4, Item 13), 2-ft bolt-on extension material retaining plate (Figure 4, Item 6), and three level 3 vertical supports (Figure 4, Items 4, 5, and 14) into the screed extension kit box (Figure 4, Item 9) with assistance. 5. Install the level 3 horizontal divider (Figure 4, Item 15) into the screed extension kit box (Figure 4, Item 9).

WARNING

The end gate weighs 168 lb (76 kg). Four personnel are required to lift component. Failure to comply may cause injury or death to personnel.

CAUTION
Properly support the item being lifted. Failure to comply may cause damage to equipment. 6. Install end gate (Figure 4, Item 1), 2-ft bolt-on extension material retaining plate (Figure 4, Item 3), and level 2 vertical support (Figure 4, Item 2) into the screed extension kit box (Figure 4, Item 9) with assistance. 7. Install the vertical divider (Figure 4, Item 10) into the screed extension kit box (Figure 4, Item 9).

0023-10

TM 5-3895-385-10

0023

PACKING BOLT-ON SCREED EXTENSION KIT, CUTOFF SHOES, AND END GATES CONTINUED.

Figure 5. Bolt-On Screed Extension Installation.

0023-11

TM 5-3895-385-10

0023

PACKING BOLT-ON SCREED EXTENSION KIT, CUTOFF SHOES, AND END GATES CONTINUED. 8. Install inner cutoff shoe (Figure 5, Item 9), screed extension multiple angle bracket (Figure 5, Item 10), cardboard sleeve (Figure 5, Item 8), cutoff shoe plate (Figure 5, Item 7), and 4-ft bolt-on extension material retaining plate (Figure 5, Item 11) into right side of screed extension kit box (Figure 5, Item 12). 9. Install two outer cutoff shoes (Figure 5, Items 3 and 4), screed extension multiple angle bracket (Figure 5, Item 6), inner cutoff shoe (Figure 5, Item 5), cardboard sleeve (Figure 5, Item 1), cutoff shoe plate (Figure 5, Item 2), and 4-ft bolt-on extension material retaining plate (Figure 5, Item 17) into left side of screed extension kit box (Figure 5, Item 16).

WARNING

Each bolt-on screed extension weighs 236 pounds (lb) (107 kilograms (kg)). Six personnel are required to lift component. Failure to comply may cause injury or death to personnel.

CAUTION
Properly support the item being lifted. Failure to comply may cause damage to equipment. 10. Install bolt-on screed extensions (Figure 5, Items 14 and 15) into the front side of screed extension kit box (Figure 5, Item 13) with assistance.

0023-12

TM 5-3895-385-10

0023

PACKING BOLT-ON SCREED EXTENSION KIT, CUTOFF SHOES, AND END GATES CONTINUED.

Figure 6. Screed Extension Kit Panels Installation.

0023-13

TM 5-3895-385-10

0023

UNPACKING BOLT-ON SCREED EXTENSION KIT, CUTOFF SHOES, AND END GATES CONTINUED.

WARNING

The top panel weighs 142 lb (64 kg). Four personnel are required to lift component. Failure to comply may cause injury or death to personnel.

CAUTION
Properly support the item being lifted. Failure to comply may cause damage to equipment. 11. Install top panel (Figure 6, Item 1) into screed extension kit box (Figure 6, Item 4) with assistance.

WARNING

The front panel weighs 55 lb (25 kg). Two personnel are required to lift component. Failure to comply may cause injury or death to personnel.

CAUTION
Properly support the item being lifted. Failure to comply may cause damage to equipment. 12. Install front panel (Figure 6, Item 7), 13 bolts (Figure 6, Item 6), and flat washers (Figure 6, Item 5) into screed extension kit box (Figure 6, Item 4) with assistance. 13. Install 22 bolts (Figure 6, Item 2) and flat washers (Figure 6, Item 3) securing top panel (Figure 6, Item 1) to screed extension kit box (Figure 6, Item 4). END OF TASK END OF WORK PACKAGE

0023-14

TM 5-3895-385-10

0024

OPERATOR MAINTENANCE BITUMINOUS MATERIAL PAVING MACHINE (BMPM) PREPARATION FOR STORAGE OR SHIPMENT

INITIAL SETUP: Tools and Special Tools 7/16 inch combination wrench (WP 0031, Item 14) 3/4 inch combination wrench (WP 0031, Item 17) Ratchet strap (WP 0031, Item 12) Materials/Parts JP 8 (WP 0033, Item 17) Duct tape (WP 0033, Item 16) General purpose lubricating oil (WP 0033, Item 13) Plastic bags (WP 0033, Item 2) Personnel Required 12V (2) References MIL-STD-3003B TM 38-470 WP 0004 WP 0013 WP 0014 WP 0015 WP 0016 WP 0017 WP 0023 Time Required 0.2 hr

LEVEL A PREPARATION

NOTE
Equipment processed Level A is intended to provide protection for the equipment stored for up to 48 months in an unheated warehouse environment or 24 months in an outdoor environment such as the weather deck of an ocean-going vessel for a period of up to 24 months without exercising, inspections, or maintenance. Additional information about Level A storage requirements can be found in MIL-STD-3003B and TM 38-470.

1. Perform After PMCS (WP 0013). 2. Remove end gates (WP 0014). 3. Remove cutoff shoes (WP 0016). 4. Remove bolt-on screed extension kit (WP 0015). 5. Apply preservative film to bare metal portions of bolt-on screed extension kit (WP 0023). 6. Pack end gates, cutoff shoes, and bolt-on screed extension kit (WP 0023). 7. Park Bituminous Material Paving Machine (BMPM) on level lot. 8. Turn keyless engine switch to the OFF position (WP 0004). 9. Turn BATTERY DISCONNECT switch OFF (WP 0004). 10. Unless otherwise specified, notify field maintainer to disconnect batteries for storage exceeding 30 days, and secure cable ends from contact with terminals using ratchet straps. 0024-1

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0024

LEVEL A PREPARATION CONTINUED. 11. Place tag stating, BATTERIES ARE DISCONNECTED, on the keyless engine switch, and include quantity, proper shipping name, and identification of hazardous materials aboard machine in shipment data. 12. Seal the engine exhaust muffler opening with duct tape. 13. Cover control pedestals, screed keypads, and operator seats with plastic bag, securing with duct tape. 14. Notify field maintenance personnel to perform Level A Storage Preparation. END OF TASK LEVEL A REMOVE FROM STORAGE 1. Notify field maintenance personnel to perform Level A Storage Removal. 2. Remove plastic bag and duct tape from control pedestals, screed keypads, and operator seats. 3. Remove duct tape from engine exhaust muffler. 4. Perform Before PMCS (WP 0013). END OF TASK LEVEL B PREPARATION

NOTE
Equipment processed Level B is intended to provide protection for up to 48 months of storage under controlled humidity conditions or outside storage for 90 days maximum without any exercising or maintenance. All equipment to be operational, drive-on/drive-off, with minimal processing. Additional information about Level B storage requirements can be found in MIL-STD-3003B and TM 38-470.

1. Fill fuel tanks, unless another volume of fuel is specified, to a level between one-half and three-quarters full (WP 0017). 2. Perform After PMCS (WP 0013). 3. Remove end gates (WP 0014). 4. Remove cutoff shoes (WP 0016). 5. Remove bolt-on screed extension kit (WP 0015). 6. Apply preservative film to bare metal portions of bolt-on screed extension kit (WP 0023). 7. Pack end gates, cutoff shoes, and bolt-on screed extension kit (WP 0023). 8. Park BMPM on level lot. 9. Turn keyless engine switch to the OFF position (WP 0004). 10. Turn BATTERY DISCONNECT switch OFF (WP 0004). 11. Unless otherwise specified, notify field maintainer to disconnect batteries for storage exceeding 30 days, and secure cable ends from contact with terminals using ratchet straps.

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0024

LEVEL B PREPARATION CONTINUED. 12. Place tag stating, BATTERIES ARE DISCONNECTED, on the keyless engine switch, and include quantity, proper shipping name, and identification of hazardous materials aboard machine in shipment data. 13. Seal the engine exhaust muffler opening with duct tape. 14. Cover control pedestals, screed keypads, and operator seats with plastic bag, securing with duct tape. END OF TASK LEVEL B REMOVE FROM STORAGE 1. Remove plastic bag and duct tape from control pedestals, screed keypads, and operator seats. 2. Remove duct tape from engine exhaust muffler. 3. Perform Before PMCS (WP 0013). END OF TASK END OF WORK PACKAGE

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CHAPTER 5
TRANSPORT PROCEDURES FOR BITUMINOUS MATERIAL PAVING MACHINE (BMPM)

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0025

OPERATOR MAINTENANCE BITUMINOUS MATERIAL PAVING MACHINE (BMPM) PREPARATION FOR TRANSPORT INTRODUCTION

INITIAL SETUP: Tools and Special Tools 7/16 inch combination wrench (WP 0031, Item 14) Materials/Parts Lock washer (5) (WP 0033, Item 20) Personnel Required 12V References FM 21-60 WP 0002 WP 0009 WP 0026 References Continued WP 0027 WP 0028 WP 0029 Equipment Conditions End gates removed (WP 0014) Cutoffs removed (WP 0016) Bolt-on screed extension kit removed (WP 0015) Truck hitch fully retracted (WP 0006) Time Required 0.2 hr

INTRODUCTION

0026

1. This chapter describes how to prepare the Bituminous Material Paving Machine (BMPM) for the following modes of transport: a. Highway transport (WP 0026) b. Rail transport (WP 0027) c. Marine transport (WP 0028) d. Air transport (WP 0029) 2. The BMPM has eight tie down points. 3. The BMPM has four lifting points. 4. The front lifting points are accessed by opening the front lifting point access covers. 5. Ground guide assistance will be necessary for all modes of transport (FM 21-60). END OF TASK

0025-1

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0025

OPEN FRONT LIFTING POINT ACCESS COVERS

Figure 1. Front Lifting Point Access Covers. Remove four bolts (Figure 1, Item 3), lock washers (Figure 1, Item 2), and flat washers (Figure 1, Item 1), open front lifting point access covers (Figure 1, Item 4), and discard lock washers. Store removed hardware in BMPM toolbox (WP 0002). END OF TASK

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0025

CLOSE FRONT LIFTING POINT ACCESS COVERS 1. Retrieve four bolts (Figure 1, Item 3), new lock washers (Figure 1, Item 2), and flat washers (Figure 1, Item 1) from BMPM toolbox (WP 0002). 2. Close front lifting point access covers (Figure 1, Item 4). 3. Install four bolts (Figure 1, Item 3), new lock washers (Figure 1, Item 2), and flat washers (Figure 1, Item 1) into front lifting point access covers (Figure 1, Item 4). END OF TASK

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BMPM LIFTING POINTS

Figure 2. BMPM Lifting Points. 1. The front lifting points (Figure 2, Item 1) are located near the hopper. 2. The rear lifting points (Figure 2, Item 2) are located on the operator platform. 3. The lifting and tie down shipping data plate (Figure 2, Item 3) is located on the left side of the BMPM (WP 0009). END OF TASK

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BMPM TIE DOWN POINTS

Figure 3. BMPM Tie Down Points. 1. The front tie down points (Figure 3, Item 1) are located under the left and right hopper wings (Figure 3, Item 2). Hopper wings must be fully closed and tie down points must be brought forward before use. 2. The forward screed arm tie down points (Figure 3, Item 5) are located on the left and right forward screed arms. 3. The rear screed arm tie down points (Figure 3, Item 3) are located on the left and right rear screed arms. 4. The rear operator platform tie down points (Figure 3, Item 4) are located just behind the operator platform. 5. The lifting and tie down shipping data plate (Figure 3, Item 6) is located on the left side of the BMPM (WP 0009). END OF TASK

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0025

LOWERING FUME VENT

Figure 4. Fume Vent. 1. Remove bolt (Figure 4, Item 2), lock washer (Figure 4, Item 3), and flat washer (Figure 4, Item 4) from raised fume vent (Figure 4, Item 1). Lower fume vent (Figure 4, Item 5) and discard lock washers. 2. Install bolt (Figure 4, Item 2), new lock washer (Figure 4, Item 3), and flat washer (Figure 4, Item 4) onto lowered fume vent (Figure 4, Item 5). END OF TASK

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RAISING FUME VENT 1. Remove bolt (Figure 4, Item 2), lock washer (Figure 4, Item 3), and flat washer (Figure 4, Item 4) from lowered fume vent (Figure 4, Item 5). Discard lock washers. 2. Raise fume vent (Figure 4, Item 1), and install bolt (Figure 4, Item 2), new lock washer (Figure 4, Item 3), and flat washer (Figure 4, Item 4) into raised fume vent (Figure 4, Item 1). END OF TASK END OF WORK PACKAGE

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0026

OPERATOR MAINTENANCE BITUMINOUS MATERIAL PAVING MACHINE (BMPM) HIGHWAY TRANSPORT

INITIAL SETUP: Materials/Parts Ratchet strap (2) (WP 0031, Item 12) Personnel Required 12V (2) References FM 21-60 WP 0002 WP 0004 WP 0022 WP 0025 Equipment Conditions End gates removed (WP 0014) Cutoffs removed (WP 0016) Bolt-on screed extension kit removed (WP 0015) INTRODUCTION 1. Check with proper authorities to obtain necessary permits or licenses before transporting Bituminous Material Paving Machine (BMPM). 2. Ensure cooling system of BMPM has proper antifreeze protection while in transit and for climate at destination (WP 0022). END OF TASK Equipment Conditions Continued Seat slide assembly pushed in (WP 0006) Engine on (WP 0006) Screed fully raised (WP 0006) Hopper wings fully closed (WP 0006) Screed extensions fully retracted (WP 0006) Cutoffs fully raised (WP 0006) Augers fully raised (WP 0006) Truck hitch fully retracted (WP 0006) Fume vent lowered (WP 0026) Time Required 0.3 hr

0026-1

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0026

LOADING BMPM ONTO TRAILER

WARNING

Always use a ground guide when operating machine up or down ramps (FM 21-60). Failure to comply may cause injury or death to personnel or damage to equipment. Operating the BMPM exposes personnel to a high noise level. While operating or working within 37 ft (11 m) of a running BMPM wear hearing protection. Failure to comply may cause hearing loss. Drive with extreme caution, at low speed. Be sure area surrounding BMPM is clear of personnel and objects before moving the unit, opening hopper wings, lowering screed, or deploying screed extensions. Sound unit horn before moving unit from stopped position. Turn on beacon when unit is in motion. Failure to comply may cause injury or death to personnel or damage to equipment. Exhaust discharge contains deadly gases, including carbon monoxide. Do not operate BMPM in an enclosed area unless the exhaust discharge is properly vented. Failure to comply may cause injury or death to personnel.

1. Obtain two ratchet straps (Figure 1, Item 1) from BMPM toolbox (WP 0002). 2. Ensure guide posts (Figure 1, Item 2) are pointing to the rear of the BMPM. 3. Attach two ratchet straps (Figure 1, Item 1) through hopper wing strap points (Figure 1, Item 2).

CAUTION
BMPM must be loaded screed first to prevent damage. Failure to comply may cause damage to equipment. To prevent an excessive jolt to the BMPM and undercarriage, reduce traveling speeds to a minimum before the tracks come in contact with loading ramps or an abrupt change in the surface. If rough terrain or bumps are encountered, the track sprocket or other components may be damaged because of the excessive jolt. Failure to comply may cause damage to equipment.

4. Engage joysticks slightly so BMPM moves very slowly (WP 0006) using ground guide assistance (FM 21-60).

0026-2

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0026

LOADING BMPM ONTO TRAILER CONTINUED.

Figure 1. Hopper Wing Strap Points.

0026-3

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0026

LOADING BMPM ONTO TRAILER CONTINUED.

Figure 2. BMPM Ramp Loading. 5. Move BMPM to base of ramp with the screed end leading (Figure 2) using ground guide assistance (FM 2160). 6. Guide BMPM up ramp slowly, screed first. 7. Maneuver the BMPM to the desired position. 8. Return joysticks to the neutral position (WP 0006). 9. Lower screed fully (WP 0006). 10. Shut down engine (WP 0006). 11. Set BATTERY DISCONNECT switch to OFF (WP 0004). 12. Secure BMPM on trailer bed with tie downs In Accordance With (IAW) lift and tie down shipping data plate on machine (WP 0025) with assistance. END OF TASK

0026-4

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0026

UNLOADING BMPM FROM TRAILER

WARNING

Always use a ground guide when operating machine up or down ramps (FM 21-60). Failure to comply may cause injury or death to personnel or damage to equipment. Operating the BMPM exposes personnel to a high noise level. While operating or working within 37 feet (ft) (11 meters (m)) of a running BMPM wear hearing protection. Failure to comply may cause hearing loss. Drive with extreme caution, at low speed. Be sure area surrounding BMPM is clear of personnel and objects before moving the unit, opening hopper wings, lowering screed, or deploying screed extensions. Sound unit horn before moving unit from stopped position. Turn on beacon when unit is in motion. Failure to comply may cause injury or death to personnel or damage to equipment. Exhaust discharge contains deadly gases, including carbon monoxide. Do not operate BMPM in an enclosed area unless the exhaust discharge is properly vented. Failure to comply may cause injury or death to personnel.

1. Remove tie downs on BMPM (WP 0025) with assistance. 2. Set BATTERY DISCONNECT switch to ON (WP 0004). 3. Start the engine (WP 0006). 4. Raise screed fully (WP 0006).

CAUTION
BMPM must be unloaded hopper first to prevent damage. Failure to comply may cause damage to equipment. To prevent an excessive jolt to the BMPM and undercarriage, reduce traveling speeds to a minimum before the tracks come in contact with loading ramps or an abrupt change in the surface. If rough terrain or bumps are encountered, the track sprocket or other components may be damaged because of the excessive jolt. Failure to comply may cause damage to equipment.

5. Engage joysticks slightly so BMPM moves very slowly using ground guide assistance (FM 21-60). 6. Move BMPM to the top of the ramp with the hopper end leading using ground guide assistance (FM 21-60).

0026-5

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0026

UNLOADING BMPM FROM TRAILER CONTINUED. 7. Guide BMPM down ramp slowly, hopper first (Figure 3).

Figure 3. BMPM Ramp Unloading.

0026-6

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0026

UNLOADING BMPM FROM TRAILER CONTINUED.

Figure 4. Hopper Wing Strap Points. 8. Remove two ratchet straps (Figure 4, Item 1) from hopper wing strap points (Figure 4, Item 2), and store in BMPM toolbox (WP 0002). END OF TASK END OF WORK PACKAGE

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0027

OPERATOR MAINTENANCE BITUMINOUS MATERIAL PAVING MACHINE (BMPM) RAIL TRANSPORT

INITIAL SETUP: Materials/Parts Ratchet strap (2) (WP 0031, Item 12) Personnel Required 12V (2) References FM 21-60 WP 0002 WP 0004 WP 0025 Equipment Conditions End gates removed (WP 0014) Cutoffs removed (WP 0016) Bolt-on screed extension kit removed (WP 0015) Seat slide assembly pushed in (WP 0006) INTRODUCTION Equipment Conditions Continued Fuel tank no more than three-quarters full Engine on (WP 0006) Screed fully raised (WP 0006) Hopper wings fully closed (WP 0006) Screed extensions fully retracted (WP 0006) Cutoffs fully raised (WP 0006) Augers fully raised (WP 0006) Truck hitch fully retracted (WP 0006) Fume vent lowered (WP 0026) Time Required 0.3 hr

0026

1. This Work Package (WP) describes how to load and unload the Bituminous Material Paving Machine (BMPM) on a flatcar for rail transport within the Continental United States (CONUS), Canada, and Mexico. The BMPM is most often loaded/unloaded on a rail flatcar using drive-on/drive-off procedures at the railhead. 2. CONUS rail transport is governed by Association of American Railroads (AAR) regulations. CONUS rail transport requires no disassembly. 3. Outside Continental United States (OCONUS) rail transport is governed by Gabarit International de Chargement (International Loading Gauge) (GIC) regulations. OCONUS rail transport requires no disassembly. 4. Before transporting machine, check with proper authorities to obtain necessary permits.

WARNING

Rail transport with fuel tank more than three-quarters full is prohibited. Failure to comply may cause injury or death to personnel or damage to equipment. 5. Safest rail transport is with fuel tank as close to empty as possible. Rail transport with fuel tank more than three-quarters full is prohibited. END OF TASK 0027-1

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0027

LOADING BMPM ONTO FLATCAR

WARNING

Always use a ground guide when operating machine up or down ramps (FM 21-60). Failure to comply may cause injury or death to personnel or damage to equipment. Operating the BMPM exposes personnel to a high noise level. While operating or working within 37 feet (ft) (11 meters (m)) of a running BMPM wear hearing protection. Failure to comply may cause hearing loss. Drive with extreme caution, at low speed. Be sure area surrounding BMPM is clear of personnel and objects before moving the unit, opening hopper wings, lowering screed, or deploying screed extensions. Sound unit horn before moving unit from stopped position. Turn on beacon when unit is in motion. Failure to comply may cause injury or death to personnel or damage to equipment. Exhaust discharge contains deadly gases, including carbon monoxide. Do not operate BMPM in an enclosed area unless the exhaust discharge is properly vented. Failure to comply may cause injury or death to personnel.

1. Obtain two ratchet straps (Figure 1, Item 1) from BMPM toolbox (WP 0002). 2. Ensure guide posts (Figure 1, Item 2) are pointing to the rear of the BMPM. 3. Attach two ratchet straps (Figure 1, Item 1) through hopper wing strap points (Figure 1, Item 2).

CAUTION
BMPM must be loaded screed first to prevent damage. Failure to comply may cause damage to equipment. To prevent an excessive jolt to the BMPM and undercarriage, reduce traveling speeds to a minimum before the tracks come in contact with loading ramps or an abrupt change in the surface. If rough terrain or bumps are encountered, the track sprocket or other components may be damaged because of the excessive jolt. Failure to comply may cause damage to equipment.

4. Engage joysticks slightly so BMPM moves very slowly (WP 0006) using ground guide assistance (FM 21-60).

0027-2

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0027

LOADING BMPM ONTO FLATCAR CONTINUED.

Figure 1. Hopper Wing Strap Points.

0027-3

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0027

LOADING BMPM ONTO FLATCAR CONTINUED.

Figure 2. BMPM Ramp Loading/Unloading. 5. Move BMPM to base of ramp with the screed end leading (Figure 2) using ground guide assistance (FM 2160). 6. Guide BMPM up ramp slowly, screed first. 7. Maneuver the BMPM to the desired position. 8. Return joysticks to the neutral position (WP 0006). 9. Lower screed fully (WP 0006). 10. Shut down engine (WP 0006). 11. Set BATTERY DISCONNECT switch to OFF (WP 0004). 12. Secure BMPM on flatcar with tie downs In Accordance With (IAW) lift and tie down shipping data plate on machine (WP 0025) with assistance. END OF TASK

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0027

UNLOADING BMPM FROM FLATCAR

WARNING

Always use a ground guide when operating machine up or down ramps (FM 21-60). Failure to comply may cause injury or death to personnel or damage to equipment. Operating the BMPM exposes personnel to a high noise level. While operating or working within 37 ft (11 m) of a running BMPM wear hearing protection. Failure to comply may cause hearing loss. Drive with extreme caution, at low speed. Be sure area surrounding BMPM is clear of personnel and objects before moving the unit, opening hopper wings, lowering screed, or deploying screed extensions. Sound unit horn before moving unit from stopped position. Turn on beacon when unit is in motion. Failure to comply may cause injury or death to personnel or damage to equipment. Exhaust discharge contains deadly gases, including carbon monoxide. Do not operate BMPM in an enclosed area unless the exhaust discharge is properly vented. Failure to comply may cause injury or death to personnel.

1. Remove tie downs from BMPM (WP 0025) with assistance. 2. Set BATTERY DISCONNECT switch to ON (WP 0004). 3. Start the engine (WP 0006). 4. Raise screed fully (WP 0006).

CAUTION
BMPM must be unloaded hopper first to prevent damage. Failure to comply may cause damage to equipment. To prevent an excessive jolt to the BMPM and undercarriage, reduce traveling speeds to a minimum before the tracks come in contact with loading ramps or an abrupt change in the surface. If rough terrain or bumps are encountered, the track sprocket or other components may be damaged because of the excessive jolt. Failure to comply may cause damage to equipment.

5. Engage joysticks slightly so BMPM moves very slowly (WP 0006) using ground guide assistance (FM 21-60). 6. Move BMPM to the top of the ramp with the hopper end leading using ground guide assistance (FM 21-60). 7. Guide BMPM down ramp slowly, hopper first (Figure 2).

0027-5

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UNLOADING BMPM FROM FLATCAR CONTINUED.

Figure 3. Hopper Wing Strap Points. 8. Remove two ratchet straps (Figure 3, Item 1) from hopper wing strap points (Figure 3, Item 2), and store in BMPM toolbox (WP 0002). END OF TASK END OF WORK PACKAGE

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0028

OPERATOR MAINTENANCE BITUMINOUS MATERIAL PAVING MACHINE (BMPM) MARINE TRANSPORT (ROLL-ON/ROLL-OFF (RO/RO) PROCEDURES)

INITIAL SETUP: Materials/Parts Ratchet strap (2) (WP 0031, Item 12) Personnel Required 12V (2) References FM 21-60 WP 0002 WP 0004 WP 0025 Equipment Conditions End gates removed (WP 0014) Cutoffs removed (WP 0016) Bolt-on screed extension kit removed (WP 0015) INTRODUCTION 1. The Bituminous Material Paving Machine (BMPM) may be transported on the following types of marine vessels: a. Roll-On/Roll-Off (RO/RO) b. Break bulk (general cargo) c. Barge carrying (LASH and SEABEE) 2. This Work Package (WP) describes how to load and unload machine onto vessels using RO/RO procedures. 3. At all times, the machine's movements are under the overall control of the RO/RO vehicle director. Loading and unloading is accomplished by following the vehicle director's traffic control pattern. 4. Machines are loaded by moving them from dockside to the appropriate level and hold onboard ship. Once parked, crews secure machines for shipping. Unloading is accomplished by moving machines from onboard ship to dockside. 5. In order to accomplish RO/RO, the machine must operate up and down ramps. The grade of the ramps will vary, depending on the tide and the weight of the ship at the time of loading or unloading. Ground guide assistance is mandatory when operating on ramps (FM 21-60). 6. In order to ensure the safety of all personnel involved, the machine's operator must be familiar with all RO/RO regulations and procedures. END OF TASK Equipment Conditions Continued Seat slide assembly pushed in (WP 0006) Engine on (WP 0006) Screed fully raised (WP 0006) Hopper wings fully closed (WP 0006) Screed extensions fully retracted (WP 0006) Cutoffs fully raised (WP 0006) Augers fully raised (WP 0006) Truck hitch fully retracted (WP 0006) Fume vent lowered (WP 0026) Time Required 0.3 hr

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0028

RO/RO REGULATIONS

WARNING
Safe RO/RO operation depends on strict adherence to RO/RO regulations. Failure to comply may result in injury or death to personnel or damage to equipment. 1. Only qualified and screened operators are permitted to drive machine in RO/RO operations.

WARNING

Operating the BMPM exposes personnel to a high noise level. While operating or working within 37 feet (ft) (11 meters (m)) of a running BMPM wear hearing protection. Failure to comply may cause hearing loss. 2. All personnel working in machine operating areas must wear hearing protection. 3. Do not move machine about vessel without ground guide assistance (FM 21-60). 4. Do not start machine until directed to do so. Before moving out, test brakes. 5. Operate machine with lights on (WP 0004). 6. Only one machine may transit a ramp at any time. 7. Do not leave machine engine running unattended. 8. Fuel tank on machine must be filled In Accordance With (IAW) Surface Deployment and Distribution Command (SDDC) port call message. 9. Ground guide assistance is mandatory when driving machine on or off ship (FM 21-60). END OF TASK LOADING BMPM ONTO SHIP

WARNING

Always use a ground guide when operating machine up or down ramps (FM 21-60). Failure to comply may cause injury or death to personnel or damage to equipment. Operating the BMPM exposes personnel to a high noise level. While operating or working within 37 ft (11 m) of a running BMPM wear hearing protection. Failure to comply may cause hearing loss. Drive with extreme caution, at low speed. Be sure area surrounding BMPM is clear of personnel and objects before moving the unit, opening hopper wings, lowering screed, or deploying screed extensions. Sound unit horn before moving unit from stopped position. Turn on beacon when unit is in motion. Failure to comply may cause injury or death to personnel or damage to equipment.

0028-2

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LOADING BMPM ONTO SHIP CONTINUED.

WARNING

Exhaust discharge contains deadly gases, including carbon monoxide. Do not operate BMPM in an enclosed area unless the exhaust discharge is properly vented. Failure to comply may cause injury or death to personnel.

Figure 1. Hopper Wing Strap Points. 1. Obtain two ratchet straps (Figure 1, Item 1) from BMPM toolbox (WP 0002). 2. Ensure guide posts (Figure 1, Item 2) are pointing to the rear of the BMPM. 3. Attach two ratchet straps (Figure 1, Item 1) through hopper wing strap points (Figure 1, Item 3). 0028-3

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0028

LOADING BMPM ONTO SHIP CONTINUED.

CAUTION
BMPM must be loaded screed first to prevent damage. Failure to comply may cause damage to equipment. To prevent an excessive jolt to the BMPM and undercarriage, reduce traveling speeds to a minimum before the tracks come in contact with loading ramps or an abrupt change in the surface. If rough terrain or bumps are encountered, the track sprocket or other components may be damaged because of the excessive jolt. Failure to comply may cause damage to equipment.

4. Engage joysticks slightly so BMPM moves very slowly using ground guide assistance (FM 21-60).

Figure 2. BMPM Ramp Loading/Unloading. 5. Move BMPM to base of ramp with screed end leading (Figure 2) using ground guide assistance (FM 21-60). 6. Guide BMPM up ramp slowly, screed first. 7. Maneuver the BMPM to the desired position. 8. Return joysticks to the neutral position (WP 0006). 9. Lower screed fully (WP 0006). 10. Shut down engine (WP 0006). 11. Set BATTERY DISCONNECT switch to OFF (WP 0004). 12. Secure BMPM with tie downs IAW lift and tie down shipping data plate (WP 0025) with assistance. END OF TASK 0028-4

TM 5-3895-385-10

0028

UNLOADING BMPM FROM SHIP 1. Removing tie downs from BMPM (WP 0025) with assistance.

WARNING

Always use a ground guide when operating machine up or down ramps (FM 21-60). Failure to comply may cause injury or death to personnel or damage to equipment. Operating the BMPM exposes personnel to a high noise level. While operating or working within 37 ft (11 m) of a running BMPM wear hearing protection. Failure to comply may cause hearing loss. Drive with extreme caution, at low speed. Be sure area surrounding BMPM is clear of personnel and objects before moving the unit, opening hopper wings, lowering screed, or deploying screed extensions. Sound unit horn before moving unit from stopped position. Turn on beacon when unit is in motion. Failure to comply may cause injury or death to personnel or damage to equipment. Exhaust discharge contains deadly gases, including carbon monoxide. Do not operate BMPM in an enclosed area unless the exhaust discharge is properly vented. Failure to comply may cause injury or death to personnel.

2. Set BATTERY DISCONNECT switch to ON (WP 0004). 3. Start the engine (WP 0006). 4. Raise screed fully (WP 0006).

CAUTION
BMPM must be unloaded hopper first to prevent damage. Failure to comply may cause damage to equipment. To prevent an excessive jolt to the BMPM and undercarriage, reduce traveling speeds to a minimum before the tracks come in contact with loading ramps or an abrupt change in the surface. If rough terrain or bumps are encountered, the track sprocket or other components may be damaged because of the excessive jolt. Failure to comply may cause damage to equipment.

5. Engage joysticks slightly so BMPM moves very slowly using ground guide assistance (FM 21-60). 6. Move BMPM to the top of the ramp with the hopper end leading using ground guide assistance (FM 21-60). 7. Guide BMPM down ramp slowly, hopper first (Figure 2).

0028-5

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UNLOADING BMPM FROM SHIP CONTINUED.

Figure 3. Hopper Wing Strap Points. 8. Remove two ratchet straps (Figure 4, Item 1) from hopper wing strap points (Figure 4, Item 2), and store in BMPM toolbox (WP 0002). END OF TASK END OF WORK PACKAGE

0028-6

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0029

OPERATOR MAINTENANCE BITUMINOUS MATERIAL PAVING MACHINE (BMPM) AIR TRANSPORT PROCEDURES

INITIAL SETUP: Materials/Parts Ratchet strap (2) (WP 0031, Item 12) Personnel Required 12V (2) References FM 21-60 WP 0002 WP 0004 WP 0025 Equipment Conditions End gates removed (WP 0014) Cutoffs removed (WP 0016) Bolt-on screed extension kit removed (WP 0015) Equipment Conditions Continued Seat slide assembly pushed in (WP 0006) Fuel tank no more than one-half full Engine on (WP 0006) Screed fully raised (WP 0006) Hopper wings fully closed (WP 0006) Screed extensions fully retracted (WP 0006) Cutoffs fully raised (WP 0006) Augers fully raised (WP 0006) Truck hitch fully retracted (WP 0006) Fume vent lowered (WP 0026) Time Required 0.3 hr

LOADING BITUMINOUS MATERIAL PAVING MACHINE (BMPM)

WARNING

Always use a ground guide when operating machine up or down ramps (FM 21-60). Failure to comply may cause injury or death to personnel or damage to equipment. Operating the BMPM exposes personnel to a high noise level. While operating or working within 37 feet (ft) (11 meters (m)) of a running BMPM wear hearing protection. Failure to comply may cause hearing loss. Drive with extreme caution, at low speed. Be sure area surrounding BMPM is clear of personnel and objects before moving the unit, opening hopper wings, lowering screed, or deploying screed extensions. Sound unit horn before moving unit from stopped position. Turn on beacon when unit is in motion. Failure to comply may cause injury or death to personnel or damage to equipment. Exhaust discharge contains deadly gases, including carbon monoxide. Do not operate BMPM in an enclosed area unless the exhaust discharge is properly vented. Failure to comply may cause injury or death to personnel.

0029-1

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0029

LOADING BITUMINOUS MATERIAL PAVING MACHINE (BMPM) CONTINUED.

Figure 1. Hopper Wing Strap Points. 1. Obtain two ratchet straps (Figure 1, Item 1) from BMPM toolbox (WP 0002). 2. Ensure guide posts (Figure 1, Item 2) are pointing to the rear of the BMPM. 3. Attach two ratchet straps (Figure 1, Item 1) through hopper wing strap points (Figure 1, Item 2).

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0029

CAUTION
BMPM must be loaded screed first to prevent damage. Failure to comply may cause damage to equipment. To prevent an excessive jolt to the BMPM and undercarriage, reduce traveling speeds to a minimum before the tracks come in contact with loading ramps or an abrupt change in the surface. If rough terrain or bumps are encountered, the track sprocket or other components may be damaged because of the excessive jolt. Failure to comply may cause damage to equipment.

4. Engage joysticks slightly so BMPM moves very slowly (WP 0006) using ground guide assistance (FM 21-60).

Figure 2. BMPM Ramp Loading. 5. Move BMPM to base of ramp with screed end leading (Figure 2) using ground guide assistance (FM 21-60). 6. Guide BMPM up ramp slowly, screed first. 7. Maneuver the BMPM to the desired position. 8. Return joysticks to the neutral position (WP 0006). 9. Lower screed fully (WP 0006). 10. Shut down engine (WP 0006). 11. Set BATTERY DISCONNECT switch to OFF (WP 0004). 12. Secure BMPM with tie downs In Accordance With (IAW) lift and tie down shipping data plate on machine (WP 0025) with assistance. END OF TASK 0029-3

TM 5-3895-385-10

0029

UNLOADING BMPM 1. Remove tie downs from BMPM (WP 0025) with assistance.

WARNING

Always use a ground guide when operating machine up or down ramps (FM 21-60). Failure to comply may cause injury or death to personnel or damage to equipment. Operating the BMPM exposes personnel to a high noise level. While operating or working within 37 ft (11 m) of a running BMPM wear hearing protection. Failure to comply may cause hearing loss. Drive with extreme caution, at low speed. Be sure area surrounding BMPM is clear of personnel and objects before moving the unit, opening hopper wings, lowering screed, or deploying screed extensions. Sound unit horn before moving unit from stopped position. Turn on beacon when unit is in motion. Failure to comply may cause injury or death to personnel or damage to equipment. Exhaust discharge contains deadly gases, including carbon monoxide. Do not operate BMPM in an enclosed area unless the exhaust discharge is properly vented. Failure to comply may cause injury or death to personnel.

2. Set BATTERY DISCONNECT switch to ON (WP 0004). 3. Start the engine (WP 0006). 4. Raise screed fully (WP 0006).

CAUTION
BMPM must be unloaded hopper first to prevent damage. Failure to comply may cause damage to equipment. To prevent an excessive jolt to the BMPM and undercarriage, reduce traveling speeds to a minimum before the tracks come in contact with loading ramps or an abrupt change in the surface. If rough terrain or bumps are encountered, the track sprocket or other components may be damaged because of the excessive jolt. Failure to comply may cause damage to equipment.

5. Engage joysticks slightly so BMPM moves very slowly (WP 0006) using ground guide assistance (FM 21-60). 6. Move BMPM to the top of the ramp with the hopper end leading using ground guide assistance (FM 21-60). 7. Guide BMPM down ramp slowly, hopper first (Figure 3).

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0029

UNLOADING BMPM CONTINUED.

Figure 3. BMPM Ramp Unloading.

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0029

UNLOADING BMPM CONTINUED.

Figure 4. Hopper Wing Strap Points. 8. Remove two ratchet straps (Figure 4, Item 1) from hopper wing strap points (Figure 4, Item 2), and store in BMPM toolbox (WP 0002). END OF TASK END OF WORK PACKAGE

0029-6

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CHAPTER 6
SUPPORTING INFORMATION FOR BITUMINOUS MATERIAL PAVING MACHINE (BMPM)

TM 5-3895-385-10

0030

OPERATOR MAINTENANCE BITUMINOUS MATERIAL PAVING MACHINE (BMPM) REFERENCES INTRODUCTION Scope This Work Package (WP) lists all forms, Technical Manuals (TMs), and miscellaneous publications referenced in this manual. FORMS DA Form 2028 DA Form 2404 DA Form 5988E SF 368 PUBLICATIONS AR 700-138 CTA 8-100 CTA 50-909 CTA 50-970 DA PAM 750-8 FM 3.11.5 FM 4-25.11 FM 21-60 MIL-STD-3003B Army Logistics Readiness and Sustainability Army Medical Department Expendable/Durable Items Field and Garrison Furnishings and Equipment Expendable/Durable Items (Except Medical, Class V, Repair Parts, and Heraldic Items) The Army Maintenance Management System (TAMMS) Users Manual CBRNE Decontamination First Aid for Soldiers Visual Signals Department of Defense Standard Practice: Vehicles, Wheeled: Preparation for Shipment and Storage Of Lubrication Order for Bituminous Material Paving Machine (BMPM) Warranty Technical Bulletin for Bituminous Material Paving Machine (BMPM) Field Maintenance Manual for Bituminous Material Paving Machine (BMPM) Field and Sustainment Maintenance Repair Parts and Special Tools List for Bituminous Material Paving Machine (BMPM) Storage and Maintenance of Army Prepositioned Stock Materiel Procedures for Destruction of Equipment to Prevent Enemy Use (Mobility Equipment Command) Recommended Changes to Publications and Blank Forms Equipment Inspection and Maintenance Worksheet Equipment Inspection and Maintenance Worksheet (electronic version) Product Quality Deficiency Report (PQDR)

TECHNICAL MANUALS LO 5-3895-385-13 TB 5-3895-385-14 TM 5-3895-385-23 TM 5-3895-385-24P TM 38-470 TM 750-244-3

END OF WORK PACKAGE

0030-1/2 blank

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0031

OPERATOR MAINTENANCE BITUMINOUS MATERIAL PAVING MACHINE (BMPM) COMPONENTS OF END ITEM (COEI) AND BASIC ISSUE ITEMS (BII) LISTS INTRODUCTION Scope This Work Package (WP) lists Components of End Item (COEI) and Basic Issue Items (BII) for the Bituminous Material Paving Machine (BMPM) to help you inventory items for safe and efficient operation of the equipment. General The COEI and BII information is divided into the following lists: Components of End Item (COEI). This list is for information purposes only and is not authority to requisition replacements. These items are part of the BMPM. As part of the end item, these items must be with the end item whenever it is issued or transferred between property accounts. Items of COEI are removed and separately packaged for transportation or shipment only when necessary. Illustrations are furnished to help you find and identify the items. Basic Issue Items (BII). These essential items are required to place the BMPM in operation, operate it, and to do emergency repairs. Although shipped separately packaged, BII must be with the BMPM during operation and when it is transferred between property accounts. Listing these items is your authority to request/requisition them for replacement based on authorization of the end item by the Table of Organization and Equipment (TOE)/Modified Table of Organization and Equipment (MTOE). Illustrations are furnished to help you find and identify the items. Explanation of Columns in the COEI List and BII List Column (1) Item Number. Gives you the number of the item illustrated. Column (2) National Stock Number (NSN) and Illustration. Identifies the stock number of the item to be used for requisitioning purposes and provides an illustration of the item. Column (3) Description, Part Number/(CAGEC). Identifies the Federal item name (in all capital letters) followed by a minimum description when needed. The stowage location of COEI and BII is also included in this column. The last line below the description is the Part Number (P/N) and the Commercial and Government Entity Code (CAGEC) (in parentheses). Column (4) Usable On Code. When applicable, gives you a code if the item you need is not the same for different models of equipment. These codes are identified below: Code MAT Used on Model 8816M

Column (5) U/I. Unit of Issue (U/I) indicates the physical measurement or count of the item as issued per the NSN shown in column (2). Column (6) Qty Rqr. Indicates the quantity required.

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0031

Table 1. COEI List. (1) Item Number 1 (2) National Stock Number (NSN) and Illustration (3) Description, Part Number/(CAGEC) BOX, EXTENSION KIT, (58785) (4) Usable On Code MAT (5) U/I EA (6) Qty Rqr 1

COIL CORD, 980550/(58785)

MAT

EA

KIT, 20 ft. EXTENSION, 1001977/(58785)

MAT

EA

LIFT STICK, 37160-25/(58785)

MAT

EA

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0031

Table 1. COEI List Continued. (1) Item Number 5 (2) National Stock Number (NSN) and Illustration (3) Description, Part Number/(CAGEC) SENSOR, SONIC AUGER, 980540/(58785) (4) Usable On Code MAT (5) U/I EA (6) Qty Rqr 2

SHOE, CUTOFF, LH, 1003821/(58785)

MAT

EA

SHOE, CUTOFF, RH, 1003820/(58785)

MAT

EA

SHOE, OUTER CUTOFF, 1002738/(58785)

MAT

EA

0031-3

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0031

Table 1. COEI List Continued. (1) Item Number 9 (2) National Stock Number (NSN) and Illustration (3) Description, Part Number/(CAGEC) SHOE, PLATE CUTOFF, 1002797/(58785) (4) Usable On Code MAT (5) U/I EA (6) Qty Rqr 2

Table 2. BII List. (1) Item Number 1 (2) National Stock Number (NSN) and Illustration 4210-00-134-8958 (3) Description, Part Number/(CAGEC) FIRE EXTINGUISHER, 431571/(03670) (4) Usable On Code MAT (5) (6) Qty Rqr 1

U/I EA

6545-00-922-1200

FIRST AID KIT, 11677011/(19207)

MAT

EA

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0031

Table 2. BII List Continued. (1) Item Number 3 (2) National Stock Number (NSN) and Illustration 6230-00-264-8261 (3) Description, Part Number/(CAGEC) FLASHLIGHT, N47-1B/(84609) (4) Usable On Code MAT (5) (6) Qty Rqr 1

U/I EA

FLEX HOSE WITH COUPLER, YA732A3/(55719) 5120-00-541-8444 HANDLE, SOCKET WRENCH, GL715/(C7127)

MAT

EA

MAT

EA

LO 5-3895-385-13/(58785)

MAT

EA

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0031

Table 2. BII List Continued. (1) Item Number 7 (2) National Stock Number (NSN) and Illustration 4930-00-253-2478 (3) Description, Part Number/(CAGEC) LUBRICATING GUN, HAND, 1142/(1PL57) (4) Usable On Code MAT (5) (6) Qty Rqr 1

U/I EA

5120-01-079-8033

SCREWDRIVER ATTACHMENT, SOCKET WRENCH, 14 MM, SAM14E/(55719)

MAT

EA

5120-01-594-0331

SCREWDRIVER, SPEC, SHD8R/(55719)

MAT

EA

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0031

Table 2. BII List Continued. (1) Item Number 10 (2) National Stock Number (NSN) and Illustration 5120-01-335-0796 (3) Description, Part Number/(CAGEC) SOCKET, SOCKET WRENCH, 9/16 IN, SW181A/(55719) (4) Usable On Code MAT (5) (6) Qty Rqr 1

U/I EA

11

5120-01-335-0803

SOCKET, SOCKET WRENCH, 15/16 IN, SW301/(55719)

MAT

EA

12

STRAP, RATCHET, 26422/(23755)

MAT

EA

13

TM 5-3895-385-10/(58785)

MAT

EA

0031-7

TM 5-3895-385-10

0031

Table 2. BII List Continued. (1) Item Number 14 (2) National Stock Number (NSN) and Illustration 5120-01-335-1233 (3) Description, Part Number/(CAGEC) WRENCH, BOX AND OPEN END, COMBINATION, 7/16 IN, OEX14B/(55719) (4) Usable On Code MAT (5) (6) Qty Rqr 1

U/I EA

15

5120-01-335-1234

WRENCH, BOX AND OPEN END, COMBINATION, 1/2 IN, OEX16B/(55719)

MAT

EA

16

5120-01-335-1235

WRENCH, BOX AND OPEN END, COMBINATION, 9/16 IN, OEX18B/(55719)

MAT

EA

0031-8

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0031

Table 2. BII List Continued. (1) Item Number 17 (2) National Stock Number (NSN) and Illustration 5120-01-335-1258 (3) Description, Part Number/(CAGEC) WRENCH, BOX AND OPEN END, COMBINATION, 3/4 IN, OEX24B/(55719) (4) Usable On Code MAT (5) (6) Qty Rqr 1

U/I EA

18

5120-01-335-1261

WRENCH, BOX AND OPEN END, COMBINATION, 15/16 IN, OEX30B/(55719)

MAT

EA

19

5120-01-335-1266

WRENCH, BOX AND OPEN END, COMBINATION, 1 1/4 IN, OEX40B/(55719)

MAT

EA

END OF WORK PACKAGE

0031-9/10 blank

TM 5-3895-385-10

0032

OPERATOR MAINTENANCE BITUMINOUS MATERIAL PAVING MACHINE (BMPM) ADDITIONAL AUTHORIZATION LIST (AAL) INTRODUCTION Scope This Work Package (WP) lists additional items authorized for the support of the Bituminous Material Paving Machine (BMPM). General This list identifies items that do not have to accompany the BMPM and that do not have to be turned in with it. These items are all authorized by Common Table of Allowances (CTA), Modified Table of Organization and Equipment (MTOE), Tables of Distribution and Allowances (TDA), or Joint Table of Allowances (JTA). Explanation of Columns in the Additional Authorization List (AAL) Column (1) National Stock Number (NSN). Identifies the stock number of the item to be used for requisitioning purposes. Column (2) Description, Part Number/(CAGEC). Identifies the Federal item name (in all capital letters) followed by a minimum description when needed. The last line below the description is the Part Number (P/N) and the Commercial and Government Entity Code (CAGEC) (in parentheses). Column (3) Usable On Code. When applicable, gives you a code if the item you need is not the same for different models of equipment. These codes are identified below: Code MAT Used on Model 8816M

Column (4) U/I. Unit of Issue (U/I) indicates the physical measurement or count of the item as issued per the NSN shown in column (1). Column (5) Qty Recm. Indicates the quantity recommended. Table 1. AAL. (1) National Stock Number (NSN) 7920-00-267-2967 5120-01-121-5030 5120-00-224-9326 (2) Description, Part Number/(CAGEC) BROOM, PUSH, H-B-71-TY-1/(80244) RAKE, ASPHALT, 16193/(89942) SHOVEL, HAND, GGG-5-326/(80244) (3) Usable On Code MAT MAT MAT (4) U/I EA EA EA (5) Qty Recm 1 2 2

END OF WORK PACKAGE

0032-1/2 blank

TM 5-3895-385-10

0033

OPERATOR MAINTENANCE BITUMINOUS MATERIAL PAVING MACHINE (BMPM) EXPENDABLE AND DURABLE ITEMS LIST INTRODUCTION Scope This Work Package (WP) lists expendable and durable items that you will need to operate and maintain the Bituminous Material Paving Machine (BMPM). This list is for information only and is not authority to requisition the listed items. These items are authorized to you by CTA 50-970, Expendable/Durable Items (Except Medical, Class V Repair Parts, and Heraldic Items), CTA 50-909, Field and Garrison Furnishings and Equipment, or CTA 8-100, Army Medical Department Expendable/Durable Items. Explanation of Columns in the Expendable/Durable Items List Column (1) Item No. This number is assigned to the entry in the list and is referenced in the narrative instructions to identify the item (e.g., Use brake fluid (WP 0098, Item 5)). Column (2) Level. This column identifies the lowest level of maintenance that requires the listed item (C = Crew). Column (3) National Stock Number (NSN). This is the NSN assigned to the item, which can be used to requisition the item. Column (4) Item Name, Description, Part Number/(CAGEC). This column provides additional information identifying the item. The last line below the description is the Part Number (P/N) and the Commercial and Government Entity Code (CAGEC) (in parentheses). Column (5) U/I. Unit of Issue (U/I) code shows the physical measurement or count of an item, such as gallon, dozen, gross, etc. Table 1. Expendable and Durable Items List. (1) Item No. 1 (2) Level C 6850-01-464-9125 6850-01-441-3221 2 3 C C 7930-01-314-6133 (3) National Stock Number (NSN) (4) Item Name, Description, Part Number/(CAGEC) Antifreeze, A-A-52624/(58536) 1 Gallon Can 5 Gallon Can Bag, Plastic, 55 Gallon, 6 Mil, S-15584/(7Z049) Cleaning Compound, Solvent-Detergent, 185915/(56883) GL CN PG DR (5) U/I

0033-1

TM 5-3895-385-10

0033

Table 1. Expendable and Durable Items List Continued. (1) Item No. 4 5 (2) Level C C 8030-00-062-5866 8030-00-526-1605 6 7 8 C C C 9150-01-197-7688 9150-01-197-7693 9150-01-197-7690 9150-01-197-7692 9 C 9150-00-111-6256 9150-00-111-6255 10 C 9150-01-152-4117 9150-01-421-1424 6810-00-107-1510 (3) National Stock Number (NSN) 7930-01-380-9028 (4) Item Name, Description, Part Number/(CAGEC) Cleaning Lubricant, Greaseless, LPS-1 GREASELESS LUBRICANT/(66724) Corrosion Preventive Compound, MIL-PRF16173/(81349) 1 Gallon 5 Gallon Can Distilled Water, ACS, A-A-59282/(58536) Filter Element, Primary, Air, C 20 500/(5FNT1) Grease, Automotive and Artillery, MIL-PRF10924/(81349) 2.25 oz Tube 14 oz Cartridge 1.75 lb Can 35 lb Can Hydraulic Fluid, Fire Resistant, MIL-PRF46170/(81349) 1 Quart Can 5 Gallon Can Lubricating Oil, Engine, OE/HDO-15/40, MIL-PRF2104/(81349) 1 Quart Can 5 Gallon Can QT CN QT CN TU CA CN CN GL CN DR EA (5) U/I BX

0033-2

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0033

Table 1. Expendable and Durable Items List Continued. (1) Item No. 11 (2) Level C 9150-00-234-5197 9150-00-530-7293 12 C 9150-01-422-9329 9150-01-422-9335 13 C 9150-00-261-8146 9150-00-231-9062 9150-00-231-6689 9150-00-231-9045 14 15 16 17 C C C C 9130-01-525-4050 9130-01-527-7832 18 19 20 C C C 5310-01-476-1622 5310-01-524-7656 5310-01-533-6196 5310-01-586-8294 7920-00-140-0869 5640-00-103-2254 (3) National Stock Number (NSN) (4) Item Name, Description, Part Number/(CAGEC) Lubricating Oil, Exposed Gear, VVL751/(81348) 5 lb Can 35 lb Drum Lubricating Oil, Gear, GO-80/90, MIL-PRF2105/(81349) 1 Quart Can 5 Gallon Can Lubricating Oil, General Purpose, MIL-PRF32033/(81349) Ounce Can Quart Gallon Nut, Self-Locking, HE 91342A250/(3A054) Rag, Wiping, 8722-0088/(03950) Tape, Duct, 1791K70/(89428) Turbine Fuel, Aviation, MIL-DTL-83133/(81349) 1 Gallon Can 5 Gallon Can Washer, Lock, 91102A031/(39428) Washer, Lock, 91102A755/(39428) Washer, Lock, 91202A234/(39428) GL GL EA EA EA OZ CN QT GL EA BOX RL QT CN CN DR (5) U/I

END OF WORK PACKAGE

0033-3/4 blank

RECOMMENDED CHANGES TO PUBLICATIONS AND BLANK FORMS

For use of this form, see AR 25-30; the proponent agency is OAASA.

Use Part II (reverse) for Repair Parts and Special Tool Lists (RPSTL) and Supply Catalogs/Supply Manuals (SC/SM).

DATE Date you filled out this form.

TO (Forward to proponent of publication or form) (Include ZIP Code) U.S. Army TACOM Life Cycle Management Command ATTN: AMSTA-LCL-MPP/TECH PUBS

FROM (Activity and location) (Include ZIP Code)

Your mailing address

6501 E. 11 Mile Road, Warren, MI 48397-5000 PART I ALL PUBLICATIONS (EXCEPT RPSTL AND SC/SM) AND BLANK FORMS PUBLICATION/FORM NUMBER DATE TITLE

TM Number
ITEM PAGE PARAGRAPH LINE FIGURE TABLE NO.

Date of the TM

Title of the TM

RECOMMENDED CHANGES AND REASON (Exact wording of recommended change must be given)

0007-3 0018-2

Figure 2, Item 9 should show a lockwasher. Currently shows a flat washer. Cleaning and inspection, Step 6, reference to governor support pin (14) is wrong reference. Reference should be change to (12).

SAMPLE

TYPED NAME, GRADE OR TITLE

TELEPHONE EXCHANGE/AUTOVON, PLUS EXTENSION

SIGNATURE

Your Name
DA FORM 2028, FEB 74

Your Phone Number

Your Signature
APD V4.00

REPLACES DA FORM 2028, 1 DEC 68, WHICH WILL BE USED.

TO (Forward direct to addressee listed in publication) U.S. Army TACOM Life Cycle Management Command ATTN: AMSTA-LCL-MPP/TECH PUBS

FROM (Activity and location) (Include ZIP Code)

DATE Date you filled out this form

Your Address

6501 E. 11 Mile Road, Warren, MI 48397-5000 PART II REPAIR PARTS AND SPECIAL TOOL LISTS AND SUPPLY CATALOGS/SUPPLY MANUALS PUBLICATION NUMBER DATE TITLE

TM Number
PAGE NO. COLM NO. LINE NO. NATIONAL STOCK NUMBER

Date of the TM

Title of the TM
RECOMMENDED ACTION

TOTAL NO. REFERENCE FIGURE ITEM OF MAJOR NO. NO. NO. ITEMS SUPPORTED

SAMPLE
PART III REMARKS (Any general remarks, or recommendations, or suggestions for improvement of publications and blank forms. Additional blank sheets may be used if more space is needed.)

TYPED NAME, GRADE OR TITLE

Your Name

TELEPHONE EXCHANGE/AUTOVON, SIGNATURE PLUS EXTENSION

Your Phone Number

Your Signature
APD V4.00

RECOMMENDED CHANGES TO PUBLICATIONS AND BLANK FORMS

For use of this form, see AR 25-30; the proponent agency is OAASA

Use Part II (reverse) for Repair Parts and Special Tool Lists (RPSTL) and Supply Catalogs/Supply Manuals (SC/SM).

DATE

TO (Forward to proponent of publication or form) (Include ZIP Code) U.S. Army TACOM Life Cycle Management Command ATTN: AMSTA-LCL-MPP/TECH PUBS

FROM (Activity and location) (Include ZIP Code)

6501 E. 11 Mile Road, Warren, MI 48397-5000 PART I ALL PUBLICATIONS (EXCEPT RPSTL AND SC/SM) AND BLANK FORMS PUBLICATION/FORM NUMBER DATE 28 November 2011 LINE FIGURE TABLE NO.

TM 5-3895-385-10
ITEM PAGE PARAGRAPH

TITLE Operators Manual for Bituminous Material Paving Machine (BMPM) (Model 8816M)

RECOMMENDED CHANGES AND REASON

TYPED NAME, GRADE OR TITLE

TELEPHONE EXCHANGE/AUTOVON, PLUS EXTENSION

SIGNATURE

DA FORM 2028, FEB 74

REPLACES DA FORM 2028, 1 DEC 68, WHICH WILL BE USED.

APD V4.00

TO (Forward direct to addressee listed in publication) U.S. Army TACOM Life Cycle Management Command ATTN: AMSTA-LCL-MPP/TECH PUBS

FROM (Activity and location) (Include ZIP Code)

DATE

6501 E. 11 Mile Road, Warren, MI 48397-5000 PART II REPAIR PARTS AND SPECIAL TOOL LISTS AND SUPPLY CATALOGS/SUPPLY MANUALS PUBLICATION/FORM NUMBER DATE 28 November 2011 NATIONAL STOCK NUMBER REFERENCE FIGURE ITEM NO. NO. NO.

TM 5-3895-385-10
PAGE NO. COLM NO. LINE NO.

TITLE Operators Manual for Bituminous Material Paving Machine (BMPM) (Model 8816M) TOTAL NO. OF MAJOR ITEMS SUPPORTED

RECOMMENDED ACTION

PART III REMARKS (Any general remarks, or recommendations, or suggestions for improvement of publications and blank forms. Additional blank sheets may be used if more space is needed.)

TYPED NAME, GRADE OR TITLE

TELEPHONE EXCHANGE/AUTOVON, SIGNATURE PLUS EXTENSION

APD V4.00

RECOMMENDED CHANGES TO PUBLICATIONS AND BLANK FORMS

For use of this form, see AR 25-30; the proponent agency is OAASA

Use Part II (reverse) for Repair Parts and Special Tool Lists (RPSTL) and Supply Catalogs/Supply Manuals (SC/SM).

DATE

TO (Forward to proponent of publication or form) (Include ZIP Code) U.S. Army TACOM Life Cycle Management Command ATTN: AMSTA-LCL-MPP/TECH PUBS

FROM (Activity and location) (Include ZIP Code)

6501 E. 11 Mile Road, Warren, MI 48397-5000 PART I ALL PUBLICATIONS (EXCEPT RPSTL AND SC/SM) AND BLANK FORMS PUBLICATION/FORM NUMBER DATE 28 November 2011 LINE FIGURE TABLE NO.

TM 5-3895-385-10
ITEM PAGE PARAGRAPH

TITLE Operators Manual for Bituminous Material Paving Machine (BMPM) (Model 8816M)

RECOMMENDED CHANGES AND REASON

TYPED NAME, GRADE OR TITLE

TELEPHONE EXCHANGE/AUTOVON, PLUS EXTENSION

SIGNATURE

DA FORM 2028, FEB 74

REPLACES DA FORM 2028, 1 DEC 68, WHICH WILL BE USED.

APD V4.00

TO (Forward direct to addressee listed in publication) U.S. Army TACOM Life Cycle Management Command ATTN: AMSTA-LCL-MPP/TECH PUBS

FROM (Activity and location) (Include ZIP Code)

DATE

6501 E. 11 Mile Road, Warren, MI 48397-5000 PART II REPAIR PARTS AND SPECIAL TOOL LISTS AND SUPPLY CATALOGS/SUPPLY MANUALS PUBLICATION/FORM NUMBER DATE 28 November 2011 NATIONAL STOCK NUMBER REFERENCE FIGURE ITEM NO. NO. NO.

TM 5-3895-385-10
PAGE NO. COLM NO. LINE NO.

TITLE Operators Manual for Bituminous Material Paving Machine (BMPM) (Model 8816M) TOTAL NO. OF MAJOR ITEMS SUPPORTED

RECOMMENDED ACTION

PART III REMARKS (Any general remark, or recommendations, or suggestions for improvement of publications and blank forms. Additional blank sheets may be used if more space is needed.)

TYPED NAME, GRADE OR TITLE

TELEPHONE EXCHANGE/AUTOVON, SIGNATURE PLUS EXTENSION

APD V4.00

RECOMMENDED CHANGES TO PUBLICATIONS AND BLANK FORMS

For use of this form, see AR 25-30; the proponent agency is OAASA

Use Part II (reverse) for Repair Parts and Special Tool Lists (RPSTL) and Supply Catalogs/Supply Manuals (SC/SM).

DATE

TO (Forward to proponent of publication or form) (Include ZIP Code) U.S. Army TACOM Life Cycle Management Command ATTN: AMSTA-LCL-MPP/TECH PUBS

FROM (Activity and location) (Include ZIP Code)

6501 E. 11 Mile Road, Warren, MI 48397-5000 PART I ALL PUBLICATIONS (EXCEPT RPSTL AND SC/SM) AND BLANK FORMS PUBLICATION/FORM NUMBER DATE 28 November 2011 LINE FIGURE TABLE NO.

TM 5-3895-385-10
ITEM PAGE PARAGRAPH

TITLE Operators Manual for Bituminous Material Paving Machine (BMPM) (Model 8816M)

RECOMMENDED CHANGES AND REASON

TYPED NAME, GRADE OR TITLE

TELEPHONE EXCHANGE/AUTOVON, PLUS EXTENSION

SIGNATURE

DA FORM 2028, FEB 74

REPLACES DA FORM 2028, 1 DEC 68, WHICH WILL BE USED.

APD V4.00

TO (Forward direct to addressee listed in publication) U.S. Army TACOM Life Cycle Management Command ATTN: AMSTA-LCL-MPP/TECH PUBS

FROM (Activity and location) (Include ZIP Code)

DATE

6501 E. 11 Mile Road, Warren, MI 48397-5000 PART II REPAIR PARTS AND SPECIAL TOOL LISTS AND SUPPLY CATALOGS/SUPPLY MANUALS PUBLICATION/FORM NUMBER DATE 28 November 2011 NATIONAL STOCK NUMBER REFERENCE FIGURE ITEM NO. NO. NO.

TM 5-3895-385-10
PAGE NO. COLM NO. LINE NO.

TITLE Operators Manual for Bituminous Material Paving Machine (BMPM) (Model 8816M) TOTAL NO. OF MAJOR ITEMS SUPPORTED

RECOMMENDED ACTION

PART III REMARKS (Any general remarks, recommendations, or suggestions for improvement of publications and blank forms. Additional blank sheets may be used if more space is needed.)

TYPED NAME, GRADE OR TITLE

TELEPHONE EXCHANGE/AUTOVON, SIGNATURE PLUS EXTENSION

APD V4.00

By Order of the Secretary of the Army: RAYMOND T. ODIERNO General, United States Army Chief of Staff

Official: JOYCE E. MORROW Administrative Assistant to the Secretary of the Army

1129012

Distribution: To be distributed in accordance with the initial distribution number (IDN) 257890 requirements for TM 5-3895-385-10.

THE METRIC SYSTEM AND EQUIVALENTS

LINEAR MEASURE 1 Centimeter = 10 Millimeters = 0.01 Meters = 0.3937 Inches 1 Meter = 100 Centimeters = 1000 Millimeters = 39.37 Inches 1 Kilometer = 1000 Meters = 0.621 Miles WEIGHTS 1 Gram = 0.001 Kilograms = 1000 Milligrams = 0.035 Ounces 1 Kilogram = 1000 Grams = 2.2 Lb. 1 Metric Ton = 1000 Kilograms = 1 Megagram = 1.1 Short Tons LIQUID MEASURE 1 Milliliter = 0.001 Liters = 0.0338 Fluid Ounces 1 Liter = 1000 Milliliters = 33.82 Fluid Ounces 32 Fahrenheit is equivalent to 0 Celsius TO CHANGE TO MULTIPLY BY

SQUARE MEASURE 1 Sq. Centimeter = 100 Sq. Millimeters = 0.155 Sq. Inches 1 Sq. Meter = 10,000 Sq. Centimeters = 10.76 Sq. Feet 1 Sq. Kilometer = 1,000 Sq. Meters = 0.386 Sq. Miles CUBIC MEASURE 1 Cu. Centimeter = 1000 Cu. Millimeters = 0.06 Cu. Inches 1 Cu. Meter = 1,000,000 Cu. Centimeters = 35.31 Cu. Feet TEMPERATURE 5/9 (F - 32) = C 212 Fahrenheit is equivalent to 100 Celsius 90 Fahrenheit is equivalent to 32.2 Celsius 32 Fahrenheit is equivalent to 0 Celsius (9/5 x C) + 32 = F

Inches .................................... Centimeters................................ 2.540 Feet ........................................ Meters ....................................... 0.305 Yards ...................................... Meters ....................................... 0.914 Miles ....................................... Kilometers ................................. 1.609 Square Inches ........................ Square Centimeters ................... 6.451 Square Feet............................ Square Meters ........................... 0.093 Square Yards.......................... Square Meters .......................... 0.836 Square Miles........................... Square Kilometers .................... 2.590 Acres ...................................... Square Hectometers ................. 0.405 Cubic Feet .............................. Cubic Meters.............................. 0.028 Cubic Yards ........................... Cubic Meters.............................. 0.765 Fluid Ounces .......................... Milliliters .................................. 29.573 Pints........................................ Liters ......................................... 0.473 Quarts..................................... Liters ......................................... 0.946 Gallons ................................... Liters ......................................... 3.785 Ounces ................................... Grams ...................................... 28.349 Pounds ................................... Kilograms .................................. 0.454 Short Tons ............................. Metric Tons ............................... 0.907 Pound-Feet............................. Newton-Meters........................... 1.356 Pounds per Square Inch......... Kilopascals................................. 6.895 Miles per Gallon...................... Kilometers per Liter.................... 0.425 Miles per Hour ........................ Kilometers per Hour .................. 1.609 TO CHANGE TO MULTIPLY BY Centimeters ............................ Inches ....................................... 0.394 Meters..................................... Feet............................................ 3.280 Meters..................................... Yards.......................................... 1.094 Kilometers............................... Miles........................................... 0.621 Square Centimeters................ Square Inches............................ 0.155 Square Meters ....................... Square Feet. ............................ 10.764 Square Meters ....................... Square Yards ............................ 1.196 Square Kilometers ................. Square Miles ............................. 0.386 Square Hectometers............... Acres.......................................... 2.471 Cubic Meters ......................... Cubic Feet................................. 35.315 Cubic Meters ......................... Cubic Yards .............................. 1.308 Milliliters.................................. Fluid Ounces.............................. 0.034 Liters....................................... Pints .......................................... 2.113 Liters....................................... Quarts ........................................ 1.057 Liters....................................... Gallons........................................ 0.264 Grams..................................... Ounces........................................ 0.035 Kilograms................................ Pounds....................................... 2.205 Metric Tons............................. Short Tons ................................. 1.102 Newton-Meters ...................... Pound-Feet ............................... 0.738 Kilopascals ............................ Pounds per Square Inch ........... 0.145 Kilometers per Liter ............... Miles per Gallon ......................... 2.354 Kilometers per Hour................ Miles per Hour............................ 0.621

PIN: 086333-000