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Blaw-Knox PF-200 - User Manual

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Drive Train Highway Class Paver/Finishers
A-1
TABLE OF CONTENTS
TASK PAGE NO.
Table of Contents ............................................................................................................... A-1
Alphabetical Index .............................................................................................................. A-2
Safety Precautions ............................................................................................................. A-3
Theory of Operation............................................................................................................ A-4
System Maintenance and Service ...................................................................................... A-7
Drive Train Troubleshooting ............................................................................................... A-8
Engine Assembly .............................................................................................................. A-14
Radiator ............................................................................................................................ A-19
Water Temperature and Oil Pressure Sending Units ....................................................... A-22
Hour Meter Switch ............................................................................................................ A-24
Air Cleaner Assembly ...................................................................................................... A-25
Exhaust Muffler................................................................................................................. A-29
Throttle Cylinder ............................................................................................................... A-31
PTO and Clutch Assembly ............................................................................................... A-33
Pump Drive Transmission ................................................................................................ A-43
Three Speed Traction Transmission Assembly (Wheeled) .............................................. A-47
Three Speed Traction Transmission Assembly (Tracked) ............................................... A-51
Traction Drive Shaft Assembly ......................................................................................... A-56
Traction Drive Motor (see Hydraulics)
Drive Axle and Brake Assembly (Wheeled)...................................................................... A-58
Electric Axle Shift Unit ...................................................................................................... A-62
Drive Wheel and Tire (Wheeled) ...................................................................................... A-64
Drive Wheel Spindle and Hub Assembly (Wheeled) ........................................................ A-68
Drive Chain and Tightener Assembly (Wheeled) ............................................................. A-72
Traction Case Assembly (Drop Box) (PF-510) ................................................................. A-75
Traction Drive Track Assembly (PF-510) ......................................................................... A-89
Track Band (PF-510) ........................................................................................................ A-95
Track Pad (PF-510) .......................................................................................................... A-99
Bogie Wheel Assembly (Wheeled) ................................................................................. A-103
Bogie Wheel Assembly (Tracked) .................................................................................. A-108
Take-Up Wheel Assembly (PF-510) ............................................................................... A-113
Front Wheel Assist (see Hydraulics)
Appendix A – Vendor Component Publications Listing .......................................... Appdx–A-1
Appendix B – Fabricated Tools .............................................................................. Appdx–B-1
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Summary

THEORY OF OPERATION

DRIVE TRAIN POWER FLOW

Explains how power flows through the drive train system.

DRIVE TRAIN TROUBLESHOOTING

TROUBLESHOOTING GUIDES

Lists common malfunctions and their corrective actions.

ENGINE ASSEMBLY

MACHINE SET-UP

Details steps for machine setup before engine assembly.

REMOVAL

Step-by-step instructions for removing the engine assembly.

INSTALLATION

Steps for installing the engine assembly.

RADIATOR

MACHINE SET-UP

Details machine setup steps before radiator work.

REMOVAL

Step-by-step instructions for removing the radiator.

COMPONENT TEST

Procedure for testing the radiator's integrity.

EQUIPMENT PREPARATION

Steps for preparing equipment after radiator work.

WATER TEMPERATURE AND OIL PRESSURE SENDING UNITS

MACHINE SET-UP

Details machine setup before working on sending units.

REMOVAL

Steps to remove the temperature and oil pressure sending units.

INSTALLATION

Steps to install the temperature and oil pressure sending units.

EQUIPMENT PREPARATION

Steps for preparing equipment after installation.

HOUR METER SWITCH (IF EQUIPPED)

MACHINE SET-UP

Details machine setup before working on the hour meter switch.

AIR CLEANER ASSEMBLY

MACHINE SET-UP

Details machine setup before working on the air cleaner assembly.

REMOVAL

Step-by-step instructions for removing the air cleaner assembly.

DISASSEMBLY

Step-by-step instructions for disassembling the air cleaner assembly.

INSPECTION

Steps for inspecting the air cleaner assembly.

ASSEMBLY

Steps for assembling the air cleaner assembly.

INSTALLATION

Steps for installing the air cleaner assembly.

EXHAUST MUFFLER

MACHINE SET-UP

Details machine setup before working on the exhaust muffler.

REMOVAL

Step-by-step instructions for removing the exhaust muffler.

INSTALLATION

Step-by-step instructions for installing the exhaust muffler.

THROTTLE CYLINDER

MACHINE SET-UP

Details machine setup before working on the throttle cylinder.

REMOVAL

Step-by-step instructions for removing the throttle cylinder.

INSTALLATION

Steps for installing the throttle cylinder.

ADJUSTMENT

Procedures for adjusting the throttle cylinder settings.

PTO AND CLUTCH ASSEMBLY

MACHINE SET-UP

Details machine setup before working on the PTO and clutch assembly.

REMOVAL

Step-by-step instructions for removing the PTO and clutch assembly.

DISASSEMBLY

Step-by-step instructions for disassembling the PTO and clutch assembly.

ASSEMBLY

Steps for reassembling the PTO and clutch assembly.

ADJUSTMENT

Procedure for adjusting the clutch engagement torque.

PUMP DRIVE TRANSMISSION

MACHINE SET-UP

Details machine setup before working on the pump drive transmission.

REMOVAL

Step-by-step instructions for removing the pump drive transmission.

DISASSEMBLY

Step-by-step instructions for disassembling the pump drive transmission.

THREE SPEED TRACTION TRANSMISSION ASSEMBLY (WHEELED)

MACHINE SET-UP

Details machine setup before working on the wheeled traction transmission.

REMOVAL

Step-by-step instructions for removing the wheeled traction transmission.

DISASSEMBLY

Steps for draining and disassembling the wheeled traction transmission.

INSPECTION

Procedures for inspecting the wheeled traction transmission.

ASSEMBLY

Steps for assembling the wheeled traction transmission.

INSTALLATION

Steps for installing the wheeled traction transmission assembly.

EQUIPMENT PREPARATION

Steps for preparing equipment after installation.

THREE SPEED TRACTION TRANSMISSION ASSEMBLY (TRACKED)

MACHINE SET-UP

Details machine setup before working on the tracked traction transmission.

REMOVAL

Step-by-step instructions for removing the tracked traction transmission.

DISASSEMBLY

Steps for draining and disassembling the tracked traction transmission.

INSPECTION

Procedures for inspecting the tracked traction transmission.

ASSEMBLY

Steps for assembling the tracked traction transmission.

INSTALLATION

Steps for installing the tracked traction transmission assembly.

EQUIPMENT PREPARATION

Steps for preparing equipment after installation.

TRACTION DRIVE SHAFT ASSEMBLY

MACHINE SET-UP

Details machine setup before working on the traction drive shaft.

REMOVAL

Step-by-step instructions for removing the traction drive shaft.

INSPECTION

Procedures for inspecting the traction drive shaft.

INSTALLATION

Steps for installing the traction drive shaft.

DRIVE AXLE AND BRAKE ASSEMBLY (All Machines Except PF-510)

MACHINE SET-UP

Details machine setup before working on drive axle and brake assembly.

REMOVAL

Step-by-step instructions for removing the drive axle and brake assembly.

INSTALLATION

Steps for installing the drive axle and brake assembly.

EQUIPMENT PREPARATION

Steps for preparing equipment after drive axle and brake assembly.

ELECTRIC AXLE SHIFT UNIT

MACHINE SET-UP

Details machine setup before working on the electric axle shift unit.

REMOVAL

Step-by-step instructions for removing the electric axle shift unit.

INSTALLATION

Steps for installing the electric axle shift unit.

EQUIPMENT PREPARATION

Steps for preparing equipment after installation.

DRIVE WHEEL AND TIRE (All Machines Except PF-510)

MACHINE SET-UP

Details machine setup before working on the drive wheel and tire.

REMOVAL

Step-by-step instructions for removing the drive wheel and tire.

INSPECTION

Procedures for inspecting the drive wheel and tire.

COMPONENT TEST

Procedures for testing the drive wheel and tire.

ADJUSTMENT

Procedures for adjusting tire air pressure and mixture.

INSTALLATION

Steps for installing the drive wheel and tire.

DRIVE WHEEL SPINDLE AND HUB ASSEMBLY (All Machines Except PF-510)

MACHINE SET-UP

Details machine setup before working on the spindle and hub assembly.

REMOVAL

Step-by-step instructions for removing the spindle and hub assembly.

DISASSEMBLY

Steps for disassembling the hub assembly.

INSPECTION

Procedures for inspecting bearings, studs, lug nuts, and spindle.

ASSEMBLY

Steps for assembling the hub assembly.

INSTALLATION

Steps for installing the wheel spindle, chain tensioner, hub, and tire.

EQUIPMENT PREPARATION

Steps for preparing equipment after installation.

DRIVE CHAIN AND TIGHTENER ASSEMBLY

MACHINE SET-UP

Details machine setup before working on the drive chain and tightener.

REMOVAL

Step-by-step instructions for removing the drive chain and tensioner.

INSPECTION

Procedures for inspecting the drive chain.

INSTALLATION

Steps for installing the chain tensioner.

INSTALLATION

Steps for installing the drive chain.

ADJUSTMENT

Procedures for adjusting drive chain tension.

TRACTION CASE ASSEMBLY (DROP BOX) (PF-510 Only)

MACHINE SET-UP

Details machine setup before working on the traction case assembly.

REMOVAL

Step-by-step instructions for removing the traction case assembly.

DISASSEMBLY

Steps for removing the top traction case cover plate.

REMOVE PINION SUBASSEMBLY

Steps to remove the pinion subassembly.

REMOVE RING GEAR SUBASSEMBLY

Steps to remove the ring gear subassembly.

REMOVE INTERMEDIATE GEAR

Steps to remove the intermediate gear.

REMOVE DRIVE SPROCKET

Steps to remove the drive sprocket.

REMOVE OUTPUT SHAFT SUBASSEMBLY

Steps to remove the output shaft subassembly.

DISASSEMBLE PINION SUBASSEMBLY

Steps to disassemble the pinion subassembly.

DISASSEMBLE RING GEAR SUBASSEMBLY

Steps to disassemble the ring gear subassembly.

INSPECTION

Procedures for inspecting ring, pinion, gears, and shafts.

ASSEMBLE PINION SUBASSEMBLY

Steps to assemble the pinion subassembly for preload.

ADJUST PINION PRELOAD

Procedure for adjusting pinion preload.

ASSEMBLE PINION SUBASSEMBLY

Steps to assemble the pinion subassembly after preload adjustment.

INSTALL OUTPUT GEAR IN CASE

Steps to install the output gear in the case.

ADJUST OUTPUT SHAFT PRE-LOAD

Procedure for adjusting output shaft preload.

ASSEMBLE AND INSTALL INTERMEDIATE GEAR

Steps to assemble and install the intermediate gear.

ASSEMBLE RING GEAR SUBASSEMBLY

Steps to assemble the ring gear subassembly.

INSTALLING GEAR SUBASSEMBLY IN CASE AND ADJUST

Steps to install gear subassemblies and adjust.

DETERMINE PINION SHIM PACK THICKNESS

Procedure to determine the correct pinion shim pack thickness.

ADJUST PINION TO RING GEAR BACKLASH

Procedure to adjust backlash between pinion and ring gear.

CHECK TOOTH PATTERN

Procedure to check and obtain correct gear tooth pattern.

INSTALL THREE PIECE DRIVE SPROCKET

Steps to install the three-piece drive sprocket.

INSTALL SINGLE PIECE DRIVE SPROCKET

Steps to install the single-piece drive sprocket.

ADJUSTMENT

Procedure for checking and adjusting backlash.

INSTALLATION

Steps for installing the traction case assembly.

EQUIPMENT PREPARATION

Steps for preparing equipment after installation.

TRACTION DRIVE TRACK ASSEMBLY (PF-510 only)

MACHINE SET-UP

Details machine setup before working on the track assembly.

REMOVAL - SHOP REPAIR

Steps for shop repair removal of the drive track.

REMOVAL - DRIVE-OFF (FIELD REPLACEMENT)

Steps for field removal of the drive track.

INSTALLATION - SHOP REPAIR

Steps for shop repair installation of the drive track.

INSTALLATION - DRIVE ON (FIELD REPLACEMENT)

Steps for field installation of the drive track.

TRACK TENSION ADJUSTMENT

Procedure to adjust track tension.

EQUIPMENT PREPARATION

Steps for preparing equipment after track work.

TRACK BAND

MACHINE SET-UP

Details machine setup before working on track bands.

REMOVAL

Step-by-step instructions for removing track bands.

INSTALLATION

Steps for installing track bands.

TRACK TENSION ADJUSTMENT

Procedure to adjust track tension.

EQUIPMENT PREPARATION

Steps for preparing equipment after track band work.

TRACK PAD

MACHINE SET-UP

Details machine setup before working on track pads.

REMOVAL

Step-by-step instructions for removing track pads.

INSTALLATION

Steps for installing track pads.

TRACK TENSION ADJUSTMENT

Procedure to adjust track tension.

EQUIPMENT PREPARATION

Steps for preparing equipment after track pad work.

BOGIE WHEEL ASSEMBLY (TRACKED)

MACHINE SET-UP

Details machine setup before working on tracked bogie wheels.

REMOVAL

Step-by-step instructions for removing tracked bogie wheels.

DISASSEMBLY

Steps for disassembling bogie wheels.

ASSEMBLY

Steps for assembling bogie wheels.

INSTALLATION

Steps for installing bogie wheel assemblies.

EQUIPMENT PREPARATION

Steps for preparing equipment after installation.

BOGIE WHEEL ASSEMBLY (WHEELED)

MACHINE SET-UP

Details machine setup before working on wheeled bogie wheels.

REMOVAL

Step-by-step instructions for removing wheeled bogie wheels.

REMOVE TIE ROD

Steps to remove the tie rod from between bogie wheels.

REMOVE STEERING CYLINDER

Steps to remove the steering cylinder.

REMOVE KING PIN ARMS

Steps to remove the king pin arms.

DISASSEMBLY (STANDARD FRONT BOGIE)

Steps for disassembling the standard front bogie wheel.

DISASSEMBLY (FRONT WHEEL POWER ASSIST)

Steps for disassembling the front wheel power assist.

ASSEMBLY (FRONT WHEEL POWER ASSIST)

Steps for assembling the front wheel power assist.

ASSEMBLY (STANDARD FRONT BOGIE)

Steps for assembling the standard front bogie wheel.

TAKE-UP WHEEL ASSEMBLY (PF-510 only)

MACHINE SET-UP

Details machine setup before working on the take-up wheel assembly.

REMOVAL

Step-by-step instructions for removing the take-up wheel assembly.

DISASSEMBLY

Steps for removing the track tension cylinder and bearings.

ASSEMBLY

Steps for assembling the take-up wheel.

INSTALLATION

Steps for installing the take-up wheel.

ADJUSTMENT

Procedures for adjusting take-up wheel position and track tension.

APPENDIX A VENDOR COMPONENT PUBLICATIONS LISTING

APPENDIX B FABRICATED TOOLS

Blaw-Knox PF-200 Specifications

General IconGeneral
BrandBlaw-Knox
ModelPF-200
CategoryUtility Vehicle
LanguageEnglish