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LeeBoy 1000G - User Manual

LeeBoy 1000G
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Operations, Service, and Parts Manual
Manual No. 1012035-04
LeeBoy Model 1000G Tilt Hopper Paver
This manual applies to
Serial Number 206561
and above.

Table of Contents

Questions and Answers

Summary

Section 1 SAFETY

Safety

General safety information for product and safety labels.

Safety Precautions

General and specific safety guidelines and precautions.

Safety Decals

Information on safety decals and their importance.

Safety Decal Locations

Visual guide to the placement of safety decals on the paver.

Section 2 INFORMATION AND SPECIFICATIONS

Information and Specifications

Details about the paver's specifications, warranty, and contact info.

Two Year Limited Warranty

Terms and conditions of the limited warranty provided by LeeBoy.

Contact Information

How to contact LeeBoy for support, parts, and repairs.

Specification Charts

Tables detailing paver dimensions, weights, and performance.

Section 3 COMPONENT LOCATION

Component Location

Overview of major component locations and functions on the paver.

Components Overview

Description of major components for the LeeBoy Model 1000G Tilt Hopper Paver.

Operator Platform

Description of the operator platform and its main controls.

Engine

Details about the Kubota diesel engine powering the paver.

Section 4 OPERATION

Operation

Instructions for safely operating the LeeBoy 1000G Tilt Hopper Paver.

RECEIVING THE MACHINE

Initial checks and procedures when receiving the paver.

Initial and Daily Inspection

Essential pre-operation inspection checklist for the paver.

START-UP PROCEDURE

Step-by-step guide for starting the paver's engine and systems.

DPF REGENERATION AND DISPLAY

DPF REGENERATION (REGEN)

Explanation of the Diesel Particulate Filter regeneration process.

PV480 POWERVIEW DISPLAY

Overview of the PV480 digital display unit and its functions.

Gauge Screens

Description of the default gauge screen displaying operational data.

OPERATION SETTINGS AND MENUS

Set Points and Throttle Speed

How to set engine speed points and adjust throttle speed.

Main Menu Screen

Navigating the main menu to access various settings and diagnostics.

Diagnostics

Accessing and viewing active or logged diagnostic information.

PV480 DISPLAY INFORMATION

Logged Diagnostics

Viewing non-active warnings or faults stored in the system.

System Info

Displaying engine model, serial number, and system configuration details.

Lamp Info

Explains DPF lamp symbols and provides cautionary information.

PV480 USER SETTINGS

User Settings

Customizing screen color, brightness, language, and units.

Screen Color

Adjusting screen preferences for day or night vision.

Screen Brightness

Adjusting the backlight brightness of the display.

PV480 DISPLAY UNITS AND TIME

Units

Setting unit preferences for display (US Standard, Metric).

Date and Time Setting

Adjusting the date and time settings on the PV480 display.

DPF REGENERATION PROCEDURES

DPF Regeneration

Detailed explanation of the DPF regeneration process and its importance.

DPF Levels

Explains DPF levels and associated warning messages for regeneration.

Perform Parked Regeneration

Step-by-step instructions for performing a manual parked regeneration.

PAVER OPERATION STATUS AND CONTROL

Status and Warning Alert Icons

Identifies status and warning icons displayed on the screen.

DRIVING THE PAVER

Instructions on how to safely drive and maneuver the paver.

Steering and Speed Control

How to use joysticks for steering and controlling paver speed.

PAVER OPERATIONAL PROCEDURES

PAVER OPERATION

General procedures for operating the paver.

Spray Down

Procedure for spraying the paver with cleaning solvent or release agent.

Heating the Screed

How to heat the screed plate to prevent material sticking.

HOPPER AND AUGER OPERATION

To operate the hopper wings

Steps for opening and closing the hopper wings for material loading.

Under Auger Material Cut-Offs

Function and operation of the under auger material cut-off gates.

Set the Screed, Flight Screw and End Gates

Adjusting screed components for proper paving.

SCREED ADJUSTMENTS

Screed Extension Wear Plate Replacement

Procedure for replacing the screed extension wear plate.

Vertical Height Adjustment

How to adjust the vertical height of the screed extensions.

Setting the Crown

Adjusting the screed for pavement slope or crown.

MAT TEXTURE AND AUGER CONTROL

Mat Texture Adjustment

Adjusting the screed's angle of attack for desired mat texture.

Auger and Optional Sonic Auger Sensor

Manual and automatic control of augers using sonic sensors.

PAVING PROCEDURES

Starting To Pave

Initial steps and considerations before starting the paving process.

Basic Paving

Step-by-step guide for performing a basic paving pass.

PAVER UNLOADING AND LOADING

UNLOADING AND LOADING

Procedures for safely loading and unloading the paver.

Unloading

Steps for safely unloading the paver from a trailer.

Loading

Steps for safely loading the paver onto a trailer.

TRANSPORT AND OPTIONAL COMPONENTS

Tie-Down Procedure

How to properly secure the paver for transport using tie-down chains.

OPTIONAL COMPONENTS

Descriptions of optional features available for the paver.

Umbrella Option

Information about the optional umbrella kit for operator shelter.

OPTIONAL EQUIPMENT AND SCREED FEATURES

Slope Meter

Function and installation of the slope meter for paving.

Topcon Sonic Slope and Dual Grade Control

Overview of the Topcon grade control system for paving.

Sonic Auger Sensor

Function of the sonic auger sensor for automatic auger control.

Section 5 MAINTENANCE

Maintenance

General information and schedule for paver maintenance.

GENERAL INFORMATION

Important notes and safety before performing maintenance.

Routine Maintenance

Routine maintenance tasks and schedules.

Prepare Paver for Maintenance

Steps to prepare the paver before performing maintenance.

ROUTINE MAINTENANCE SCHEDULES

Routine Maintenance Schedule

Schedule for routine maintenance tasks based on operating hours.

LUBRICATION PROCEDURES

LUBRICATION

Importance and procedures for proper paver lubrication.

Lubrication Points

Illustrated schedule of lubrication points on the paver.

SPECIFIC LUBRICATION TASKS

Daily Lubrication

Daily lubrication tasks for specific components.

Weekly Lubrication

Weekly lubrication tasks for screed and extension components.

Monthly Lubrication

Monthly lubrication tasks for tracks.

Quarterly Lubrication

Quarterly lubrication tasks for pillow block bearings.

TORQUE HUB AND MONTHLY MAINTENANCE

Torque Hub Lubrication

Procedures for checking and maintaining torque hub oil levels.

MAINTENANCE ADJUSTMENTS

MAINTENANCE ADJUSTMENTS

Procedures for making maintenance adjustments to paver components.

Auger Drive Chain

Steps for aligning and tightening the auger drive chains.

Screed Extension Top Guide Adjustment

Procedure for adjusting the screed extension top guide.

ENGINE AND AIR FILTER MAINTENANCE

ENGINE MAINTENANCE

Routine maintenance procedures for the paver's engine.

Check Engine Lubrication Oil

How to check and maintain the engine oil level.

Change Air Filter

Procedure for changing the air filter elements.

BELT AND OIL SEPARATOR MAINTENANCE

Engine Drive Belt

Adjusting and replacing the engine drive belt.

Change Oil Separator Element

Procedure for changing the oil separator element.

DPF AND COOLING SYSTEM MAINTENANCE

DPF Service

Information on servicing the Diesel Particulate Filter (DPF).

COOLING SYSTEM

Maintenance procedures for the paver's cooling system.

Replace Radiator Hoses

Procedure for replacing worn or damaged radiator hoses.

FUEL SYSTEM MAINTENANCE

FUEL SYSTEM

Information on maintaining the paver's fuel system.

Fuel Tank

How to fill the fuel tank and important safety notes.

FUEL FILTER AND WATER SEPARATOR

Change Fuel Filter

Procedure for changing the fuel filter element.

Fuel Water Separator

How to drain and clean the fuel water separator.

HYDRAULIC SYSTEM MAINTENANCE

HYDRAULIC SYSTEM

Information on maintaining the paver's hydraulic system.

Check Hydraulic Oil

How to check and maintain the hydraulic oil level.

Change Hydraulic Oil and Filter

Procedure for changing the hydraulic oil and filter.

ELECTRICAL SYSTEM MAINTENANCE

ELECTRICAL SYSTEM

Overview of the paver's electrical system.

Battery Servicing

Safety precautions and procedures for servicing the battery.

Alternator

Information on the alternator and precautions to prevent damage.

FUSE PANEL AND LIGHTS

Fuse Panel

How to check the fuse panel for blown fuses.

Beacon and Work Lights

Troubleshooting steps for lights that do not function.

ELECTRICAL CONNECTOR CARE

Dielectric Grease

Proper application of dielectric grease to electrical connectors.

COMPONENT REPLACEMENT PROCEDURES

REPLACEMENT PROCEDURES

General procedures for replacing major components.

Hydraulic Pumps

Procedure for replacing hydraulic pumps.

Hydraulic Motor Installation Start-Up Procedure

Steps for installing and starting up hydraulic motors.

TRACK AND DRIVE SYSTEM REPLACEMENT

Replace Tracks

Procedure for replacing the paver's tracks.

Drive Tires

Procedure for removing and replacing drive tires.

Front Idler

Procedure for replacing the front idler assembly.

TORQUE HUB AND HYDRAULIC MOTOR REPLACEMENT

Torque Hub

Procedure for replacing the torque hub assembly.

Single-Speed Hydraulic Motors

Procedure for replacing single-speed hydraulic motors.

AUGER COMPONENT REPLACEMENT

Under Auger Material Cut-Offs

Procedure for removing and replacing under auger material cut-offs.

Auger Motor

Procedure for removing and replacing the auger motor.

Auger End Mounts

Procedure for removing and replacing auger end mounts.

AUGER AND BEARING SERVICE

Auger and Inner Bearings

Procedure for servicing auger and inner bearings.

SCREED WEAR PLATE REPLACEMENT

Screed Extension Wear Plate

Procedure for replacing the screed extension wear plate.

Main Screed Wear Plate

Procedure for replacing the main screed wear plate.

WELDING AND STORAGE PREPARATION

WELDMENT

Procedures and safety precautions for welding on the machine.

WINTERIZING FOR STORAGE

Procedures for preparing the machine for winter storage.

TROUBLESHOOTING HYDRAULICS AND CONTROLS

TROUBLESHOOTING

Identifying and resolving common paver failures.

Hydraulic Test Ports

How to check hydraulic pressure at various test ports.

Plus One

Information about the Plus One controller and its functions.

TRACK AND PUMP TROUBLESHOOTING

Track Tension Pressure

How to check and adjust track tension pressure.

Torque Hub Hydraulic Motor Gear Adjustment

How to adjust the torque hub hydraulic motor for track speed equalization.

SPRAY DOWN PUMP TROUBLESHOOTING

Spray Down Pump

Troubleshooting information for the spray down pump.

PAVER TROUBLESHOOTING CHART

Troubleshooting Chart

A chart to identify symptoms, causes, and remedies for common paver failures.

PV480 DIAGNOSTIC TROUBLE CODES

PV480 DIAGNOSTIC TROUBLE CODE (DTC) CHART

Codes, symptoms, and recovery actions for PV480 diagnostic trouble codes.

Section 6 SCHEMATICS

Schematics

Diagrams illustrating the electrical and hydraulic systems of the paver.

MAIN ELECTRICAL SCHEMATIC (1 OF 2)

Primary electrical schematic diagram of the paver (part 1 of 2).

MAIN ELECTRICAL SCHEMATIC (2 OF 2)

Primary electrical schematic diagram of the paver (part 2 of 2).

MAIN ELECTRICAL HARNESS (1 OF 2)

Diagram of the main electrical harness wiring (part 1 of 2).

ELECTRICAL HARNESS AND SYSTEM SCHEMATICS

MAIN ELECTRICAL HARNESS (2 OF 2)

Diagram of the main electrical harness wiring (part 2 of 2).

SYSTEM POWER HARNESS

Schematic diagram for the system power harness.

NEUTRAL SAFETY HARNESS

Schematic diagram for the neutral safety harness.

CONTROL BOX ASSEMBLY SCHEMATICS

CONTROL BOX ASSEMBLY (1 OF 3)

Illustrated breakdown of the control box assembly (part 1 of 3).

CONTROL BOX ASSEMBLY (2 OF 3)

Illustrated breakdown of the control box assembly (part 2 of 3).

CONTROL BOX ASSEMBLY (3 OF 3)

Illustrated breakdown of the control box assembly (part 3 of 3).

OPTIONAL AND PUMP HARNESS SCHEMATICS

SPRAYDOWN PUMP HARNESS

Schematic diagram for the spraydown pump harness.

OPTION - ULTRASONIC POWER HARNESS

Schematic for the optional ultrasonic power harness.

OPTION - ELECTRIC SCREW REMOTE ASSEMBLY

Schematic for the electric screw remote assembly option.

HYDRAULIC SCHEMATICS

HYDRAULIC SCHEMATIC (1 OF 2)

Hydraulic schematic diagram of the paver (part 1 of 2).

HYDRAULIC SCHEMATIC (2 OF 2)

Hydraulic schematic diagram of the paver (part 2 of 2).

Section 7 ILLUSTRATED PARTS LIST

Illustrated Parts List

Comprehensive list of parts with diagrams and part numbers.

QUICK REFERENCE

Quick reference guide for filters, engine components, electrical parts, and wear plates.

TRACK DRIVE ASSEMBLY

Illustrated breakdown of the paver's track drive system.

Track Drive Assembly

Detailed list of parts for the track drive assembly.

HOPPER AND AUGER COMPONENTS

HOPPER WING ASSEMBLY

Illustrated breakdown of the hopper wing components.

Hopper Wing Assembly

Detailed list of parts for the hopper wing assembly.

HOPPER DETAILS

Illustrated breakdown of hopper components.

Hopper Details

Detailed list of parts for the hopper.

ENGINE AND HYDRAULIC COMPONENTS

HOPPER LIFT HYDRAULICS

Illustrated breakdown of the hopper lift hydraulic system.

Hopper Lift Hydraulics

Detailed list of parts for the hopper lift hydraulics.

AUGER ASSEMBLY

Illustrated breakdown of the auger assembly.

Auger Assembly

Detailed list of parts for the auger assembly.

TANK, CONTROLS, AND ENGINE PARTS

HYDRAULIC TANK ASSEMBLY

Illustrated breakdown of the hydraulic tank components.

Hydraulic Tank Assembly

Detailed list of parts for the hydraulic tank assembly.

CONTROLS - LEFT SIDE

Illustrated breakdown of the left-side controls.

Controls - Left Side

Detailed list of parts for the left-side controls.

CONTROL PANEL AND RIGHT SIDE COMPONENTS

CONTROLS - CONTROL PANEL

Illustrated breakdown of the control panel components.

Controls - Control Panel

Detailed list of parts for the control panel.

CONTROLS - RIGHT SIDE;HYDRAULIC PUMPS

Illustrated breakdown of the right-side controls and hydraulic pumps.

Controls - Right Side;Hydraulic Pumps

Detailed list of parts for the right-side controls and hydraulic pumps.

VALVE MANIFOLD AND FUEL SYSTEM PARTS

CONTROLS - VALVE MANIFOLD

Illustrated breakdown of the valve manifold components.

Controls - Valve Manifold

Detailed list of parts for the valve manifold.

CONTROLS - VALVE MANIFOLD DETAILS

Detailed illustration of valve manifold components.

SEAT, BATTERY, AND ENGINE COMPONENTS

FUEL TANK ASSEMBLY

Illustrated breakdown of the fuel tank components.

Fuel Tank Assembly

Detailed list of parts for the fuel tank assembly.

SEAT AND EQUIPMENT DETAILS

Illustrated breakdown of seat and associated equipment.

Seat and Equipment Details

Detailed list of parts for seat and equipment.

ENGINE COVER AND COMPONENT PARTS

BATTERY BOX ASSEMBLY

Illustrated breakdown of the battery box assembly.

Battery Box Assembly

Detailed list of parts for the battery box assembly.

ENGINE - COVERS

Illustrated breakdown of engine covers.

Engine - Covers

Detailed list of parts for engine covers.

ENGINE RADIATOR AND HYDRAULIC PUMPS

ENGINE - RADIATOR, INTAKE AND EXHAUST

Illustrated breakdown of engine radiator, intake, and exhaust components.

Engine - Radiator, Intake and Exhaust

Detailed list of parts for engine radiator, intake, and exhaust.

ENGINE - COMPONENTS

Illustrated breakdown of engine components.

Engine - Components

Detailed list of parts for engine components.

ENGINE PUMPS AND SPRAYDOWN ASSEMBLY

ENGINE - HYDRAULIC PUMPS

Illustrated breakdown of engine hydraulic pumps.

Engine - Hydraulic Pumps

Detailed list of parts for engine hydraulic pumps.

SPRAYDOWN ASSEMBLY - STANDARD AND OPTIONAL

Illustrated breakdown of the spraydown assembly components.

Spraydown Assembly - Standard and Optional

Detailed list of parts for the spraydown assembly.

SCREED ASSEMBLY COMPONENTS

SCREED OVERVIEW

Illustrated overview of the screed assembly.

Screed Overview

List of components included in the screed overview.

SCREED - FRAME

Illustrated breakdown of the screed frame components.

Screed - Frame

Detailed list of parts for the screed frame.

SCREED BASE AND EXTENSION PARTS

SCREED - BASE

Illustrated breakdown of the screed base components.

Screed - Base

Detailed list of parts for the screed base.

SCREED - EXTENSION, LH

Illustrated breakdown of the left-hand screed extension.

Screed - Extension, LH

Detailed list of parts for the left-hand screed extension.

RIGHT EXTENSION AND JOINTERS

SCREED - EXTENSION, RH

Illustrated breakdown of the right-hand screed extension.

Screed - Extension, RH

Detailed list of parts for the right-hand screed extension.

SCREED - JOINTERS

Illustrated breakdown of the screed jointers.

Screed - Jointers

Detailed list of parts for the screed jointers.

PULL ARMS AND WALKBOARDS

SCREED - PULL ARMS

Illustrated breakdown of the screed pull arms.

Screed - Pull Arms

Detailed list of parts for the screed pull arms.

SCREED - WALKBOARDS

Illustrated breakdown of the screed walkboards.

Screed - Walkboards

Detailed list of parts for the screed walkboards.

LP HEAT ASSEMBLY AND GRADE CONTROL

SCREED - LP HEAT ASSEMBLY

Illustrated breakdown of the screed LP heat assembly.

Screed - LP Heat Assembly

Detailed list of parts for the screed LP heat assembly.

OPTION - ELECTRIC SCREW FOR GRADE CONTROL

Illustrated breakdown of the electric screw for grade control option.

Option - Electric Screw for Grade Control

Detailed list of parts for the electric screw for grade control option.

WORK LIGHTS AND TIRE DRIVE OPTIONS

OPTION - WORK LIGHTS

Illustrated breakdown of the work lights option.

Option - Work Lights

Detailed list of parts for the work lights option.

OPTION - RUBBER TIRE DRIVE

Illustrated breakdown of the rubber tire drive option.

Option - Rubber Tire Drive

Detailed list of parts for the rubber tire drive option.

BRAKE AND DRIVE SYSTEM OPTIONS

OPTION - FAIL-SAFE BRAKE KIT (SINGLE SPEED DRIVE)

Illustrated breakdown of the fail-safe brake kit.

Option - Fail-Safe Brake Kit (Single Speed Drive)

Detailed list of parts for the fail-safe brake kit.

OPTION - 2 SPEED DRIVE W;BRAKE

Illustrated breakdown of the 2-speed drive with brake option.

Option - 2 Speed Drive w;Brake

Detailed list of parts for the 2-speed drive with brake option.

AUGER AND TOPCON OPTIONS

OPTION - AUGER ADAPTERS W;SONICS

Illustrated breakdown of auger adapters with sonics.

Option - Auger Adapters w;Sonics

Detailed list of parts for auger adapters with sonics.

OPTION - TOPCON P-32, ONE SIDE

Illustrated breakdown of the TopCon P-32 option.

Option - TopCon P-32, One Side

Detailed list of parts for the TopCon P-32 option.

HOSE SCHEDULE AND DECALS

HYDRAULIC HOSE SCHEDULE

Schedule listing hydraulic hoses with part numbers and descriptions.

DECAL SCHEDULE

List of decals, their part numbers, and descriptions.

ALPHABETICAL PARTS INDEX

Alphabetical listing of all parts with part numbers and figure references.

Summary

Section 1 SAFETY

Safety

General safety information for product and safety labels.

Safety Precautions

General and specific safety guidelines and precautions.

Safety Decals

Information on safety decals and their importance.

Safety Decal Locations

Visual guide to the placement of safety decals on the paver.

Section 2 INFORMATION AND SPECIFICATIONS

Information and Specifications

Details about the paver's specifications, warranty, and contact info.

Two Year Limited Warranty

Terms and conditions of the limited warranty provided by LeeBoy.

Contact Information

How to contact LeeBoy for support, parts, and repairs.

Specification Charts

Tables detailing paver dimensions, weights, and performance.

Section 3 COMPONENT LOCATION

Component Location

Overview of major component locations and functions on the paver.

Components Overview

Description of major components for the LeeBoy Model 1000G Tilt Hopper Paver.

Operator Platform

Description of the operator platform and its main controls.

Engine

Details about the Kubota diesel engine powering the paver.

Section 4 OPERATION

Operation

Instructions for safely operating the LeeBoy 1000G Tilt Hopper Paver.

RECEIVING THE MACHINE

Initial checks and procedures when receiving the paver.

Initial and Daily Inspection

Essential pre-operation inspection checklist for the paver.

START-UP PROCEDURE

Step-by-step guide for starting the paver's engine and systems.

DPF REGENERATION AND DISPLAY

DPF REGENERATION (REGEN)

Explanation of the Diesel Particulate Filter regeneration process.

PV480 POWERVIEW DISPLAY

Overview of the PV480 digital display unit and its functions.

Gauge Screens

Description of the default gauge screen displaying operational data.

OPERATION SETTINGS AND MENUS

Set Points and Throttle Speed

How to set engine speed points and adjust throttle speed.

Main Menu Screen

Navigating the main menu to access various settings and diagnostics.

Diagnostics

Accessing and viewing active or logged diagnostic information.

PV480 DISPLAY INFORMATION

Logged Diagnostics

Viewing non-active warnings or faults stored in the system.

System Info

Displaying engine model, serial number, and system configuration details.

Lamp Info

Explains DPF lamp symbols and provides cautionary information.

PV480 USER SETTINGS

User Settings

Customizing screen color, brightness, language, and units.

Screen Color

Adjusting screen preferences for day or night vision.

Screen Brightness

Adjusting the backlight brightness of the display.

PV480 DISPLAY UNITS AND TIME

Units

Setting unit preferences for display (US Standard, Metric).

Date and Time Setting

Adjusting the date and time settings on the PV480 display.

DPF REGENERATION PROCEDURES

DPF Regeneration

Detailed explanation of the DPF regeneration process and its importance.

DPF Levels

Explains DPF levels and associated warning messages for regeneration.

Perform Parked Regeneration

Step-by-step instructions for performing a manual parked regeneration.

PAVER OPERATION STATUS AND CONTROL

Status and Warning Alert Icons

Identifies status and warning icons displayed on the screen.

DRIVING THE PAVER

Instructions on how to safely drive and maneuver the paver.

Steering and Speed Control

How to use joysticks for steering and controlling paver speed.

PAVER OPERATIONAL PROCEDURES

PAVER OPERATION

General procedures for operating the paver.

Spray Down

Procedure for spraying the paver with cleaning solvent or release agent.

Heating the Screed

How to heat the screed plate to prevent material sticking.

HOPPER AND AUGER OPERATION

To operate the hopper wings

Steps for opening and closing the hopper wings for material loading.

Under Auger Material Cut-Offs

Function and operation of the under auger material cut-off gates.

Set the Screed, Flight Screw and End Gates

Adjusting screed components for proper paving.

SCREED ADJUSTMENTS

Screed Extension Wear Plate Replacement

Procedure for replacing the screed extension wear plate.

Vertical Height Adjustment

How to adjust the vertical height of the screed extensions.

Setting the Crown

Adjusting the screed for pavement slope or crown.

MAT TEXTURE AND AUGER CONTROL

Mat Texture Adjustment

Adjusting the screed's angle of attack for desired mat texture.

Auger and Optional Sonic Auger Sensor

Manual and automatic control of augers using sonic sensors.

PAVING PROCEDURES

Starting To Pave

Initial steps and considerations before starting the paving process.

Basic Paving

Step-by-step guide for performing a basic paving pass.

PAVER UNLOADING AND LOADING

UNLOADING AND LOADING

Procedures for safely loading and unloading the paver.

Unloading

Steps for safely unloading the paver from a trailer.

Loading

Steps for safely loading the paver onto a trailer.

TRANSPORT AND OPTIONAL COMPONENTS

Tie-Down Procedure

How to properly secure the paver for transport using tie-down chains.

OPTIONAL COMPONENTS

Descriptions of optional features available for the paver.

Umbrella Option

Information about the optional umbrella kit for operator shelter.

OPTIONAL EQUIPMENT AND SCREED FEATURES

Slope Meter

Function and installation of the slope meter for paving.

Topcon Sonic Slope and Dual Grade Control

Overview of the Topcon grade control system for paving.

Sonic Auger Sensor

Function of the sonic auger sensor for automatic auger control.

Section 5 MAINTENANCE

Maintenance

General information and schedule for paver maintenance.

GENERAL INFORMATION

Important notes and safety before performing maintenance.

Routine Maintenance

Routine maintenance tasks and schedules.

Prepare Paver for Maintenance

Steps to prepare the paver before performing maintenance.

ROUTINE MAINTENANCE SCHEDULES

Routine Maintenance Schedule

Schedule for routine maintenance tasks based on operating hours.

LUBRICATION PROCEDURES

LUBRICATION

Importance and procedures for proper paver lubrication.

Lubrication Points

Illustrated schedule of lubrication points on the paver.

SPECIFIC LUBRICATION TASKS

Daily Lubrication

Daily lubrication tasks for specific components.

Weekly Lubrication

Weekly lubrication tasks for screed and extension components.

Monthly Lubrication

Monthly lubrication tasks for tracks.

Quarterly Lubrication

Quarterly lubrication tasks for pillow block bearings.

TORQUE HUB AND MONTHLY MAINTENANCE

Torque Hub Lubrication

Procedures for checking and maintaining torque hub oil levels.

MAINTENANCE ADJUSTMENTS

MAINTENANCE ADJUSTMENTS

Procedures for making maintenance adjustments to paver components.

Auger Drive Chain

Steps for aligning and tightening the auger drive chains.

Screed Extension Top Guide Adjustment

Procedure for adjusting the screed extension top guide.

ENGINE AND AIR FILTER MAINTENANCE

ENGINE MAINTENANCE

Routine maintenance procedures for the paver's engine.

Check Engine Lubrication Oil

How to check and maintain the engine oil level.

Change Air Filter

Procedure for changing the air filter elements.

BELT AND OIL SEPARATOR MAINTENANCE

Engine Drive Belt

Adjusting and replacing the engine drive belt.

Change Oil Separator Element

Procedure for changing the oil separator element.

DPF AND COOLING SYSTEM MAINTENANCE

DPF Service

Information on servicing the Diesel Particulate Filter (DPF).

COOLING SYSTEM

Maintenance procedures for the paver's cooling system.

Replace Radiator Hoses

Procedure for replacing worn or damaged radiator hoses.

FUEL SYSTEM MAINTENANCE

FUEL SYSTEM

Information on maintaining the paver's fuel system.

Fuel Tank

How to fill the fuel tank and important safety notes.

FUEL FILTER AND WATER SEPARATOR

Change Fuel Filter

Procedure for changing the fuel filter element.

Fuel Water Separator

How to drain and clean the fuel water separator.

HYDRAULIC SYSTEM MAINTENANCE

HYDRAULIC SYSTEM

Information on maintaining the paver's hydraulic system.

Check Hydraulic Oil

How to check and maintain the hydraulic oil level.

Change Hydraulic Oil and Filter

Procedure for changing the hydraulic oil and filter.

ELECTRICAL SYSTEM MAINTENANCE

ELECTRICAL SYSTEM

Overview of the paver's electrical system.

Battery Servicing

Safety precautions and procedures for servicing the battery.

Alternator

Information on the alternator and precautions to prevent damage.

FUSE PANEL AND LIGHTS

Fuse Panel

How to check the fuse panel for blown fuses.

Beacon and Work Lights

Troubleshooting steps for lights that do not function.

ELECTRICAL CONNECTOR CARE

Dielectric Grease

Proper application of dielectric grease to electrical connectors.

COMPONENT REPLACEMENT PROCEDURES

REPLACEMENT PROCEDURES

General procedures for replacing major components.

Hydraulic Pumps

Procedure for replacing hydraulic pumps.

Hydraulic Motor Installation Start-Up Procedure

Steps for installing and starting up hydraulic motors.

TRACK AND DRIVE SYSTEM REPLACEMENT

Replace Tracks

Procedure for replacing the paver's tracks.

Drive Tires

Procedure for removing and replacing drive tires.

Front Idler

Procedure for replacing the front idler assembly.

TORQUE HUB AND HYDRAULIC MOTOR REPLACEMENT

Torque Hub

Procedure for replacing the torque hub assembly.

Single-Speed Hydraulic Motors

Procedure for replacing single-speed hydraulic motors.

AUGER COMPONENT REPLACEMENT

Under Auger Material Cut-Offs

Procedure for removing and replacing under auger material cut-offs.

Auger Motor

Procedure for removing and replacing the auger motor.

Auger End Mounts

Procedure for removing and replacing auger end mounts.

AUGER AND BEARING SERVICE

Auger and Inner Bearings

Procedure for servicing auger and inner bearings.

SCREED WEAR PLATE REPLACEMENT

Screed Extension Wear Plate

Procedure for replacing the screed extension wear plate.

Main Screed Wear Plate

Procedure for replacing the main screed wear plate.

WELDING AND STORAGE PREPARATION

WELDMENT

Procedures and safety precautions for welding on the machine.

WINTERIZING FOR STORAGE

Procedures for preparing the machine for winter storage.

TROUBLESHOOTING HYDRAULICS AND CONTROLS

TROUBLESHOOTING

Identifying and resolving common paver failures.

Hydraulic Test Ports

How to check hydraulic pressure at various test ports.

Plus One

Information about the Plus One controller and its functions.

TRACK AND PUMP TROUBLESHOOTING

Track Tension Pressure

How to check and adjust track tension pressure.

Torque Hub Hydraulic Motor Gear Adjustment

How to adjust the torque hub hydraulic motor for track speed equalization.

SPRAY DOWN PUMP TROUBLESHOOTING

Spray Down Pump

Troubleshooting information for the spray down pump.

PAVER TROUBLESHOOTING CHART

Troubleshooting Chart

A chart to identify symptoms, causes, and remedies for common paver failures.

PV480 DIAGNOSTIC TROUBLE CODES

PV480 DIAGNOSTIC TROUBLE CODE (DTC) CHART

Codes, symptoms, and recovery actions for PV480 diagnostic trouble codes.

Section 6 SCHEMATICS

Schematics

Diagrams illustrating the electrical and hydraulic systems of the paver.

MAIN ELECTRICAL SCHEMATIC (1 OF 2)

Primary electrical schematic diagram of the paver (part 1 of 2).

MAIN ELECTRICAL SCHEMATIC (2 OF 2)

Primary electrical schematic diagram of the paver (part 2 of 2).

MAIN ELECTRICAL HARNESS (1 OF 2)

Diagram of the main electrical harness wiring (part 1 of 2).

ELECTRICAL HARNESS AND SYSTEM SCHEMATICS

MAIN ELECTRICAL HARNESS (2 OF 2)

Diagram of the main electrical harness wiring (part 2 of 2).

SYSTEM POWER HARNESS

Schematic diagram for the system power harness.

NEUTRAL SAFETY HARNESS

Schematic diagram for the neutral safety harness.

CONTROL BOX ASSEMBLY SCHEMATICS

CONTROL BOX ASSEMBLY (1 OF 3)

Illustrated breakdown of the control box assembly (part 1 of 3).

CONTROL BOX ASSEMBLY (2 OF 3)

Illustrated breakdown of the control box assembly (part 2 of 3).

CONTROL BOX ASSEMBLY (3 OF 3)

Illustrated breakdown of the control box assembly (part 3 of 3).

OPTIONAL AND PUMP HARNESS SCHEMATICS

SPRAYDOWN PUMP HARNESS

Schematic diagram for the spraydown pump harness.

OPTION - ULTRASONIC POWER HARNESS

Schematic for the optional ultrasonic power harness.

OPTION - ELECTRIC SCREW REMOTE ASSEMBLY

Schematic for the electric screw remote assembly option.

HYDRAULIC SCHEMATICS

HYDRAULIC SCHEMATIC (1 OF 2)

Hydraulic schematic diagram of the paver (part 1 of 2).

HYDRAULIC SCHEMATIC (2 OF 2)

Hydraulic schematic diagram of the paver (part 2 of 2).

Section 7 ILLUSTRATED PARTS LIST

Illustrated Parts List

Comprehensive list of parts with diagrams and part numbers.

QUICK REFERENCE

Quick reference guide for filters, engine components, electrical parts, and wear plates.

TRACK DRIVE ASSEMBLY

Illustrated breakdown of the paver's track drive system.

Track Drive Assembly

Detailed list of parts for the track drive assembly.

HOPPER AND AUGER COMPONENTS

HOPPER WING ASSEMBLY

Illustrated breakdown of the hopper wing components.

Hopper Wing Assembly

Detailed list of parts for the hopper wing assembly.

HOPPER DETAILS

Illustrated breakdown of hopper components.

Hopper Details

Detailed list of parts for the hopper.

ENGINE AND HYDRAULIC COMPONENTS

HOPPER LIFT HYDRAULICS

Illustrated breakdown of the hopper lift hydraulic system.

Hopper Lift Hydraulics

Detailed list of parts for the hopper lift hydraulics.

AUGER ASSEMBLY

Illustrated breakdown of the auger assembly.

Auger Assembly

Detailed list of parts for the auger assembly.

TANK, CONTROLS, AND ENGINE PARTS

HYDRAULIC TANK ASSEMBLY

Illustrated breakdown of the hydraulic tank components.

Hydraulic Tank Assembly

Detailed list of parts for the hydraulic tank assembly.

CONTROLS - LEFT SIDE

Illustrated breakdown of the left-side controls.

Controls - Left Side

Detailed list of parts for the left-side controls.

CONTROL PANEL AND RIGHT SIDE COMPONENTS

CONTROLS - CONTROL PANEL

Illustrated breakdown of the control panel components.

Controls - Control Panel

Detailed list of parts for the control panel.

CONTROLS - RIGHT SIDE;HYDRAULIC PUMPS

Illustrated breakdown of the right-side controls and hydraulic pumps.

Controls - Right Side;Hydraulic Pumps

Detailed list of parts for the right-side controls and hydraulic pumps.

VALVE MANIFOLD AND FUEL SYSTEM PARTS

CONTROLS - VALVE MANIFOLD

Illustrated breakdown of the valve manifold components.

Controls - Valve Manifold

Detailed list of parts for the valve manifold.

CONTROLS - VALVE MANIFOLD DETAILS

Detailed illustration of valve manifold components.

SEAT, BATTERY, AND ENGINE COMPONENTS

FUEL TANK ASSEMBLY

Illustrated breakdown of the fuel tank components.

Fuel Tank Assembly

Detailed list of parts for the fuel tank assembly.

SEAT AND EQUIPMENT DETAILS

Illustrated breakdown of seat and associated equipment.

Seat and Equipment Details

Detailed list of parts for seat and equipment.

ENGINE COVER AND COMPONENT PARTS

BATTERY BOX ASSEMBLY

Illustrated breakdown of the battery box assembly.

Battery Box Assembly

Detailed list of parts for the battery box assembly.

ENGINE - COVERS

Illustrated breakdown of engine covers.

Engine - Covers

Detailed list of parts for engine covers.

ENGINE RADIATOR AND HYDRAULIC PUMPS

ENGINE - RADIATOR, INTAKE AND EXHAUST

Illustrated breakdown of engine radiator, intake, and exhaust components.

Engine - Radiator, Intake and Exhaust

Detailed list of parts for engine radiator, intake, and exhaust.

ENGINE - COMPONENTS

Illustrated breakdown of engine components.

Engine - Components

Detailed list of parts for engine components.

ENGINE PUMPS AND SPRAYDOWN ASSEMBLY

ENGINE - HYDRAULIC PUMPS

Illustrated breakdown of engine hydraulic pumps.

Engine - Hydraulic Pumps

Detailed list of parts for engine hydraulic pumps.

SPRAYDOWN ASSEMBLY - STANDARD AND OPTIONAL

Illustrated breakdown of the spraydown assembly components.

Spraydown Assembly - Standard and Optional

Detailed list of parts for the spraydown assembly.

SCREED ASSEMBLY COMPONENTS

SCREED OVERVIEW

Illustrated overview of the screed assembly.

Screed Overview

List of components included in the screed overview.

SCREED - FRAME

Illustrated breakdown of the screed frame components.

Screed - Frame

Detailed list of parts for the screed frame.

SCREED BASE AND EXTENSION PARTS

SCREED - BASE

Illustrated breakdown of the screed base components.

Screed - Base

Detailed list of parts for the screed base.

SCREED - EXTENSION, LH

Illustrated breakdown of the left-hand screed extension.

Screed - Extension, LH

Detailed list of parts for the left-hand screed extension.

RIGHT EXTENSION AND JOINTERS

SCREED - EXTENSION, RH

Illustrated breakdown of the right-hand screed extension.

Screed - Extension, RH

Detailed list of parts for the right-hand screed extension.

SCREED - JOINTERS

Illustrated breakdown of the screed jointers.

Screed - Jointers

Detailed list of parts for the screed jointers.

PULL ARMS AND WALKBOARDS

SCREED - PULL ARMS

Illustrated breakdown of the screed pull arms.

Screed - Pull Arms

Detailed list of parts for the screed pull arms.

SCREED - WALKBOARDS

Illustrated breakdown of the screed walkboards.

Screed - Walkboards

Detailed list of parts for the screed walkboards.

LP HEAT ASSEMBLY AND GRADE CONTROL

SCREED - LP HEAT ASSEMBLY

Illustrated breakdown of the screed LP heat assembly.

Screed - LP Heat Assembly

Detailed list of parts for the screed LP heat assembly.

OPTION - ELECTRIC SCREW FOR GRADE CONTROL

Illustrated breakdown of the electric screw for grade control option.

Option - Electric Screw for Grade Control

Detailed list of parts for the electric screw for grade control option.

WORK LIGHTS AND TIRE DRIVE OPTIONS

OPTION - WORK LIGHTS

Illustrated breakdown of the work lights option.

Option - Work Lights

Detailed list of parts for the work lights option.

OPTION - RUBBER TIRE DRIVE

Illustrated breakdown of the rubber tire drive option.

Option - Rubber Tire Drive

Detailed list of parts for the rubber tire drive option.

BRAKE AND DRIVE SYSTEM OPTIONS

OPTION - FAIL-SAFE BRAKE KIT (SINGLE SPEED DRIVE)

Illustrated breakdown of the fail-safe brake kit.

Option - Fail-Safe Brake Kit (Single Speed Drive)

Detailed list of parts for the fail-safe brake kit.

OPTION - 2 SPEED DRIVE W;BRAKE

Illustrated breakdown of the 2-speed drive with brake option.

Option - 2 Speed Drive w;Brake

Detailed list of parts for the 2-speed drive with brake option.

AUGER AND TOPCON OPTIONS

OPTION - AUGER ADAPTERS W;SONICS

Illustrated breakdown of auger adapters with sonics.

Option - Auger Adapters w;Sonics

Detailed list of parts for auger adapters with sonics.

OPTION - TOPCON P-32, ONE SIDE

Illustrated breakdown of the TopCon P-32 option.

Option - TopCon P-32, One Side

Detailed list of parts for the TopCon P-32 option.

HOSE SCHEDULE AND DECALS

HYDRAULIC HOSE SCHEDULE

Schedule listing hydraulic hoses with part numbers and descriptions.

DECAL SCHEDULE

List of decals, their part numbers, and descriptions.

ALPHABETICAL PARTS INDEX

Alphabetical listing of all parts with part numbers and figure references.

LeeBoy 1000G Specifications

General IconGeneral
BrandLeeBoy
Model1000G
CategoryFarm Equipment
LanguageEnglish

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