Page 1
Operations, Service, and Parts Manual
LeeBoy Model 8616B Conveyor Paver
Manual No. 1013539-01
This manual applies
to machines beginning
with Serial Number
101158
Page 2
Page 3
Thumb Index
Safety
Information and Specifications
Component Location
Operation
1
2
3
4
Maintenance
Schematics
Illustrated Parts List (IPL)
5
6
7
LeeBoy 8616B Conveyor Paver
Page 4
DISCLAIMER AND COPYRIGHT
Disclaimer:
All information, illustrations and specications in this manual are based on the latest information available at the time
of publishing. The illustrations used in this manual are intended as representative reference views only. Moreover,
because of our continuous product improvement policy, we may modify information, illustrations and/or specications
to explain and/or exemplify a product, service or maintenance improvement. We reserve the right to make any
change at any time without notice. VT LeeBoy, Inc., VT LeeBoy, LeeBoy, and Rosco are all the same entity and are
used interchangeably.
©2015 VT LeeBoy, Inc.
LeeBoy reserves all copyright and other rights in this manual and the manual’s content. No part of this manual may
be reproduced or used in any way without the written permission of LeeBoy, except as necessary to operate LeeBoy
equipment.
California Proposition 65 WARNING
Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth
defects, and other reproductive harm.
Battery posts, terminals and other related accessories contain lead and lead compounds, chemicals known to the
State of California to cause cancer and other reproductive harm. Wash hands after handling.
LeeBoy 8616B Conveyor Paveriv
Page 5
TABLE OF CONTENTS
Page
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Safety Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Safety Decals Care . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Decal Installation (Sticker Type) . . . . . . . . . . . . . . . . . . . 1-9
Decal Installation (Top Protected) . . . . . . . . . . . . . . . . . . 1-9
Machine Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Hot Material Precautions . . . . . . . . . . . . . . . . . . . . . . . 1-10
Hydraulic Systems Precautions . . . . . . . . . . . . . . . . . . . 1-10
Refueling Precautions . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Battery Precautions . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Starting and Stopping Precautions . . . . . . . . . . . . . . . . . . 1-11
Parking Precautions . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Operating Precautions . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Storage Precautions . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
Maintenance Precautions . . . . . . . . . . . . . . . . . . . . . . 1-12
Information and Specications . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Limited Warranty Policy . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Contact Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Specications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Torque Specications . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Standard Inch Fasteners . . . . . . . . . . . . . . . . . . . . . . . 2-10
Metric Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Hydraulic Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Determining Proper Torque . . . . . . . . . . . . . . . . . . . . . 2-12
Component Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Components Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Torque Hubs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
LeeBoy 8616B Conveyor Paver v
Page 6
viIntroduction
Machine Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Steering and Speed Control Box . . . . . . . . . . . . . . . . . . . . . . 3-5
Operator Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Screed Control Boxes . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Steering Wheel (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Receiving the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Hopper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Augers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Operator Platform . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Screed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Electric Screed Operation Controls . . . . . . . . . . . . . . . . . 3-9
Initial and Daily Inspection . . . . . . . . . . . . . . . . . . . . . . 4-3
Start-Up Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
DP700 PLUS+1® Display Unit . . . . . . . . . . . . . . . . . . . . 4-4
Start-Up Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Engine Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Paver Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Time Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Fault Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
DPF Regeneration (REGEN) . . . . . . . . . . . . . . . . . . . . . 4-7
Status Icons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Driving the Paver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Operator Control Station . . . . . . . . . . . . . . . . . . . . . . . 4-10
Steering and Speed Control . . . . . . . . . . . . . . . . . . . . . 4-10
Paver Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Spray Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Set the Screed and Endgates . . . . . . . . . . . . . . . . . . . . 4-12
Hopper Wings . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
Conveyor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
Hydraulic Cut-Off Gates . . . . . . . . . . . . . . . . . . . . . . . 4-15
Sonic Auger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
Tow Point Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
Starting to Pave . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
LeeBoy 8616B Conveyor Paver
Page 7
Introduction
Basic Paving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
Setting the Crown . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
Mat Texture Adjustment . . . . . . . . . . . . . . . . . . . . . . . 4-19
Unloading And Loading . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
Unloading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
Loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
Tie-Down Procedure . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
Optional Components . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
Auger Extensions Option . . . . . . . . . . . . . . . . . . . . . . . 4-21
Power Crown Option . . . . . . . . . . . . . . . . . . . . . . . . . 4-22
Umbrella Option . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22
Truck Hitch Attachment Option . . . . . . . . . . . . . . . . . . . . 4-22
Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Lubrication Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Torque Hub Lubrication . . . . . . . . . . . . . . . . . . . . . . . 5-5
Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Preparing Machine for Maintenance . . . . . . . . . . . . . . . . . 5-6
Every 10 Hours or Daily Routine Maintenance . . . . . . . . . . . . 5-6
Every 50 Hours or Weekly Routine Maintenance . . . . . . . . . . . 5-6
Every 100 Hour or Monthly Maintenance . . . . . . . . . . . . . . . 5-6
Every 250 Hours or Quarterly Routine Maintenance . . . . . . . . . 5-7
Every 500 Hours or Semi-Annual Routine Maintenance . . . . . . . 5-7
Every 1000 Hours or Annual Routine Maintenance . . . . . . . . . . 5-7
Maintenance Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Conveyor Flight Chain . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Conveyor Drive Chain . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Conveyor Paddle Adjustment. . . . . . . . . . . . . . . . . . . . . 5-8
Auger Drive Chain Adjustment . . . . . . . . . . . . . . . . . . . . 5-9
Screed Extension Top Guide Adjustment . . . . . . . . . . . . . . . 5-9
Track Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
High Gear Adjustment . . . . . . . . . . . . . . . . . . . . . . . . 5-11
Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
Battery Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
Generator Voltage Testing . . . . . . . . . . . . . . . . . . . . . . 5-13
Generator Capacitor Replacement . . . . . . . . . . . . . . . . . . 5-14
LeeBoy 8616B Conveyor Paver
vii
Page 8
Introduction
Engine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
Screed Electric Heat Elements . . . . . . . . . . . . . . . . . . . . 5-14
Element Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15
Element Resistance Testing . . . . . . . . . . . . . . . . . . . . . 5-16
Heating Elements . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
Check Engine Lubrication Oil . . . . . . . . . . . . . . . . . . . . 5-17
Change Engine Oil and Filter . . . . . . . . . . . . . . . . . . . . . 5-17
Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
Change Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
Change Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
Check Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
Change Hydraulic Oil and Filter . . . . . . . . . . . . . . . . . . . 5-20
Change Hydraulic Oil Strainer . . . . . . . . . . . . . . . . . . . . 5-21
Replacement
2-Speed Motor Replacement . . . . . . . . . . . . . . . . . . . . 5-21
Drive Torque Hub Replacement . . . . . . . . . . . . . . . . . . . 5-22
Track Sprocket Replacement . . . . . . . . . . . . . . . . . . . . 5-22
Front Idler and Bushing . . . . . . . . . . . . . . . . . . . . . . . 5-23
Rear Conveyor Shaft, Bearings and Sprockets . . . . . . . . . . . . 5-23
Conveyor Wear Plates . . . . . . . . . . . . . . . . . . . . . . . . 5-24
Conveyor Drive Motors. . . . . . . . . . . . . . . . . . . . . . . . 5-25
Cut-Off Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25
Auger And Inner Bearing . . . . . . . . . . . . . . . . . . . . . . . 5-25
Replacing Auger Motors . . . . . . . . . . . . . . . . . . . . . . . 5-26
Rear Hopper Wing Cylinders . . . . . . . . . . . . . . . . . . . . . 5-27
Front Hopper Wing Cylinders . . . . . . . . . . . . . . . . . . . . 5-27
Pumps and Hood . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28
Screed Extension Wear Plates . . . . . . . . . . . . . . . . . . . . 5-28
Weldment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29
Procedures . . . . . . . . . . . . . . . . . . . . . . . . . 5-21
viii
Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30
DP700 Diagnostic Trouble Code (DTC) Chart . . . . . . . . . . . . . . .5-33
Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Screed Control Box Assembly, Left Side . . . . . . . . . . . . . . . . . . 6-3
Screed Control Box Assembly, Right Side . . . . . . . . . . . . . . . . . 6-5
LeeBoy 8616B Conveyor Paver
Page 9
Operator Control Panel Assembly . . . . . . . . . . . . . . . . . . . . . 6-7
Harness, Jumper, 31 Pin Dash to Pedestal . . . . . . . . . . . . . . . . . 6-9
Harness, Jumper, 47 Pin Dash to Pedestal . . . . . . . . . . . . . . . . . 6-11
Harness, Main Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
Harness, Front Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15
Harness, Hydraulic Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . 6-17
Main Harness Electrical Overview . . . . . . . . . . . . . . . . . . . . . 6-19
Main Harness Electrical (1 of 6) . . . . . . . . . . . . . . . . . . . . . . . 6-21
Main Harness Electrical (2 of 6) . . . . . . . . . . . . . . . . . . . . . . 6-23
Main Harness Electrical (3 of 6) . . . . . . . . . . . . . . . . . . . . . . 6-25
Main Harness Electrical (4 of 6) . . . . . . . . . . . . . . . . . . . . . . 6-27
Main Harness Elelctrical (5 of 6) . . . . . . . . . . . . . . . . . . . . . . 6-29
Main Harness Electrical (6 of 6) . . . . . . . . . . . . . . . . . . . . . . 6-31
Main Harnass Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-33
Hydraulic Schematic Overview - Version A . . . . . . . . . . . . . . . . . 6-35
Hydraulic Schematic Layout - Version A (1 of 3) . . . . . . . . . . . . . . . 6-37
Hydraulic Schematic Layout - Version A (2 of 3) . . . . . . . . . . . . . . 6-39
Hydraulic Schematic Layout - Version A (3 of 3) . . . . . . . . . . . . . . 6-41
Hydraulic Schematic Overview - Version B . . . . . . . . . . . . . . . . . 6-43
Hydraulic Schematic Layout - Version B (1 of 3) . . . . . . . . . . . . . . . 6-45
Hydraulic Schematic Layout - Version B (2 of 3) . . . . . . . . . . . . . . 6-47
Hydraulic Schematic Layout - Version B (3 of 3) . . . . . . . . . . . . . . 6-49
Electric Heat Control (Standard) . . . . . . . . . . . . . . . . . . . . . . 6-51
Electric Heat Control with 110 Outlet (Option) . . . . . . . . . . . . . . . . 6-53
Electric Heat Endgates (Option) . . . . . . . . . . . . . . . . . . . . . . 6-55
Illustrated Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Quick Reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Track Assembly - Poly Pads . . . . . . . . . . . . . . . . . . . . . . . . 7-4
Track Assembly - Tension and Propel . . . . . . . . . . . . . . . . . . . 7-6
Conveyor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
Pushbar Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
Drive Conveyor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
Engine Assembly with Pumps . . . . . . . . . . . . . . . . . . . . . . . 7-14
Engine Components (1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . 7-16
Engine Components (2 of 2) . . . . . . . . . . . . . . . . . . . . . . . . 7-18
Tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20
LeeBoy 8616B Conveyor Paver
ix
Page 10
Hydraulic Components . . . . . . . . . . . . . . . . . . . . . . . . . . 7-22
Secondary Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-24
Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-26
Hopper Wings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-28
Hoods and Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-30
Engine Cover Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 7-32
Spray Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-34
Dash Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-36
Dash Control Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-38
Rear Auger Assembly (1 of 1) . . . . . . . . . . . . . . . . . . . . . . . . 7-40
Rear Auger Assembly (2 of 2) . . . . . . . . . . . . . . . . . . . . . . . 7-42
Screed Frame Assembly - Electric . . . . . . . . . . . . . . . . . . . . 7-44
Walk Board Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-46
Screed Vibrator Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 7-48
Screed Slide Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-50
Screed Extension (Left) Assembly . . . . . . . . . . . . . . . . . . . . . 7-52
Screed Extension (Right) Assembly . . . . . . . . . . . . . . . . . . . . 7-54
Screed Endgate (Left) Assembly . . . . . . . . . . . . . . . . . . . . . 7-56
Screed Endgate (Right) Assembly . . . . . . . . . . . . . . . . . . . . . 7-58
Screed Heated Endgate Option (Right) . . . . . . . . . . . . . . . . . . . 7-60
Screed Heated Endgate Option (Left) . . . . . . . . . . . . . . . . . . . 7-62
Screed Heated Edge Endgate Option (Right) . . . . . . . . . . . . . . . . 7-64
Screed Heated Edge Endgate Option (Left) . . . . . . . . . . . . . . . . 7-66
Screed Pull Arm (Left) Assembly . . . . . . . . . . . . . . . . . . . . . . 7-68
Screed Pull Arm (Right) Assembly . . . . . . . . . . . . . . . . . . . . . 7-70
Screed Thickness Adjuster Assembly . . . . . . . . . . . . . . . . . . . 7-72
Electric Heat Control Assembly (Standard) . . . . . . . . . . . . . . . . . 7-74
Screed Heat Control Box w/Heated Endgates (Option) . . . . . . . . . . . 7-76
Screed Heat Control Box, 110 VAC (Option) . . . . . . . . . . . . . . . . . 7-78
Screed Optional Components . . . . . . . . . . . . . . . . . . . . . . . 7-80
Paver Leveling Ski, 20 Feet (Option) . . . . . . . . . . . . . . . . . . . . 7-82
Paver Leveling Ski, 30 - 40 Feet (Option) . . . . . . . . . . . . . . . . . . 7-84
TOPCON P-32 Control Kit (Option) . . . . . . . . . . . . . . . . . . . . . 7-86
Truck Hitch Assembly (Option) . . . . . . . . . . . . . . . . . . . . . . . 7-88
Alphabetical Parts Index . . . . . . . . . . . . . . . . . . . . . . . . . . 7-90
x
LeeBoy 8616B Conveyor Paver
Page 11
Introduction
Thank you for purchasing the LeeBoy Model 8616B
Conveyor Paver. We wish you many years of safe and
efcient operation of your paver.
READ THIS MANUAL PRIOR TO OPERATING the
paver. This manual is an important part of the paver
and should be kept with the paver at all times in the
dedicated storage container on the paver. Even though
you may be familiar with similar equipment, you MUST
read and understand this manual before operating this
paver. Reading the manual will help you and others
avoid injury and help prevent any damage to the paver.
If this manual becomes lost or damaged, contact your
authorized LeeBoy Dealer immediately to order a
replacement (see Contact Information in Section 2).
This manual is intended as a guide for the safe and
efcient use of the paver. This manual covers the
procedures for proper operation and maintenance
of the paver. This manual contains information that
was available at the time of printing and are subject to
change without notice.
This manual should be used with all related
supplemental books, engine and transmission manuals,
and parts books. Related service bulletins should be
reviewed to provide information regarding some of the
recent changes.
If any questions arise concerning this publication or
others, contact your local LeeBoy Dealer for the latest
available information.
NOTE: This manual is accompanied by an engine
instruction manual provided by the engine’s
manufacturer. Please follow the operation
and maintenance instructions as specied in
both the machine and engine manuals.
LeeBoy 8616B Conveyor Paver
xi
Page 12
NOTES
xii
LeeBoy 8616B Conveyor Paver
Page 13
Section 1
SAFETY
Page
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Safety Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Safety Decals Care . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Decal Installation (Sticker Type) . . . . . . . . . . . . . . . . . . . 1-9
Decal Installation (Top Protected) . . . . . . . . . . . . . . . . . . 1-9
Machine Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Hot Material Precautions . . . . . . . . . . . . . . . . . . . . . . . 1-10
Hydraulic Systems Precautions . . . . . . . . . . . . . . . . . . . 1-10
Refueling Precautions . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Battery Precautions . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Starting and Stopping Precautions . . . . . . . . . . . . . . . . . . 1-11
Parking Precautions . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Operating Precautions . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Storage Precautions . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
Maintenance Precautions . . . . . . . . . . . . . . . . . . . . . . 1-12
LeeBoy 8616B Conveyor Paver
1-1
Page 14
NOTES
LeeBoy 8616B Conveyor Paver1-2
Page 15
This manual provides important information to familiarize
you with safe operating and maintenance procedures.
Even though you may be familiar with similar equipment,
you MUST read and understand this manual before
operating the LeeBoy 8616B Conveyor Paver and follow
its instructions when operating the paver.
Safety is everyone’s business and our top concern.
Knowing the guidelines covered in this section will help
ensure your safety, the safety of those around you, as
well as proper paver operation.
Keep safety labels in good condition. If safety labels
become missing or damaged, replace them with
new matching labels. Replacement safety labels are
available from your LeeBoy dealer (see Safety Labels
on Page 1-8).
You can nd more information about occupational health
and safety in the paving industry on the internet. A few
resources are listed below:
www.osha.gov
cdc.gov
www.asphaltpavement.org
LOOK FOR THESE SYMBOLS THROUGHOUT
THIS MANUAL. THESE ITEMS ARE EXTREMELY
IMPORTANT FOR THE SAFETY OF YOU AND
YOUR COWORKERS. READ AND UNDERSTAND
THOROUGHLY. HEED THE WARNINGS AND
FOLLOW THE INSTRUCTIONS.
1
Indicates a hazardous situation which,
if not avoided, will result in death or serious injury.
Indicates a hazardous situation which,
if not avoided, could result in death or serious injury.
Indicates a hazardous situation which,
if not avoided, could result in minor or moderate
injury.
Indicates a situation which can cause
damage to the equipment, personal property and/
or the environment, or cause the LeeBoy 8616B
Conveyor Paver to operate improperly.
www.safety.fhwa.dot.gov/
NOTE: Indicates a procedure, practice or condition
that should be followed in order for the
machine or component to function in the
manner intended.
LeeBoy 8616B Conveyor Paver 1-3
Page 16
SAFETY PRECAUTIONS
The safety messages that follow have CAUTION level
hazards.
Pre-Operation Hazard
Read and understand this Operation Manual
before operating or servicing the engine to
ensure that safe operating practices and maintenance
procedures are followed.
• Never permit anyone to service or operate the LeeBoy
8616B Conveyor Paver without proper training.
• Safety signs and labels are additional reminders for
safe operating and maintenance techniques.
• Contact LeeBoy or an authorized LeeBoy dealer for
additional training.
• Make sure you are aware of all laws and regulations
that are in effect for the location in which the paver is
operated.
• Make sure you have all necessary licenses to operate
the paver.
Electrocution Hazard
Disconnect the battery before welding anywhere on the
machine.
Suffocation Hazard
Carbon monoxide poisoning is a serious
condition that occurs as a result of improper
ventilation.
• Never operate the internal combustion engine on this
machine in an enclosed area with poor ventilation.
Ensure proper ventillation to reduce risk of carbon
monoxide poisoning or death.
Exhaust Hazard
All internal combustion engines create
carbon monoxide gas during operation and
special precautions are required to avoid
carbon monoxide poisoning:
• Never block windows, vents or other means of
ventilation.
• Always ensure that all connections are tightened to
specications after repair is made to the exhaust
system.
The safety messages that follow have DANGER level
hazards.
Power Lines Hazard
If your machine comes into contact with
electric power lines, observe the following:
• Stay in the operators seat.
• Warn other workers to stay away and do not touch any
control or any part of the machine.
• If contact can be broken, drive the machine away from
the danger zone.
• If contact cannot be broken, stay in the operators seat
until told that power is off.
• Failure to observe these directions could result in
electrocution or death.
The safety messages that follow have WARNING
level hazards.
Crush Hazard
Keep bystanders away from work area before and
during operation.
Modification Hazard
Never modify the LeeBoy machine without the written
consent of LeeBoy. Any modication can affect the safe
operation of the paver and may cause personal injury or
death.
LeeBoy 8616B Conveyor Paver1-4
Page 17
Exposure Hazard
Operators of the paver must be aware of
their work environment and the equipmnet
needed to work safely.
• Always wear personal protective equipment, including
appropriate clothing, gloves, work shoes, and
protection for eyes and ears, as required by the task
at hand.
Explosion Hazard
While the engine is running or the battery is
charging, hydrogen gas is being produced
and can be easily ignited. Keep the area
around the battery well-ventilated and keep
sparks, open ame, and any other form of
ignition out of the area.
• Always disconnect the negative (-) battery cable
before servicing the paver.
• Do not start the engine by shorting the starter circuit
or any other starting method not stated in this manual.
Only use the starting procedure as described in this
manual to start the engine.
• Never charge a frozen battery. Always slowly warm the
battery to room temperature before charging.
Fire Hazard
When operating machinery there is a risk for
re. Always have appropriate safety
equipment available.
• Keep a charged re extinguisher within reach when
working in an environment where a re may occur.
• Have all re extinguishers checked periodically for
proper operation and/or readiness.
• Always read and follow safety-related precautions
found on containers of hazardous substances
like parts cleaners, primers, sealants and sealant
removers.
• Undersized wiring systems can cause electrical res.
Entanglement/Sever Hazard
Verify there are no people, obstacles or
other equipment near the machine before
starting the engine. Sound the horn as a
warning before starting the engine.
If the engine must be serviced while it is
operating, remove all jewelry and tie back
long hair before operating or servicing the
machine.
• Keep hands, other body parts, and clothing away from
moving/rotating parts.
1
Fire and Explosion Hazard
• Diesel fuel is ammable and explosive under certain
conditions.
• Never use a shop rag to catch fuel.
• Wipe up all spills immediately.
• Never refuel with the engine running.
• Store any containers containing fuel in a well-
ventilated area, away from any combustibles or
sources of ignition.
• Always stop the engine before beginning service.
Before maintenance, remove negative battery cable
from battery post to ensure vehicle is not operated
during maintenance.
• Verify that all guards and covers are properly attached
before starting the engine. Do not start the engine if
any guards or covers are not properly installed on the
paver.
• If you must run the engine during maintenance
procedures, make sure you have a helper to keep
bystanders clear of the paver and make observations
of moving parts as requested by the operator.
LeeBoy 8616B Conveyor Paver 1-5
Page 18
• Always turn the start switch to the OFF position after
operation is complete and remove the key from the
switch. Keep the key in your possession when the
paver is not operating.
• Attach a “Do Not Operate” tag near the key switch
while performing maintenance on the equipment.
• Never operate the engine while wearing a headset to
listen to a radio or music because it will be difcult to
hear the warning signals.
• Always start the engine and operate the controls while
seated in the operators seat.
Alcohol and Drug Hazard
Never operate the machine while under the
inuence of alcohol, drugs, or when ill.
Piercing Hazard
High-pressure hydraulic uid or fuel can
penetrate your skin and result in serious
injury. Avoid skin contact with high-pressure
hydraulic uid or diesel fuel spray caused by
a hydraulic or fuel system leak such as a
broken hydraulic hose or fuel injection line.
• If you are exposed to high-pressure hydraulic uid or
fuel spray, obtain prompt medical treatment.
• Never check for a hydraulic uid or fuel leak with your
hands. Always use a piece of wood or cardboard.
Have your authorized LeeBoy dealer or distributor
repair the damaged parts.
Coolant Hazard
Coolant must be handled properly to ensure
operator safety.
• Wear eye protection and rubber gloves when handling
engine coolant.
• If contact with the eyes occurs, ush eyes with clean
water for 15 minutes.
• If contact with skin occurs, wash immediately with
soap and clean water.
Burn Hazard
Some of the machine’s surfaces become
very hot during operation and shortly after
shutdown.
• Keep hands and other body parts away from hot
machine surfaces.
• Handle hot components with heat-resistant gloves.
The safety messages that follow have CAUTION level
hazards.
Poor Lighting Hazard
The work area must be well lit to ensure safe and proper
operation.
• Ensure that the work area is adequately illuminated.
Flying Object Hazard
Always wear eye protection when cleaning
the LeeBoy 8616B Conveyor Paver with
compressed air or high-pressure water.
Dust, ying debris, compressed air,
pressurized water or steam may cause eye
injury.
• Always install wire cages on portable safety lights.
Tool Hazard
Always use tools appropriate for the task at hand and
use the correct size tool for loosening or tightening
LeeBoy machine parts.
LeeBoy 8616B Conveyor Paver1-6
Page 19
The safety messages that follow have NOTICE level
hazards.
Any part that is found defective as a result of inspection
or any part whose measured value does not satisfy the
standard or limit must be replaced.
Always tighten components to the specied torque.
Loose parts can cause damage to the LeeBoy 8616B
Conveyor Paver or cause it to operate improperly.
Only use replacement parts approved by LeeBoy. Other
replacement parts may affect warranty coverage.
Follow the guidelines of the EPA or other
governmental agencies for the proper
disposal of hazardous materials such as
engine oil, diesel fuel, and engine coolant.
Consult the local authorities or
reclamation facility.
Dispose of hazardous materials in accordance with
all applicable laws and regulations. Never dispose of
hazardous materials by dumping them into a sewer, on
the ground, or into groundwater or waterways.
Clean all accumulated dirt and debris away from the
body of the paver and its components before you
inspect the paver or perform preventive maintenance
procedures or repairs. Operating a paver with
accumulated dirt and debris will cause premature wear
of paver components. Accumulated dirt and debris also
hinders effective paver inspection.
1
Retrieve any tools or parts that may have dropped inside
of the paver to avoid improper paver operation.
If any alert indicator illuminates during paver operation,
stop the engine immediately. Determine the cause and
repair the problem before continuing to operate the
paver.
LeeBoy 8616B Conveyor Paver 1-7
Page 20
DANGER
DANGER
PELIGRO
856437
PINCH POINT
PUNTO DE APRIETE
POINT DE PINCEMENT
856438
PINCH POINT
PUNTO DE APRIETE
POINT DE PINCEMENT
DANGER
PELIGRO
DANGER
Loosen bolts on side when
adjusting crown and valley.
Retighten after reaching desired
crown.
Aflojar los pernos del costado
cuando se ajusta la corona o valle.
Volver a apretar después de haber
alcanzado la corona deseada.
Desserrer les boulons sur le côté,
lors du réglage du bombement et du
creux.
Le resserrer une fois le bombement
désiré obtenu (couronne +).
CAUTIONPRECAUCION ATTENTION
856483 REV 1
859773
Keep guidebar latched when transporting.
Keep all adjustments tight.
856441
CAUTION
Mantener la barra guía trabada durante el transporte.
Mantener todos los ajustes bien apretados.
PRECAUCION
Maintenir la barre de guidage verrouillée pendant le
transport. Maintenir tous les ajustements serrés.
ATTENTION
8
5
9
7
89
WATCH YOUR STEP!
Failure to comply may result in minor or moderate injury.
CAUTION
856446
Hydraulic oil only
Keep clean
Huile hydraulique
seulement
Maintenir propre
PRECAUCION
ATTENTION
Aceite hidráulico solamente
Mantener limpio
CAUTION
SONIC AUGERS
859801
CAUTION
Ensure cord points
toward front.
856438
PINCH POINT
PUNTO DE APRIETE
POINT DE PINCEMENT
DANGER
PELIGRO
DANGER
CAUTION
Flight screw handle must be in
locked position when raising
screed.
Damage may occur to hand, seat o
screw if not locked.
Always remove hand when raising
screed.
La manija del tornillo de recorrido
debe estar en la posición trabada
al elevar la plataforma. Se pueden
sufrir lesiones en la mano, o dañar
el asiento o tornillo si no está
trabada. Siempre quitar las manos
al elevar la plataforma.
PRECAUCION
La poignée de vis d’ailette doit
être en position verrouillée lors du
levage de la plaque de finition.
Une blessure à la main risque de
se produire et le siège ou la vis
d’être endommagé(e) si elle n’est
pas verrouillée. Toujours enlever
la main lors du levage de la
plaque de finition.
ATTENTION
856482
39168-11
CAUTION
D
856631
FLAMMABLE
Diesel Fuel
Keep Clean
DANGER
VALLEY
CROWN
8
5
6484 Rev 1
CROWN AND VALLEY ADJUSTMENT
1. Loosen bolt at slotted end of vibrator plate (N/A 8515 & 8816).
2. Loosen bolt at right end of third step or slopebar.
3. Turn crown handle down for crown and up for valley.
4. Once you have correct adjustment tighten 1 and 2 back.
Note: Ratchet wrench in tool box to loosen bolts
VALLE
CORONA
AJUSTE DE CORONA Y VALLE
1. Soltar el perno en el extremo ranurado de la placa del vibrador (N/A 8515 & 8816).
2. Aflojar el perno del extremo derecho del tercer escalón o barra de pendiente.
3. Girar la manija hacia abajo para los baches, y hacia arriba para los hoyos.
4. Una vez que se tiene el ajuste correcto, apretar 1 y 2 nuevamente.
Nota: Usar la llave de trinquete que se encuentra en la caja de herramientas para
soltar los pernos
CAUTIONPRECAUCIONATTENTION
CREUX
(couronne -)
BOMBEMENT
(couronne +)
RÉGLAGE DE BOMBEMENT ET DE CREUX (couronne + et -)
1. Desserrer le boulon à l’extrémité fendue du plateau du vibrateur (N/A 8515 & 8816).
2. Desserrer le boulon à l’extrémité droite du troisième gradin ou de la barre d’inclinaison.
3. Tourner la manette de bombement vers le bas pour le bombement (couronne +) et vers le haut pour le
creux (couronne -).
4. Une fois le réglage correct obtenu, resserrer les boulons 1 et 2.
Remarque : Utiliser la clé dynamométrique qui se trouve dans la boîte à outils pour desserrer les boulons
SAFETY DECALS
If your machine is repainted, it is extremely important
that you replace all the CAUTION, WARNING and
DANGER safety decals in the proper locations. (Figure
1-1) For additional help, refer to the parts listing in
Section 7 and contact your authorized LeeBoy dealer to
order a replacement kit.
NOTE: It is the responsibility of the owner and
operator to make sure that all safety labels are
readable and located on the paver as designated by
LeeBoy.
Figure 1-1. Safety Labels and Safety Label Locations
LeeBoy 8616B Conveyor Paver1-8
Page 21
Safety Decals Care
1. Keep safety decals and signs clean and legible at all
times.
2. Become familiar with the content and the position
of each safety decal. Decals include important
information.
3. Replace decals and signs that are missing or
become impossible to read.
4. When replacing parts that display a safety decal,
ensure that the new part is tted with a decal as well.
5. Obtain replacement safety decals or signs from
your authorized LeeBoy dealer.
Decal Installation (Sticker Type)
1. Be sure that the installation area is clean and dry.
Use hot, soapy water to clean the surface where the
decal will be applied.
2. Thoroughly dry the surface.
3. Measure and t decal before removing the paper
backing.
Decal Installation (Top Protected)
1. If the decal has a protective top paper, use hot
soapy water on the surface where the decal will be
applied. Leave wet.
2. Determine the proper location, remove protective
back paper and soak decal in clean soapy water
before application. This will help to alleviate air
bubbles in the applied decal.
3. Smooth decal into place with a squeegee and check
for air bubbles.
4. Small air pockets can be pierced with a pin and
smoothed out using a piece of the decal backing.
5. When decal is completely smoothed, carefully
remove top paper.
1
4. For decals with no top protection paper, remove the
smallest split-backed paper.
5. Align decal over the specied area and carefully
press exposed portion into place.
6. Slowly remove the remaining backing and carefully
smooth the remaining portion of the decal into
place.
7. Small air pockets can be pierced with a pin and
smoothed using a piece of the decal backing.
LeeBoy 8616B Conveyor Paver 1-9
Page 22
MACHINE PRECAUTIONS
Hot Material Precautions
• Wear protective gear for face, hands, feet, and body
when operating the paver.
• Allow machine to cool before repairing or maintaining
working components.
• If hot asphalt touches skin, ush area immediately with
cold water. DO NOT apply ice to the affected area.
DO NOT ATTEMPT TO REMOVE ASPHALT CEMENT
with products containing solvents or ammonia.
Natural separation will occur in about 48 to 72 hours.
Get medical attention as soon as possible.
• DO NOT remove radiator cap, drain plugs, service
grease ttings, or pressure taps while engine is hot.
Add coolant to the radiator and perform other services
only when the engine is stopped and fully cooled.
Hydraulic Systems Precautions
• Ensure all components are in good working condition.
Replace any worn, cut, abraded, attened or crimped
hoses and metal lines.
• DO NOT attempt makeshift repairs using tape, clamps
or cements. The hydraulic system operates under
extremely high pressure and such repairs could
cause serious injury.
• Wear proper hand and eye protection when checking
for a high pressure leak. Use a piece of wood or
cardboard as a back stop to isolate and identify leaks.
Hydraulic oil under pressure can
cause serious personal injury. Check for oil leaks
with a piece of cardboard. DO NOT expose hands to
possible high-pressure oil. Turn off engine before
attempting to tighten oil lines and ttings.
• Escaping pressurized hydraulic uid has force
sufcient to penetrate the skin, which could cause
serious personal injury. Ensure all pressure is
relieved before disconnecting line, hoses or valves.
Refueling Precautions
• Do NOT overll the fuel tank as overow creates a re
hazard when spilled on hot components.
• DO NOT smoke when refueling and never refuel when
the engine is running. Fuel is highly ammable and
should be handled with care. Death or serious injury
can occur due to explosion and/or re.
• DO NOT ll tank to capacity. Allow room for expansion
to reduce the risk of fuel expanding and spilling from
the tank.
• Tighten fuel cap securely. Should fuel cap be lost,
replace it with an original manufacturer’s approved
cap. Pressurization of the tank may result from use of
non-approved cap.
• Prevent res by keeping the machine clean of
accumulated debris, grease, and spilled fuel.
• Use ultra-low sulfur diesel fuel (ULSD) only.
Battery Precautions
• Keep all sparks and ames away from batteries, as
gas given off by electrolytes is explosive.
• Acid propelled by an explosion can cause blindness
if it comes in contact with eyes. Always wear safety
glasses when working near batteries.
• If you come in contact with battery electrolyte solution,
wash off immediately. Chemicals can cause burns.
• Always disconnect the battery ground cable before
working on the electrical system to avoid injury from
spark or short circuit. Electrical shock and burns can
occur.
• To avoid electrolyte loss, DO NOT tip batteries more
than 45 degrees.
• Use jumper cables ONLY as directed on Page
5-?. Improper use can result in battery explosion or
unexpected paver motion.
• If injury from concentrated high pressure steam
or hydraulic uid occurs, seek medical attention
immediately. Injuries resulting from hydraulic uid
penetrating the skin’s surface can result in serious
infections or toxic reactions.
LeeBoy 8616B Conveyor Paver1-10
Page 23
Starting and Stopping Precautions
• Check all around the paver to make sure there are no
people working on the machine or in the path of the
machine before starting. DO NOT start until area is
clear. Death or serious injury can occur to bystanders
from being crushed under a moving machine.
• Check brakes, steering and other control devices in
accordance with instructions before starting. Be sure
both steering levers (joysticks) are in neutral with the
neutral lock engaged. (Page 3-?
• DO NOT bypass the paver neutral-start system.
DO NOT operate the engine in an
enclosed area without proper ventillation. Exhaust
gasses are odorless and deadly.
Parking Precautions
• Park paver on level ground whenever possible, set
steering levers in neutral and lock. Apply the parking
brake (if this optional comonent is installed). Park the
paver with wheels securely blocked on grades.
• Before leaving operator’s station:
1. Place Forward/Reverse handle in neutral and lock
in place.
2. Turn off all accessories.
3. Throttle back to idle using the DP700 Display.
4. Set parking brake (if installed).
5. Lower screed to ground.
6. Shut off engine.
• Remove ignition key when leaving paver parked or
unattended.
Operating Precautions
• Always comply with local regulations regarding
moving equipment on public roads and highways.
• Know and use the hand signals required for a
particular job. Know who has the responsibility for
signaling.
• Make sure that all lights and reectors comply with
state and local regulations. Make sure that they are
clean, in good working order, and can be seen clearly
by all trafc.
• DO NOT stand between the equipment and the truck
while the truck is being backed to the paver. Death or
serious injury can result from being crushed between
the two machines.
• DO NOT ride on attachments.
• Check all gauges and warning instruments for proper
operation. If malfunctions are found, shut down the
machine and report the problem for resolution. If the
failure causes loss of steering control, loss of brake
control, or loss of engine power, stop paver motion as
quickly as possible. Apply parking brake (if equipped).
Keep the machine securely parked until the failure is
corrected or the machine can be safely towed.
• Drive the machine with care. Make sure speed is
compatible with conditions. Use caution on rough
ground, slopes, and while turning.
• Be alert for hazards and obstructions such as ditches,
trees, cliffs, overhead power lines, and areas where
there is danger of a slide.
• Be aware of and understand the job site trafc ow
patterns.
• Obey agmen, road signs, and signals.
• Watch for bystanders. Never allow anyone to be
under the machine during operation. Never allow
anyone to reach into the machine during use.
1
• Operator must know how to use signaling devices
when roading with a paver. Operator must also
understand which circumstances require use of each
signal. Use tail lights, slow moving vehicle signs, and
warning beacon as needed when traveling on public
roads. It is recommended that you provide an escort
on the road.
• DO NOT tow the paver, except to remove from road or
to load on trailer.
• DO NOT tow the paver, except to remove from road or
to load on trailer.
LeeBoy 8616B Conveyor Paver 1-11
Page 24
Storage Precautions
• Store paver in an area away from human activity.
• Do not permit children to play on or around the stored
machine. Serious injury or death can occur from
improper/unauthorized use of the machine.
• Make sure the unit is stored on a surface that is rm,
level, and free of debris.
• Store the machine inside a building or cover securely
with a weatherproof tarpaulin.
Maintenance Precautions
• DO NOT attempt repairs unless trained to do so.
Refer to manuals and experienced repair personnel
for help.
• Before working on the machine, securely block the
machine and any components that may fall. Block
any working components to prevent unexpected
movement while repairs are being made.
• Always wear safety glasses and other required safety
equipment when servicing or making repairs.
• Disconnect battery before working on the electrical
system.
• Avoid lubrication or mechanical adjustments while the
paver is in motion or while engine is operating.
• If lubrication or mechanical adjustment is necessary,
use extreme caution and complete the following
steps:
1. Place Forward/Reverse control in neutral.
2. Apply neutral lock.
3. Lower screed to ground.
4. Shut off engine.
5. Place equipment in a safe position.
6. Securely block wheels and tracks.
• Never make repairs on pressurized components such
as uid lines, the gas system, or mechanical items until
the pressure has been relieved.
• When servicing or replacing hardened pins, use a
brass drift or other suitable material between the
hammer and pin.
• Keep brake and steering systems in good operating
condition.
• Safety signs that are missing, illegible or damaged
must be replaced. Keep all safety signs clean.
LeeBoy 8616B Conveyor Paver1-12
Page 25
Section 2
INFORMATION AND SPECIFICATIONS
Page
Information and Specications . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Limited Warranty Policy . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Contact Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Specications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Torque Specications . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Standard Inch Fasteners . . . . . . . . . . . . . . . . . . . . . . . 2-10
Metric Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Hydraulic Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Determining Proper Torque . . . . . . . . . . . . . . . . . . . . . 2-12
LeeBoy 8616B Conveyor Paver
2-1
Page 26
Information and Specications
LIMITED WARRANTY POLICY
Warranty
Subject to the limitations, exclusions, and claims procedures set
forth herein, VT LeeBoy, Inc. warrants [to the rst retail purchaser]
that this product will be free from substantial defects in materials
and workmanship during the warranty period.
If a defect in material or workmanship is found, your authorized
LeeBoy Dealer is to be notied during the warranty period.
LeeBoy and its authorized Dealer will repair or replace any part or
component of the unit or part that fails to conform to the warranty
during the warranty period.
The warranty period will begin on the initial start-up, training and
delivery of the unit by the Dealer to the customer, and will expire
after twelve (12) months following the delivery of the product to the
rst retail purchaser. (See Dealer for additional warranty.)
Manufacturers’ Warranties: Engines are warranted by their
manufacturers and may have warranty coverage that differs from
that of LeeBoy. LeeBoy does not warrant any engine.
Replacement parts furnished by LeeBoy are covered for the
remainder of the warranty period applicable to the unit or
component in which such parts are installed.
LeeBoy has the right to repair any component or part before
replacing it with a new one.
All new replacement parts purchased by a LeeBoy Dealer will carry
a six-month warranty.
This Limited Warranty is governed by the laws of the State of North
Carolina.
THE FOREGOING WARRANTY IS EXCLUSIVE AND IN LIEU
OF ALL OTHER EXPRESSED, STATUTORY AND IMPLIED
WARRANTIES APPLICABLE TO UNITS, ENGINES, OR PARTS
INCLUDING WITHOUT LIMITATION, ALL IMPLIED WARRANTIES
OF MERCHANTABILITY OR FITNESS FOR ANY PARTICULAR USE
OR PURPOSE OR AGAINST INFRINGEMENT.
Items Not Covered
LeeBoy is not responsible for the following:
All used units or used parts of any kind.
Repairs due to normal wear and tear or brought about by abuse or
lack of maintenance of the machine.
Attachments not manufactured or installed by LeeBoy.
Liability for incidental or consequential damages of any type
including, but not limited to, lost prots or expenses of acquiring
replacement equipment.
Limitations
VT LeeBoy , Inc. has no obligation for:
Any defects caused by misuse, misapplication, negligence, accident,
or failure to maintain or use in accordance with the most current
operating instructions.
Unauthorized alterations.
Defects or failures caused by any replacement parts or attachments
not manufactured by or approved by LeeBoy.
Failure to conduct normal maintenance and operating service
including, without limitation, providing lubricants, coolant, fuel, tuneups, inspections, or adjustments.
Unreasonable delay, as established by LeeBoy, in making the
applicable units or parts available upon notication of a service notice
ordered by same.
Warranty Responsibility: The warranty responsibility on all engines
rests with the manufacturer of the engine.
Warranty and Parts Support: LeeBoy may have support agreements
with some engine manufacturers for warranty and parts support.
However, LeeBoy does not warrant the engine.
This Limited Warranty sets forth your sole remedy in connection
with the sale or use of the LeeBoy product covered by this Limited
Warranty.
This Limited Warranty extends only to the rst retail purchaser, and is
not transferable.
In the event any portion of this Limited Warranty shall be determined
to be invalid under any applicable law, such provision shall be deemed
null and void and the remainder of the Limited Warranty shall continue
in full force and effect.
Other Limitations
IN NO EVENT, WHETHER AS A RESULT OF BREACH OF CONTRACT
OR WARRANTY OR ALLEGED NEGLIGENCE OR LIABILITY WITHOUT
FAULT, SHALL LEEBOY BE LIABLE FOR SPECIAL, INCIDENTAL OR
CONSEQUENTIAL DAMAGES INCLUDING, WITHOUT LIMITATION,
LOSS OF PROFIT OR REVENUE, COST OF CAPITAL, COST
OF SUBSTITUTED EQUIPMENT, FACILITIES OR SERVICES,
DOWNTIME COSTS, LABOR COSTS OR CLAIMS OF CUSTOMERS,
PURCHASERS OR LESSEES FOR SUCH DAMAGES. IN NO EVENT
WILL WARRANTY COMPENSATION, OR OTHER DAMAGES
AVAILABLE FROM LEEBOY EXCEED THE PURCHASE PRICE OF
THE PRODUCT.
2-2
LeeBoy 8616B Conveyor Paver
Page 27
CONTACT INFORMATION
Information and Specications
For information regarding parts and repairs about
your LeeBoy product, contact your authorized LeeBoy
dealer. If your dealer is unable to resolve the problem,
contact LeeBoy directly.
Sales Representative:
Dealership Name:
Dealership Address:
Dealership Phone:
Record dealer information in the space provided.
For additional information about LeeBoy, please visit:
www.leeboy.com.
Record of Ownership
Please complete the following information to use if you need to contact your authorized LeeBoy dealer for service,
parts or literature.
Machine Model Number: _____________________________________________
Paver Serial Number:
Date of Purchase:
Nameplate
The nameplate contains the model and serial numbers used to identify the machine and its components for parts or
service information. Refer to the Engine Operator’s Manual for the location of the engine nameplate.
2
LeeBoy 8616B Conveyor Paver
Figure 2-1. Nameplate Location
2-3
Page 28
Information and Specications
SPECIFICATIONS
The specications provided in this section include
screed weights, dimensions, performance, and torque
values for both metric and standard inch fastener.
Replace original equipment only with
LeeBoy approved components.
8’
15’4”
2-4
8’6”
10’
Figure 2-2. Machine Dimensions
LeeBoy 8616B Conveyor Paver
Page 29
Information and Specications
Table 2-1. Dimension Specications
ITEM SPECIFICATION
Overall Length 15 ft 4 in (4,674 mm)
Overall Height 8 ft (2,438 mm)
Transport Height (less exhaust) 8 ft (2,438 mm)
Overall Transport Width (with hopper up) 8 ft 6 in (2,591 mm)
Overall Width (with hopper down) 10 ft (3,048 mm)
Weight (with screed) 20,600 lb (9,344 kg)
Main Screed Width 96 in (2,438.40 mm)
Main Screed Wear Plate Depth 16.75 in (425.45 mm)
Main Screed Wear Plate Material .5 in (12.7 mm) AR400 Steel
Main Screed Wear Plate Thickness .50 in (12.7mm)
Bullnose Radius 2 in (50.80 mm)
Extensions Wear Plate Material .375 in (9.52 mm) AR400 Steel
Extensions Wear Plate Thickness .375 in (9.52 mm)
Extensions Bullnose Radius 1.50 in (38.10 mm)
Wheelbase Track Ground Contact Length 7 ft 7 in (2302 mm)
Ground Clearance 6.62 in (168 mm)
Gauge Width Outside Wheels and Tracks 7 ft 7 in (2302 mm)
Table 2-2. Kubota Tier 4 Engine Specications
ITEM SPECIFICATION
Manufacturer Kubota, Tier 4i, Turbo-Charged
Model V3800-CR-TE4
Fuel Type Diesel
Cylinders 4
Rated Speed 2,600 rpm
High Idle 2,400 rpm
2
Max Gross Power 99.9 hp (73.8 Kw)
Max Gross Torque 249.44 ft lb (338 Nm)
Displacement 230 in 3 (3.769 L)
LeeBoy 8616B Conveyor Paver
2-5
Page 30
Information and Specications
Table 2-3. Electrical Specications
ITEM SPECIFICATION
Battery One (1), Maintenance-Free
Battery Ampere per Hour Rating 1,125 CCA
Battery Voltage 12 V
Alternator Type and Voltage 12 V, Negative Ground
Alternator Output Amperage 100 Amps
Alternator Fan Belt Tension
Starter Voltage and Type 12 V, Negative Ground
Starter Rating 3 kW
Table 2-4. Performance Specications
ITEM SPECIFICATION
Transport Speed 3.64 mph (5.56 kph)
Paving Speed 1.32 mph (2.12 kph)
Maximum Paving Depth 6 in (152 mm)
Maximum Paving Width (Hydraulic) 15 ft (4.57 m)
Basic Paving Width 8 ft (2.44 m)
Turning Radius 5.5 ft (1,676.4 mm) (Capable of Counter-Rotation)
Table 2-5. Machine System Capacity Specications
ITEM SPECIFICATION
Hydraulic 41 gal (155 L)
Fuel 32 gal (121 L)
Engine Oil with Filter 14 qt (13.24 L)
Coolant 14.4 qt (13.6 L)
Washdown 7 gal (26.50 L)
Hopper 9 T
Automatic belt tension mechanism keeps serpentine
belt under tension at all times.
Table 2-6. Hydraulic Filters
ITEM SPECIFICATION
Primary Filter Type Charge Filter
Primary Filter Size 7 Microns
Primary Filter Location Engine Compartment (right side mounted to fuel tank)
Secondary Filter/Strainer Type
Secondary Filter/Strainer Size
Secondary Filter/Strainer Location
2-6
Suction Strainers (Stauff TMF-2534-0-5); Return Filter
(Schroeder KBZ10)
Suction Strainers (125 Micron) Return Filter (10 Micron)
Suction Strainers (inside hydraulic tank); Return Filter
(top of hydraulic tank)
LeeBoy 8616B Conveyor Paver
Page 31
Information and Specications
Table 2-7. Hydraulic Pressures Specications
ITEM SPECIFICATION
Drive 3,625 psi (250 Bar)
Conveyors/Augers 3,000 psi (207 Bar)
Cylinders 3,000 psi (207 Bar)
Vibrator 3,000 psi (207 Bar)
Track Tension Pressure Reducing 1,200 psi (83 Bar)
Track Tension Relieving 2,300 psi (159 Bar)
Standby Pressure 400 - 500 psi (27.5 - 34.5 Bar)
Table 2-8. Hydraulic System Specications
ITEM SPECIFICATION
Drives Variable volume hydraulic proportional pump
Vibrator/Conveyors/Augers Load sense pump
Other Hydraulic Functions Load sense pump
Hydraulic Oil Reservoir w/Oil Cooler 41 gal (155 L)
Figure 2-3. Lubricant Specications
ITEM SPECIFICATION
Engine Oil 15W-40
Hydraulic Oil All Weather 32
Torque Hub 80W-90 Gear Oil
Grease Shell Avania EP Grease or Equivalent
Chain Lube Chain Lube
Front Idler 90 WT Gear Oil
Figure 2-4. Washdown
ITEM SPECIFICATION
Components Electric pump, two (2) hose reels with a 15’x 5/16” hose.
Citrus Wash-down 7 gal (26.501 L)
2
Figure 2-5. Electric Legend Screed Specications
ITEM SPECIFICATION
Heat
Extensions Two (2) 44-inch hydraulically operated extensions.
Vibration Two (2) hydraulic vibrators producing 2,900 vpm.
Crown/Invert
Extension Vibrators - Model Vibco B-190
Extension Vibrators - Vibrations per Minute 4,600 vpm
Extension Vibrators - Input Flow Max (gpm -> lpm) 4.8 gpm (18.17 lpm) @ 800 psi (Adjustable)
Extension Vibrators - Force 332 lbs (77 N)
LeeBoy 8616B Conveyor Paver
Four (4) Electric Heat Strips (1500 W) on Main
Screed,one (1) per extension (1500 W @ 220 V).
Adjustable, 2-inch crown, 1-1/2 inch of valley, with level
indicator.
2-7
Page 32
Information and Specications
Table 2-9. Propulsion and Pump Specications
ITEM SPECIFICATION
Displacement (Maximum) 2.75 in 3 (45 cc)
Relief Pressure 3,625 psi (250 bar)
Input Speed 2,600 rpm
Flow at Input Speed 30 gpm (113.50 lpm)
Input Flange and Spline 2-bolt "B" 14T 12/24
Auxiliary Pad 13T B
Controls EDC
Table 2-10. Motor Specications
ITEM SPECIFICATION
Displacement (Maximum) 3.66 in (60 cc)
Input Flow max 30 gpm (113.50 lpm)
Maximum Output Torque 167.30 ft-lbs (226.80 Nm)
Output Speed 1,873 rpm
Output Flange and Spline 14T Cartridge
Weight 59 lbs (27 kg)
Table 2-11. Auger and Conveyor Motor Specications
ITEM SPECIFICATION
Displacement (Maximum) 15.26 in (250 cc)
Input Flow (Maximum) 19.8 - 23.8 gpm (75 - 90 lpm)
Output Speed 300 - 360 rpm
Output Flange and Spline 4-Bolt Magneto Flange w/Cyl 1"- Splined 1"
Table 2-12. Auger and Conveyor Drive Specications
ITEM SPECIFICATION
Max Auger Speed 116 rpm
Max Conveyor Speed 51.16 fpm (15.59 mpm)
Table 2-13. Planetary Drive Specications
ITEM SPECIFICATION
Model PGRF 1703
Ratio–Gear 82.188:1
Parking Brake Fail-safe
Parking Brake Release Pressure 200 psi (13.8 bar)
Gearbox Oil Designation (i.e 80W-90) 80W-90
Oil Capacity 3 qt (2.84 L)
2-8
LeeBoy 8616B Conveyor Paver
Page 33
Information and Specications
Table 2-14. Generator Specications
ITEM SPECIFICATION
Model HMCC-1201DHW-18
Power 12 KW (12,000 Watt)
Voltage 120/240 V
Frequency 58 - 60 HZ
Table 2-15. General Purpose Pump Specications
ITEM SPECIFICATION
Model Series 45
Displacement (Maximum) 4.58 in3 (75 cc)
Relief Pressure 2,900 psi (200 bar)
Input Speed 2,600 rpm
Flow at Input Speed 47.4 gpm (179.40 lpm)
Input Flange and Spline 2-bolt B 13T 8/16
Controls Load Sensing
2
Table 2-16. Track Specications
ITEM SPECIFICATION
Length 220.47 in (5600 mm)
Width 14 in (355.6 mm)
Type Poly (Smooth Poly - Optional)
Brand Berco - Poly (Superior - Smooth)
Quantity of Pads 40 pads per side (80 total)
Planetary Drive Yes
Number of Speeds 2-Speed
Brakes Spring-Applied Hydraulic Released (SAHR)
LeeBoy 8616B Conveyor Paver
2-9
Page 34
Information and Specications
TORQUE SPECIFICATIONS
The following tables list torque values for standard
hardware. This is a guide for average application
involving typical stresses and machined surfaces.
Values are based upon physical limitations of clean,
plated and lubricated hardware. Under more extreme
conditions, individual torque value should be followed.
Conversion formulas are provided below:
Conversion Formula
ft-lb to N•m [ft-lb]*1.3558 = [N•m)
ft-lb to in-lb [ft-lb]*12 = [in-lb]
N•m to in-lb [N•m]*8.8508 = [in-lb]
Standard Inch Fasteners
Table 2-17. Torque Specications for Standard Inch Fasteners
CAPSCREWS: SAE GRADE 5 CAPSCREWS: SAE GRADE 8
SIZE THREAD
1/4 20 UNC 8 6 11 8 12 9 16 12
28 UNF 10 7 14 9 14 10 19 14
5/16 18 UNC 17 13 23 18 25 18 34 24
24 UNF 19 15 26 20 27 20 37 27
3/8 16 UNC 31 23 42 31 44 33 60 45
24 UNF 35 26 47 35 49 37 66 50
7/16 14 UNC 49 37 66 50 70 52 95 71
20 UNF 55 41 75 56 78 58 106 79
1/2 13 UNC 75 57 102 77 106 80 144 108
20 UNF 85 64 115 87 120 90 163 122
9/16 12 UNC 109 82 148 111 154 115 209 156
18 UNF 121 91 164 123 171 128 232 174
5/8 11 UNC 150 113 203 153 212 159 287 216
18 UNF 170 127 230 172 240 180 325 244
3/4 10 UNC 267 200 362 271 376 282 510 382
16 UNF 297 223 403 302 420 315 569 427
7/8 9 UNC 429 322 582 437 606 455 822 617
14 UNF 474 355 643 481 669 502 907 681
1 8 UNC 644 483 873 655 909 681 1232 923
14 UNF 722 542 979 735 1020 765 1383 1037
1-1/4 7 UNC 1121 840 1520 1139 1817 1363 2464 1848
12 UNF 1241 930 1683 1261 2012 1509 2728 2046
1-1/2 6 UNC 1950 1462 2644 1982 3162 2371 4287 3215
12 UNF 2194 1645 2975 2230 3557 2668 4823 3617
TORQUE (ft lb) TORQUE N•m TORQUE (ft lb) TORQUE N•m
Dry Lubed Dry Lubed Dry Lubed Dry Lubed
2-10
LeeBoy 8616B Conveyor Paver
Page 35
Information and Specications
Metric Fasteners
Table 2-18. Torque Specications for Metric Fasteners
CLASS 8.8 [GRADE 5 EQUIVALENT] CLASS 10.9 [GRADE 8 EQUIVALENT]
NOMINAL SIZE
AND PITCH
M4 x 0.7 2 2 3 2 3 2 4 3
M5 x 0.8 5 3 7 4 7 5 9 7
M6 x 1 8 6 11 8 11 8 15 11
M8 x 1.25 19 14 26 19 27 20 37 27
M10 x 1.5 37 28 50 38 53 40 72 54
M12 x 1.75 65 49 88 66 93 70 126 95
M14 x 2 104 78 141 106 148 111 201 150
M16 x 2 161 121 218 164 230 173 312 235
M18 x 2.5 222 167 301 226 318 239 431 324
M20 x 2.5 314 236 426 320 449 337 609 457
M22 x 2.5 428 321 580 435 613 460 831 624
M24 x 3 543 407 736 552 777 582 1053 789
M27 x 3 796 597 1079 809 1139 854 1544 1158
M30 x 3.5 1079 809 1463 1097 1544 1158 2093 1570
TORQUE (ft lb) TORQUE N•m TORQUE (ft lb) TORQUE N•m
Dry Lubed Dry Lubed Dry Lubed Dry Lubed
2
Hydraulic Fittings
Tightening Flare-Type Tube Fittings
1. Check the are and are seat for defects that might
cause leakage.
2. Align tube with tting before tightening.
3. Lubricate connection.
4. Hand tighten swivel nut until snug.
5. To prevent twisting the tube(s), use two wrenches.
Place one wrench on the connector body and
tighten the swivel nut with the second to the torque
shown in Table 2-11.
NOTE: The torque values shown are based upon
lubricated connections.
Table 2-19. Torque Specications for Steel Flare
Type Tube Fittings
TUBE SIZE
OUTER
DIAMETER
(IN) (IN) (LB FT) (N•m)
3/16 7/16 8 11
1/4 9/16 12 16
5/16 5/8 16 22
3/8 11/16 23 31
1/2 7/8 38 52
5/8 1 54 73
3/4 1 1/4 75 102
7/8 1 3/8 83 113
NUT SIZE
ACROSS
FLATS
TORQUE VALUE
LeeBoy 8616B Conveyor Paver
2-11
Page 36
LA
L
E
LA
LH
Information and Specications
Determining Proper Torque
The only reliable method of creating a consistently
leak-free and long-lasting connection is to ensure the
coupling is brought to the proper torque. Using a torque
wrench with crowfoot is the best method, but the ats
method can be used if a torque wrench is not available.
The most straightforward method of determining the
correct torque setting is to multiply the desired torque
by the length of the wrench from the center of the handle
to the center of the drive (L); divided by the length of the
wrench from the center of the handle to the crowfoot
center (LA) as shown below:
L
Figure 2-6. Torque Wrench - Crowfoot
The minimum torque values are
adequate for sealing most applications. Maximum
torque values should never be exceeded.
There are several methods of determining the correct
setting on the torque wrench when using a crowfoot. All
of the methods involve making the setting proportional
to the effective change in length of the wrench multiplied
by the desired nal torque. The equations and
illustration below describe proper measurements. (Use
LEGEND under Figure 2-4)
Equations
• Torque setting if the crowfoot is placed in line with
respect to the wrench:
TS = TD * L / LA
OR
TS = TD * L / (L+E)
Figure 2-7. Measurements Needed
LEGEND
L = Distance from center of torque wrench handle to the
center of socket drive
E = Distance from center of socket drive to the center of
crowfoot
LA = Distance from center of torque wrench handle to
the center of crowfoot
LH = Distance from center of torque wrench handle to
the center of crowfoot, when mounted at 90°
TD = Desired torque at the tting
TS = Torque setting indicated on wrench
• Torque setting if the crowfoot is placed at 90° with
respect to the wrench
TS = TD * L / LH
OR
TS = TD * L / √(L2 + E2)
• To estimate the crowfoot size (E)
E = Drive Size * 0.5 + Distance between Drive and
Open End + Wrench Size * 0.5774
2-12
LeeBoy 8616B Conveyor Paver
Page 37
Coupling Installation
Mark Line on Nut
Use the following steps for proper coupling installation:
1. Determine the correct torque value for your
coupling.
NOTE: Only use the torque values specied from
the manufacturer. DO NOT use SAE torque
recommendations.
2. Ensure the seal face and threads are clean and in
good condition. O-Rings should be lubricated with
light oil, but threads should be completely dry unless
making pipe thread connections (interference seal).
NOTE: Attach the male end of the hose onto the
equipment rst since it may be necessary to
rotate the entire hose assembly to tighten
the male threads. Then route the hose into
position while avoiding twisting the hose.
3. Tighten the connection (by hand), bringing the seal
face into contact and rotating the nut until it stops.
4. Mark a line across the coupling nut and backup hex
for the ats method verication of coupling torque
(Figure 2-12).
5. Apply a wrench to the backup hex to prevent the
coupling and hose from moving while tightening the
nut with a torque wrench.
Failure to retain the backup hex during
installation will also result in additional clamp load
force that could cause damage to the seal face.
NOTE: The coupling nut must be in motion for an
accurate torque reading. If the nut is stopped
before nal torque value is achieved, it must
be loosened and retightened until the torque
is attained while the nut is in motion.
If a torque wrench cannot t into the coupling area or if
it is unavailable, the ats method may be used to ensure
that the coupling is properly tightened, as shown in
Figure 2-5:
Information and Specications
Example 2 Flats
difference
Figure 2-8. Flats Method Tightening
NOTE: The mark placed on the nut and backup hex
after tightening by hand should rotate during
nal tightening according to the table below.
(Figure 2-12) The nut and backup hex can
then be marked to indicate if the coupling
loosens over time.
Table 2-20. Flats Method Values for Selected
Terminations
FLATS METHOD VALUES
Termination
Type
JIC -4 1.5 - 1.75
JIC -6 1.0 - 1.5
JIC -8 1.5 - 1.75
JIC -10 1.0 - 1.5
JIC -12 1.0 - 1.5
JIC -16 .75 - 1.0
JIC -20 .75 - 1.0
JIC -24 .75 - 1.0
JIC -32 .75 - 1.0
JIS -4 .5 - 1.5
1. Seal faces must be in contact with the tting fully
tightened by hand before marking ats.
Dash Size Flats
2
LeeBoy 8616B Conveyor Paver
2. The ats method is most accurate for the rst
assembly cycle. For multiple disassembly and
assembly cycles, torque values are more reliable.
3. Tightening two (2) ats or more may damage seal
faces.
2-13
Page 38
Information and Specications
Table 2-21. Torque Specications For US Style Coupling Terminations
JIC, SAE 45°, ORFS, O-RING BOSS, GATES ADAPTERLESS AND MEGASEAL
JIC 37°, SAE 45°
DASH
SIZE
-3 8 10
-4 10 11 5 6 10 12 14 16 14 16
-5 13 15 7 9 18 20
-6 17 19 12 15 18 20 24 26 24 26
-8 34 38 20 24 32 40 37 44 50 60
-10 50 56 34 40 46 56 50 60 72 80
-12 70 78 53 60 65 80 75 83 125 135
-14 65 80 160 180
-16 94 104 74 82 92 105 111 125 200 220
-20 124 138 75 83 125 140 133 152 210 280
-24 156 173 79 87 150 180 156 184 270 360
-32 219 243 158 175
& Mega-Seal
(Steel)
Min Max Min Max Min Max Min Max Min Max
JIC 37°, SAE 45°
& Mega-Seal
(Brass)
Flat Face O-Ring
Seal (Steel)
SAE O-Ring Boss
(Steel) & Gates
Adapterless
≤ 4000 PSI
SAE O-Ring Boss
(Steel) & Gates
Adapterless
> 4000 PSI
Table 2-22. Torque Specications for DIN 24, DIN
60, and Inverted Cone Style Coupling Terminations
DIN 24, DIN 60, AND INVERTED CONE
Size (MM) Torque (LB FT)
Light
Series
Tube OD
6 7 15
8 15 26
10 8 18 30
12 10 22 33
14 12 26 37
15 14 30 52
18 20 44 74
22 25 59 89
28 30 74 111
35 133 184
42 148 221
Heavy
Series
Tube OD
16 30 52
38 74 162
Min Max
Table 2-23. Torque Specications for 4-Bolt
Flange Connections
4-BOLT FLANGES
Dash Size Bolt Size (IN) Torque (LB FT)
-8 0.31 17
-12 0.38 26
-16 0.44 43
-20 0.50 65
-24 0.63 130
-32 0.75 220
1. Align faces and tighten bolts (by hand) before
applying nal torque in a pattern. The seal faces
must be parallel with an even bolt tension to seal
properly.
2. Torque values apply to bolts that are plated or
coated in light engine oil.
3. Before assembly, lubricate O-Ring with light oil
(SAE 10W or 20W).
2-14
LeeBoy 8616B Conveyor Paver
Page 39
Information and Specications
Table 2-24. Torque Specications for NPTF Dry Seal
Pipe Threads
NPTF
Dash Size Max Torque (ft-lb)
-2 20
-4 25
-6 35
-8 45
-12 55
-16 65
-20 80
-24 95
-32 120
1. The torque values obtained from tightening pipe
threads can vary considerably depending upon
thread condition. Adequate sealing can occur at
values much lower than the maximum values listed
above. Only enough torque to achieve adequate
sealing should be used.
2. When using a male tapered pipe thread with a
female straight or parallel pipe thread, maximum
values are 50% of those listed in the table above.
Table 2-25. Torque Specications for BSP 30°
Inverted Cone and JIS Coupling Terminations
BSP 30° INVERTED CONE AND JIS
Torque (ft-lb)
Dash Size
Min Max
-2 7 9
-4 11 18
-6 19 28
-8 30 36
-10 37 44
-12 50 60
-16 79 95
-20 127 152
-24 167 190
-32 262 314
2
3. If thread sealant is used, maximum values shown
should be decreased by 25%.
LeeBoy 8616B Conveyor Paver
2-15
Page 40
Information and Specications
NOTES
2-16
LeeBoy 8616B Conveyor Paver
Page 41
Section 3
COMPONENT LOCATION
Page
Component Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Components Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Torque Hubs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Hopper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Augers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Operator Platform . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Screed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Machine Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Steering and Speed Control Box . . . . . . . . . . . . . . . . . . . . . . 3-5
Operator Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Screed Control Boxes . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Electric Screed Operation Controls . . . . . . . . . . . . . . . . . 3-9
Steering Wheel (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
LeeBoy 8616B Conveyor Paver
3-1
Page 42
Component Location
NOTES
LeeBoy 8616B Conveyor Paver3-2
Page 43
Component Location
COMPONENTS OVERVIEW
This section describes the major components for the
LeeBoy 8616B Conveyor Paver. Become familiar with
these components before operating the machine.
Engine
The LeeBoy Model 8616B Conveyor Paver is equipped
with a Kubota, 99 hp (74 kW) diesel engine, which is
mounted near the center of the paver and accessible
through several access doors on the engine cover.
A fuel lift pump mounted to the right side of the engine
draws diesel fuel from the fuel tank, which is also
mounted on the right side of the engine compartment.
The air cleaner is mounted at the back of the hood,
which removes ne particles such as dust, sand, chaff
and lint from the air. As air is taken into the air cleaner
assembly, the cyclone action deposits some of the ne
particles in the evacuator that is mounted on the bottom
of the air cleaner housing. The evacuator is held closed
during engine operation by suction. When the engine
is shut off, the weight of the debris opens rubber aps,
allowing the debris to fall out. These aps can also be
squeezed open for cleaning.
The fuel lter removes contaminants from diesel fuel
before it ows into the injection pump where it is injected
into the engine combustion chamber.
The radiator mounted in front of the engine cools the
engine. As coolant ows through the radiator, airow
from the engine-driven fan removes heat.
Refer to the Engine Operator’s Manual accompanying
your paver for additional engine information.
Hopper
The hopper wings are hydraulically controlled to raise
and lower the hopper. When fully open, the hopper can
hold a payload up to nine tons.
Material in the hopper is moved toward the back of the
paver to the screed by conveyors. The conveyor is
activated at the operator platform.
Augers
Right and left augers rotate counterclockwise to move
material from the conveyors to the screed. The auger
can be manually controlled at the operator platform or
by a screed operator on the screed.
The auger can also be controlled automatically when
the optional auger/conveyor sonic sensor system is
installed and active. The sensor is mounted on the
screed endgates and used to monoitor and control
the pile height of material at the discharge end of the
augers.
Operator Platform
The operator platform allows easy and convenient
access for controls of most paver functions. The paver
can be operated from the left or right side depending
upon which control panel side is active and best suited
to the working conditions. Controls can also be lowered
to operate as a lowdeck or by standing on the screed
walkboard.
3
Screed
Hydraulic System
The hydraulic system includes four hydraulic pumps
driven by the engine: 1) Left Drive Pump; 2) Right Drive
Pump; 3) Load Sense Pump and; 4) Charge Pump.
Torque Hubs
The paver drive system contains two torque hubs that
provide power to propel the tracks.
LeeBoy 8616B Conveyor Paver 3-3
The screed is the last part of the paver that contacts the
paving material. A screed operator usually operates the
screed while the operator drives the machine. Paving
material is fed from the hopper and conveyor to the
augers to the front of the screed.
The screed has hydraulically-controlled extensions that
move in and out to allow a paving base from 8 - 15 feet.
Screed heating is accomplished by electric heating
elements mounted directly to the wear plates.
The hydraulically-driven vibrators mounted on the main
screed frame can be used to increase paving material
compaction.
Page 44
Component Location
Electrical System
The electrical system is powered by one 12-volt
battery mounted in the engine compartment next to
the generator. Each battery produces 12 volts DC
and maintains 1,260 cold cranking amperes (CCA).
An engine-mounted alternator with a minimum of 60
amperes charging capacity keeps the battery charged
during normal operation. The battery charge rate can
be monitored using the voltmeter on the center operator
control panel.
Electrically-heated pavers come equipped with a
generator mounted on the left side of the paver (inside
door under the hydraulic manifolds). The generator is
hydraulically-driven by a load-sense pump on the engine
pump stack. When the paver is at a preset engine
speed of 1600 RPMs and the hydraulic system is at
normal operating temperature, the generator operates
at a sufcient speed to produce 220 - 240 VAC.
All LeeBoy generators are equipped with an integrated
speed-control manifold. This manifold should not
require adjustment, but if there is a need to “ne tune”
the generator speed, there is an adjustment on the
manifold.
Once the heat cycle is started, a pre-programmed timer
controls the amount of time for output power from the
generator to go through the element connection supply
plugs coming out of the bottom of the Heating Control
Box to the heating elements.
Any element lead can be plugged into any supply plug
under the heating control/distribution box. All plugs are
equally rated.
Each element is sized to t properly in your screed, and
provide sufcient power to heat your screed plate to a
temperature that mix will not drag or stick to the lower
surface of the screed plate.
To know that the element is correct, you should read a
resistance between 25 ohms and 35 ohms.
Generator speed tuning should only
be done by an authorized LeeBoy dealer.
Heating controls provide the necessary connection
and control of the output power from the generator
to the heating elements. It is important to maintain all
components of the heating controls system in good
working order for safe and efcient screed heating.
The heating control is mounted near the middle of the
screed and is easily accessible to the screed operator
when a heating cycle is required.
There is a ve-second delay after the heat cycle is
initiated before the actual electric load is sent to the
heating elements to allow the generator to reach optimal
operating speed before the electrical load is required.
LeeBoy 8616B Conveyor Paver3-4
Page 45
MACHINE OVERVIEW
Component Location
5
4
6
2
3
5
7
1
7
8
13
10
12
11
9
Figure 3-1. Operation Panels and Controls
ITEM
NO.
1 Hopper
2 Work Light Used for illuminate the path of the paver.
3 Spray Down Hose Used to spray the paver clean.
4 Beacon Light Used to alert surrounding vehicles and pedestrians.
5
6 Control Panel Contains major paver systems and controls.
7 Screed Control Box Contains various screed controls (one on each side of machine).
8 Electric Heat Control Box Provides electric heat to the screed. Houses element breakers.
9 Flight Screw Controls the depth of the asphalt (one on each side).
10
11 Endgate Creates a clean edge in the paved base. Has vertical and angle adjustments.
12 Sonic Sensor Bracket
13 Truck Rollers
CONTROL NAME FUNCTION
Receives and holds paving material load as conveyors move material to back
of the paver and screed.
Steering and Speed Control Box
Power Crown Control
(Option)
Contains various steering and screed controls (one on each side of
operator’s platform).
Toggle switch up or down for power crown.
Holds the optional Sonic Conveyor/Auger Sensor in position. Connected to
the Sonic Auger Adjustment.
These rollers pushes the material delivery truck along as it delivers asphalt
into the paver hopper.
9
3
LeeBoy 8616B Conveyor Paver 3-5
Page 46
2
Component Location
STEERING AND SPEED CONTROL BOX
1
3
Figure 3-2. Steering and Speed Control Box
ITEM NO. CONTROL NAME FUNCTION
1 Left Steer Joystick Lever controls the speed and direction of travel forward and reverse. Pushing
joystick forward moves machine forward. The farther forward, the faster the
speed. Pulling joystick backward moves machine backward. The farther
backward, the faster the speed. When joystick is centered, the machine is in
neutral and brake comes on. Pushing left joystick farther forward than right
joystick steers the paver to the right. The farther forward, the more the paver
turns.
2 Right Steer
Joystick
3 Run/Stop Switch The Run/Stop switch controls stopping the machine and activating/deactivating
Lever controls the speed and direction of travel forward and reverse. Pushing joystick forward moves machine forward. The farther forward the faster the
speed. Pulling joystick backward moves machine backward. The farther backward, the faster the speed. When joystick is centered, the machine is in neutral
and brake comes on. Pushing right joystick farther forward than left joystick
steers the paver to the left. The farther forward, the more the paver turns.
the operator control station. When the switch is set to the STOP position,
operator control station is deactivated, parking brake is applied, and machine
will not move. When switch is set to RUN, operator control station is activated,
parking brake is released, and machine resumes to previously set speed.
LeeBoy 8616B Conveyor Paver3-6
Page 47
OPERATOR CONTROL PANEL
2
3
4
1
5
8
6
7
19
9
18
17
13 11 10
14
15
16
12
Component Location
3
Figure 3-3. Control Panel, Indicators and Gauges
ITEM
NO.
1 Ignition Switch Starts and stops engine.
2 DP700 Digital Display
3 E-Stop Button
4
5 2-Speed Switch
CONTROL NAME FUNCTION
Right Tow Thicker/
Thinner Switch
Displays paver setup and calibration information, engine operating information,
and engine and paver system fault information.
Immediately stops the paver engine and all electronic functions. Turn clockwise
to release E-Stop button.
Sets the thickness of the asphalt.
Used to change machine speed. Place switch in OFF position for low speed.
Place the switch in ON for high speed position.
LeeBoy 8616B Conveyor Paver 3-7
Page 48
Component Location
ITEM
NO.
6 Horn Sounds horn.
7 Screed Lift Switch
8
9 Right Extension Switch
10
11 Hopper Wings Switch
12 Right Cut-Off Switch
13 Right Conveyor Dial
14
15 Left Cut-Off Switch
16 Left Extension Switch
17
18 Left Conveyor Dial
CONTROL NAME FUNCTION
Raises or oats the screed. Center position is hold. When released, switch
automatically returns to center position.
Right Auger Manual
Overide Switch
Left Auger Manual
Overide Switch
Right Conveyor Sonic
Paddle Switch
Left Conveyor Sonic
Paddle Switch
Center position is OFF. Pull switch down to manually overide right auger.
Used to move the right extension in or out. Push switch to right arrow
) position to move right extension out. Push switch to left arrow ( )
(
position to move in the right extension.
Center positionis OFF. Pull switch down to manually overide left auger.
Used to move the hopper wings in and out. Push switch to OUT position to
open hopper wings. Push switch to IN position to close hopper wings.
Used to open or close the right cutoff. Push switch to the OPEN position to
open right cutoff. Push switch to CLOSE position to close right cutoff.
Controls right conveyor speed when Right Conveyor Switch is set to AUTO or
MANUAL. Turning clockwise increases conveyor speed.
Selects sonic or paddle override for right conveyor. Center is OFF position.
Set switch to SONIC position for conveyors to work with sonics. PADDLE
position controls conveyors with paddles.
Used to open or close the left cut-off. Push switch to the OPEN position to open
left cut-off. Push switch to CLOSE position to close left cut-off.
Used to move the left extension in or out. Push switch to left arrow position to
move left extension out. Push switch to right arrow position to move in the left
extension.
Selects sonic or paddle override for left conveyor. Center is OFF position. For
sonic operation, set switch to SONIC position for conveyors to work with sonics.
PADDLE position controls conveyors with paddles.
Controls left conveyor speed when Left Conveyor Switch is set to AUTO or
MANUAL. Turning clockwise increases conveyor speed.
19 Left Tow Switch
Sets the thickness of the asphalt. Place switch in THICKER position for thicker
asphalt. Place switch in THINNER position for thinner asphalt.
LeeBoy 8616B Conveyor Paver3-8
Page 49
SCREED CONTROL BOXES
1
2
7
6
3
4
5
2
1
7
Component Location
3
4
6
5
Figure 3-4. Left Screed Control Box
ITEM
NO.
1 Left E-Stop Button
2 Horn Sounds horn.
3 Left Slope Swtich
4 Left Auger Dial
5
6 Left Extension Switch
7
CONTROL NAME FUNCTION
Immediately stops
paver engine and all
electronic functions.
Optional Component:
Raises and lowers left
Left Auger Manual
Switch
Left Tow Switch
slope.
Controls pile height
and speed for the left
auger.
Selects automatic or
manual override for left
auger.
Moves left extension in
and out.
Moves tow up and
down.
ITEM
NO.
Figure 3-5. Right Screed Control Box
CONTROL NAME FUNCTION
Immediately stops
1 Right E-Stop Button
2 Horn Sounds horn.
3 Right Slop Switch
4 Right Tow Switch
5 Right Extension Switch
Right Auger Manual
6
Switch
7 Right Auger Dial
paver engine and all
electronic functions.
Optional
Component: Raises
and lowers left
slope.
Adjusts right tow iup
or down.
Moves right
extension in or out.
Selects automatic
or manual override
for right auger.
Controls pile height
and speed for the
left auger.
3
LeeBoy 8616B Conveyor Paver 3-9
Page 50
Component Location
Electric Screed Operation Controls
1
10
2
4
3
6
7
5
Figure 3-6. Screed Operation Controls
ITEM NO. CONTROL NAME FUNCTION
1 Screed Operator Controls Controls for screed functions.
2 Sonic Auger Sensor
Bracket
3 Depth Screw Controls the depth of the endgate.
4 Extension Angle of Attack
Screw
5 Tilt Screw Adjusts the tilt of the endgate.
6 Extension Vertical
Adjustment Screws (2)
7 Screed Vibrator Provides vibration to the screed frame for better mat compaction.
8 Flight Screw Controls the depth of the asphalt.
9 Crown and Valley Adjuster
10 Electric Heat Box Provides electric heat to the screed. Houses element breakers.
Holds the sonic auger sensor in proper position to maintain the proper
height of augered material. Connected to the sonic auger adjustment.
Adjusts the front of the extension wearplate to provide the best mat.
Moves up or down and can level extension at wide widths.
Adjusts the front of the extension wearplate to provide the best mat.
Moves up or down and can level extension at wide widths.
Adjusts for positive crown or negative valley in wear plate.
NOTE: Powered adjustment option available.
9
8
LeeBoy 8616B Conveyor Paver3-10
Page 51
STEERING WHEEL (OPTION)
2
1
3
Component Location
3
4
Figure 3-7. Steering Wheel Option
ITEM NO. CONTROL NAME FUNCTION
Controls the speed of travel forward and reverse. The farther moved
1 Forward/Reverse Joystick
2 Steering Wheel Controls the direction of travel right or left.
3 Neutral Lock Locks the Forward/Reverse joystick in neutral.
4 Run/Stop Switch
in either direction, the faster the speed. When joystick is centered, the
machine is in neutral and the brake is engaged.
Controls stopping the machine and activating or deactivating the operator
controls station. Operator control station is deactivated when the switch
is set to the STOP position, parking brake is applied and the machine will
not move. When setting the switch to RUN, the operator control station
is activitated, parking brake is released and the machine resumes to the
previously set speed.
NOTE: Only one operator control station can be active at a time.
LeeBoy 8616B Conveyor Paver 3-11
Page 52
Section 4
OPERATION
Page
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Receiving the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Initial and Daily Inspection . . . . . . . . . . . . . . . . . . . . . . 4-3
Start-Up Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
DP700 PLUS+1® Display Unit . . . . . . . . . . . . . . . . . . . . 4-4
Start-Up Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Engine Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Paver Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Time Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Fault Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
DPF Regeneration (REGEN) . . . . . . . . . . . . . . . . . . . . . 4-7
Status Icons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Driving the Paver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Operator Control Station . . . . . . . . . . . . . . . . . . . . . . . 4-10
Steering and Speed Control . . . . . . . . . . . . . . . . . . . . . 4-10
Paver Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Spray Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Set the Screed and Endgates . . . . . . . . . . . . . . . . . . . . 4-12
Hopper Wings . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
Conveyor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
Hydraulic Cut-Off Gates . . . . . . . . . . . . . . . . . . . . . . . 4-15
Sonic Auger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
Tow Point Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
LeeBoy 8616B Conveyor Paver
4-1
Page 53
Operation
Starting to Pave . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
Basic Paving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
Setting the Crown . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
Mat Texture Adjustment . . . . . . . . . . . . . . . . . . . . . . . 4-19
Unloading And Loading . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
Unloading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
Loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
Tie-Down Procedure . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
Optional Components . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
Auger Extensions Option . . . . . . . . . . . . . . . . . . . . . . . 4-21
Power Crown Option . . . . . . . . . . . . . . . . . . . . . . . . . 4-22
Umbrella Option . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22
Truck Hitch Attachment Option . . . . . . . . . . . . . . . . . . . . 4-22
LeeBoy 8616B Conveyor Paver4-2
Page 54
GENERAL INFORMATION
Operation
The LeeBoy Model 8616B Conveyor Paver is equipped
with hydrostatic-driven tracks that propel the paver
using friction-controlled joysticks. The two joysticks
control the speed and direction of the paver in
conjunction with the machine speed setting. Ramping
for acceleration and deceleration are proportional to the
movement of the joysticks. (Page 3-5)
The propel system utilizes a dual path proportional
system to control the tracks. In low speed, the inside
track counter-rotates.
Steering the tracks is controlled by a hydraulic
proportional pump. The amount of steering is controlled
by the amount of joystick movement and the speed of
the paver. As the paver speed increases, steering will
be reduced.
Engine RPM is set manually by using the throttle up
and throttle down buttons located on the DP700 digital
display unit on the operator control panel. Always set
throttle before starting to pave.
The engine RPM automatically increases to 1800 RPM
when the conveyor or augers are engaged.
If the joysticks are set to the neutral position for 10
seconds, the engine will idle. When the joysticks are
taken out of neutral, the engine immediately returns to
the last set RPM.
Only authorized personnel who are
properly trained should operate the LeeBoy Model
8616B Conveyor Paver.
RECEIVING THE MACHINE
Although the machine has been checked thoroughly by
the manufacturer, road hazards or other factors during
transport may result in damage. Be sure to check the
machine thoroughly before operating it:
1. Check engine oil. (Page 5-17)
2. Check hydraulic uid level. (Page 5-19)
3. Check machine hoses for any damage or leaks.
4. Inspect machine for any damage during transport.
Contact your authorized dealer immediately if any
damage has occured.
Initial and Daily Inspection
The following inspection is essential and should be
performed before the initial start-up. Visually inspect the
unit to check its general condition and for familiarization.
Continue with a check of the systems and components
shown in Table 4-1 below:
Only trained personnel should operate
the LeeBoy 8616B Conveyor Paver.
Table 4-1. Initial Inspection
INSPECT PROCEDURE
Engine Oil
Level
Fuel Tank
Hydraulic
Tank
Radiator Check coolant level.
Battery
Air Cleaner
Drain Plugs Make sure plugs are inserted and tight.
Engine Belt Check for proper belt tension.
Grease
Fittings
Maintain oil level between ADD and
FULL marks on dipstick.
Check for adequate fuel supply. Fill if
needed. Always ll tank at end of the day
to prevent condensation in the tank.
Check the tank for oil level and leaks.
Ensure all cables are tight and clean.
Check for corrosion on the battery
terminals.
Check the air lter element and hose
connections. Air cleaner has both a
primary and secondary lter.
Ensure ttings are greased and in good
working order.
4
LeeBoy 8616B Conveyor Paver 4-3
Page 55
Operation
START-UP PROCEDURE
DO NOT leave the operator station
unattended while the paver is in gear or in motion.
Operator must return joysticks to the neutral position
and turn the RUN/STOP switch to the STOP position
before leaving the operator platform.
Verify there are no people, obstacles
or other equipment in the machine’s path before
starting the engine.
1. Clear auger and conveyors before starting engine.
2. Position joysticks to NEUTRAL.
3. Insert key into the ignition and turn clockwise to the
START position.
DO NOT hold the starter longer than
10 - 15 seconds. If the engine does not start, allow
the starter to cool two or three minutes.
Using starting additives, such as
ether, is not recommended as severe engine damage
can occur.
4. Allow engine to warm up a few minutes before
moving paver for more efcient operation. In cold
weather let hydraulic oil warm to 60° (16°C) before
moving.
DP700 PLUS+1® Display Unit
The LeeBoy Model 8616B Conveyor Paver is equipped
with a DP700 PLUS+1® Digital Display unit that slides
to either side of the operator station for convenience.
The digital display unit functions as a master control unit
that gathers operating information. This high-resolution
system displays engine and paver function screens and
performs in the most extreme machine environments.
Numbered buttons along each side of the display
screen, Left/Right, and Up/Down buttons are used to
navigate within specic functions. The “X” button allows
you to exit the current screen back to the previous
control screen.
When turning the ignition key to the ON position, a
sequence of screens will display on the controller.
Start-Up Screen
The Start-Up screen will appear when the paver is
started. The start-up screen is displayed for a few
seconds as the system “boots,” and will display the “rev”
levels of the propel, screed and display codes. The
screen will then automatically move into the engine
screen.
5. Set engine RPM using the throttle up and down
buttons on the Engine Screen on the digital display
screen. (Engine RPM will automatically increase to
1800 RPMs when conveyor or augers are engaged.)
Figure 4-1. Start-Up Screen
LeeBoy 8616B Conveyor Paver4-4
Page 56
Operation
Engine Screen
The engine screen displays water temperature, oil
pressure, voltage, engine RMPs, fuel level and hydraulic
oil temperature. Indicators also show the operator
warnings for low fuel, high coolant or hydraulic oil
temperature low voltage, and low engine oil pressure.
Other indicators include beacon or work lights ON,
spray-down ON and generator ON. There will be an
indicator for left or right console “in control” to let the
operator know which joystick console is in control.
The Left/Right arrow buttons provide IN/OUT
functionality for the truck hitch.
1
2
3
4
5
6
Paver Screen
You can navigate to the paver screen by pressing the
top left button (Paver Screen) in the engine screen.
The paver screen displays indicators and status of the
left and right augers and conveyors, material height
setting (when in AUTO mode), auger and conveyor
speed, vibrator ON/OFF, Grade (AUTO or MANUAL) and
screed oat. Warning indicators from the engine screen
will also display. The paver screens has a ground speed
indicator showing 1 - 100 percent ground speed with
maximum speed setting.
NOTE: The maximum travel speed is determined by
the set ground speed percentage.
1
2
3
4
5
6
7
8
Figure 4-2. Engine Screen
1 - Paver Screen
2 - Engine Fault
3 - Set-Up Tools/Password
4 - System Faults
5 - Throttle Up
6 - Throttle Down
4
9 10 11 12
Figure 4-3. Paver Screen
1 - Beacon Lights
2 - Work Lights
3 - Spray Down
4 - System Faults
5 - Grade Auto/Manual
6 - Vibrator
7 - Throttle Up
8 - Throttle Down
9 - Truck Hitch In
10 - Ground Speed Up
11 - Ground Speed Down
12 - Truck Hitch Out
• The Up/Down arrow buttons control ground speed
percentage.
• The Left/Right arrow buttons provide IN/
OUT functionality for the truck hitch (optional
component).Spray Down Button:
LeeBoy 8616B Conveyor Paver 4-5
Page 57
Operation
• The Spray Down function is set to default 10
minutes. Pressing the button turns the pump on
and off.
• Grade AUTO: The Grade AUTO output energizes
a relay that connects the System V outputs to the
tow valves. When turned off, the tow switches are
connected to the tow valves.
• Vibrator: The vibrator will only operate when both
joysticks are in the forward position. The vibrator
will not operate in the neutral or reverse position.
• The oat position inputs to the digital display
and energizes the screed oat output. When the
joysticks are placed in the neutral position, “screed
hold” will be illuminated on the screen.
• The fuel level, battery voltage, coolant temperature,
hydraulic oil temperature, engine oil pressure, park
brake, work lights, beacon light, spray down and
generator warning icons are also displayed.
Time Adjust
You can easily set the hour and minute on the digital
clock using the buttons on the display.
Fault Screens
The Fault screens inform the operator that a problem
exists. These screens indicate system faults, joystick or
sensor problems, valve or pump output problems and
loss of controller network.
Figure 4-5. Faults Screen
Use the Right/Left arrow buttons to scroll through the
fault pages. To exit the screen, press the “X” button.
• Output Fault - The output is on and no current is
measured (open or short circuit).
Figure 4-4. Time Adjust
• Input Sensor Fault - The sensor voltage is outside
acceptable limits.
• Input Sensor Cal - The sensor has not been calibrated.
• Controller Ofine - No CAN communication with
controller.
LeeBoy 8616B Conveyor Paver4-6
Page 58
Operation
DPF Regeneration (REGEN)
DPF regeneration is the term given to the cleaning
process where the exhaust temperature is raised in
an attempt to safely burn off any soot and undesired
combustion gas captured in the Diesel Particulate
Filter (DPF) in the exhaust system. When the DPF
lter reaches a soot saturation level bewteen 25 - 45
percent, the onboard engine ECU (Engine Control Unit)
will activate a regeneration cycle.
To reduce the amount of particulate
matter and maximize efciency, use API-CJ4 (or
ACEA-E9 European equivalent) engine oil.
During normal operation, the DPF is cleaned
automatically. Under certain conditions, the operator
may have to instruct the control system to perform the
cleaning process.
The DPF level icon is shown on the engine screen.
(Figure 4-8) The DPF icon indicates the level of soot
build-up on a scale of Level 0 - 5 and changes color.
Regeneration will occur automatically at Level 1 - 2.
It is important to perform a parked, manual
regeneration BEFORE the engine reaches as high as
Level 4. If the DPF reaches Level 4 - 5, non-warranty
factory assistance from the engine manufacturer is
required.
NOTE: See Section 5 Troubleshooting Chart on Page
5-33 for a complete list of fault codes.
The engine speed will increase during regeneration
and there may be a noticeable sound difference.
Once regeneration is complete, the engine will return
to normal idle speed and a green screen will appear
notifying operator the process is complete. Press the
“X” button to clear this screen.
Once the DPF cycle has been activated, it is important
not to shut off the engine as the regeneration cycle will
fail and could possibly damage the engine. Therefore, it
is important to allow the regeneration process to nish.
If the regeneration cycle fails, the ECU may attempt a
second regeneration depending upon how blocked the
lter has become. If the system does not allow a second
regeneration, this means the lter is blocked more than
80 percent and needs to be cleaned or replaced.
Level
Figure 4-6. DPF Level Icon in Engine Screen
At Level 3, a screen will appear notifying the operator
that a manual regeneration is required. (Figure 4-9)
DPF
There are several factors that affect how often your DPF
regenerates and the life expectancy of your DPF lter:
• Grade of engine oil.
• Grade of diesel fuel.
• Use of additives.
• Mileage.
• Wear of other components.
DO NOT attempt to operate the unit,
change engine RPM or move from Park/Neutral
during the regeneration process.
4
Figure 4-7. DPF Warning Screen
LeeBoy 8616B Conveyor Paver 4-7
Page 59
Operation
Status Icons
The Status icons on the engine screen illuminate to provide information for the operator.
Table 4-2. Status Icons
Icon Status Description
Generator. Illuminates when the generator is on.
Work Lights. Illuminates when lights are on.
Beacon Light. Illuminates when beacon light is on.
Spray Down. Illuminates when the spray down system is on.
Alternator. Illuminates when the alternator isn’t charging.
Regen. Communicates that engine regeneration is
Low Charge Pressure. Illuminates when the charge pressure is low.
Fuel. Illuminates when the fuel tank is almost empty.
Battery. Illuminates when the battery voltage is low.
Coolant. Illuminates when the engine is running too hot.
Parking Brake. Illuminates when the parking brake is on.
HEST (High Exhaust System Temperature). Illuminates when the exhaust temperature is high.
Hydraulic Oil. Illuminates to warn operator when the hydraulic oil is too hot.
LeeBoy 8616B Conveyor Paver4-8
Page 60
Icon Status Description
Check Engine. Warning light that illuminates when the engine needs attention.
Force Regen. Illuminates when the system is forcing engine regeneration.
DPF Notice. A solid lamp is the initial warning that soot levels are rising.
DPF Flashing. Any time the lamp begins ashing, the operator should increase loading on the engine
so regeneration is possible. If increased load does not cause an automatic regeneration, the operator
should IMMEDIATELY perform a parked, manual regeneration.
DPF (Diesel Particulate Filter) Level. Indicates current DPF level. Changes color with each level.
Levels are 0 - 5. If the DPF reaches Level 4 - 5, non-warranty factory assistance from the engine
manufacturer is required.
Regen Uninhibit. Communicates with the engine that regeneration is not wanted or is unsafe to
regenerate at this time.
Operation
DPF Regen Inhibit. The user may choose to inhibit the regeneration if conditions are too hazardous for
high-exhaust temperatures. When this lammp is illuminated, a regeneration cannot be performed and
soot levels will continue to rise. Unless hazardous conditions exist, the Regen Inhibit switch and this
lamp should remain off.
W- Warning. Warns operator there is a condition with the ECM (Engine Control Module).
P - Protect. Noties operator ECM has gone into protect mode. Engine will not start.
S - Stop. Noties operator to shut the engine down.
All three warning lights are directly broadcast from the engine ECM on the CAN bus.
Engine Faults. If this light illuminates, push soft key to display all active and inactive engine faults.
System Faults. When this light illuminates, push soft key to display all active system faults.
4
LeeBoy 8616B Conveyor Paver 4-9
Page 61
1
Operation
DRIVING THE PAVER
The operator can operate the paver from either side of
the operator platform. Multiple switches and dials allow
the operators to control all paving functions. (Page 3-6)
DO NOT leave the operator station
unattended while the paver is in gear or in motion.
Operator must return joysticks to the neutral position
and turn the RUN/STOP switch to the STOP position
before leaving the operator platform.
Operator Control Station
The paver is typically operated from the left side
of the operator platform, but the paver can also be
operated from the right side for your convenience. A
steering and speed control box with dual joysticks are
located on each side of the platform. The main control
panel console is located in the center. (Figure 4-8)
1
2
The paver can only operate using one station at a time.
The operator must activate the side being used and
deactivate the other using the following procedure:
• Place both joysticks in the neutral position on the
side being deactivated. (Figure 4-9)
• Move the RUN/STOP switch to the STOP position.
• Operator can then move to the other operator
station to activate that side by simply ipping the
RUN/STOP switch to the RUN position.
• Follow the start-up procedure. (Page 4-4)
Ensure there are no people, obstacles
or other equipment in the path of the paver before
moving in either direction.
Figure 4-8. Operator Control Station
1 - Steering and Speed Control Box
2 - Operator Control Panel
2
Figure 4-9. Steering and Speed Control Box
1 - Dual Joysticks
2 - RUN/STOP Switch
Steering and Speed Control
After activating the desired control station, you are ready
to drive the paver using the dual joysticks for steering
and speed control. It is important to move the joysticks
SLOWLY. The RUN/STOP switch applies parking brake
when set to the STOP position. (Figure 4-9)
Rapid counter-rotation in either
direction can result in the operator being thrown
from the machine and suffer personal injury or
death. Counter-rotation occurs if one joystick is in
the extreme forward position and the other is in the
extreme rear position while the machine is in gear
and moving. Make only slow adjustments to joysticks
or steering wheel to turn machine.
LeeBoy 8616B Conveyor Paver4-10
Page 62
Operation
NOTE: To slow the paver, move joysticks closer to
the neutral position.
NOTE: To stop the paver, pull joysticks back to the
neutral position.
• To drive the paver forward, lift up on the joysticks
and push forward to reach the desired speed.
• To move in reverse, lift up on the joysticks and move
backwards to reach desired speed.
• Return joysticks to the neutral position to stop
paver.
• To steer the unit to the left, SLOWLY push the right
joystick farther forward than the left joystick. The
farther the joystick is pushed, the more the paver
turns. Slow and easy adjustments are required for
safe operation.
• To steer the unit to the right, SLOWLY push the left
joystick farther forward than the right joystick. The
farther the joystick is pushed, the more the paver
turns. Slow and easy adjustments are required for
safe operation.
NOTE: Ground speed percentages can be changed
on the Paver Screen using the Up and
Down arrows. The maximum travel speed
is determined by the set ground speed
percentage.
PAVER OPERATION
Spray Down
Always spray down the LeeBoy Model 8616B Conveyor
Paver before and after paving.
Spray clean with solvent or release agent on any part of
the paver that comes into contact with asphalt to prevent
buildup that will damage the machine over time.
There is a spray down system on both sides of the
Leeboy 8616B paver for your convenience. The wand
is conveniently located on each side of the operator’s
station. (Figure 4-10) The hose reel is located inside
the panel.
1. Extend hose from the reel.
2. Navigate to the paver screen on the DP700 digital
display to activate spray down system. (Page 4-5)
3. Squeeze the wand handle and spray area. Release
the wand handle when nished.
4. Press the Paver screen Spray Down again to turn
the spray down system off and rewind the hose onto
the reel.
NOTE: The spray down function will automatically
turn off after 10 minutes. Press the button on
the paver screen to restart if needed.
4
Stopping the Engine
1. Throttle back to idle using settings on the digital
display screen or bring joysticks to the neutral
position.
2. Turn ignition key on instrument panel
counterclockwise to the OFF position and remove
key.
NOTE: If the engine does not shut down when key is
turned to OFF, press the E-Stop button on the
control panel to terminate power.
Before leaving the operator platform,
the operator must return joysticks to the neutral
position and switch the Run/Stop (on the Steering
and Speed Control Box) to the STOP position.
Figure 4-10. Spray Down Wand
LeeBoy 8616B Conveyor Paver 4-11
Wand
Page 63
Operation
Never spray cleaning solvent or
release agent near the screed heating element or
near open ame. These agents are highly ammable
and can ignite, causing serious personal injury.
When using, consider the environment
and DO NOT allow cleaning solvent to run onto the
ground.
Screed Electric Heat Control
The LeeBoy 8616B Conveyor Paver features a
hydraulically-driven generator that powers the electric
heat control box mounted in the center of the screed for
easy access. This control box is where you will select
the heating function before you begin to pave. (Figure
4-11).
NOTE: Engine speed automatically increases to
1,600 RPMs when the heat cycle is active.
To operate the screed heating system:
1. Start the paver and idle until the engine reaches
normal operating temperature.
2. Raise the screed plate one or two inches off the
ground.
NOTE: The engine speed automatically decreases to
idle after the heat cycle completes.
6. If the heat cycle has completed but the screed
plates still require heating, restart the cycle by
repeating Step 4.
Once the heating function has been enabled, the
distribution/control box will apply electrical power to the
heating elements and the heating cycle will begin. The
heating cycle is timed to optimize the heat generated at
the screed plates.
NOTE: You can set the screed directly onto a fresh
mat of hot asphalt while running the heating
system, allowing the heat of the asphalt to
help heat the screed plate.
Set the Screed and Endgates
1. Move paver to the starting position for paving.
2. Extend the screed to the desired width.
3. To set the depth, you can place a small starter block
under the screed while you make adjustments.
4
Figure 4-11. Electric Heat Control Box
3. Turn the electric heat control box power ON by
ipping the switch up.
4. Press the Start Heat button.
5. The HEAT ON indicator light will illuminate and stay
on as long as the element is heating the screed
plates (approximately 20 minutes).
1
2
3
Figure 4-12. Screed, Endgate and Flight Screw
1 - Endgate Depth Screw
2 - Endgate
3 - Endgate Tilt Screw
4 - Flight Screw
4. Level the screed with the ight screw. (Figure 4-13)
5. Turn the ight screw one turn (clockwise) to get
started and adjust accordingly if needed.
LeeBoy 8616B Conveyor Paver4-12
Page 64
Figure 4-13. Flight Screw Adjustment
6. On the rst pass, turn the endgate depth screw to
lower the endgate until it is about 1/4-inch (6.35 mm)
below the screed. (Figure 4-14)
Operation
NOTE: Never allow the endgate to carry the weight
of the screed to prevent uneven compaction.
Figure 4-14. Endgate Depth Screw Adjustment
7. Turn the tilt screw so the front of the endgate tilts
down slightly when the screed is lifted. This will allow
the endgate to set itself to the grade. (Figure 4-15)
4
Figure 4-15. Endgate Tilt Screw Adjustment
8. If the endgate digs into the asphalt at the front,
adjust the tilt screw until the endgate tilts back more.
9. When making a joint, the endgate must be set to
where it ts ush with bottom of screed.
10. On the rst pass, leave approximately six to eight
inches (15 - 20 cm) of unrolled asphalt where the
joint will be made.
11. When making a joint, the endgate must be set to
where it ts ush with bottom of screed.
NOTE: Keep runners clean. When making a joint,
spray solvent on the runners.
12. If the joint looks too high or too low, adjust the ight
screw on the screed one turn at a time and allow
four to ve feet (1.2 - 1.4 m) of travel to correct itself.
NOTE: Too much adjustment up or down may cause
uneven pavement.
13. If making a cold joint, set the endgate down about
1/4 inch (6.35 mm) for a nice, even edge.
LeeBoy 8616B Conveyor Paver 4-13
Page 65
1
Operation
Hopper Wings
The hopper wings are hydraulically opened so the
hopper can be lled with paving material. (Figure 4-16)
Conveyor paddles in the bottom move the asphalt back
to the auger, where the mix ows through the cut-off
gates to the screed.
To operate the hopper wings:
1. Push the hopper wings switch to OUT on the
operator control panel to fold out hopper wings.
(Page 3-6)
2. Be sure the hopper wings are completely extended
before receiving paving material from the truck.
3. Push the hopper wings switch to IN to close the
hopper wings.
DO NOT fold in the hopper wings when
the hopper is full of asphalt. DO NOT fold in the
hopper until the material truck has moved completely
away from the paver.
Conveyor
The conveyor is a very important part of the paver. Pay
close attention to integrating its operation into the total
operation of the paver. (Figure 4-16)
NOTE: Operating the conveyors in manual mode
with the augers in automatic mode is the
preferred method for paving with the LeeBoy
Model 8616B Conveyor Paver.
When operating the conveyor:
• Spray down the conveyor drive chains with cleaning
solvent or release agent several times during the
work day for optimum performance.
• If the conveyors are running while the cut-off gates
are closed, there will be spillage, which is normal.
To help prevent this spillage, work conveyors
manually when loading hopper and not paving.
• Irregular movement of the conveyor indicates that
the conveyor chains need adjustment. (Figure
4-17)
NOTE: Check conveyor chain adjustment every 100
hours. (Pages 5-7 to 5-8)
2
Figure 4-16. Hopper, Conveyor and Auger
1 - Hopper Wings
2 - Auger
3 - Conveyor
3
Conveyor
Chains
Conveyor
Paddles
Figure 4-17. Conveyor Chains and Paddles
Never leave the paver unattended
while the conveyor is operating.
To operate the conveyor:
1. On the operator control panel, turn the left and right
sonic paddle switches to the PADDLE position.
2. Slowly turn the left and right conveyor dials
clockwise until reaching desired speed.
NOTE: Start with the left and right dials set to the
mid-range position, adjusting speed as needed to
avoid overlling the auger.
LeeBoy 8616B Conveyor Paver4-14
Page 66
Cut-O
Gate
Operation
Hydraulic Cut-Off Gates
The cut-off gates are another important function of the
paver. The cut-off gates are used primarily to control
the ow of asphalt to the screed. (Figure 4-18)
Figure 4-18. Cut-Off Gate
The sonic auger sensors are most often used when
paving widths of nine to 15 feet (2.7 - 4.6 meters).
Auger
Sonic
Auger
Sensor
Cut-offs can be used to limit material ow when making
narrow passes at the beginning and ending of each
pass or pull.
NEVER backup with the cut-off gates
open. The cut-off gates are designed to break away
from cylinders when hitting a manhole or other
object when forward, but not in reverse.
• The right and left cut-off switches on the operator
control panel open and close the cut-off gates.
• Holding the switch in the OPEN positions increases
asphalt ow to the screed. Holding the switch in
the CLOSED position decreases asphalt ow to the
screed.
Sonic Auger
The sonic auger controls the amount of material owing
to the endgates, gauging the amount of paving material
in the extensions. An operator can operate the sonic
auger from either side of the paver. (Figure 4-19)
A sonic auger sensor connects from the paver to the
screed. It detects the pile height and controls the
conveyor and auger speed by regulating the hydraulic
pump output.
4
Figure 4-19. Sonic Auger Sensor
• The right and left auger dials on the screed control
box (Page 3-8) controls pile height. Turning
the dials clockwise increases pile height while
counterclockwise decreases pile height.
• When the pile height moves into the sonic range,
the auger speed will slow down proportionately
and turn off. It will turn back on when the material
level drops.
• The sonic auger sensors are not used in the
manual mode.
NOTE: Auger speed is adjusted only in the
manual mode. Conveyors can be adjusted
separately in both manual or auto modes.
LeeBoy 8616B Conveyor Paver 4-15
Page 67
Tow Point
Cylinder
Operation
Tow Point Cylinders
The tow point cylinders are an added convenience to
the operator for adjusting the depth of the screed. This
feature makes it possible to lay down an asphalt mat of
uniformly desired thickness.
A tow point cylinder gauge is located on both sides of
the LeeBoy Model 8616B Conveyor Paver. (Figure
4-20)
STARTING TO PAVE
The LeeBoy 8616B Conveyor Paver provides superior
paving for driveways, small to large parking lots,
and secondary roads. It has a production rate of
approximately 250 tons per hour.
This paver is capable of placing a mat thickness of six
inches (20 centimeters) for:
• Bituminous base.
• Binder or surface course.
• Lime or Portland cement-stabilized sub-base.
• Graded aggregate materials.
Operators should be trained to operate the various
machine components along with proper paving
techniques before operating the machine.
Before starting to pave, keep these items in mind:
• Plan the project so you pave the most narrow
passes rst (the width of the paver), leaving the
widest passes until last.
• Always pave in low range.
Figure 4-20. Tow Point Cylinder
1. Before paving, center the tow point by referring
to the screed elevation gauge on each side of the
paver. Raise or lower until the rod end is ush with
the “0” on the indicator.
2. While paving, refer to both gauges and make minor
adjustments to the screed using the tow point
adjustment or ight screw.
NOTE: Tow point cylinders will not function manually
when the machine is in the AUTO mode.
• It is the operator’s job to guide the material truck
back to the hopper and signal the driver when to
stop dumping the asphalt into the hopper.
• Use a reference guide such as a curb, gutter,
adjacent mat or string line.
• It is very important that the rst pass be straight as it
will serve as your guideline for the following passes.
• Extend the upper and lower guide bar gauges to
further assist you in paving a straight line from the
operator’s station. (Figures 4-21 and 4-22)
Upper
Guide
Bar
Figure 4-21. Upper Guide Bar Gauge
LeeBoy 8616B Conveyor Paver4-16
Page 68
Lowe
r
Guide
Bar
Figure 4-22. Lower Guide Bar Gauge
Avoid low limbs, power lines, and
other objects that can endanger crew or paver.
Components operate in both automatic and manual
mode.
The paver can operate using one side only. Material
from the opposite side cannot be augered to the
working side. It is possible to leave both cut-off gates
shut and open the endgates on the screed for paving
potholes and patching.
Operation
7. Turn the left and right auger switches AUTO, using
the dials to control the pile height at the endgate.
(Page 3-6)
8. When the material starts moving into the sonic
range, the auger speed will slow proportionately
and turn off, then turn back on when the material
level drops.
NOTE: The pile height must be set to the highest
point when the endgates are closed. When
the endgates are open, the pile height will
lower to prevent material from pushing in
front of the endgates.
9. When the material begins to discharge from under
the screed, set the screed lift switch to the FLOAT
position. (Page 3-6)
10. Begin paving, moving slowly at rst to adjust the
screed if needed.
11. Make a paving pass until the asphalt level in the
hopper is low.
NOTE: To prevent excessive handwork, set the left
Never back up with cut-off gates open.
and right conveyor sonic paddle switches
to the OFF position and set both cut-off
switches to the CLOSE position about three
feet from the end of the pull to prevent
excessive handwork.
4
Basic Paving
1. Follow the start-up procedure. (Page 4-4)
2. Position paver at the starting point for the mat.
3. Adjust screed as needed. (Page 4-12)
4. Open cut-off gates under auger. (Page 4-15)
5. Open hopper wings. (Page 4-14)
NOTE: Allow only a partial load of asphalt to enter
the hopper when rst starting to pave.
6. Turn the left and right conveyor sonic paddle
switches to the PADDLE position and set speed
using the right and left conveyor dials. The conveyor
speed can be adjusted while paving if needed.
NOTE: When in the AUTO mode, the conveyors will
operate at the selected speed but will turn on
and off when using the sonic auger. (Page
4-15)
12. Return paver back to starting position to begin the
next pull.
13. Position and set the screed endgate on the joint
side back to “0” feet, or ush with bottom of the
screed.
14. Repeat these steps as you continue to pave.
LeeBoy 8616B Conveyor Paver 4-17
Page 69
Operation
Setting the Crown
The screed can also be set to control the pavement
slope, or crown. A pavement crown is the elevation of
the middle in relation to the edges, and insures proper
drainage of the pavement.
To adjust the crown:
1. Loosen the lock-down bolts in slotted bars before
adjusting crown mechanism on the screed. (Figure
4-23)
Figure 4-23. Lock Down Bolts
2. Use the gauge located at the center of the screed
above the standing platform.
3. Set the pointer rod for the crown to “0.”
4. Place the lever at the desired number for the proper
crown. (The setting is based on a 10-foot mat.)
NOTE: Always check that proper crown is achieved
by using a string or straight edge to measure
the distance between a at, level surface to
the center bottom portion of the screed.
Figure 4-24. Crown Control Lever
5. Make adjustments using the crown control lever.
(Figure 4-24)
NOTE: The maximum crown is two inches.
NOTE: The leading edge crown is set at 0 when
shipped from the factory. The chain
connecting the leading and trailing edge
crown control assures that the relationship
of the edges remains constant as the trailing
edge is changed to meet job conditions.
• Positive crown is when the middle of the mat is
raised to permit water to drain to each side.
• Negative crown is the lower in the center of the
screed plate, often used in an alley where drainage
is necessary.
LeeBoy 8616B Conveyor Paver4-18
Page 70
Figure 4-25. Crown Settings
1 - Positive (+)
2 - Zero (0)
3 - Negative (-)
NOTE: Crown may be placed in the leading edge
and/or the trailing edge of the screed plate.
Crown in the leading edge aids material ow
under the screed plate only. Trailing edge
crown puts a crown in the mat.
Example: The trailing edge crown is 0 and the
leading edge crown is 1/8 inch. There will not be
any crown in the mat, but the material ow under the
screed plate will be improved.
Operation
Mat Texture Adjustment
The screed can be adjusted for a smoother or
coarser mat texture by using the Angle of Attack (AOA)
adjustment screw. (Figure 4-26)
There are three adjusters in each extension. The two
adjusters at each end of the screed extensions are
preset by the dealer and should not need adjustment.
You can adjust the mat texture using the AOA
adjustment screw in the center. (Figure 4-26)
To make the AOA adjustment:
1. Spray down the screed.
2. Turn on the screed heat.
3. Turn the screw in the direction for desired result:
• Turning the AOA adjuster counterclockwise
will increase the pressure on the back of the
extension, which gives a smoother, slicker
nish.
• Turning the adjusters clockwise will decrease
the pressure on the back of the extension,
resulting in a coarser nish.
NOTE: Too much pressure on the back of the
screed extension will take the weight off the
screed wearplate and cause poor material
compacting, resulting in a poor nish.
Angle-of-Attack
Adjustor
4
Figure 4-26. AOA Adjustment
LeeBoy 8616B Conveyor Paver 4-19
Page 71
Operation
UNLOADING AND LOADING
Ensure the transport trailer has the capacity to carry
the paver’s weight. Park the trailer in a clear, level area
when loading or unloading the machine.
ALWAYS position an assistant to be a
ground guide when loading and unloading the paver.
Work slowly and carefully to avoid
accidents. Keep the loading area clear.
Unloading
1. Remove tie-down equipment.
2. Start and warm up engine.
3. Set throttle at half the operating RPMs, but enough
to ensure the hydraulic pump is providing sufcient
ow to operate all functions properly.
4. Set steering control lever so paver moves very
slowly.
5. BEFORE moving the machine, ensure:
• The screed position is UP.
• Auger extensions are removed.
• The extendible screed is IN.
• The cut-off gates below the augers are
CLOSED.
6. Move paver forward down the ramp as shown on
Figure 4-27.
Never move the paver in reverse while
the cut-off gates are open.
Loading
To prevent damage to the
undercarriage and throughout the paver, reduce
traveling speed before the paver tracks come into
contact with loading ramps or any abrupt change
in the surface. The track drive sprocket or other
components can be damaged by excessive shock.
The paver must be loaded screed-end
rst to prevent damage.
1. Move paver to base of ramp. Line up tracks with the
ramp.
2. BEFORE moving the machine, ensure:
• The screed position is UP.
• Auger extensions are removed.
• The extendible screed is IN.
• The cut-off gates below the augers are
CLOSED.
3. Load the paver screed-end rst. Set throttle at half
the operating RPMs.
4. Set steering control lever so paver moves very
slowly onto the ramp.
5. Using the steering control joysticks, SLOWLY guide
paver up the ramp.
6. Position paver in center of trailer.
7. Lower the screed.
8. Shut down the engine.
9. Secure paver to transport using the following tie-
down procedures.
DO NOT allow the screed to strike the
ramp as this can damage bearings on the thickness
control screws or welds on the leveling arms. A
longer ramp to reduce the loading angle may be
needed.
Figure 4-27. Correct Unloading Position
Figure 4-28. Incorrect Loading Position
LeeBoy 8616B Conveyor Paver4-20
Page 72
Operation
Tie-Down Procedure
1. Position paver in center of the trailer. (Figure 4-29)
Figure 4-29. Paver on Transport
2. Attach tie-down chains to the front weight block
and the D-Rings in front of the torque hubs. (Figure
4-30).
3. Place chocks at wheels or tracks.
4. Ensure that all chains are tightly secured before
transporting the paver.
OPTIONAL COMPONENTS
Auger Extensions Option
The auger extensions should be attached to the main
auger to increase the ow of asphalt to the endgates
and screed extensions when paving at widths wider than
15 feet (4.6 m). This makes it possible to lay asphalt at a
higher rate.
Left and right auger extension covers
or shields must be installed on the correct side of the
machine.
To attach the auger extensions proceed as follows:
1. Identify the right and left auger extensions by
observing the left or right on the end of the auger
extension shaft.
2. After identifying the right and left auger extensions,
extend the screed extension fully as follows:
• Set the left and right auger switches to the OFF
position.
• Set the left and right extension switches to the
OUT position and extend fully.
3. Shut off engine.
4
Figure 4-30. Tie-Down D-Ring Locations
Serious injury can result when
attaching extensions if the engine is running.
4. Remove bolt, nut cap on end of main auger.
5. Attach the correct side auger extension to the main
auger with hardware just removed.
6. Secure end of extension auger to main auger.
7. Install guard. Make sure extension auger is running
at.
8. Repeat this procedure for opposite side.
LeeBoy 8616B Conveyor Paver 4-21
Page 73
Operation
Power Crown Option
The Power Crown Switch option automatically adjusts
the positive or negative crown as needed.
Figure 4-31. Power Crown Option
Umbrella Option
The umbrella kit option provides shelter from sun and
other weather conditions for the operator. The umbrella
kit assembly includes the mounting bracket and
umbrella frame assembly that can be mounted on either
side of the operator platform. (Figure 4-32)
Umbrella
Mounts
Truck Hitch Attachment Option
The truck hitch is an optional attachment thatt prevents
excessive and uneven braking from the paving material
truck. (Figure 4-33)
Figure 4-33. Truck Hitch Attachment Option
To engage the hitch with the rear wheels of the asphalt
truck:
1. Extend the arm extensions of the truck hitch by
pushing and holding theTruck Hitch button in the
OUT position.
2. The paving material truck then SLOWLY backs up to
the paver until the hitch makes contact with the rear
tires of the truck.
3. Retract the arm extension by pushing and holding
the Truck Hitch switch in the IN position until both
guide rollers are fully locked onto the truck wheel
rims.
4. It may be necessary to adjust the roller guides to the
inside of the wheel rims.
Figure 4-32. Umbrella Mount Locations
LeeBoy 8616B Conveyor Paver4-22
Page 74
Section 5
Maintenance
Page
Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Lubrication Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Torque Hub Lubrication . . . . . . . . . . . . . . . . . . . . . . . 5-5
Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Preparing Machine for Maintenance . . . . . . . . . . . . . . . . . 5-6
Every 10 Hours or Daily Routine Maintenance . . . . . . . . . . . . 5-6
Every 50 Hours or Weekly Routine Maintenance . . . . . . . . . . . 5-6
Every 100 Hour or Monthly Maintenance . . . . . . . . . . . . . . . 5-6
Every 250 Hours or Quarterly Routine Maintenance . . . . . . . . . 5-7
Every 500 Hours or Semi-Annual Routine Maintenance . . . . . . . 5-7
Every 1000 Hours or Annual Routine Maintenance . . . . . . . . . . 5-7
Maintenance Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Conveyor Flight Chain . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Conveyor Drive Chain . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Conveyor Paddle Adjustment. . . . . . . . . . . . . . . . . . . . . 5-8
Auger Drive Chain Adjustment . . . . . . . . . . . . . . . . . . . . 5-9
Screed Extension Top Guide Adjustment . . . . . . . . . . . . . . . 5-9
Track Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
High Gear Adjustment . . . . . . . . . . . . . . . . . . . . . . . . 5-11
Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
Battery Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
Generator Voltage Testing . . . . . . . . . . . . . . . . . . . . . . 5-13
Generator Capacitor Replacement . . . . . . . . . . . . . . . . . . 5-14
LeeBoy 8616B Conveyor Paver
5-1
Page 75
Screed Electric Heat Elements . . . . . . . . . . . . . . . . . . . . 5-14
Element Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15
Element Resistance Testing . . . . . . . . . . . . . . . . . . . . . 5-16
Heating Elements . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
Engine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
Check Engine Lubrication Oil . . . . . . . . . . . . . . . . . . . . 5-17
Change Engine Oil and Filter . . . . . . . . . . . . . . . . . . . . . 5-17
Change Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
Change Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
Check Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
Change Hydraulic Oil and Filter . . . . . . . . . . . . . . . . . . . 5-20
Change Hydraulic Oil Strainer . . . . . . . . . . . . . . . . . . . . 5-21
Replacement
2-Speed Motor Replacement . . . . . . . . . . . . . . . . . . . . 5-21
Drive Torque Hub Replacement . . . . . . . . . . . . . . . . . . . 5-22
Track Sprocket Replacement . . . . . . . . . . . . . . . . . . . . 5-22
Front Idler and Bushing . . . . . . . . . . . . . . . . . . . . . . . 5-23
Rear Conveyor Shaft, Bearings and Sprockets . . . . . . . . . . . . 5-23
Conveyor Wear Plates . . . . . . . . . . . . . . . . . . . . . . . . 5-24
Conveyor Drive Motors. . . . . . . . . . . . . . . . . . . . . . . . 5-25
Cut-Off Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25
Auger And Inner Bearing . . . . . . . . . . . . . . . . . . . . . . . 5-25
Replacing Auger Motors . . . . . . . . . . . . . . . . . . . . . . . 5-26
Rear Hopper Wing Cylinders . . . . . . . . . . . . . . . . . . . . . 5-27
Front Hopper Wing Cylinders . . . . . . . . . . . . . . . . . . . . 5-27
Pumps and Hood . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28
Screed Extension Wear Plates . . . . . . . . . . . . . . . . . . . . 5-28
Weldment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29
Procedures . . . . . . . . . . . . . . . . . . . . . . . . . 5-21
Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30
DP700 Diagnostic Trouble Code (DTC) Chart . . . . . . . . . . . . . . .5-33
LeeBoy 8616B Conveyor Paver5-2
Page 76
MAINTENANCE SCHEDULE
Before performing any maintenance procedures on the
LeeBoy Model 8616B Conveyor Paver, review the safety
information in Section 2.
Always use the appropriate and
correct sized tools for the task at hand to prevent
damage or possible injury.
Always wear heat-resistant gloves
when handing hot components.
Following the maintenance schedules and procedures
will maintain the paver in top operating condition and
provide years of trouble-free operation. Refer to the
Table 5-1. Periodic Maintenance Schedule
SYSTEM ITEM
Paver Lubricate paver. X
Check oil level. X
Check coolant level. X
Engine Operator’s Manual accompanying your paver for
more detailed engine service information.
When performing any routine maintenance, always
include the previous routine maintenance hours in the
higher hourly schedule.
NOTE: For convenience there is an oil drain hose
located inside of the right-hand door on the
paver.
Changing oil and cleaning the paver
should only be done in a designated area where
the oil and chemicals can be contained. These byproducts should be discarded in accordance with
environmental regulations.
Daily
Every 10 Hours
Weekly
Every 50 Hours
Monthly
Every 100 Hours
Quarterly
Every 250 Hours
Semi-Annually
Every 500 Hours
Every 1000
Hours Annually
Engine
Hydraulic
Mechanical
Replace coolant. X
Check air lter. X
Change air lters. X
Replace fuel lter. X
Change oil and oil lter. (Initial 50 Hours) X
Check main engine belt. X
Check hydraulic oil level. X
Change hydraulic oil. X
Change hydraulic lter. X
Check torque hub oil. X
Change torque hub oil. X
Drain hydraulic tank. Replace strainer. X
Adjust conveyor drive chains. X
Adjust conveyor ight chains. X
Adjust auger chains. X
Adjust screed extension top guide. X
5
LeeBoy 8616B Conveyor Paver 5-3
Page 77
LUBRICATION POINTS
14
10
13
9
8
11
5
11
1
2
7
3
Figure 5-1. Lubrication Points
6
4
12
10
LeeBoy 8616B Conveyor Paver5-4
Page 78
Table 5-2. Lubrication Points Schedule
Torque Hub
Plugs
TYPE
ITEM
NO.
1 B Conveyor chains and between track pads. Weekly
2 A Tilt screws. Weekly
3 A
4 A Screed pivot. Weekly
5 A Slope cylinder pivot. Weekly
6 A All screws on screed extension and bearing. Weekly
7 A Extension slides. Weekly
8 B Cut-off pivot at augers. Daily
9 A Grease auger tting on end mount. Daily
10 B Conveyor and auger. Daily
11 B Auger chains. Daily
12 A Main ight screw components. Weekly
13 A Rear auger bearings. Quarterly
14 B Front and rear conveyor idler and drive tubes. Monthly
LUBE
A Grease With Shell Avania EP Grease 2 or Equivalent
B Spray with Release or Chain Lube Agent
Depth Screw. First grease in lock position, then unlock, turn 180° and grease
again).
DESCRIPTION AND LOCATION
INTERVAL
Weekly
Torque Hub Lubrication
1. Position the torque hub so that either of the plugs
are at the 3 o’clock position. (Figure 5-2)
2. Remove the plug at the 3 o’clock position rst. If oil
comes out, no oil is needed. Insert plug and tighten.
3. If oil does not come out, remove the plug at the 12
o’clock position and ll torque hub with 80W-90
gear oil until oil starts to appear at the other hole.
4. Replace both plugs and repeat process on other
torque hub.
5
Figure 5-2. Torque Hub Plugs
LeeBoy 8616B Conveyor Paver 5-5
Page 79
ROUTINE MAINTENANCE
Preparing Machine for Maintenance
1. Park the paver on a at surface.
2. Lower all attachments to ground level.
3. Place joysticks in neutral.
4. Run engine at 1/2 speed (RPMs) without load for
three to ve minutes.
5. Reduce engine speed (RPMs) to slow idle.
6. Place ignition switch in the OFF position.
If any maintenance must be
performed while the engine is running, DO NOT leave
paver unattended.
Every 10 Hours or Daily Routine Maintenance
1. Scrape off paving material and spray cleaning
solvent or release agent on the wearplate,
extensions, and any other area that has been in
contact with the paving material. Cleaning should
be performed while the paver is hot.
2. Remove any debris from screed and check for
leaks.
3. Lubricate the required parts. (Pages 5-4 and 5-5)
4. Check light bulbs and replace if needed.
5. Check battery cables and connections.
6. Check coolant level. Fill if needed.
7. Check for loose, worn or damaged hoses, tubes
clamps. Tighten, repair or replace promptly.
Every 50 Hours or Weekly Routine Maintenance
1. Check air lter. (Page 5-18)
2. The FIRST 50 HOURS, change engine oil and lters,
then every 250 hours thereafter. (Page 5-17)
3. Check all battery connections and remove any
corrosion present.
4. Check torque hub oil level. Relle if needed. (Page
5-5)
5. Lubricate grease ttings on the ight screw on both
sides of the screed, the tting on the depth screw,
and the ttings on the ange bearings located on top
of the extension screed. Grease nuts on extension
screws. (Pages 5-4 and 5-5)
6. Perform previous routine maintenance and any
other engine preventive maintenance described in
the Engine Operator’s Manual.
Every 100 Hour or Monthly Maintenance
1. Check main engine belt. Replace if needed.
2. Check and adjust conveyor drive chains. (Page
5-8)
3. Check and adjust conveyor ight chains. (Page 5-7)
4. Check auger drive chains, lubricate and adjust.
(Page 5-9)
5. Check and adjust screed extension top guide.
(Page 5-9)
6. Perform previous routine maintenance and any
other engine preventive maintenance described in
the Engine Operator’s Manual.
8. Keep the fuel tank full to prevent condensation.
Always ll at the end of the day.
9. Check engine oil level. (Page 5-17)
10. Check hydraulic oil level. (Page 5-19)
11. Perform any other engine preventive maintenance
described in the Engine Operator’s Manual.
LeeBoy 8616B Conveyor Paver5-6
Page 80
Every 250 Hours or Quarterly Routine Maintenance
1. Replace fuel lter. (Page 5-19)
2. Change engine oil and lter. (Page 5-17)
3. Change the hydraulic oil and charge lter. (Page
5-20)
4. Perform previous routine maintenance and any
other engine preventive maintenance described in
the Engine Operator’s Manual.
Every 500 Hours or Semi-Annual Routine Maintenance
1. Replace coolant.
2. Change air lter and replace if needed. (Page 5-18)
3. Change torque hub oil. (Page 5-5)
4. Perform previous routine maintenance and any
other engine preventive maintenance described in
the Engine Operator’s Manual.
MAINTENANCE ADJUSTMENTS
Certain components of the paver need adjustments
for optimum performance, operation and general
maintenance.
Conveyor Flight Chain
The conveyor ight chains must be adjusted every 100
hours. If irregular movement of the conveyor occurs, an
adjustment is needed regardless of the time interval.
Every 1000 Hours or Annual Routine Maintenance
1. Replace strainers in the hydraulic tank. (Page 5-21)
2. Perform previous routine maintenance and any
other engine preventive maintenance described in
the Engine Operator’s Manual.
Adjustment Bolts
Figure 5-3 Conveyor Flight Chain Adjustment
Use the following procedure to make this adjustment on
both sides of the conveyor:
1. Move front of paver onto a ramp.
2. Loosen the jam nuts in front of the adjustment bolts.
(Figure 5-3)
3. Turn each adjustment bolt alternately the same
amount. For example, turn one bolt one half turn,
then the other bolt one half turn, etc.
4. Continue alternating tightening until the ight
chains are tight. (The pressure on the chain will be
noticeable as the bolts are tightened.)
NOTE: Drag chains should be 1/2-inch away from
rear frame channel.
5. After the conveyor chain tension is set, retighten
locknuts and bolts holding the ight chain assembly.
6. Repeat steps 1 through 4 for the opposite side.
7. Grease front and rear conveyor tubes at grease
blocks on each side of conveyor.
5
LeeBoy 8616B Conveyor Paver 5-7
Page 81
1 2 3
Keep conveyor ight chain properly
oiled with cleaning solvent or release agent during
cold weather to keep conveyors functioning
smoothly.
Conveyor Drive Chain
Keep chains clean, lubricated. and properly adjusted.
Inspect both drive chains at the rear track. If the chains
are loose, adjustment is necessary.
NEVER perform any adjustments on
the paver while the engine is running.
1. Shut off paver.
2. Loosen the jam nuts on the chain adjuster. (Figure
5-4)
3. Turn the chain adjuster to loosen or tighten the
chain, leaving approximately 1/4-inch of slack. DO
NOT overtighten.
4. Retighten jam nuts.
5. Repeat steps on the opposite conveyor drive chain.
Conveyor Paddle Adjustment
The conveyor paddle must be adjusted on both sides of
the paver using the following procedure:
1. Loosen conveyor paddle bolt. (Paddle will rest
against conveyor paddle stop.) (Figure 5-5)
2. Turn limit switch shaft counterclockwise until
conveyor stops.
3. Turn limit switch shaft clockwise until conveyors
begin operating again, then turn switch 1/16-inch
(1.59 mm).
4. Tighten conveyor paddle bolt.
5. When adjusted correctly, the paddle should be
approximately six (6) inches (15.24 cm) from the top
of the tubing where the limit switch is mounted to
the lowest edge of conveyor paddle. This shuts the
conveyor off.
6. Repeat on the opposite side.
1
2
3
Figure 5-4. Conveyor Drive Chain Bolts
1 - Chain Adjuster
2 - Jam Nuts
3 - Conveyor Drive Chain
4
5
6
6
Inches
Figure 5-5. Conveyor Paddle Adjustment
1 - Limit Switch
2 - Limit Switch Shaft
3 - Paddle Linkage
4 - Tubing
5 - Conveyor Paddle
6 - Chain Stop
LeeBoy 8616B Conveyor Paver5-8
Page 82
Auger Drive Chain Adjustment
The auger chains should be snug, not loose. If the
chains need to be tightened, follow this procedure:
1. Loosen the motor bolts on the right and left auger
chains. (Figure 5-6)
2. Loosen jam nuts and turn the tension adjusters
counterclockwise to tighten chains.
3. Once adjusted, retighten motor bolts and jam nuts.
1
2,3
Screed Extension Top Guide Adjustment
1. Set left and right screed extension switches to the
OUT position.
2. Slightly loosen the top guide and hold-down bolts.
(Figure 5-7)
3. Push guide down against the slide and tighten allen
screws until snug.
4. Using a jack, raise extension up until it ts the
bottom guide level.
5. Adjust top guide to allow for .008-inch clearance
across top guide.
6. Grease slide with multipurpose grease.
7. Retighten the hold-down bolts, securing guides to
1
specication.
8. Adjust allen screws until proper setting is achieved.
9. Tighten hold-down bolts to 90 ft. lbs.
10. Check operation and adjust if needed.
1
Figure 5-6. Conveyor Drive Chain Bolts
1 - Motor Bolts
2 - Jam Nuts
3 - Tension Adjuster
2
5
3
Figure 5-7. Screed Extension Top Guide Adjustment
1 - Screed Extension Top Guide
2 - Allen Screws
3 - Hold-Down Bolts
LeeBoy 8616B Conveyor Paver 5-9
Page 83
2
e
Track Tension
The hydraulic adjustment cylinders are automatic and
provide even tension on the tracks to prevent excessive
wear to the paver’s undercarraige.
This feature requires the operator to maintain at least
a three-quarter throttle setting when backing with a
loaded hopper to maintain the proper track adjustment.
Failure to maintain adequate throttle
setting can result in poor performance or damage to
the machine.
Track tension is controlled by a load-sense pump that
operates all cylinders. The track tension is set on the
main manifold located at the hopper end of the electrical
valve manifold.
Pressure Check
The track hydraulic pressure is set at 1200 PSI at the
track tension main manifold.
Too much track tension pressure
will cause premature wear on the chains, idler and
sprockets.
3. If adjustment is needed, locate the pressure-
reducing valve on left side of main manifold. (Figure
5-8)
4. Remove valve cap with an allen wrench.
5. Adjust the pressure-reducing valve clockwise for
more tension or counterclockwise for less tension.
Track Pressure Relief
Relieving track tension pressure is set to 2300 PSI. The
pressure-relief valve is located on opposite side of the
main manifold. (Figure 5-9)
Pressur
Relief
Valve
To check pressure:
1. Connect a 3000 PSI gauge to the gauge port on the
manifold.
2. Start engine, setting engine to 1400 RPM and
observe gauge. Pressure should read 1200 PSI.
Figure 5-8. Main Manifold
1 - Gauge Port
2 - Pressure-Reducing Valve
Figure 5-9. Main Manifold
1. Remove valve cap with an allen wrench.
2. Adjust the pressure-relief valve clockwise for more
tension or counterclockwise for less tension.
1
valve adjuster below 1200 PSI or all pressure will be
lost to the hydraulic tank, causing a heat problem.
function to reach the 1200 PSI level.
DO NOT screw the pressure-relief
You will need to “deadhead” a cylinder
LeeBoy 8616B Conveyor Paver5-10
Page 84
High Gear Adjustment
This adjustment should only be
performed by an authorized LeeBoy dealer. Work
not performed by an authorized dealer can damage
machine and void the warranty.
Your authorized LeeBoy dealer will perform the tracking
adjustment on the high side gear by adjusting the
screw on the underside of the hydraulic motor. This
adjustment on the motor for the fast track must be
screwed in to equalize track speed.
Your LeeBoy dealer will perform the following
procedures:
1. With paver running, push the 2-Speed switch to the
ON position, activating high gear.
2. Adjust screw on bottom of hydraulic motor until you
feel back pressure on the adjustment screw. This
indicates adjustment is close.
3. Finalize adjustment by making a one-quarter
(1/4) turn at a time until the correct adjustment is
accomplished.
NOTE: If hydraulic motor has not been previously set,
ten revolutions of the adjustment screw may be
required before noticing any difference in travel.
ELECTRICAL SYSTEM
The electrical system is a 12-volt negative ground
system. Connect the positive (+) cable to the positive
(+) post of the battery. Connect the ground cable to
the negative (-) post of the battery. It is advisable to
disconnect the negative (-) cable rst and connect it last.
Reversed polarity can damage the electrical system.
Fire and Explosion Hazard! Always
observe battery polarity when connecting a battery
charger or jumper cables to the battery: negative (-)
to negative (-), positive (+) to positive (+). Failure to
do so can produce sparks.
When connecting a booster battery, connect one end
of the rst jumper cable to the positive (+) terminal of
the dead battery and the other end to the positive (+)
terminal of the booster battery. Connect one end of the
second jumper cable to the negative (-) terminal of the
booster battery and the other end to the frame of the
paver with the dead battery.
Fire and Explosion Hazard! Be sure
that the battery charger is in the OFF position before
connecting it to the battery.
Be sure to keep the battery fully charged during cold
weather to keep it from freezing. Freezing weather has
little effect on a fully-charged battery.
Battery
5
Figure 5-10. Battery Location
LeeBoy 8616B Conveyor Paver 5-11
Page 85
Battery Servicing
Batteries contain sulfuric acid.
ALWAYS wear safety goggles and protective clothing
when servicing the battery.
NEVER allow battery uid to come into
contact with clothing, skin or eyes. If battery uid
contacts the eyes or skin, immediately ush with
clean water and obtain prompt medical treatment.
Keep sparks and ames away from the
batteries as electrolyte gas is highly ammable.
1. Open cover on left side of the paver to access
battery.
NOTE: When replacing the battery, discard the old
battery properly.
2. Before connecting the batteries, turn off the master
switch, located under the operator control panel.
(Figure 5-11)
ALWAYS turn the master battery
switch off when working on the electrical system
or welding anywhere on the machine. Damage to
electrical components could result.
ALWAYS turn the battery disconnect
switch to the OFF position when nished operating
the paver. This will eliminate the possibility of a
battery or cable short that could cause a re.
Alternator
The alternator supplies electrical power to electronic
controls and charges the battery. Its built-in regulator
controls voltage output. (Figure 5-12)
Alternator
Battery
Disconnect
Switch
Figure 5-11. Battery Master Switch
3. Be certain that battery terminals and posts are clean
and that the battery cable terminals are tight.
Dirty or loose battery connections can
create high electrical resistance and permit arcing.
4. If corrosion is present around terminal connections,
remove and wash with ammonia or a solution of
1/4-pound (0.11 kg) baking soda added to one quart
of warm water. Ensure the vent caps are tight to
prevent solution from entering the cells.
5. Pour clean water over the battery and surrounding
area to rinse away the solution.
6. Check vent cap breather openings to ensure they
are clear.
Figure 5-12. Alternator
Use the following precautions to prevent damage to the
alternator or regulator:
• Never polarize the alternator.
• Never ground any alternator terminals or circuits.
• Always disconnect the battery before disconnecting
or connecting the alternator.
• Never disconnect the alternator while machine is
operating.
• Ensure wiring is properly connected before
connecting the battery.
• Always connect a booster battery in the proper
polarity: negative (-) to negative (-) and positive (+) to
positive (+).
LeeBoy 8616B Conveyor Paver5-12
Page 86
Generator Voltage Testing
The generator is hydraulically-driven. When the paver
engine is at 1600 RPMs and the hydraulic system is at
normal operating temperature, the generator should
produce between 220 VAC and 240 VAC.
The generator voltage depends upon speed (RPMs),
increasing voltage as RPMs increase and decreasing
voltage as RPMs decrease. The voltage will decrease
signicantly if the generator speed is slower than 3480
RPMs.
NOTE: When testing the generator voltage ensure the
paver engine is at 1600 rpm and the hydraulic
temperature is at normal operating levels.
To test the generator voltage:
1. Use volt meter to measure between the two main
input wires L-1 (black wire) and L-2 (white wire).
(Figure 5-13)
2. If you measure from L-1 to the frame of the paver, or
ground, the voltage will be half the rated output of
the generator. The voltage should be the same as
measured at the control box.
Generator Speed Tuning
This adjustment should only be
performed by an authorized LeeBoy dealer. Work
not performed by an authorized dealer can damage
machine and void the warranty.
A voltmeter set to read frequency (Hz) can be used to
test generator speed. When the engine is running at
1600 RPMs, the generator should operate at 58 to 62
Hz, or a speed of 3480 to 3720 RPMs. If the generator
speed drops below 3480 RPMs, the voltage output
and performance of the heating system will decrease
signicantly.
The generator should never be
operated at a speed of 3800 RPMs or greater.
Generator damage will occur and void your warranty.
Your authorized LeeBoy dealer will perform the
following procedure:
1. Remove back panel from generator housing to
access the rear of the generator.
2. Set voltmeter to read frequency (Hz), to measure
between the two main input wires L1 and L2. (Figure
5-12) A photo tachometer may also be used to
check the speed of the generator at the motor
coupling by removing the motor coupling shield.
Figure 5-13. Generator
If the voltage is lower, make certain the generator is
turning the correct speed by testing with a Hz meter or
photo tachometer.
NOTE: When testing the generator speed, make
certain that the paver engine is at 1600 rpm
and the hydraulic temperature is at normal
operating levels.
3. Note that 60 Hz is exactly 3600 RPMs. For every
Hz above 60, an increase of 60 RPMs can be added
to 3600 RPMs. For every Hz below 60, a decrease
of 60 RPMs can be subtracted from 3600 RPMs.
Example: 60 Hz is 3600 RPMs. A reading of 62 Hz
would be 3720 RPMs. A reading of 58 Hz would be
3480 RPMs.
Always replace shields and panels
when nished testing.
5
LeeBoy 8616B Conveyor Paver 5-13
Page 87
Flow Control Adjuster
Generator Capacitor Replacement
There are no other voltage adjustments that can be
made to the generator.
The capacitor controls and regulates voltage while the
machine operates. If the capacitor fails, the voltage will
drop below or no output at all. (Figure 5-13)
If experiencing a drop in voltage, replacing the capacitor
will help determine if the capacitor is at fault.
To perform this procedure:
Figure 5-14. Generator Flow Control Adjuster
Adjusting the ow-control adjuster on the front of the
manifold controls speed of the generator. (Figure 5-14)
NOTE: The integrated ow-control manifold is pre-
set and will maintain the generator at it’s
proper speed if the correct amount of oil is
supplied to the set. If the temperature of the
hydraulic system rises above 160°F, some
slippage may occur through the gear set of
the generator motor, and the generator may
slow slightly.
Improper adjusting will overspeed and
cause damage to the generator.
To perform this adjustment:
• Locate the Flow Control Adjuster and turn to increase
or decrease the speed as needed.
• Turning clockwise will decrease the generator speed.
Turning counterclockwise will increase the generator
speed.
If the generator will not operate at the correct speed,
test the hydraulic ow from the pump or check the
generator motor for excessive case drain ow. The
case drain should not leak more than one gallon per
minute. Replace the generator motor or paver pump if
either are operating incorrectly.
1. Shut down the machine.
2. Detach the wires on top of the capacitor.
3. Remove the capacitor and replace with new one.
4. Reattach wires.
Screed Electric Heat Elements
The electric heat control box contains the element
breakers and main outputs for the screed heating
system. Powered by 220VAC and 240VAC, each
element has two breakers. (Figure 5-15)
The control box consists of three major types of
components:
• The system timer is located in the upper left hand
corner of the box.
• The element relays are located in the upper right hand
corner of the box.
• The element breakers are located in the lower surface
of the box.
The other block in the center is used as a wire junction
block only. Refer to the wiring schematic at the end
of this manual, and you will note how the following
connections are made.
NOTE: Control boxes are manufactured to t all
screed and paver combinations. If not all
plugs are connected to wires, it may be
normal. Be sure to keep open plugs with the
plug terminator(s).
LeeBoy 8616B Conveyor Paver5-14
Page 88
When the HEAT ON button is depressed, 12VDC is
5
1
momentarily applied to this terminal to start the timer
cycle. During the timer cycle, power will not be applied
to this terminal unless the HEAT ON button is depressed
again.
6
2
3
4
Figure 5-15. Electric Heat Elements
1 - Timer
2 - L-1 Circuit Breakers
3 - Power On Toggle
4 - Heat On Button
5 - Wire Junction Block
6 - L-2 Circuit Breaker
Any element lead can be plugged into any supply plug
under the heating control/distribution box. All six plugs
are equally rated.
• Each element output consists of two wires--one
connects to the L-1 circuit and the other to the L-2
circuit.
• Each breaker has two terminals--one is connected
to the main input and the other terminal to an element
output wire.
• The L-1 circuit is the left bank of element breakers.
• The L-2 circuit is the right bank of element breakers
and wired slightly different. Each leg goes from the
main L-2 power lead through a breaker, then through
one of the six contacts on the element relays.
It is these relays that “make” or “break” the circuit to
each element to start or stop the heating cycles.
There are six terminals on the timer:
• The top two left terminals are the main 12VDC input
terminals.
• The ground is on the left.
• The power is on the right.
• The top right terminal is the common terminal to the
internal timer relay that controls the heat system.
When power is applied to the input terminal, it is also
jumped to the common (or COM) terminal on the timer.
• The lower right two terminals on the timer are the
outputs of the internal timer relay.
Element Relays
There are three relays in the control box. Each relay has
two separate sets of contacts operated by one coil.
One set of contacts are the two terminals at the top left
of the relay, and the other set is at the bottom left. When
the coil is energized, both sets of contacts will close.
The element relays are 12-volt, DC-controlled with dual
contacts rated for 240VAC.
To test the relays, perform the following procedure:
1. Disconnect any wires to the relay, or completely
remove it from the control box. (Figure 5-15).
2. Place the leads of an ohm meter or continuity tester
across the contact terminals (2 - 4) or (6 - 8).
NOTE: Without 12VDC applied to the coil of the
relay, the contact terminals should have
no continuity through them (open). If you
do not have 12VDC applied to the coil and
the contacts are closed, your contacts are
incorrect and the relay should be replaced.
3. With the ohm meter still on the contact terminals,
apply 12VDC to the coil terminals of the relay.
4. The contact terminals should now close and show a
path for power to the electrical elements. If not, the
relay needs to be replaced.
5
LeeBoy 8616B Conveyor Paver 5-15
Page 89
Element Resistance Testing
The breakers are wired into each leg of each element.
If an element has a fault, either in the wiring, or in the
element itself, the breaker will trip and power will no
longer be applied to that leg of the element.
When a breaker in the control box has “tripped,” there
may be a problem in the wiring or an element in the
circuit.
The breakers can be manually reset by depressing the
trip button back into place when they are extended. If
the breaker still does not reset, you need to test or
possibly replace an element.
If the element is functioning correctly, you should read
a resistance between 25 and 35 ohms when testing. A
faulty element will read “open” or show little resistance
(less than one ohm), indicating a shortage through the
element.
To test the element:
1. Disconnect elements one at a time from the
connection point on the lower side of the control
box.
2. Using an ohm meter, test the resistance through the
element between the two pins in the plug.
NOTE: You do not have to test the plug attached to
the lower side of the control box.
3. Before replugging the element, check each wire
pin with an ohm meter test lead, placing the lead
on a steel section of the screed frame. If there is
any continuity through the element to the frame, the
element must be replaced.
Heating Elements
Each element is sized to t properly and provide
sufcient power to heat your screed plate to a
temperature that prevents mix from sticking to the lower
surface of the screed plate.
An element assembly consists of four main components:
• The element.
• The wire protector adapter.
• The wire protector.
• The two-pin wire plug at the end of the element
protector.
Each element is covered by a thin strip of insulation
to keep heat from escaping. A support bar and shield
protects the element assembly.
Each element is clamped onto the screed plate to
provide a positive and efcient connection. Enough
pressure should be applied to the element assembly
to sufciently hold it securely against the screed plate
surface.
To remove an element:
4. Remove top cover from the extension screed plate.
5. Loosen all the clamping studs over the element.
6. Remove and replace element.
7. After tightening the clamping stud, lock the clamp by
tightening the stud jam nut.
DO NOT operate an element with a
known shortage. Replace faulty elements and wiring
immediately.
LeeBoy 8616B Conveyor Paver5-16
Page 90
ENGINE MAINTENANCE
These general maintenance procedures are most often
required for the engine. Refer to the Engine Operator’s
Manual for more specic maintenance information and
procedures.
Check Engine Lubrication Oil
The engine lubrication oil must be kept at a level above
the ADD mark, but not above the FULL mark, on the
engine lubrication oil dipstick.
DO NOT check the oil while the
engine running. Hot oil can spew and cause serious
personal injury.
Filter
Change Engine Oil and Filter
The engine lubrication oil and oil lter must be changed
at the same time.
To change the engine lubrication oil:
1. Park the paver on a level surface and turn off the
engine.
Change the engine lubrication oil
while the engine is WARM, not hot. Hot oil can cause
serious personal injury.
2. If needed, wait until the engine lubrication oil has
cooled a little. Oil should be warm, not hot.
3. Locate oil drain hose on right side of the engine.
4. Place a container large enough to hold 14 quarts
(13.24 liters) of oil underneath the drain hose.
5. Remove cap on end of the hose and drain all engine
oil into the container.
6. Reinstall cap back onto the hose and reinsert hose
back into place.
7. Fill the engine with 14 quarts (13.24 liters) of oil at the
oil ll cap.
Dipstick
Figure 5-16. Engine Oil Dipstick and Oil Filter
To check the engine lubrication oil level:
1. Park the machine on a level surface and turn off the
engine.
2. Wait ve minutes to allow the oil to return to the oil
pan so you can obtain an accurate measurement of
the engine oil level.
3. Clean the area around the engine oil dipstick before
removing it from the engine. (Figure 5-16)
4. Remove the dipstick from the engine and checking
the oil level. The oil level should be above the
ADD mark--but not above the FULL mark--on the
dipstick.
8. Check oil level using the oil dipstick.
9. Dispose of used oil in accordance with local and
federal environmental laws.
DO NOT change the engine lubrication
oil lter while the engine is running. Serious engine
damage will occur.
Use the following procedures to change the oil lter:
1. Wipe the area around the oil lter and its mounting
base with a clean cloth.
2. Place the empty container under the lter element.
3. Use a lter removal wrench to remove the lter,
turning counterclockwise.
4. Drain and discard the oil lter in accordance with
Step 9 above..
NOTE: Discard the used rubber gasket with the lter
element.
5. Wipe inside the oil lter head using a clean, lint-free
cloth.
6. Rub a little oil on the rubber gasket area of the new
lter element.
5
5. Add oil if needed.
LeeBoy 8616B Conveyor Paver 5-17
7. Fill the new lter with fresh oil.
8. Install the new lter element onto the lter head.
Carefully tighten the lter (by hand only).
Page 91
Change Air Filter
Never operate the engine without an
air lter installed. Severe damage to the machine will
occur.
Air
Filter
Cover
Figure 5-17. Air Filter Cover
FUEL SYSTEM
Fuel Tank
The fuel level is indicated on the digital display fuel
gauge. Use only diesel fuel and always ll the fuel tank
full.
Fill up with diesel fuel at the end of the
day to reduce condensation in the tank.
Diesel fuel is highly FLAMMABLE.
DO NOT smoke while lling the fuel tank. Fill the
fuel tank in a designated area that provides proper
ventilation with a re extinguisher available.
Explosion Hazard! Never ll the fuel
tank near an open ame, or near equipment that can
create sparks. Never check fuel level or fuel system
components near an open ame.
Fuel
Cap
To change the air lter elements:
1. Unclamp and remove air lter cover. (Figure 5-17)
2. Remove the primary and secondary air lter
elements. Discard.
3. Clean the inside of the air cleaner body with a clean
cloth.
4. Install new air lter elements inside the canister.
5. Reclamp cap onto the air lter cover.
6. Check clamps to ensure lter elements are tight and
lter elements are making proper contact.
7. Start engine. If engine does not run smoothly,
recheck lter element contact.
Figure 5-18. Fuel Cap
To ll the fuel tank:
1. Stop engine.
2. Remove fuel cap from fuel tank.
3. Fill with diesel fuel until full.
4. Replace fuel cap.
LeeBoy 8616B Conveyor Paver5-18
Page 92
Change Fuel Filter
DO NOT change the fuel lter while
the engine is running.
DO NOT smoke or change fuel
lter near open ames as diesel fuel is highly
combustible. Be careful not to spill fuel.
Fuel Filter
Figure 5-19. Fuel Filter
HYDRAULIC SYSTEM
Check Hydraulic Oil
The hydraulic motors and hydraulic cylinders use the
same hydraulic oil reservoir and hydraulic oil supply.
Take care when working with the
hydraulic system to ensure it is completely clean.
Never allow the hydraulic oil level to
fall too low. Pump damage will occur.
Check the hydraulic reservoir oil level daily using the
sight gauge on the left side of the paver. (Figure 5-20)
Check the hydraulic oil level when the hydraulic oil is at
normal operating temperature for an accurate reading.
If the hydraulic oil level falls below the black line, add
more hydraulic oil.
Hydraulic Oil
Level Line
Replace the fuel lter using the following general
procedure.
1. Stop the engine and allow it to cool.
2. Put a container under the lter before removing it.
3. Wipe the area around the fuel lter and mounting
head using a clean, lint-free cloth.
4. Use a lter removal wrench to loosen and remove
the lter by turning it clockwise. (Figure 5-19)
5. Drain and discard the removed lter in compliance
with local and federal environmental laws..
6. Wipe inside the lter head with a clean, lint-free
cloth.
7. Fill the new fuel lter element with the diesel fuel.
8. Wipe a little fuel on the rubber gasket.
9. Install the new fuel lter element onto the lter head,
carefully tightening the element by hand.
Tighten the fuel lter as directed on by
the lter manufacturer. DO NOT overtighten the fuel
lter element onto the lter head.
10. Start the engine and check for any fuel leaks.
Explosion Hazard! Stop the engine
immediately if any fuel leakage is noted. DO NOT
start the engine until the leak has been corrected.
5
Figure 5-20. Hydraulic Oil Sight Gauge
DO NOT loosen or remove the
hydraulic oil strainer ll cap when the hydraulic oil
is hot. Always loosen the cap slowly to relieve any
pressure in the hydraulic oil reservoir.
LeeBoy 8616B Conveyor Paver 5-19
Page 93
Strainer Filter Gauge
Wing Nuts
Figure 5-21. Hydraulic Oil Strainer Fill Cap
• Slowly unscrew the three wing nuts to remove the
hydraulic oil strainer ll cap and add hydraulic oil,
replacing the wing nuts after lling the tank. (Figure
5-21)
• DO NOT use unltered hydraulic oil.
• Check the hydraulic oil level using the sight gauge.
(Figure 5-20)
• Keep the hydraulic oil lled to the correct level.
Use the following procedures to change the hydraulic
oil:
1. Stop the engine.
2. Allow the hydraulic oil to cool until it is at a warm
temperature.
3. Slowly remove the hydraulic oil strainer ll cap. Do
not remove the strainer portion under the cap.
4. Place a clean, lint-free cloth over the reservoir ll
tube opening and secure in place with tape.
5. Place a container sufcient to hold the hydraulic oil
as it drains from the drain hose by the access panel
on the right side of machine (close enough for the
drain hose to reach).
6. Carefully remove the plugs from the hydraulic drain
hose and open the valve over the container.
7. Allow all the hydraulic oil to drain from the hydraulic
tank into the container.
8. Reinstall the hydraulic oil drain plug on the drain
hose and tighten securely. Close valve.
9. Change the hydraulic oil lter by turning lter
counterclockwise, then replace with new lter
turning clockwise until snug (by hand only). (Figure
5-22)
DO NOT overll the hydraulic oil
reservoir.
Leeboy uses a lead-detection dye that
may turn the hydraulic oil a slight yellow tint.
Change Hydraulic Oil and Filter
Changing the hydraulic oil removes the accumulation
of dirt, water and mechanical wear particles from the
hydraulic oil system. Clean, ltered oil is critical to
optimize hydraulic system operation. The hydraulic oil
system holds approximately 41 gallons.
Contaminated hydraulic oil can
shorten the expected service life of components in
the hydraulic system.
is hot. Hot hydraulic oil can cause serious personal
injury.
safety glasses when working on hydraulic system
components.
DO NOT drain the hydraulic oil when it
Protect your eyes by wearing
Hydraulic
Charge
Filter
Figure 5-22. Hydraulic Oil Filter
10. Carefully remove the cloth from the hydraulic oil
reservoir ll tube opening.
11. Remove the strainer. Replace if necessary. (Page
5-21)
LeeBoy 8616B Conveyor Paver5-20
Page 94
DO NOT ll the hydraulic oil reservoir
with new hydraulic oil until the strainer inside the ll
cap has been serviced.
12. Fill the hydraulic oil tank with ltered hydraulic oil.
The cold oil level should be about 1/2-inch below the
ll level black line on the sight gauge. (Figure 5-20)
13. Reinstall the hydraulic oil strainer ller cap and
tighten the three wingnuts securely.
14. Start the engine and check the hydraulic system for
possible leaks.
DO NOT use your hands on any
hydraulic hoses, ttings or system component when
checking for leaks. Serious personal injury can
result from an oil leak under high pressure. Oil can
be injected under the skin by high pressure. Protect
the eyes by wearing safety glasses.
Stop the engine immediately if any
hydraulic leak is noted. DO NOT start the engine until
any problem noted has been corrected.
Change Hydraulic Oil Strainer
The hydraulic oil strainer lter is mounted in the oil ll
opening under the ller cap. The sight glass on top
of the cap displays a red and green zone. When the
indicator moves into the red zone, it is time to change
the strainer lter. (Figure 5-21)
1. Remove the hydraulic oil ll cap.
REPLACEMENT
PROCEDURES
2-Speed Motor Replacement
1. Drive paver onto a ramp to access the
undercarraige.
2. Refer to Page 7-6 for the track assembly diagram.
3. Label and disconnect all hydraulic hoses and plug
the cap ttings.
4. Remove the two bolts holding the motor to the
torque hub.
5. Slide motor out of torque hub.
1. Lubricate O-ring and install onto motor.
2. Slide motor into the torque hub.
3. Attach motor to torque hub with the two bolts.
4. Torque bolts to 120 ft. lbs. (162 N.m).
5. Clean all hoses and ttings.
6. Reconnect hoses.
7. Fill oil tank through the charge lter ll port to
recharge the motor with oil.
8. Start engine and allow it to run for about 10 minutes
before moving the the paver to prevent damage to
the new motor.
9. Check hydraulic oil level.
5
2. Remove the three wingnuts securing the strainer.
3. Remove the strainer lter and gasket.
4. Install the new strainer lter and reinsert the spring
in the mounting head.
5. Fill the hydraulic oil tank with ltered hydraulic oil
until proper level is shown on the sight gauge.
(Figure 5-20)
6. Replace ll cap and tighten wingnuts securely.
DO NOT overll the hydraulic oil tank.
LeeBoy 8616B Conveyor Paver 5-21
Page 95
Drive Torque Hub Replacement
1. Drive paver onto a ramp to access the
undercarraige.
2. Remove the track master pin at the bottom rear of
the sprocket.
3. Release track tension by screwing the relief
cartridge out of the manifold (about three turns).
Torque Hub
Figure 5-23. Torque Hub Location
4. Drive paver forward to disconnect the track from the
top of the sprocket. (Figure 5-24)
5. Follow directions for 2-Speed Motor Replacement
on Page 5-21.
21. Tighten the relief cartridge in the manifold.
22. Rotate torque hub so that either of the plugs are at
3 o’clock position. Remove the plug at the 3 o’clock
position. If oil comes out, no oil is needed. Insert
plug and tighten. If oil does not come out, remove
the plug at the 12 o’clock position and ll torque hub
with 80W-90 gear oil until oil starts to appear at the
other hole. Replace both plugs and repeat process
on other torque hub.
Track Sprocket Replacement
1. Rotate the track master pin to the bottom of the
sprocket.
2. Release track tension by screwing the relief
cartridge out of the manifold (about three turns).
3. Remove track master pin at bottom rear of sprocket.
Drive paver forward to disconnect track from the top
of the sprocket.
4. Jack up the paver until the sprocket clears the track.
1 2
6. Jack up the sprocket to remove from the track.
7. Remove bolts holding sprocket.
8. Slide sprocket off out of the way.
9. Use a hoist to hold the torque hub.
10. Remove bolts from rear of the torque hub and slide
torque hub with the hoist.
11. Use hoist to replace new torque hub onto the frame.
12. Place thread-locking adhesive on bolts and reinstall.
13. Torque bolts to 180 ft. lbs. (244 N.m).
14. Slide sprocket onto the torque hub.
15. Place thread-locking adhesive on bolts and reinstall
the sprocket.
16. Torque bolts to 180 ft. lbs. (244 N.m).
17. Follow directions for installing 2-Speed Motor
Replacement. (Page 5-21)
18. Lower the paver ensuring the sprocket goes back
into the track chain. Drive paver forward to rotate
track onto the top of the sprocket.
19. Reinsert the master pin back onto the track.
20. Place thread-locking adhesive on bolts.
Figure 5-24. Track Sprocket
1 - Sprocket
2 - Bolts
5. Remove bolts holding sprocket. (Figure 5-24)
6. Slide sprocket off and replace.
7. Slide sprocket back in place.
8. Place thread-locking adhesive on bolts and install
bolts holding sprocket.
LeeBoy 8616B Conveyor Paver5-22
Page 96
9. Lower paver so that sprocket goes back into track
chain. Drive paver forward to rotate track onto top of
the sprocket.
10. Place master pin back in track and place threadlocking adhesive on bolts.
11. Tighten relief cartridge in manifold.
Front Idler and Bushing
Follow this procedure for replacing the front idler and
bushing: (Figure 5-25)
1
2
Figure 5-25. Front Idler
1 - Front Idler
2 - Tension Cylinder
1. Rotate the track so the master pin is at the rear
bottom of the front idler.
2. Loosen track by screwing out the tension relief
cartridge (about three turns).
3. Remove the master pin.
4. Back paver so that track is not on the idler.
5. Remove the idler by removing the top guide on slide
and disconnect cylinder.
6. Lift idler out and replace new bushing.
7. Remove hub cap at the end and slide idler wheel off.
Repair and reinstall.
NOTE: Use a winch or a strap to hold the track
forward. Remove the tension cylinder, top
guide, and idler.
NOTE: Rebuilding the bushing and seals can be
performed without taking idler off paver.
Front Idler Installation After Bushing
Replacement
1. Slide idler wheel back onto the idler shaft.
2. Place hub cap back on by using a bolt screwed into
idler axle to act like a press. Align roll pin hole in the
cap and axle.
3. Drive in the roll pin.
4. Fill with 90 WT gear oil.
5. Place the master pin back into the track.
6. Tighten the track tension relief cartridge.
New Front Idler Installation
1. Place new idler with slide block back into the bottom
guide.
2. Lubricate slide.
3. Place top guide against idler slide. Set bolts and tap
down the guide.
4. Once snug, torque bolts to 180 ft. lbs. (244 N.m).
5. Connect cylinder.
6. Place master pin back into the track.
7. Tighten the track tension relief cartridge.
8. Check oil level in the torque hub.
5
Rear Conveyor Shaft, Bearings and Sprockets
1. Drive paver onto a ramp to access undercarraige.
2. Disconnect the main conveyor chains.
3. Disconnect any link.
4. Rotate chains away from the assembly.
5. Remove chain from drive motor to the conveyor
sprocket.
6. Remove bolt and washers holding the sprocket.
7. Remove the sprocket and bearing from the frame.
8. Remove bolts on the inner sprocket.
9. Slide out shaft and outer conveyor sprocket through
frame side.
NOTE: Rear tube can be removed for changing the
inner bearings.
LeeBoy 8616B Conveyor Paver 5-23
Page 97
NOTE: Remove the inner seals from replaced
bearings in the tubes to allow grease to
enter into the bearing area.
10. Place conveyor shaft into the inner conveyor
sprocket.
11. Insert bolt into shaft.
NOTE: The outer conveyor sprocket must be
aligned with the inner sprocket.
12. Rotate the outer sprocket on the shaft until properly
aligned.
13. Reinstall the outer bearing and outer sprocket.
14. Place thread-locking adhesive on the bolt and
torque to 180 ft. lbs. (244 N.m).
15. Reinstall the conveyor and drive chains and adjust.
16. Grease bearings in the tubes by using grease
blocks on each side below the hopper wing.
Conveyor Wear Plates
There are four wearplates on the conveyor. Spraying
down the hopper before and after paving prevents
asphalt buildup that can damage or clog the wearplates.
(Figure 5-26)
4. Remove front conveyor idlers.
5. Remove bolts from rear tube assemblies.
6. Remove the 24 bolts holding the oor onto the
frame.
7. Using a hoist, lift wear plate out of the paver.
8. Clean the frame.
9. Insert new conveyor plate onto the frame.
10. Coat the bolts with thread-locking adhesive and
tighten the new conveyor plate to the frame.
11. Torque bolts to 180 ft. lbs. (244 N.m).
12. Place rear drive assembly back in place.
13. Place thread-locking adhesive on bolts and torque
to 180 ft. lbs. (244 N.m).
14. Tighten adjuster against assembly to keep from
slipping.
15. Place front idler assemblies back in place.
16. Place main conveyor chains in and adjust chain
tension. Once adjusted, torque all idler hold down
bolts to 180 ft. lbs. (244 N.m).
17. Adjust tension bolts tight against assembly when
done and lock jam nuts.
18. Place all guards over conveyor chains and front lip
panel.
1
2
Figure 5-26. Conveyor Wear Plates
1 - Wear Plates
2 - Conveyor Chains
If the conveyor wearplate(s) needs to be replaced,
follow these procedures:
1. Position paver on a ramp.
2. Remove all guards over the conveyor oor and front
lip panel.
3. Remove main conveyor chains.
1
2
19. Grease bearings by using grease blocks on each
side below hopper wing.
NOTE: Remove the inner seals from replaced
bearings in the tubes to allow grease to
enter into the bearing area.
LeeBoy 8616B Conveyor Paver5-24
Page 98
Conveyor Drive Motors
1. Remove hydraulic hoses from motor.
2. Remove four bolts holding hydraulic motor to slide
mount.
3. Slide drive motor out of slide mount.
4. Slide new or repaired drive motor into slide mount.
5. Secure with four bolts.
6. Reconnect hydraulic hoses to motor.
7. Check for leaks.
Cut-Off Assembly
1. Remove clevis pin that connects the cutoff cylinder
to the cutoff.
2. Remove roll pin out of outer cutoff hinge.
3. Insert a 3/8” bolt in the end of the hinge pin to use to
remove pin.
4. Cutoff will slide down.
5. Clean area around cutoff hinge.
6. Align cutoff hinge.
7. Grease and insert hinge pin.
8. Insert roll pin into outer cutoff hinge.
9. Connect cylinder back to cutoff.
Auger And Inner Bearing
1. Remove rear grating over auger assembly.
2. Run screed extension all the way out.
3. Remove two (2) nuts holding top cover on and pry
cover apart.
4. Clean asphalt build up from around cover.
NOTE: Heating asphalt may be required.
5. Remove bottom portion of cover by laying on
conveyor under engine [six (6) bolts].
6. Rotate augers so that master link is centered at
front.
7. Loosen auger chains by sliding auger motors down
from backside after loosening the two (2) bolts
securing mounting brackets.
8. Remove bottom clamps that hold auger bearings in.
NOTE: Roll pin is used to line up bearing grease hole
with the grease tting hole. If installed improperly,
no grease will get to bearing.
9. Remove auger end mounts so that augers can be
removed through opening in sides.
10. Remove augers and lay augers on the ground in
the same position as removed. This will help insure
proper installation of the new augers.
11. Check inner auger bearing and replace at this time
if faulty.
NOTE: When installing the new augers, be sure
to align augers the same as the removed
augers. It is very easy to install augers
backwards.
5
NOTE: When installing auger, make sure roll pin
is aligning grease tting hole with grease
tting before tightening clamps on inner
auger bearings.
1. Install new augers making sure that they are on
correct side to auger material outward.
2. Tighten bearing setscrew to help hold auger shaft
from moving outward.
3. Slide auger collar on end of auger shaft and bolt
end mount back on. Torque mounting bolts to 78 ft.
lbs. (106 N•m)
4. Push collar all the way in against end mount and
attach with two (2) setscrews, one (1) on outside and
one (1) on inside.
LeeBoy 8616B Conveyor Paver 5-25
Page 99
5. Replace bronze bushing in the end mounts.
6. Place auger chains back on and adjust auger
motors up to tighten chains. Use adjusting bolt to
tighten motor, then snug bottom motor mount bolts
(make sure chains have approximately 1/4” of slack).
7. Make sure the motor bolts at top and bottom are
tight and torque to 150 ft. lbs. (155 N•m). Do the
same for the other side.
8. Lubricate chains.
9. Place grating back on over auger.
10. Run augers and make sure everything is correct.
NOTE: Auger chains can be lubricated each day by
spraying oil or chain lube in through slots where
auger motor is adjusted.
Replacing Auger Motors
1. Extend screed extension completely.
2. Remove oor grating.
3. Clean asphalt buildup around cover.
4. Disconnect and label the hydraulic hoses. Plug
ttings.
5. Remove the two nuts on the cover and pry the cover
apart. (Figure 5-27)
NOTE: Heating asphalt may be required.
6. Loosen auger tension adjusters.
7. Loosen the the two bolts securing the auger motor
mounting brackets. (Figure 5-27)
8. Loosen the auger chains by sliding the auger
motors out from backside.
9. Slide the long screw through the bolt side of the
chain to prevent it from falling down into the cover.
Once chain is secure, remove the bolt holding the
sprocket.
1
2
3
4
5
Figure 5-27. Auger Motors
1 - Floor Grating
2 - Front Auger Cover
3 - Auger Motors
4 - Auger Mounting Bolts
5 - Auger Tension Adjusters
10. Hold the sprocket at the chain as you slide out the
motor.
11. Remove the sprocket from the chain.
12. Slide off the sprocket and remove the auger motor
mount.
13. Place the new auger motor onto the mount.
14. Reinsert the sprocket back onto the chain.
15. Reinsert the motor.
16. Cover bolts with thread-locking adhesive, reinsert
and tighten.
17. Adjust the chain for 1/4 inches of slack.
18. Lubricate with chain lube.
19. Reconnect the hydraulic hoses and check for leaks.
3
4
LeeBoy 8616B Conveyor Paver5-26
Page 100
Rear Hopper Wing Cylinders
1. Fold in the hopper wings completely.
2. Secure wings to prevent them from falling open
when the cylinder is disconnected.
3. Open the front cover on the hood to access the bolt
cover at the rod end of the cylinder.
4. Remove top bolt. (Figure 5-28)
5. Fold out cylinder and disconnect hoses.
6. Disconnect the cylinder mount and slide off cylinder.
7. Slide new cylinder onto the mount.
8. Cover bolts with thread-locking adhesive before
attaching new cylinder back onto the mount.
9. Clean the hydraulic hoses and reattach.
10. Extend the cylinder so that the bolt at the rod end
lines up with the mount.
11. Cover the mount bolt with thread-locking adhesive
and tighten.
12. Reattach bolt cover and close hood.
Front Hopper Wing Cylinders
1. Fold hopper wing all the way in.
2. Secure wing closed so that wing will not fall open
after cylinder is disconnected.
3. Disconnect hose. (Figure 5-29)
4. Remove clevis pin and bolt from cylinder mount.
5. Slide cylinder off.
6. Slide cylinder on bottom mount.
7. Attach bolt to cylinder mount.
8. Clean hydraulic hoses and connect the cylinder.
9. Extend cylinder so that hole in rod lines up with
upper mount.
10. Attach clevis pin
1
2
1
2
3
Figure 5-28. Rear Hopper Wing Cylinder
1 - Top Bolt
2 - Cylinder
3 - Hoses
3
Figure 5-29. Front Hopper Wing Cylinder
1 - Clevis Pin
2 - Cylinder
3 - Cylinder Mount
5
LeeBoy 8616B Conveyor Paver 5-27
Loading...