How To Handle Technical Malfunctions And Perform Routine Maintenance On Pavers?

A paver is a construction tool that is primarily used to pave different materials for the surface and base layers of roads. A transportation system, a hydraulic system, and a material conveying system are the main systems that collaborate to finish the paving operation. This article primarily explains how to deal with technical issues and carry out regular paver maintenance.

Definition, Use, and Main Benefits of Pavers

Definition

A paver is a specialized road construction machine whose primary purpose is to uniformly distribute concrete, asphalt mixtures, or other road construction materials onto the base course or subgrade, creating a dense, smooth layer of road paving with a predetermined camber and thickness. In the construction of contemporary high-grade highways, metropolitan roads, airport runways, and other infrastructure projects, it is an essential piece of equipment. Slurry sealing pavers, cement pavers, and asphalt pavers are among the varieties.

Principal Roles
A. Uniform Material Distribution: Ensures that the paving material is distributed uniformly without segregation by receiving, transporting, and continually spreading hot-mix asphalt mixtures and other materials from trucks.
B. Preliminary Shaping: It forms the camber, slope, and smoothness required by the engineering design by performing preliminary compaction and shaping of loose materials through its central component, the screed.
C. Establishing the Basis for Compaction: The first important stage in the development of a road surface is paving. Its paving quality immediately affects the final smoothness and quality of the road surface, and it serves as the basis for later final compaction by road rollers.

Key Benefits
A. High Efficiency: This greatly reduces the construction time by enabling continuous, large-area robotic paving at a construction speed substantially faster than human paving.
B. High Quality: Accurate control over pavement density, thickness, and smoothness guarantees that the pavement satisfies design requirements, successfully lowering later flaws like rutting and waviness and prolonging the life of the road.
C. High Uniformity: By reducing material segregation, sophisticated material conveying and distribution systems guarantee a uniform pavement structure.
D. Economic Efficiency: Despite the large equipment investment, there are substantial overall economic benefits because of fewer labor, material waste, and maintenance expenses.

Technical Errors

1.1 Overheating of Hydraulic Oil
Reduced oil viscosity, increased leakage, damage to the oil layer in lubricated parts, and accelerated component wear are all consequences of a paver‘s hydraulic system overheating. In addition, high temperatures will degrade seals composed of materials like rubber and cause premature aging. As a result, maintaining the proper oil temperature is essential.
The equipment needs to be halted for examination when the oil temperature is too high. In general, the following can be checked to address this:
(1) Determine whether the tank’s oil level is too low.Oil should be promptly refilled when necessary because experience has shown that low oil levels in the tank are frequently the cause of excessive oil temperatures.

(2) Check if the hydraulic oil filter and circuit are clogged.

(3) Verify that the radiator is operating correctly. Inadequate heat dissipation and elevated oil temperature can result from a lot of dust sticking to the radiator. The radiator needs to be cleaned on a regular basis because the paver’s working area is frequently dusty.

 (4) Verify the quality of the hydraulic oil. An excessively high system oil temperature might also result from poor oil quality. Additionally, when the hydraulic system lacks oil, the pump and motor are vulnerable to harm. As a result, after resolving the oil scarcity issue, it is essential to assess the pump and motor’s operational condition and, if required, replace any damaged components.

1.2 The spiral conveyor’s malfunction
The paver’s left and right conveyors may occasionally malfunction; this is typically the result of a problem with the hydraulic replenishment system. Low pressure in the replenishment system can be caused by an obstruction in the replenishment pump’s oil inlet, low pressure in the overflow valve, a malfunction in the replenishment pump itself, or a significant leak in the hydraulic motor. The main focus of the inspection should be the replenishment pump and its overflow valve.
Precautions: During paver operation, proper hydraulic system maintenance can greatly minimize malfunctions. In general, it is important to note the following:

(1) Use a clean container before filling the hydraulic oil tank with hydraulic oil. Before being put to the hydraulic oil tank, the hydraulic oil needs to be filtered. The quality of the oil used determines how often hydraulic oil needs to be changed (usually every 1000 hours). Replacing hydraulic oil ought to be done at operating temperature. Regular cleaning of the hydraulic oil cooler is necessary to guarantee optimal heat dissipation of the hydraulic system.
(2) The replacement cycle of hydraulic oil filters should be shortened (preferably 750 hours) due to the generally severe working environment of asphalt pavers. Deformed, polluted, or rusty filters should not be utilized; instead, a check should be done before changing them.

(3) Before turning on any actuators, let the engine idle for a while after starting it every day. The hydraulic pump benefits from this.
(4) The paver’s hydraulic system specifications may alter as a result of extended use. As a result, it is important to regularly examine and quickly modify the hydraulic system parameter settings.

Regular Upkeep of Technology

(1) Clean the paver:Clear the paver’s surface of any accumulated mud, sand, and asphalt; also, clean the engine, hydraulic parts, and other components of dust and grease. Note: Keep impurities out of the air filter and filling ports.
(2) Examine the air tanks, switches, connecting pipes, and nozzles in the heating system.
(3) Verify the tightness and connections of every paver component, particularly the bolts connecting the screed, material distribution device, scraper conveyor, and left and right track beams and frame. Replace or tighten as needed.

(4) Look for and fix any leaks.
(5) Verify the engine oil, fuel, coolant, and hydraulic oil levels, then add fresh oil to the designated level.
(6) Examine the centralized lubrication system’s grease level.
(7) Look for cracks in the auger material distribution device’s blades and replace them if necessary.
(8) Check for looseness in all electrical plugs.

Maintenance Cycle

Upkeep for Extended Storage

The following maintenance guidelines should be adhered to if the paver will be stored for three months:
(1) Apply rust prevention treatment and carry out long-term storage technical maintenance as specified in the instruction manual.
(2) Clean the hopper, screed, auger distribution device, scraper conveyor, and machine’s exterior and interior surfaces. If at all feasible, store it in a warehouse; if not, cover it with a tarpaulin and put it in an area with good ventilation.
(3) Use wooden blocks to support the screed.

(4) Apply lubricating grease after fully retracting the hopper and leveling cylinder.
(5) The main unit should only have the screed and distribution device’s basic portions installed for long-term storage.
(6) After cleaning, treat the paver’s attachments to prevent corrosion and keep them in a spotless, well-ventilated space.
(7) Fill every lubrication point on the paver with fresh grease or lubricating oil.