Fayat Bomag CR 820 T Tier 4 Instructions for use

00808924 05/20
Operating Instructions
Maintenance Instructions
CR 820 T Tier 4
Hot Mix Asphalt Paver

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Table of Contents
Date May 2020
Page 1
Operations Manual
CR 820 T
TABLE OF CONTENTS

Table of Contents
Operations Manual
CR 820 T
Date May 2020
Page 2
Table of Contents
1 INTRODUCTION....................................................................................................1-1
Notes to the Operations Manual .............................................................................. 1-2
Safety Information ..................................................................................................... 1-2
Safety Alert Symbol .............................................................................................. 1-2
Safety Notes...................................................................................................... 1-2
California 65 Warnings ......................................................................................... 1-2
USA Federal Clean Air Act ........................................................................................ 1-3
Customer Assistance ........................................................................................... 1-3
Normal Non-Road Engine Use............................................................................. 1-3
Non-Road Engine Maintenance ........................................................................... 1-3
Service Performed by a Local Authorized Dealer or Distributor...................... 1-3
Preventative Maintenance Program .................................................................... 1-4
Fuel System........................................................................................................... 1-4
Fuel Recommendations................................................................................... 1-4
Check for Fuel Leaks ....................................................................................... 1-4
Check the condition of the fuel hoses ........................................................... 1-4
Check the Turbocharger .................................................................................. 1-4
Product Identication Plate ...................................................................................... 1-4
Intended Use .............................................................................................................. 1-4
Prohibited Use ........................................................................................................... 1-4
Bulletin Compliance .................................................................................................. 1-5
Contacting Authorized Bomag Dealer/Distributor.................................................. 1-5
Register Machine....................................................................................................... 1-5
Transfer of Machine Ownership ............................................................................... 1-5
2 SAFETY .................................................................................................................2-1
Owners, Users, and Operators:................................................................................ 2-2
General Safety ........................................................................................................... 2-2
Safety Alert Symbol .............................................................................................. 2-2
ANSI Hazard Classication System .................................................................... 2-2
Property Damage .................................................................................................. 2-3
Procedure .............................................................................................................. 2-3
Personal Protective Equipment ............................................................................... 2-3
Safety Sign Maintenance .......................................................................................... 2-4
Safety Sign Pictorials ........................................................................................... 2-4
ANSI Decals........................................................................................................... 2-5
Additional Decals.................................................................................................. 2-9
Safety Sign Locations ........................................................................................ 2-16
Personal Safety........................................................................................................ 2-18
Introduction ......................................................................................................... 2-18
Operation and Repair Precautions ........................................................................ 2-18
Lockout and Tagout Procedure ......................................................................... 2-18

Table of Contents
Date May 2020
Page 3
Operations Manual
CR 820 T
Operation of Control Interlocks......................................................................... 2-19
General ..................................................................................................................... 2-19
Lifting Precautions ............................................................................................. 2-19
Crushing or Cutting Prevention ........................................................................ 2-19
Safe Paver Operation.......................................................................................... 2-20
Equipment and Tools.......................................................................................... 2-20
Fire or Explosion Prevention ............................................................................. 2-20
Questions ............................................................................................................ 2-21
3 TECHNICAL DATA ................................................................................................3-1
Dimensions ................................................................................................................ 3-2
Average Shipping Weight ......................................................................................... 3-2
Capacities................................................................................................................... 3-2
Recommended Fluids ............................................................................................... 3-2
4 OPERATOR CONTROLS......................................................................................4-1
Controls...................................................................................................................... 4-2
Screed Controls ........................................................................................................ 4-4
Operator’s Console .................................................................................................. 4-5
Display Icon Buttons ............................................................................................ 4-6
Additional Display Icon Buttons.......................................................................... 4-7
Warning Lamp Icons............................................................................................. 4-9
Operator’s Display................................................................................................... 4-10
Display Screens....................................................................................................... 4-10
Splash Screen ..................................................................................................... 4-10
Main Run #1 Screen............................................................................................ 4-13
Left Gauge Cluster ......................................................................................... 4-13
Right Gauge Cluster....................................................................................... 4-13
Center Gauge Cluster .................................................................................... 4-13
Lower Screen Area......................................................................................... 4-13
Left Side Button Icons ................................................................................... 4-14
Right Side Button Icons................................................................................. 4-14
Lower Cursor Buttons ................................................................................... 4-14
Warning Lamps ................................................................................................... 4-15
Main Run #2 Screen............................................................................................ 4-15
Left Gauge Cluster ......................................................................................... 4-17
Right of Center Gauge Cluster...................................................................... 4-17
Center Gauge Cluster .................................................................................... 4-17
Lower Screen Area......................................................................................... 4-17
Left Side Button Icons ................................................................................... 4-18
Right Side Button Icons ................................................................................ 4-18
Lower Cursor Buttons ................................................................................... 4-18
Warning Lamps ................................................................................................... 4-19
Advanced Functions Screen .................................................................................. 4-19

Table of Contents
Operations Manual
CR 820 T
Date May 2020
Page 4
Left of Center Gauge Cluster ........................................................................ 4-20
Right of Center Gauge Cluster...................................................................... 4-20
Center Gauge Cluster .................................................................................... 4-20
Lower Screen Area......................................................................................... 4-20
Left Side Button Icons .................................................................................. 4-20
Right Side Button Icons ................................................................................ 4-21
Lower Cursor Buttons ................................................................................... 4-21
Warning Lamps ................................................................................................... 4-21
Ground Controls, Gauges, and Levers.................................................................. 4-22
Vacuum Indicator ................................................................................................ 4-22
Master Switch...................................................................................................... 4-22
5 SHIPPING AND LIFTING ......................................................................................5-1
Receive the Machine ................................................................................................. 5-2
Initial Inspection of the Equipment ..................................................................... 5-2
Load/Unload Paver on/off a Trailer .......................................................................... 5-2
Ground Clearance................................................................................................. 5-2
Driving the Paver On/Off the Trailer .................................................................. 5-3
Preparation for Transport ......................................................................................... 5-4
6 INITIAL SETUP AND ADJUSTMENTS .................................................................6-1
Unload and Install the Screed .................................................................................. 6-2
7 STANDARD OPERATING PROCEDURES...........................................................7-1
Pre-Operating Checks............................................................................................... 7-2
Raising the Center Hood ...................................................................................... 7-2
Lowering the Center Hood ................................................................................... 7-3
Inspection................................................................................................................... 7-4
Start Up....................................................................................................................... 7-5
Starting the Engine .............................................................................................. 7-5
Preparing to Pave ...................................................................................................... 7-6
Raise/Lower Screed .................................................................................................. 7-6
Fume Recovery System ....................................................................................... 7-6
Fume Fan Speed Control ..................................................................................... 7-7
Null the Screed ..................................................................................................... 7-7
Joints .................................................................................................................... 7-8
Transverse Joints ............................................................................................ 7-8
Joint Construction ........................................................................................... 7-8
Operating Hints ....................................................................................................... 7-10
Asphalt Buildup ................................................................................................. 7-10
Hydraulic Tunnel ................................................................................................. 7-10
Manual Material Retaining Plates .......................................................................7-11
Electrical System..................................................................................................... 7-12
Engine Protection System ................................................................................. 7-12
Engine Protection Shutdown............................................................................. 7-13

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Date May 2020
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Operations Manual
CR 820 T
Engine Protection Shutdown Override ............................................................ 7-13
Shutting the Engine Off...................................................................................... 7-13
Generation IV Sonic Sensor Cleaning ................................................................... 7-14
Pressure Cleaning ................................................................................................... 7-15
Inducements ............................................................................................................ 7-15
Inducements Impacts ......................................................................................... 7-16
Final Inducement ............................................................................................... 7-16
DEF Related Inducements.................................................................................. 7-16
Tampering/Malfunction ........................................................................................... 7-18
Primary/Secondary Inducement ............................................................................ 7-19
Deactivation......................................................................................................... 7-19
ESC - Exhaust System Cleaning ............................................................................ 7-20
8 EMERGENCY PROCEDURES..............................................................................8-1
Engine Start-up After Stall........................................................................................ 8-2
Jump Starting/Charging Batteries....................................................................... 8-2
Emergency Stop ........................................................................................................ 8-3
Lockout and Tagout Procedure................................................................................ 8-3
Emergency Towing ................................................................................................... 8-4
9 MAINTENANCE.....................................................................................................9-1
Service Parts.............................................................................................................. 9-2
Maintenance Schedule.............................................................................................. 9-2
When Needed ........................................................................................................ 9-2
Every 8 Service Hours or Daily............................................................................ 9-2
After First 40 Service Hours Only........................................................................ 9-3
Every 40 Service Hours ........................................................................................ 9-3
After First 150 Service Hours............................................................................... 9-3
Every 250 Service Hours ...................................................................................... 9-3
After First 500 Service Hours............................................................................... 9-4
Every 500 Service Hours ...................................................................................... 9-4
Every 1000 Service Hours .................................................................................... 9-4
Every 2000 Service Hours .................................................................................... 9-4
Yearly ..................................................................................................................... 9-4
Every 4500 Hours (3 Years).................................................................................. 9-4
Systems...................................................................................................................... 9-5
Electronic Controlled Fuel System ..................................................................... 9-5
Engine Protection System ................................................................................... 9-5
Hydraulic Fluid Reservoir .................................................................................... 9-5
Rubber Track Hydraulic System.......................................................................... 9-5
Filters ..................................................................................................................... 9-6
Maintenance Procedures .......................................................................................... 9-6
Engine .................................................................................................................... 9-6
Check Engine Oil .................................................................................................. 9-6

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Operations Manual
CR 820 T
Date May 2020
Page 6
Change Engine Oil and Filter............................................................................... 9-7
Inspect Engine Belt............................................................................................... 9-8
Check Engine Coolant.......................................................................................... 9-8
Replace Engine Coolant....................................................................................... 9-9
Inspect Cooler Assembly ................................................................................... 9-10
Inspect Cooler Fan...............................................................................................9-11
Aftertreatment System .............................................................................................9-11
Miscellaneous ......................................................................................................9-11
Flush DEF Tank and Replace Filter ...............................................................9-11
Maintenance 1 - Supply Module.................................................................... 9-12
Air Intake System .................................................................................................... 9-12
Replace Primary Air Filter Element ................................................................... 9-12
Replace Secondary Air Filter Element .............................................................. 9-13
Check Air Inlet Connections .............................................................................. 9-14
Check Fuel Level................................................................................................. 9-14
Drain Fuel Filter/Water Separator ...................................................................... 9-15
Replace Fuel Filter/Water Separator ................................................................. 9-15
Hydraulic System .................................................................................................... 9-16
Check Hydraulic Tank Oil Level......................................................................... 9-16
Clean Strainer and Replace Hydraulic Fluid .............................................. 9-16
Check Hydraulic Lines and Components ......................................................... 9-17
Replace Charge Filters ....................................................................................... 9-18
Replace Auxiliary Pump Filter ........................................................................... 9-18
Adjust Pump Drive Belt Tension ....................................................................... 9-19
Electrical System..................................................................................................... 9-21
Inspect Battery Cables ....................................................................................... 9-21
Storing Batteries ................................................................................................. 9-22
Ground Drive System.............................................................................................. 9-22
Check Final Drive Oil .......................................................................................... 9-22
Change Final Drive Oil........................................................................................ 9-22
Slat Conveyor System............................................................................................. 9-23
Conveyor Bearings ............................................................................................. 9-23
Check and Adjust Spreading Auger Drive Chains.......................................... 9-24
Lubrication ............................................................................................................... 9-24
Clean Truck Hitch .................................................................................................... 9-24
Check Fume Recovery System ........................................................................ 9-24
Clean Fume Recovery System........................................................................... 9-25
Tracks Corrective Maintenance ......................................................................... 9-26
Check Hood Raise Reservoir Oil Level............................................................. 9-27
10 STORAGE..........................................................................................................10-1

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Date May 2020
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Operations Manual
CR 820 T
Storing the Machine ................................................................................................ 10-2
Machine Storage Preparation ............................................................................ 10-2
Release Track Tension ....................................................................................... 10-2

Table of Contents
Operations Manual
CR 820 T
Date May 2020
Page 8
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