OPERATOR’S

MANUAL

MODEL M2
TRUCK MOUNTED PAVER
 
3040 Emulsion Drive  Salina, Kansas 67401  Phone (785) 825‐1375  Fax (785) 825‐4269  www.bergkampinc.com 
© 20 Bergkamp Inc. All rights reserved.

No part of this publication may be reproduced, photocopied, stored on a retrieval system, or transmitted
without the express written consent of Bergkamp Inc.

BERGKAMP INC.
3040 Emulsion Drive
Salina, KS 67401-8966

Ph: 785.825.1375
Fx: 785.825.4269
Email: [email protected]
Web: http://www.bergkampinc.com
 TABLE OF CONTENTS
1 Introduction .......................................................................................................................... 1
2 Safety .................................................................................................................................... 2
2.1 Hazards .......................................................................................................................................2
2.2 Operation And Maintenance ........................................................................................................2
2.3 Hazards From Modifying Equipment ...........................................................................................3
2.4 Safety Decals...............................................................................................................................4
3 Operators Station................................................................................................................. 8
4 Fill Hoppers And Tanks ....................................................................................................... 9
4.1 Water Tank ..................................................................................................................................9
4.2 Emulsion Tank .............................................................................................................................9
4.3 Additive Tank .............................................................................................................................10
4.4 Mineral Filler (Cement) Hopper .................................................................................................10
4.5 Aggregate Hopper .....................................................................................................................10
4.6 Engine Startup ...........................................................................................................................10
4.6.1 Before Starting Engine .......................................................................................................................... 10
4.6.2 Engine Startup ...................................................................................................................................... 12
5 Calibration Procedure ....................................................................................................... 13
5.1 Emulsion Calibration ..................................................................................................................13
5.2 Aggregate Calibration ................................................................................................................13
5.3 Mineral Filler (Cement) Calibration ............................................................................................14
5.4 Water Calibration .......................................................................................................................15
5.5 Additive Calibration ....................................................................................................................15
6 Operation ............................................................................................................................ 16
6.1 Load Materials ...........................................................................................................................16
6.2 Adjusting Machine For Mix Design ............................................................................................16
6.2.1 Activate Controls ................................................................................................................................... 16
6.2.2 Set Gate Opening, Conveyor And Auger Speed .................................................................................. 16
6.2.3 Pugmill Speed ....................................................................................................................................... 16
6.2.4 Attach Spreader Box ............................................................................................................................. 16
6.3 Mix Materials And Apply To Roadway .......................................................................................16
6.3.1 Open Supply Valves ............................................................................................................................. 16
6.3.2 Mix Start ................................................................................................................................................ 17
6.3.3 Emulsion Time Delay Adjustment ......................................................................................................... 17
6.3.4 Spreader Box ........................................................................................................................................ 17
6.3.5 Water And Additive ............................................................................................................................... 17
6.3.6 Diverter Auger Speed and Direction ..................................................................................................... 17
7 Inspections And Maintenance .......................................................................................... 18
7.1 Paver .........................................................................................................................................18
7.2 Engine Group.............................................................................................................................19
7.3 Hydraulic Group .........................................................................................................................19
7.4 Pneumatic Filters & Water Strainers..........................................................................................19
7.5 Daily Before Use ........................................................................................................................20
7.5.1 Verify All Guards And Covers Are In Place .......................................................................................... 20
7.5.2 Verify Lights Are Operable .................................................................................................................... 20
7.5.3 Check Engine Oil Level ........................................................................................................................ 20
7.5.4 Check Engine Coolant Level ................................................................................................................ 20
7.5.5 Check Hydraulic Oil Level ..................................................................................................................... 20
7.5.6 Grease Conveyor Bearings .................................................................................................................. 21
7.5.7 Grease Pugmill Bearings ...................................................................................................................... 21
7.5.8 Grease Mineral Filler (Cement) Hopper Bearings ................................................................................ 21
7.5.9 Grease Jackshaft Bearings................................................................................................................... 21
7.5.10 Water Supply Strainer ........................................................................................................................... 21
7.5.11 Check Air System Pressure .................................................................................................................. 22
7.5.12 Check Hydraulic System Pressure ....................................................................................................... 22
7.5.13 Truck Maintenance ............................................................................................................................... 22
7.6 Daily After Use ...........................................................................................................................22
 TABLE OF CONTENTS
7.6.1 Drain Air Tanks ..................................................................................................................................... 22
7.6.2 Clean Residue From Pugmill ................................................................................................................ 22
7.6.3 Inspect Pugmill Paddle Tips ................................................................................................................. 22
7.6.4 Inspect Augers ...................................................................................................................................... 23
7.6.5 Wash Paver .......................................................................................................................................... 23
7.6.6 Check Air System Filters ...................................................................................................................... 23
7.6.7 Drain Water, Emulsion And Additive Tanks ......................................................................................... 23
7.6.8 Empty Mineral Filler (Cement) Hopper ................................................................................................. 23
7.7 Weekly ...................................................................................................................................... 23
7.7.1 Add Air Tool Oil To Air Valves And Clutches ....................................................................................... 23
7.7.2 Check Aggregate Clutch Chain Tension .............................................................................................. 24
7.7.3 Check Emulsion Clutch Chain Tension ................................................................................................ 24
7.7.4 Check Mineral Filler (Cement) Hopper Auger Chain Tension .............................................................. 24
7.7.5 Check Jackshaft Chain Tension ........................................................................................................... 24
7.7.6 Lubricate All Chains .............................................................................................................................. 24
7.7.7 Grease Conveyor Gate Pinion Shaft Bearing....................................................................................... 25
7.7.8 Check Conveyor Gearbox Oil Level ..................................................................................................... 25
7.7.9 Inspect Conveyor Belt .......................................................................................................................... 25
7.7.10 Check Conveyor Belt Tension .............................................................................................................. 25
7.8 Monthly ..................................................................................................................................... 26
7.8.1 Inspect Pugmill Timing Gears............................................................................................................... 26
7.8.2 Check Conveyor Gate Gearbox Oil Level ............................................................................................ 26
8 Troubleshooting ................................................................................................................. 27
8.1 Air System ................................................................................................................................. 27
8.2 Aggregate Conveyor ................................................................................................................. 27
8.3 Emulsion ................................................................................................................................... 27
8.3.1 Emulsion Front Load Pump .................................................................................................................. 27
8.4 Mineral Filler (Cement) Auger ................................................................................................... 27
8.5 Water System ........................................................................................................................... 28
8.5.1 Spray Bar .............................................................................................................................................. 29
8.5.2 Pressure Washer .................................................................................................................................. 29
8.6 Additive System ........................................................................................................................ 29
8.7 Pugmill ...................................................................................................................................... 30
 INTRODUCTION
contingencies, which may arise during operation,
1 INTRODUCTION setup, or maintenance. Should special problems
arise, or further information be desired, please
Congratulations on your purchase of the Bergkamp contact the Bergkamp Customer Service Department.
Inc., M2 Paver. The M2 has been designed and
manufactured to the strictest specifications. It is our This manual is the property of Bergkamp, Inc. and is
utmost desire that you achieve success and are provided to the owner of Bergkamp M2 Paver to
rewarded years of service from your equipment assist in the maintenance and operation of the
purchase. equipment, and is not to be used in any manner
detrimental to the interests of Bergkamp, Inc., nor
Carefully examine your equipment upon receipt. duplicated, in whole or in part, without the express
Report any damage immediately to the freight carrier permission of Bergkamp, Inc.
and register any claim. Should any material or
manufacturing defects be discovered, report your The text contained in this manual is for current
findings to our service department along with the production models. Some instructions and
model, serial number and date of purchase. We want maintenance procedures may not apply to your
to know that you are satisfied with the equipment and specific unit.
when it is less than perfect. As always, we welcome
any and all input on how our products can be If you have any questions, please contact our
improved to serve you better. Parts and Service Department.
Read and understand this manual before using your Equipment modifications from original design and
machine and follow all of the safety instructions. specifications without written permission are strictly
Keep this manual with your machine at all times. prohibited. Modifications may compromise safe
operation of the machine, subjecting users to serious
Some components may have separate operation and injury or death and may void any remaining warranty.
maintenance manuals. Where this manual indicates
that you should read another manual, and you do not Bergkamp Inc. reserves the right to change,
have that manual, contact Bergkamp, Inc. for improve, modify or expand features of this equipment
assistance. at any time. Specifications, models, or equipment
are subject to change without notice, and without
Information provided in this manual was current as of incurring any obligations to change, improve or
the issue date. Bergkamp, Inc. reserves the right to expand features of previously delivered equipment.
make design changes without further notice or Because of the variations in optional equipment and
liability. continued design improvement, certain information
contained within this manual may not apply.
This manual explains the operation and routine
maintenance of your machine. It does not instruct you
This Operator’s manual does not replace, nor does
how to transport, travel and/or operate on specific
its use discharge the owner from observing all safety
roadways or terrain.
codes or operating limitations as well as any
applicable federal, state, provincial or local
Information furnished in this manual does not include
regulations.
all of the details of design, production, or variations of
the equipment. It does not cover all the possible

1
 SAFETY
2 SAFETY 2.2 OPERATION AND MAINTENANCE
This manual covers the M2 Paver produced by
Bergkamp, Inc. Before setting up, operating or ^ WARNING
servicing a Bergkamp M2 machine, you must read, Risk of serious injury or death.
understand and follow the instructions and safety
warnings in this manual. Your machine may not be Do not operate, work on or around this
equipped with some of the optional equipment shown
machine while under the influence of
in the illustrations in this manual.
alcohol, drugs or if feeling ill.
All personnel that will be operating, maintaining and
working around this machine must review these ^ WARNING
documents before interacting with the Bergkamp
M2 machine. NEVER ALLOW ANYONE TO Crushing hazard.
OPERATE THIS EQUIPMENT WITHOUT PROPER
TRAINING! Before performing inspections, service or
maintenance:
If you have any safety concerns or questions that are • Park the machine on firm, level
not covered by this manual, please contact surface.
Bergkamp Inc. at 1-785-825-1375.
• Turn off truck engine and remove key.
The safety information in this manual is denoted by • Turn paver engine off.
the safety alert symbol: • Lock control cabinet door and install
do not operate tag.
The level of risk is indicated by the following signal • Install lockouts and do not operate
words. tags on jackshaft control lever and
pugmill control lever.
^ DANGER
Indicates a hazardous situation, which, if ^ WARNING
not avoided, will result in death or serious Risk of skin irritation.
injury.
Chemical additives are potentially
^ WARNING hazardous.
Indicates a hazardous situation, which, if
Read and follow the handling instructions
not avoided, could result in death or
and MSDS for the additive.
serious injury.

^ WARNING
^ CAUTION
Inhalation hazard.
Indicates a hazardous situation, which, if
not avoided, could result in minor or
Cement dust is potentially hazardous.
moderate injury.
Read and follow the handling instructions
NOTICE and MSDS for the cement.
Indicates a situation that could result in
damage to the machine or other property. ^ WARNING
Crushing and severing hazard.
2.1 HAZARDS
M2 Pavers are complex machines and their operation Moving and rotating parts can crush a
requires a high level of machine knowledge and skill. persons body or severe limbs and digits.
Safe use is dependant on the correct operation and
proper maintenance. Keep away from moving parts.

2
 SAFETY
^ WARNING ^ WARNING
Entanglement hazard. Noise hazard.

Loose fitting clothing and long hair can Prolonged exposure to loud noise can
become entangled in moving or rotating cause impairment or loss of hearing
parts.
Operator, workers and bystanders must
Do not wear loose fitting clothing. use ear protection while machine is in
operation.
Long hair must be tied back or netted.
NOTICE
Never operate machine with open or
missing guards or shields. Dispose of waste properly.

Improper disposal of waste can harm the

^ WARNING environment.
Falling hazard.
Use leak proof container when draining
The walk platforms and covers may be fluids. Do not use food or beverage
slippery. containers.

Use caution while walking on the machine Contact your local environmental or
to avoid falling. recycling center for the proper way to
recycle or dispose of waste.
^ WARNING
Observe federal, state/provincial and local
2.3 HAZARDS FROM MODIFYING
safety codes and regulations that apply to EQUIPMENT
the job site. Before making any alteration to your machine,
contact Bergkamp, Inc. and describe the alteration
you are contemplating. Altering may cause your
^ WARNING equipment to be unsafe and may void the
Air pressure hazard. manufacturers’ warranty.

Drain air system before removing air

system filters or disconnecting air lines.

^ WARNING
Pressurized fluids can penetrate the skin.

Hydraulic hoses can fail from age, damage

and exposure.

Do not search for hydraulic leaks without

body and face protection. A tiny, almost
invisible leak can penetrate the skin,
thereby requiring immediate medical
attention.

Use wood or cardboard to detect

hydraulic leaks, never use your hands.

3
 SAFETY
2.4 SAFETY DECALS

4
 SAFETY

Decal A – Part Number 13165 Decal B – Part Number 13235

5
 SAFETY
Decal C – Part Number 13245 Decal E – Part Number 13366

Decal F – Part Number 13236

Decal G – Part Number 13238

Decal H – Part Number 13232

Decal D – Part Number 13169

6
 SAFETY

Decal I – Part Number 13237 Decal J – Part Number 13234

Decal K – Part Number 13230 Decal L – Part Number 13231

Decal M – Part Number 13244 Decal N – Part Number 13265

7
 OPERATORS STATION
3 OPERATORS STATION
1 – Hour Meter
2 – Volt Meter
3 – Failsafe Override
4 – Mineral Filler (Cement) Counter
5 – Rock Counter
6 – Emulsion Counter
7 – System Selector Switches
8 – Emulsion Start/Stop Delay
9 – Rock & Mineral Ratio Indicator
10 – Fines Feeder Ratio Control
11 – Production Control
12 – Jackshaft On/Off Lever
13 – Pugmill Directional On/Off
Lever
14 – Rear Spraybar Flow
15 – Pugmill Speed Control
16 – Jackshaft Pressure Gauge
17 – Engine Start Button
18 – Engine Throttle Switch
19 – Emergency Stop Button
20 – 20 Amp Fuse
21 – System Air Pressure Gauge
22 – Right Auger Speed Control
23 – Left Auger Speed Control
24 – Additive Flow Control
25 – Box Side Shift
26 – Box Lift
27 – Box Right Auger
On/Off/Reverse Control
28 – Box Left Auger
On/Off/Reverse Control
29 – Water Flow Control
30 – Water Spraybar On/Off
Control
31 – Mix Start Override
32 – Mix Start Control
33 – Pugmill Diverter Control

8
 FILL HOPPERS AND TANKS
4 FILL HOPPERS AND TANKS
Note: If performing calibration, go to Calibration
Procedure section of this manual before filling 4.2 EMULSION TANK
hoppers and tanks. Optional Front Load Pump

1. Connect emulsion supply hose to connector (1).

4.1 WATER TANK
1. Attach fill hose to connector (1). 2. Open coupler valve (2) and tank valve (3).

2. Open fill valve (2).

NOTICE
3. Move knife gate valve switch (3) to open position. Risk of equipment damage.
4. Open water supply source. Adjust the flow rate of Verify that coupler valve (2) and tank valve
the fill water to avoid unnecessary water
(3) are open before starting emulsion
splashing.
pump.
5. Close fill valve (2) when water tank gauge (4)
indicates full. 3. Start engine on unit. See Engine Startup in this
manual.
6. Close water supply source.
4. Move hydraulic control valve to open position.
7. Move knife gate valve switch (3) to close position.
5. Close hydraulic control valve (4) when emulsion
8. Disconnect fill hose from connector (1) tank gauge (5) indicates full.

6. Close coupler valve (2) and tank valve (3).

7. Disconnect emulsion supply hose from connector

(1).

8. Stop engine on unit.

9
 FILL HOPPERS AND TANKS
4.3 ADDITIVE TANK

^ WARNING
Risk of skin irritation.

Chemical additives are potentially

hazardous.

Read and follow the handling instructions

and MSDS for the additive.

1. Open cap (1) and fill additive tank.

2. Install cap (1) after filling.

4.5 AGGREGATE HOPPER

1. Load the aggregate hopper with aggregate to be
used on the project.

4.6 ENGINE STARTUP

4.6.1 Before Starting Engine
^ Before operation of your equipment, read and
understand this manual and all other manuals
associated with your machine.

^ Inspect hoses, fittings and hydraulic components

daily for indication of leaks and potential hazards.

^ WARNING
4.4 MINERAL FILLER (CEMENT) HOPPER Pressurized fluid hazard.

Escaping fluid under pressure can

^ WARNING penetrate the skin, thereby requiring
Inhalation hazard. immediate medical attention.

Mineral filler is potentially hazardous. Use wood or cardboard to detect leaks,

never your hands.
Read and follow the handling instructions
and MSDS for the mineral filler. ^ If any fluid is injected into the skin, it must be
surgically removed within a few hours by a doctor
1. Open mineral filler hopper cover (1). familiar with this type of injury or gangrene may
result.
2. Fill hopper and close cover (1).
^ Operate equipment only if all guards, covers and
access doors or panels are properly fastened in
place. Make sure all personnel are out of and clear
of moving parts prior to starting or operating
equipment. SAFETY IS YOUR RESPONSIBILITY.

10
 FILL HOPPERS AND TANKS
1 - Jackshaft Off
^ WARNING 2 - Pugmill Off
Severing and entanglement hazard. 3 - Water Pumps Off
4 - Side Shift Neutral
Clothing and limbs may be caught in 5 - Box Lift Neutral
6 - Box Augers Neutral
moving parts.
7 - Mix Start Switch Off
8 - Water Spray Bar Off
Never operate machine with open or 9 - Power Washer Off
missing guards or shields.

^ Follow the manufacturers’ maintenance

recommendations to ensure safe and continued
service of machinery and components. Lock out
power and/or disable system before removing access
panels and covers. If guards become misplaced or
damaged, replace or repair as necessary.

^ Observe manufactures’ safe handling procedures

for materials such as emulsion, emulsion additives
and hydraulic fluid. Respirators may be required
while filling mineral filler (cement) hopper.

^ Be prepared for emergencies. Devise a plan with

detailed instructions incase of emergency situations
(runaway equipment, equipment fires, chemical spills,
etc.).

^ Set park brake when machine is stopped and

when dismounting machine.

Perform prestart checks on truck as recommended

by the truck manufacturer.

Verify all valves on the bottom of the hydraulic tank

are in operational positions.

Refer to the manufacturers manual provided for

engine startup procedure, routine care and additional
safety information pertinent to the engine.
Familiarize yourself with it before beginning
operation.

Before starting the engine check that all of the

following hydraulic valves and switches are in the off
or neutral position.

11
 FILL HOPPERS AND TANKS
4.6.2 Engine Startup 3. Release start button when engine starts. Continue
to hold the override button until the oil pressure
rises above 20 psi (1.4 bar) then release button.
^ WARNING
4. After the engine has run a few minutes, move
Entanglement hazard. throttle switch (3) right to run mode.

Verify all persons are safely away from

equipment and all machine guards are
installed before starting engine.

1. Check engine oil and coolant levels. Refer to the

engine manual for proper levels, grade and quality
of oil and coolant.

2. Press and hold override button (1) and press start

button (2).

12
 CALIBRATION PROCEDURE
4. Start the jackshaft. Move emulsion switch (3) to the
5 CALIBRATION on position and leave all other switches off.
PROCEDURE
1. Start the auxiliary engine and move throttle switch 5. Pump enough emulsion to fill the hose to ensure
to run mode. See Engine Startup in this section. an accurate calibration.
Verify that the hydraulic system pressure is 1800- 5. Reset rock counter (4) to zero.
1850 psi (124-128 bar). A calibration worksheet is
included after Section 8 of this manual.

2. Using a calibration worksheet, calibrate the

machine for emulsion, cement and aggregate. It
will be necessary to obtain weights of the truck
and loaded materials at different stages of the
calibration.

5.1 EMULSION CALIBRATION

Note: Calibrate emulsion first with an empty
aggregate hopper because counts are derived from
the aggregate conveyor belt.
6. Turn mix start lever (5) to on while holding down
1. Pump emulsion into the machine’s emulsion tank. mix start override button (6). It is necessary to hold
See Fill Emulsion Tank in this manual. down the mix start override while calibrating
emulsion and mineral filler (cement) because the
2. Remove the emulsion hose (1) from the pugmill machine is equipped with a rock flow sensor to
sprayhood manifold and attach hose (1) to another automatically stop the flow of materials any time
truck or tank. the aggregate flow out of the hopper has stopped.
Run the emulsion pump for a sufficient number of
Note: Overflow line from emulsion tank may be counts of the rock counter.
connected to the fitting on top of pump for calibration.

3. Open valve (2) between the emulsion tank and 7. Obtain the weight of the truck or the tank the
pump. emulsion was pumped into. Calculate the
emulsion weight per rock count using the
calibration worksheet.

8. Repeat steps 5 through 7 to obtain a total of three

samples. Average the results to calculate the
weight per rock count (Lbs/cnt, [kg/cnt]) of the
emulsion pumping system.

5.2 AGGREGATE CALIBRATION

1. Load the aggregate hopper with aggregate to be
used on the project.

13
 CALIBRATION PROCEDURE
2. Set the rock gate to 3 inch (8 cm) setting.

3. Move truck to location where the aggregate can be

run through the pugmill onto the ground.

4. Move jackshaft (1) and pugmill (2) levers to on.

9. Run two more samples with a gate setting of 3

inches (8 cm), three more each at 4 inch (10 cm)
and 5 inch (12 cm) gate settings. Perform the
calculations and plot the graph on a calibration
work sheet. The graph will be used to select the
proper gate setting for desired production rate and
5. Run a small amount of rock through to fill the belt. mix design.

6. Weigh the loaded truck.

5.3 MINERAL FILLER (CEMENT)
7. Reset rock counter (3) to zero. Move rock switch CALIBRATION
(4) to the on position and leave all other switches 1. Load two bags of mineral filler (cement) into the
off. mineral filler hopper. See Mineral Filler Hopper in
this manual.

2. Move mineral filler (cement) switch (1) to on, leave

all other switches off.

3. Move mix start lever (2) to on and run the mineral

filler (cement) until a good even flow is coming out
of the auger and turn mix start lever off.

4. Reset mineral filler (cement) counter (3) to zero.

Place a pan under the mineral filler (cement)
auger discharge to collect a sample. Run the
auger for 10 counts of the mineral filler (cement)
counter. Weigh the mineral filler (cement) sample.
8. With the pugmill running, Turn mix start lever (5) to Repeat this procedure to obtain three samples and
on while holding down mix start override button then enter the weights and perform the
(6). Mix start override (6) will need to be held down calculations on the calibration work sheet. Adjust
until the rock is flowing out of the hopper. Run the mineral filler (cement) percentage to the mix
rock conveyor for a sufficient number of counts. design by turning knob (4).
Weigh the truck and enter the weights and
calculations on a calibration work sheet.

14
 CALIBRATION PROCEDURE

5.5 ADDITIVE CALIBRATION

The additive digital flow meter is preset at the factory
to display gallons per minute (gpm) or liters/min. If
necessary to check the meter for accuracy, uncouple
the hose end at the pugmill, place into a 5 gal (20 L)
container and run the system for one minute with the
adjustment set to 5 gpm (20 L/m). The additive
system is designed to pump one part of additive to
ten parts of water. Therefore, when the meter reads
10 gpm (38 L/m), you are putting 1 gpm (3.8 L/m) of
additive into the mix.

An optional peristaltic system applies non-diluted

additive into the mix.
5.4 WATER CALIBRATION
Move water switch (1) to on. You should be able to
obtain 45 gal/min (170 L/m) to the pugmill.

The digital readout is calibrated at the factory to read

gallons per minute (gpm) or liters per minute (L/m).

If necessary to check the meter for accuracy,

uncouple the hose at the pugmill, place into a 5 gal
(20 L) container and run the system for 15 seconds
with the adjustment set to 20 gpm (76 L/m). At 20
gpm, the pump should fill the 5 gallon bucket in 15
seconds.

15
 OPERATION
6 OPERATION 6.3 MIX MATERIALS AND APPLY TO
ROADWAY
6.1 LOAD MATERIALS 6.3.1 Open Supply Valves
Load the machine with materials if not already full. Open water tank valve (1), emulsion tank valve (2)
and additive tank valve (3).
6.2 ADJUSTING MACHINE FOR MIX
DESIGN
6.2.1 Activate Controls
Turn on the pugmill (1), jackshaft (2) and auxiliary
water pump. Turn all material switches (3) on. Reset
all counters (4) to zero.

6.2.2 Set Gate Opening, Conveyor

And Auger Speed
Determine aggregate gate setting, rock conveyor
speed, and mineral filler (cement) auger speed by
performing calibrations. See Calibration Procedure in
this manual. Adjust jackshaft speed to approximately
half of full speed.

6.2.3 Pugmill Speed

Pugmill speed can be altered by adjusting the pugmill
speed control. The speed should be set to 225 rpm
and can be adjusted to 250 rpm max to obtain good
mixing.

6.2.4 Attach Spreader Box

Refer to spreader box manual.
16
 OPERATION
6.3.2 Mix Start Move spreader box levers to control the sideshift (1),
raise/lower (2), left auger (3) and right auger (4).
Move mix start switch (1) to on and all functions will
Auger shafts run forward or reverse and can be sped
start immediately except emulsion which is equipped
up or slowed down.
with a time delay. It may be necessary to hold down
mix start override (2) button for several seconds to
The augers should only turn fast enough to move the
override the auto shutdown.
materials to the outside of the spreader box quickly.
If material is being thrown from the auger, the auger
is most likely turning too fast.

Communicate with the truck driver to start moving

and adjust speed as necessary.

You have now started making a quality mix with your

BERGKAMP M2 PAVER.

6.3.3 Emulsion Time Delay

Adjustment
The start and stop delay time will delay the emulsion
start or stop time after the switch is turned on or off.

Take note of the emulsion content of the mix from the

pugmill at start and stop events and adjust as
necessary.
6.3.5 Water And Additive
Turn the screws clockwise to increase the delay time Adjust water and additive levels as needed. Please
or counter clockwise to decrease the delay time. consult your emulsion supplier.

Turn screw (1) to adjust the stop delay time. Turn 6.3.6 Diverter Auger Speed and
screw (2) to adjust the start delay time.
Direction
Adjust diverter as needed to keep a sufficient amount
of mix in each side of the spreader box. Reverse
direction of diverter as needed to keep a sufficient
amount of mix in the spreader box. Refer to the
spreader box manual for additional information.

6.3.4 Spreader Box

Refer to Spreader Box Manuals for settings and
adjustments.

17
 INSPECTIONS AND MAINTENANCE
7 INSPECTIONS AND MAINTENANCE
7.1 PAVER
Daily Daily
Qty Before After Weekly Monthly
Item Use Use
Verify all guards and covers are in place •
Verify all lights are operable •
Check engine oil level 1 •
Check engine coolant level 1 •
Check hydraulic oil level at sight gauge 1 •
Grease aggregate conveyor bearings 4 •
Grease pugmill bearings 2 •
Grease mineral filler (cement) hopper bearings 6 •
Grease jackshaft bearings 2 •
Inspect and clean main water strainer 1 •
Inspect and clean spraybar water strainer 1 •
Inspect and clean power washer strainer 1 •
Check vehicle tire air pressure AR •
Check air system pressure 1 •
Drain air tanks 2 •
Clean and scrape residue from pugmill 1 •
Inspect pugmill paddle tips. Replace if necessary 36 •
Inspect augers. Replace if necessary AR •
Inspect squeegees. Replace if necessary 2 •
Wash dust from paver 1 •
Check air system filter 1 •
Drain water, emulsion & additive if freeze expected AR •
Empty mineral filler (cement) hopper if humid or damp 1 •
Add air tool oil to air valves and clutches •
Check aggregate clutch chain tension 1 •
Check emulsion clutch chain tension 1 •
Check mineral filler (cement) hopper auger chain tension 1 •
Check conveyor chain tension 1 •
Check additive system chain tension (10:1 only) 1 •
Lubricate all chains 7 •
Lubricate conveyor gate pinion shaft bearing 1 •
Check system hydraulic pressures 6 •
Check conveyor gearbox oil level 1 •
Inspect conveyor belt. Repair or replace if necessary 1 •
Inspect pugmill gears. Replace if necessary 1 •
Check conveyor gate gearbox oil level 1 •

18
 INSPECTIONS AND MAINTENANCE

7.2 ENGINE GROUP

Description Capacity/Qty Change Interval Manufacturer Type / #

Engine Oil (API CE/SG) 3.5 gal (14.5 L) 250 HR / 3 MO * 15W-40

Engine Oil Filter 1 EA 250 HR / 3 MO FLEETGUARD LF3805

Engine Coolant 5 gal (19 L) 6000 HR / 2 YR * 50-50 Mix

Fuel Filter * 250 HR / 6 MO FLEETGUARD FF-5052

Fuel Filter (Primary) * 250 HR / 6 MO FLEETGUARD FS19068

Air Filter Element (Primary) * 250 HR / 6 MO FLEETGUARD AF4059K

Air Filter Element (Secondary) * 250 HR / 6 MO FLEETGUARD AF4103

7.3 HYDRAULIC GROUP

Description Capacity/Qty Change Interval Manufacturer Type / #

Hydraulic Oil 55 gal (210 L) 6000 HR / 2 YR MOBIL MobilFluid 424

TRACTOR-HYD.

Hydraulic Oil High Pressure 3 Per Filter Determined SCHROEDER K10

Filter Element By Indicator BI#: 002539

Hydraulic Tank Breather 1 Ea Yearly SCHROEDER ABF-3/10

BI#: 001262

Hydraulic Load Pump Spin On 1 Ea Yearly GRESEN K-22001

Filter BI#: 002553

Oilgear VAR/VOL Pump 1 Ea Yearly GRESEN K-22001

Suction Spin On Filter BI#: 002553

7.4 PNEUMATIC FILTERS & WATER STRAINERS

Description Qty Change Interval Manufacturer Type / #

Air Filter Element 1 EA Yearly WILKERSON MSP-95-989

(Oil Removal) BI#: 000654

Air Filter Element 1 EA Yearly WILKERSON FRP-95-115

(Dirt Removal) BI#: 001637

Water Pump Strainer 1 EA Check Weekly CLAY & BAILEY 890CI-2

2-in, 40 Mesh BI#: 001633

Water Pump Strainer 2 EA Check Weekly SPRAYING BI#: 001634

3/4-in, 40 MESH SYSTEMS
19
 INSPECTIONS AND MAINTENANCE

7.5 DAILY BEFORE USE 7.5.4 Check Engine Coolant Level

Check the engine coolant level. The coolant must be
between the MIN and MAX level. Refer to the engine
^ WARNING manufacturers manual for coolant specifications.
Crushing, severing and entanglement
hazard. 7.5.5 Check Hydraulic Oil Level
Hydraulic oil level must be between the high and low
Before performing inspections, service or marks on sight gauge (1) with engine stopped.
maintenance:
• Park the machine on firm, level
surface.
• Turn off truck engine and remove key.
• Turn paver engine off.
• Lock control cabinet door and install
do not operate tag.
• Install lockouts and do not operate
tags on jackshaft control lever and
pugmill control lever.

7.5.1 Verify All Guards And Covers

Are In Place If necessary to add hydraulic oil, remove fill hose (2)
Check the entire machine to verify that all guards and from storage bracket and place in container of
shields are in place and access doors closed and hydraulic oil.
latched.

7.5.2 Verify Lights Are Operable

Verify that all lights installed on your vehicle are
operational. Do not operate machine if any light is
not operational.

7.5.3 Check Engine Oil Level

To check the engine oil level, the machine must be
on level ground.

Push dipstick (1) down fully and pull out. If the oil
level is below the add mark, add the proper grade
and viscosity of oil through filler tube (2) to raise oil Move switch (3) on hydraulic reservoir fill pump to on.
level to the full mark. Do not overfill. Refer to the Add hydraulic oil until level is in the middle of the
engine manufacturers manual for oil specifications. sight gauge (1). Turn fill pump off and place hose on
storage bracket on reservoir.

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 TROUBLESHOOTING

7.5.6 Grease Conveyor Bearings

Pump grease into zerks (1) on each side of the
conveyor. The top zerk is for the front bearing.

7.5.9 Grease Jackshaft Bearings

Pump grease into zerks (1) on each end of jackshaft.

7.5.7 Grease Pugmill Bearings

Pump grease into zerks (1) at rear of pugmill.

7.5.10 Water Supply Strainer

Close valve on water supply line. Remove main
strainer from manifold (1), spray bar strainer from
housing (2) and power washer strainer from housing
(3). Clean and inspect each strainer. Install strainers
and open water supply valve. Check for leaks.
7.5.8 Grease Mineral Filler (Cement)
Hopper Bearings
Pump grease into zerks (1) on each end of mineral
auger and fluffer shaft.

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 TROUBLESHOOTING
7.6 DAILY AFTER USE

^ WARNING
Crushing, severing and entanglement
hazard.

Before performing inspections, service or

maintenance:
• Park the machine on firm, level
surface.
• Turn off truck engine and remove key.
• Turn paver engine off.
• Lock control cabinet door and install
do not operate tag.
• Install lockouts and do not operate
tags on jackshaft control lever and
pugmill control lever.

7.6.1 Drain Air Tanks

Stop vehicle engine and drain the vehicle air tanks at
the end of the day. This will release moisture trapped
inside air tanks.

7.6.2 Clean Residue From Pugmill

7.5.11 Check Air System Pressure Clean pugmill shafts and mixer walls at the end of
Air pressure in the system should be 80 psi (6 bar). each days use. If not cleaned, the pugmill may stall
Read pressure on gauge at rear panel. Adjust air or plug.
pressure on regulator (1) if necessary.
7.6.3 Inspect Pugmill Paddle Tips
Inspect pugmill paddle tips for wear. Paddle tips
must be replaced before worn down to the auger
paddle. Paddle tip (2) is worn past the point of
replacement and paddle tip (3) is new.

7.5.12 Check Hydraulic System

Pressure
Verify that hydraulic system pressure is 1850 psi (129
bar). If pressure is not 1850 psi (129 bar), refer to M2
Maintenance Manual for adjustment procedure.

7.5.13 Truck Maintenance

Perform maintenance on truck as recommended by
the truck manufacturer.

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 TROUBLESHOOTING

Inspect Pugmill Bottom Pan

Inspect pugmill bottom pan (1) for wear. Replace if 7.6.7 Drain Water, Emulsion And
visibly worn or damaged.
Additive Tanks
Drain water, emulsion and additive tanks after each
days use if the machine will be exposed to
temperatures at or below freezing. Dispose of water,
emulsion and additive in a manner that is safe for the
environment.

7.6.8 Empty Mineral Filler (Cement)

Hopper
Empty mineral filler (cement) hopper after each days
use if there is a possibility of rain, damp or humid
conditions.

7.7 WEEKLY
7.6.4 Inspect Augers
Inspect augers in cement hopper and spreader box
for wear and damage. Replace if necessary. ^ WARNING
Crushing, severing and entanglement
7.6.5 Wash Paver hazard.
Wash paver as necessary to remove dust and dirt.
Before performing inspections, service or
maintenance:
7.6.6 Check Air System Filters
• Park the machine on firm, level
^ WARNING surface.
• Turn off truck engine and remove key.
Air pressure hazard.
• Turn paver engine off.
Drain air system before removing air • Lock control cabinet door and install
system filters. do not operate tag.
The machine is equipped with two air system filters • Install lockouts and do not operate
for dirt (1) and oil (2) removal. Remove, clean and tags on jackshaft control lever and
inspect air system filters after each days use. pugmill control lever.
Replace filters at least once per year.
7.7.1 Add Air Tool Oil To Air Valves
And Clutches

23
 TROUBLESHOOTING
7.7.4 Check Mineral Filler (Cement)
^ WARNING Hopper Auger Chain Tension
Air pressure hazard. A properly tensioned chain will move ¼ - ⅜ inch in
each direction at location (1). Loosen capscrews (2)
Drain air system before removing air and turn turnbuckle (3) to set proper chain tension.
Tighten turnbuckle jam nuts and capscrews (2).
system filters.

Disconnect each air line and add a few drops of air

tool oil to each clutch and air valve. This will help
prevent valves and clutches from sticking.
Reconnect air lines.

7.7.2 Check Aggregate Clutch Chain

Tension
A properly tensioned chain will move ¼ inch up and
¼ inch down at location (1). Loosen jam nuts on
gearbox turnbuckle and adjust turnbuckle to set
proper chain tension. Tighten jam nuts.

7.7.5 Check Jackshaft Chain

Tension
A properly tensioned chain will move ¼ inch in each
direction at location (1). Loosen mounting capscrews
and turn turnbuckle (2) to set proper chain tension.
Tighten turnbuckle jam nuts and mounting
7.7.3 Check Emulsion Clutch Chain capscrews.
Tension
A properly tensioned chain will move ¼ inch up and
¼ inch down at location (1). Loosen setscrew (2) on
idler and move idler to set proper chain tension.
Tighten setscrew (2).

7.7.6 Lubricate All Chains

Lubricate all chains with a quality chain lubricant.

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 TROUBLESHOOTING
7.7.7 Grease Conveyor Gate Pinion
Shaft Bearing
Pump grease into zerk (1) on end of shaft.

7.7.10 Check Conveyor Belt Tension

Compression springs are located at the front of the
conveyor to maintain tension on belt. Turn
7.7.8 Check Conveyor Gearbox Oil compression spring adjustment nuts to set spring
Level length to 5-1/2 in (140 mm) (1). Relaxed spring
tension is 6 in (152 mm) (2).
Clean area around plug (1) to ensure no dirt enters
the gearbox. Remove plug (1) on conveyor gearbox.
Gearbox oil must be at bottom of plug hole with
machine on level ground. Fill if necessary with AGMA
No 5EP, ISO-ASTM viscosity Grade 220 oil. Install
and tighten plug.

7.7.9 Inspect Conveyor Belt

Inspect conveyor belt, cross slats, chains and belt
splice for wear and damage. Repair or replace as
necessary.

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 TROUBLESHOOTING
7.8 MONTHLY

^ WARNING
Crushing, severing and entanglement
hazard.

Before performing inspections, service or

maintenance:
• Park the machine on firm, level
surface.
• Turn off truck engine and remove key.
Pugmill Paddle Timing
• Turn paver engine off.
• Lock control cabinet door and install The orientation of both timing diagrams is from the
do not operate tag. rear of the paver looking forward. The pugmill
• Install lockouts and do not operate paddles shown are at the forward end of the shafts.
tags on jackshaft control lever and
pugmill control lever. 7.8.2 Check Conveyor Gate Gearbox
Oil Level
7.8.1 Inspect Pugmill Timing Gears Clean area around plugs to ensure no dirt enters the
Inspect pugmill timing gears for wear and damage. gearbox. Remove plug (1) on conveyor gate gearbox.
Replace both gears if wear or damage is found on Gearbox oil must be at bottom of plug hole with
either gear. machine on level ground. If necessary, remove plug
(2) and add 90 wt. gear oil to proper level. Install and
NOTICE tighten plugs. Plug (3) is used to drain gearbox if
necessary.
Timing of the pugmill shafts is critical.

Machine damage will result if operated

with improperly timed pugmill shafts.

Timing of the pugmill shafts is critical. If the pugmill

shafts have been removed or disassembled, verify
that shafts have been properly time as illustrated in
the following graphics. If the shafts are out of time, do
not operate the pugmill, machine damage will result.

Pugmill Gear Timing

26
 TROUBLESHOOTING
gauge. Does conveyor function properly? If not, go
8 TROUBLESHOOTING to step 4.

^ WARNING 4. If clutch is engaging and jackshaft pressure is OK

then there is apparent damage in the conveyor or
Crushing, severing and entanglement gearbox. Maybe a cross slat or wear slat has
hazard. come loose or has broken. Remove conveyor
from machine, disassemble, inspect and repair as
Before performing inspections, service or necessary. Does conveyor function properly? If
maintenance: not, contact Bergkamp Customer Service.
• Park the machine on firm, level
surface. 8.3 EMULSION
• Turn off truck engine and remove key. Problem: Pump will not run.
• Turn engine off.
• Lock control cabinet door and install 1. Jackshaft not turning: Jackshaft hydraulic relief
do not operate tag. pressure set too low. Pressure setting should be
• Install lockouts and do not operate 3000 psi (207 bar). Does emulsion system
tags on jackshaft control lever and function properly? If not, go to step 2.
pugmill control lever.
2. Clutch not engaging. Check air valves and air
circuit supplying the clutch. Air pressure must
8.1 AIR SYSTEM maintain a minimum of 80 psi (5.5 bar) as read on
Problem: Difficult to maintain or achieve the truck gauge, not the paver gauge. Does
adequate air pressure. emulsion system function properly? If not, go to
step 3.
1. Check for air leaks throughout truck and
machine. Turn the truck and paver engine off with 3. Cold emulsion has set up in pump. Check hot
air present in the system. Operate all air actuated water circuit and operating valves of the heat
functions and listen for air leaks. Check for worn jacketing. Does emulsion system function
air compressor and verify truck air supply properly? If not, contact Bergkamp Customer
pressure. Make repairs as necessary. Service.

2. Drain air tanks daily. While draining tanks, check Problem: Pump runs but no emulsion flow.
for moisture and/or oil in the air. Make repairs as
necessary. 1. Check tank shut-off valve. Verify operation of the
air actuated emulsion valve.

8.2 AGGREGATE CONVEYOR 2. Pump is badly worn or damaged. Inspect pump

Problem: Conveyor does not operate. and repair or replace.

1. Jackshaft not turning: Jackshaft hydraulic relief 8.3.1 Emulsion Front Load Pump
pressure set too low. Pressure setting should be
3000 psi (207 bar). Refer to Jackshaft Pressure Problem: Pump will not run.
Adjustment Procedure in Repair Manual. Does
conveyor function properly? If not, go to step 2. 1. Verify hydraulic system pressure is set to 1850 psi
(128 bar). Check shut-off valve operation. Does
2. Air clutch partially engaging or not engaging at all. emulsion system function properly? If not, go to
Remove air line from clutch, check for air supply to step 2.
clutch. If no air to clutch, check the air valve for
operation and also check for air supply going to air 2. Hydraulic motor malfunction. Replace. Does
valve. Check switch components. Clean and emulsion system function properly? If not, contact
lubricate clutch splines. Does conveyor function Bergkamp Customer Service.
properly? If not, go to step 3.

3. Air clutch slipping. A ratcheting sound will be 8.4 MINERAL FILLER (CEMENT) AUGER
heard. Supply air pressure to clutch has become
Problem: Mineral filler (cement) auger does not
too low. Maintain pressure to a minimum of 80 psi
run.
(5.5 bar) as read on the truck gauge, not the paver
27
 TROUBLESHOOTING
1. Check for lumps or foreign objects caught in
auger. Press mineral filler (cement) auger reverse
knob (1) to loosen. Does mineral filler (cement)
auger function properly? If not, go to step 2.

2. Air actuated hydraulic valve not receiving air

signal. Disconnect air line to hydraulic valve (1)
and check for air flow. Test switches and lines
between supply and air actuator. Does water
2. Air pressure is not getting to hydraulic valve. pump run properly? If not, go to step 3.
Disconnect air lines (2) from valve with switch on,
to check for air pressure. If no air to valve, check 3. If hydraulic motor is getting signal but pump does
for air supply going to switch at control panel. not turn. Remove pump and disassemble,
Does mineral auger function properly? If not, go to checking for damage. Does water pump run
step 3. properly? If not, contact Bergkamp Customer
Service.

Problem: Pump turns but no water flow.

1. Ensure that ball valve at bottom of water tank is in

the on position and that the opening into the
suction line is unobstructed. Does water system
function properly? If not, go to step 2.

2. Check water strainer (1) for obstructions and clean

if necessary. Replace strainer if damaged. Does
water system function properly? If not, go to step
3.

3. Hydraulic valve is stuck and not sending oil to

motor. Remove the air actuators from end of
hydraulic valve and clean and lubricate with light
grease and install. Does mineral auger function
properly? If not, contact Bergkamp Customer
Service.

8.5 WATER SYSTEM

Problem: Pump does not turn.

1. Hydraulic valve (1) is stuck and not sending oil to 3. Check air signal to water shut-off valve (2)
motor. Remove air actuator (2). Clean and between pump and pugmill. Does water system
lubricate with light grease and install. Does water function properly? If not, contact Bergkamp
pump run properly? If not, go to step 2. Customer Service.

28
 TROUBLESHOOTING

3. Turn pressure regulating valve (2) in to raise

Problem: Pump and valve are off but water pressure. Does pressure washer function
continues to flow into pugmill. properly? If not, contact Bergkamp Customer
Service.
1. Disassemble water shut-off valve(2) between Problem: Pump does not turn.
pump and pugmill. Foreign objects or deposits will
build up on seats preventing it from closing.
1. Auxiliary pump hydraulic valve (1) is stuck and not
sending oil to motor. Remove air actuator (2).
8.5.1 Spray Bar Clean and lubricate with light grease and install.
Does water pump run properly? If not, go to step
2.
Problem: Not enough or no water flow.

1. Check ball valve at bottom of water tank.

2. Check water strainer for obstruction.

3. Check speed of pump, 3200-3400 RPM. (This

requires a strobe tachometer to check the speed.)

8.5.2 Pressure Washer

Problem: Pump is turning, no water flow.

1. Check ball valve at bottom of water tank. Does

2. Air actuated hydraulic valve not receiving air
pressure washer function properly? If not, go to
signal. Disconnect air line to valve (1) and check
step 2.
for air flow. Test switches and lines between
supply and air actuator. Does water pump run
2. Check water strainer (1) for obstructions and clean
properly? If not, go to step 3.
if necessary. Replace strainer if damaged. Does
pressure washer function properly? If not, go to
3. If hydraulic motor is getting signal but pump does
step 3.
not turn. Remove pump and disassemble,
checking for damage. Does water pump run
properly? If not, contact Bergkamp Customer
Service.

8.6 ADDITIVE SYSTEM

Problem: Pump does not turn.

1. Hydraulic valve (1) is stuck and not sending oil to

motor. Remove air actuator (2). Clean and
lubricate with light grease and install. Does
29
 TROUBLESHOOTING
additive system function properly? If not, go to
step 2.

3. Check air pressure to diaphragm valve between

pump discharge and pugmill. Does additive
2. Inspect additive system air lines for leaks. Verify system function properly? If not, contact
regulator (3) pressure is set to 80 - 85 psi (5.5 - Bergkamp Customer Service.
5.7 bar). Check switches and valves. Does
additive system function properly? If not, go to Problem: Pump and valve are off but additive
step 3. continues to flow into pugmill.

1. Inspect diaphragm valve located between mixer

discharge and pugmill. Foreign objects or
deposits will build up on seats preventing the valve
from proper closure.

8.7 PUGMILL
Problem: Pugmill will not turn.

1. Pugmill is dirty. The pugmill must be cleaned after

every use to counteract build-up on the shafts and
walls of the mixer. If the mixer is not clean, the
pugmill may stall or plug. Also, ensure that all
3. Remove the additive pump and inspect for paddles are in place to maintain mixer shaft
damage if the hydraulic circuit is verified as balance. Does pugmill function properly? If not, go
operable. Does additive system function properly? to step 2.
If not, contact Bergkamp Customer Service.
2. Oversized rocks in the mix. Reverse mixer and
Problem: Pump turns but no additive flow. dislodge oversized rock. If the problem persists, it
may be necessary to screen the aggregate. Does
1. Check ball valve at bottom of water and additive pugmill function properly? If not, go to step 3.
(1) tanks. Check supply of water and additive
within tanks. Does additive system function 3. Material sets too quick and causes the pugmill to
properly? If not, go to step 2. lock up. There may not be enough emulsion or
water or additive in mix, recheck mix design.
2. 10:1 Systems Only: Inspect water strainer (2) for Does pugmill function properly? If not, go to step
obstruction and clean as needed. Does additive 4.
system function properly? If not, go to step 3.
4. Relief setting of control valve set too low. Relief
should be set to 500 psi (34 bar) above system
pressure. Relief valve (1) is located on bottom of
directional valve. Does pugmill function properly?
If not, go to step 5.

5. Pugmill shafts may be improperly timed. If the

pugmill shafts have been removed, gear, bearings
and/or shafts replaced or disassembled, the shafts
30
 TROUBLESHOOTING
must be timed properly. Verify shaft timing is
correct. Does pugmill function properly? If not,
contact Bergkamp Customer Service.

Pugmill Gear Timing

Pugmill Paddle Timing

The orientation of both timing diagrams is from the

rear of the paver looking forward. The pugmill
paddles shown are at the forward end of the shafts.

31