Operator Controls
Center Console
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| Illustration 1 | g01166687 |
(1) Operator station selector switch | |
Operator station selector switch (1) is located on the center console. This two-position toggle switch provides input to the machine ECM. The machine ECM uses the input from this switch in order to control the operator station relays.
When operator station selector switch (1) is in the left position, the operator station relays are de-energized. The operator controls on the left operator station are active. When the switch is in the right position, the operator station relays are energized. The operator controls on the right operator station are active.
Left Side of Instrument Panel
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| Illustration 2 | g01166689 |
(2) Speed ratio dial (left drag conveyor) (3) Left drag conveyor mode switch (4) Left auger conveyor mode switch (5) Speed ratio dial (right drag conveyor) (6) Right drag conveyor mode switch (7) Right auger conveyor mode switch (8) Auger conveyor reverse switch | |
The operator platform is equipped with one operator station on the left side of the machine. A second operator station is located on the right side of the machine. The instrument panels for these operator stations are identical.
Each operator station contains the following:
- Speed ratio dial (2) (left drag conveyor)
- Left drag conveyor mode switch (3)
- Left auger conveyor mode switch (4)
- Speed ratio dial (5) (right drag conveyor)
- Right drag conveyor mode switch (6)
- Right auger conveyor mode switch (7)
- Auger conveyor reverse switch (8)
Speed Ratio Dial
Left drag conveyor speed ratio dial (2) and right drag conveyor speed ratio dial (5) allow the operator to vary the relative speed of the drag conveyors to the auger conveyors. The speed ratio dial is enabled when the drag conveyor is operating in the automatic mode. The left dial controls the left drag conveyor. The right dial controls the right drag conveyor.
The speed ratio dials for the drag conveyors are connected to individual potentiometers. The farthest counterclockwise position on the dials provides the maximum speed differential between the drag conveyors and the auger conveyors. When the dial is in this position, the drag conveyor operates at the minimum speed. The farthest clockwise position on the dials provides the minimum speed differential between the drag conveyors and the auger conveyors. When the dials are in this position, the drag conveyor operates at the maximum speed.
Drag Conveyor Mode Switches
Left drag conveyor mode switch (3) and right drag conveyor mode switch (6) are toggle switches with three positions. These switches control the drag conveyors. The left switch controls the left drag conveyor. The right switch controls the right drag conveyor. The middle position of each switch is the OFF position. The bottom position of each switch is the MANUAL position. The top position of each switch is the AUTOMATIC position.
When a drag conveyor mode switch is in the OFF position, the associated drag conveyor does not operate. When a drag conveyor mode switch is in the AUTOMATIC position, the machine ECM uses input from the corresponding drag conveyor speed ratio dial to operate the associated drag conveyor. When a drag conveyor mode switch is in the MANUAL position, the associated drag conveyor operates at maximum speed. The drag conveyor mode switches will return from the MANUAL position to the OFF position by the return spring force.
Note: In order for right-drag conveyor mode switch (6) to function, the right screed extension and the feeder mode switches must be in the AUTOMATIC position. The feeder mode switches are on the right screed operator panel. The left side of the machine functions identically to the right side of the machine.
Auger Conveyor Mode Switches
Left auger conveyor mode switch (4) and right auger conveyor mode switch (5) are toggle switches with three positions. These switches control the left auger conveyors and the switches control the right auger conveyor. The middle position of each switch is OFF. The top position of each switch is the MANUAL position. The bottom position of each switch is the AUTOMATIC position.
When an auger conveyor mode switch is in the OFF position, the associated auger conveyor does not operate. When an auger conveyor mode switch is in the AUTOMATIC position, the machine ECM analyzes the input from the corresponding material sensor and the corresponding material height dial. The machine ECM uses this information to operate the associated auger conveyor. When an auger conveyor mode switch is in the MANUAL position, the associated auger conveyor operates at maximum speed. The auger conveyor mode switches will return from the MANUAL position to the OFF position by return spring force.
Note: The feeder mode switches must be in the AUTOMATIC position in order for right auger conveyor mode switch (5) to function. The feeder mode switches are on the right-screed operator panel and on the right screed extension. The left side of the machine works in the same manner.
Auger Conveyor Reverse Switch
Auger conveyor reverse switch (8) is a momentary three-position toggle switch. This switch allows the operator to reverse the direction of the auger conveyors. Only one auger conveyor can be reserved at a time. The center position of the switch is the FORWARD position. The left position of the switch is the LEFT REVERSE position. The right position of the switch is the RIGHT REVERSE position. The switch is spring centered to the FORWARD position. The auger conveyor reverse switch provides input signals to the machine ECM. When a reverse input signal is present, the machine ECM energizes the corresponding electric displacement control valve in order to reverse the auger conveyor. In this situation, the auger conveyor operates at full speed in reverse.
Right Screed Operator Station
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| Illustration 3 | g01166724 |
Material Height Dial
Right material height dial (9) allows the operator to vary the amount of material which is present at the end of the right auger conveyor. The dial is connected to a potentiometer. The potentiometer is connected to a pulse width modulated buffer. The buffer converts the voltage signal which comes from the potentiometer into a pulse width modulated signal. The buffer directs the pulse width modulated signal to the machine ECM.
The machine ECM compares the input from right material height dial (9) to input from a sensor which monitors the amount of material at the end of the right auger conveyor. The machine ECM analyzes the input signals. The machine ECM then controls the drag conveyor and the auger conveyor in order to maintain the desired material height. The farthest counterclockwise position of the right material height dial provides the minimum amount of material. The farthest clockwise position of the right material height dial provides the maximum amount of material.
Note: Right material height dial (9) must be in the AUTOMATIC mode in order to control the material height at the end of the right auger conveyor.
Feeder Mode Switch
Right feeder mode switch (10) on the right screed operator panel is one of two feeder mode switches on the right side of the machine. The second switch is located at the right screed extension control box. These switches are momentary three-position toggle switches. The two feeder mode switches are wired in parallel. Either switch can override the other switch. The center switch position is AUTOMATIC. The top switch position is OVERRIDE. The bottom switch position is OFF. The feeder mode switches are returned to the AUTOMATIC position from the OVERRIDE position by the return spring force. Also, the feeder mode switches are returned to the AUTOMATIC position from the OFF position by the return spring force.
The feeder mode switches provide input to the machine ECM. When either right-feeder mode switch is in the OVERRIDE position, the machine ECM operates the right drag conveyor at full speed. Also, the machine ECM operates the right auger conveyor at full speed. When a right-feeder mode switch is in the OFF position, the machine ECM stops the right drag conveyor and the machine ECM stops the right auger conveyors. This action happens regardless of the position of the right-auger conveyor mode switches or the position of the right drag conveyor mode switches on the instrument panels.
Left Screed Operator Station
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| Illustration 4 | g01166726 |
Material Height Dial
Left material height dial (11) allows the operator to vary the amount of material which is present at the end of the left auger conveyor. The dial is connected to a potentiometer. The potentiometer is connected to a pulse width modulated buffer. The buffer converts the voltage signal which comes from the potentiometer into a pulse width modulated signal. The buffer directs the pulse width modulated signal to the machine ECM.
The machine ECM compares the input from left material height dial (9) to input from a sensor which monitors the amount of material at the end of the left auger conveyor. The machine ECM analyzes the input signals. The machine ECM controls the drag conveyor and the auger conveyor in order to maintain the desired material height. The farthest counterclockwise position of the left material height dial provides the minimum amount of material. The farthest clockwise position of the left material height dial provides the maximum amount of material.
Note: The auger conveyor system on the left side of the machine must be in the AUTOMATIC mode for left material height dial (11) in order to affect the material height which is at the end of the left auger conveyor.
Feeder Mode Switch
Left feeder mode switch (12) on the left screed operator panel is one of two feeder mode switches on the left side of the machine. The second switch is located at the left screed extension control box. These switches are momentary three-position toggle switches. The two feeder mode switches are wired in parallel. Either switch can override the other switch. The center switch position is the AUTOMATIC position. The top switch position is the OVERRIDE position. The bottom switch position is the OFF position. The feeder mode switches are returned to the AUTOMATIC position from the OVERRIDE position by return spring force. Also, the feeder mode switches are returned to the AUTOMATIC position from the OFF position by return spring force.
The feeder mode switches provide input to the machine ECM. When either left feeder mode switch is in the OVERRIDE position, the machine ECM operates the left drag conveyor at full speed. Also, the machine ECM operates the right auger conveyor at full speed. When a left feeder mode switch is in the OFF position, the machine ECM stops the left drag conveyor and the left auger conveyors. This action happens regardless of the position of the left auger conveyor mode switches on the instrument panels or the position of the left drag conveyor mode switches on the instrument panels.
Screed Extension Control Box
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| Illustration 5 | g01166727 |
The left screed extension and the right screed extension are equipped with screed extension control boxes. The left screed extension control box contains left feeder mode switch (13) . The right-screed extension control box contains a right feeder mode switch. These switches follow the same principles of operation as the feeder mode switches that are located at the screed operator stations.
Electrical System
Center Console (Front)
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| Illustration 6 | g01166728 |
(14) Circuit breaker (sensor) (15) Circuit breaker (machine ECM) (16) Circuit breaker (screed) (17) Circuit breaker (propel control system) (18) Circuit breaker (right screed extension) (19) Circuit breaker (left screed extension) | |
Circuit breakers protect the electrical components in the material feed system. These circuit breakers are located on the circuit breaker panel. This panel is located on the front of the center console. A decal below each circuit breaker identifies the function of the circuit breaker.
Circuit breaker (15) for the machine ECM receives power when the electrical disconnect switch is closed. The other circuit breakers in the material feed system receive power when the main power relay is energized.
Circuit breaker (14) (sensor) supplies power to the left paddle sensor and to the right paddle sensor. Circuit breaker (16) for the screed supplies power to electrical components on the right screed operator station. Also, the circuit breaker for the screed supplies power to the components on the left screed operator station. Circuit breaker (17) for the propel control system transfers power to the operator station selector switch. Circuit breaker (18) (right screed extension) supplies power to the switches on the right screed extension. Circuit breaker (19) (left screed extension) supplies power to the switches on the left screed extension.
Center Console (Interior)
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| Illustration 7 | g01166731 |
(20) "J1" connector (21) Machine ECM (22) "J2" connector | |
Machine ECM (21) is mounted to the left side of the center console. The machine ECM has two 70-pin connectors. "J1" connector (20) is the top connector. "J2" connector (22) is the bottom connector.
The machine ECM controls the material feed system. This ECM receives input signals from components around the machine which monitor current machine operating conditions. The software compares the gathered input to information that is stored in the memory of the ECM. The software evaluates the current conditions. The software then generates an output signal in order to control the material feed system within the set parameters.
Note: Machine ECM (21) is programmed with self-diagnostic logic. The service information can be accessed by using the Caterpillar Monitoring System.
Input Components
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| Illustration 8 | g02221314 |
Machine ECM (21) receives power from circuit breaker (15) at following three terminals:
- "J2-1"
- "J2-23"
- "J2-47"
The machine ECM is grounded at the following three terminals:
- "J2-2"
- "J2-22"
- "J2- 46"
In order to control the material feed system, machine ECM (21) gathers input from the following components:
- Operator station selector switch (right)
- Operator station selector switch (left)
- Implement lockout switch
- Left auger conveyor reverse switch
- Right auger conveyor reverse switch
- Right feeder mode switches (OFF)
- Right feeder mode switches(OVERRIDE)
- Left feeder mode switches(OFF)
- Left feeder mode switches(OVERRIDE)
- Left auger conveyor mode switches (MANUAL)
- Left auger conveyor mode switches (AUTOMATIC)
- Right auger conveyor mode switches (MANUAL)
- Right auger conveyor mode switches (AUTOMATIC)
- Right drag conveyor mode switches (MANUAL)
- Right drag conveyor mode switches (AUTOMATIC)
- Left drag conveyor mode switches (MANUAL)
- Left drag conveyor mode switches (AUTOMATIC)
- Left material height dial
- Right material height dial
- Right drag conveyor speed ratio dial
- Left drag conveyor speed ratio dial
- Left paddle sensor signal
- Left sonic sensor select switch
- Right paddle sensor signal
- Right sonic sensor select switch
Note: During automatic operation of the feeder system, machine ECM (21) monitors components in the propel control system in order to determine if the following conditions are met:
- The propel lever is in the FORWARD position.
- The speed dial is out of the MINIMUM position.
- The decelerator pedal is not fully depressed.
- The propel mode switch is in the PAVE position.
If any of these conditions are not met, the machine ECM will not automatically operate the feeder system. For additional information about the propel control system, refer to Specifications, Systems Operation/Testing and Adjusting, KENR5044.
Output Terminals
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| Illustration 9 | g02221315 |
The software in machine ECM (21) analyzes the input signals.
Then, the software determines if an output signal should be sent to the following components:
- Number one operator station relay
- Number two operator station relay
- Reverse electric displacement control valve (left auger conveyor)
- Forward electric displacement control valve (right auger conveyor)
- Reverse electric displacement control valve (right auger conveyor)
- Forward electric displacement control valve (left auger conveyor)
- Electric displacement control valve (right drag conveyor)
- Electric displacement control valve (left drag conveyor)
The circuits that should be completed are determined by the input signals that are analyzed by the machine ECM (21) . These circuits go to the operator station status indicators. The machine ECM completes the circuit at terminal "J2-33" when the operator station selector switch is in the RIGHT position. The machine ECM completes the circuit at terminal "J2-32" when the operator station selector switch is in the LEFT position.
Number One Operator Station Relay and Number Two Operation Station Relay
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| Illustration 10 | g01166829 |
(23) Number one operator station relay (24) Number two operator station relay | |
Number one operator station relay (23) and number two operator station relay (24) are located inside the center console.
Note: A decal which is on the door of the center console shows the location of each component inside the center console.
Machine ECM (21) uses the input from the operator station selector switch in order to control number one operator station relay (23) and number two operator station relay (24) . When the operator station selector switch is in the LEFT position, these relays are de-energized. When the operator station selector switch is in the RIGHT position, the machine ECM energizes these relays.
When number one operator station relay (23) is de-energized, power transfers to the following components:
- Left drag conveyor speed ratio dial on the left instrument panel
- Right drag conveyor speed ratio dial on the left instrument panel
When number one operator station relay (23) is energized, power is available at the following components:
- Left drag conveyor speed ratio dial on the right instrument panel
- Right drag conveyor speed ratio dial on the right instrument panel
When number two operator station relay (24) is de-energized, machine ECM (21) uses input from the following components in order to control the material feed system:
- Auger conveyor reverse switch on the left instrument panel
- Left drag conveyor mode switch on the left instrument panel
- Right drag conveyor mode switch on the left instrument panel
- Left auger conveyor mode switch on the left instrument panel
- Right auger conveyor mode switch on the left instrument panel
When number two operator station relay (24) is energized, machine ECM (21) uses input from the following components in order to control the material feed system:
- Auger conveyor reverse switch on the right instrument panel
- Left drag conveyor mode switch on the right instrument panel
- Right drag conveyor mode switch on the right instrument panel
- Left auger conveyor mode switch on the right instrument panel
- Right auger conveyor mode switch on the right instrument panel
Material Height Paddle
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| Illustration 11 | g01166833 |
(25) Rod (26) Protective Housing | |
A material height paddle is located on each side of the machine. During paving, the paddle rests on the asphalt at the outboard side of the auger conveyor. The paddle is pushed farther toward the outside of the machine as the amount of asphalt increases at the end of the auger conveyor. The paddle is connected to rod (25) which is connected to a sensor. The rod and the sensor are located inside protective housing (26) .
The paddle sensors provide pulse width modulated signals to the machine ECM. The machine ECM compares the input signals from the paddle sensors to the input signals from the material height dials. Then, the machine ECM determines if the actual amount of asphalt in front of the screed matches the desired amount (setpoint). If the actual amount of asphalt is greater than the desired amount on either side of the machine, the machine ECM stops the corresponding drag conveyor and auger conveyor motors. If the actual amount of asphalt is less than the desired amount, the machine ECM operates the drag conveyor and auger conveyor motors at varying speeds. As a result, the speed of the motors are proportional to the distance of the paddle from the setpoint.
Note: Sonic sensors can be used in place of the material height paddles. The sonic sensors operate by emitting sound waves. The amount of time that is needed for the sound waves to travel from the sonic sensor, to the asphalt pile, and then back to the sensor is monitored by the sonic sensor. The elapsed time is proportional to the amount of asphalt that is present in the auger conveyor. The machine ECM automatically determines the type of sensor that is being used.
Hydraulic System
Hydraulic Tank
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| Illustration 12 | g01166835 |
(27) Cap (28) Hydraulic tank (29) Sight gauge | |
Hydraulic tank (28) is located under the operator platform.
The following systems share a common hydraulic tank:
- Propel hydraulic system
- Auxiliary hydraulic system
- Material feed hydraulic system
- Vibratory hydraulic system
- Fan hydraulic system
Sight gauge (29) indicates the oil level in the tank. The capacity of the hydraulic tank is 152 L (40 US gal). Cap (27) for the hydraulic tank is equipped with a breather. The breather limits the maximum pressure in the tank to 50 ± 20 kPa (7.3 ± 3 psi). The breather also limits the vacuum which can be created in the tank to a maximum of 2 ± 0.7 kPa (0.3 ± 0.1 psi).
The vibratory pump supplies charge oil to the material feed hydraulic system. The vibratory pump draws oil from the tank through a 150µ suction screen. This screen is located inside the tank.
Charge Filter for the Material Feed Hydraulic System
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| Illustration 13 | g01166838 |
(30) Pressure tap (31) Pressure switch (32) Scheduled oil sampling tap (33) Charge filter (material feed system) | |
Charge filter (33) for the material feed system is located in the pump compartment, which is on the left side of the machine. The vibratory pump diverts oil through the charge filter. The base of the filter contains pressure switch (31) . The Caterpillar Monitoring System uses the input from the pressure switch on the hydraulic filter. This pressure switch is activated when the filter is plugged.
The base of charge filter (33) also contains pressure tap (30) and an scheduled oil sampling tap (32) . Charge pressure in the material feed system can be measured at the pressure tap in the filter base. When the material feed system is not operating, the charge pressure should be 2240 ± 172 kPa (325 ± 25 psi).
Vibratory Bypass Manifold
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| Illustration 14 | g01166839 |
(34) Vibratory bypass manifold | |
The vibratory pump directs oil to the inlet port on vibratory bypass manifold (34) . The vibratory bypass manifold is located on the left side of the machine under the operator platform.
When the vibratory system is off, supply oil from the vibratory pump flows through a check valve which is in vibratory bypass manifold (34) . After flowing through the check valve, the supply oil is sent to charge filter (33) for the material feed system.
When the vibratory system is operating, vibratory bypass manifold (34) forces oil through the vibratory motors. Return oil from the vibratory motors is directed to charge filter (33) for the material feed system.