AP-1000D and BG-260D Asphalt Pavers Caterpillar

To prevent injury, check around the machine. Keep all personnel clear of the machine prior to moving the machine. Keep the machine under control at all times in order to prevent injury.

Note: Do not allow riders on the operator's platform unless the rider is in the extra operator's seat. All riders must have a fastened seat belt.

Note: Do not allow riders on the screed when you road the machine.

To start down a grade, select the necessary propel range.

Note: When the grade is greater than 6 percent, select the PAVE position. After you start down a hill, do not change propel ranges.

Do not allow the engine to overspeed during downhill travel.

Moving the Machine

1. Adjust the operator's seat.

2. Fasten the seat belt.
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3. Move screed switch (5) to the RAISE position. Place the screed on the screed travel locks.

4. Move speed range switch (1) to either the PAVE or the TRAVEL position.

5. Move throttle control (6) to the FAST position. Do not move the machine until the engine reaches full speed.

6. Pull parking brake switch (4) to the OFF position in order to release the parking brake.

   Note: Make sure that both parking brake switches are in the OFF position before moving the machine.

7. Set the maximum speed with potentiometer (2). The potentiometer must be set higher than the lowest setting in order to move the machine.

8. Select forward travel or reverse travel with propel lever (3). Select the travel speed by moving the propel lever toward the rabbit until the desired travel speed is reached.

Receiving the First Load of Asphalt

1. Heat the screed. Refer to the Operation and Maintenance Manual for your screed in order to obtain information on heating the screed.
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2. Center the tow points to midstroke in order to allow equal travel in both directions.

3. Set the desired paving width. Refer to Operation and Maintenance Manual, "Screed Width Control" for information on setting the screed width.
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   Manual Crown Control

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   Power Crown Control

4. Set the main screed crown. Refer to the Operation and Maintenance Manual for your screed in order to obtain information on setting the main screed crown.
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   Manual Height Adjustment

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   Power Height Adjustment

5. Set the height of the extensions. Ensure that the height of the extensions match the height of the front of the main screed. The height of the extender is set at the factory with a positive angle of attack of 6.35 mm (0.25 inch). Set the height of the right extender and left extender at 6.35 mm (0.25 inch) above the zero mark. Refer to the Operation and Maintenance Manual for your screed in order to obtain information on setting the height of the extensions.

   Note: If a front extender is used, the height of the extenders should be 0.64 cm (0.25 inch) below the main screed. This will be different for each type of screed.

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   Manual Slope Control

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6. Set the desired slope for the extensions.

7. Adjust the screed. Refer to Operation and Maintenance Manual, "Screed Adjustment" for more information.
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8. Set the proper auger height by adjusting the switch for auger height (1).

9. Adjust the conveyor speed ratio dials (2) to the CENTER position. Turn the switches for the conveyors to the AUTO position.

10. Turn the switches (3) for the augers to the AUTO position.

Receiving the First Load of Asphalt

1. Move the truck toward the paver, until the truck wheels contact the paver push roller. If the machine is equipped with a truck hitch, the truck hitch must be in the OPEN position.
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2. When the truck is positioned, move switch (5) to the CLOSE position in order to close the truck hitch.

   Note: The paver has a slot in the tow point connection. The slot absorbs most of the shock that is caused by the contact of the truck and the paver.

   If the shock is great enough, the mat can be damaged. In order to stop the truck close to the paver, but not in contact with the paver, use spotters. The paver should move into contact with the truck.

3. When the truck is in the correct position, the spotter should start to dump the truck.

4. Hold feeder switch (4) in the "MANUAL" position. This will convey the material to the rear of the paver. This will distribute the material across the front of the screed.

5. When the head of the material at the outer edges of the screed is at the middle of the auger conveyor, move feeder switch (4) to the "AUTO" position.

Starting to Pave

1. Check the following switches. The switches must be in the proper position.

   • The speed control must be set to the PAVE position.

   • The parking brake switch must be set to the OFF position.

   • The conveyor control switches must be set to the AUTO position.

   • The auger control switches must be in the AUTO position.

   • Both vibrator switches should be in the ON position.

   • Both screed hoist controls should be in the LOWER position.

2. Push the propel lever completely forward.

3. Slowly turn the speed potentiometer until the paver reaches the desired ft/min. When you reach the correct ft/min, starts and stops should be done with the propel lever.

   Note: The brakes on the truck must be released enough to allow the paver to push the truck. There must be enough braking in order to keep the truck from rolling away from the paver.

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4. Make sure that the vibrator control (6) on the screed is in the ON position. To achieve the desired finish, adjust the speed of the vibratory system.

5. Check the head of material at the auger conveyor. Adjust the control for the conveyor speed in order to keep the head of material at the middle of the auger conveyor.

   Turning the control clockwise will increase the amount of material in front of the screed. Turning the control counterclockwise will decrease the amount of material in front of the screed.

   If the sensors are moved too far, a material shortage will occur at the outer edges of the screed.

   Moving the sensors outward will increase the outward flow of the material. If you move the sensors too far, the material will flow around the end plates.

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6. Check the mat thickness at several places across the mat. Make any adjustments to the controls that are needed.

   Note: Do not adjust the controls too often. Allow at least three lengths of the tow arm. This allows the adjustment to take effect before you make another adjustment. Whenever you make an adjustment, do not turn the thickness control more than 360 degrees at a time.

7. To increase the thickness of the mat, turn the thickness control clockwise. To increase the screed attack angle, turn the thickness control clockwise.

Setting the Paver Speed

After the paver has been set up and the paver has been adjusted, the best mats are produced when the paver is operated at a constant rate of speed.

The best paving speed is slightly faster than the delivery of the asphalt. Paving slightly faster than the delivery of the asphalt allows time for tasks such as raking joint surfaces.

When you change the speed of the paver, you must readjust the conveyor system in order to provide the proper amount of material. When you change the speed of the paver, the height of the screed may change. The screed will cause waves in the mat.

If it is necessary to speed up the paver in order to exhaust a group of waiting trucks, the operator must watch the finish of the mat. The operator must adjust the conveyor speeds in order to maintain a constant rpm. An increase in speed will decrease the thickness of the mat.

Note: The thickness controls may be different on different screeds.

Switching Operator Stations

Use the following procedure to switch operating stations during paving.

1. Bring the machine to a stop with the propel control at neutral.

2. Set the parking brake.

3. Maintain the screed hoist control in the DOWNWARD (float) setting.

4. Set all other machine functions to neutral.

5. Set the station select switch on the main console to the other station.

6. Set the parking brake at the new station.

7. Release the parking brake at the old station.

8. Sit at the new station and fasten the seat belt.

9. Release the parking brake and continue operation.

Ending a Mat

Several methods are used in order to obtain a good vertical edge at the end of a mat. The methods will allow a compactor to move on the mat and off the mat.

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One method of ending a mat uses a piece of paper (1) about 914 mm (3 ft) wide. The paper should be a little longer than the width of the mat.

The paver is run until all of the material in the hopper is used. The conveyors and the vibrators are stopped when the hopper is empty. The screed is lifted and the paver is moved away from the mat.

Rake the material evenly across the width of mat (3) in order to form an opening for the paper. The paper is laid across the width of the mat in the opening. Material (2) is raked onto the paper. The material is raked to the same depth as the mat that was laid.

A layer of dirt or other material can be used instead of the paper in order to achieve the same results.

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Another method of ending a mat uses board (5) that is the same thickness as compacted mat (6). An opening for the board is raked across the end of the mat. The board is placed into the opening. The remaining material is raked against the board in order to form ramp (4) for the compactor. The ramp will hold the board in place.

Parallel Joints

To make a parallel joint, a matching joint must be made between the two mats. It is preferable to match the mats before the first mat has cooled.

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To make a parallel joint, do not allow the compactor to roll closer than 150 to 300 mm (6 to 12 inches) to the edge of first mat (3) closest to joint surfaces (2). Roll the parallel joint when second mat (1) is rolled.

To make the parallel joint, the edge of the screed should overlap the first mat 25 to 50 mm (1 to 2 inches). The edge of the screed should be flush with the first mat.

If the first mat has been rolled, raise the screed in order to allow enough material for compaction. In order to match the second mat to the first mat, the second mat must be thick enough for the compaction of the second mat. Roll the parallel joint as soon as possible.

The parallel joint must be bonded to a cooled mat. When you lay the second mat, you must allow enough material to compact in order to match the cool mat thickness. A compactor should roll the joint immediately after the paver.

Transverse Joints

The quality of a transverse joint depends on the preparation that was made for the joint surface at the end of the first mat. The edge of the first mat should be vertical so a good bond can be made between the joint surfaces.

Note: When forming a joint surface before the first mat has had time to cool, do not compact the last 1.8 m (6 ft) of the first mat.

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When you are ready to make the joint surface, raise the screed and move the paver backward. Stop the paver when the edge of the first mat is 75 to 100 mm (3 to 4 inch) in front of the screed. Lower the screed onto the slats that are thick enough for the compaction of the mat.

With the screed on the first mat, adjust the thickness controls if the thickness controls have been changed. Fill the auger conveyor with asphalt. Start paving.

When you set the thickness controls, you must allow enough material in order to compact the second mat. Adjust the thickness controls in order to achieve the desired mat thickness.

Paving Around Manholes

The procedure for laying asphalt around a manhole depends on the course that is paved.

The surface of the mat will usually be higher than the top of the manhole after you lay the top course.

When you are laying two layers of asphalt, and you are laying the bottom course, the screed will not pass over the manhole. The screed must be raised in order to allow the screed to pass over the manhole. Return the screed to the proper height after passing over the manhole.

To mark the position of the manhole, place a mark alongside the mat. The mark will help the operator judge the position of the manhole while the manhole is under the paver.

The paver should be stopped when the screed is almost in contact with the manhole. The screed should be raised at this point in order to allow the screed to pass over the manhole. Raise the screed. Move the paver forward until the screed is just past the manhole. When the screed is just past the manhole, the screed is lowered to the original position.

Rake the excess material that is left on the ground around the manhole.

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If the position of the manhole will cause one of the tracks to pass over the manhole, use the thickness controls to keep the screed at the desired height as the track passes over the manhole.

For the track to travel over a manhole, a ramp must be constructed if the manhole is more than 76 mm (3 inch) above the surface.

To make the ramps, use material from the hopper of the machine.

Any asphalt on top of the manhole should be removed before the compactor passes over the manhole.