AP655D Asphalt Paver Propel System Caterpillar

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Do not operate or work on this machine unless you have read and understand the instructions and warnings in the Operation and Maintenance Manual. Failure to follow the instructions or heed the warnings could result in injury or death. Contact your Caterpillar dealer for replacement manuals. Proper care is your responsibility.

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Escaping fluid under pressure, even a pinhole size leak, can penetrate body tissue, causing serious injury, and possible death. If fluid is injected into your skin, it must be treated immediately by a doctor familiar with this type of injury. Always use a board or cardboard when checking for a leak.

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Personal injury can result from rotating and moving parts. Stay clear of all rotating and moving parts. Never attempt adjustments while the machine is moving or the engine is running unless otherwise specified. The machine must be parked on a level surface and the engine stopped. Attach a "Do Not Operate" or similar warning tag to the start switch and controls before servicing, repairing, or making adjustments to the machine.

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Personal injury or death can result from sudden machine movement. Sudden movement of the machine can cause injury to persons on or near the machine. To prevent injury or death, make sure that the area around the machine is clear of personnel and obstructions before operating the machine.

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Personal injury can result from hydraulic oil pressure and hot oil. Hydraulic oil pressure can remain in the hydraulic system after the engine has been stopped. Serious injury can be caused if this pressure is not released before any service is done on the hydraulic system. Make sure all of the attachments have been lowered, and the oil is cool before removing any components or lines. Remove the oil filler cap only when the engine is stopped, and the filler cap is cool enough to touch with your bare hand.

A visual inspection of the propulsion system and the components that are part of this system is the first step during the diagnosis of a problem. Stop the engine, and make the following inspections.

1. Measure the oil level in the hydraulic oil tank.

2. Use a clear container to obtain an oil sample from the hydraulic tank immediately after the engine is stopped. Examine the sample for air bubbles.

3. Check all oil lines and check all connections for damage. Look for oil on the ground under the machine.

4. Remove the hydraulic oil filter and examine the filter element for debris.

   1. Shiny steel particles indicate a pump failure or shiny steel particles could indicate deterioration of the internal components of the pump. Shiny steel particles can also indicate failure of the motor or shiny steel particles could indicate deterioration of the internal components of the motor.

   2. Rubber particles indicate seal failures or hose failures.

   3. Bronze colored particles indicate a failure of a pump or a motor piston slipper.

   4. Aluminum particles indicate a failure of a fan motor.

Note: When foreign particles are found, all hydraulic systems on the machine must be thoroughly flushed. Each hydraulic system must be filtered independently. Do not reuse damaged parts.

5. Inspect the control linkages for damaged components.

6. Inspect the tracks for wear. Inspect the tracks for damage. The tracks may show the following signs of wear or damage:
   • Loose tracks

   • Broken parts

   • Worn rollers and wheels

   • Damaged tracks

   Repair the tracks if the tracks are worn or damaged.

7. Check the machine for loose wiring. Check the machine for frayed wiring.

8. Inspect the lights for broken bulbs. Inspect the lights for broken lenses. Replace the bulbs or the lenses if the bulbs or the lenses are broken.

9. Inspect the following for damage or wear:
   • Steps

   • Walkways

   • Handholds

   Repair any damaged components or worn components. Inspect these areas for cleanliness. Clean the components.

Checks During Operation

Operation checks can be used in order to find a valve or a pump that is not working. The speed of rod movement or the torque on a motor can be used to check the condition of the cylinders, motors, and pumps.

1. Monitor the extension and monitor the retraction of the cylinders. The movement of the cylinders should be smooth.

2. Listen for irregular noise that may come from the pumps.

3. Listen to the relief valves. Low pressure in the relief valves may cause an increase in oil temperature. Also, cycle time of the cylinders may increase.

   Note: High pressure in the hydraulic system may decrease the service life of hydraulic system components.

4. Observe the drift rates of the cylinders. Excessive drift rates can be caused by the following:
   • Cylinder leakage

   • Damaged O-ring seals on the control valves

   • Improper adjustment of the relief valves