AP600D and BG600D Asphalt Pavers Propel System Caterpillar

Pump Synchronization - Test and Adjust

Usage:

Note: Perform this procedure if the machine drifts to one side during straight travel operation.

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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.

Drive the machine to a smooth, horizontal surface.

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Illustration 1	g01477434

Move propel lever (4) to the NEUTRAL position.

Rotate speed dial (2) to the MINIMUM position.

Move parking brake switch (1) to the ON position.

Move travel mode switch (3) to the TRAVEL position.

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Illustration 2	g01477436

Move lift switch (5) for the screed to the RAISE position. Completely lift the screed.

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Illustration 3	g01477437

Engage mechanism (6) for the lock for the screed on both sides of the machine.

Move lift switch (5) for the screed to the FLOAT position. Allow the tow arms to rest on screed locks (6) .
Note: The lift switch for the screed on the inactive operator station must also be in the FLOAT position in order to lower the screed.

Rotate speed dial (2) to the MAXIMUM position.

Move parking brake switch (1) to the OFF position.
Note: The parking brake switch on the inactive operator station must also be in the OFF position.

Use propel lever (4) in order to control the speed and direction of travel (forward or reverse).

Drive the machine to a clear area that is free from personnel and equipment. The area must be clear within a minimum radius of the machine of 30.5 m (100 ft). The area must be level. The area must have a hard, consistent surface.

Move propel lever (4) to the NEUTRAL position.

Move parking brake switch (1) to the ON position.

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Illustration 4	g01477438

Turn the steering wheel to the STRAIGHT position. The assistant will need to place a straight edge against the rims of left wheels (7). Turn the steering wheel until the rims are parallel. If the rims are not parallel, adjust tie rod (8) until the rims are parallel. Do not turn the steering wheel after the wheels are aligned.

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Illustration 5	g01477519

The assistant will need to place a straight edge against the rims of the right wheels. If the rims are not parallel, adjust tie rod (9) until the rims are parallel.
Note: If an adjustment was made in Step 15 or Step 16, recalibrate the settings in order to center the steering to the electronic control module (ECM) for the machine. For the calibration procedure, refer to Troubleshooting, KENR5919, "Electrical Systems".

Move travel mode switch (3) to the PAVE position.

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Illustration 6	g01477439

Monitor the hydraulic oil temperature on the operator display. Operate the machine until the oil temperature reaches 43 ± 5.6 °C (110 ± 10 °F).

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Illustration 7	g01477441

Remove two screws (10). Remove access panel (11) from the bottom of the left instrument panel.

Establish a 6 m (20 ft) string line in front of the machine. The string line should run from the center of the front wheels, which should also be parallel with the rear wheels.

Move parking brake switch (1) to the OFF position.

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Illustration 8	g01477443

If the gauge cluster is not displayed on the operator display screen, press home key (12) and then press escape key (13) .

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Illustration 9	g01477444

Simultaneously move the following switches into the FORWARD position:
- Left override switch (14) for propel
- Right override switch (15) for propel
Note: The FORWARD position of the override switches is up.

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Illustration 10	g01477445

A fault will appear on the display. Press OK key (16) in order to acknowledge the fault and return the display to the screen of the gauge cluster.

Use the gauge cluster in the operator display in order to record the travel speed in the forward direction.

After the machine has moved 6 m (20 ft), simultaneously release the following switches:
- Left override switch (14) for propel
- Right override switch (15) for propel
Note: The REVERSE position of the override switches is down.

Move parking brake switch (1) to the ON position.

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Illustration 11	g01477446
(A) 6 m (20 ft) (distance of stringline) (B) 127 mm (5 inch) (allowable drift to left) (C) 127 mm (5 inch) (allowable drift to right)

Measure the distance of the drift. The machine may drift to left (B) or the machine may drift to right (C). The drift cannot exceed the amount that has been specified. refer to Illustration 11.

Establish a 6 m (20 ft) string line to the rear of the machine. The string line should run from the center of the front wheels, parallel with the rear wheels.

Move parking brake switch (1) to the OFF position.

Simultaneously move the following switches into the REVERSE position:
- Left override switch (15) for propel
- Right override switch (15) for propel

A fault will appear on the display. Press OK key (16) in order to acknowledge the fault and return the display to the screen of the gauge cluster.

Use the gauge cluster in the operator display in order to record the travel speed in the reverse direction.

After the machine has moved 6 m (20 ft), simultaneously release the following switches:
- Left override switch (14) for propel
- Right override switch (15) for propel

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Illustration 12	g01477520

Move parking brake switch (1) to the ON position.

Move throttle control switch (17) to the LOW IDLE position. Hold the switch in this position for less than 1 second.

After the engine reaches low idle, move engine start switch (18) to the OFF position.

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Illustration 13	g01477449
(D) 6 m (20 ft) (distance of stringline) (E) 305 mm (12 inches) (allowable drift to left) (F) 305 mm (12 inches) (allowable drift to right)

Measure the distance of machine drifts. The machine may drift to left (E) or the machine may drift to right (F). The drift cannot exceed the amount that has been specified. Refer to Illustration 13.

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Table 1
Adjustment for Pump Neutral
Speed Condition	Travels Straight Forward Using Override Switches for the Propel.	Excessive Drift to Left in Forward Using Override Switches for the Propel	Excessive Drift to Right in Forward Using Override Switches for the Propel
Speed Forward and Speed Reverse Within 7.0 m/min (23 ft/min).	No adjustment is necessary.	Adjust the screw for the left pump neutral counterclockwise for one-eighth of a turn.	Adjust the screw for the left pump neutral clockwise for one-eighth of a turn.
	No adjustment is necessary.	Adjust the screw for the right pump neutral clockwise for one-eighth of a turn.	Adjust the screw for the right pump neutral counterclockwise for one-eighth of a turn.
Speed Forward 7.0 m/min (23 ft/min) is Less Than Speed Reverse.	Adjust the screw for the left pump neutral counterclockwise for one-eighth of a turn.	Adjust the screw for the left pump neutral counterclockwise for one-eighth of a turn.	Adjust the screw for the right pump neutral counterclockwise for one-eighth of a turn.
	Adjust the screw for the right pump neutral counterclockwise for one-eighth of a turn.
Speed Forward 7.0 m/min (23 ft/min) is Greater Than Speed Reverse.	Adjust the screw for the left pump neutral clockwise for one-eighth of a turn.	Adjust the screw for the right pump neutral clockwise for one-eighth of a turn.	Adjust the screw for the right pump neutral clockwise for one-eighth of a turn.
	Adjust the screw for the left pump neutral clockwise for one-eighth of a turn.

Use the information in Table 1 in order to determine if an adjustment should be made.

If no adjustment is necessary, go to Step 50. If an adjustment is necessary, go to Step 41.

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Illustration 14	g01477458

Open pump compartment (19), which is on the right side of the machine.

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Illustration 15	g01477459

Move hopper switch (20) to the RAISE position. Release the switch when the hopper cylinders are completely retracted.

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Illustration 16	g01477461

Engage lock pin (21) for the hopper on both sides of the machine.

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Illustration 17	g01477451
(22) Locknut on right pump (23) Adjustment screw on right pump

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Illustration 18	g01477452
(24) Locknut on left pump (25) Adjustment screw on left pump

Loosen the locknut on the adjustment mechanism for the pump that has been indicated in Table 1. Turn the adjustment screw that has been indicated in Table 1. It may be necessary to adjust both pumps.

Hold the adjustment screw, and tighten the locknut to 52 N·m (39 lb ft).

Close pump compartment door (19).

Move engine start switch (18) to the START position. Release the engine start switch when the engine starts.

Operate the engine at low idle for a few minutes.

Move throttle control switch (17) to the HIGH IDLE position. Hold the switch in this position for less than 1 second. The engine speed should increase to 2200 rpm. Go to Step 20.

Replace the cover for the override switch (11) for the propel and install screws (10) .

If an adjustment was made, recalibrate the initial current setting to the electronic control module (ECM) for the pump. Refer to the "Forward Currents-Calibrate" procedure and the "Reverse Currents-Calibrate" procedure that is contained within this manual for the calibration procedure.