AP600D Asphalt Paver Machine Systems Caterpillar

Illustration 1	g01586108
Front of Center Console (1) Circuit breaker panel (2) Circuit breaker for the machine ECM (3) Circuit breaker for the operator ECM (4) Circuit breaker for the screed ECM (5) Circuit breaker for the screed (6) Circuit breaker for limp home mode (7) Circuit breaker for the sensor (8) Circuit breaker for grade and slope

The circuit breaker panel is mounted to the door of the compartment at the front of the operator platform. The compartment door provides access to this panel. A decal below each circuit breaker identifies the function of the circuit breaker. The circuit breaker panel contains the following circuit breakers, which are part of the material feed system:

• Circuit breaker for the machine ECM (2)

• Circuit breaker (3) for the operator ECM

• Circuit breaker (4) for the screed ECM

• Circuit breaker (5) for the screed

• Circuit breaker (6) for limp home mode

• Circuit breaker (7) for the sensor

• Circuit breaker (8) for grade and slope

When the electrical disconnect switch is in the ON position, power from the main circuit breaker is available at the following circuit breakers: circuit breaker (2) for the machine ECM, circuit breaker (3) for the operator ECM and circuit breaker (4) for the screed ECM. When the main power relay is energized, power is available at the following circuit breakers: circuit breaker (5) for the screed, circuit breaker (6) for limp home mode, Circuit breaker (7) for the sensor and circuit breaker (8) for grade and slope.

Circuit breaker (2) for the machine ECM is a manual reset breaker. This circuit breaker is rated at 20 amp. Power transfers from the circuit breaker for the machine ECM to the following locations:

• Terminal "J1-31" of the machine ECM

• Terminal "J1-39" of the machine ECM

• Terminal "J1-47" of the machine ECM

Circuit breaker (3) for the operator ECM is a manual reset breaker. This circuit breaker is rated at 15 amp. Power transfers from the circuit breaker for the operator ECM to the following locations:

• Terminal "J1-31" of the operator control unit

• Terminal "J1-39" of the operator control unit

• Terminal "J1-47" of the operator control unit

Screed ECM circuit breaker (4) is a manual reset breaker. This circuit breaker is rated at 15 amp. Power transfers from the screed ECM circuit breaker to the following locations:

• Terminal "J1-31" of the screed ECM

• Terminal "J1-39" of the screed ECM

Circuit breaker (5) for the screed is a manual reset breaker. This circuit breaker is rated at 15 amp. Power transfers from the circuit breaker for the screed to terminal "J1-1" of the screed ECM.

Circuit breaker (6) for limp home mode is a manual reset breaker. This circuit breaker is rated at 15 amp. Power transfers from the circuit breaker for limp home mode to terminal "J1-1" of the machine ECM.

Circuit breaker (7) for the sensor is a manual reset breaker. This circuit breaker is rated at 15 amp. Power transfers from the circuit breaker for the sensor to the following locations:

• Contact "A" of the sonic sensor for the left conveyor

• Contact "A" of the sonic sensor for the right conveyor

Circuit breaker (8) for grade and slope is a manual reset breaker. This circuit breaker is rated at 15 amp. Power transfers from the circuit breaker for grade and slope to the following locations:

• Terminal "1" of the left material height sonic sensor

• Terminal "1" of the right sonic sensor for height of material

Illustration 2	g01586113
Top of Operator Station (9) Connector "J1" (10) Operator control unit (11) Connector "J2"

Operator control unit (10) is mounted to the door of the compartment at the top of the operator station. This control unit has two 70-pin connectors. Connector "J1" (9) is the connector which is farthest from the hinge of the compartment door. Connector "J2" (11) is the connector which is closest to the hinge of the compartment door.

Operator control unit (10) monitors input devices which are located in the operator station. The operator control unit communicates with the machine ECM through the Cat Data Link and the CAN lines.

Illustration 3	g01586134
Connector "J1" for the Operator Control Unit

When the electrical disconnect switch is in the ON position, power transfers from circuit breaker (3) for the operator ECM to the following terminals of operator control unit (10) : terminal "J1-31", terminal "J1-39" and terminal "J1-47". This voltage input provides the power for the processor. When the engine start switch is in the ON position, power transfers from contact "R" of the switch to terminal "J1-1" of the operator control unit. This voltage input provides the wakeup signal to the operator control unit. The operator control unit is grounded at the following terminals: terminal "J1-13", terminal "J1-23" and terminal "J1-57".

In order to control the material feed system, operator control unit (10) gathers input from the following components at connector "J1":

• Left auger reverse switch (terminal "J1-35")

• Left auger mode switch (terminal "J1-40" and terminal "J1-41")

• Left conveyor mode switch (terminal "J1-42" and terminal "J1-43")

• Right conveyor speed dial (terminal "J1-29")

• Left conveyor speed dial (terminal "J1-22")

Operator control unit (10) monitors the condition of the circuit at terminal "J1-35" in order to determine the position of the auger reverse switch. When the circuit at terminal "J1-35" is grounded, the control unit determines that the auger reverse switch is in the LEFT position.

Note: Operator control unit (10) also monitors the circuit at terminal "J2-37" in order to determine the position of the auger reverse switch for the right auger. If the circuit at "J1-35" and the circuit at "J2-37" are both floating, the operator control unit determines that the auger reverse switch is in the OFF position.

Operator control unit (10) simultaneously monitors the condition of the circuit at terminal "J1-40" and the circuit at terminal "J1-41" in order to determine the position of the left auger mode switch. When the circuit at terminal "J1-40" is grounded and the circuit at terminal "J1-41" is floating, the control unit determines that the left auger mode switch is in the AUTOMATIC position. When the circuit at terminal "J1-40" is floating and the circuit at terminal "J1-41" is grounded, the control unit determines that the left auger mode switch is in the MANUAL position. If the circuit at "J1-40" and the circuit at "J1-41" are both floating, the operator control unit determines that the left auger mode switch is in the OFF position.

Operator control unit (10) simultaneously monitors the condition of the circuit at terminal "J1-42" and the circuit at terminal "J1-43" in order to determine the position of the left conveyor mode switch. When the circuit at terminal "J1-42" is grounded and the circuit at terminal "J1-43" is floating, the control unit determines that the left conveyor mode switch is in the AUTOMATIC position. When the circuit at terminal "J1-42" is floating and the circuit at terminal "J1-43" is grounded, the control unit determines that the left conveyor mode switch is in the MANUAL position. If the circuit at "J1-42" and the circuit at "J1-43" are both floating, the operator control unit determines that the left conveyor mode switch is in the OFF position.

Operator control unit (10) analyzes input signals from the left conveyor speed dial and from the right conveyor speed dial. The sensor on the left conveyor speed dial is connected to terminal "J1-22" of the operator control unit. The sensor on the right conveyor speed dial is connected to terminal "J1-29" of the operator control unit. The operator control unit monitors each sensor. Each circuit works in the following way. The ECM provides an internal 5 volt power source. The circuit between this power source and the machine ground contains two resistors. One resistor has a fixed resistance. This resistor is located inside the ECM. The second resistor is a variable pull -down resistor. This resistor is the sensor on the conveyor speed dial.

Operator control unit (10) can determine the position of the left conveyor speed dial by monitoring the voltage at terminal "J1-22". When the dial is in the MINIMUM position, the voltage at terminal "J1-22" is approximately 1.75 volts. When the dial is in the MAXIMUM position, the voltage at terminal "J1-22" is approximately 3.25 volts.

Operator control unit (10) can determine the position of the right conveyor speed dial by monitoring the voltage at terminal "J1-29". The right conveyor speed dial follows the same principles of operation as the left conveyor speed dial.

Externally, the machine ECM and operator control unit (10) appear to be identical. However, because of the internal differences, the machine ECM has a different part number than the part number for the operator control unit. In order to prevent incorrect software installation, the harness configuration at each control unit provides a series of input signals from the switches. These signals identify the unit's function. The operator control unit is wired in the following way:

• Terminal "J1-26" (open)

• Terminal "J1-27" (ground)

• Terminal "J1-28" (ground)

• Terminal "J1-32" (open)

Operator control unit (10) communicates with the machine ECM with electronic service tools through the Cat Data Link. The Cat Data Link is a proprietary standard for communication that was developed by Caterpillar. The Cat Data Link requires a positive line and a negative line. The positive line is connected to terminal "J1-10" of the machine ECM. The negative line is connected to terminal "J1-20" of the machine ECM.

Illustration 4	g01586135
Connector "J2" for the Operator Control Unit

Operator control unit (10) monitors input signals from the following components in the material feed system at connector "J2":

• Right auger reverse switch (terminal "J2-37")

• Conveyor reverse switch (terminal "J2-36")

• Right auger mode switch (terminal "J2-38" and terminal "J2-39")

• Right conveyor mode switch (terminal "J2-44" and terminal "J2-45")

Operator control unit (10) monitors the condition of the circuit at terminal "J2-37" in order to determine the position of the auger reverse switch. When the circuit at terminal "J2-37" is grounded, the control unit determines that the auger reverse switch is in the RIGHT position.

Note: Operator control unit (10) also monitors the circuit at terminal "J1-35" in order to determine the position of the auger reverse switch for the left auger. If the circuit at "J1-35" and the circuit at "J2-37" are both floating, the operator control unit determines that the auger reverse switch is in the OFF position.

Operator control unit (10) monitors the condition of the circuit at terminal "J2-36" in order to determine the position of the conveyor reverse switch. When the circuit at terminal "J2-36" is grounded, the control unit determines that the conveyor reverse switch is in the REVERSE position. When the circuit at terminal "J2-36" is floating, the control unit determines that the conveyor reverse switch is in the FORWARD position.

Operator control unit (10) simultaneously monitors the condition of the circuit at terminal "J2-38" and the circuit at terminal "J2-39" in order to determine the position of the right auger mode switch. When the circuit at terminal "J2-38" is grounded and the circuit at terminal "J2-39" is floating, the control unit determines that the right auger mode switch is in the AUTOMATIC position. When the circuit at terminal "J2-38" is floating and the circuit at terminal "J2-39" is grounded, the control unit determines that the right auger mode switch is in the MANUAL position. If the circuit at "J2-38" and the circuit at "J2-39" are both floating, the operator control unit determines that the right auger mode switch is in the OFF position.

Operator control unit (10) simultaneously monitors the condition of the circuit at terminal "J2-44" and the circuit at terminal "J2-45" in order to determine the position of the right conveyor mode switch. When the circuit at terminal "J2-44" is grounded and the circuit at terminal "J2-45" is floating, the control unit determines that the right conveyor mode switch is in the AUTOMATIC position. When the circuit at terminal "J2-44" is floating and the circuit at terminal "J2-45" is grounded, the control unit determines that the right conveyor mode switch is in the MANUAL position. If the circuit at "J2-44" and the circuit at "J2-45" are both floating, the operator control unit determines that the right conveyor mode switch is in the OFF position.

Terminal "J2-22" of operator control unit (10) provides a common ground for the following digital input devices in the material feed system:

• Left conveyor mode switch

• Right conveyor mode switch

• Conveyor reverse switch

• Left auger mode switch

• Right auger mode switch

• Auger reverse switch

• Left conveyor speed dial

• Right conveyor speed dial

Illustration 5	g01586139
Inside Center Console (12) Machine ECM (13) Connector "J2" (14) Connector "J1"

Machine ECM (12) is mounted to the door of the compartment at the front of the operator station. The compartment door provides access to this component.

Machine ECM (12) works in conjunction with the operator control unit in order to control the material feed system. This ECM has two 70-pin connectors. Connector "J1" (14) and connector "J2" (13) receive input signals from components around the machine which monitor current machine operating conditions. System software compares the gathered input to information which is stored in the memory of the ECM. The software evaluates the current conditions. Then, the software generates an output signal in order to control the material feed system within set parameters.

Illustration 6	g01586140
Connector "J1" for the Machine ECM

When the electrical disconnect switch is in the ON position, power transfers from circuit breaker (2) for the machine ECM to the following terminals of machine ECM (12) : terminal "J1-31", terminal "J1-39" and terminal "J1-47". This voltage input provides the power for the processor. When the main power relay is energized, power transfers from circuit breaker (6) for limp home mode to terminal "J1-1" of the machine ECM. This voltage input provides the wakeup signal to the machine ECM. The machine ECM is grounded at the following terminals: terminal "J1-13", terminal "J1-23" and terminal "J1-57",

The electronic control system analyzes input signals and the electronic control system determines if an output signal should be sent to the EDC valves on the auger pumps. The forward solenoid on the EDC valve on the left auger pump is controlled at terminal "J1-58" of machine ECM (12). The reverse solenoid on the EDC valve on the left auger pump is controlled at terminal "J1-59" of the machine ECM. The forward solenoid on the EDC valve on the right auger pump is controlled at terminal "J1-61" of the machine ECM. The reverse solenoid on the EDC valve on the right auger pump is controlled at terminal "J1-62" of the machine ECM.

The electronic control system analyzes input signals and the electronic control system determines if an output signal should be sent to the EDC valves on the conveyor pumps. The forward solenoid on the EDC valve on the left conveyor pump is controlled at terminal "J1-67" of machine ECM (12). The reverse solenoid on the EDC valve on the left conveyor pump is controlled at terminal "J1-68" of the machine ECM. The forward solenoid on the EDC valve on the right conveyor pump is controlled at terminal "J1-65" of the machine ECM. The reverse solenoid on the EDC valve on the right conveyor pump is controlled at terminal "J1-66" of the machine ECM.

Machine ECM (12) provides a ground path for the EDC valve for the auger pump at terminal "J1-60". The machine ECM provides a ground path for the EDC valve for the conveyor pump at terminal "J1-55".

Machine ECM (12) simultaneously monitors the condition of the circuit at terminal "J1-40" and the circuit at terminal "J1-41" in order to determine whether the machine is using sonic sensors for the conveyor. If sonic sensors for the conveyor are installed, conveyor speed is controlled independently of the auger speed. When operating the machine in automatic mode, the speed of the conveyor is determined by the height of the material at the end of the conveyors and the position of the conveyor speed dials.

Externally, machine ECM (12) and operator control unit (10) appear to be identical. However, due to internal differences, the machine ECM has a different part number than the operator control unit. In order to prevent incorrect software installation, the harness configuration at each control unit provides a series of input signals from the switch. These signals identify the unit's function. The machine ECM is wired in the following way:

• Terminal "J1-26" (ground)

• Terminal "J1-27" (open)

• Terminal "J1-28" (open)

• Terminal "J1-32" (ground)

Machine ECM (12) communicates with the other control units on the machine and with electronic service tools through the Cat Data Link. The Cat Data Link is a proprietary standard of communication that was developed by Caterpillar. The Cat Data Link requires a positive line and a negative line. The positive line is connected to terminal "J1-10" of the machine ECM. The negative line is connected to terminal "J1-20" of the machine ECM.

Illustration 7	g01586141
Connector "J2" for the Machine ECM

In machines that are equipped with optional sonic sensors for the conveyor, machine ECM (12) receives a digital input signal from the left sonic sensor for the conveyor at terminal "J2-24" and the right sonic sensor for the conveyor at terminal "J2-25". The machine ECM uses the input of these sensors to determine the height of the material at the end of the conveyors.

When sonic sensors for the conveyors are providing input signals to the machine ECM, the conveyor speed is determined by the height of material at the end of the conveyor and by the position of the conveyor speed dials. In this case, conveyor speed is independent of auger speed.

Machine ECM (12) provides a ground path for the sonic sensors for the conveyors at terminal "J2-22".

Illustration 8	g01586143
Screed Platform (15) Connector "J2" (16) Screed ECM (17) Connector "J1"

Screed ECM (16) is located below the walkway on the right side of the screed. This ECM has two 70-pin connectors. Connector "J1" (17) is the left connector. Connector "J2" (15) is the right connector.

Screed ECM (16) works in conjunction with the operator control unit and the machine ECM in order to control the material feed system. The screed ECM receives input signals from components on the screed. This information transfers to machine ECM (12) through the Cat Data Link.

Illustration 9	g01586145
Connector "J1" for the Screed ECM

When the electrical disconnect switch is in the ON position, power transfers from circuit breaker (4) for the screed ECM to terminal "J1-31" and to terminal "J1-39" of screed ECM (16). This voltage input provides the power for the processor. When the main power relay is energized, power transfers from circuit breaker (5) for the screed to terminal "J1-1" of the screed ECM. This voltage input provides the wakeup signal to the screed ECM. The screed ECM is grounded at terminal "J1-13".

Screed ECM (16) monitors input signals from the following components in the material feed system:

• Left conveyor master switch (terminal "J1-27" and terminal "J1-28")

• Left conveyor stop switch (terminal "J1-34" and terminal "J1-35")

• Right conveyor stop switch (terminal "J1-40" and terminal "J1-41")

• Left auger master switch (terminal "J1-32" and terminal "J1-33")

• Left material height dial (terminal "J1-22")

• Right material height dial (terminal "J1-29")

Screed ECM (16) simultaneously monitors the condition of the circuit at terminal "J1-27" and the circuit at terminal "J1-28" in order to determine the position of the left conveyor master switch. When the circuit at terminal "J1-27" is grounded and the circuit at terminal "J1-28" is floating, the control unit determines that the left conveyor master switch is in the MANUAL position. When the circuit at terminal "J1-27" is floating and the circuit at terminal "J1-28" is grounded, the control unit determines that the left conveyor master switch is in the REVERSE position. If the circuit at "J1-27" and the circuit at "J1-28" are both floating, the control unit determines that the left conveyor master switch is in the AUTOMATIC position.

Screed ECM (16) simultaneously monitors the condition of the circuit at terminal "J1-32" and the circuit at terminal "J1-33" in order to determine the position of the left auger master switch. When the circuit at terminal "J1-33" is grounded and the circuit at terminal "J1-32" is floating, the control unit determines that the left auger master switch is in the REVERSE position. When the circuit at terminal "J1-33" is floating and the circuit at terminal "J1-32" is grounded, the control unit determines that the left auger master switch is in the MANUAL position. If the circuit at "J1-32" and the circuit at "J1-33" are both floating, the control unit determines that the left auger master switch is in the AUTOMATIC position.

Screed ECM (16) simultaneously monitors the condition of the circuit at terminal "J1-34" and the circuit at terminal "J1-35" in order to determine the position of the left conveyor stop switch. When the circuit at terminal "J1-34" is grounded and the circuit at terminal "J1-35" is floating, the control unit determines that the left conveyor stop switch is in the LEFT position. When the circuit at terminal "J1-34" is floating and the circuit at terminal "J1-35" is grounded, the control unit determines that the left conveyor stop switch is in the BOTH position. If the circuit at "J1-34" and the circuit at "J1-35" are both floating, the control unit determines that the left conveyor stop switch is in the AUTOMATIC position.

Screed ECM (16) simultaneously monitors the condition of the circuit at terminal "J1-40" and the circuit at terminal "J1-41" in order to determine the position of the right conveyor stop switch. When the circuit at terminal "J1-40" is grounded and the circuit at terminal "J1-41" is floating, the control unit determines that the right conveyor stop switch is in the RIGHT position. When the circuit at terminal "J1-40" is floating and the circuit at terminal "J1-41" is grounded, the control unit determines that the right conveyor stop switch is in the BOTH position.

Screed ECM (16) monitors the condition of the circuit at terminal "J1-22" in order to determine the position of the left material height dial. The screed ECM monitors the condition of the circuit at terminal "J1-29" in order to determine the position of the right material height dial. Each dial is connected to a potentiometer.

Screed ECM (16) analyzes input signals from the left material height dial and from the right material height dial. The sensor on the left material height dial is connected to terminal "J1-22" of the screed ECM. The sensor on the right material height dial is connected to terminal "J1-29" of the screed ECM. The screed ECM monitors each sensor. Each circuit works in the following way. The ECM provides an internal 5 volt power source. The circuit between this power source and the machine ground contains two resistors. One resistor has a fixed resistance. This resistor is located inside the ECM. The second resistor is a variable pull-down resistor. This resistor is the sensor on the material height dial.

Screed ECM (16) can determine the position of the left material height dial by monitoring the voltage at terminal "J1-22". When the dial is in the MINIMUM position, the voltage at terminal "J1-22" is approximately 1.75 volts. When the dial is in the MAXIMUM position, the voltage at terminal "J1-22" is approximately 3.25 volts.

Screed ECM (16) can determine the position of the right material height dial by monitoring the voltage at terminal "J1-29". The right material height dial follows the same principles of operation as the left material height dial.

Screed ECM (16) communicates with the other control units on the machine through the Cat Data Link. The Cat Data Link is a proprietary standard of communication that was developed by Caterpillar. The Cat Data Link requires a positive line and a negative line. The positive line is connected to terminal "J1-10" of the machine ECM. The negative line is connected to terminal "J1-20" of the machine ECM.

Illustration 10	g01586146
Connector "J2" for the Screed ECM

Screed ECM (16) analyzes input signals from the electronic control system and and the screed ECM determines if an output signal should be sent to the conveyor stop indicators that are on the screed operator stations. When both conveyors are stopped by the left conveyor stop switch or by the right conveyor stop switch, the screed ECM provides a ground path for the left conveyor stop indicator at terminal "J2-11" and for the right conveyor stop indicator at terminal "J2-12".

Screed ECM (16) simultaneously monitors the condition of the circuit at terminal "J2-34" and the circuit at terminal "J2-35" in order to determine the position of the right conveyor master switch. When the circuit at terminal "J2-35" is grounded and the circuit at terminal "J2-34" is floating, the control unit determines that the right conveyor master switch is in the REVERSE position. When the circuit at terminal "J2-35" is floating and the circuit at terminal "J2-34" is grounded, the control unit determines that the right conveyor master switch is in the MANUAL position. If the circuit at "J2-34" and the circuit at "J2-35" are both floating, the operator control unit determines that the right conveyor master switch is in the AUTOMATIC position.

Screed ECM (16) simultaneously monitors the condition of the circuit at terminal "J2-40" and the circuit at terminal "J2-41" in order to determine the position of the right auger master switch. When the circuit at terminal "J2-41" is grounded and the circuit at terminal "J2-40" is floating, the control unit determines that the right auger master switch is in the REVERSE position. When the circuit at terminal "J2-41" is floating and the circuit at terminal "J2-40" is grounded, the control unit determines that the right auger master switch is in the MANUAL position. If the circuit at "J2-40" and the circuit at "J2-41" are both floating, the operator control unit determines that the right auger master switch is in the AUTOMATIC position.

The screed ECM monitors the signal from the left material height sensor at terminal "J2-25". The screed ECM monitors the signal from the right material height sensor at terminal "J2-24". The screed ECM compares the input signals from the material height sensors to the input signals from the material height dials. Then, the screed ECM determines if the actual amount of asphalt in front of the screed matches the desired amount (set point). If the actual amount of asphalt is greater than the desired amount on either side of the machine, the machine ECM stops the corresponding auger motors. If the actual amount of asphalt is less than the desired amount, the machine ECM operates the auger motors at varying speeds. In this case, the speed of the motors is proportional to the height of the asphalt as it is determined by the material height sensors.

The machine can be equipped with sonic sensors. The sensor is automatically detected by the screed ECM. If the machine is equipped with sonic sensors, the screed ECM detects a ground signal at terminal "J2-26" and at terminal "J2-27".

Illustration 11	g01586148
Right Side of Screed (18) Sonic sensor

Sonic sensors (18) (right shown) are mounted on the left side of the screed and the right sides of the screed.

The sonic sensors operate by emitting sound waves and then monitoring the time that is required for the waves to reflect off the asphalt pile and return to the sensor. The elapsed time is proportional to the amount of asphalt that is present.

The machine can also be equipped with optional conveyor sonic sensors (not shown). Machine ECM (12) automatically detects the conveyor sonic sensors. For machines that are equipped with the conveyor sonic sensors, the machine ECM controls the conveyors independently in order to maintain the desired height of material at the rear of the conveyor. For machines without the conveyor sonic sensors, the machine ECM controls the conveyor and the auger simultaneously in order to maintain the desired height of material at the rear of the screed.