AP1000F Asphalt Paver Propel System Caterpillar

Piston Pump Flow - Test

Usage:

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Diesel engine exhaust contains products of combustion which may cause personal injury.

Always start and operate the engine in a well ventilated area, and, if in an enclosed area, vent the exhaust to the outside.

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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 rotating and moving parts.
Moving fan blades and moving parts will throw or cut any object or tool that falls or is pushed into them.

Make sure no one is working on, underneath or close to an engine that is running. Make sure the area is free of personnel.

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Injury to personnel can result if they are not in the operator's view. Allow only essential personnel near the machine, and make sure the personnel are in the operator's view when testing, to prevent injury. Make sure checks are done in an open area.

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To prevent injury or death, never work under a machine while a test is being performed.

Specifications

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Table 1
Machine Test Parameters
Date	Product or Component SN
Measurement Location	Measurement	Actual
Engine High Idle Test Speed	2200 rpm
Hydraulic oil temperature for test	43° ± 6°C (110° ± 10°F)
Approximate Machine Weight With SE60XW VT Screed Attached.	20516 kg (45230 lb)
Approximate Machine Weight Without Screed	15621 kg (34440 lb)

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Table 2
Piston Pump Flow Tests
Date	Product or Component SN
Test	Rates	Actual
Charge Relief Pressure	3200 kPa (464 psi)
Target speed value maximum setting in "PAVE" mode.	61 m/min (200 ft/min)
Maximum PAVE speed forward	15.0 ± 2.5 rpm
Maximum PAVE speed reverse	15.0 ± 2.5 rpm
Target speed value maximum setting in "TRAVEL" mode	19.9 km/h (12.4 mph)
Maximum TRAVEL speed forward	74 ± 3.5 rpm
Maximum TRAVEL speed reverse	74 ± 3.5 rpm

Introduction

This procedure tests the pump flow rate by measuring the speed of the wheels. This machine is equipped with two identical propulsion pumps. One pump provides the flow to drive the right drive wheel. The second pump provides the flow to drive the left drive wheel. This test should be performed on both sides of the machine.

Required Tools

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Table 3
Required Tools
Tool	Item	Qty	Part No	Description
A		1	351-8635	Tachometer Kit

Test Preparation

Drive the machine to a smooth, horizontal surface.

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Illustration 1	g03425361

Move propel lever (4) to the NEUTRAL position.

Press parking brake switch (5) in order to change the status of the parking brake to "engaged". When the parking brake status is "engaged", LED (2) next to the parking brake switch will be illuminated.

Use travel mode switch (3) to select the PAVE mode. When the travel mode switch is set to PAVE mode, an LED next to PAVE symbol (1) will be illuminated.
Note: The machine must be in PAVE mode in order to operate the screed lift system, hopper system, apron system and auger lift system.

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Illustration 2	g03425717

Press the up arrow on screed raise/lower switch (6) to lift the screed. Completely raise the screed.

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Illustration 3	g03425987

Engage screed service lock mechanism (7) on both sides of the machine.

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Illustration 4	g03425999

Use screed float switch (9) to place the screed in the FLOAT position. When the screed is in the FLOAT position, an LED next to the screed float switch will illuminate. Allow the tow arms to rest on screed service locks (7) .

Press the down arrow on throttle control switch (10) once in order to operate the engine in low idle.

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Illustration 5	g03426016

Shut off the engine. Either place machine power switch (11) in the OFF position or press and hold push to start switch (8) for 3 seconds. An LED next to the push to start switch will flash when the engine is in shutdown mode.
Note: The engine may run for several minutes when placed in the shutdown mode.

If the engine was shut down using the push to start switch (8), move machine power switch (11) to the OFF position.

Use a suitable lifting device in order to raise the machine. For this test both rear wheels must be off the ground. Use supports adequate for the machine weight. Refer to "Specifications", Table 1 for approximate machine weights.

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Illustration 6	g03524136

Place a small strip of reflective tape from Tool (A) on final drive housing (12). Repeat this process for the other side of the machine.

Test Procedure

Clear all personnel away from the machine except the operator and an assistant. The assistant must remain 1.25 m (4 ft) away from the machine. The assistant must also be in full view of the operator.

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Illustration 7	g03524437

If necessary, press front wheel assist switch (13) once to disable the front wheel assist system.
Note: When the front wheel assist is disengaged, the LED next to front wheel assist switch (13) will not be illuminated.

Move machine power switch (11) to the ON position.

Press push to start switch (8) for 2 seconds in order to start the engine. An LED next to the push to start switch will flash when the engine is in start mode. When the engine has started, the LED will remain illuminated.
Note: Only one attempt to start the engine is allowed per key cycle. A new key cycle will need to be done in order to restart the process.

Operate the engine at low idle for a few minutes.

Press the up arrow on throttle control switch (10) in order to place in engine in high idle. The engine speed should increase to 2200 rpm.

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Illustration 8	g03664671

Monitor the hydraulic oil temperature on operator display (14). Operate the machine until the oil temperature reaches 43 ± 5.6 °C (110 ± 10 °F).

Rotate speed dial (15) clockwise until target speed value has reached the maximum setting, 61 m/min (200 ft/min).

Press parking brake switch (5) in order to change the status of the parking brake to "disengaged".

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Illustration 9	g03664676

Squeeze trigger (16), and move propel lever (4) to the FULL FORWARD position.

Use Tool (A) to measure the rotational speed of final drive housing (12). The speed should be 15.0 ± 2.5 rpm. Perform this step for both sides of the machine.

Squeeze trigger (16), and move propel lever (4) to the FULL REVERSE position.

Use Tool (A) to measure the rotational speed of final drive housing (12). The speed should be 15.0 ± 2.5 rpm. Perform this step for both sides of the machine.

Move propel lever (4) to the NEUTRAL position.

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Illustration 10	g03664679

Use travel mode switch (3) to select the TRAVEL mode. When the travel mode switch is set to TRAVEL mode, an LED next to TRAVEL symbol (17) will be illuminated.

Rotate speed dial (15) clockwise until target speed value has reached the maximum setting, 19.9 km/h (12.4 mph).

Squeeze trigger (16), and move propel lever (4) to the FULL FORWARD position.

Use Tool (A) to measure the rotational speed of final drive housing (12). The speed should be 74 ± 3.5 rpm. Perform this step for both sides of the machine.

Squeeze trigger (16), and move propel lever (4) to the FULL REVERSE position.

Use Tool (A) to measure the rotational speed of final drive housing (12). The speed should be 74 ± 3.5 rpm. Perform this step for both sides of the machine.

Move propel lever (4) to the NEUTRAL position.

Rotate speed dial (15) to the MINIMUM position.

Press parking brake switch (5) in order to change the status of the parking brake to "engaged". When the parking brake status is "engaged", LED (2) next to the parking brake switch will be illuminated.

Press the down arrow on throttle control switch (10) once in order to operate the engine in low idle.

Shut off the engine. Either place machine power switch (11) in the OFF position or press and hold push to start switch (8) for 3 seconds. An LED next to the push to start switch will flash when the engine is in shutdown mode.
Note: The engine may run for several minutes when placed in the shutdown mode.

If the engine was shut down using the push to start switch (8), move machine power switch (11) to the OFF position.

If the right drive wheel and the left drive wheel perform differently, go to "Adjustment Procedure", Step 1.

If the machine is unable to achieve the required rotational speeds, go to "Adjustment Procedure", Step 2.

Adjustment Procedure

If the right drive wheel and the left drive wheel perform differently, adjust the neutral on the propulsion pumps. Refer to AP1000F Paver Specification, Systems Operation, Testing and Adjusting, "Piston Pump Neutral–Test and Adjust".

If the machine is unable to achieve the required rotational speeds, test the relief pressures and troubleshoot the pump for repair or replacement. Go to "Test Procedure", Step 1.