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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 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. |
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Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the machine. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop Products Guide", for tools and supplies suitable to collect and contain fluids in Caterpillar machines. Dispose of all fluids according to local regulations and mandates. |
| Machine Test Parameters | ||
|---|---|---|
| Date | Product or Component SN | |
| Measurement Location | Measurement | Actual |
| Engine High Idle Test Speed | 2200 rpm | |
| Hydraulic oil temperature for test | |
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| Illustration 1 | g03667218 |
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| Illustration 2 | g03667238 |
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| Illustration 3 | g03667239 |
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| Illustration 4 | g03577137 |
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| Illustration 5 | g03577178 |
| Pressure Limiter Valve Specifications | ||
|---|---|---|
| Date | Product or Component SN | |
| Test | Measurements | Actual |
| Tightening torque for retaining nut (15) securing the coil of parking brake solenoid coil (14). | |
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| The pressure differential pressure between port "M1" (18) and charge pressure port (20). | |
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| The pressure differential pressure between port "M2" (19) and charge pressure port (20). | |
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| Pressure at charge pressure tap (20). | |
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| Tightening torque for locknut (25) on forward multifunction valve adjustment screw (26). | |
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| Amount of pressure change with one revolution of adjustment screw (26). | |
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| Tightening torque for locknut (27) on reverse multifunction valve adjustment screw (28) | |
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The propel pumps are equipped with two multifunction valves. One valve for the forward propel circuit and one for the reverse propel circuit. The multifunction valves act as make up valves, high-pressure relief valves and system pressure limiters.
Note: Verify that charge relief pressure is within specifications prior to performing this procedure. Refer to Specification, Systems Operation, Testing and Adjusting, "Relief Valve (Charge, Right Pump) Test and Adjust".
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| Illustration 6 | g02571852 |
| Required Tools | ||||
|---|---|---|---|---|
| Tool | Item | Qty | Part No | Description |
| A | 198-4240 | Digital Pressure Indicator Gp | ||
| A1 | 1 | 198-4234 | Digital Indicator | |
| A2 | 2 | 251-9600 | Pressure Sensor Gp
(0 to 70 000 kPa (0 to 10,000 psi)) |
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| A3 | 2 | 198-4236 | Adapter Cable As | |
- Connect one Tool (A2) to each Tool (A3).
- Connect each Tool (A3) to Tool (A1).
| Optional Tools(1) | ||||
|---|---|---|---|---|
| Tool | Item | Qty | Part No | Description |
| B | 2 | 8T-0861 | Pressure Gauges | |
| C | 2 | 171-1879 | Fitting Adapters | |
| D | 2 | 187-3547 | Quick Disconnect Coupler As | |
| E | 4 | 187-3546 | Quick Disconnect Couplers | |
| F | F1 | 1 | 8T-0855 | Pressure Gauge |
| F2 | 1 | 6V-4144 | Quick Connect Coupler | |
| G | G1 | 1 | 177-7860 | Hose As |
| G2 | 1 | 6V-4142 | Fitting | |
| G3 | 1 | 6V-4143 | Quick Connect Couplers | |
| (1) | The optional tools can be used to replace the digital pressure gauges in the required tool list. |
- Assembly two sets of Tool (A) through Tool (E).
- Assemble Tool (F).
- Assemble Tool (G).
- Connect Tool (F) to Tool (G).
- Drive the machine to a smooth, horizontal surface.
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Illustration 7 g03667723 - 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 8 g03667730 - Use the up arrow on screed raise/lower switch (6) to lift the screed. Completely raise the screed.
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Illustration 9 g03661783 - Engage screed service lock mechanism (7) on both sides of the machine.
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Illustration 10 g03667734 - 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 lock mechanism (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 11 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.
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Illustration 12 g03663696 - Unhook latch (12) and open access panel (13) on the left side of the machine.
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Illustration 13 g03667218 - Remove retaining nut (15) on the coil of parking brake solenoid (14). Remove the coil of the parking brake solenoid from the valve stem.
Note: The parking brake solenoid (14) can be identified as having wire 374-PK(Pink) and 200-BK(Black) wires on the connector.
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Illustration 14 g03663698 - Unhook latch (16) and open access panel (17) on the right side of the machine.
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Illustration 15 g03667238 - Remove the cap from port "M1" (18) on the right propel pump. Connect one Tool (A) to port "M1".
- Remove the cap from port "M2" (19) on the right propel pump. Connect the second Tool (A) to port "M2".
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Illustration 16 g03667239 - Remove the cap from charge pressure tap (20) on the right propel pump. Connect Tool (A2) to the pressure tap.
- 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.
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 the engine in high idle. The engine speed should increase to 2200 rpm.
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Illustration 17 g03668260 - Monitor the hydraulic oil temperature on operator display (21). Operate the machine until the oil temperature reaches
43° ± 6°C (109° ± 11°F) .Show/hide table
Illustration 18 g03668261 - 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 (22) will be illuminated.
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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.
- Press parking brake switch (5) in order to change the status of the parking brake to "disengaged".
- Rotate speed dial (23) to 50 percent of the MAXIMUM position.
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Illustration 19 g03789822 - Squeeze trigger (24), and move propel lever (4) to the FULL FORWARD position.
- Record the pressure at port "M1" (18).
- Record the pressure at charge pressure tap (20).
Note: This pressure should be
2700 ± 175 kPa (392 ± 25 psi) . If this pressure is outside specification, charge pressure must be adjusted. Refer to AP1055F Paver Propel System Operations, Testing and Adjusting, "Relief Valve (Charge) Test and Adjust (Right Pump)". - Move propel lever (4) back to the NEUTRAL position.
- Subtract the pressure that was recorded in Step 11 from the pressure that was recorded in Step 10. The pressure differential should be
42000 ± 1400 kPa (6090 ± 200 psi) . - Squeeze trigger (24), and move propel lever (4) to the FULL REVERSE position.
- Record the pressure at port "M2" (19).
- Record the pressure at charge pressure tap (20).
- Move propel lever (4) to the NEUTRAL position.
- Subtract the pressure that was recorded in Step 16 from the pressure that was recorded in Step 15. The pressure differential should be
42000 ± 1400 kPa (6090 ± 200 psi) . - Rotate speed dial (23) back 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 place 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 forward pressure is outside the specified range, go to "Adjustment Procedure", Step 1. If the forward pressure is inside the specified range, go to Step 25.
- If the reverse pressure is outside the specified range, go to "Adjustment Procedure", Step 3. If the reverse pressure is inside the specified range, go to Step 26.
- If an adjustment was made, go to Step 1. If no adjustment was made, go to Step 27.
- Remove the tooling.
- Close right access panel (17) and secure latch (16).
- Reinstall the coil of parking brake solenoid (14), and tighten retaining nut (15) to a torque of
4 N·m (3 lb ft) to6 N·m (4.4 lb ft) . - Close left access panel (13) and secure latch (12).
- Loosen locknut (25) on the forward multifunction valve. Use a 5 mm hex wrench to rotate adjustment screw (26). In order to increase pressure, rotate the adjustment screw clockwise. In order to decrease pressure, rotate the adjustment screw counterclockwise.
Note: One revolution of adjustment screw (26) changes the pressure by approximately
9000 kPa (1305 psi) . - Hold adjustment screw (26), and tighten locknut (25) on forward multifunction valve to
23 N·m (17 lb ft) . Go to "Test Procedure", Step 14.Show/hide table
Illustration 21 g03577178 Right Propel Pump - Loosen locknut (27) on reverse multifunction valve. Use a 5 mm hex wrench to rotate adjustment screw (28). In order to increase pressure, rotate the adjustment screw clockwise. In order to decrease pressure, rotate the adjustment screw counterclockwise.
Note: One revolution of the adjustment screw (28) changes the pressure by approximately
9000 kPa (1305 psi) . - Hold adjustment screw (28), and tighten locknut (27) on reverse multifunction valve to
23 N·m (17 lb ft) . Go to "Test Procedure", Step 1.
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| Illustration 20 | g03577137 |
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Right Propel Pump | |