AP500F Asphalt Paver Propel System Caterpillar

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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

Introduction

This procedure tests the pump flow rate by measuring the speed of the wheels. This machine is equipped with two identical propel 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

Test Preparation

1. Drive the machine to a smooth, horizontal surface.
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   Illustration 1	g03862885

2. Move propel lever (4) to the NEUTRAL position.

3. Press parking brake switch (3) to change the status of the parking brake to "engaged". When the parking brake status is "engaged", an LED next to the parking brake switch will be illuminated.

4. Use travel mode switch (2) 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 to operate the screed lift system, hopper system, apron system, and auger lift system.

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   Illustration 2	g03862892

5. Press the screed raise switch (5) to lift the screed. Completely raise the screed.
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   Illustration 3	g03862916

6. Engage screed service lock mechanism (6) on both sides of the machine.
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   Illustration 4	g03862922

7. Use screed float switch (8) 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 (6).

8. Press rpm decrease switch (9) for the throttle control once to operate the engine in low idle.
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   Illustration 5	g03862928

9. Shut off the engine. Either place machine power switch (10) in the OFF position or press and hold push to start switch (7) for 3 seconds. An LED next to the push to start switch will flash when the engine is in shutdown mode.

10. If the engine was shut down using push to start switch (7), move machine power switch (10) to the OFF position.
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    Illustration 6	g03862944

11. Place a small strip of reflective tape from Tool (A) on final drive housing (11). Repeat this process for the other side of the machine.

    Note: If necessary, remove the screed before lifting the tractor. Refer to Disassembly and Assembly, "Screed - Remove and Install".

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

Test Procedure

1. 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.

2. Move machine power switch (10) to the ON position.

3. Press push to start switch (7) for 2 seconds 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 is necessary to restart the process.

4. Operate the engine at low idle for a few minutes.
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   Illustration 7	g03862951

5. Press rpm increase switch (13) on the throttle control to place the engine in high idle. The engine speed should increase to 2200 rpm.

6. Monitor the hydraulic oil temperature on operator display (12). Operate the machine until the oil temperature reaches 43 ± 5.6 °C (110 ± 10 °F).

7. Rotate speed dial (14) clockwise until speed value has reached the maximum setting, 76.2 m/min (250 ft/min).

8. Press parking brake switch (3) to change the status of the parking brake to "disengaged".
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   Illustration 8	g03862957

9. Squeeze trigger (15), and move propel lever (4) to the FULL FORWARD position.

10. Use Tool (A) to measure the rotational speed of final drive housing (11). The speed should be 19.7 ± 2.5 rpm. Perform this step for both sides of the machine.

11. Squeeze trigger (15), and move propel lever (4) to the FULL REVERSE position.

12. Use Tool (A) to measure the rotational speed of final drive housing (11). The speed should be 19.7 ± 2.5 rpm. Perform this step for both sides of the machine.

13. Move propel lever (4) to the NEUTRAL position.
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    Illustration 9	g03863149

14. Use travel mode switch (2) to select the TRAVEL mode. When the travel mode switch is set to TRAVEL mode, an LED next to travel symbol (16) will be illuminated.

15. Rotate speed dial (14) clockwise until speed value has reached the maximum setting, 16.8 km/h (10.4 mph).

16. Squeeze trigger (15), and move propel lever (4) to the FULL FORWARD position.

17. Use Tool (A) to measure the rotational speed of final drive housing (11). The speed should be 70.7 ± 3.5 rpm. Perform this step for both sides of the machine.

18. Squeeze trigger (15), and move propel lever (4) to the FULL REVERSE position.

19. Use Tool (A) to measure the rotational speed of final drive housing (11). The speed should be 70.7 ± 3.5 rpm. Perform this step for both sides of the machine.

20. Move propel lever (4) to the NEUTRAL position.

21. Rotate speed dial (14) to the MINIMUM position.

22. Press parking brake switch (3) 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.

23. Press rpm decrease switch (9) for the throttle control once to operate the engine in low idle.

24. Shut off the engine. Either place machine power switch (10) in the OFF position or press and hold push to start switch (7) for 3 seconds. An LED next to the push to start switch will flash when the engine is in shutdown mode.

25. If the engine was shut down using push to start switch (7), move machine power switch (10) to the OFF position.

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

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

28. Use a suitable lifting device to lower the machine to the ground. Refer to 1 for approximate machine weights.

Adjustment Procedure

1. If the forward and reverse dir\ection perform differently, adjust the neutral on the propel pumps. Refer to AP500F Paver Specification, Systems Operation, Testing and Adjusting,, "Piston Pump Neutral Test and Adjust".

2. 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.