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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 | g03863307 |
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| Illustration 2 | g03863315 |
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| Illustration 3 | g03863330 |
| Test Specifications | ||
|---|---|---|
| Date | Product or Component SN | |
| Test | Rates | Actual |
| Maximum pressure difference between port "M4" (11) and port "M5" (12). | |
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| Torque for plugs in port "M4" (11) and port "M5" (12). | |
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| Torque for locknut (17) on adjustment screw (18). | |
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A servo cylinder controls the position of the swashplate within the propel pump. This procedure provides the method to determine if servo cylinder is centered when the machine is in neutral. If necessary, this procedure also provides the method to adjust the pump neutral.
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| Illustration 4 | g02571852 |
| Required Tools | ||||
|---|---|---|---|---|
| Tool | Item | Qty | Part No | Description |
| A | 198-4240 | Digital Pressure Indicator Gp | ||
| A1 | 1 | 198-4234 | Digital Indicator | |
| A2 | 1 | 198-4237 | Pressure Sensor Gp
Zero to |
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| A3 | 1 | 198-4236 | Adapter Cable As | |
- Connect one Tool (A2) to Tool (A3).
- Connect each Tool (A3) to Tool (A1).
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| Illustration 5 | g03850826 |
| Optional Tools(1) | ||||
|---|---|---|---|---|
| Tool | Item | Qty | Part No | Description |
| B | B1 | 1 | 8T-0855 | Pressure Gauges
(0 - 4000 kPa (0 - 580 psi)) |
| B2 | 1 | 6V-4144 | Quick Connect Couplers | |
| C | C1 | 1 | 6V-4142 | Fittings |
| C2 | 1 | 177-7860 | Hose As | |
| C3 | 1 | 6V-4143 | Quick Connect Couplers | |
| (1) | The optional tools can be used to replace the digital pressure gauges in the required tool list. |
- Connect Tool (C) to Tool (B).
| Required Tools | ||||
|---|---|---|---|---|
| Tool | Item | Qty | Part No | Description |
| D | 2 | 110-6349 | Fitting As | |
- Drive the machine to a smooth, horizontal surface.
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Illustration 6 g03862885 - Move propel lever (4) to the NEUTRAL position.
- 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.
- 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 7 g03863269 - Use screed float switch (6) 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. Lower the screed to the ground.
- Press rpm decrease switch (7) for the throttle control once to operate the engine in low idle.
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Illustration 8 g03863272 - Shut off the engine. Either place machine power switch (8) in the OFF position or press and hold push to start switch (5) for 3 seconds. An LED next to the push to start switch will flash when the engine is in shutdown mode.
- If the engine was shut down using push to start switch (5), move machine power switch (8) to the OFF position.
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Illustration 9 g03863280 - Remove four bolts (9) and washers. Open hopper doors (10).
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Illustration 10 g03863307 - Remove the plug from port "M4" (11).
- Install Tool (D) in port "M4" (11). Install Tool (A2) on Tool (D).
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Illustration 11 g03863315 - Remove the plug from port "M5" (12).
- Install Tool (D) in port "M5" (12). Install a second Tool (A2) on Tool (D).
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Illustration 12 g03863319 - Disconnect reverse EDC connector (14). Mark the connector for identification.
Note: The A333-PK(Pink)wire and the H862-GY(Grey)wire are connected to the reverse EDC connector for the right propel pump. Disconnection of the EDC connector will cause a fault to appear in the monitoring system when the machine is started. After this procedure is completed, the fault will no longer be active.
- Disconnect forward EDC (13). Mark this connector for identification.
Note: The 336-GY(Grey)wire and the H862-GY(Grey)wire are connected to the forward EDC connector for the right propel pump. Disconnection of the EDC connector will cause a fault to appear in the monitoring system when the machine is started. After this procedure is completed, the fault will no longer be active.
- Move machine power switch (8) to the ON position.
- Press push to start switch (5) 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.
- Operate the engine at low idle for a few minutes.
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Illustration 13 g03863324 - Press rpm increase switch (16) on the throttle control to place the engine in high idle. The engine speed should increase to 2200 rpm.
- Monitor the hydraulic oil temperature on operator display (15). Operate the machine until the oil temperature reaches
43 ± 5.6 °C (110 ± 10 °F) . - Read pressure on Tool (A1) for port "M4" (11). Read pressure on Tool (A1) for port "M5" (12). The pressures should agree within
130 kPa (19 psi) . If the pressures agree within specification, go to Step 7. If the pressures differ beyond specification, go to "Adjustment Procedure". - Press rpm decrease switch (7) for the throttle control once to operate the engine in low idle.
- Shut off the engine. Either place machine power switch (8) in the OFF position or press and hold push to start switch (5) for 3 seconds. An LED next to the push to start switch will flash when the engine is in shutdown mode.
- If the engine was shut down using push to start switch (5), move machine power switch (8) to the OFF position. Allow the oil to cool.
- Remove the tooling. Install the plugs removed from port "M4" (11) and port "M5" (12). Tighten the plugs to a torque of
12 N·m (9 lb ft) . - Reconnect reverse EDC (14) and forward EDC (13).
- If an adjustment was made, recalibrate the initial current setting to the electronic control module (ECM) for the pump. For the calibration procedure, refer to AP500F Asphalt Paver Systems Operation, Testing and Adjusting, Propel System,, "Forward Currents (EDC) - Calibrate" and Systems Operation, Testing and Adjusting, Propel System,, "Reverse Currents (EDC) - Calibrate".
- Close the hopper doors. Secure with four bolts and washers.
- Loosen locknut (17) on the pump adjustment mechanism. Turn adjustment screw (18) until the pressure at port "M4" (11) starts to increase over the pressure at port "M5" (12). Record the pressure reading at port "M4". Note the angular position of the wrench.
- Rotate adjustment screw (18) the opposite direction until the pressure at port "M5" (12) is equal to the pressure which was recorded during Step 1. Note the angular position of the wrench.
- Rotate adjustment screw (18) to the center of the two positions which were noted in Step 1 and Step 2.
Note: If this procedure does not adjust the pressures within specification, the pump must be repaired or replaced.
- Hold the adjustment screw in place, and tighten locknut (17) to
13 N·m (10 lb ft) . Go back to "Test Procedure" , Step 7.
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| Illustration 14 | g03863330 |
Note: Do not adjust the pressure beyond the rating of the gauges during the next two steps.