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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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.

Specifications

Illustration 1	g03865653

Illustration 2	g03865678
Right Propel Pump

Illustration 3	g03865690
Right Propel Pump

Illustration 4	g03865716
Right Propel Pump

Illustration 5	g03865804
Right Propel Pump

Introduction

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 the 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".

Required Tools

Illustration 6	g02571852

1. Connect Tool (A2) to each Tool (A3).

2. Connect each Tool (A3) to Tool (A1).

Illustration 7	g03852926

1. Connect one Tool (B) to each Tool (C).

Test Preparation

Note: Verify that the charge relief valve is within specification prior to performing this procedure. Refer to AP500F Paver Propel System Operations, Testing and Adjusting, "Relief Valve (Charge) Test and Adjust (Left Pump)".

1. Drive the machine to a smooth, horizontal surface.
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   Illustration 8	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 9	g03862892

5. Press the screed raise switch (5) to lift the screed. Completely raise the screed.
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   Illustration 10	g03862916

6. Engage screed service lock mechanism (6) on both sides of the machine.
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   Illustration 11	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 12	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 13	g03865650

11. Unhook latch (11) and open access panel (12) on the left side of the machine.
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    Illustration 14	g03865653

12. Remove retaining nut (14) on the coil of parking brake solenoid (13). Remove the coil of the parking brake solenoid from the valve stem.

    Note: Parking brake solenoid (13) can be identified as having wire 374-PK(Pink)and 200-BK(Black)wires on the connector.

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    Illustration 15	g03865661

13. Remove four bolts (15) and washers. Open hopper doors (16).
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    Illustration 16	g03865678
    Right Propel Pump

14. Remove the cap from port "M1" (17) on the right propel pump. Connect one Tool (A2) to port "M1".
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    Illustration 17	g03865690
    Right Propel Pump

15. Remove the cap from port "M2" (18) on the right propel pump. Connect second Tool (A2) to port "M2".
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    Illustration 18	g03865716
    Right Propel Pump

16. Remove the cap from charge pressure tap (19) on the right propel pump. Connect third Tool (A2) to the pressure tap.

Test Procedure

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

2. 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.

3. Operate the engine at low idle for a few minutes.
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   Illustration 19	g03865750

4. Press rpm increase switch (21) on the throttle control to place the engine in high idle. The engine speed should increase to 2200 rpm.

5. Monitor the hydraulic oil temperature on operator display (20). Operate the machine until the oil temperature reaches 43 ± 5.6 °C (110 ± 10 °F).
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   Illustration 20	g03865793

6. 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 (22) will be illuminated.

7. Press parking brake switch (3) to change the status of the parking brake to "disengaged".

8. Rotate speed dial (23) to 50 percent of the MAXIMUM position.
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   Illustration 21	g03865797

9. Squeeze trigger (24), and move propel lever (4) slowly to the FULL FORWARD position.

10. Record the pressure at port "M2" (18).

11. Record the pressure at charge pressure tap (19).

    Note: The charge pressure should be 2300 ± 175 kPa (334 ± 25 psi). If the charge pressure is outside specification, charge pressure must be adjusted. Refer to AP500F Paver Propel System Operations, Testing and Adjusting, "Relief Valve (Charge) Test and Adjust (Right Pump)".

12. Move propel lever (4) back to the NEUTRAL position.

13. Subtract the pressure recorded in Step 11 from the pressure recorded in Step 10. The pressure differential should be 42000 ± 1400 kPa (6090 ± 200 psi).

14. If the forward pressure is inside the specified range, go to Step 15. If the forward pressure is outside the specified range, go to "Adjustment Procedure".

15. Squeeze trigger (24), and move propel lever (4) slowly to the FULL REVERSE position.

16. Record the pressure at port "M1" (17).

17. Record the pressure at charge pressure tap (19).

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

19. Subtract the pressure recorded in Step 17 from the pressure recorded in Step 16. The pressure differential should be 42000 ± 1400 kPa (6090 ± 200 psi).

20. Rotate speed dial (24) back to the MINIMUM position.

21. 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.

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

23. 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.

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

25. If the forward pressure is outside the specified range, go to "Adjustment Procedure" , Step 11. If the forward pressure is inside the specified range, go to Step 26.

26. 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 27.

27. Remove the tooling.

28. Reinstall the coil of parking brake solenoid (13), and tighten retaining nut (14) to a torque of 4 N·m (3 lb ft) to 6 N·m (4.4 lb ft).

29. Close left access panel (12) and secure latch (11).

30. Close hopper doors (16). Secure with four bolts (15) and washers.

Adjustment Procedure

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Illustration 22	g03865804
Right Propel Pump

1. Loosen locknut (27) on the forward multifunction valve "M2". Use a 5 mm hex wrench to rotate adjustment screw (28). To increase pressure, rotate the adjustment screw clockwise. To decrease pressure, rotate the adjustment screw counterclockwise.

   Note: One revolution of adjustment screw (28) changes the pressure by approximately 9000 kPa (1305 psi).

2. Hold adjustment screw (28), and tighten locknut (27) on forward multifunction valve to 23 N·m (17 lb ft). Go to "Test Procedure" , Step 1.

3. Loosen locknut (25) on reverse multifunction valve "M1". Use a 5 mm hex wrench to rotate adjustment screw (26). To increase pressure, rotate the adjustment screw clockwise. To decrease pressure, rotate the adjustment screw counterclockwise.

   Note: One revolution of adjustment screw (26) changes the pressure by approximately 9000 kPa (1305 psi).

4. Hold adjustment screw (26), and tighten locknut (25) on reverse multifunction valve to 23 N·m (17 lb ft). Go to "Test Procedure" , Step 1.