AP300F Asphalt Paver Propel System Caterpillar

Show/hide table

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.

Show/hide table

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.

Show/hide table

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.

Show/hide table

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

Introduction

The right propel pump is equipped with two combination relief valves and one pressure override relief (POR) valve. Each circuit of the hydrostatic loop contains one combination relief valve.

The combination relief valves and the POR valve work together to control system pressure. The combination relief valves are fast-acting valves and are set to open at a higher pressure than the POR valve. The combination relief valves relieve short-duration pressure surges, giving the slower-acting POR valve time to react.

Low propel pressure can indicate a faulty combination relief valve or a faulty POR valve. Perform the following test if the machine is exhibiting any of the following conditions:

• The machine will not reach full speed.

• The machine will not operate in one direction.

• The hydraulic oil is overheating.

Required Tools

Illustration 1	g02571852

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

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

Test Preparation

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

   Note: The machine will move during this test. Make sure that the test area has adequate space to perform this procedure.

   Show/hide table

   Illustration 2	g03890163

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

3. Press parking brake switch (5) 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 (3) to select the pave mode. When the travel mode is set to pave, an LED next to pave symbol (2) will be illuminated.

   Note: The machine must be in pave mode to operate the screed lift system, hopper system, tow point system, and auger lift system.

5. Press and hold screed raise switch (1). Release the switch when the screed is raised fully.
   Show/hide table

   Illustration 3	g03890192

6. Engage screed lock lever (6) on each side of the machine.
   Show/hide table

   Illustration 4	g03890385

7. Use screed float switch (7) 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 the screed lock mechanisms.
   Show/hide table

   Illustration 5	g03891412

8. If necessary, press left hopper raise switch (8) and right hopper raise switch (9) to raise the hoppers off the hopper service locks.
   Show/hide table

   Illustration 6	g03891434

9. If necessary, retract hopper service lock mechanism (10) on each side of the machine.
   Show/hide table

   Illustration 7	g03891437

10. Use left hopper lower switch (11) and right hopper lower switch (12) to lower the hoppers.
    Show/hide table

    Illustration 8	g03892461

    Show/hide table

    Illustration 9	g03892463

11. Press rpm decrease switch (14) once to operate the engine in low idle.

12. Use travel mode switch (3) to select the travel mode. When the travel mode is set to travel, an LED next to travel symbol (13) will be illuminated.

13. Rotate speed dial (15) until target speed (16) is 2 km/hr (1.2 mph).
    Show/hide table

    Illustration 10	g03892469

14. Examine the display. If "Regen Conditions Not Met" warning (17) is shown and the banner is yellow, allow the engine to operate until the regeneration cycle is complete. The cycle may require up to 1 hour to complete. If the warning banner is red, use Cat^® ET to complete a regeneration cycle as soon as possible. If no engine regeneration warning is shown, go to the next step.
    Show/hide table

    Illustration 11	g03892474

15. Press and hold push to start switch (18). Release the switch when the engine stops.
    Show/hide table

    Illustration 12	g03892481

16. Move machine power switch (19) to the OFF position.
    Show/hide table

    Illustration 13	g03892483

17. Open pump compartment door (20).
    Show/hide table

    Illustration 14	g03892503

18. Disconnect balance line (21) from port "MA".

19. Use Tool (C) to plug the hose, and use Tool (B) to cap the port.
    Show/hide table

    Illustration 15	g03892509

20. Disconnect balance line (22) from port "MB".

21. Use Tool (C) to plug the hose, and use Tool (B) to cap the port.
    Show/hide table

    Illustration 16	g03892534

22. Connect one Tool (A2) to forward pressure tap (24) in port "MB".

23. Connect one Tool (A2) to reverse pressure tap (23) in port "MA".
    Show/hide table

    Illustration 17	g03892536

24. Open compartment door (25).
    Show/hide table

    Illustration 18	g03892600

25. Loosen the retaining screw on brake solenoid connector (26). Disconnect the brake solenoid connector from the brake solenoid. Make sure the seal at the base of the solenoid connector remains on the connector.
    Show/hide table

    Illustration 19	g03892611

26. Remove cap (27) from the POR valve.
    Show/hide table

    Illustration 20	g06016557

27. Loosen locknut (28). Turn adjustment screw (29) clockwise two turns to increase POR pressure.

28. Hold adjustment screw (29). Tighten locknut (28).

Test Procedure

Show/hide table

Illustration 21	g03892682

1. Move machine power switch (19) into the ON position. After the home screen is shown on display (30), press, and hold push to start switch (18). Release the switch when the engine starts.
   Show/hide table

   Illustration 22	g03892691

2. Actuate screen unlock switch (31) to enable the touch screen on the display.

   Note: When the display is enabled, an LED next to the screen unlock switch is illuminated.

   Show/hide table

   Illustration 23	g03892700

3. Tap status icon (32) to enter the status screen.
   Show/hide table

   Illustration 24	g03892701

4. Operate the engine at low idle for a few minutes. Press rpm increase switch (33) once to operate the engine in high idle.
   Show/hide table

   Illustration 25	g03892705

5. Monitor the hydraulic oil temperature on display (34). Operate the machine until the oil temperature reaches a minimum of 45 ± 10 °C (113 ± 18 °F).

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

   Note: If the machine moves in the next step, immediately return propel lever (4) to the NEUTRAL position. Troubleshoot the parking brake system before this test is resumed.

   Show/hide table

   Illustration 26	g03892714

7. Squeeze trigger (35), and move propel lever (4) slowly into the forward range. Allow the pressure to stabilize. Record the pressure at forward pressure tap (24) in port "MB". The pressure should be 43000 kPa (6237 psi) to 42000 kPa (6092 psi). Move the propel lever to the NEUTRAL position.

   Note: If the machine moves in the next step, immediately return propel lever (4) to the NEUTRAL position. Troubleshoot the parking brake system before this test is resumed.

8. Squeeze trigger (35), and move propel lever (4) slowly into the reverse range. Allow the pressure to stabilize. Record the pressure at reverse pressure tap (23) in port "MA". The pressure should be 43000 kPa (6237 psi) to 42000 kPa (6092 psi). Move the propel lever to the NEUTRAL position.

9. Press parking brake switch (5) 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.

10. Press rpm decrease switch (14) once to operate the engine in low idle.

    Note: If necessary. perform a regeneration cycle before the engine is stopped.

11. Press and hold push to start switch (18). Release the switch when the engine stops.

12. Move machine power switch (19) to the OFF position.

13. If the pressure recorded in Step 7 and/or in Step 8 is outside the specified range, perform the Adjustment Procedure. If the pressure readings were inside the specified range, go to the next step.

14. Loosen locknut (28) on the POR valve. Turn adjustment screw (29) counterclockwise two turns to decrease POR pressure.

15. Hold adjustment screw (29). Tighten locknut (28). Go to System Operation Testing and Adjusting, Relief Valve (Pressure Override) - Test and Adjust (Right Pump).

Adjustment Procedure

Note: The same adjustment procedure is used for the forward main relief valve and the reverse main relief valve.

Show/hide table

Illustration 27	g03892760

Show/hide table

Illustration 28	g03892762

1. Use the following procedure to adjust the main relief valves:

   1. Remove cap (36) or (37) from the relief valve that is to be adjusted.

      Note: Cap (36) is the forward relief valve, and cap (37) is the reverse relief valve.

      Show/hide table

      Illustration 29	g03892767

   2. Remove spring (39) and relief valve cartridge (38) from the pump. Reinstall cap (36) or (37) to prevent oil from leaking out the ports.
      Show/hide table

      Illustration 30	g03892770

   3. Clamp the relief valve cartridge in a soft vise jaw. Loosen locking setscrew (41) with a 3 mm Allen wrench.

      Note: The spring must be compressed in the next step. Spindle (40) will be damaged if the spring is not compressed.

   4. Compress the spring. With the spring compressed, use a 5 mm wrench to turn spindle (40). Turn the spindle clockwise to increase pressure. Turn the spindle counterclockwise to decrease pressure.

      Note: One full revolution of spindle (40) changes the pressure setting by approximately 4340 kPa (630 psi).

   5. Tighten locking setscrew (41).

   6. Remove relief valve cartridge (38) from the vise.

   7. Remove relief valve cap (36) or (37) and install relief valve cartridge (38) in the pump. Install spring (39) in the pump. Reinstall the relief valve cap. Tighten the cap to a torque of 90 Nm (66 lb ft).

2. Perform the test procedure.