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AP1000F Asphalt Pavers TA2 Technical Inspection {0372, 1000, 7000, 753T, 7565} Caterpillar


AP1000F Asphalt Pavers TA2 Technical Inspection {0372, 1000, 7000, 753T, 7565}

Usage:

AP-1000F AC4
Asphalt Paver
AP1000F (S/N: AC41-UP)

Introduction

Inspections are the most basic form of condition monitoring. Inspections are easy to do and surprisingly effective at helping you spot equipment health issues. Proactive monitoring and analysis of equipment information will allow Dealers to intervene effectively before problems occur.

Note: Before adjusting product settings to comply with listed baseline TA2 values, consult SIS for the latest specification values.

Creating an Electronic Copy

Use the following procedure to create an editable electronic copy from SIS web.

  1. Click format to print.

  2. Save the document as an HTML format.

  3. Open the document with Microsoft Word.

Electrical System

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Table 1
Status(1)  Description  Specification  Actual  Comments 
  Inspect Battery Cables  Cables between the battery, the starter, and the engine ground must be the correct size. Wires and cables must be free of corrosion. Wires and cables must have cable support clamps in order to prevent stress on battery connections (terminals).    Refer to Operation and Maintenance Manual, KEBU7061, "Battery or Battery Cable - Inspect/Replace". 
  Battery Test      Refer to Special Instruction, SEHS9326, "Battery Test Sheet Report".
Refer to Testing and Adjusting, UENR4467, "Battery - Test". 
  Charging System Test      Refer to Testing and Adjusting, UENR4467, "Charging System - Test".
Refer to Special Instruction, REHS0354, "Charging System Troubleshooting". 
  Electric Starting System Test      Refer to Testing and Adjusting, UENR4467, "Electric Starting System - Test". 
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(1) N = Normal, M = Monitor, A = Action

Engine

Cooling System

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Table 2
Status(1)  Description  Specification  Actual  Comments 
  Radiator Pressure Relief (Radiator Cap)(2)      Use Pressurizing Pump to test the radiator pressure cap. 20 kPa (3 psi) more than the pressure marked on the cap. 
  Freezing Point of Engine Coolant       
  Conditioner Test of Engine Coolant       
  Belt Tension  535 N (120 lb) for new belts.
355 N (80 lb) for used belts. 		   Auto Adjust Belt Tensioner 
  Difference between the Upper and Lower Radiator Tank Temperatures       
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(1) N = Normal, M = Monitor, A = Action
(2) Test for the pressure that is listed on the cap.

Fuel System

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Table 3
Status(1)  Description  Specification  Actual  Comments 
  Fuel Pressure of the Low-Pressure Fuel System at Idle Speed  150 kPa (22 psi)     
  Maximum Fuel Pressure of the High-Pressure Fuel System  200000 kPa (29008 psi)     
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(1) N = Normal, M = Monitor, A = Action

Lubrication System

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Table 4
Status(1)  Description  Specification  Actual  Comments 
  Minimum Oil Pressure at Full Engine Speed and at Normal Operating Temperature  315 kPa (46 psi)     
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(1) N = Normal, M = Monitor, A = Action

Basic Engine

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Table 5
Status(1)  Description  Specification  Actual  Comments 
  Engine Speed at Low Idle       
  Engine Speed at High Idle       
  Cylinder Cutout Test      Caterpillar Electronic Technician 
  Engine Crankcase Pressure (Blowby)       
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(1) N = Normal, M = Monitor, A = Action

Air Inlet and Exhaust System

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Table 6
Status(1)  Description  Specification  Actual  Comments 
  Cylinder # 1 Exhaust Temperature(2)  -     
  Cylinder # 2 Exhaust Temperature (2)  -     
  Cylinder # 3 Exhaust Temperature (2)  -     
  Cylinder # 4 Exhaust Temperature (2)  -     
  Cylinder # 5 Exhaust Temperature (2)  -     
  Cylinder # 6 Exhaust Temperature (2)  -     
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(1) N = Normal, M = Monitor, A = Action
(2) Compare the exhaust temperature variance at each exhaust port.

Auxiliary System

Reference: Refer to Testing & Adjusting, UENR3136 for more detail on the following test.

Conveyor Drive Chain (Auger)

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Table 7
Status(1)  Description  Specification  Actual  Comments 
  Correct amount of deflection at the midpoint of the auger chain  5.0 ± 1.0 mm (0.20 ± 0.04 inch)     
  Pull force applied to the midpoint of the auger chain to check auger chain deflection  67 N (15 lb)     
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(1) N = Normal, M = Monitor, A = Action

Conveyor Drive Chain (Drag)

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Table 8
Status(1)  Description  Specification  Actual  Comments 
  Conveyor drag drive chain tension  7.0 ± 3.0 mm (0.28 ± 0.12 inch)     
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(1) N = Normal, M = Monitor, A = Action

Piston Pump Flow (Auxiliary) Test

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Table 9
Status(1)  Description  Specification  Actual  Comments 
  Engine high idle test speed  2200 RPM     
  Hydraulic oil temperature for test  43° ± 6°C (109.4° ± 42.8°F)     
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(1) N = Normal, M = Monitor, A = Action

Auxiliary Pump Flow Test

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Table 10
Status(1)  Description  Specification  Actual  Comments 
  Time Required to retract the tow point cylinder  8.5 ± 2.0 seconds     
  Time Required to extend the tow point cylinder  11.5 ± 2.0 seconds     
  Time required to raise the hopper  4.9 ± 0.5 seconds     
  Time required to lower the hopper  4.4 ± 0.5 seconds     
  Time required to raise the apron  5.5 ± 1.0 seconds     
  Time required to lower the apron  4.1 ± 1.0 seconds     
  Time required to retract the auger height cylinder  5.0 ± 1.0 seconds     
  Time required to extend the auger height cylinder  3.5 ± 1.5 seconds     
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(1) N = Normal, M = Monitor, A = Action

Gear Pump Flow (Vibratory) Test

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Table 11
Status(1)  Description  Specification  Actual  Comments 
  Vibratory shaft speed  3000 ± 300 RPM     
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(1) N = Normal, M = Monitor, A = Action

Gear Pump Flow (Cooling Fan) Test

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Table 12
Status(1)  Description  Specification  Actual  Comments 
  Fan speed  2025 ± 25 RPM     
  Fan pump Pressure  26000 ± 350 kPa (3771 ± 51 psi)     
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(1) N = Normal, M = Monitor, A = Action

Pressure Reducing Valve Test

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Illustration 1g06177528

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Table 13
Status(1)  Description  Specification  Actual  Comments 
  Port "G1" tap (6) of the auxiliary valve  5000 ± 350 kPa (725 ± 51 psi)     
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(1) N = Normal, M = Monitor, A = Action

Pump Control Valve (Auxiliary) Test

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Illustration 2g06177525
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Illustration 3g06177526

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Table 14
Status(1)  Description  Specification  Actual  Comments 
  Hydraulic pressure at port "G" (1) on right grade and slope valve (2).  14000 ± 175 kPa (2030 ± 25 psi)     
  Torque for set screw (4) on "PC" adjustment screw (5) in pump control valve (3).  9.15 ± 1.65 N·m (6.75 ± 1.2 lb ft)     
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(1) N = Normal, M = Monitor, A = Action

Pump Control Valve (Generator) Test

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Table 15
Status(1)  Description  Specification  Actual  Comments 
  The pressure at the generator cooling circuit filter  Less than 700 kPa (102 psi)     
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(1) N = Normal, M = Monitor, A = Action

Propel System

Reference: Refer to Testing & Adjusting, UENR3134 for more detail on the following test.

Piston Pump Neutral Test

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Table 16
Status(1)  Description  Specification  Actual  Comments 
  Engine high idle test speed  2200 RPM     
  Hydraulic oil temperature for test  43° ± 6°C (110° ± 43°F)     
  Torque for adjustment mechanism locknut on the piston pumps  13 N·m (10 lb ft)     
  Torque for plugs in ports "M4" and "M5" on the piston pumps  12 N·m (9 lb ft)     
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(1) N = Normal, M = Monitor, A = Action

Conveyor System

Reference: Refer to Testing & Adjusting, UENR3134 for more detail on the following test.

Conveyor Speed (Drag) Check

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Table 17
Status(1)  Description  Specification  Actual  Comments 
  The conveyor sprocket shaft speed  119 ± 15 RPM     
  The time required for the conveyor to make a full revolution  10.5 ± 1.5 seconds     
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(1) N = Normal, M = Monitor, A = Action

Conveyor Speed (Auger) Check

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Table 18
Status(1)  Description  Specification  Actual  Comments 
  The auger speed  151 ± 5 RPM     
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(1) N = Normal, M = Monitor, A = Action

Relief Valve (Charge, Auger Conveyor and Drag Conveyor) - Test and Adjust

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Table 19
Status(1)  Description  Specification  Actual  Comments 
  Charge Pressure at feed charge filter  2700 ± 175 kPa (392 ± 25 psi)     
  Charge pressure at right material feed pump  2850 ± 200 kPa (413 ± 29 psi)     
  Charge pressure at left material feed pump  2850 ± 200 kPa (413 ± 29 psi)     
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(1) N = Normal, M = Monitor, A = Action

Piston Motor Case Drain Flow (Auger Conveyor and Drag Conveyor)

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Table 20
Status(1)  Description  Specification  Actual  Comments 
  Auger motor flow rate  Less than 4.5 L/min (1.2 US gpm)     
  Conveyor motor flow rate  Less than 4.5 L/min (1.2 US gpm)     
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(1) N = Normal, M = Monitor, A = Action

Relief Valve (Main, Auger Conveyor and Drag Conveyor) Test and Adjust

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Illustration 4g06177567
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Illustration 5g06177568
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Illustration 6g06177569
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Illustration 7g06177571
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Illustration 8g06177572
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Illustration 9g06177573
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Illustration 10g06177578
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Illustration 11g06177574

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Table 21
Status(1)  Description  Specification  Actual  Comments 
  Right Conveyor Pump, Forward Pressure, Port "MC" (1)  34500 ± 2100 kPa (5009 ± 305 psi)     
  Right Conveyor Pump, Reverse Pressure, Port "D" (2)  34500 ± 2100 kPa (5009 ± 305 psi)     
  Left Conveyor Pump, Reverse Pressure, Port "MB" (3)  34500 ± 2100 kPa (5009 ± 305 psi)     
  Left Conveyor Pump, Forward Pressure, Port "MA" (4)  34500 ± 2100 kPa (5009 ± 305 psi)     
  Right Auger Pump, Forward Pressure, Port "MB" (5)  34500 ± 2100 kPa (5009 ± 305 psi)     
  Right Auger Pump, Reverse Pressure, Port "A" (6)  34500 ± 2100 kPa (5009 ± 305 psi)     
  Left Auger Pump, Forward Pressure, Port "MD" (9)  34500 ± 2100 kPa (5009 ± 305 psi)     
  Left Auger Pump, Reverse Pressure, Port "C" (8)  34500 ± 2100 kPa (5009 ± 305 psi)     
  Torque Applied to Plug on Main Relief Valves  80 N·m (59 lb ft)     
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(1) N = Normal, M = Monitor, A = Action

S·O·S Samples

Reference: Refer to Operation and Maintenance Manual, KEBU7061, "Maintenance Interval Schedule" for more detail on performing S.0.S samples.

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Table 22
Status(1)  Description  Obtain  Comments 
  Engine Oil Sample     
  Engine Coolant Sample (level II)     
  Hydraulic System Oil Sample     
  Pump Drive Oil Sample     
  Right Final Drive Planetary Oil Sample     
  Left Final Drive Planetary Oil Sample     
  Right Conveyor Planetary Drive (Auger) Oil Sample     
  Left Conveyor Planetary Drive (Auger) Oil Sample     
  Right Conveyor Planetary Drive (Drag) Oil Sample     
  Left Conveyor Planetary Drive (Drag) Oil Sample     
Show/hide table
(1) N = Normal, M = Monitor, A = Action

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