AP600D and BG600D Asphalt Pavers Machine Systems Caterpillar

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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.

Auger Motor

Note: The following procedure describes the steps which are used to test the case drain flow for the right auger motor. The procedure for testing the case drain flow for the left auger motor is similar.

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

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Illustration 1	g01511403

2. Move propel lever (3) to the NEUTRAL position.

3. Rotate speed dial (2) to the MINIMUM position.

4. Move parking brake switch (1) to the ON position.

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Illustration 2	g01511404

5. Move screed lift switch (4) to the FLOAT position. Allow the screed to lower to the ground.

   Note: The screed lift switch on the inactive operator station must also be in the FLOAT position in order to lower the screed.

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Illustration 3	g01511462

6. Move throttle control switch (5) to the LOW IDLE position. Hold the switch in this position for less than 1 second.

7. Move engine start switch (6) to the OFF position.

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Illustration 4	g01513288
Tool (C) (configuration)

8. Assemble the tooling.

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Illustration 5	g01513271

9. Disconnect fitting (7) from elbow (8) of the right auger motor.

   Note: The left auger motor is similar.

10. Connect Tool (B) to elbow (8). Connect fitting (7) to Tool (A) .

11. Disconnect fitting (9) from fitting (10) in port "B" of the right auger motor. Plug fitting (9) with Tool (G) and cap fitting (10) with Tool (H) .

    Note: If the left auger motor is being tested, disconnect the hose from the fitting in port "A". The ports are labelled on the motor.

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Illustration 6	g01513272

12. Disconnect fitting (12) on flushing line from elbow (11). Plug fitting (12) with Tool (J). Cap elbow (11) with Tool (K) .

13. Move screed lift switch (4) to the HOLD position.

14. Move engine start switch (6) to the START position. Release the engine start switch when the engine starts.

15. Operate the engine at low idle for a few minutes.

16. Move throttle control switch (5) to the HIGH IDLE position. Hold the switch in this position for less than 1 second. The engine speed should increase to 2200 rpm.

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Illustration 7	g01511413

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

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Illustration 8	g01513275

18. Move right auger switch (13) to the MANUAL position. Hold the switch in this position.

    Note: If the left auger motor is being tested, move left auger switch (14) to the MANUAL position. Hold the switch in this position.

19. Read the flow on Tool (F). The flow should be 15 to 17 L/min (4 to 4.5 US gpm).

20. Release auger switch (13) or (14) .

21. Move throttle control switch (5) to the LOW IDLE position. Hold the switch in this position for less than 1 second.

22. After the engine reaches low idle, move engine start switch (6) to the OFF position.

23. Remove the tooling. Reconnect the hydraulic lines to the auger motor.

24. If the flow is greater than the specification, the motor has excessive case drain flow. Replace the auger motor.

Conveyor Motor

Note: The following procedure describes the steps which are used to test the case drain flow for the right conveyor motor. The procedure for testing the case drain flow for the left conveyor motor is similar.

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

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Illustration 9	g01511403

2. Move propel lever (3) to the NEUTRAL position.

3. Rotate speed dial (2) to the MINIMUM position.

4. Move parking brake switch (1) to the ON position.

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Illustration 10	g01511404

5. Move screed lift switch (4) to the FLOAT position. Allow the screed to lower to the ground.

   Note: The screed lift switch on the inactive operator station must also be in the FLOAT position in order to lower the screed.

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Illustration 11	g01511462

6. Move throttle control switch (5) to the LOW IDLE position. Hold the switch in this position for less than 1 second.

7. Move engine start switch (6) to the OFF position.

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Illustration 12	g01513288

8. Assemble the tooling.

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Illustration 13	g01513289

9. Open access door (7) on the right side of the machine.

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Illustration 14	g01513290

10. Disconnect fitting (8) from elbow (9) of the right conveyor motor.

    Note: The left conveyor motor is similar. The access door on the left side of the machine provides access to this conveyor motor.

11. Connect Tool (B) to elbow (9). Connect fitting (8) to Tool (A) .

12. Disconnect fitting (10) from elbow (11) in port "B" of the right conveyor motor. Plug fitting (10) with Tool (G). Cap elbow (11) with Tool (H) .

    Note: If the left conveyor motor is being tested, disconnect the fitting from the elbow in the port "A". The ports are labelled on the motor.

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Illustration 15	g01513293

13. Disconnect fitting (12) on flushing line from elbow (13). Plug fitting (12) with Tool (J). Cap elbow (13) with Tool (K) .

14. Move screed lift switch (4) to the HOLD position.

15. Move engine start switch (6) to the START position. Release the engine start switch when the engine starts.

16. Operate the engine at low idle for a few minutes.

17. Move throttle control switch (5) to the HIGH IDLE position. Hold the switch in this position for less than 1 second. The engine speed should increase to 2200 rpm.

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Illustration 16	g01511413

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

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Illustration 17	g01513295

19. Move right conveyor speed dial (14) to the MAXIMUM position.

    Note: If the left conveyor motor is being tested, move left conveyor speed dial (16) to the MAXIMUM position.

20. Move right conveyor switch (15) to the MANUAL position. Hold the switch in this position.

    Note: If the left conveyor motor is being tested, move left conveyor switch (17) to the MANUAL position.

21. Read the flow on the Tool (F). The flow should be 15 to 17 L/min (4 to 4.5 US gpm).

22. Release conveyor switch (15) or (17) .

23. Move throttle control switch (5) to the LOW IDLE position. Hold the switch in this position for less than 1 second.

24. Move engine start switch (6) to the OFF position.

25. Remove the tooling. Reconnect the hydraulic lines to the conveyor motor.

26. If the flow is greater than the specification, the motor has excessive case drain flow. Replace the conveyor motor.