AP500F Asphalt Pavers TA2 Technical Inspection {0372, 1000, 7000, 753T, 7565} Caterpillar

Asphalt Paver

AP500F (S/N: 5031-UP; 4491-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.

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Electrical System

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, KEBU7178, "Battery or Battery Cables - Inspect/Replace".
	Battery Test	12.4 VDC or more		Refer to Special Instruction, SEHS9326, "Battery Test Sheet Report". Refer to Testing and Adjusting, UENR4524, "Battery - Test".
	Charging System Test			Refer to Testing and Adjusting, UENR4515, "Charging System - Test" Refer to Testing and Adjusting, UENR4524, "Charging System- Test". Refer to Special Instruction, REHS0354, "Charging System Troubleshooting"
	Electric Starting System Test			Refer to Testing and Adjusting, UENR4515, "Electrical Starting System - Test" Refer to Testing and Adjusting, UENR4524, "Electrical Starting System - Test".

(1)	N = Normal, M = Monitor, A = Action

Engine

Cooling System

Table 2

Status(1)	Description	Specification	Actual	Comments
	Radiator Pressure Relief (Radiator Cap)(2)			Use 9S-8140 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
	Jacket Water Outlet Temperature
	After cooler Water Outlet Temperature
	Jacket Water Inlet Temperature from Cooling System
	Oil Cooler Water Outlet Temperature

(1)	N = Normal, M = Monitor, A = Action
(2)	Test for the pressure that is listed on the cap.

Fuel System

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)

(1)	N = Normal, M = Monitor, A = Action

Lubrication System

Table 4

Status(1)	Description	Specification	Actual	Comments
	Minimum Engine Oil Pressure at Maximum Engine Speed	280 kPa (41 psi)

(1)	N = Normal, M = Monitor, A = Action

Basic Engine

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)

(1)	N = Normal, M = Monitor, A = Action

Air Inlet and Exhaust System

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)

(1)	N = Normal, M = Monitor, A = Action
(2)	Compare the exhaust temperature variance at each exhaust port.

Auxiliary System

Reference: Refer to Testing & Adjusting, UENR5536 for more detail on the following test.

Conveyor Drive Chain (Auger) Test

Table 7

Status(1)	Description	Specification	Actual	Comments
	Pull force applied to the midpoint of the auger chain to check auger chain deflection	67.0 N (15.1 lb)
	Correct amount of deflection at the midpoint of the auger chain	5.0 ± 1.0 mm (0.20 ± 0.04 inch)
	The auger speed	151± 5 RPM

(1)	N = Normal, M = Monitor, A = Action

Conveyor Drive Chain (Drag) Test

Table 8

Status(1)	Description	Specification	Actual	Comments
	Conveyor drag drive chain tension	25 ± 5 mm (0.9 ± 0.2 inch)

(1)	N = Normal, M = Monitor, A = Action

Conveyor Speed (Drag) - Check

Table 9

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

(1)	N = Normal, M = Monitor, A = Action

Conveyor Chain (Drag) - Check and Adjust

Table 10

Status(1)	Description	Specification	Actual	Comments
	Conveyor drag chain tension	No part of the conveyor drag chains should hang below the level of main frame

(1)	N = Normal, M = Monitor, A = Action

Piston Pump Flow (Auxiliary) - Test

Table 11

Status(1)	Description	Specification	Actual	Comments
	Time Required to retract the tow point cylinder	8.0 ± 2.0 seconds
	Time Required to extend the tow point cylinder	12.0 ± 3.0 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	4.5 ± 1.0 seconds
	Time required to lower the apron	3.1 ± 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

(1)	N = Normal, M = Monitor, A = Action

Vibratory Shaft Speed - Calibrate

Table 12

Status(1)	Description	Specification	Actual	Comments
	Vibratory shaft speed	3000 ± 300 RPM

(1)	N = Normal, M = Monitor, A = Action

Gear Pump Flow (Cooling Fan) - Test

Table 13

Status(1)	Description	Specification	Actual	Comments
	The cooling fan gear pump target rate of flow	Greater than 60.5 L/min (15.9 US gpm)

(1)	N = Normal, M = Monitor, A = Action

Pump Control Valve (Auxiliary) - Test and Adjust

Illustration 1	g06179547

Illustration 2	g06179548

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 lock nut (3) on the auxiliary pump.	9.0 ± 1.6 N·m (6.6 ± 1.2 lb ft)

(1)	N = Normal, M = Monitor, A = Action

Pressure Reducing Valve - Test and Adjust (Shift Solenoid)

Illustration 3	g06180245

Table 15

Status(1)	Description	Specification	Actual	Comments
	Port "G1" tap (4) of the auxiliary valve	5000 ± 350 kPa (725 ± 51 psi)

(1)	N = Normal, M = Monitor, A = Action

Rotary Position Sensor (Decelerator Pedal) - Test and Adjust

Table 16

Status(1)	Description	Specification	Actual	Comments
	Target value when the decelerator pedal is released	19 ± 5 percent
	Target value when the decelerator pedal is depressed	79 ± 5 percent

(1)	N = Normal, M = Monitor, A = Action

Propel System

Reference: Refer to Testing & Adjusting, UENR5534 for more detail on the following test.

Piston Pump Neutral - Test and Adjust (Right Propel)

Illustration 4	g06179560

Illustration 5	g06179561

Illustration 6	g06179564

Table 17

Status(1)	Description	Specification	Actual	Comments
	Pressure reading at port "M4" (1) and the pressure reading at port "M5" (2)	The pressures should agree within 130.0 kPa (18.9 psi)
	Torque applied to plug in port "M4" (1) and port "M5" (2)	12.0 N·m (8.9 lb ft)
	Torque applied to locknut (3) securing adjustment screw (4)	13.0 N·m (9.6 lb ft)

(1)	N = Normal, M = Monitor, A = Action

Piston Pump Neutral - Test and Adjust (Left Propel)

Illustration 7	g06179566

Illustration 8	g06179569

Illustration 9	g06179570

Table 18

Status(1)	Description	Specification	Actual	Comments
	Pressure reading at port "M4" (5) and the pressure reading at port "M5" (6)	The pressures should agree within 130.0 kPa (18.9 psi)
	Torque applied to plug in port "M4" (5) and port "M5" (6)	12.0 N·m (8.9 lb ft)
	Torque applied to locknut (7) securing adjustment screw (8)	13.0 N·m (9.6 lb ft)

(1)	N = Normal, M = Monitor, A = Action

Relief Valve (Charge) - Test and Adjust (Right Propel)

Illustration 10	g06179581

Illustration 11	g06179582

Illustration 12	g06179583

Table 19

Status(1)	Description	Specification	Actual	Comments
	Pressure at the case drain tap (9)	138 kPa (20 psi) to 410 kPa (60 psi)
	The pressure at charge pressure tap (10)	2300 ± 175 kPa (334 ± 25 psi)
	The differential pressure between charge pressure tap (10) and case drain tap (9)	1950 kPa (283 psi) to 2500 kPa (363 psi)
	Approximate pressure change from one turn of charge pressure adjustment screw (12)	390 kPa (57 psi)
	Charge pressure adjustment screw lock nut (11)	52 N·m (38 lb ft)

(1)	N = Normal, M = Monitor, A = Action

Relief Valve (Charge) - Test and Adjust (Left Propel)

Illustration 13	g06180039

Illustration 14	g06180042

Illustration 15	g06180045

Table 20

Status(1)	Description	Specification	Actual	Comments
	The pressure at charge pressure tap (13)	2300 ± 175 kPa (334 ± 25 psi)
	Pressure at case drain tap (14)	138 kPa (20 psi) to 410 kPa (60 psi)
	The differential pressure between charge pressure tap (13) and case drain tap (14)	1950 kPa (283 psi) to 2500 kPa (363 psi)
	Approximate pressure change from one turn of charge pressure adjustment screw (16)	390 kPa (57 psi)
	Charge pressure adjustment screw lock nut (15)	52 N·m (38 lb ft)

(1)	N = Normal, M = Monitor, A = Action

Piston Pump Flow - Test

Table 21

Status(1)	Description	Specification	Actual	Comments
	Charge relief pressure	3200 kPa (464 psi)
	Maximum "PAVE" speed in forward	19.7 ± 2.5 RPM
	Maximum "PAVE" speed in reverse	19.7 ± 2.5 RPM
	Maximum "TRAVEL" speed in forward	70.7 ± 3.5 RPM
	Maximum "TRAVEL" speed in reverse	70.7 ± 3.5 RPM

(1)	N = Normal, M = Monitor, A = Action

Pressure Limiter Valve - Test and Adjust (Left Propel)

Illustration 16	g06180047

Illustration 17	g06180051

Illustration 18	g06180052

Illustration 19	g06180053

Illustration 20	g06180055

Table 22

Status(1)	Description	Specification	Actual	Comments
	Tightening torque for retaining nut (18) securing the coil of parking brake solenoid coil (17)	4 N·m (3 lb ft) to 6 N·m (4 lb ft)
	The pressure differential pressure between port "M1" (20) and charge pressure port (19) in reverse	42000 ± 1400 kPa (6092 ± 203 psi)
	The pressure differential pressure between port "M2" (21) and charge pressure port (19) in forward	42000 ± 1400 kPa (6092 ± 203 psi)
	Tightening torque for locknut (22) on forward multifunction valve adjustment screw (23)	23 N·m (17 lb ft)
	Tightening torque for locknut (25) on reverse multifunction valve adjustment screw (24)	23 N·m (17 lb ft)

(1)	N = Normal, M = Monitor, A = Action

Pressure Limiter Valve - Test and Adjust (Right Propel)

Illustration 21	g06180063

Illustration 22	g06180064

Illustration 23	g06180065

Illustration 24	g06180066

Illustration 25	g06180067

Table 23

Status(1)	Description	Specification	Actual	Comments
	Tightening torque for retaining nut (27) securing the coil of parking brake solenoid coil (26)	4 N·m (3 lb ft) to 6 N·m (4 lb ft)
	The pressure differential pressure between port "M1" (28) and charge pressure port (30)	42000 ± 1400 kPa (6092 ± 203 psi)
	The pressure differential pressure between port "M2" (29) and charge pressure port (30)	42000 ± 1400 kPa (6092 ± 203 psi)
	Pressure at charge pressure tap (30)	2300 ± 175 kPa (334 ± 26 psi)
	Tightening torque for locknut (31) on forward multifunction valve adjustment screw (32)	23 N·m (17 lb ft)
	Amount of pressure change with one revolution of adjustment screw (32)	9000 kPa (1305 psi)
	Tightening torque for locknut (33) on reverse multifunction valve adjustment screw (34)	23 N·m (17 lb ft)

(1)	N = Normal, M = Monitor, A = Action

Seal Leakage for Final Drive Planetary - Test

Table 24

Status(1)	Description	Specification	Actual	Comments
	Brake system pressures	3445 kPa (500 psi)

(1)	N = Normal, M = Monitor, A = Action

Conveyor System

Reference: Refer to Testing & Adjusting, UENR5536 for more detail on the following test.

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

Table 25

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)

(1)	N = Normal, M = Monitor, A = Action

Conveyor Speed (Drag) Check

Table 26

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

(1)	N = Normal, M = Monitor, A = Action

Conveyor Speed (Auger) Check

Table 27

Status(1)	Description	Specification	Actual	Comments
	The auger speed	151 ± 5 RPM

(1)	N = Normal, M = Monitor, A = Action

Drag Conveyor - Calibrate

Table 28

Status(1)	Description	Specification	Actual	Comments
	The drag conveyor sprocket shaft speed	119 ± 15 RPM
	Time required for conveyor to make a complete revolution	10.5 ± 1.5 seconds

(1)	N = Normal, M = Monitor, A = Action

Auger Conveyor - Calibrate

Table 29

Status(1)	Description	Specification	Actual	Comments
	The auger shaft speed	150 ± 5 RPM

(1)	N = Normal, M = Monitor, A = Action

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

Illustration 26	g06180134

Illustration 27	g06180143

Table 30

Status(1)	Description	Specification	Actual	Comments
	Charge Pressure at feed charge filter	2500 ± 175 kPa (363 ± 25 psi)
	Charge pressure at isolated right material feed pump	2850 ± 200 kPa (413 ± 29 psi)
	Charge pressure at isolated left material feed pump	2850 ± 200 kPa (413 ± 29 psi)
	Locknut (1) on adjustment screw (2) torque	17 N·m (13 lb ft)
	Locknut (3) on adjustment screw (4) torque	17 N·m (13 lb ft)

(1)	N = Normal, M = Monitor, A = Action

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

Illustration 28	g06180155

Illustration 29	g06180158

Illustration 30	g06180164

Illustration 31	g06180167

Table 31

Status(1)	Description	Specification	Actual	Comments
	Right Conveyor Pump, Forward Pressure, Port "MC" (6)	36500 ± 2500 kPa (5294 ± 363 psi)
	Right Conveyor Pump, Reverse Pressure, Port "D" (5)	36500 ± 2500 kPa (5294 ± 363 psi)
	Left Conveyor Pump, Reverse Pressure, Port "MB" (7)	36500 ± 2500 kPa (5294 ± 363 psi)
	Left Conveyor Pump, Forward Pressure, Port "MA" (8)	36500 ± 2500 kPa (5294 ± 363 psi)
	Right Auger Pump, Forward Pressure, Port "MB" (9)	36500 ± 2500 kPa (5294 ± 363 psi)
	Right Auger Pump, Reverse Pressure, Port "A" (10)	36500 ± 2500 kPa (5294 ± 363 psi)
	Left Auger Pump, Forward Pressure, Port "MD" (11)	36500 ± 2500 kPa (5294 ± 363 psi)
	Left Auger Pump, Reverse Pressure, Port "C" (12)	36500 ± 2500 kPa (5294 ± 363 psi)
	Torque Applied to Plug on Main Relief Valves	80 N·m (59 lb ft)

(1)	N = Normal, M = Monitor, A = Action

Piston Pump Neutral (Auger Conveyor and Drag Conveyor) - Test and Adjust

Table 32

Status(1)	Description	Specification	Actual	Comments
	Engine high idle test speed	2200 RPM
	Hydraulic oil temperature for test	43° ± 6°C (77 ° ± 11 °F)
	Torque for adjustment mechanism locknut on the piston pumps	10 N·m (7 lb ft)
	Torque for plugs in ports "M4" and "M5" on the piston pumps	12 N·m (9 lb ft)

(1)	N = Normal, M = Monitor, A = Action

S·O·S Samples

Reference: Refer to Operation and Maintenance Manual, KEBU7178 and KEBU7181, "Maintenance Interval Schedule" for more detail on performing S.0.S samples.

Table 33

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

(1)	N = Normal, M = Monitor, A = Action