Caterpillar ASPHALT PAVERS AP600D, BG600D Repair Service Manuals
Caterpillar ASPHALT PAVERS AP600D, BG600D Repair Service Manuals
Complete service repair manuals with electrical wiring diagrams for Caterpillar ASPHALT PAVERS AP600D, BG600D, with all the workshop service information to maintain, diagnose, repair, and rebuild.
Caterpillar ASPHALT PAVERS AP600D/BG600D Repair Service Manuals
workshop service manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
KENR6676 - Schematic (AP600D Asphalt Paver Electrical System 269-7264)
KENR6677 - Schematic (AP600D and BG600D Asphalt Paver Hydraulic System)
KENR5919 - Troubleshooting (AP600D, AP655D, BG600D and BG655D Asphalt Pavers).pdf
KENR6410 - Disassembly and Assembly (AP600D and BG600D Asphalt Pavers C6.6 Engine Supplement).pdf
KENR6411 - Disassembly and Assembly (AP600D and BG600D Asphalt Pavers Machine Systems).pdf
KENR6960 - Specifications (AP600D Asphalt Paver Propel System).pdf
KENR6960 - Systems Operation (AP600D Asphalt Paver Propel System).pdf
KENR6960 - Testing and Adjusting (AP600D Asphalt Paver Propel System).pdf
KENR6961 - Specifications (AP600D Asphalt Paver Machine Systems).pdf
KENR6961 - System Operation (AP600D Asphalt Paver Machine Systems).pdf
KENR6961 - Testing and Adjusting (AP600D Asphalt Paver Machine Systems).pdf
RENR6489 - Systems Operation (AP600D, AP655D, BG600D and BG655D Asphalt Pavers Monitoring System).pdf
RENR6489 - Testing and Adjusting (AP600D, AP655D, BG600D and BG655D Asphalt Pavers Monitoring System).pdf
Total Pages: 1,701 pages
File Format: PDF (bookmarked, ToC, Searchable, Printable, high quality)
Manual Type: Disassembly & Assembly, Testing & Adjusting, Specifications, Systems Operation, Electrical Schematic, Troubleshooting...
Language: English
AP-600D ASPHALT PAVER TFM
AP-600D ASPHALT PAVER TFZ
BG600D ASPHALT PAVER B6K
TABLE OF CONTETNS
KENR6410 - Disassembly and Assembly (AP600D and BG600D Asphalt Pavers C6.6 Engine Supplement)..............2
Air Cleaner - Remove and Install..............3
Exhaust (Muffler) - Remove and Install..............7
Engine Enclosure (Hood) - Remove and Install..............12
Hydraulic System Pressure - Release..............18
Battery - Remove and Install..............19
Alternator - Remove and Install..............24
Electric Starting Motor - Remove and Install..............28
Fuel Filter (Primary) and Fuel Filter Base - Remove and Install..............31
Fuel Filter (Secondary) and Fuel Filter Base - Remove and Install..............33
Fan - Remove and Install..............36
Gear Pump (Fan Drive) - Remove..............39
Gear Pump (Fan Drive) - Disassemble..............41
Gear Pump (Fan Drive) - Assemble..............45
Gear Pump (Fan Drive) - Install..............49
Gear Motor (Hydraulic Fan) - Remove..............51
Gear Motor (Hydraulic Fan) - Disassemble..............54
Gear Motor (Hydraulic Fan) - Assemble..............60
Gear Motor (Hydraulic Fan) - Install..............66
Radiator and Hydraulic Oil Cooler - Remove and Install..............68
Engine - Remove..............95
Engine - Install..............101
KENR6411 - Disassembly and Assembly (AP600D and BG600D Asphalt Pavers Machine Systems)..............107
Hydraulic System Pressure - Release..............113
Battery and Battery Cable - Separate and Connect..............114
Fuel Tank - Remove and Install..............117
Electric Motor (Washdown Pump) - Remove and Install..............122
Hydraulic Oil Filter (Return) - Remove..............124
Hydraulic Oil Filter (Return) - Disassemble..............127
Hydraulic Oil Filter (Return) - Assemble..............129
Hydraulic Oil Filter (Return) - Install..............131
Hydraulic Tank - Remove and Install..............133
Piston Pump (Left Drag Conveyor and Left Auger Conveyor) - Remove..............140
Piston Pump (Right Drag Conveyor and Right Auger Conveyor) - Remove..............142
Piston Pump (Drag Conveyor and Auger Conveyor) - Disassemble..............146
Piston Pump (Drag Conveyor and Auger Conveyor) - Assemble..............156
Piston Pump (Left Drag Conveyor and Left Auger Conveyor) - Install..............165
Piston Pump (Right Drag Conveyor and Right Auger Conveyor) - Install..............168
Piston Motor (Drag Conveyor) - Remove..............171
Piston Motor (Drag Conveyor) - Disassemble..............173
Piston Motor (Drag Conveyor) - Assemble..............178
Piston Motor (Drag Conveyor) - Install..............183
Chain (Drag Conveyor) - Remove and Install..............185
Final Drive Planetary (Drag Conveyor) - Remove..............189
Final Drive Planetary (Drag Conveyor) - Disassemble..............190
Final Drive Planetary (Drag Conveyor) - Assemble..............204
Final Drive Planetary (Drag Conveyor) - Install..............218
Drag Conveyor - Remove and Install..............219
Feeder Drive Shaft Group - Remove..............225
Feeder Drive Shaft Group - Disassemble..............229
Feeder Drive Shaft Group - Assemble..............233
Feeder Drive Shaft Group - Install..............238
Footshaft - Remove..............242
Footshaft - Disassemble..............244
Footshaft - Assemble..............248
Footshaft - Install..............253
Plates (Drag Pans) - Remove and Install..............255
Piston Motor (Auger Conveyor) - Remove..............258
Piston Motor (Auger Conveyor) - Disassemble..............260
Piston Motor (Auger Conveyor) - Assemble..............265
Piston Motor (Auger Conveyor) - Install..............270
Chain (Auger Conveyor) - Remove and Install..............272
Final Drive Planetary (Auger Conveyor) - Remove..............275
Final Drive Planetary (Auger Conveyor) - Disassemble..............278
Final Drive Planetary (Auger Conveyor) - Assemble..............292
Final Drive Planetary (Auger Conveyor) - Install..............307
Hydraulic Cylinder (Auger Hoist) - Remove and Install..............310
Auger Conveyor - Remove and Install..............314
Hydraulic Filter (Suction Return) - Remove and Install..............318
Piston Pump (Right Propel) - Remove..............322
Piston Pump (Left Propel) - Remove..............325
Piston Pump (Propel) - Disassemble..............327
Piston Pump (Propel) - Assemble..............348
Piston Pump (Right Propel) - Install..............374
Piston Pump (Left Propel) - Install..............377
Piston Motor (Propel) - Remove..............379
Piston Motor (Propel) - Disassemble..............384
Piston Motor (Propel) - Assemble..............397
Piston Motor (Propel) - Install..............410
Brake Pump and Valve - Remove..............414
Brake Pump and Valve - Disassemble..............416
Brake Pump and Valve - Assemble..............418
Brake Pump and Valve - Install..............420
Pump Drive - Remove..............421
Pump Drive - Disassemble..............424
Pump Drive - Assemble..............427
Pump Drive - Install..............430
Wheel (Front Wheel Assist) - Remove and Install..............433
Front Wheel Drive Manifold - Remove..............440
Front Wheel Drive Manifold - Disassemble..............442
Front Wheel Drive Manifold - Assemble..............445
Front Wheel Drive Manifold - Install..............447
Piston Motor (Front Wheel Assist) - Remove..............449
Piston Motor (Front Wheel Assist) - Disassemble..............455
Piston Motor (Front Wheel Assist) - Assemble..............462
Piston Motor (Front Wheel Assist) - Install..............468
Wheel (Rear) - Remove and Install..............472
Final Drive Planetary - Remove..............474
Final Drive Planetary - Disassemble..............479
Duo-Cone Conventional Seals - Install..............491
Final Drive Planetary - Assemble..............503
Final Drive Planetary - Install..............515
Piston Pump (Auxiliary) - Remove..............519
Piston Pump (Auxiliary) - Disassemble..............521
Piston Pump (Auxiliary) - Assemble..............534
Piston Pump (Auxiliary) - Install..............547
Control Valve (Auxiliary) - Remove..............549
Control Valve (Auxiliary) - Disassemble..............553
Control Valve (Auxiliary) - Assemble..............556
Control Valve (Auxiliary) - Install..............558
Control Valve (Right Tow Point and Hopper Hoist) - Remove..............561
Control Valve (Hopper Hoist and Tow Point) - Disassemble..............564
Control Valve (Hopper Hoist and Tow Point) - Assemble..............566
Control Valve (Right Tow Point and Hopper Hoist) - Install..............568
Control Valve (Left Tow Point) - Remove..............571
Control Valve (Left Tow Point) - Disassemble..............573
Control Valve (Left Tow Point) - Assemble..............575
Control Valve (Left Tow Point) - Install..............577
Hydraulic Cylinder (Hopper Hoist) - Remove and Install..............579
Hydraulic Cylinder (Apron) - Remove and Install..............584
Control Valve (Apron) - Remove..............587
Control Valve (Apron) - Disassemble..............589
Control Valve (Apron) - Assemble..............591
Control Valve (Apron) - Install..............593
Hopper - Remove and Install..............594
Seat - Remove and Install..............598
Steering Wheel - Remove and Install..............600
Metering Pump (Steering) - Remove and Install..............603
Hydraulic Cylinder (Steering) - Remove and Install..............608
Operator Platform - Remove and Install..............613
Piston Pump (Tamper Bar) - Remove..............623
Piston Pump (Tamper Bar) - Disassemble..............626
Piston Pump (Tamper Bar) - Assemble..............636
Piston Pump (Tamper Bar) - Install..............646
Control Valve (Vibratory) - Remove..............648
Control Valve (Vibratory) - Disassemble..............650
Control Valve (Vibratory) - Assemble..............652
Control Valve (Vibratory) - Install..............654
Screed - Remove and Install..............655
Hydraulic Cylinder (Screed Hoist) - Remove and Install..............663
Hydraulic Cylinder (Tow Point) - Remove and Install..............666
Tow Arm - Remove and Install..............669
Gear Motor (Ventilation System) - Remove..............673
Gear Motor (Ventilation System) - Disassemble..............676
Gear Motor (Ventilation System) - Assemble..............678
Gear Motor (Ventilation System) - Install..............680
Return Manifold and Oil Cooler Bypass Valve - Remove and Install..............682
Push Roller - Remove..............685
Push Roller - Disassemble..............687
Push Roller - Assemble..............689
Push Roller - Install..............691
Transverse Beam - Remove and Install..............693
Control Valve (Truck Hitch) - Remove..............695
Control Valve (Truck Hitch) - Disassemble..............697
Control Valve (Truck Hitch) - Assemble..............699
Control Valve (Truck Hitch) - Install..............701
Hydraulic Cylinder (Truck Hitch) - Remove and Install..............702
Truck Hitch - Remove..............710
Truck Hitch - Disassemble..............713
Truck Hitch - Assemble..............718
Truck Hitch - Install..............723
Piston Pump (Hydraulic Generator) - Remove..............725
Piston Pump (Hydraulic Generator) - Disassemble..............728
Piston Pump (Hydraulic Generator) - Assemble..............734
Piston Pump (Hydraulic Generator) - Install..............741
Control Valve (Hydraulic Generator) - Remove..............743
Control Valve (Hydraulic Generator) - Disassemble..............745
Control Valve (Hydraulic Generator) - Assemble..............748
Control Valve (Hydraulic Generator) - Install..............751
Piston Motor (Hydraulic Generator) - Remove - 25K..............753
Piston Motor (Hydraulic Generator) - Disassemble..............755
Piston Motor (Hydraulic Generator) - Assemble..............760
Piston Motor (Hydraulic Generator) - Install - 25K..............765
Hydraulic Generator - Remove..............767
Hydraulic Generator - Install..............773
KENR6960 - Specifications (AP600D Asphalt Paver Propel System)..............779
Hydraulic Tank..............780
Piston Pump (Propel)..............782
Pump Drive..............784
Hydraulic Oil Filter (Charge Pump)..............785
Piston Motor (Propel)..............787
Final Drive Planetary..............788
Bogie..............790
Front Wheel Assist - Four-Wheel Drive..............795
Front Wheel Assist - Two-Wheel Drive..............802
Piston Motor (Front Wheel Assist)..............810
Front Wheel Drive Manifold..............811
KENR6960 - Systems Operation (AP600D Asphalt Paver Propel System)..............812
General Information (Propel System)..............813
Graphic Color Codes..............815
Propel Electrical System..............817
Propel Hydraulic System..............832
Front Wheel Assist Hydraulic System..............835
Operator Controls..............837
Piston Pump (Propel)..............844
Piston Motor (Propel)..............852
Piston Motor (Front Wheel Assist)..............855
Final Drive Planetary..............857
Electrical Schematic (Propel System)..............861
Hydraulic Schematic (Propel System)..............872
KENR6960 - Testing and Adjusting (AP600D Asphalt Paver Propel System)..............884
Machine Preparation for Troubleshooting..............885
Visual Inspection..............887
Propel System Troubleshooting..............891
Hydraulic Oil Contamination - Test..............894
Piston Pump Flow - Test..............898
Piston Pump Neutral - Test and Adjust..............904
Pump Synchronization - Test and Adjust..............921
Relief Valve (Charge) - Test and Adjust..............933
Pressure Limiter Valve - Test and Adjust..............951
Seal Leakage (Brake Piston) - Test..............973
Solenoid (Shift) - Test..............979
Lever (Propel Control) and Electronic Sensor - Test..............983
Harness (Speed Potentiometer) and Electronic Sensor - Test..............988
Rotary Position Sensor (Steering) - Test and Adjust..............993
Relief Valve (Front Wheel Assist) - Test and Adjust..............1000
Potentiometer (Front Wheel Assist) - Test..............1007
Forward Currents (EDC)- Calibrate..............1012
Reverse Currents (EDC)- Calibrate..............1022
Propel Lever - Calibrate..............1032
Speed Sensor (Propel Motor) - Adjust..............1038
Rotary Position Sensor (Brake Pedal) - Test and Adjust..............1042
KENR6961 - Specifications (AP600D Asphalt Paver Machine Systems)..............1047
Hydraulic Tank..............1049
Suction Strainer..............1051
Radiator and Hydraulic Oil Cooler..............1053
Oil Cooler Bypass Valve..............1056
Hydraulic Oil Filter (Charge Pump)..............1057
Hydraulic Oil Filter (Return) - Main..............1059
Pump Drive..............1061
Control Valve (Auxiliary)..............1062
Control Valve (Apron)..............1064
Hydraulic Cylinder (Apron)..............1066
Hydraulic Cylinder (Tow Point)..............1067
Tow Point Cylinder and Mounting..............1069
Control Valve (Truck Hitch)..............1071
Hydraulic Cylinder (Truck Hitch)..............1072
Tow Arm..............1073
Push Roller..............1074
Truck Hitch..............1076
Oscillating Hitch..............1078
Hydraulic Cylinder (Hopper Hoist)..............1080
Hydraulic Cylinder (Auger Hoist) - Right Cylinder..............1081
Hydraulic Cylinder (Auger Hoist) - Left Cylinder..............1082
Counterbalance Valve (Screed)..............1083
Hydraulic Cylinder (Screed Hoist)..............1085
Hopper..............1088
Access Door..............1090
Access Cover..............1092
Conveyor Drive Motor..............1094
Conveyor Planetary Drive (Drag)..............1095
Drag Conveyor..............1097
Footshaft..............1099
Feeder Drive Shaft (Drag)..............1100
Sensor (Paddle)..............1102
Auger Drive Motor..............1103
Conveyor Planetary Drive (Auger)..............1104
Auger Conveyor..............1105
Auger Extension - 610 mm (24.0 inch)..............1107
Auger Extension - 305 mm (12.0 inch)..............1108
Auger Extension - 152.4 mm (6.00 inch)..............1109
Main Frame Extension..............1110
Gear Pump (Hydraulic Fan)..............1111
Gear Motor (Hydraulic Fan)..............1112
Control Valve (Vibratory)..............1114
Gear Pump (Vibratory)..............1115
Piston Pump (Vibratory)..............1117
Gear Motor (Ventilation System)..............1119
Control Valve (Generator)..............1121
Piston Pump (Generator)..............1123
Piston Motor (Generator)..............1124
Generator..............1125
Washdown Group - Ecological..............1127
Washdown Hose Reel..............1130
Platform..............1131
Operator Console..............1133
Metering Pump (Steering)..............1135
Hydraulic Cylinder (Steering)..............1137
Air Cleaner..............1138
KENR6961 - System Operation (AP600D Asphalt Paver Machine Systems)..............1139
General Information (Auxiliary Hydraulic System)..............1141
Operator Controls (Auxiliary Hydraulic System)..............1142
Electrical System (Auxiliary Hydraulic)..............1149
Hydraulic System (Auxiliary)..............1164
Hydraulic Oil Cooler..............1169
Piston Pump (Auxiliary)..............1170
Manifold Valve (Screed Extend)..............1173
Control Manifold (Auxiliary)..............1175
Control Valve (Apron Fold)..............1179
Control Valve (Tow Point)..............1180
Manifold Valve (Steering)..............1183
Metering Pump (Steering)..............1184
Paver Ventilation System..............1185
Electrical Schematic (Auxiliary Hydraulic System)..............1187
Hydraulic Schematic (Auxiliary Hydraulic System)..............1198
General Information (Fan Hydraulic System)..............1217
Electrical System (Cooling Fan)..............1218
Hydraulic Oil Filter (Hydraulic Fan)..............1224
Oil Cooler Bypass Manifold..............1226
Gear Pump (Fan Drive)..............1228
Gear Motor (Fan Drive)..............1229
Electrical Schematic (Hydraulic Fan)..............1231
Hydraulic Schematic (Hydraulic Fan)..............1233
General Information (Auger and Conveyor System)..............1236
Operator Controls (Auger and Conveyor System)..............1237
Electrical System (Auger and Conveyor)..............1243
Piston Pump (Auger and Conveyor)..............1257
Electrical Schematic (Auger and Conveyor System)..............1265
Hydraulic Schematic (Auger and Conveyor System)..............1273
Operator Controls (Vibratory System)..............1280
Electrical System (Vibratory)..............1282
Location of Components (Vibratory System)..............1288
Gear Motor (Vibratory)..............1290
Electrical Schematic (Vibratory System)..............1291
Hydraulic Schematic (Vibratory System)..............1293
General Information (Tamper System)..............1297
Operator Controls (Tamper System)..............1298
Electrical System (Tamper)..............1301
Piston Pump (Tamper)..............1309
Gear Motor (Tamper)..............1316
Electrical Schematic (Tamper System)..............1317
Hydraulic Schematic (Tamper System)..............1320
General Information (Washdown System)..............1325
Location of Components (Washdown System)..............1326
Electrical Schematic (Washdown System)..............1333
General Information (Generator System)..............1335
Operator Controls (Generator)..............1336
Location Of Components (Generator System)..............1338
Piston Pump (Generator)..............1345
Control Valve (Generator)..............1349
Piston Motor (Generator)..............1351
Electrical Schematic (Generator System)..............1354
Hydraulic Schematic (Generator System)..............1359
KENR6961 - Testing and Adjusting (AP600D Asphalt Paver Machine Systems)..............1363
Machine Preparation for Troubleshooting..............1365
Visual Inspection..............1367
Machine System Troubleshooting..............1371
Piston Pump Flow (Auxiliary) - Test..............1375
Solenoid Valve (Vibratory Motor) - Calibrate..............1380
Piston Pump Neutral (Tamper) - Test and Adjust..............1390
Pressure Limiter Valve (Tamper Pump) - Test and Adjust..............1396
Relief Valve (Charge; Tamper Pump) - Test and Adjust..............1404
Solenoid Valve (Tamper) - Calibrate..............1410
Gear Pump Flow (Cooling Fan) - Test..............1420
Pump Control Valve (Auxiliary) - Test and Adjust..............1425
Relief Valve (Charge; Auger Conveyor and Drag Conveyor) - Test and Adjust - Left Auger Conveyor and Drag Conveyor..............1431
Relief Valve (Charge; Auger Conveyor and Drag Conveyor) - Test and Adjust - Right Auger Conveyor and Drag Conveyor..............1441
Relief Valve (Main; Auger Conveyor and Drag Conveyor) - Test and Adjust..............1451
Piston Pump Neutral (Auger Conveyor and Drag Conveyor) - Test and Adjust..............1475
Piston Motor Case Drain Flow (Auger Conveyor and Drag Conveyor) - Test..............1492
Conveyor Drive Chain (Auger) - Check and Adjust..............1504
Conveyor Drive Chain (Drag) - Check and Adjust..............1509
Conveyor Chain (Drag) - Check and Adjust..............1514
Conveyor Speed (Auger) - Check..............1519
Conveyor Speed (Drag) - Check..............1524
Pressure Reducing Valve (Shift) - Test and Adjust..............1529
Pressure Reducing Valve (Tow Point) - Test and Adjust..............1535
Relief Valve (Screed Counterbalance) - Test and Adjust..............1544
Steering Priority Valve - Test and Adjust..............1548
Pump Control Valve (Generator) - Test and Adjust..............1555
Piston Motor Case Drain Flow (Generator) - Test..............1564
Fan Speed (Ventilation) - Test..............1573
Generator Frequency - Test and Adjust..............1580
Solenoid Valve (Left Auger) - Calibrate..............1587
Solenoid Valve (Left Conveyor) - Calibrate..............1597
Solenoid Valve (Right Auger) - Calibrate..............1607
Solenoid Valve (Right Conveyor) - Calibrate..............1617
Sensor (Paddle) - Calibrate..............1627
Vibratory Shaft Speed - Calibrate..............1640
RENR6489 - Systems Operation (AP600D, AP655D, BG600D and BG655D Asphalt Pavers Monitoring System)..............1647
Control Menu..............1648
Data Link..............1651
Display Module..............1653
General Information..............1657
Menu Contents..............1659
Menu Navigation..............1661
Monitoring System..............1662
Operator Profile Menu..............1666
Output Components..............1671
Performance Menu..............1672
Service Menu..............1677
Settings Menu..............1682
Totals Menu..............1685
Warning Operation..............1688
RENR6489 - Testing and Adjusting (AP600D, AP655D, BG600D and BG655D Asphalt Pavers Monitoring System)..............1691
Connector Contact Description..............1692
Module - Replace..............1694
Self Test..............1696
System Schematic..............1697
