User manual CATERPILLAR MD6540 BROCHURE

[. . . ] EVERY DAY. 3 MONEY MAKING FEATURES HIGH PERFORMANCE, RELIABLE AND DURABLE Delivering the tonnage and producing smooth mats day after day leads to profitability. Combine these features with years of service, comfort, visibility and you have the #1 choice of paving contractors. LEADING-EDGE TECHNOLOGY ­ Tier 4 Interim/Stage IIIB compliant with Cat® C7. 1 engine ­ Advisor display provides visual reference ­ Self diagnostics from multiple ECMs displayed through Advisor ­ Cruise control feature matches paving train ­ Eco-mode increases fuel efficiency ­ Integrated Cat Grade and Slope System ­ Screed lock feature prevents settling ­ Friction steer (MD6540) holds steering direction in turns ­ Product Link option with VisionLinkTM software ADVANCED MIX DELIVERY ­ Independent control of each auger and each conveyor leads to consistent head of material ­ 2 or 4 sensor mix delivery system provides flexibility ­ Hydraulic mainframe extensions optimize flow ­ Reversible augers and conveyors limits spillage ­ Rigid screeds deliver excellent stability EXCEPTIONAL VISIBILITY AND COMFORT ­ Dual operating stations swing out for better all-around visibility ­ Front-mounted cooling system: - directs hot engine air away from crew - re-directs fumes cloud that occurs when truck dumping ­ Quiet operation supports easy communication 4 DURABLE MOBIL-TRACTM UNDERCARRIAGE ­ Oscillating bogies minimize tow-point movement for a smoother mat ­ Long-belt life leads to low life-time operating cost ­ Excellent traction on soft or hard base materials ­ Smooth or tread-bar pattern belts available ­ Smooth-belt leads to less base disturbance and minimizes handwork ­ Speeds similar to wheeled pavers WHEEL UNDERCARRIAGE ­ Tight turning radius ­ High travel speeds ­ Front wheel assist or all-wheel drive options ­ Excellent traction on soft or hard base materials FUMES MANAGEMENT ­ Cooling exhaust, truck dumping surge, and fumes extraction are directed away from crew ­ Operator-friendly environment ­ Fumes extraction removes vapors from tunnels and auger chamber CAT® C7. 1 ENGINE WITH ACERTTM TECHNOLOGY * ­ 168 kW (225 hp) rated power ­ Meets U. S. EPA Tier 4 Interim/EU Stage IIIB emissions standards ­ Engine power management modifies output ­ Automatic engine speed control improves fuel efficiency * C6. 6 engine utilized for markets that require U. S. [. . . ] EPA Tier 3/EU Stage IIIA emission standards. EXCELLENT SERVICEABILITY ­ Advisor display lists service codes ­ Manual overrides on hydraulics ­ Visual indicators for routine service checks ­ Electronic Control Modules (ECM) monitor system performance ­ Long service intervals minimize costs 5 1. Hardtop Canopy 1 10 2 3 5 4 6 6 15 14 13 12 11 LOADED WITH TECHNOLOGY CONTINUING TO LEAD WITH SOLUTIONS THAT WORK. 9 8 7 7 SMOOTH DELIVERY CONTINUOUS FLOW LEADS TO BETTER MAT QUALITY. Automated controls and well-designed components reduce segregation potential, maximize efficiency, and deliver a consistent head of material that leads to better mat quality. AUTOMATED DELIVERY ­ Four pumps enable individual control of each auger and each conveyor for precise mix delivery to the screed ­ Two sensor system with ratio control dials automatically adjusts mix flow when changing paving widths ­ Four sensor system utilized with the AS4251C and AS4252C screeds monitor conveyors and augers for precise mix control ­ Cat Grade and Slope provides accurate control, optimizes mix utilization, and enables easy setup through a visual display SMOOTH FLOW ­ Wide tunnel and narrowly spaced conveyor bars of 215 mm (8. 5") ensure smooth flow to the auger chamber ­ 4-position adjustable push-roller conforms to trucking fleet for smoother exchanges ­ Reversible augers and conveyors minimize spillage at the end of the paving pass DURABLE, LONG-LIFE COMPONENTS ­ Thick floor plates, heavy-duty chains, and stout conveyor bars deliver lasting performance and lower lifetime operating costs ­ Narrow chain guards protect chains and bolt heads for extended long-term performance ­ Greaseable bearings with remote fittings flush contaminates away from seals for longer life 8 1 2 3 3 4 5 6 4 7 8 9 1. 11. Fumes extraction system Mix deflector plate Independent control of each auger and each conveyor Narrow chain guard covers Thick conveyor bars Narrow bar spacing ­ 215 mm (8. 5") Heavy-duty conveyor chains Thick floor plates Independent hopper actuation Hydraulic folding front apron (optional) Adjustable push-roller 10 11 9 OPERATING ENVIRONMENT COMFORT AND VISIBILITY INCREASE PERFORMANCE. Good visibility enables effective communication that leads to smooth truck exchanges and steady material flow. Long hours of operation can take a toll on the crew -- that's why Caterpillar designs operating stations that provide good control, visibility and comfort. DUAL INDEPENDENT OPERATING STATIONS ­ Controls move with the operator ­ Dual independent stations offer back-up capability ­ Stations extend beyond frame for increased all-around visibility ­ Operator customization with multiple seat adjustments and tilting consoles ­ 12-volt power receptacle, supports communication devices ­ Upper and lower tow-point indicators simplify height adjustment for tractor and screed operators ­ Cup holders offer convenience 1 60 EXCEPTIONAL VISIBILITY AND COMFORT ­ Low profile front-mounted cooling system improves forward visibility ­ Quiet operation supports easy communication; sound suppression material located throughout the machine ­ Tilting consoles conform to operator FUMES MANAGEMENT SYSTEM MORE COMFORT FOR YOUR CREW. The ventilation system draws fumes from the conveyor tunnel as well as the auger chamber and redirects them away from the operator for a more comfortable working environment. BETTER OPERATING CONDITIONS ­ Operator-friendly environment ­ Top-mounted cooling system directs fumes and hot air away from crew ­ Fumes surge when dumping mix is redirected by the dual cooling fans ­ Fumes extraction system removes vapors from the conveyor tunnels and auger chamber 11 OPERATING CONSOLE OPERATE WITH CONFIDENCE. The Advisor display provides visual references, self diagnostics, and planning tools that keep the operator informed for better overall job site performance. ADVISOR DISPLAY ­ Multiple language selections ­ Monitor machine conditions, including regeneration status ­ Set automatic engine speed control; reduces engine speed when delays occur ­ Activate Eco-mode for increased fuel efficiency; engine speed is reduced to 1650 rpm ­ Calibrate machine components ­ Access service code information ­ Access Paving Calculator ­ Reference Paving by the Numbers and start-up checklist ­ Store operating preferences for multiple operators ­ Set friction steering tension (MD6540) 12 Cat® operating consoles utilize positive feedback switches; the feel of fingertip activation promotes operator confidence. INTUITIVE CONSOLES ­ Grouped toggle switches ensure efficiency and performance ­ Cruise-control feature maintains paving speed for smoother mats ­ Three propel/steering modes: pave, travel, and maneuver ­ When utilizing 2-sensor system, ratio control dials automatically adjust mix flow when changing paving widths ­ Screed lock function prevents settling, eliminates bumps in the mat 13 1 2 3 4 WHEEL UNDERCARRIAGE RESPONSIVE POWER, SMOOTH RIDE. EXCELLENT MANEUVERABILITY Quick reacting speed control ensures that responsive power is immediately available, while the wheeled undercarriage provides mobility and high speed capability when moving around the job site. ­ Tight turning radius for quick mobility ­ A position sensor located in the left steering cylinder helps maintain consistent travel speeds when making turns by adjusting the drive speed of the propel motors according to the steering angle of the front wheels, leading to better mat quality and less wear on the drive system ­ The oscillating design easily overcomes obstacles, eliminates jarring effects and minimizes tow-point movement 14 6 5 1. 6. Oscillating Bogies Steering Position Sensor Dual Solid Front Steering Wheels Front Wheel Assist All-Wheel Drive Large 18. 00 R25 Sand-Rib Drive Tires Inside Turning Radius of 0. 50 m (1. 5 ft) MOBILITY ­ Pave, Travel and Maneuver modes - Pave: Improved steering control when paving - Travel: Speeds of 0 - 20 km/hr (0 - 12 mph) - Maneuver: Optimizes steering control and delivers an inside turning radius of 0. 50 m (1. 5 ft) FRONT WHEEL ASSIST OR ALL-WHEEL DRIVE ­ Front wheel assist option provides power to the front bogie wheels for added traction when pushing trucks or working on soft base ­ All-wheel drive option provides power to the front and rear bogie wheels, maximizing traction 15 4 2 4 2 1 MOBIL-TRAC UNDERCARRIAGE TM EXCELLENT TRACTION, HIGH SPEEDS. MOBILITY Maintenance-free and unmatched traction in both a smooth or tread-bar style belt; the Mobil-TracTM undercarriage system provides mobility and high speed capability when moving around the job site. ­ High speed capability; similar to wheeled pavers ­ Pave, Travel and Maneuver modes - Pave: Improved steering control when paving - Travel: Speeds of 0 - 14. 5 km/hr (0 - 9 mph) - Maneuver: Optimizes steering control and enables the paver to rotate within its own footprint SMOOTH RIDE ­ Oscillating bogie design delivers ride of wheeled paver ­ Easily overcomes obstacles, eliminates jarring effects ­ Guide lugs keep the tracks centered for reliable performance 16 4 3 1 5 6 1. 6. Oscillating Bogies Rubber-Coated Components Automatic Belt Tensioning Pivot Point Smooth Belt Tread-bar Belt PERFORMANCE ­ Mobil-Trac undercarriage design minimizes tow-point movement ­ Front and rear bogie sets crawl over obstacles; maintaining ground contact and minimizing tow-point movement ­ Smooth belt performs well on soft base materials and fresh mats ­ Tread-bar belt excels on loose paving/transport conditions ­ Outstanding traction in any condition, excellent flotation DURABILITY ­ Self-tensioning accumulators, center guide blocks and rugged internal belt cables ensure durability ­ Rubber-coated components designed to shed material and prevent accumulation 17 1 CLEANER POWER SELF-ACTIVATING, LOWER EMISSIONS. U. S. EPA TIER 4 INTERIM/EU STAGE IIIB EMISSIONS STANDARDS ­ Reduces oxides of nitrogen by 50 percent from Tier 3/Stage IIIA levels ­ Reduces particulate matter by 90 percent from Tier 3/Stage IIIA levels ­ Ultra Low Sulfur Diesel (ULSD) fuel is required - Sulfur content is reduced to 15 ppm (mg/kg) - Bio-diesel up to B20 can be utilized when blended with ULSD ­ Engine oil must meet Caterpillar ECF-3, API CJ-4/ACEA E9 specifications - Reduced sulfated ash, phosphorus, and sulfur EMISSIONS REDUCTION TECHNOLOGY ­ The Cat C7. 1 engine is equipped with a Diesel Particulate Filter (DPF) that traps soot from the exhaust stream. EPA Tier 3/EU Stage IIIA emissions standards ­ Provides 168 kW (225 hp) of power ­ The 6. 6 liter engine has a displacement of (403 in3) and utilizes the Cat common rail fuel delivery system ­ Utilizes ACERT Technology ­ Oil change interval of 500 hour Cat® C7. 1 20 Cat C6. 6 SERVICE FEATURES QUALITY COMPONENTS LAST LONGER, SAVE MONEY. Maintaining productivity requires durable components that limit wear and extend equipment life. QUICK RESOLUTION Trouble-shooting has never been easier with the Advisor display and electronic control modules (ECM). It is entirely supported by Caterpillar; ensuring the control system and paver are setup to optimize performance and meet job site requirements. Cat Dealers offer exceptional knowledge of the grade and slope system, as well as paver and screed operation, providing a single source that meets all your paving needs. 28 2 1 1. Sealed Sonic Sensor GRADE AND SLOPE FEATURES SINGLE OR DUAL DISPLAYS ­ EASY VISUALIZATION ­ Each LCD display is able to control one or both sides of the screed ­ Text-based menus offer multiple languages ­ Equipped with brightness and contrast controls for good visibility in various lighting conditions SONIC AVERAGING BEAM ­ Equipped with up to three sensors; when paving super elevations, the front and rear sensor can be turned off for better control of mat thickness ­ Averages total deviations and adjusts tow-point by 1/3 for true averaging; Note: When utilizing two grade sensors, tow-point is adjusted by 1/2 of the total deviation. ­ Sensor height can be individually adjusted ­ Easily move to the next starting point without disassembly. DURABLE ENCLOSURE ­ Swivel capability enables visibility from a various positions ­ Heavy-duty design provides overnight protection SONIC GRADE SENSORS ­ Sonic sensor is equipped with five ceramic transducers in each sensor, two readings are discarded, three are averaged ­ 457 mm (18") optimal height ­ Built-in temperature sensor accounts for temperature variation; sealed, reliable CONTACTING GRADE SENSORS ­ Two designs; ground contacting ski, wand-type for string lines ­ Effective for curbs and joints Averaged SLOPE SENSOR ­ Range of ±10 degrees (17. 6%) ­ Effective on super elevations Discarded S1 S2 S3 Travel Direction S1+S2+S3 3 = Tow-point Movement (True Averaging) 29 ADVANCED ELECTRIC SCREED HEAT TOUCH-PAD TECHNOLOGY WITH MULTI-ZONE HEATING AND EVEN-HEAT DISTRIBUTION. ELECTRIC HEAT FEATURES ­ Touch-pad technology and LED indicator lights create a user-friendly interface ­ Three pre-set temperature settings for each screed section ensure even heat distribution ­ Manual adjustments provide override capability ­ Flattened bar type heating elements deliver reliability ­ Temperature sensors in each screed section, including extensions ­ On-board diagnostics enable operator to verify fault indicators TRACTOR-MOUNTED GENERATOR ­ GFCI circuit breaker protection ­ Fast heat-up at low idle. ­ Manual breaker reset ­ 25 kW generator - supplies 25 kW at 60 Hz with engine speed 1275 or higher - provides power to the electric screed and auxiliary power panel - utilized for normal lighting packages ­ 35 kW generator - supplies 35 kW with engine speed at 1500 rpm or higher - provides power to the electric screed and two auxiliary power panels - utilized for large lighting packages and wide width tamper bar screed 1 AUXILIARY POWER ­ 7 kW of available power ­ Six, 120-volt receptacles ­ One, 240-volt receptacle ­ Supports high intensity discharge lighting (HID), power tools 2 3 1. 5. 30 Even Heat Distribution Electric Heat Panel Heating Element Generator Auxiliary Panel 4 5 PRODUCT LINK REDUCE COSTS. Product Link gets you accurate, timely and useful information about the location, utilization and condition of your equipment. TIMELY MAINTENANCE MANAGEMENT ­ Easily plan and track maintenance ­ Start with "built-in" Caterpillar recommended service intervals and customize to match your fleet and job needs ­ See what service has been done and what is due at a glance ­ "Click-through" features make it easy to contact your Cat Dealer for service and maintenance ROBUST GEO-FENCING ­ Street maps and satellite view simplify set up of site boundaries ­ Easily draw complex, accurate boundary shapes ­ Provides valuable asset tracking and security monitoring tools IDLE TIME VS. WORKING TIME ­ Instantly relate and compare utilization of all assets on a job site ­ Make better informed equipment decisions. Are there enough trucks delivering material or too few? CUSTOMIZED ALERTS & DISPLAYS ­ See all alerts on one screen, or any that you specify ­ Prioritize information; service alerts, operator-generated errors, etc. [. . . ] Are there enough trucks delivering material or too few? CUSTOMIZED ALERTS & DISPLAYS ­ See all alerts on one screen, or any that you specify ­ Prioritize information; service alerts, operator-generated errors, etc. ­ Send alerts to the people who need them via email or text message FAST PARTS ORDERING ­ VisionLinkTM provides "to do" checklists for common preventive maintenance and service procedures. ­ "Built-in" parts lists for common procedures ­ Click-through to PartStoreTM and automatic loading of parts lists speed and simplify ordering. USER-FRIENDLY DASHBOARD ­ See individual machine status instantly ­ Monitor current fuel level and total usage ­ Stay on top of past due alerts ­ Idle vs. [. . . ]