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2010 Caterpillar
All Rights Reserved
KEBU7046
February 2010
Operation and
Maintenance
Manual
AP555E and BG555E Asphalt Pavers
A5D1-Up (Machine)
B5P1-Up (Machine)
SAFETY.CAT.COM
112
Maintenance Section
Maintenance Interval Schedule
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When Required
Auger Slide - Lubricate ........................................ 115
Battery - Recycle ................................................. 116
Battery or Battery Cable - Inspect/Replace ......... 116
Engine Air Cleaner Inlet - Clean ......................... 129
Engine Air Filter Primary Element - Clean/
Replace ............................................................. 129
Engine Air Filter Secondary Element - Replace .. 130
Fuel System - Prime ........................................... 134
Fuses - Replace .................................................. 138
Hopper Flashing - Inspect/Replace .................... 143
Oil Filter - Inspect ................................................ 145
Ventilation Blower Wheel - Inspect/Clean ........... 152
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113
Maintenance Section
Maintenance Interval Schedule
120
120
121
121
131
132
133
134
138
140
144
145
147
143
145
150
150
Every Year
Cooling System Coolant Sample (Level 2) Obtain ............................................................... 126
114
Maintenance Section
Alternator - Inspect
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Alternator - Inspect
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Illustration 149
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Illustration 148
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Maintenance Section
Auger Slide - Adjust
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Illustration 152
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Left plate
Illustration 150
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Illustration 153
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Right plate
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Illustration 151
Center plate
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Maintenance Section
Backup Alarm - Test
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Illustration 154
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Start the engine, and run the engine at low idle. Turn
speed potentiometer (1) to the lowest setting.
Battery - Recycle
SMCS Code: 1401-561
Always recycle a battery. Never discard a battery.
Always return used batteries to one of the following
locations:
A battery supplier
An authorized battery collection facility
Recycling facility
Belts - Inspect/Adjust/Replace
SMCS Code: 1357-025; 1357-040; 1357-510
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117
Maintenance Section
Braking System - Test
Alternator
Illustration 155
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Generator
Illustration 157
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118
Maintenance Section
Conveyor Drive Chains (Auger) - Adjust
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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.
Illustration 159
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119
Maintenance Section
Conveyor Drive Chains (Drag) - Adjust
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Illustration 160
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Illustration 161
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120
Maintenance Section
Conveyor Planetary Drive (Auger) Oil Level - Check
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Illustration 163
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Illustration 165
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Illustration 164
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Maintenance Section
Conveyor Planetary Drive (Drag) Oil Level - Check
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2. Obtain an oil sample from the hole for the oil level
sight gauge.
3. Clean the oil level sight gauge. Replace the oil
level sight gauge.
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Chain Guards
Illustration 166
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Illustration 168
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Conveyor Chain
There are several methods for determining the
stretch of the conveyor chain. Each of these methods
is listed below in reverse order of preference.
In order to access the conveyor chain, lower the left
hopper and the right hopper to the lowest positions.
Illustration 167
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122
Maintenance Section
Conveyor System - Inspect
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Drag Bars
Illustration 169
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Illustration 170
Illustration 171
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Illustration 172
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123
Maintenance Section
Cooling System Coolant (ELC) - Change
Auger Conveyor
Illustration 173
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Drag Pans
There are two ways to measure the wear of a drag
pan.
Ultrasonic Measurement
1. Use an ultrasonic gauge in order to measure the
thickness of the drag pans. New drag pans have
a thickness of 12.7 mm (0.5 inch). Once the pans
are worn to a thickness of 3.175 mm (0.125 inch),
the drag pans need to be replaced.
Illustration 174
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124
Maintenance Section
Cooling System Coolant (ELC) - Change
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NOTICE
Do not change the coolant until you read and understand the material in the Cooling System Specifications section.
NOTICE
Mixing Extended Life Coolant (ELC) with other products reduces the effectiveness of the coolant and
shortens coolant life. Use only Caterpillar products or commercial products that have passed the
Caterpillar EC-1 specifications for premixed or concentrate coolants. Use only Caterpillar Extender with
Caterpillar ELC. Failure to follow these recommendations could result in the damage to cooling systems
components.
If ELC cooling system contamination occurs, refer to
Operation and Maintenance, Extended Life Coolant
(ELC) under the topic ELC Cooling System Contamination.
Illustration 175
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12. Start the engine. Run the engine without the filler
cap on the shunt tank until the thermostat opens
and the coolant level stabilizes.
Illustration 177
Illustration 176
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125
Maintenance Section
Cooling System Coolant Extender (ELC) - Add
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Recommended Amount
of Caterpillar Extender
22 to 30 L (6 to 8 US gal)
31 to 38 L (8 to 10 US gal)
39 to 49 L (10 to 13 US gal)
50 to 64 L (13 to 17 US gal)
65 to 83 L (17 to 22 US gal)
Illustration 178
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126
Maintenance Section
Cooling System Coolant Sample (Level 2) - Obtain
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NOTICE
Always use a designated pump for oil sampling, and
use a separate designated pump for coolant sampling.
Using the same pump for both types of samples may
contaminate the samples that are being drawn. This
contaminate may cause a false analysis and an incorrect interpretation that could lead to concerns by both
dealers and customers.
Illustration 179
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Illustration 180
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127
Maintenance Section
Cooling System Water Temperature Regulator - Replace
Illustration 181
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128
Maintenance Section
Drag Conveyors - Adjust
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Illustration 184
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Illustration 183
(1)
(2)
(3)
(4)
(5)
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Drag conveyor
Supports
Roller
Side Plate
Conveyor's Support
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Illustration 185
129
Maintenance Section
Engine Air Cleaner Inlet - Clean
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Illustration 187
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Illustration 186
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The grease points are located behind the right access door.
pressure air
pressure water
detergent washing
When you use pressure air, the maximum air
pressure is 205 kPa (30 psi). When you use pressure
water, the maximum water pressure is 280 kPa
(40 psi).
130
Maintenance Section
Engine Air Filter Secondary Element - Replace
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Illustration 188
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Illustration 189
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NOTICE
Always replace the secondary filter element. Never attempt to reuse the secondary filter element by cleaning the element.
When the primary filter element is replaced, the secondary filter element should be replaced.
The secondary filter element should also be replaced
if the exhaust smoke is still black.
1. Open the engine compartment.
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131
Maintenance Section
Engine Crankcase Breather - Clean
Illustration 190
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Illustration 192
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132
Maintenance Section
Engine Oil Sample - Obtain
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2. Check the engine oil level with oil level gauge (2).
NOTICE
Do not overfill crankcase. The oil level must not be
above the FULL RANGE on the dipstick.
3. Maintain the engine oil level on the oil level gauge
between the FULL mark and the ADD mark .
4. Clean oil filler cap (1). Remove the oil filler cap. If
necessary, add oil.
5. Install the oil filler cap (1).
Illustration 195
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Illustration 196
Illustration 194
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133
Maintenance Section
Engine Valve Lash - Check
NOTICE
Only qualified service personnel should perform this
maintenance. Refer to the Service Manual or your
Caterpillar dealer for the complete valve lash adjustment procedure.
Operation of Caterpillar engines with improper valve
adjustments can reduce engine efficiency. This reduced efficiency could result in excessive fuel usage
and/or shortened engine component life.
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Illustration 197
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Illustration 198
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134
Maintenance Section
Final Drive Planetary Oil Level - Check
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Illustration 200
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Illustration 199
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135
Maintenance Section
Fuel System Filter (Washdown) - Clean
Fuel leaked or spilled onto hot surfaces or electrical components can cause a fire. To help prevent possible injury, turn the start switch off when
changing fuel filters or water separator elements.
Clean up fuel spills immediately.
Fuel leaked or spilled onto hot surfaces or electrical components can cause a fire. To help prevent possible injury, turn the start switch off when
changing fuel filters or water separator elements.
Clean up fuel spills immediately.
NOTICE
Do not allow dirt to enter the fuel system. Thoroughly
clean the area around a fuel system component that
will be disconnected. Fit a suitable cover over disconnected fuel system component.
NOTICE
Do not allow dirt to enter the fuel system. Thoroughly
clean the area around a fuel system component that
will be disconnected. Fit a suitable cover over disconnected fuel system component.
NOTICE
Do not use a tool in order to remove the fuel filter.
Attempting to remove the fuel filter with a filter wrench
or a filter strap could damage the locking ring.
Illustration 203
Illustration 202
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136
Maintenance Section
Fuel System Secondary Filter - Replace
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NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.
Refer to Special Publication, NENG2500, Caterpillar
Dealer Service Tool Catalog for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.
Dispose of all fluids according to local regulations and
mandates.
2. Clean the outside of fuel filter assembly. Open the
drain (4) on the bottom of the fuel filter. Drain the
fuel and the water from the element into a suitable
container.
3. Hold the element and rotate the locking ring (2)
counterclockwise. Remove the locking ring (2).
The used filter element should be removed and
discarded.
4. Remove the sediment bowl (3) from the element.
5. Thoroughly clean the sediment bowl (3). Inspect
the O-ring seals. Install new O-ring seals, if
necessary.
Fuel leaked or spilled onto hot surfaces or electrical components can cause a fire. To help prevent possible injury, turn the start switch off when
changing fuel filters or water separator elements.
Clean up fuel spills immediately.
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.
Refer to Special Publication, NENG2500, Caterpillar
Dealer Service Tool Catalog for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.
Dispose of all fluids according to local regulations and
mandates.
Illustration 204
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137
Maintenance Section
Fuel System Third Filter - Replace
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Illustration 205
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138
Maintenance Section
Fuel Tank Cap, Filter, and Strainer - Clean/Inspect/Replace
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Illustration 206
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Fuses - Replace
SMCS Code: 1417-510
Illustration 207
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139
Maintenance Section
Fuses - Replace
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Illustration 209
Table 15
Brake Lights
15A
Spare Switched
15A
Machine ECM
15A
Autolube
15A
Brake Lights
Relay
Glow Plugs
20A
Operator Control
15A
Parking Lights
20A
Spare Unswitched
15A
Screed
25A
HID Lights
25A
Work Lights
20A
Travel Lights
20A
12 V Power Supply
15A
Parking Lights
Relay
Generator
15A
Slave ECM
15A
Spray Down
15A
Travel Lights
Relay
Sensor
10A
Display
10A
Screed ECM
15A
Spray Down
Relay
Grade Slope
15A
Horn
10A
Operator ECM
15A
Work Lights
Relay
140
Maintenance Section
Generator - Clean
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Generator - Clean
SMCS Code: 4450-070
Illustration 210
Table 16
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Maintenance Section
Ground Fault - Check
Illustration 211
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dirt
dust
grease
salt
oil film
If moisture is allowed to remain in contact with
an electrical winding, some of the moisture will
eventually be retained in voids or cracks of the
insulation. This will lower the resistance of the
winding insulation. The insulation that is used on
the windings of Caterpillar generators is moisture
resistant. However, constant exposure to moisture
will gradually lower the insulation's resistance.
Illustration 212
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Illustration 213
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142
Maintenance Section
Hopper Cylinder Bearings - Lubricate
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Illustration 216
Illustration 214
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Generator
Illustration 215
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Maintenance Section
Hopper Flashing - Inspect/Replace
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Illustration 217
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Illustration 219
(1)
(2)
(3)
(4)
(5)
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Charge Filter
Return Filter Indicator
Hydraulic Tank Cap
Hydraulic Oil Level Gauge
Return Filter
Illustration 220
Illustration 218
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144
Maintenance Section
Hydraulic System Oil Sample - Obtain
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Illustration 222
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Illustration 223
Illustration 221
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Maintenance Section
Oil Filter - Inspect
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Illustration 225
Illustration 224
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Illustration 226
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1. Remove the cap from the drain hose (1). Allow the
oil to drain into a suitable container.
Note: Refer to Operation and Maintenance Manual,
General Hazard Information for information on
containing fluid spillage.
2. Clean the cap for the drain hose. Install the cap
on the drain hose.
146
Maintenance Section
Pump Drive Oil Level - Check
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Illustration 230
Illustration 227
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6. Check the oil level with oil level gauge (4). The oil
level can also be viewed through sight gauge (5)
on the pump drive which can be seen through the
access doors in the hopper.
7. Maintain the pump drive oil level on oil level gauge
(4) between the FULL mark and the ADD mark.
8. Clean the breather and install the breather (2).
9. Clean the plug and install the plug (3).
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Illustration 228
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Illustration 229
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Illustration 231
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Maintenance Section
Pump Drive Oil Sample - Obtain
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Illustration 232
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1. Check the oil level with oil level gauge (1). The oil
level can also be viewed through sight gauge (2)
on the pump drive which can be seen through the
access doors in the hopper.
Illustration 234
Note:
2. Maintain the pump drive oil level on oil level gauge
(1) between the FULL mark and the ADD mark .
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Illustration 235
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148
Maintenance Section
Seat Belt - Inspect
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Illustration 237
(1)
(2)
(3)
(4)
Illustration 236
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Typical example
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149
Maintenance Section
Toggle Switch - Inspect
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Illustration 239
Illustration 238
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Tracks - Inspect
Illustration 240
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150
Maintenance Section
Track Roller Bearings - Inspect
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Illustration 241
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Illustration 243
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Illustration 242
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Illustration 244
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Maintenance Section
Track Tension - Check
Illustration 246
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There are two roller bearings (1) for the truck hitch.
There is one bearing on each side of the truck hitch.
Lubricate each bearing.
There are two fittings (2) on the truck hitch system.
There is one fitting on each end of the assembly.
Lubricate each fitting.
Illustration 245
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Turbocharger - Inspect
SMCS Code: 1052-040
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Illustration 247
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152
Maintenance Section
Ventilation Blower Wheel - Inspect/Clean
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Minor leakage of a turbocharger housing under extended low idle operation should not cause problems
as long as a turbocharger bearing failure has not occurred.
Illustration 248
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Illustration 249
153
Maintenance Section
Ventilation Blower Wheel - Inspect/Clean
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Illustration 252
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Illustration 250
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Illustration 253
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Illustration 251
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Illustration 254
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8. Remove the hose for the pitot tube from the back
of manometer (7).
154
Maintenance Section
Ventilation Inlet Ducts - Inspect/Clean
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13. Inspect the ducts for the inlet side of the blower
assembly. Clean the ducts with nonflammable
solvent.
14. Reverse steps 1 through 11 in order to reassemble
the ventilation system.
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Illustration 258
Illustration 256
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Illustration 257
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Illustration 259
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Maintenance Section
Wheel Nuts (Final Drive) - Tighten
Illustration 260
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