Procedure to Install an Improved Lever Group on a AP300 Asphalt Paver{1265, 1269} Caterpillar

Asphalt Paver:

AP300 (S/N: B2Y1-UP)

Introduction

This special instruction outlines the recommended basic procedure to install an improved 339-1670 Lever Gp . The new lever group has a stronger throttle cable which provides a better connection between the throttle control lever and the throttle.

Safety Section

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Do not operate or work on this machine unless you have read and understand the instructions and warnings in the Operation and Maintenance Manuals. Failure to follow the instructions or heed the warnings could result in injury or death. Contact your Caterpillar dealer for replacement manuals. Proper care is your responsibility.

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Hot oil and hot components can cause personal injury. Do not allow hot oil or hot components to contact the skin.

Required Parts

Installation Procedure

1. Park the paver on a flat, level surface.

2. Turn the start switch to the OFF position.

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Illustration 1	g02126848
(1) Cover (2) Rod (3) Disconnect switch (Battery)

3. Open cover (1) and install support rod (2). Refer to Illustration 1.

4. Turn disconnect switch (3) to the OFF position. Refer to Illustration 1.

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Illustration 2	g00104545

5. Attach a "Do not Operate" warning tag or a similar warning tag to the start switch or to the controls before you service the equipment or before you repair the equipment. These warning tags Special Instruction, SEHS7332 are available from your Caterpillar dealer.

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Illustration 3	g02126879
(4) Cover

6. Open cover (4) in order to gain access to the engine compartment. Refer to Illustration 3.

Procedure to Remove the Former 309-8926 Lever Gp

1. Use the following procedure to remove the former 309-8926 Lever Gp from the machine.
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   Illustration 4	g02126873
   (1a) Throttle control lever (5) Bolt (209029 Bitelli Part Number)

   1. Remove the existing throttle control lever (1a) by removing four bolts (5) that secures the throttle control lever to the side of the control panel. Refer to Illustration 4.

   2. Remove the existing throttle control lever (1a). Refer to Illustration 4.
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   Illustration 5	g02126890
   (1b) Throttle cable (1c) Nut (6) 8T-4171 Bolt (7) 295-0812 Pin (8) 310-6421 Plate (9) Bracket (10) 9X-8256 Washer (11) 129-3178 Locknut (12) 6V-7357 Bolt (13) Spring lever (14) 129-3178 Locknut (15) 9X-8256 Washer (16) Retainer (17) Bolt

   3. Remove bolt (17) from retainer (16). Refer to Illustration 5.

   4. Remove 8T-4171 Bolt (6) from 295-0812 Pin (7). Refer to Illustration 5.

   5. Remove 129-3178 Locknut (14) and 9X-8256 Washer (15) from pin (7). Remove pin (7) from spring lever (13). Refer to Illustration 5.

   6. Loosen nut (1c) that secures throttle cable (1b) to 310-6421 Plate (8). Completely remove the existing 309-8926 Lever Gp (1) from the machine. Refer to Illustration 5.

   7. Remove 310-6421 Plate (8) from support (9) by removing three 129-3178 Locknuts (11), six 9X-8256 Washers (10), and three 6V-7357 Bolts (12). Refer to Illustration 5.

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Illustration 6	g02126895

2. Reinstall 310-6421 Plate (8) on the opposite side of bracket (9) that is shown in Illustration 6. Secure plate (8) to bracket (9) by reusing three bolts (12), six washers (10), and three locknuts (11). Refer to Illustration 6.

Procedure to Install the New 339-1670 Lever Gp

1. Use the following procedure to install the new 339-1670 Lever Gp on the machine.
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   Illustration 7	g02126898
   (1a) Throttle control lever (5) Bolt (209029 Bitelli Part Number)

   1. Position the new throttle control lever (1a) on the side of the operator console. Reinstall four bolts (5). Refer to Illustration 7.
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   Illustration 8	g02126908
   (1b) Throttle cable (1c) Nut (1d) Ball joint assembly (1e) Locknut (8) Plate (13) Spring lever (15) 9X-8256 Washer (18) Filter

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   Illustration 9	g02126920

   2. Route the new throttle cable (1b) behind filter (18). Refer to Illustration 8 and Illustration 9.

   3. Install the new throttle cable into the slot on top of plate (8). Secure the new throttle cable to plate (8) by tightening new bolt (1c). Refer to Illustration 8 and Illustration 9.

   4. Install the threaded end of new ball joint assembly (1d) into the hole in spring lever (13). Secure the ball joint assembly to the spring lever by reusing 9X-8256 Washer (15) and new locknut (1e). Refer to Illustration 8 and Illustration 9.
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   Illustration 10	g02126879
   (4) Cover

   5. Close cover (4) .
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   Illustration 11	g02126848
   (1) Cover (2) Rod (3) Disconnect switch (Battery)

   6. Turn disconnect switch (3) to the ON position. Refer to Illustration 11.

   7. Remove support rod (2) and close cover (1). Refer to Illustration 11.