Procedure to Properly Connect and Disconnect the High-Voltage Connectors on "F" Series Asphalt Pavers {1408} Caterpillar

Asphalt Paver

AP1000F (S/N: AC41-UP)

AP1055F (S/N: TJ51-UP; RLM1-UP)

AP500F (S/N: 5031-UP; AF51-UP; 4491-UP; F5M1-UP)

AP555F (S/N: AP51-UP; M451-UP; 5F51-UP; RBM1-UP)

AP600F (S/N: AP61-UP; JA61-UP; LR61-UP; D6F1-UP)

AP655F (S/N: 4801-UP; 4521-UP; 4531-UP; P651-UP; 6551-UP; MH61-UP; ML61-UP; 4791-UP)

AP655F L (S/N: AC61-UP)

Asphalt Screed

SE50 V (S/N: J971-UP)

SE50 VT (S/N: B861-UP; J6K1-UP)

SE60 V (S/N: JJ31-UP)

SE60V XW (S/N: JS91-UP)

SE60VT XW (S/N: E991-UP; TLW1-UP)

Introduction

This Special Instruction will provide the proper procedure to inspect, clean and dry, torque, lock wire, and to cap unmated connections on "F" Series Asphalt Pavers.

Read the entire Special Instruction before performing the following procedure.

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Shock/Electrocution Hazard! Do not work on this equipment 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 serious injury or death.

Inspect

You should always inspect both connectors prior to mating the connectors.

The connector pair to be mated shall be free of physical damage in order for electric screed heat to work reliably. The presence of the physical damage will eventually lead to loss of screed heating to either partial or entire screed.

Below are some, but not all, the visual indicators of a damaged connector that require replacement. Any of the damages below deem the connector unfit for use. The connectors are non-serviceable, so the harness and or component containing the connector shall be replaced for new part.

• Bent pins, or insert

• Damaged threads

• Damaged rubber seal

• Signs of rust, oxidation, or other non-conformity

Note: Never try to straight out the connector pins. Even though the pins may look straight, an uneven contact could result in hotspots and could lead to contact arching, oxidation, and eventual ground faults.

Clean and Dry

The contacts on both the plug and the receptacles must be free of dirt, debris, oils, grease, oxidation, water, and moisture. Failure to do so likely will cause a low-resistance path between the adjacent pins and or pins and connector body.

Low-resistance path will eventually cause arcing, ground fault in the system, and permanent connector damage. Another failure mode is that contaminants in the contacts may cause additional resistance, which could lead to excessive heating and or open circuit.

The following are acceptable to do on connectors.

• Only use isopropyl alcohol to clean the pins, the sockets, and rubber insert if you spot any dirt, debris, or oil.

• Isopropyl alcohol may be applied using cotton swabs or a clean shop towel.

• Use clean shop towel to dry water spots on connectors with pins.

• Use canned pressurized air to blow away water.

The following are not acceptable to do on connectors.

• Do not use LPS contact cleaner or any other commercial contact cleaner. Such chemical cleaners dry the rubber in the connector, making the rubber brittle and unfit for proper function.

• Do not use diesel fuel to clean the electrical components.

• Do not use compressed air to from a compressor. Compressed air may contain oil particles that may compromise the connection over time.

Torque

Illustration 1	g03666364

Illustration 2	g03666329
(1) Tighten to a torque of 10.5 ± 0.3 N·m (93 ± 3 lb in). (2) Tighten to a torque of 11.9 ± 0.6 N·m (105 ± 5 lb in).

Illustration 3	g03678597
(3) Power cable from the tractor to the screed inverter. (3) Tighten to a torque of 14.3 ± 1.2 N·m (127 ± 11 lb in).

Proper torque is critical for proper operation on the high-voltage system. Too much torque can damage the seal and too little torque will allow water into the connector. Do not rely on hand tightening the connectors. Hand tightening will not provide enough torque.

Illustration 4	g03666330
The illustration shows the optional electric heater cable for the end gate shoe.

Lock Wire

All mated connectors must be lock wired to withstand the screeds extreme vibration. Loose connectors will result in moisture entering the connection and eventual system failure. Also, lock wire is a safety feature required to prevent unintentional system disconnection by the operator.

Note: Failure to lock wire the connectors will result in the connector coming loose.

Illustration 5	g03666331
Install lockwire to the next hole in the clockwise direction.

Cap Unmated Connections

An unmated connector left open either inside the shop or outdoors will gather contaminants. Contaminants are the root cause for connector failures and electric screed heat system malfunction.

Note: Immediately capping the unmated connectors is required to prevent connector contamination and therefore ensuring long life of the electric screed heat high-voltage components.

Note: Every time a connector pair is unmated, both connectors of that pair shall be capped. The connector and the cap to be mated shall be clean and dry.