Rework Procedure to Update AP800D Asphalt Pavers with 25KW Generator Group {4450} Caterpillar

Asphalt Paver

AP-800D (S/N: A5P1-UP)

Introduction

This Special Instruction provides the procedure necessary to replace the discontinued 25KW hydraulic generator group with the replacement 25KW hydraulic generator group on the machines listed above.

Important Safety Information

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Accidental engine starting can cause injury or death to personnel working on the equipment. To avoid accidental engine starting, disconnect the battery cable from the negative (−) battery terminal. Completely tape all metal surfaces of the disconnected battery cable end in order to prevent contact with other metal surfaces which could activate the engine electrical system. Place a Do Not Operate tag at the Start/Stop switch location to inform personnel that the equipment is being worked on.

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Never connect or disconnect the magnet unless the engine is shut down and the main switch for the generator is in the OFF position. Failure to follow this procedure may result in personal injury or death.

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Personal injury or death can result from high voltage. When power generation equipment must be in operation to make tests and/or adjustments, high voltage and current are present. Improper test equipment can fail and present a high voltage shock hazard to its user. Make sure the testing equipment is designed for and correctly operated for high voltage and current tests being made. When servicing or repairing electric power generation equipment: Make sure the unit is off-line (disconnected from utility and/or other generators power service) , and either locked out or tagged DO NOT OPERATE. Remove all fuses. Make sure the generator engine is stopped. Make sure all batteries are disconnected. Make sure all capacitors are discharged. Failure to do so could result in personal injury or death. Make sure residual voltage in the rotor, stator and the generator is discharged.

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Personal injury or death can result from improper assembly procedures. Do not attempt any assembly until you have read and understand the assembly instructions.

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Improper operation, lubrication, maintenance or repair of this product can be dangerous and could result in injury or death. Do not operate or perform any lubrication, maintenance or repair on this product, until you have read and understood the operation, lubrication, maintenance and repair information.

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To prevent personal injury or death, do not work under the machine with the body (bed) raised. When it is necessary to work under the machine with the body (bed) raised, install the body (bed) retaining cable end through the rear tow pin at the rear of the machine.

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Personal injury can result from working with cleaning solvent. Because of the volatile nature of many cleaning solvents, extreme caution must be exercised when using them. If unsure about a particular cleaning fluid, refer to the manufacturer's instructions and directions. Always wear protective clothing and eye protection when working with cleaning solvents.

Before you inspect the area, clean the area with an appropriate high-pressure washer. Be careful not to damage wires or other components. Use an appropriate degreaser to remove any oil or grease from the frame assembly. Use a wire brush or a scraper to remove excessive dirt and grease. Make sure that the substances that follow are removed from the area that will be inspected.

• Oil

• Grease

• Dirt

Warnings

The warning label informs the technician that an injury or death can occur as a result of a condition that may exist.

Notices

A notice informs the technician that component damage can occur as a result of a condition that exists.

Notes

A note contains general information for the technician about the operation that is being performed.

Proper repair is important to the safe operation and the reliable operation of this machine. This document outlines basic recommended procedures. Some of the procedures require special tools, devices, or work methods.

Before you perform any repairs or before you perform any maintenance, read all safety information. Understand all safety information before you perform any repairs or before you perform any maintenance.

Safety information is provided in this document and on the machine. If these hazard warnings are not heeded, bodily injury or death could occur to you or other persons.

Parts List

Rework Procedure to Replace 231-1332 Generator Gp (25KW) with 399-5150 Hydraulic Generator Gp (25KW)

Removal of Old 231-1332 Generator Gp

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Illustration 1	g03667937

1. Remove cover (A) (can be modified to work. Move door and slots in back.) Save mounting hardware and seal around the door.

2. Remove latch plate and hardware from old cover. Save all parts.

3. Remove (B) 8T-9007 Seal and save the part.

4. Remove bracket (C) and rubber plate (D) from the cover .
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   Illustration 2	g03667939

5. Remove hardware mounting with rubber plate (D) to bracket (E) and save the parts.
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   Illustration 3	g03667941

6. Remove harness (F) and harness (G). Discard all parts.

7. Save all harness mounting hardware. Stauff Clamps (H), P-clips (J), and Brackets (K).

8. Remove and discard bracket (L).
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   Illustration 4	g03667942

9. Remove hydraulic motor mount (M) from the generator. Easier if hydraulic motor is left attached to mount (M). Save Lovejoy coupler to generator. Save all hardware.

10. Disconnect ground strap (N) from generator.

11. Remove bolts (P) and remove generator (R) from the deck of the paver. Save hardware.

12. Remove Generator (R) from mounting plate (S) Save hardware.

Installation of New 399-5150 Hydraulic Generator Gp

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Illustration 5	g03667950
(1) 8T-4138 Bolt (2) 9X-8256 Washer (3) 9X-2038 Washer (4) 344-5673 Nut (5) 421-1832 Rubber Plate (6) 421-1833 Plate

1. Install rubber plate (5) on plate (6) Bolt (1), Washer (2), Washer (3), Nut (4), Rubber Plate (5), and reinstall Plate with existing hardware.
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   Illustration 6	g03667953

   Note: Ensure that, the bolt (T) is not installed as shown in illustration 6. Failing to do so will rub the harness assembly.

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   Illustration 7	g03667958
   (7) 421-1825 Plate As (8) 421-1829 Rubber Plate

2. Install rubber plate (8) to plate assembly (7) using existing hardware.
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   Illustration 8	g03667960
   (9) 417-9515 Panel Cover Assembly

3. Install bracket and rubber plate assembly to panel cover assembly (9) using existing hardware .
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   Illustration 9	g03667963
   (10) 417-9514 Plate As

4. Mount generator to generator mounting plate assembly (10) using existing hardware (U). Note the orientation of the bracket.
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   Illustration 10	g03667975

5. Mount generator and generator mounting plate assembly (10) to the deck of the paver using existing hardware.
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   Illustration 11	g03667976

6. Install Lovejoy coupler (W) and hydraulic motor mount (V).

7. Remove paint, dirt, grease, and oil around hole on base of generator.
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   Illustration 12	g03674817

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   Illustration 13	g03667978
   (11) 5P-4115 Hard Washer

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   Illustration 14	g03667987
   (12) 8T-4205 Hard Washer (13) 1H-3338 Lockwasher

8. Install grounding strap (N) to base of generator using Bolt (1), Hard Washer (11), Hard Washer (12), Lockwasher (13), and Nut (4) as shown in Illustration 12, Illustration13, and Illustration 14.
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   Illustration 15	g03667996
   (X) knockouts for auxiliary wire harness (if installed) (Y) knockouts for installation of block-stud (Z) knockouts for screed wire harness (14) 399-5150 Hydraulic Generator Gp

9. Remove knockout (X), knockout (Y), and knockout (Z) in the hydraulic generator group (14) as shown in Illustration 15.
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   Illustration 16	g03668004

10. Remove screws (AA) to remove cover on generator electrical box for purposes of wiring and installing the harnesses. Remove screws (AB) for more access.
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    Illustration 17	g03668039
    (15) 6V-8801 Nut (16) 445-7531 Ground Wire As (17) 4D-1326 Lockwasher (18) 420-0612 Ground Wire As (19) 8T-4896 Hard Washer (20) 099-2374 Bolt (21) 398-8389 Stud (22) 5C-2874 Nut

11. Install stud (21) with bolt (20), and nut (22).

12. Assemble ground wire assembly (18) and ground wire assembly (16) outside of the block-stud in the sequence : ground wire assembly (18), hard washer (19), ground wire assembly (16), hard washer (1), lock washer (17), and nut (15).Tighten the nut to 25 ± 6 N·m (221 ± 53 lb in).
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    Illustration 18	g03669116

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    Illustration 19	g03669120

13. Remove paint, dirt, grease, and oil on the generator foot to create a reliable connection (AC) as shown in Illustration 19.

14. Assemble terminal of ground wire assembly (16) to the generator foot with bolt (1) , hard washer (12), lock washer (13), nut (4).
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    Illustration 20	g03669122

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    Illustration 21	g03669123
    (23) 8T-4224 Hard Washer (24) 7H-3937 Lockwasher (25) 344-5674 Nut

15. Remove paint, dirt, grease, and oil on the ground stud to create a reliable connection. Assemble the ring terminal of ground wire assembly (18) to the ground stud (AD) as shown in Illustration 21 on the generator electrical box cover with washer (23), lock washer (24) and nut (25).

16. Tighten nut to 15 ± 3 N·m (133 ± 27 lb in)
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    Illustration 22	g03669129

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    Illustration 23	g03669130

17. Remove existing hardware. Assemble the ground wire assembly (18) to the lower right stud (AE) on the generator terminal block, use washer (23) , lock washer (24), and nut (25). Tighten nut (25) to 10 ± 2 N·m (89 ± 18 lb in).

18. Install additional ground wires on to the stud (20), Leave the nut loosen.
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    Illustration 24	g03669214
    Machines equipped only with the auxiliary power panel (AJ) AC105-BK(Black) (AK) AC115-RD(Red) (26) 3S-2093 Cable Strap (27) 425-8636 Wiring Harness (28) 420-0784 Circuit Breaker

    Note: Steps 19 to 27 are only applied if the machine is equipped with the Wiring Gp - Power Option (Auxiliary power panel).

19. Assemble the white nylon washer in between the 90 degrees flex connector and the outside of the generator electrical box.

20. Assemble the wiring harness (27) into the generator electrical box.

21. Install the nut (AG) with the teeth towards the box.

22. Route the main bundle (AH) and ground wire (AF) as shown in Illustration 24.

23. Assemble cable strap (26) through both slots of the harness tie down clips. Do not secure yet. as shown in Illustration24

24. Assemble cable strap (26) through one slot of the harness. Tie down clip closest to the circuit breaker board. Secure the ground wire. as shown in Illustration24

25. Install circuit breaker (28) and tighten wire lugs to 4.0 ± 0.5 N·m (35.4 ± 4.4 lb in).
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    Illustration 25	g03669656

26. Assemble cable strap (26) through the slot of the harness tie down clip closest to the box . Do not secure yet.

27. Assemble cable strap (26) through both slots of the harness tie down clip. Do not secure yet.
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    Illustration 26	g03673262
    (AP) AC114-RD(Red) (AR) AC104-BK(Black) (AS) AC113-RD(Red) (AT) AC103-BK(Black) (AU) AC101-BK(Black) (AV) AC111-RD(Red) (AW) AC102-BK(Black) (AX) AC112-RD(Red) (29) 425-8637 Engine Harness As

28. Assemble the white nylon washer in between the 90 degrees flex connector and the outside of the generator electrical box.

29. Assemble engine harness assembly (29) into the generator electrical box.

30. Route the main bundles (AN) and ground wire (AL) as shown in illustration 26.

31. Install the nut (AL) with the teeth towards the box.

32. Secure cable strap (26) around both wire bundles of the wiring harness (27) such that the nearest lay on the side of the clip near the electrical box as shown in Illustration26.

33. Secure cable strap (26) around the longer wire bundle of wiring harness (27), so the harness lays on the side of the clip near the electrical box as shown in Illustration26.

34. Secure cable strap (26) around the wiring harness (27) as shown in Illustration26.

35. Assemble cable strap (26) around the engine harness assembly (29), and wiring harness (27) as shown in Illustration26.
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    Illustration 27	g03673291
    (30) 362-6644 Circuit Breaker As

36. Unravel neutral wire (BA) and neutral wire (BB) from the circuit breaker assembly (30).

37. Assemble cable strap (26) through one slot of the harness tie down clip closest to the circuit breaker board and secure so the neutral wire bundle lays on the side near the circuit breaker board. As shown in Illustration27.

38. Unravel neutral wire (AY) and neutral wire (AZ) from the circuit breaker assembly (30) so the ring terminal can be assembled to the top left stud (BC) of the terminal block .

39. Assemble cable strap (26) through one slot of harness tie down clip closest to the circuit breaker board and secure the neutral and ground wires such that the wires lay on the side near the circuit breaker board. As shown in Illustration27.
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    Illustration 28	g03673331

40. Assemble cable strap (26) through both slots of the harness tie down clips and secure the neutral wire bundle.

41. Assemble the ring terminals to the top right stud (BC) of the terminal block use existing hardware and tighten stud to 10 ± 2 N·m (89 ± 18 lb in).

42. Use existing hardware to secure ring terminals and tighten to 10 ± 2 N·m (89 ± 18 lb in).

43. Assemble cable strap (26) through side of clip nearest the circuit breaker board and secure the neutral wires. As shown in Illustration28.

44. Route neutral wires (BD) to avoid rubbing on bracket .
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    Illustration 29	g03673344

45. Ensure neutral wires (BE) are assembled such that the wires do not extend above the generator electrical box (BF) and come in contact with the cover.
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    Illustration 30	g03673450

46. Assemble the wire harness ground ring terminals (BG) and the ground wire ring terminal (BH) to the block stud such that hard washer (19) separates the terminals and another wire harness ground ring terminals (BJ), hard washer (19), lock washer (17), nut (15) secure the stack up.

47. Tighten the nut to 25 ± 6 N·m (221 ± 53 lb in).
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    Illustration 31	g03673480
    (BK) 50 ± 5 mm (2.0 ± 0.2 inch) (BL) 43 ± 5 mm (1.7 ± 0.2 inch) (31) 421-4076 Film

48. Assemble film (31) decal to the bottom of the generator electrical box door per the dimensions shown. Clean surface to remove dirt, dust, grease, and oil.
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    Illustration 32	g03673517
    (BP) 19 ± 3 mm (0.7 ± 0.1 inch) (BR) 14 ± 3 mm (0.6 ± 0.1 inch) (BS) 85 ± 3 mm (3.3 ± 0.11 inch) (BT) 156 ± 3 mm (6.1 ± 0.1 inch) (32) 7Y-8555 Seal

49. Remove knockouts (BM) in the circuit breaker cover plate (BN) which is mounted to the underside of the generator electrical box cover.

50. Remove knockout (BU) in the circuit breaker cover plate if the auxiliary power panel is installed.

51. Install seal (32) as per dimension shown in Illustration 32.
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    Illustration 33	g03674000

52. Install hydraulic motor (M) mount using existing hardware that were saved in Step 11.

53. Ensure that the Lovejoy coupler (W) is properly aligned.

54. Ensure to put the harness support bracket (BV) back on.

55. Reuse 1M-4543 Grommet (BW).
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    Illustration 34	g03674008

56. Route harnesses (BX) using previous routing provisions.
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    Illustration 35	g03674009

57. Install new cover 417-9515 Panel Cover Assembly (BY) using existing hardware that were saved in Step 1.

58. Reinstall 153 mm (6.0 inch) of seal (32) around door.

AP800D Tuning Generator Hydraulic Circuit

1. Warm hydraulic oil to 50 °C (122 °F).

2. Turn generator ON, do not put any electric load on generator.

3. Set margin pressure to 17 bar (247 psi).

4. Have paver at high idle and adjust flow control achieve a generator output frequency of 63 hz.

5. Turn on the screed heat and verify that the frequency stays within 57 to 63 hz.

6. Further adjustment may be needed to tune out any hydraulic instability or achieve desired output frequency.

Generator Control Card Settings

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Illustration 36	g06193126

1. It is recommended to verify that the generator control card is set to "3". For this setting and other settings, refer to Illustration 36