Rework Procedure to Update AP1000B and AP1055B Asphalt Pavers with 25KW Generator Group {5639} Caterpillar

Asphalt Paver

AP-1000B (S/N: AGP1-UP)

AP-1055B (S/N: A3P1-UP)

Introduction

This Special Instruction provides the procedure necessary to replace the discontinued 25KW hydraulic generator group 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	g03692646

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 bracket (B) and rubber plate (C) from the cover .
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   Illustration 2	g03692647

3. Remove hardware mounting with rubber plate (C) to bracket (D) and save the parts.

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

5. Remove door seal and save the part.
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   Illustration 3	g03692657

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

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

8. Remove and discard bracket (K).
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   Illustration 4	g03692664

9. Remove hydraulic motor mount (L) from the generator.

10. It is recommended to leave the hydraulic motor attached to mount (L). Save Lovejoy coupler to generator. Save all hardware.

11. Disconnect ground strap (M) from generator.

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

13. Remove Generator (P) from mounting plate (R) Save hardware.

Installation of New 399-5150 Hydraulic Generator Gp

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Illustration 5	g03692665
(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). Use existing hardware for all other hardware shown, that is not called out.
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   Illustration 6	g03692666

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

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   Illustration 7	g03692667
   (7) 421-1825 Plate As (8) 421-1829 Rubber Plate

2. Install rubber Plate (8) to bracket (7) using existing hardware.
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   Illustration 8	g03692668

3. Install bracket and rubber plate assembly to cover (T) using existing hardware .
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   Illustration 9	g03692670
   (9) 417-9514 Plate As

4. Mount generator to generator mounting plate (9) using existing hardware (N). Note the orientation of the bracket.
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   Illustration 10	g03692671

5. Mount generator and generator mounting plate to the deck of the paver using existing hardware .
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   Illustration 11	g03692676

6. Install Lovejoy coupler (U) and hydraulic motor mount (V).
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   Illustration 12	g03692677

7. Remove paint, dirt, grease, and oil around hole on base of generator, where grounding strap will attach as shown in Illustration 12.
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   Illustration 13	g03692678
   (10) 5P-4115 Hard Washer

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   Illustration 14	g03692679
   (11) 8T-4205 Hard Washer (12) 1H-3338 Lockwasher (4) 344-5673 Nut

8. Install grounding strap (M) to base of generator using Bolt (1), Hard Washer (10), Hard Washer (11), Lockwasher (12), and Nut (4) as shown in Illustration 12, Illustration13, and Illustration 14.
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   Illustration 15	g03692680
   (W) knockouts for auxiliary wire harness (if installed) (X) knockouts for installation of block-stud (Y) knockouts for screed wire harness (13) 399-5150 Hydraulic Generator Gp

9. Remove knockout (W) if applicable, knockout (X), and knockout (Y) in the 399-5150 Hydraulic Generator Gp (13) as shown in Illustration 15.
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   Illustration 16	g03692682

10. Remove screws (Z) to remove cover on generator electrical box for purposes of wiring and installing the harnesses. Remove screws (AA) for more access.
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    Illustration 17	g03692685
    (14) 6V-8801 Nut (15) 445-7531 Ground Wire As (16) 4D-1326 Lockwasher (17) 420-0612 Ground Wire As (18) 8T-4896 Hard Washer (19) 099-2374 Bolt (20) 398-8389 Stud (21) 5C-2874 Nut

11. Install 398-8389 Stud (20) with 099-2374 Bolt (19), and 5C-2874 Nut (21).

12. Assemble 420-0612 Ground Wire As (17) and 445-7531 Ground Wire As (15) outside of the block-stud in the sequence : 420-0612 Ground Wire As (17), 8T-4896 Hard Washer (18), 445-7531 Ground Wire As (15) 8T-4896 Hard Washer (18), 4D-1326 Lockwasher (16), and 6V-8801 Nut (14).Tighten the nut to 25 ± 6 N·m (221 ± 53 lb in).
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    Illustration 18	g03692686

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    Illustration 19	g03692687

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

14. Assemble terminal of 445-7531 Ground Wire As (15) to the generator foot with 8T-4138 Bolt (1) , 8T-4205 Hard Washer (11), 1H-3338 Lockwasher (12), 344-5673 Nut (4).
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    Illustration 20	g03692688

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    Illustration 21	g03692689
    (22) 7H-3937 Lockwasher

15. Remove paint, dirt, grease, and oil on the ground stud to create a reliable connection. Assemble the ring terminal of 420-0612 Ground Wire As (17) to the ground stud (AE) as shown in Illustration 21 on the generator electrical box cover with 7H-3937 Lockwasher (22).
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    Illustration 22	g03692691

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    Illustration 23	g03692692

16. Remove existing hardware. Assemble the 420-0612 Ground Wire As (17) to the lower right stud (AF) on the generator terminal block, 7H-3937 Lockwasher (22).

17. Install additional ground wires on to the 398-8389 Stud (20), Leave the nut loose.
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    Illustration 24	g03692693
    Machines equipped only with the auxiliary power panel (AK) AC105-BK(Black) (AL) AC115-RD(Red) (23) 3S-2093 Cable Strap (24) 423-3240 Panel Harness As (25) 420-0784 Circuit Breaker

    Note: Steps 18 to 26 are only applied if the machine is equipped with the Wiring GP - Power Option (Auxiliary Power Panel).

18. Assemble the 423-3240 Wiring Harness (24) into the generator electrical box.

19. Route the main bundle (AJ) and ground wire (AG) as shown in Illustration 24.

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

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

22. Assemble 3S-2093 Cable Strap (23) through both slots of the harness tie down clips. Do not secure yet.

23. Assemble 3S-2093 Cable Strap (23) through one slot of the harness. Tie down clip closest to the circuit breaker board. Secure the ground wire.

24. Install 420-0784 Circuit Breaker (25) and tighten wire lugs to 4.0 ± 0.5 N·m (35.4 ± 4.4 lb in).
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    Illustration 25	g03692694

25. Assemble 3S-2093 Cable Strap (23) through the slot of the harness tie down clip closest to the box . Do not secure yet.

26. Assemble 3S-2093 Cable Strap (23) through both slots of the harness tie down clip. Do not secure yet.
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    Illustration 26	g03692698
    (AR) AC114-RD(Red) (AS) AC104-BK(Black) (AT) AC113-RD(Red) (AU) AC103-BK(Black) (AV) AC101-BK(Black) (AW) AC111-RD(Red) (AX) AC102-BK(Black) (AY) AC112-RD(Red) (26) 423-3241 Harness As

27. Assemble 423-3241 Harness As (26) into the generator electrical box.

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

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

30. Install the nut (AM) with the teeth towards the box.

31. Secure 3S-2093 Cable Strap (23) around both wire bundles of the 423-3241 Wiring Harness (26) such that the nearest lay on the side of the clip near the electrical box.

32. Secure 3S-2093 Cable Strap (23) around the longer wire bundle of 423-3241 Wiring Harness (26) so the harness lays on the side of the clip near the electrical box.
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    Illustration 27	g03692699
    (27) 362-6644 Circuit Breaker As

33. Secure 3S-2093 Cable Strap (23) around both Wiring Harness (AZ).

34. Assemble 3S-2093 Cable Strap (23) around the 423-3241 Engine Harness As, and 423-3240 Wiring Harness .

35. Unravel neutral wire (BC) and neutral wire (BD) from the 362-6644 Circuit Breaker As (27).

36. Assemble 3S-2093 Cable Strap (23) 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.

37. Unravel neutral wire (BA) and neutral wire (BB) from the 362-6644 Circuit Breaker As (27) so the ring terminal can be assembled to the top left stud (BE) of the terminal block .

38. Assemble 3S-2093 Cable Strap (23) 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.
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    Illustration 28	g03692700

39. Assemble 3S-2093 Cable Strap (23) through both slots of the harness tie down clips and secure the neutral wire bundle.

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

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

42. Assemble 3S-2093 Cable Strap (23) through side of clip nearest the circuit breaker board and secure the neutral wires.

43. Route neutral wires (BF) to avoid rubbing on bracket .
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    Illustration 29	g03692701

44. Ensure neutral wires (BG) are assembled such that the wires do not extend above the generator electrical box (BH) and come in contact with the cover.
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    Illustration 30	g03692702

45. Assemble the wire harness ground ring terminals (BJ) and the ground wire ring terminal (BK) to the block stud such that 8T-4896 Hard Washer (18) separates the terminals and a 8T-4896 Hard Washer (18), 4D-1326 Lockwasher (16), 6V-8801 Nut (14) secure the stack up.

46. Tighten the nut to 25 ± 6 N·m (221 ± 53 lb in).
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    Illustration 31	g03692703
    (BL) 50 ± 5 mm (2.0 ± 0.2 inch) (BM) 43 ± 5 mm (1.7 ± 0.2 inch) (28) 421-4076 Film

47. Assemble 421-4076 Film (28) 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	g03692705
    (BR) 19 ± 3 mm (0.7 ± 0.1 inch) (BS) 14 ± 3 mm (0.6 ± 0.1 inch) (BT) 85 ± 3 mm (3.3 ± 0.11 inch) (BU) 156 ± 3 mm (6.1 ± 0.1 inch) (29) 128-2596 Seal

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

49. Remove knockout (BV) in the circuit breaker cover plate if the auxiliary power panel option is installed.

50. Install 128-2596 Seal (29) as per dimension shown in Illustration 32.
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    Illustration 33	g03692708

51. Install hydraulic motor (L) mount using existing hardware that were saved in Step 10.

52. Ensure that the Lovejoy coupler (Z) is properly aligned.

53. Ensure to put the harness support bracket (BW) back on.
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    Illustration 34	g03692709

54. Route harnesses (BX) using previous routing provisions.
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    Illustration 35	g03692710
    (30) 417-9515 Panel Cover Assembly (31) 8T-9007 Seal

55. Install new cover 417-9515 Panel Cover Assembly (30) using existing hardware that were saved in Step 1.

56. Install 153 mm (6.0 inch) of 8T-9007 Seal (31) around door.

AP1055B Tuning Generator Hydraulic Circuit

Note: Refer to Testing and Adjusting, KENR5019, "Pump Control Valve (Generator)". Substitute the margin pressure shown below for the pressure shown in the procedure.

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 18 bar (261 psi) .

4. Operate paver at high idle and adjust flow control achieve a generator output frequency of 63 hz. Refer to Testing and Adjusting, KENR5019, "Generator Frequency".

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

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

AP1000B Tuning Generator Hydraulic Circuit

Note: Refer to Testing and Adjusting, KENR3507, "Pump Control Valve (Generator)". Substitute the margin pressure shown below for the pressure shown in the procedure.

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. Operate paver at high idle and adjust flow control achieve a generator output frequency of 63 hz. Operate paver at high idle and adjust flow control achieve a generator output frequency of 63 hz. Refer to Testing and Adjusting, KENR3507, "Generator Frequency".

5. Turn on the screed heat and verify that the frequency stays within 57 hz 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	g06191055

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.