Installation Instructions for Optional Stiffener Group On Certain SE60V Asphalt Screeds {6643} Caterpillar

Asphalt Screed

SE60 V (S/N: JJ31-UP)

Introduction

This special instruction lists the required parts and procedures to install 512-2430 Plate Gp-Stiffener on asphalt screeds listed above.

Do not perform any procedure in this Special Instruction until you have read the information and you understand the information.

Safety Section

Work safely. Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs.

A person must be alert to potential hazards. This person must also have the necessary training, skills, and tools to perform these functions properly.

Safety precautions and warnings are provided in this instruction and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons. Caterpillar cannot anticipate every possible circumstance of a potential hazard.

Therefore, the warnings in this publication and the warnings that are on the product are not all inclusive. Avoid using a tool, a procedure, a work method, or operating technique that is not recommended by Caterpillar.

Ensure that the product will not be damaged or the product will be made unsafe by the operation, lubrication, maintenance, or the repair procedures.

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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 Cat dealer for replacement manuals. Proper care is your responsibility.

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Accidental machine starting can cause injury or death to personnel working on the machine. To avoid accidental machine starting, turn the battery disconnect switch to the OFF position and remove the key. If the machine is not equipped with a battery disconnect switch, disconnect the battery cables from the battery and tape the battery clamps. Place a do not operate tag at the battery disconnect switch location to inform personnel that the machine is being worked on.

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Personal injury or death can result from sudden machine movement. Sudden movement of the machine can cause injury to persons on or near the machine. Prevent possible injury by performing the procedure that follows before working on the machine. Move the machine to a smooth horizontal location. Move away from working machines and personnel and lower the implement to the ground. Permit only one operator on the machine. Keep all other personnel away from machine or in view of the operator. Engage the parking brake. Stop the engine. Move the hydraulic control levers to all positions to release the pressure in the hydraulic system.

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Personal injury can result from flame cutting or welding on painted areas. The effect of gasses from burned paint is a hazard to the person doing the cutting or welding. Do not flame cut or weld on painted areas.

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Personal injury or death can result from fumes, gases and ultraviolet rays from the weld arc. Welding can cause fumes, burn skin and produce ultraviolet rays. Keep your head out of the fumes. Use ventilation, exhaust at the arc, or both, to keep fumes and gases from your breathing area. Wear eye, ear and body protection before working. Protect yourself and others; read and understand this warning. Fumes and gases can be dangerous to your health. Ultraviolet rays from the weld arc can injure eyes and burn skin. Electric shock can cause death. Read and understand the manufacturer's instructions and your employer's safety practices. Do not touch live electrical parts. See "American National Standard Z49.1, Safety in Welding and Cutting" published by the American Welding Society. American Welding Society 2501 N.W. 7th Street Miami, Florida 33125 See "OSHA Safety and Health Standards, 29 CFR 1910", available from U.S. Department of Labor. U.S. Department of Labor Washington, D.C. 20210

Required Parts

Machine Preparation

1. Drive the machine onto a smooth level surface that can support the weight of the machine.

2. Turn off the engine and remove the key from the starting switch.
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   Illustration 1	g00104545

3. Perform Lockout Tag Out procedure by attaching a warning tag to the machine controls.

4. The screed stiffening kit needs to be installed on a cold, flat screed.  Preform a screed check and adjust. Refer to Testing and Adjusting section of , UENR3139, “Screed Plate – Check and Adjust”.

5. Remove the screed walkways. Refer to Disassembly and Assembly section of , UENR3139 , “Walkway – Remove and Install”.

6. Remove the rubber flaps that cover the rear of the extenders.  These will be re-used later.

Reference Section

UENR3139 Disassembly and Assembly , "Walkway - Remove and Install"

, UENR3139 Testing and Adjusting , "Screed Plate - Check and Adjust"

Installation Procedure

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Illustration 2	g06155874
(A) Height indicator

1. Remove four height indicators (A) from the adjuster group. The parts will be re-installed later.
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   Illustration 3	g06155887
   (B) Deflector plate

2. Remove two deflector plates (B) from the deflector group. The parts will be re-installed later.
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   Illustration 4	g06155964
   Main plate

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   Illustration 5	g06155960
   RH plate

3. Loosen all screed plate attaching hardware on main plate as well as both extender plates (48 total). Re-torque all nuts to 50 N·m (37 lb ft).
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   Illustration 6	g06155977
   (1) 329-3356 Nut

4. After plate attaching hardware is re-torqued, install nut (1) to each stud and torque to 80 N·m (59 lb ft). It may be necessary to use a back up wrench to hold the lower nut while torquing the upper nut. Re-install the deflector plates that were saved in Step 2.
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   Illustration 7	g06157465
   Right side view

5. If the screed is equipped with heated end gates, detach the orange cable by removing fir-tree mount (C) and cable strap (D). The cable gets detached from two places..
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   Illustration 8	g06159055
   RH Frame view (2) 510-9986 Plate (11) 510-9987 Plate (E) 160 mm (6.3 inch) (F) Flat bar (G) "C" clamp

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   Illustration 9	g06157567
   Orientation of weld preparation

6. Use flat bar (F) and "C" clamp (G) to locate ear prior to tack welding the ear. Make sure the ear surface is even with frame surface. Tack weld plate (2) in place. Repeat procedure for plate (11) on opposite side.
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   Illustration 10	g06159058
   RH Frame view (3) 503-7375 Plate (4) 510-9984 Clamp Bar (5) 510-9988 Plate (6) 503-7376 Plate (7) 510-9989 Plate (8) 8T-4192 Bolt (9) 5P-1076 Hard Washer

7. Pre-assemble plate (3), clamp bar (4) and plate (5).

   Pre-assemble plate (6) and plate (7).

   After pre-assembly, secure the assemblies to the frame using 10 bolts (8) and 10 hard washers (9).

   Note: Ensure that the bevel on 510-9988 Plate and 510-9989 Plate faces the front of the machine. This is intended to provide clearance for existing weld on frame.

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   Illustration 11	g06157597
   RH Frame view

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   Illustration 12	g06157621
   View of area H (J) 4.0 mm (0.15 inch) (K) 24.0 mm (0.94 inch)

8. Align the covers and check the gaps. Ensure that the nominal clearances are in-line with the dimensions indicated in the Illustration 12. Nominal clearance between bottom edge of cover and bottom edge of frame is (J) and nominal clearance between cover and frame is (K).
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   Illustration 13	g06157659
   RH Frame view (L) Adjuster

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   Illustration 14	g06157678
   (5) 510-9988 Plate (7) 510-9989 Plate (M) Walkway support bracket

9. Visually check that the adjusters (L) are centered in the cutouts of the cover and that covers are generally centered side to side. For adjusting, loosen the cover bolts, adjust and slightly tighten the bolts.

   After visual checks are verified, tack weld plate (5) and plate (7) to the walkway support bracket (M).

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   Illustration 15	g06157690

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   Illustration 16	g06157701
   (10) 7Y-9308 Bar

10. Use center punch or transfer punch to locate the center of each lower hole of the cover. Remove covers and with punched location as reference, place bars (10) and secure the bars by tack welding.
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    Illustration 17	g06157974
    RH Frame view (2) 510-9986 Plate (5) 510-9988 Plate (7) 510-9989 Plate (10) 7Y-9308 Bar (11) 510-9987 Plate (W1) 8 mm (0.3 inch) bevel weld (W2) 6 mm (0.2 inch) fillet weld

11. Finish weld plate (2) and plate (11) to the flat bar as shown in Illustration 17.

    Finish weld plate (5) and plate (7) to the walkway support bracket as shown in Illustration 17

    Finish weld seven bars (10) to the frame as shown in Illustration 17.

    After welding is completed, paint all parts black.

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    Illustration 18	g06158017
    RH Frame view (12) 503-7382 Plate (R) 12.0 mm (0.47 inch) (W2) 6 mm (0.2 inch) fillet weld

12. Remove the end cap from the extender frame and locate plate (12) on the frame, tack and finish weld the plate as shown in Illustration 18. Re-install the end caps after welding. Paint all parts black.

    Note: Before finish welding, remove paint from mating parts as required.

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    Illustration 19	g06158028
    RH Frame view (3) 503-7375 Plate (6) 503-7376 Plate (8) 8T-4192 Bolt (9) 5P-1076 Hard Washer

13. When the paint is dry, install plate (3) and plate (6) using 17 bolts (8) and 17 hard washers (9). Torque the bolts to 100 N·m (74 lb ft)
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    Illustration 20	g06158032
    Right side view (13) 327-0325 Cable Strap (14) 204-2281 Cable Strap

14. Re-secure the orange cable that was detached in Step 5 using cable strap (13) and cable strap (14).
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    Illustration 21	g06158040
    LH Frame view (2) 510-9986 Plate (5) 510-9988 Plate (7) 510-9989 Plate (10) 7Y-9308 Bar (11) 510-9987 Plate (12) 503-7382 Plate (15) 503-7377 Plate (16) 503-7378 Plate

15. Rework the LH extender frame by repeating Step 5 to Step 14 using the parts shown in Illustration 21.
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    Illustration 22	g06158047
    Main frame view (S) Weld bracket (T) End cap cover

16. In the center of main screed, remove four weld brackets (S) and grind flush the surface.

    Unbolt and discard two end cap covers (T).

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    Illustration 23	g06158060
    Main frame RH view (17) 503-7384 Plate (U) 8 mm (0.3 inch) (W2) 6 mm (0.2 inch) fillet weld

17. Locate the plate (17), tack and finish weld to the frame as shown in Illustration 23.
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    Illustration 24	g06158306
    Main frame RH view (18) 503-7383 Plate (Z) 10 mm (0.4 inch) (W2) 6 mm (0.2 inch) fillet weld

18. Locate, tack and finish weld plate (18) as shown in Illustration 24.

    Earlier models may have a M16 nut welded to the frame that would interfere with the placement of this plate. If nut is present, grind it off.

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    Illustration 25	g06158125
    Main frame RH view

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    Illustration 26	g06158307
    View of area AA (19) 510-9990 Plate (W1) 8 mm (0.3 inch) bevel weld

19. Locate plate (19) by flushing the plate to the bottom of the ears, tack and finish weld as shown in Illustration 26.
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    Illustration 27	g06158313
    (20) 510-9991 Channel (AB) 16 mm (0.6 inch) (AC) 7 mm (0.3 inch) (W3) 3 mm (0.1 inch) square groove weld

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    Illustration 28	g06158314
    Top view (20) 510-9991 Channel (W2) 6 mm (0.2 inch) fillet weld

20. Weld the corner seams of the channel (20) (2 places) prior to assembly into the frame and locate the channel as shown in Illustration 27, tack and finish weld at top and bottom of the channel by following the weld information given in Illustration 28.
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    Illustration 29	g06158220
    Main frame LH view (AF) Connector

21. Rework the left main frame using same parts and process used for right main frame. The parts will be rotated by 180 degrees to install on the left main frame. Remove connector (AF) of slope actuator from Deutsch clip on frame as shown in Illustration 29. This will be re-located once the left side is welded.

    After welding is completed, paint all parts on left and right main frame with black.

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    Illustration 30	g06158237
    Main frame LH view (13) 327-0325 Cable Strap (20) 510-9991 Channel (AF) Connector

22. Route electrical connection for slope actuator around channel (20) as shown in Illustration 30. Secure connector (AF) to channel (20) using cable strap (13). Refer Illustration 30.
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    Illustration 31	g06159069

23. Re-install screed walkways removed during machine preparation.

    Re-install extender height adjusters that were saved in Step1.

    Trim bottom tabs off both flaps and re-install the rubber flaps to the extenders as shown in Illustration 31.

    String line the main screed and re-check flatness. Flatten trailing edges as required.

    To check the screed settings, ensure that the following settings are applied.

    • Main screed deflectors are set to 19 mm (0.7 inch) above main plate.

    • Extender deflectors are set to 13 mm (0.5 inch) above the extender plates.

    • Extender angle of attack is maximum 1.0 mm (0.04 inch) in relationship to the main screed.

    • Check and reset scales if necessary (Crown, slope, and extender height).