- Asphalt Paver
- AP300D (S/N: TEN1-UP)
Introduction
The following instructions provide the steps needed to install new water proof protections for electrical and generator boxes on AP300D Asphalt Pavers.
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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| Illustration 1 | g00104545 |
Prevent the machine from movement. Park the machine on a level surface.
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 . These warning tags (Special Instruction, SEHS7332) are available from your Machine Preparation
Machine Preparation
- Park the machine in a smooth surface and extend both the extenders and screed lowered on the ground.
- Switch off the engine and leave the key in the "OFF" position.
Required Parts
| Required parts | |||
|---|---|---|---|
| Item | Qty | Part Number | Description |
| 1 | 2 | 461-3120 | Connector As |
| 2 | 2 | 461-3122 | Locknut |
| 3 | 1 | 522-7219 | Plate As |
| 4 | 1 | 8X-8096 | Film |
| 5 | 1 | 522-7216 | Cover As |
| 6 | 1 | 416-7687 | Film |
| 7 | 1 | 416-7686 | Film |
| 8 | 2 | 8T-6412 | Screw |
| 9 | 2 | 8T-4205 | Hard Washer |
| 10 | 1 | 6K-6307 | O-Ring Seal |
| 11 | 1 | 4K-1388 | O-Ring Seal |
| 12 | |
432-5918 | Flexible Conduit |
Installation Procedure
- Remove existing plate assembly (A) by removing three screws (B) and three washers (C) as shown in Illustration 2. Save the parts.
Note: Before removing the plate completely, some wires need to be disconnected to fit the lateral waterproof connectors into the box.
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Illustration 3 g06161782 (D) Ground point terminal - Disconnect ground point terminal (D) on the machine frame as shown in Illustration 3.
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Illustration 4 g06161784 (E) Red wire - Disconnect red wire (E) coming from first relay as shown in Illustration 4.
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Illustration 5 g06161787 (1) 461-3120 Connector As
(2)461-3122 Locknut - Remove existing seal and install connector (1) and locknut (2).
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Illustration 6 g06161800 Show/hide table
Illustration 7 g06161803 (F) Wires - If machine is equipped with canopy, remove wires (F) of canopy circuit breaker as shown in Illustration 7.
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Illustration 8 g06161804 (G) White deutsch Show/hide table
Illustration 9 g06161805 (H) Connector - Remove white deutsch (G) connector and 6-pin deutsch connector (H) inside the box to install correct fitting of water proof connector.
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Illustration 10 g06161807 (J) Battery cable (Red) - Remove battery cables (Red) (J) as shown in Illustration 10.
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Illustration 11 g06161809 (1) 461-3120 Connector AsShow/hide table
Illustration 12 g06161811 (2) 461-3122 Locknut - Remove existing seal and install connector (1) and locknut (2). Install wires and connectors as shown in Illustration 12.
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Illustration 13 g06161815 (K) Screw
(L) Bolt
(M) Washer - Remove plate, circuit breakers, and fuse blocks by removing bolts (L), washers (M), and screws (K).
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Illustration 14 g06161817 (3) 522-7219 Plate As
(4)8X-8096 Film
(N) Optional circuit breakers - Install new plate assembly (3) and install all relays and fuse block using bolts (L), washers (M), and screws (K).
Note: If optional circuit breakers are missing, proceed to install film cover (4) on free holes.
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Illustration 15 g06161820 (5) 522-7216 Cover As
(6)416-7687 Film
(7)416-7686 Film
(8)8T-6412 Screw
(9)8T-4205 Hard Washer - Install cover (5) using bolt (8) and washer (9). Place film (6) and film (7) on cover (5).
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Illustration 16 g06161843 (10) 6K-6307 O-Ring Seal
(11)4K-1388 O-Ring Seal - Install o-ring (10) and o-ring (11) in connectors of generator box and add a drain hole of diameter
15.0 mm (0.59 inch) on bottom side of the generator box.Show/hide table
Illustration 17 g06194468 (P) Conduit Show/hide table
Illustration 18 g06194461 (P) Conduit
(R) Wire
(S) Generator box - To replace conduit (P) remove the wire (R) on the generator box (S) as shown in Illustration 18.
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Illustration 19 g06163517 (11) 4K-1388 O-Ring Seal
(12)432-5918 Flexible Conduit - Install O-ring (11) and flexible conduit (12) on bottom side of the generator box as shown in Illustration 19.
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| Illustration 2 | g06161780 |
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(A) Plate assembly
(B) Screw (C) Washer | |
