Installation Procedure for Upgraded Extender Deflectors and Main Frame End Caps on Certain SE60V. {6631, 6641, 7051} Caterpillar

Asphalt Paver

AP1000F (S/N: AC4356-UP)

AP1055F (S/N: TJ5709-UP)

AP655F (S/N: MH6182-UP)

Introduction

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

Safety Section

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Do not operate or work on this product unless you have read and understood the instruction and warnings in the relevant Operation and Maintenance Manuals and relevant service literature. Failure to follow the instructions or heed the warnings could result in injury or death. Proper care is your responsibility.

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Failure to follow all safety guidelines prescribed in this document and by governing authorities and regulatory agencies may result in severe injury or death of personnel or machine damage.

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When removing a major component or attachment, ensure that it is properly blocked or secured before removing mounting hardware. An assembly that is disconnected without proper blocking may shift or fall, resulting in serious injury or death of personnel or machine damage.

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Personal injury or death can result from improper maintenance procedures. To avoid injury or death, follow the procedures exactly as stated below.

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Personal injury can result from improper handling of chemicals. Make sure you use all the necessary protective equipment required to do the job. Make sure that you read and understand all directions and hazards described on the labels and material safety data sheet of any chemical that is used. Observe all safety precautions recommended by the chemical manufacturer for handling, storage, and disposal of chemicals.

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Climbing equipment may be required to access this service point. Refer to the Operation and Maintenance Manual, "Mounting and Dismounting" topic for safety information.

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Before servicing/performing maintenance on the machine, electrical power must be physically disconnected; battery plugs must be disconnected from the batteries, or the trailing cable must be unplugged, and warning tags and padlocks shall be applied by a certified electrician. Certified electricians shall perform or direct any electrical work, including any energized testing, repair work in controllers, motors, or other approved compartments, and shall insure that all compartments are properly closed and inspected prior to re-energization. All applicable lock out and tag out procedures must be followed.

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Do not operate the machine if any guards or covers are missing or inadequately secured. Personnel could be seriously injured or machine damage may occur.

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Observe the safe working load limits of all lifting and blocking devices and keep a safe distance from suspended/blocked loads. Personnel may be seriously injured or killed by falling loads.

Torque Specifications

English (SAE) Fasteners

The following table has the recommended standard torque values.

Metric (ISO) Fasteners

The following table has the recommended standard torque values.

Note: All fasteners are standard torque unless otherwise noted.

Required Parts

Illustration 1	g06278715
Overview of Required Parts - Left and Right Side Assembled

Illustration 2	g06278519
Screed Left Side

Illustration 3	g06278717
Screed Right Side

Left Side Procedure

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Illustration 4	g06280312
(A) Main frame end cap (B) Upper deflector cover (C) Extender upper deflector (D) Extender lower deflector

1. Starting on the left side of screed, remove main frame end cap (A), Extender upper deflector (C), and extender lower deflector (D). Now remove upper deflector cover (B) from extender upper deflector (C) and set aside to be reused later. Save old hardware for future use.
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   Illustration 5	g06279535

2. Remove the inside main frame cover (E) and inner extender heat chamber cover (F). Save hardware for future use.
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   Illustration 6	g06279538

3. Remove three upper deflector mounting brackets (G) and discard. Save hardware for future use. Clean up all asphalt buildup around deflector/cover mounting areas as needed.

   Note: Some early screeds have a shaft that sticks out on both sides of slope jack. If the screed your working on has this, the rear most portion of the shaft will need 20 mm (0.78 inch) removed from both slope jacks as shown in Illustration 7. Use caution when cutting not to create too much heat causing damage to seals on slope jack.

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   Illustration 7	g06307444

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   Illustration 8	g06279093

4. Install new lower extender deflector (11). Adjust bottom of deflector to be 13 mm (0.51 inch) above the bottom of screed plate. Torque mounting hardware to 40 N·m (29.5 lb ft).
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   Illustration 9	g06280980

5. Install new deflector brackets: two of (12) and one of (13). Use the original hardware that was removed with the old brackets. Hand tighten components to allow for adjustment in Step 6 and 7.
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   Illustration 10	g06283163
   (D1) 14 mm (0.55 inch)

6. To locate upper brackets, place a straight edge on face of lower deflector and place off-set of bracket to 14 mm (0.55 inch) for all three brackets (12) and (13).
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   Illustration 11	g06283165
   (D2) 124 mm (4.88 inch) (D3) 1414 mm (55.66 inch)

7. Set from center mounting hole on bracket to the inner surface of the end gate wall per dimensions in Illustration 10. Ensure that center mounting bracket is in line with the two outer brackets. After completing adjustments, tighten the bolts that holds the brackets (5) to standard torque.
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   Illustration 12	g06283432

8. Complete this step off machine. Reinstall original upper deflector cover (B) to new upper deflector assembly (14) using existing hardware that was previously removed. Leave hardware hand tight for further adjustment once on screed.
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   Illustration 13	g06283429

9. Install new extender upper deflector assembly (14) with new bolts (5) and existing washers.
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   Illustration 14	g06304160

   Note: Some early screed models have a grease fitting mounted on the side of this frame location. This grease fitting needs to be moved to the top of the frame as shown per Illustration 13. This allows for the new main frame end cap to be installed without interfering with the grease fitting.

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   Illustration 15	g06279229

10. Install new main frame end cap (15) using existing hardware.

    1. Adjust the end cap to be flush with main frame deflector.

    2. Apply RTV silicone sealant to setscrews and insert setscrews. Install so that the outside face of setscrew is 2 ± 2 mm (0.079 ± 0.079 inch) inside the end plate surface.

    3. Adjust upper deflector cover (B) to minimize gap to new main frame end cap. Tighten hardware once adjusted.
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    Illustration 16	g06279264

11. Install new inside main frame cover assembly (10) using three hard washers (6) and three bolts (4). Adjust to minimize material leakage between this piece and extender deflectors.
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    Illustration 17	g06279293

12. Install new inner extender heat chamber cover (7) reusing existing mounting hardware. Bring front portion of cover down to flush with bottom of screed plate.

Right Side Procedure

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Illustration 18	g06304213
(A) Main frame end cap (B) Upper deflector cover (C) Extender upper deflector (D) Extender lower deflector (H) Cover Assembly

1. Starting on the right side of screed, remove main frame end cap (A), Extender upper deflector (C), and extender lower deflector (D) and cover assembly (H). Now remove upper deflector cover (B) from extender upper deflector (C) and set aside to be reused later.
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   Illustration 19	g06283037

2. Remove the inside main frame cover (E) and inner extender heat chamber cover (F).
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   Illustration 20	g06283149
   (D1) Locating Dimension - 35 mm (1.37 inch) (D2) Locating Dimension - 147 mm (5.78 inch) (D3) Locating Dimension - 177 mm (6.96 inch)

3. Remove right-hand side end gate. Drill and tap two holes in the right upper outer frame. Drill holes to 8.7 mm (0.34 inch.), and tap holes to M10 X 1.5-6 per Illustration 19.
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   Illustration 21	g06270749

4. Drill and tap two holes in the right upper inner frame per Illustration 20 and 21. Drill holes to 8.7 mm (0.34 inch), and tap holes to M10 X 1.5-6
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   Illustration 22	g06283153
   (D4) Locating Dimension - 35 mm (1.37 inch) (D5) Locating Dimension - 147 mm (5.78 inch) (D6) Locating Dimension - 177 mm (6.96 inch)

5. Drill two holes and add two weld nuts on extender height motor mount bracket. Per Illustration 20 and 21.
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   Illustration 23	g06270778

6. Modify the highlighted bracket in the next step.
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   Illustration 24	g06283154
   (L-D7) 86 mm (3.38 inch) (M-D8) 56 mm (2.20 inch) (N-D9) 38.5 mm (1.51 inch)

7. Drill two holes 13.8 mm (0.54 inch) per Illustration 23.
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   Illustration 25	g06283044

8. Weld on two weld nuts (2) per Illustration 24.
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   Illustration 26	g06283046

9. Reinstall previously removed end gate. Install new lower extender deflector (17) using existing hardware. Be sure that end deflector is flush with end gate. Torque mounting hardware to 40 N·m (29.5 lb ft). Adjust bottom of deflector to be 13 mm (0.51 inch) above the bottom of screed plate.
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   Illustration 27	g06293471

10. Install new deflector brackets: two of (19) and one of (20) using new hardware. Hand tighten components to allow for adjustment in Step 11 and 12.
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    Illustration 28	g06283160
    (D10) 14 mm (0.55 inch)

11. To locate upper brackets, place a straight edge on face of lower deflector and place off-set of bracket to 14 mm (0.55 inch) for all three brackets (19) and (20).
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    Illustration 29	g06283161
    (D11) 135 mm (5.31 inch)

12. Set height of all three mounting brackets to 135 mm (5.315 inch) above lower extender deflector. After completing adjustments, tighten the bracket bolts that holds brackets (19) and (20) to standard torque.
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    Illustration 30	g06304758

13. Reinstall original cover assembly (H) using existing hardware that was previously removed. Fully tighten hardware.
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    Illustration 31	g06293499

14. Install new extender upper deflector assembly (18) with new bolts (5) and new washers (1). Fully tighten hardware (1) and (5) before proceeding.
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    Illustration 32	g06304763

15. Install hardware on the top of the deflector assembly using existing hardware.
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    Illustration 33	g06304765

16. Reinstall original upper deflector cover (B) to new upper deflector assembly (18) using existing hardware that was previously removed. Leave hardware hand tight for further adjustment once on screed.
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    Illustration 34	g06304160

    Note: Some early screed models have a grease fitting mounted on the side of this frame location. This grease fitting needs to be moved to the top of the frame as shown per Illustration 33. This allows for the new main frame end cap to be installed without interfering with the grease fitting.

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    Illustration 35	g06283107

17. Install new main frame end cap (9) using existing hardware.

    1. Adjust the end cap to be flush with main frame deflector.

    2. Apply RTV silicone sealant to setscrews and insert setscrews. Install so that the outside face of setscrew is 2 ± 2 mm (0.079 ± 0.079 inch) inside the end plate surface.
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       Illustration 36	g06305016

    3. Adjust upper deflector cover (B) to minimize gap to new main frame end cap (9). Tighten hardware once adjusted.
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    Illustration 37	g06283108

18. Install new inside main frame cover assembly (16) using three hard washers (6) and three bolts (4). Adjust to minimize material leakage between this piece and extender deflectors.
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    Illustration 38	g06283111

19. Install new inner extender heat chamber cover (8) reusing existing mounting hardware. Bring front portion of cover down to flush with bottom of screed plate.