Caterpillar ASPHALT PAVERS AP655C, BG-2255C Repair Service Manuals (AYP/CDG/CKR)
Caterpillar ASPHALT PAVERS AP655C, BG-2255C Repair Service Manuals (AYP/CDG/CKR)
Complete service repair manuals with electrical wiring diagrams for Caterpillar ASPHALT PAVERS AP655C, BG-2255C, with all the workshop service information to maintain, diagnose, repair, and rebuild.
Caterpillar ASPHALT PAVERS AP655C, BG-2255C Repair Service Manuals
workshop service manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
MANUAL LIST
KENR5021 - Schematic (AP-655C Asphalt Paver Electrical System 244-5495-01).pdf
KENR5024 - Schematic (Caterpillar AP-655C and Barber Greene, BG-2255C Asphalt Paver Hydraulic System 245-0849).pdf
KENR5029 - Specifications (AP-655C and BG-2255C Asphalt Pavers Attachments).pdf
KENR5027 - Specifications (AP-655C and BG-2255C Asphalt Pavers Drag Conveyor and Auger Conveyor Systems).pdf
KENR5028 - Specifications (AP-655C and BG-2255C Asphalt Pavers Machine Systems).pdf
KENR5026 - Specifications (AP-655C and BG-2255C Asphalt Pavers Propel System).pdf
KENR5028 - Testing and Adjusting (AP-655C and BG-2255C Asphalt Pavers Machine Systems).pdf
KENR5025 - Disassembly and Assembly (AP-655C and BG-2255C Asphalt Pavers).pdf
KENR5029 - Systems Operation (AP-655C and BG-2255C Asphalt Pavers Attachments).pdf
KENR5029 - Testing and Adjusting (AP-655C and BG-2255C Asphalt Pavers Attachments).pdf
KENR5027 - Testing and Adjusting (AP-655C and BG-2255C Asphalt Pavers Drag Conveyor and Auger Conveyor Systems).pdf
KENR5027 - Systems Operation (AP-655C and BG-2255C Asphalt Pavers Drag Conveyor and Auger Conveyor Systems).pdf
KENR5026 - Systems Operation (AP-655C and BG-2255C Asphalt Pavers Propel System).pdf
KENR5026 - Testing and Adjusting (AP-655C and BG-2255C Asphalt Pavers Propel System).pdf
KENR5028 - Systems Operation (AP-655C and BG-2255C Asphalt Pavers Machine Systems).pdf
KENR5033 - Disassembly and Assembly (AP-655C and BG-2255C Asphalt Pavers Machine Systems).pdf
AP-655C ASPHALT PAVER AYP
AP-655C ASPHALT PAVER CDG
BG-2255C ASPHALT PAVER CKR
Total Pages: 1,773 pages
File Format: PDF (bookmarked, ToC, Searchable, Printable, high quality)
Manual Type: Disassembly & Assembly, Testing & Adjusting, Specifications, Systems Operation, Electrical Schematic, Troubleshooting...
Language: English
TABLE OF CONTENTS
KENR5021 - Schematic (AP-655C Asphalt Paver Electrical System 244-5495-01)......2
Collage......3
Main......35
KENR5024 - Schematic (Caterpillar AP-655C and Barber Greene, BG-2255C Asphalt Paver Hydraulic System 245-0849)......37
Collage......38
Main......53
KENR5025 - Disassembly and Assembly (AP-655C and BG-2255C Asphalt Pavers)......55
Air Cleaner - Remove and Install......56
Alternator - Remove and Install......61
Control Valve (Fan Drive) - Remove and Install......65
Electric Starting Motor - Remove and Install......68
Engine - Install......73
Engine - Remove......80
Engine Oil Filter and Oil Filter Base - Remove and Install......88
Exhaust (Muffler) - Remove and Install......92
Fuel Filter (Secondary) and Fuel Filter Base - Remove and Install......94
Gear Motor (Fan Drive) - Assemble......97
Gear Motor (Fan Drive) - Disassemble......102
Gear Motor (Fan Drive) - Install......107
Gear Motor (Fan Drive) - Remove......110
Gear Pump (Fan Drive) - Assemble......114
Gear Pump (Fan Drive) - Disassemble......119
Gear Pump (Fan Drive) - Install......124
Gear Pump (Fan Drive) - Remove......126
Radiator, Air Cooler, and Hydraulic Oil Cooler - Install......129
Radiator, Air Cooler, and Hydraulic Oil Cooler - Remove......133
Water Separator (Fuel Priming Pump and Primary Fuel Filter) - Assemble......138
Water Separator (Fuel Priming Pump and Primary Fuel Filter) - Disassemble......141
Water Separator (Fuel Priming Pump and Primary Fuel Filter) - Install......144
Water Separator (Fuel Priming Pump and Primary Fuel Filter) - Remove......145
KENR5026 - Specifications (AP-655C and BG-2255C Asphalt Pavers Propel System)......147
Accumulator (Track Tension)......148
Cooler Bypass Valve......150
Final Drive Planetary......152
Frame (Undercarriage)......156
Hydraulic Cylinder (Track Tension)......163
Hydraulic Oil Filter (Charge Pump)......165
Hydraulic Oil Filter (Return)......167
Hydraulic Tank......168
Piston Pump (Propel)......169
Pressure Control Valve (Parking Brake Release)......171
Pressure Switch (Track Tension)......172
Suction Strainer......174
Tensioner Group......176
KENR5026 - Systems Operation (AP-655C and BG-2255C Asphalt Pavers Propel System)......178
Accumulator (Track Tension)......179
Cooler Bypass Valve......181
Electrical Input Components......183
Electrical Output Components......192
Electrical Schematic......196
Electronic Control Module......198
Features......204
Final Drive Planetary......205
Frame (Undercarriage)......209
Hydraulic Cylinder (Track Tension)......216
Hydraulic Oil Filter (Charge Pump)......218
Hydraulic Oil Filter (Return)......220
Hydraulic Schematics......221
Hydraulic Tank......225
Introduction (Propel System)......226
Introduction......234
Location of Electrical Components......236
Location of Hydraulic Components......248
Multifunction Valves......266
Piston Motor (Propel)......276
Piston Pump (Propel) ......284
Piston Pump (Propel)......295
Pressure Control Valve (Parking Brake Release)......297
Pressure Switch (Track Tension)......298
Propel System......300
Suction Strainer......308
Tensioner Group......310
KENR5026 - Testing and Adjusting (AP-655C and BG-2255C Asphalt Pavers Propel System)......312
Accumulator - Test and Charge......313
Belt Alignment - Test and Adjust......322
Harness (Speed Potentiometer) and Electronic Sensor - Test......335
Lever (Propel Control) and Electronic Sensor - Test......344
Piston Motor Case Drain Flow - Test......353
Piston Pump Case Drain Flow - Test......361
Piston Pump Flow - Test......374
Piston Pump Neutral - Test and Adjust......381
Pressure Limiter Valve - Test and Adjust......391
Pump Synchronization - Test and Adjust......403
Relief Valve (Charge) - Test and Adjust......412
Rotary Position Sensor (Brake Pedal) - Test and Adjust......422
Rotary Position Sensor (Steering) - Test and Adjust......434
Seal Leakage for Final Drive Planetary - Test......448
Speed Sensor (Propel Motor) - Check and Adjust......458
Track Tension - Release......465
KENR5027 - Specifications (AP-655C and BG-2255C Asphalt Pavers Drag Conveyor and Auger Conveyor Systems)......467
Auger Conveyor......468
Auger Extension......469
Conveyor Planetary Drive (Drag)......470
Drag Conveyor......471
Footshaft......474
Gear Pump (Charge)......475
Hydraulic Oil Filter (Charge Pump)......476
Hydraulic Tank......477
Piston Motor......479
Piston Pump......482
Position Sensor (Paddle)......484
Position Sensor (Sonic)......486
KENR5027 - Systems Operation (AP-655C and BG-2255C Asphalt Pavers Drag Conveyor and Auger Conveyor Systems)......487
Auger Conveyor System......488
Charge Filter......498
Charge Pump......501
Control Valve (Auger Conveyor)......505
Control Valve (Drag Conveyor)......511
Drag Conveyor System......515
Electrical Input Components of Auger Conveyor System......525
Electrical Input Components of Drag Conveyor System......532
Electrical Output Components of Auger Conveyor System......535
Electrical Output Components of Drag Conveyor System......537
Electrical Schematic (Auger Conveyor)......538
Electrical Schematic (Drag Conveyor)......541
Features of the Auger Conveyor System......544
Features of the Drag Conveyor System......549
Hydraulic Schematic (Drag Conveyor)......554
Introduction (Auger Conveyor)......558
Introduction (Drag Conveyor)......561
Introduction......563
Location of Electrical Components (Auger Conveyor)......566
Location of Electrical Components (Drag Conveyor)......567
Location of Hydraulic Components (Auger Conveyor)......570
Location of Hydraulic Components (Drag Conveyor)......579
Piston Motor (Auger Conveyor)......587
Piston Motor (Drag Conveyor)......591
Piston Pump (Auger Conveyor)......596
Piston Pump (Drag Conveyor)......604
Planetary Drive (Auger Conveyor)......611
Planetary Drive (Drag Conveyor)......613
KENR5027 - Testing and Adjusting (AP-655C and BG-2255C Asphalt Pavers Drag Conveyor and Auger Conveyor Systems)......617
Conveyor Chain (Drag) - Check and Adjust......618
Conveyor Drive Chain (Auger) - Check and Adjust......620
Conveyor Drive Chain (Drag) - Check and Adjust......622
Conveyor Speed - Test and Adjust......624
Hydraulic Oil Contamination - Test......626
Machine Preparation for Testing and Adjusting......628
Piston Motor Case Drain Flow - Test......634
Piston Pump Case Drain Flow - Test......643
Piston Pump Flow - Test - Upper and Lower Pump Stacks......651
Piston Pump Neutral - Test and Adjust......664
Relief Valve (Charge) - Test and Adjust......679
Relief Valve - Test - Upper and Lower Pump Stacks......693
Visual Inspection......710
KENR5028 - Specifications (AP-655C and BG-2255C Asphalt Pavers Machine Systems)......714
Bank Valve - Auxiliary......715
Bank Valve - Cooling Fan......717
Cooler Bypass Valve......718
Gear Motor - Cooling Fan......720
Gear Pump (Vibratory)......721
Gear Pump - Cooling Fan......723
Hydraulic Cylinder (Auger Hoist) - Right Cylinder......724
Hydraulic Cylinder (Hopper Hoist)......725
Hydraulic Cylinder (Screed Hoist)......726
Hydraulic Cylinder (Tow Point)......727
Hydraulic Filter (Vibratory)......729
Hydraulic Oil Filter (Return) - Main......730
Hydraulic Tank......732
Manifold Valve (Screed Counterbalance)......733
Piston Pump (Auxiliary)......734
Suction Strainer......735
KENR5028 - Systems Operation (AP-655C and BG-2255C Asphalt Pavers Machine Systems)......737
Auger Lift......738
Auxiliary System......745
Bank Valve (Auxiliary)......753
Cooler Bypass Valve......762
Cooling Fan......765
Electrical Components (Cooling Fan)......775
Electrical Components (Hopper Lift)......777
Electrical Components (Screed)......780
Electrical Components (Vibratory)......787
Electrical Schematic (Auxiliary Systems)......790
Electrical Schematic (Vibratory System)......796
Hopper Lift......797
Hydraulic Schematic (Auxiliary Systems)......802
Hydraulic Schematic (Vibratory System)......808
Introduction (Auxiliary System)......810
Introduction (Vibratory System)......815
Introduction......821
Location of Electrical Components (Auxiliary Systems)......823
Location of Electrical Components (Vibratory System)......835
Location of Hydraulic Components (Auxiliary Systems)......837
Location of Hydraulic Components (Vibratory System)......855
Manifold Valve (Screed Counterbalance)......866
Piston Pump (Auxiliary)......871
Tow Point Control......877
Vibratory System......884
KENR5028 - Testing and Adjusting (AP-655C and BG-2255C Asphalt Pavers Machine Systems)......890
Gear Pump Flow - Test - Cooling Fan......891
Gear Pump Flow - Test - Vibratory......898
Piston Pump Flow - Test and Adjust - Auxiliary......904
Pressure Reducing Valve - Test and Adjust......911
Pump Control Valve (Auxiliary) - Test and Adjust......917
Relief Valve (Screed Counterbalance) - Test and Adjust......920
Relief Valve (Vibratory) - Test and Adjust......925
KENR5029 - Specifications (AP-655C and BG-2255C Asphalt Pavers Attachments)......935
Control Valve (Generator)......936
Control Valve (Truck Hitch)......938
Gear Motor (Generator) - 8 kW......940
Gear Motor (Ventilation System)......942
Hydraulic Filter (Return)......944
Piston Motor (Generator) - 23 kW......945
Piston Pump (Generator)......946
Truck Hitch......948
Washdown Group......950
KENR5029 - Systems Operation (AP-655C and BG-2255C Asphalt Pavers Attachments)......952
Control Valve (Generator) - 23 kW......953
Control Valve (Generator) - 8 kW......955
Control Valve (Truck Hitch)......960
Electrical Components (Generator) - 8 kW......966
Electrical Components (Truck Hitch)......969
Electrical Schematic......971
Flow Control Valve (Ventilation)......975
Gear Motor (Generator) - 8 kW......977
Gear Motor (Ventilation)......980
Generator Drive System - 23 kW Generator......982
Generator Drive System - 8 kW......987
Hydraulic Schematic......990
Introduction......996
Location of Electrical Components......998
Location of Hydraulic Components......1002
Piston Motor (Generator) - 23 kW......1011
Piston Pump (Generator) - 23 kW......1012
Piston Pump (Generator)......1014
Truck Hitch System......1020
Ventilation System......1022
KENR5029 - Testing and Adjusting (AP-655C and BG-2255C Asphalt Pavers Attachments)......1025
Control Valve (Truck Hitch) - Test and Adjust......1026
Fan Speed (Ventilation) - Test......1032
Gear Motor Case Drain Flow - Test - 8 kW Generator......1036
Generator Set - Test and Adjust - 8 kW Generator......1042
Piston Pump Case Drain Flow - Test - 8 kW Generator......1047
Piston Pump Control - Test and Adjust - 8 kW Generator......1053
Piston Pump Flow - Test - 8 kW Generator......1065
Piston Pump Flow - Test and Adjust......1074
Pump Control Valve - Test and Adjust - 23 kW Generator......1080
KENR5033 - Disassembly and Assembly (AP-655C and BG-2255C Asphalt Pavers Machine Systems)......1093
Accumulator (Belt Tensioner) - Remove and Install......1099
Accumulator Charging Valve (Belt Tensioner) - Assemble......1102
Accumulator Charging Valve (Belt Tensioner) - Disassemble......1104
Accumulator Charging Valve (Belt Tensioner) - Install......1106
Accumulator Charging Valve (Belt Tensioner) - Remove......1107
Auger - Assemble......1109
Auger - Disassemble......1111
Auger - Install......1113
Auger - Remove......1116
Auger Conveyor - Remove and Install......1119
Battery and Battery Cable - Separate and Connect......1124
Belt - Install......1126
Belt - Remove......1129
Belt Tensioner - Assemble......1133
Belt Tensioner - Disassemble......1138
Belt Tensioner - Install......1142
Belt Tensioner - Remove......1144
Bogie (Front) - Install......1146
Bogie (Front) - Remove......1148
Bogie (Rear) - Install......1149
Bogie (Rear) - Remove......1151
Bogie - Assemble......1152
Bogie - Disassemble......1156
Brake Pump and Valve - Assemble......1159
Brake Pump and Valve - Disassemble......1161
Brake Pump and Valve - Install......1163
Brake Pump and Valve - Remove......1164
Chain (Auger Conveyor) - Remove and Install......1166
Chain (Drag Conveyor) - Remove and Install......1169
Control Valve (Auxiliary) - Assemble......1173
Control Valve (Auxiliary) - Disassemble......1177
Control Valve (Auxiliary) - Install......1181
Control Valve (Auxiliary) - Remove......1182
Control Valve (Hydraulic Generator) - Assemble - AYP1-Up and B9G1-Up......1184
Control Valve (Hydraulic Generator) - Disassemble - AYP1-Up and B9G1-Up......1186
Control Valve (Hydraulic Generator) - Install - AYP1-Up and B9G1-Up......1188
Control Valve (Hydraulic Generator) - Remove - AYP1-Up and B9G1-Up......1198
Control Valve (Truck Hitch) - Assemble......1200
Control Valve (Truck Hitch) - Disassemble......1203
Control Valve (Truck Hitch) - Install......1206
Control Valve (Truck Hitch) - Remove......1207
Control Valve (Vibratory) - Assemble......1209
Control Valve (Vibratory) - Disassemble......1211
Control Valve (Vibratory) - Install......1213
Control Valve (Vibratory) - Remove......1214
Counterbalance Valve (Screed) - Assemble......1216
Counterbalance Valve (Screed) - Disassemble......1218
Counterbalance Valve (Screed) - Install......1220
Counterbalance Valve (Screed) - Remove......1221
Counterbalance Valve (Tow Point) - Assemble......1223
Counterbalance Valve (Tow Point) - Disassemble......1225
Counterbalance Valve (Tow Point) - Install......1227
Counterbalance Valve (Tow Point) - Remove......1228
Drag Conveyor - Remove and Install......1230
Duo-Cone Conventional Seals - Install......1235
Feeder Drive Shaft Group - Assemble......1247
Feeder Drive Shaft Group - Disassemble......1252
Feeder Drive Shaft Group - Install......1256
Feeder Drive Shaft Group - Remove......1261
Final Drive Planetary (Auger Conveyor) - Assemble......1266
Final Drive Planetary (Auger Conveyor) - Disassemble......1274
Final Drive Planetary (Auger Conveyor) - Install......1282
Final Drive Planetary (Auger Conveyor) - Remove......1285
Final Drive Planetary (Drag Conveyor) - Assemble......1288
Final Drive Planetary (Drag Conveyor) - Disassemble......1296
Final Drive Planetary (Drag Conveyor) - Install......1304
Final Drive Planetary (Drag Conveyor) - Remove......1307
Final Drive Planetary - Assemble......1309
Final Drive Planetary - Disassemble......1327
Final Drive Planetary - Install......1345
Final Drive Planetary - Remove......1348
Footshaft - Assemble......1351
Footshaft - Disassemble......1356
Footshaft - Install......1360
Footshaft - Remove......1362
Fuel Pump (Screed Burner) - Assemble......1364
Fuel Pump (Screed Burner) - Disassemble......1367
Fuel Pump (Screed Burner) - Install - AYP1-UP and B9G1-UP......1370
Fuel Pump (Screed Burner) - Remove - AYP1-Up and B9G1-Up......1373
Fuel Tank - Remove and Install......1376
Gear Motor (Ventilation System) - Assemble......1379
Gear Motor (Ventilation System) - Disassemble......1381
Gear Motor (Ventilation System) - Install......1383
Gear Motor (Ventilation System) - Remove......1385
Gear Pump (Conveyor System Charge) - Assemble......1388
Gear Pump (Conveyor System Charge) - Disassemble......1393
Gear Pump (Conveyor System Charge) - Install......1398
Gear Pump (Conveyor System Charge) - Remove......1400
Gear Pump (Vibratory) - Assemble......1403
Gear Pump (Vibratory) - Disassemble......1408
Gear Pump (Vibratory) - Install......1413
Gear Pump (Vibratory) - Remove......1415
Hopper - Remove and Install......1418
Hydraulic Cylinder (Auger Hoist) - Remove and Install......1422
Hydraulic Cylinder (Belt Tensioner) - Remove and Install......1425
Hydraulic Cylinder (Hopper Hoist) - Remove and Install......1429
Hydraulic Cylinder (Screed Hoist) - Remove and Install......1432
Hydraulic Cylinder (Tow Point) - Remove and Install......1436
Hydraulic Cylinder (Truck Hitch) - Remove and Install......1439
Hydraulic Oil Filter (Conveyor System Charge) - Remove and Install......1447
Hydraulic Oil Filter (Propel System Charge) - Remove and Install......1450
Hydraulic Oil Filter (Return) - Assemble......1453
Hydraulic Oil Filter (Return) - Disassemble......1455
Hydraulic Oil Filter (Return) - Install......1457
Hydraulic Oil Filter (Return) - Remove......1459
Hydraulic Oil Filter (Vibratory) - Remove and Install......1462
Hydraulic System Pressure - Release......1465
Hydraulic Tank - Remove and Install......1466
Operator Platform - Remove and Install......1472
Piston Motor (Auger Conveyor) - Assemble......1478
Piston Motor (Auger Conveyor) - Disassemble......1483
Piston Motor (Auger Conveyor) - Install......1488
Piston Motor (Auger Conveyor) - Remove......1489
Piston Motor (Drag Conveyor) - Assemble......1491
Piston Motor (Drag Conveyor) - Disassemble......1496
Piston Motor (Drag Conveyor) - Install......1501
Piston Motor (Drag Conveyor) - Remove......1502
Piston Motor (Propel) - Assemble......1504
Piston Motor (Propel) - Disassemble......1514
Piston Motor (Propel) - Install......1523
Piston Motor (Propel) - Remove......1524
Piston Pump (Auxiliary) - Assemble......1525
Piston Pump (Auxiliary) - Disassemble......1538
Piston Pump (Auxiliary) - Install......1551
Piston Pump (Auxiliary) - Remove......1553
Piston Pump (Conveyor) - Assemble......1555
Piston Pump (Conveyor) - Disassemble......1572
Piston Pump (Hydraulic Generator) - Assemble......1589
Piston Pump (Hydraulic Generator) - Disassemble......1601
Piston Pump (Hydraulic Generator) - Install......1613
Piston Pump (Hydraulic Generator) - Remove......1615
Piston Pump (Left Drag Conveyor and Right Auger Conveyor) - Install......1618
Piston Pump (Left Drag Conveyor and Right Auger Conveyor) - Remove......1621
Piston Pump (Left Propel) - Install......1624
Piston Pump (Left Propel) - Remove......1625
Piston Pump (Propel) - Assemble......1627
Piston Pump (Propel) - Disassemble......1653
Piston Pump (Right Drag Conveyor and Left Auger Conveyor) - Install......1676
Piston Pump (Right Drag Conveyor and Left Auger Conveyor) - Remove......1679
Piston Pump (Right Propel) - Install......1682
Piston Pump (Right Propel) - Remove......1684
Plates (Drag Pans) - Remove and Install......1687
Pump Drive - Assemble......1690
Pump Drive - Disassemble......1693
Pump Drive - Install......1696
Pump Drive - Remove......1698
Push Roller - Assemble......1700
Push Roller - Disassemble......1702
Push Roller - Install......1704
Push Roller - Remove......1706
Return Manifold and Oil Cooler Bypass Valve - Remove and Install......1708
Screed - Remove and Install......1712
Seat - Remove and Install......1715
Steering Column - Assemble......1717
Steering Column - Disassemble......1721
Steering Column - Install......1725
Steering Column - Remove......1727
Steering Wheel - Remove and Install......1730
Tow Arm - Remove and Install......1733
Track Roller Frame (Front) - Install......1736
Track Roller Frame (Front) - Remove......1739
Track Roller Frame (Rear) - Assemble......1742
Track Roller Frame (Rear) - Disassemble......1746
Track Roller Frame (Rear) - Install......1750
Track Roller Frame (Rear) - Remove......1752
Transverse Beam - Remove and Install......1754
Truck Hitch - Assemble......1756
Truck Hitch - Disassemble......1761
Truck Hitch - Install......1766
Truck Hitch - Remove......1768
Wheel (Final Drive) - Remove and Install......1771
