Caterpillar ASPHALT PAVERS AP-1000F Repair Service Manuals (SN Prefix AC4)
Complete service repair manuals with electrical wiring diagrams for Caterpillar ASPHALT PAVERS AP-1000F, with all the workshop service information to maintain, diagnose, repair, and rebuild.
Caterpillar ASPHALT PAVERS AP1000F 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.
UENR3133 - Specifications (AP1000F Asphalt Paver Propel System).pdf
UENR3134 - Systems Operation (AP1000F Asphalt Paver Propel System).pdf
UENR3134 - Testing and Adjusting (AP1000F Asphalt Paver Propel System).pdf
UENR3135 - Specifications (AP1000F Asphalt Paver Machine Systems).pdf
UENR3136 - Systems Operation (AP1000F Asphalt Paver Machine Systems).pdf
UENR3136 - Testing and Adjusting (AP1000F Asphalt Paver Machine Systems).pdf
UENR5173 - Schematic (AP1000F Asphalt Paver Hydraulic System).pdf
UENR5174 - Schematic (AP1000F and AP1055F Asphalt Paver Electrical System); Machine Electrical System 399-3173-03 483-3775-01; PDM and Electrical Options..) (SN AC41-UP TJ51-UP).pdf
UENR5581 - Disassembly and Assembly (AP1000F and AP1055F Asphalt Pavers Engine Supplement).pdf
UENR5582 - Disassembly and Assembly (AP1000F Asphalt Paver Machine Systems).pdf
AP-1000F ASPHALT PAVER AC4
Total Pages: 1,521 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
UENR3133 - Specifications (AP1000F Asphalt Paver Propel System)................1
Hydraulic Tank................2
Hydraulic Tank and Mounting................4
Propel Pump and Mounting................6
Hydraulic Oil Filter (Return)................7
Final Drive................8
Bogie................9
Pressure Switch (Track Tension)................12
Front Wheel Assist................14
UENR3134 - Systems Operation (AP1000F Asphalt Paver Propel System)................17
General Information (Propel System)................18
Location of Electrical Components (Propel System)................20
Location of Hydraulic Components (Propel System)................22
Operator Controls (Propel System)................24
Front Wheel Assist Hydraulic System................30
Piston Pump (Propel)................34
Piston Motor (Propel)................43
Flow Divider Valve (Front Wheel Assist)................46
Piston Motor (Front Wheel Assist)................49
Final Drive Planetary................52
Parking Brake................56
Electrical Schematic (Propel System)................58
Hydraulic Schematic (Propel System)................68
UENR3134 - Testing and Adjusting (AP1000F Asphalt Paver Propel System)................77
Machine Preparation for Troubleshooting................78
Visual Inspection................79
Propel System Troubleshooting................83
Hydraulic Oil Contamination - Test................86
Piston Pump (Front Wheel Assist) - Test................93
Piston Pump Flow - Test................102
Piston Pump Neutral - Test and Adjust - Right Propel................110
Piston Pump Neutral - Test and Adjust - Left Propel................121
Relief Valve (Charge) - Test and Adjust - Right Pump................131
Relief Valve (Charge) - Test and Adjust - Left Pump................142
Pressure Limiter Valve - Test and Adjust - Left Pump................154
Pressure Limiter Valve - Test and Adjust - Right Pump................170
Seal Leakage for Final Drive Planetary - Test................183
Solenoid (Shift) - Test................190
Rotary Position Sensor (Decelerator Pedal) - Test and Adjust................196
Steering Wheel - Calibrate................201
Pressure Reducing Valve (Front Wheel Assist) - Test and Adjust................211
Forward Currents (EDC)- Calibrate................221
Reverse Currents (EDC)- Calibrate................232
UENR3135 - Specifications (AP1000F Asphalt Paver Machine Systems)................243
Hydraulic Tank................246
Hydraulic Tank and Mounting................248
Oil Cooler Bypass Valve................250
- Generator................251
Hydraulic Oil Filter (Generator)................253
Hydraulic Oil Filter (Return)................255
Control Manifold................256
Lines (Auxiliary Pump)................258
Lines (Auxiliary Hydraulic)................260
Control Valve (Auxiliary)................262
Counterbalance Valve (Hopper Hoist; Tow Point)................263
Hydraulic Cylinder (Tow Point)................264
Lines (Truck Hitch)................266
Push Roller................267
Hydraulic Cylinder (Hopper Hoist)................269
Lines (Auger Hoist)................270
Hydraulic Cylinder (Auger Hoist)................271
Lines (Screed)................274
Hydraulic Cylinder (Screed Hoist)................275
Apron................277
Hopper................279
Access Door................281
Conveyor Drive (Drag)................283
Footshaft................286
Position Sensor (Paddle)................288
Auger Conveyor - Mounting................289
Transverse Beam................292
Main Frame................293
Extender Lines................295
Thickness Control................297
Power Crown Group................299
Power Sloper Group................301
Slope Lines Group................303
Drop Arm................305
Height Adjuster Group................307
Lines (Tamper)................310
Lines (Hydraulic Fan)................312
Vibratory Lines Group................314
Flow Divider Valve................316
Position Sensor (Sonic)................318
Generator................321
Washdown Group................324
Washdown Group - Ecology................326
Diaphram Pump (Washdown)................327
Walkway................328
Canopy................330
Window................331
Window - Front................332
Platform................340
Seat and Mounting................342
Grade Control................343
Grade Control Mounting................345
Operator Console................349
Steering Column................352
Steering Control................353
Lines (Steering)................354
Fuel Tank................355
Fuel Lines................357
Flood Lighting................359
Air Lines (Aftercooler)................363
Air Cleaner................365
Roading Lighting................368
Communication Electronic Control Module (Product Link)................370
Mounting Frame - After treatment................373
UENR3136 - Systems Operation (AP1000F Asphalt Paver Machine Systems)................374
General Information (Auxiliary Hydraulic System)................376
Operator Controls (Auxiliary Hydraulic System)................377
Electrical System (Auxiliary Hydraulic)................387
Hydraulic System (Auxiliary)................390
Piston Pump (Auxiliary)................398
Control Valve (Hopper Hoist; Tow Point)................401
Control Valve (Auxiliary)................403
Control Valve (Apron Fold)................405
Control Valve (Truck Hitch)................406
Paver Ventilation System................407
Electrical Schematic (Auxiliary Hydraulic System)................409
Hydraulic Schematic (Auxiliary Hydraulic System)................425
General Information (Fan Hydraulic System)................445
Location of Components (Fan Drive Hydraulic System)................446
Piston Pump (Fan Drive)................450
Gear Motor (Fan Drive)................453
Cooling Fan Manifold................454
Electrical Schematic (Hydraulic Fan)................458
Hydraulic Schematic (Hydraulic Fan)................461
General Information (Auger and Conveyor System)................465
Operator Controls (Auger and Conveyor System)................467
Electrical System (Auger and Conveyor)................473
Location of Components (Auger and Conveyor System)................475
Piston Pump (Auger and Conveyor)................477
Piston Motor (Auger and Conveyor)................484
Electrical Schematic (Auger and Conveyor System)................487
Hydraulic Schematic (Auger and Conveyor System)................494
General Information (Vibratory System)................500
Operator Controls (Vibratory System)................501
Vibratory Valve................503
Gear Pump (Vibratory and Charge)................504
Electrical Schematic (Vibratory System)................505
Hydraulic Schematic (Vibratory System)................508
General Information (Tamper System)................513
Operator Controls (Tamper System)................514
Piston Pump (Tamper)................518
Electrical Schematic (Tamper System)................521
Hydraulic Schematic (Tamper System)................524
General Information (Washdown System)................528
Operator Controls (Washdown System)................529
Location of Components (Washdown System)................533
Electrical Schematic (Washdown System)................536
General Information (Generator System)................539
Operator Controls (Generator)................540
Location Of Components (Generator System)................541
Generator................545
Electrical Schematic (Generator System)................549
Hydraulic Schematic (Generator System)................554
UENR3136 - Testing and Adjusting (AP1000F Asphalt Paver Machine Systems)................556
Machine Preparation for Troubleshooting................557
Visual Inspection................558
Machine System Troubleshooting................562
Hydraulic Oil Contamination - Test................566
Piston Pump Flow (Auxiliary) - Test................573
Solenoid Valve (Tamper) - Calibrate................582
Piston Pump Flow (Cooling Fan) - Test................591
Pump Control Valve (Auxiliary) - Test and Adjust................600
Relief Valve (Charge; Auger Conveyor and Drag Conveyor) - Test and Adjust................609
Relief Valve (Main; Auger Conveyor and Drag Conveyor) - Test and Adjust................622
Piston Pump Neutral (Auger Conveyor and Drag Conveyor) - Test and Adjust................644
Piston Motor Case Drain Flow (Auger Conveyor and Drag Conveyor) - Test................675
Conveyor Drive Chain (Auger) - Check and Adjust................685
Conveyor Drive Chain (Drag) - Check and Adjust................691
Conveyor Chain (Drag) - Check and Adjust................696
Conveyor Speed (Auger) - Check................701
Conveyor Speed (Drag) - Check................710
Pressure Reducing Valve - Test and Adjust - Shift Solenoid................720
Gear Pump (Generator Cooling) Pressure - Test................728
Fan Speed (Ventilation) - Test................735
Insulation - Test................741
Auger Conveyor - Calibrate................744
Sensor (Paddle) - Calibrate - Auger Feed................764
Sensor (Paddle) - Calibrate - Conveyor................773
Drag Conveyor - Calibrate................783
Vibratory Shaft Speed - Calibrate................801
UENR5173 - Schematic (AP1000F Asphalt Paver Hydraulic System)................813
Collage................814
Main................842
Features................842
Cover Page................843
Information................0
Component Location................844
Tap Location................845
Fluid Power Symbols................846
Electrical Symbols................847
Schematic................848
Machine Views................0
Machine - Front View 1................849
Machine - Front View 2................850
Machine - Left Side View................851
Machine - Rear View................852
Machine - Right Side View................853
Tank Gp - Right Rear View................854
UENR5174 - Schematic (AP1000F and AP1055F Asphalt Paver Electrical System); Machine Electrical System 399-3173-03 483-3775-01; PDM and Electrical Options..) (SN AC41-UP TJ51-UP)................855
Feature................855
Cover Page................857
Information................0
Component Location................0
Machine Electrical System................0
Page 1 of 2................858
Page 2 of 2................859
Power Distribution Module and Electrical Options................860
Engine and CEM Module................861
Connector Location................0
Machine Electrical System................862
Power Distribution Module and Electrical Options................863
Engine and CEM Module................864
Schematics................0
Machine Electrical System................865
Power Distribution Module and Electrical Options................866
Engine and CEM Module................867
Machine Views................0
Machine Electrical System................0
CEM Module................868
Center Console / Battery Comp.................869
Center Console Rear View................870
Engine Interface................871
Fuel Tank / LH Battery Comp. ................872
Generator / Engine LH Rear View................873
Hydraulic Propel Motors................874
Hydraulic Pumps RH Side................875
Inside RH Rear Frame................876
LH Operator Station................877
Rear Tractor LH View................878
Rear Tractor RH View................879
RH Operator Station................880
RH Rear Below Op Station................881
Steering................882
Tractor LH Front View................883
Tractor LH Middle View................884
Tractor LH Rear Side View................885
Tractor RH Front View................886
Tractor RH Rear Side View................887
Wheel Type Components................888
Power Distribution Module and Electrical Options................0
Power Distribution Module................891
Product Link PL631 / PL641................894
Optional Screed Led Lighting................890
Optional Cab With Wipers................889
Product Link PL522................893
Product Link PL421................892
Engine and CEM Module................0
DCU Front View................895
DCU LH View................896
Engine LH Front View................897
Engine LH View................900
Engine LH Rear View................899
Engine LH Lower Rear View................898
Engine RH Rear View................901
UENR5581 - Disassembly and Assembly (AP1000F and AP1055F Asphalt Pavers Engine Supplement)................902
System Pressure - Release................903
Air Cleaner - Remove and Install................904
Battery - Remove and Install................906
Alternator - Remove and Install................911
Electric Starting Motor - Remove and Install................914
Alternator Belt - Remove and Install................917
Belt Tensioner - Remove and Install................919
Water Separator; Primary Fuel Filter; and Fuel Priming Pump - Remove and Install................921
Fuel Cooler - Remove and Install................923
Fuel Filter (Secondary) and Fuel Filter Base - Remove and Install................924
Fan - Remove and Install................926
Gear Motor (Fan Drive) - Remove and Install................929
Gear Motor (Fan Drive) - Disassemble................932
Gear Motor (Fan Drive) - Assemble................936
Radiator; Hydraulic Oil Cooler; and Fuel Cooler - Remove and Install................940
Radiator; Hydraulic Oil Cooler; and Fuel Cooler - Disassemble................951
Radiator; Hydraulic Oil Cooler; and Fuel Cooler - Assemble................957
Air Aftercooler - Remove and Install................963
Access Cover (Expansion Tank) - Remove and Install................966
Clean Emissions Module - Remove and Install................979
Diesel Exhaust Fluid Tank - Remove and Install................986
Electronic Control (Diesel Exhaust Fluid) - Remove and Install................988
Engine - Remove................989
Engine - Install................998
UENR5582 - Disassembly and Assembly (AP1000F Asphalt Paver Machine Systems)................1007
System Pressure - Release................1012
Fuel Tank - Remove and Install................1013
Hydraulic Oil Filter (Return) - Remove and Install................1015
Hydraulic Oil Filter (Return) - Disassemble................1017
Hydraulic Oil Filter (Return) - Assemble................1019
Hydraulic Tank - Remove and Install................1021
Gear Pump (Conveyor System Charge) - Remove and Install................1024
Gear Pump (Conveyor System Charge) - Disassemble................1026
Gear Pump (Conveyor System Charge) - Assemble................1032
Hydraulic Oil Filter (Conveyor System Charge) - Remove and Install................1039
Piston Pump (Right Drag Conveyor and Right Auger Conveyor) - Remove and Install................1042
Piston Pump (Left Drag Conveyor and Left Auger Conveyor) - Remove and Install................1044
Piston Pump (Drag Conveyor and Auger Conveyor) - Disassemble................1046
Piston Pump (Drag Conveyor and Auger Conveyor) - Assemble................1056
Piston Motor (Drag Conveyor) - Remove and Install................1065
Piston Motor (Drag Conveyor) - Disassemble................1067
Piston Motor (Drag Conveyor) - Assemble................1072
Chain (Drag Conveyor) - Remove and Install................1077
Final Drive Planetary (Drag Conveyor) - Remove and Install................1080
Final Drive Planetary (Drag Conveyor) - Disassemble................1081
Final Drive Planetary (Drag Conveyor) - Assemble................1087
Drag Conveyor - Remove and Install................1093
Feeder Drive Shaft Group - Remove and Install................1096
Feeder Drive Shaft Group - Disassemble................1100
Feeder Drive Shaft Group - Assemble................1104
Footshaft - Remove and Install................1109
Footshaft - Disassemble................1110
Footshaft - Assemble................1114
Plates (Drag Pans) - Remove and Install................1119
Piston Motor (Auger Conveyor) - Remove and Install................1120
Piston Motor (Auger Conveyor) - Disassemble................1122
Piston Motor (Auger Conveyor) - Assemble................1127
Chain (Auger Conveyor) - Remove and Install................1132
Final Drive Planetary (Auger Conveyor) - Remove and Install................1134
Final Drive Planetary (Auger Conveyor) - Disassemble................1138
Final Drive Planetary (Auger Conveyor) - Assemble................1144
Hydraulic Cylinder (Auger Hoist) - Remove and Install................1151
Auger Conveyor - Remove and Install................1154
Auger - Disassemble................1157
Auger - Assemble................1163
Hydraulic Filter (Suction Return) - Remove and Install................1169
Piston Pump (Right Propel) - Remove and Install................1173
Piston Pump (Left Propel) - Remove and Install................1175
Piston Pump (Propel) - Disassemble................1177
Piston Pump (Propel) - Assemble................1199
Piston Motor (Propel) - Remove and Install................1225
Brake Pump and Valve - Remove and Install................1227
Brake Pump and Valve - Disassemble................1228
Brake Pump and Valve - Assemble................1230
Wheel (Front Wheel Assist) - Remove and Install................1232
Front Wheel Drive Manifold - Remove................1236
Front Wheel Drive Manifold - Disassemble................1238
Front Wheel Drive Manifold - Assemble................1241
Front Wheel Drive Manifold - Install................1243
Piston Motor (Front Wheel Assist) - Remove................1245
Piston Motor (Front Wheel Assist) - Disassemble................1247
Piston Motor (Front Wheel Assist) - Assemble................1254
Piston Motor (Front Wheel Assist) - Install................1260
Wheel (Rear) - Remove and Install................1262
Final Drive Planetary - Remove................1266
Final Drive Planetary - Disassemble................1270
Duo-Cone Conventional Seals - Install................1288
Final Drive Planetary - Assemble................1300
Final Drive Planetary - Install................1318
Piston Pump (Auxiliary) - Remove and Install................1322
Piston Pump (Auxiliary) - Disassemble................1324
Piston Pump (Auxiliary) - Assemble................1333
Control Valve (Auxiliary) - Remove and Install................1345
Control Valve (Auxiliary) - Disassemble................1348
Control Valve (Auxiliary) - Assemble................1351
Hydraulic Cylinder (Hopper Hoist) - Remove and Install................1354
Control Valve (Apron) - Remove and Install................1358
Control Valve (Apron) - Disassemble................1360
Control Valve (Apron) - Assemble................1362
Hopper - Remove and Install................1364
Seat - Remove and Install................1369
Steering Wheel - Remove and Install................1372
Steering Column - Remove and Install................1374
Steering Control (Force Control) - Remove and Install................1378
Steering Control (Force Control) - Disassemble................1382
Steering Control (Force Control) - Assemble................1386
Hydraulic Cylinder (Steering) - Remove and Install................1390
Hydraulic Cylinder (Steering) - Disassemble - Steering................1394
Hydraulic Cylinder (Steering) - Assemble - Steering................1400
Operator Platform - Remove and Install................1406
Piston Pump (Tamper Bar) - Remove and Install................1409
Control Valve (Vibratory) - Remove and Install................1411
Control Valve (Vibratory) - Disassemble................1412
Control Valve (Vibratory) - Assemble................1415
Screed - Remove and Install................1418
Main Frame Extension (Powered) - Remove and Install................1421
Main Frame Extension (Powered) - Disassemble................1423
Main Frame Extension (Powered) - Assemble................1425
Hydraulic Cylinder (Screed Hoist) - Remove and Install................1428
Solenoid Valve (Tow Point) - Remove and Install................1430
Counterbalance Valve (Hopper Hoist; Tow Point) - Remove and Install................1432
Counterbalance Valve (Hopper Hoist; Tow Point) - Disassemble................1434
Counterbalance Valve (Hopper Hoist; Tow Point) - Assemble................1436
Hydraulic Cylinder (Tow Point) - Remove and Install................1438
Tow Arm - Remove and Install................1441
Gear Motor (Ventilation System) - Remove and Install................1444
Gear Motor (Ventilation System) - Disassemble................1448
Gear Motor (Ventilation System) - Assemble................1450
Return Manifold and Oil Cooler Bypass Valve - Remove and Install................1452
Push Roller - Remove and Install................1456
Push Roller - Disassemble................1458
Push Roller - Assemble................1460
Control Valve (Truck Hitch) - Remove and Install................1462
Control Valve (Truck Hitch) - Disassemble................1464
Control Valve (Truck Hitch) - Assemble................1466
Truck Hitch - Remove and Install................1468
Truck Hitch - Disassemble................1470
Truck Hitch - Assemble................1475
Electric Motor (Washdown Pump) - Remove and Install................1480
Piston Pump (Hydraulic Fan) - Remove and Install................1482
Generator and Drive - Remove and Install................1485
Generator - Disassemble................1492
Generator - Assemble................1501
Power Inverter - Remove and Install................1511
Power Inverter - Disassemble................1516
Power Inverter - Assemble................1519
Caterpillar ASPHALT PAVERS AP-1000F Repair Service Manuals (SN Prefix AC4)
