Caterpillar ASPHALT PAVERS AP-1055D, BG-2455D Repair Service Manuals
Complete service repair manuals with electrical wiring diagrams for Caterpillar ASPHALT PAVERS AP-1055D, BG-2455D, with all the workshop service information to maintain, diagnose, repair, rebuild.
Caterpillar ASPHALT PAVERS AP1055D, BG2455D 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.
KENR5009-02 - Schematic (AP-1055D and BG-2455D Asphalt Paver Electrical System).pdf
KENR5043-01 - Disassembly & Assembly (AP-1055D and BG-2455D Asphalt Paver Engine Supplement).pdf
KENR5044 - Specifications (AP-1055D and BG-2455D Asphalt Pavers Propel Systems).pdf
KENR5044 - Systems Operation (AP-1055D and BG-2455D Asphalt Pavers Propel Systems).pdf
KENR5044 - Testing and Adjusting (AP-1055D and BG-2455D Asphalt Pavers Propel Systems).pdf
KENR5045 - Specifications (AP-1055D and BG-2455D Asphalt Pavers Conveyor Systems).pdf
KENR5045 - System Operation (AP-1055D and BG-2455D Asphalt Pavers Conveyor Systems).pdf
KENR5045 - Testing and Adjusting (AP-1055D and BG-2455D Asphalt Pavers Conveyor Systems).pdf
KENR5046 - Specifications (AP-1055D and BG-2455D Asphalt Pavers Auxiliary Systems).pdf
KENR5046 - Systems Operation (AP-1055D and BG-2455D Asphalt Pavers Auxiliary Systems).pdf
KENR5046 - Testing and Adjusting (AP-1055D and BG-2455D Asphalt Pavers Auxiliary Systems).pdf
KENR5048-03 - Disassembly & Assembly (AP-1055D and BG-2455D Asphalt Paver Machine System).pdf
KENR5049-03 - Schematic (AP-1055D and BG-2455D Asphalt Paver Hydraulic System).pdf
KENR8694-02 - Schematic (AP-1055D & BG-2455D Asphalt Paver Electrical System).pdf
Total Pages: 1,371 pages
File Format: PDF (bookmarked, ToC, Searchable, Printable, high quality)
Manual Type: Disassembly & Assembly, Testing & Adjusting, Specifications, Systems Operation, Electrical Schematic, Troubleshooting...
Language: English
AP-1055D ASPHALT PAVER A6P
AP-1055D ASPHALT PAVER FAC
BG-2455D ASPHALT PAVER BNW
BG-2455D ASPHALT PAVER BXW
TABLE OF CONTENTS
KENR5009-02 - Schematic (AP-1055D and BG-2455D Asphalt Paver Electrical System)................1
Main................2
Collage................6
KENR5043-01 - Disassembly & Assembly (AP-1055D and BG-2455D Asphalt Paver Engine Supplement)................38
Air Cleaner - Remove and Install................39
Exhaust (Muffler) - Remove and Install................45
Battery - Remove and Install................47
Alternator - Remove and Install................49
Electric Starting Motor - Remove and Install................54
Water Separator (Fuel Priming Pump and Primary Fuel Filter) - Remove................56
Water Separator (Fuel Priming Pump and Primary Fuel Filter) - Disassemble................58
Water Separator (Fuel Priming Pump and Primary Fuel Filter) - Assemble................61
Water Separator (Fuel Priming Pump and Primary Fuel Filter) - Install................64
Fan - Remove and Install................65
Gear Pump (Fan Drive) - Remove................68
Gear Pump (Fan Drive) - Disassemble................72
Gear Pump (Fan Drive) - Assemble................76
Gear Pump (Fan Drive) - Install................80
Control Valve (Fan Drive) - Remove and Install................84
Gear Motor (Fan Drive) - Remove................95
Gear Motor (Fan Drive) - Disassemble................97
Gear Motor (Fan Drive) - Assemble................103
Gear Motor (Fan Drive) - Install................109
Radiator; Air Cooler; and Hydraulic Oil Cooler - Remove................110
Radiator; Air Cooler; and Hydraulic Oil Cooler - Install................122
Engine - Remove................132
Engine - Install................139
KENR5044 - Specifications (AP-1055D and BG-2455D Asphalt Pavers Propel Systems)................146
Hydraulic Tank................147
Piston Pump (Propel)................151
Hydraulic Oil Filter (Charge Pump)................155
Hydraulic Oil Filter (Return)................156
Final Drive Planetary (Mobil-Trac)................157
Track Roller Frame (Mobil-Trac)................160
Bogie (Mobil-Trac)................163
Midroller (Mobil-Trac)................165
Track Tensioner (Mobil-Trac)................167
Final Drive (Mobil-Trac)................169
Hydraulic Cylinder (Track Tension)................171
Manifold Valve (Track Tension)................173
KENR5044 - Systems Operation (AP-1055D and BG-2455D Asphalt Pavers Propel Systems)................175
Graphic Color Codes................176
Introduction................178
Propel System................180
Location of Electrical Components................198
Location of Hydraulic Components................200
Piston Pump (Propel)................202
Piston Motor (Propel)................210
Final Drive Planetary................213
Parking Brake................217
Electrical Schematic (Propel System)................219
Hydraulic Schematic (Propel System)................232
KENR5044 - Testing and Adjusting (AP-1055D and BG-2455D Asphalt Pavers Propel Systems)................238
Machine Preparation for Troubleshooting................239
Visual Inspection................241
Propel System Troubleshooting................245
Hydraulic Oil Contamination - Test................249
Piston Pump Flow - Test................251
Piston Pump Neutral - Test and Adjust................256
Pump Synchronization - Test and Adjust................261
Relief Valve (Charge) - Test and Adjust................269
Pressure Limiter Valve - Test and Adjust................280
Seal Leakage (Brake Piston) - Test................291
Solenoid (Shift) - Test................294
Lever (Propel Control) and Electronic Sensor - Test................299
Harness (Speed Potentiometer) and Electronic Sensor - Test................306
Track Alignment................312
Rotary Position Sensor (Steering) - Test and Adjust................318
Accumulator (Track Tension) - Test and Charge................323
Speed Sensor (Propel Motor) - Adjust................332
Rotary Position Sensor (Brake Pedal) - Test and Adjust................342
KENR5045 - Specifications (AP-1055D and BG-2455D Asphalt Pavers Conveyor Systems)................347
Hydraulic Tank................348
Piston Pump (Conveyor)................352
Piston Motor (Conveyor)................356
Hydraulic Oil Filter (Return)................357
Position Sensor (Paddle)................358
Conveyor Drive (Drag)................360
Conveyor Planetary Drive (Auger)................363
Conveyor Planetary Drive (Drag)................364
Drag Conveyor................365
Auger Conveyor................366
Footshaft................368
Auger Extension................370
KENR5045 - System Operation (AP-1055D and BG-2455D Asphalt Pavers Conveyor Systems)................371
Introduction................372
Conveyor System................374
Location of Electrical Components................389
Location of Hydraulic Components................391
Piston Pump (Conveyor) - Auger Conveyor and Drag Conveyor................393
Piston Motor (Conveyor) - Auger Conveyor and Drag Conveyor................399
Electrical Schematic................404
Hydraulic Schematic - Material Feed Hydraulic System................410
KENR5045 - Testing and Adjusting (AP-1055D and BG-2455D Asphalt Pavers Conveyor Systems)................416
Machine Preparation for Troubleshooting................417
Visual Inspection................419
Hydraulic Oil Contamination - Test................423
Piston Pump Flow - Test - Conveyor and Auger................425
Relief Valve (Charge) - Test and Adjust................431
Relief Valve (Main) - Test - Drag Conveyor and Auger Conveyor................444
Piston Pump (Auger Conveyor and Drag Conveyor) Neutral - Test and Adjust................466
Conveyor Drive Chain (Auger) - Check and Adjust................484
Conveyor Drive Chain (Drag) - Check and Adjust................487
Conveyor Chain (Drag) - Check and Adjust................490
Piston Motor Case Drain Flow - Test................495
KENR5046 - Specifications (AP-1055D and BG-2455D Asphalt Pavers Auxiliary Systems)................505
Oil Cooler Bypass Valve................506
Piston Pump (Auxiliary)................508
Control Valve (Auxiliary)................509
Counterbalance Valve (Tow Point)................511
Hydraulic Cylinder (Tow Point)................512
Hydraulic Cylinder (Truck Hitch)................514
Truck Hitch................516
Hydraulic Cylinder (Hopper Hoist)................518
Hydraulic Cylinder (Auger Hoist)................520
Manifold Valve (Screed Counterbalance)................522
Hydraulic Cylinder (Screed Hoist)................524
Gear Pump (Hydraulic Fan)................525
Control Valve (Hydraulic Fan)................526
Gear Motor (Hydraulic Fan)................527
Control Valve (Vibratory)................528
Flow Control Valve (Ventilation System)................530
Gear Motor (Ventilation System)................532
Piston Pump (Generator)................533
Piston Motor (Generator)................535
Generator................536
KENR5046 - Systems Operation (AP-1055D and BG-2455D Asphalt Pavers Auxiliary Systems)................537
General Information (Cooling System)................539
Graphic Color Codes................543
Location of Components (Cooling System)................545
Electrical System (Cooling)................547
Hydraulic Oil Cooler................554
Oil Cooler Bypass Manifold................555
Cooling Fan Manifold................557
Gear Pump (Hydraulic Fan)................558
Gear Motor (Hydraulic Fan)................559
Electrical Schematic (Hydraulic Fan)................560
Hydraulic Schematic (Hydraulic Fan)................562
General Information (Generator System)................564
Location Of Components (Generator System)................565
Operator Controls (Generator)................567
Piston Pump (Generator)................570
Control Valve (Generator)................574
Piston Motor (Generator)................576
Electrical Schematic (Generator System)................578
Hydraulic Schematic (Generator System)................580
General Information (Vibratory System)................584
Location of Components (Vibratory System)................586
Electrical System (Vibratory)................588
Bypass Manifold (Vibratory)................593
Gear Pump (Vibratory)................595
Gear Motor (Vibratory)................596
Electrical Schematic (Vibratory System)................597
Hydraulic Schematic (Vibratory System)................599
General Information (Washdown System)................601
Location of Components (Washdown System)................602
Electrical Schematic (Washdown System)................606
General Information (Auxiliary Hydraulic System)................608
Auxiliary Hydraulic System................610
Location of Electrical Components (Auxiliary Hydraulic System)................614
Location of Hydraulic Components (Auxiliary Hydraulic System)................616
Operator Controls (Auxiliary System)................618
Electrical System (Auxiliary System)................625
Piston Pump (Auxiliary)................630
Control Valve (Auxiliary Manifold)................633
Manifold Valve (Screed Counterbalance)................637
Tow Point Control................639
Truck Hitch................641
Paver Ventilation................643
Electrical Schematic (Auxiliary Hydraulic System)................645
Hydraulic Schematic (Auxiliary Hydraulic System)................654
KENR5046 - Testing and Adjusting (AP-1055D and BG-2455D Asphalt Pavers Auxiliary Systems)................662
Machine Preparation for Troubleshooting................663
Visual Inspection................665
Auxiliary System Troubleshooting................669
Hydraulic Oil Contamination - Test................673
Piston Pump Flow (Auxiliary) - Test and Adjust................675
Piston Pump Case Drain Flow (Auxiliary) - Test................680
Gear Pump Flow (Vibratory) - Test................685
Gear Pump Flow (Cooling Fan) - Test................692
Pump Control Valve (Auxiliary) - Test and Adjust................698
Pressure Reducing Valve - Test and Adjust................702
Relief Valve (Vibratory) - Test and Adjust................706
Gear Motor Case Drain Flow (Generator) - Test................711
Pump Control Valve (Generator) - Test and Adjust................716
Piston Pump Case Drain Flow (Generator) - Test................722
Fan Speed (Ventilation) - Test................727
Generator Frequency - Test and Adjust................732
KENR5048-03 - Disassembly & Assembly (AP-1055D and BG-2455D Asphalt Paver Machine System)................736
Hydraulic System Pressure - Release................742
Battery and Battery Cable - Separate and Connect................743
Fuel Tank - Remove and Install................745
Fuel Pump (Screed Burner) - Remove................762
Fuel Pump (Screed Burner) - Disassemble................765
Fuel Pump (Screed Burner) - Assemble................768
Fuel Pump (Screed Burner) - Install................771
Hydraulic Oil Filter (Return) - Remove................773
Hydraulic Oil Filter (Return) - Disassemble................776
Hydraulic Oil Filter (Return) - Assemble................778
Hydraulic Oil Filter (Return) - Install................780
Hydraulic Tank - Remove and Install................784
Gear Pump (Conveyor System Charge; Vibratory) - Remove................796
Gear Pump (Conveyor System Charge; Vibratory) - Disassemble................798
Gear Pump (Conveyor System Charge; Vibratory) - Assemble................803
Gear Pump (Conveyor System Charge; Vibratory) - Install................808
Hydraulic Oil Filter (Conveyor System Charge; Vibratory) - Remove and Install................809
Piston Pump (Left Drag Conveyor and Right Auger Conveyor) - Remove................812
Piston Pump (Right Drag Conveyor and Left Auger Conveyor) - Remove................816
Piston Pump (Conveyor) - Disassemble................820
Piston Pump (Conveyor) - Assemble................837
Piston Pump (Left Drag Conveyor and Right Auger Conveyor) - Install................854
Piston Pump (Right Drag Conveyor and Left Auger Conveyor) - Install................857
Piston Motor (Drag Conveyor) - Remove................860
Piston Motor (Drag Conveyor) - Disassemble................862
Piston Motor (Drag Conveyor) - Assemble................867
Piston Motor (Drag Conveyor) - Install................872
Chain (Drag Conveyor) - Remove and Install................873
Final Drive Planetary (Drag Conveyor) - Remove................878
Final Drive Planetary (Drag Conveyor) - Disassemble................880
Final Drive Planetary (Drag Conveyor) - Assemble................888
Final Drive Planetary (Drag Conveyor) - Install................896
Drag Conveyor - Remove and Install................898
Feeder Drive Shaft Group - Remove................903
Feeder Drive Shaft Group - Disassemble................906
Feeder Drive Shaft Group - Assemble................910
Feeder Drive Shaft Group - Install................915
Footshaft - Remove................919
Footshaft - Disassemble................920
Footshaft - Assemble................924
Footshaft - Install................929
Plates (Drag Pans) - Remove and Install................930
Piston Motor (Auger Conveyor) - Remove................933
Piston Motor (Auger Conveyor) - Disassemble................935
Piston Motor (Auger Conveyor) - Assemble................940
Piston Motor (Auger Conveyor) - Install................945
Chain (Auger Conveyor) - Remove and Install................946
Final Drive Planetary (Auger Conveyor) - Remove................949
Final Drive Planetary (Auger Conveyor) - Disassemble................952
Final Drive Planetary (Auger Conveyor) - Assemble................960
Final Drive Planetary (Auger Conveyor) - Install................968
Hydraulic Cylinder (Auger Hoist) - Remove and Install................971
Auger Conveyor - Remove and Install................975
Auger - Remove................979
Auger - Disassemble................982
Auger - Assemble................984
Auger - Install................986
Hydraulic Oil Filter (Propel System Charge) - Remove and Install................989
Piston Pump (Right Propel) - Remove................992
Piston Pump (Left Propel) - Remove................995
Piston Pump (Right Propel) - Install................998
Piston Pump (Left Propel) - Install................1000
Piston Motor (Propel) - Remove................1002
Piston Motor (Propel) - Disassemble................1003
Piston Motor (Propel) - Assemble................1012
Piston Motor (Propel) - Install................1022
Brake Pump and Valve - Remove................1023
Brake Pump and Valve - Disassemble................1025
Brake Pump and Valve - Assemble................1027
Brake Pump and Valve - Install................1029
Pump Drive - Remove................1030
Pump Drive - Disassemble................1032
Pump Drive - Assemble................1035
Pump Drive - Install................1038
Belt - Remove................1040
Belt - Install................1044
Track Roller Frame (Front) - Remove................1048
Track Roller Frame (Rear) - Remove................1052
Belt Tensioner - Remove................1054
Belt Tensioner - Disassemble................1056
Belt Tensioner - Assemble................1060
Belt Tensioner - Install................1065
Hydraulic Cylinder (Belt Tensioner) - Remove and Install................1067
Bogie (Front) - Remove................1071
Bogie (Rear) - Remove................1073
Bogie - Disassemble................1075
Bogie - Assemble................1078
Bogie (Front) - Install................1082
Bogie (Rear) - Install................1084
Track Roller Frame (Front) - Install................1086
Track Roller Frame (Rear) - Install................1089
Accumulator Charging Valve (Belt Tensioner) - Remove................1091
Accumulator Charging Valve (Belt Tensioner) - Disassemble................1093
Accumulator Charging Valve (Belt Tensioner) - Assemble................1095
Accumulator Charging Valve (Belt Tensioner) - Install................1097
Accumulator (Belt Tensioner) - Remove and Install................1098
Wheel (Final Drive) - Remove and Install................1101
Final Drive Planetary - Remove................1104
Final Drive Planetary - Disassemble................1107
Duo-Cone Conventional Seals - Install................1125
Final Drive Planetary - Assemble................1136
Final Drive Planetary - Install................1153
Piston Pump (Auxiliary) - Remove................1156
Piston Pump (Auxiliary) - Disassemble................1159
Piston Pump (Auxiliary) - Assemble................1167
Piston Pump (Auxiliary) - Install................1174
Pressure Reducing Valve (Truck Hitch) - Remove and Install................1176
Hydraulic Cylinder (Hopper Hoist) - Remove and Install................1179
Hopper - Remove and Install................1184
Seat - Remove and Install................1189
Steering Wheel - Remove and Install................1191
Steering Column - Remove................1194
Steering Column - Disassemble................1196
Steering Column - Assemble................1201
Steering Column - Install................1205
Operator Platform - Remove and Install................1207
Control Valve (Vibratory) - Remove................1211
Control Valve (Vibratory) - Disassemble................1213
Control Valve (Vibratory) - Assemble................1215
Control Valve (Vibratory) - Install................1217
Screed - Remove and Install................1218
Hydraulic Cylinder (Screed Hoist) - Remove and Install................1222
Solenoid Valve (Tow Point) - Remove and Install................1226
Counterbalance Valve (Tow Point) - Remove................1229
Counterbalance Valve (Tow Point) - Disassemble................1231
Counterbalance Valve (Tow Point) - Assemble................1233
Counterbalance Valve (Tow Point) - Install................1235
Hydraulic Cylinder (Tow Point) - Remove and Install................1236
Tow Arm - Remove and Install................1239
Gear Motor (Ventilation System) - Remove................1243
Gear Motor (Ventilation System) - Disassemble................1246
Gear Motor (Ventilation System) - Assemble................1248
Gear Motor (Ventilation System) - Install................1250
Return Manifold and Oil Cooler Bypass Valve - Remove and Install................1252
Track - Remove................1255
Track - Install................1258
Push Roller - Remove................1263
Push Roller - Disassemble................1265
Push Roller - Assemble................1267
Push Roller - Install................1269
Transverse Beam - Remove and Install................1271
Control Valve (Truck Hitch) - Remove................1273
Control Valve (Truck Hitch) - Disassemble................1276
Control Valve (Truck Hitch) - Assemble................1279
Control Valve (Truck Hitch) - Install................1282
Piston Pump (Hydraulic Generator) - Remove................1284
Piston Pump (Hydraulic Generator) - Disassemble................1287
Piston Pump (Hydraulic Generator) - Assemble................1296
Piston Pump (Hydraulic Generator) - Install................1304
Control Valve (Hydraulic Generator) - Remove................1306
Control Valve (Hydraulic Generator) - Disassemble................1308
Control Valve (Hydraulic Generator) - Assemble................1310
Control Valve (Hydraulic Generator) - Install................1312
Piston Motor (Hydraulic Generator) - Remove................1313
Piston Motor (Hydraulic Generator) - Disassemble................1316
Piston Motor (Hydraulic Generator) - Assemble................1321
Piston Motor (Hydraulic Generator) - Install................1326
Hydraulic Generator - Remove................1328
Hydraulic Generator - Install................1334
KENR5049-03 - Schematic (AP-1055D and BG-2455D Asphalt Paver Hydraulic System)................1339
main................1340
Features................1340
Cover Page................1341
Information................0
Component Location................1342
Tap Location................1343
Fluid Power Symbols................1344
Electrical Symbols................1345
Schematic................1346
Machine Views................0
Machine Component Locations................1347
Two Point Control................1348
Truck Hitch................1349
Propel Pumps and Filters................1350
Hydraulic Tank................1351
Conveyor Pumps................1352
Auxiliary Control Valve................1353
Auger/Conveyor Control Circuit................1354
collage................1355
KENR8694-02 - Schematic (AP-1055D & BG-2455D Asphalt Paver Electrical System)................1371
Caterpillar ASPHALT PAVERS AP-1055D, BG-2455D Repair Service Manuals
