Caterpillar AP-1000B and BG-260C Asphalt Pavers Repair Service Manual
Complete service repair manual with Electrical Wiring Diagrams for Caterpillar AP-1000B and BG-260C Asphalt Paver (S/N prefix 7HN, AGP), with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.
Caterpillar AP1000B and BG260C Asphalt Paver (S/N prefix 7HN, AGP) workshop service repair 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.
KENR2614 - Specifications; Systems Operation; Testing & Adjusting (AP-1050B & AP-1055B EXTEND-A-MAT SCREED).pdf
KENR2624 - Specifications; Systems Operation; Testing & Adjusting (AP-1050B & AP-1055B 10B PAVEMASTER SCREED).pdf
KENR2949 - Systems Operation (AP-1000B; AP-1050B; AP-1055B; AP-650B; BG-225C; BG-2455C; BG-245C and BG-260C Asphalt Pavers Propel Electronic Control System).pdf
KENR2949 - Testing and Adjusting (AP-1000B; AP-1050B; AP-1055B; AP-650B; BG-225C; BG-2455C; BG-245C and BG-260C Asphalt Pavers Propel Electronic Control System).pdf
KENR2949 - Troubleshooting (AP-1000B; AP-1050B; AP-1055B; AP-650B; BG-225C; BG-2455C; BG-245C and BG-260C Asphalt Pavers Propel Electronic Control System).pdf
KENR3503 - Disassembly and Assembly (3116 ENGINE SUPPLEMENT FOR CATERPILLAR AP-1000B ASPHALT PAVER).pdf
KENR3504 - Specifications; Systems Operation; Testing & Adjusting (AP-1000B and BG-260C Asphalt Pavers Propel System).pdf
KENR3506 - Specifications; Systems Operation; Testing & Adjusting (AP-1000B and BG-260C Asphalt Pavers Conveyor Systems).pdf
KENR3507 - Specifications (AP-1000B and BG-260C Asphalt Pavers Auxiliary System).pdf
KENR3507 - Systems Operation (AP-1000B and BG-260C Asphalt Pavers Auxiliary System).pdf
KENR3507 - Testing and Adjusting (AP-1000B and BG-260C Asphalt Pavers Auxiliary System).pdf
KENR3509 - Schematic (Caterpillar AP-1000B Asphalt Paver Barber-Greene BG-260C Asphalt Paver Hydraulic Schematic).pdf
KENR3510 - Disassembly and Assembly (CATERPILLAR AP-1000B ASPHALT PAVER & BARBER-GREENE BG-260C ASPHALT PAVER).pdf
KENR3511 - Schematic (AP-1000B and BG-260C Asphalt Paver Electrical System).pdf
KENR5002 - Specifications; Systems Operation; Testing & Adjusting (AP-1000B and BG-260C Asphalt Pavers Vibratory System).pdf
SENR4615 - Specifications; Systems Operation; Testing & Adjusting (SUPPLEMENT for 3114; 3116 AND 3126 ENGINES FOR CATERPILLAR).pdf
PRODUCT DETAILS:
Total Pages: 1,202 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
TABLE OF CONTENTS
KENR2614 - Specifications; Systems Operation; Testing & Adjusting (AP-1050B & AP-1055B EXTEND-A-MAT SCREED)................1
Introduction SMCS - 5056; 7479................2
Extender Cylinder SMCS - 5056; 7479................3
Vibratory Flow Control Valve SMCS - 5056; 7479................4
Systems Operation SMCS - 5056; 7479................5
Testing And Adjusting SMCS - 5056; 7479................33
KENR2624 - Specifications; Systems Operation; Testing & Adjusting (AP-1050B & AP-1055B 10B PAVEMASTER SCREED)................52
Introduction................53
Strike Off Cylinder................54
Vibratory Flow Control Valve................55
Testing And Adjusting................56
KENR2949 - Systems Operation (AP-1000B; AP-1050B; AP-1055B; AP-650B; BG-225C; BG-2455C; BG-245C and BG-260C Asphalt Pavers Propel Electronic Control System)................73
General Information................74
Normal Closed Loop Steering Control................76
Normal Closed Loop Speed Control................78
Open Loop Steering And Speed Control................80
Direction And Backup Alarm Control................82
Gear Control................84
Brake Control................86
Neutral Start Control................88
Implement Control................90
Propel Enable Control................91
Limp Home Control................92
Front Wheel Assist Control................93
Motor Displacement Control................96
ECM Modes................97
Diagnostic Operation................102
Electronic Control Module (ECM)................105
Switches................110
Sensors................117
Solenoids................123
Relays................126
Indicators................127
Cat Data Link................128
Harness Code................130
KENR2949 - Testing and Adjusting (AP-1000B; AP-1050B; AP-1055B; AP-650B; BG-225C; BG-2455C; BG-245C and BG-260C Asphalt Pavers Propel Electronic Control System)................132
Calibration................133
Speed Dial - Calibrate................138
Speed Lever - Calibrate................140
Steering Wheel - Calibrate................142
Brake Pedal - Calibrate................145
Steering - Calibrate................147
Initial Propel Current - Calibrate................149
Electrical Connector - Inspect................151
Wiring Harness (Open Circuit) - Test................160
Wiring Harness (Short Circuit) - Test................161
Electronic Control Module (ECM) - Replace................162
Glossary of Terms................163
System Schematic................165
KENR2949 - Troubleshooting (AP-1000B; AP-1050B; AP-1055B; AP-650B; BG-225C; BG-2455C; BG-245C and BG-260C Asphalt Pavers Propel Electronic Control System)................178
General Information................181
Service Tools................182
Connector Locations................183
Accessing Diagnostic Information................185
Initial Troubleshooting Procedure................188
Error Codes................190
Diagnostic Code List................192
Determining Diagnostic Codes................196
P01................200
P02................203
P03................206
CID 011 FMI F00................209
CID 011 FMI F01................214
CID 011 FMI F13................217
CID 012 FMI F00................219
CID 012 FMI F01................225
CID 012 FMI F13................229
CID 013 FMI F00................231
CID 013 FMI F01................237
CID 013 FMI F13................241
CID 014 FMI F00................243
CID 014 FMI F01................248
CID 014 FMI F13................252
CID 021 FMI F11................254
CID 022 FMI F11................258
CID 023 FMI F12................262
CID 024 FMI F12................266
CID 025 FMI F12................270
CID 030 FMI F08................274
CID 031 FMI F08................280
CID 032 FMI F08................286
CID 040 FMI F03................291
CID 040 FMI F05................294
CID 040 FMI F06................297
CID 041 FMI F03................300
CID 041 FMI F05................303
CID 041 FMI F06................307
CID 042 FMI F03................310
CID 042 FMI F05................313
CID 042 FMI F06................317
CID 043 FMI F03................320
CID 043 FMI F05................323
CID 043 FMI F06................326
CID 044 FMI F03................329
CID 044 FMI F05................332
CID 044 FMI F06................336
CID 045 FMI F03................339
CID 045 FMI F05................342
CID 045 FMI F06................346
CID 046 FMI F03................349
CID 046 FMI F05................352
CID 046 FMI F06................356
CID 047 FMI F03................359
CID 047 FMI F05................362
CID 047 FMI F06................366
CID 048 FMI F03................369
CID 048 FMI F05................372
CID 048 FMI F06................376
CID 060 FMI F03................379
CID 060 FMI F04................382
CID 061 FMI F03................385
CID 061 FMI F04................388
Power Supply Circuit of Electronic Control Module................392
Backup Alarm Always Off................396
Backup Alarm Always On................399
Vibratory; Grade; Slope Not Powered................401
Machine Pulls Left or Right on Initial Machine Movement................406
Auto Calibrations Are Not Accepted or Take a Long Time to Accept................407
PWM Sensor Calibrations Are Not Accepted................408
KENR3503 - Disassembly and Assembly (3116 ENGINE SUPPLEMENT FOR CATERPILLAR AP-1000B ASPHALT PAVER)................411
Air Cleaner SMCS - 1051-010................412
Muffler SMCS - 1062-010................413
Turbocharger SMCS - 1052-010................415
Fuel Priming & Primary Filter SMCS - 1258; 1260-010................417
Fuel Filter SMCS - 1261-010................418
Fuel & Water Separator SMCS - 1263-010................419
Alternator SMCS - 1405-010................420
Water Pump SMCS - 1361-010................421
Engine Oil Cooler SMCS - 1378-010................424
Starting Motor SMCS - 1453-010................426
Engine Speed Control Cylinder SMCS - 1915-010................428
Radiator SMCS - 1353-010................429
Hydraulic Oil Cooler SMCS - 1376-010................434
Engine SMCS - 1000-010................436
KENR3504 - Specifications; Systems Operation; Testing & Adjusting (AP-1000B and BG-260C Asphalt Pavers Propel System)................441
Hydraulic Tank SMCS - 5056; 7479................442
Hydraulic Oil Filter (Case Drain) SMCS - 5068; 5091................445
Control Manifold SMCS - 3206; 5051................447
Final Drive SMCS - 4054................448
Final Drive Planetary SMCS - 4050; 4084................451
Bogie SMCS - 4192................462
Front Wheel Assist SMCS - 4203; 4208................465
Piston Pump (Front Wheel Assist) SMCS - 5070................469
Piston Motor (Front Wheel Assist) SMCS - 5058................471
Front Wheel Drive Manifold SMCS - 3206; 5051................472
Hydraulic Oil Filter (Return) SMCS - 5068................473
General Information SMCS - 4351................475
Propel Hydraulic System SMCS - 5058; 5070................479
Piston Pump (Propel) SMCS - 5070................483
Piston Motor (Propel) SMCS - 5058................497
Front Wheel Assist Hydraulic System SMCS - 5058; 5070................504
Machine Preparation for Troubleshooting SMCS - 4350-035; 5050-035................506
Visual Inspection SMCS - 4350-040; 5050-040................508
Propel System Troubleshooting SMCS - 4350-035; 5050-035................510
Piston Pump Neutral - Test and Adjust SMCS - 5070-081; 5070-025................515
Relief Valve (Main) - Test and Adjust SMCS - 5069-025; 5069-081................522
Relief Valve (Charge) - Test and Adjust SMCS - 5117-025; 5117-081................527
Relief Valve (Front Wheel Assist) - Test and Adjust SMCS - 5117-025; 5117-081................530
Wheel Alignment - Check and Adjust SMCS - 4201-024; 4201-025; 4201-535................533
KENR3506 - Specifications; Systems Operation; Testing & Adjusting (AP-1000B and BG-260C Asphalt Pavers Conveyor Systems)................535
Hydraulic Tank SMCS - 5056; 7479................537
Control Valve (Conveyor) SMCS - 5051................540
Check Valve SMCS - 5067................542
Cooling Manifold SMCS - 3206................543
Hydraulic Oil Filter (Return) SMCS - 5068................544
Footshaft SMCS - 6630................546
Feeder Drive Shaft (Drag) SMCS - 5620................548
Conveyor Planetary Drive (Drag) SMCS - 5620; 5627; 5629................550
Conveyor Planetary Drive (Auger) SMCS - 5620; 5627; 5629................552
Feeder Guard SMCS - 6630................554
Auger Extension SMCS - 6282-XT; 6631-XT................555
Position Sensor (Paddle) SMCS - 5643; 5657................557
General Information SMCS - 6630; 6631................559
Conveyor Hydraulic System SMCS - 6630; 6631................568
Piston Pump (Conveyor) SMCS - 5070................585
Piston Motor (Conveyor) SMCS - 5058................588
Drag Conveyor SMCS - 6630................591
Conveyor Planetary Drive (Drag) SMCS - 5627; 5629................596
Auger Conveyor SMCS - 6631................598
Conveyor Planetary Drive (Auger) SMCS - 5058................603
Machine Preparation for Troubleshooting SMCS - 6630-035; 6631-035................605
Visual Inspection SMCS - 6630-035; 6630-040; 6631-035; 6631-040................607
Conveyor System Troubleshooting SMCS - 6630-035; 6631-035................609
Conveyor Hydraulic System Air - Purge SMCS - 6630-542-AI; 6631-542-AI................611
Pump Control Valve (Conveyor) - Test and Adjust SMCS - 5455-025; 5455-081................616
Conveyor Drive Chain (Auger) - Check and Adjust SMCS - 6631-025-CX; 6631-535-CX................623
Conveyor Drive Chain (Drag) - Check and Adjust SMCS - 6630-025-CX; 6630-535-CX................625
Conveyor Chain (Drag) - Check and Adjust SMCS - 6630-025-CX; 6630-535-CX................628
Conveyor Speed - Test and Adjust SMCS - 6630-025-VF; 6630-081-VF; 6631-025-VF; 6631-081-VF................630
KENR3507 - Specifications (AP-1000B and BG-260C Asphalt Pavers Auxiliary System)................632
Hydraulic Tank SMCS - 5056; 7479................633
Hydraulic Oil Filter (Return) SMCS - 5068................636
Control Manifold SMCS - 3206; 5051................638
Piston Pump (Auxiliary) SMCS - 5070................639
Control Valve (Hopper Hoist; Tow Point and Truck Hitch) SMCS - 5051................640
Hydraulic Cylinder (Tow Point) SMCS - 7562................642
Hydraulic Cylinder (Truck Hitch) SMCS - 7562................643
Truck Hitch SMCS - 7122................644
Pressure Reducing Valve (Truck Hitch) SMCS - 5051; 5117; 5467................645
Hydraulic Cylinder (Hopper Hoist) SMCS - 5102; 7562................646
Hydraulic Cylinder (Auger Hoist) SMCS - 5102; 7562................647
Hydraulic Cylinder (Screed Hoist) SMCS - 5102; 7562................649
Hydraulic Cylinder (Throttle Control) SMCS - 5057; 7562................651
Flow Control Valve (Ventilation System) SMCS - 5057; 5137; 6654................652
Shutoff Valve (Ventilation System) SMCS - 1329; 5057; 6654................653
Gear Motor (Ventilation System) SMCS - 5061; 6654................654
Control Valve (Generator) SMCS - 5051................655
Piston Pump (Generator) SMCS - 5070................658
Piston Motor (Generator) SMCS - 5058................661
Generator SMCS - 1404; 4450................663
Steering Column SMCS - 4310................666
Metering Pump (Steering) SMCS - 4312................667
Hydraulic Cylinder (Steering) SMCS - 7562................669
KENR3507 - Systems Operation (AP-1000B and BG-260C Asphalt Pavers Auxiliary System)................670
Graphic Color Codes SMCS - 1359; 4250; 4300; 5050................671
General Information SMCS - 5050................673
Auxiliary Hydraulic System SMCS - 4300; 5005; 5050................683
Piston Pump (Auxiliary) SMCS - 5070................697
Bank Valve (Auger Hoist; Counterbalance and Screed Hoist) SMCS - 5051................700
Metering Pump (Steering) SMCS - 4312................704
KENR3507 - Testing and Adjusting (AP-1000B and BG-260C Asphalt Pavers Auxiliary System)................710
Machine Preparation for Troubleshooting SMCS - 5050-035................711
Visual Inspection SMCS - 5050-040................713
Auxiliary System Troubleshooting SMCS - 5050-035................715
Pressure Reducing Valve - Test and Adjust SMCS - 5117-025; 5117-081................717
KENR3509 - Schematic (Caterpillar AP-1000B Asphalt Paver Barber-Greene BG-260C Asphalt Paver Hydraulic Schematic)................719
Collage................719
Main................749
KENR3510 - Disassembly and Assembly (CATERPILLAR AP-1000B ASPHALT PAVER & BARBER-GREENE BG-260C ASPHALT PAVER)................751
Vibratory Pump SMCS - 5652-010; 5652-015................753
Fuel Pump & Motor (Screed Burner & Wash Down) SMCS - 1295-010; 1295-017................760
Auxiliary Pump SMCS - 5070-010................763
Feeder Pumps SMCS - 4351-010; 4351-017................778
Propel Pump SMCS - 3203-017; 3203-010................798
Pump Drive Group SMCS - 3108-010; 3108-O17................827
Right Grade Control & Hopper Hoist Valve Group SMCS - 5479-010; 5479-017................835
Left Grade Control & Truck Hitch Valve Group SMCS - 5479-010................840
Propel Control Solenoids SMCS - 5479-010; 5479-17................843
Two-Stack Control Valve SMCS - 5479-010; 5479-015................846
Screed Counterbalance Valve SMCS - 5420-010; 5420-015................859
Throttle; Brake & Travel_Pave Control Manifold SMCS - 5479-010; 5479-017................865
Feeder Drag Conveyor Motor SMCS - 3203-010; 3203-017................878
Hydraulic Return Filter SMCS - 5068-010; 5068-015................886
Hydraulic Oil Tank SMCS - 5056-010................889
Feeder (Conveyor) Return Manifold & Hydraulic Filter SMCS - 5068-010; 5068-015................893
Right Feeder (Conveyor) Control Manifold SMCS - 5264-010................896
Left Feeder (Conveyor) Control Manifold SMCS - 5264-010; 5264-015................898
Push Roller SMCS - 7122-010................905
Truck Hitch Group SMCS - 7122-010; 7122-015................907
Screed Lift Cylinder SMCS - 7562-010; 7562-015................914
Screed SMCS - 6640-010................917
Auger Group SMCS - 6631-010................919
Tow Arm SMCS - 7121-010................922
Auger Lift Cylinder SMCS - 7562-010; 7562-015................924
Auger Motor SMCS - 4351-010; 4351-015................927
Feeder Drag Conveyor Planetary & Chain SMCS - 5629-015; 6630-010................935
Auger Planetary & Chain SMCS - 5629-015; 6630-010................942
Auger (Screw Conveyor) SMCS - 6631-015; 6631-010................947
Propel System Electronic Control Module SMCS - 1901-010................951
Feeder System Electronic Control Module SMCS - 1901-010................952
Junction Box SMCS - 7426-010................953
Steering Wheel SMCS - 4309-010................955
Hand Metering Unit (HMU) SMCS - 4312-016; 4312-015................957
Hopper Hoist Cylinder SMCS - 7562-010; 7562-015................965
Hopper SMCS - 6639-010................968
Feeder Drag Conveyor SMCS - 6630-010................971
Front Wheel Assist Pump................974
Front Wheel Assist Manifold SMCS - 5264-010................990
Front Wheel Assist Motor SMCS - 4351-010................992
Bogie Wheel SMCS - 7217-010................994
Bogie Spindle SMCS - 7217-010................996
Bogie Assembly SMCS - 7217-010................999
Steering Cylinder SMCS - 4303-010................1001
Steering Sensor SMCS - 4806-010................1002
Propel Motor & Planetary SMCS - 4093-010; 4093-029; 4351-015; 4351................1004
Propel Planetary SMCS - 4093-015; 4093-016................1025
Drive Wheels SMCS - 4199-010................1050
Generator Pump SMCS - 5070-010; 5070-017................1052
Generator Control Valve SMCS - 5051-010................1058
Generator Motor SMCS - 5061-010................1059
Generator SMCS - 4450-010................1061
KENR3511 - Schematic (AP-1000B and BG-260C Asphalt Paver Electrical System)................1064
Collage................1064
Main................1096
KENR5002 - Specifications; Systems Operation; Testing & Adjusting (AP-1000B and BG-260C Asphalt Pavers Vibratory System)................1098
Hydraulic Tank SMCS - 5056; 7479................1099
Gear Motor (Vibratory) SMCS - 5061; 5651................1102
Cooling Manifold SMCS - 3206................1104
Hydraulic Oil Filter (Return) SMCS - 5068................1105
General Information SMCS - 5651; 5652................1107
Vibratory Hydraulic System SMCS - 6606................1111
Gear Pump (Vibratory) SMCS - 5073; 5652................1119
Machine Preparation for Troubleshooting SMCS - 5050-035; 6606-035................1124
Visual Inspection SMCS - 6606-035; 6606-040................1126
Vibratory System Troubleshooting SMCS - 5050-035; 6606-035................1128
Relief Valve (Vibratory Pump) - Test SMCS - 5073-081; 5652-081................1130
Vibratory Shaft Speed - Test and Adjust SMCS - 5622-025; 5622-081................1137
SENR4615 - Specifications; Systems Operation; Testing & Adjusting (SUPPLEMENT for 3114; 3116 AND 3126 ENGINES FOR CATERPILLAR)................1140
Introduction................1141
Primary Fuel Filter................1142
Fuel Pressure Switch................1143
Oil Pan Group................1144
Oil Pressure Switch................1145
Transmission Oil Temperature Switch................1148
Water Temperature Regulator................1149
Coolant Temperature Switch................1151
Aftercooler Group................1154
Air Cleaner Group................1155
Air Lines Group................1157
Blower Fan Group................1158
Exhaust Extension Group................1162
Muffler Group................1163
Fan Drive................1167
Pump Drive Group................1168
Flexible Coupling Group................1170
Torque Converter Group................1171
Alternators And Regulators................1173
Starting Motor................1183
Alternator Mounting Group................1190
Service Meter................1191
Speed Sensor (Magnetic)................1192
Systems Operation................1193
Testing and Adjusting................1194
Caterpillar AP-1000B and BG-260C Asphalt Pavers Repair Service Manual
