Procedure to Install Conveyor and Auger Sonic Sensors on AP255E, Paver {1408, 5657} Caterpillar

Asphalt Paver:

AP255E (S/N: D8A1-UP)

Introduction

The following instructions provide the steps needed to install the conveyor and auger sonic sensors on AP255E Asphalt Paver. Read the entire Special Instruction. Understand the information before you perform any procedures or order any parts.

Safety Section

Show/hide table

DO NOT OPERATE OR WORK ON THIS MACHINE UNLESS YOU HAVE READ AND UNDERSTAND THE INSTRUCTIONS AND WARNINGS IN THE OPERATION AND MAINTENANCE MANUALS. FAILURE TO FOLLOW THE INSTRUCTIONS OR HEED THE WARNINGS COULD RESULT IN INJURY OR DEATH. CONTACT ANY CATERPILLAR DEALER FOR REPLACEMENT MANUALS. PROPER CARE IS YOUR RESPONSIBILITY.

Show/hide table

Hot parts or hot components can cause burns or personal injury. Do not allow hot parts or components to contact your skin. Use protective clothing or protective equipment to protect your skin.

Work safely. Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skills, and tools in order to perform these functions properly. Safety precautions and warnings are provided in this instruction and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons. Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. Therefore, the warnings in this publication and the warnings that are on the product are not all inclusive. If a tool, a procedure, a work method, or operating technique that is not recommended by Caterpillar is used, make sure that procedure is safe for you and for other people to use.

Machine Preparation

Show/hide table



Illustration 1	g03828059

1. Attach a ""Do not Operate"" warning tag or a similar warning tag to the start switch or to the controls before you service the equipment or before you repair the equipment. These warning tags Special Instruction, SEHS7332, are available from your Cat dealer.

2. Park the machine on a smooth surface and extend out both the extenders and screed then lower both to the ground.

3. Switch off the machine.

Conveyor Sonic Sensor Installation

Required Parts

Show/hide table



Illustration 2	g03828062
(3) 471-8265 Support As (4) 471-8266 Plates

1. Pre- assemble two 471-8266 Plates (4) with one 471-8265 Support As (3) as shown in Illustration 2

Show/hide table



Illustration 3	g03828108
(1) 471-8263 Support As (2) 471-8264 Clamp As (6) 124-7346 Lockwasher (10) 8T-4137 Bolt (13) 9X-2027 Washer

2. Pre-assemble 471-8263 Support As (1 ) with 471-8264 Clamp As (2), using one 124-7346 Lockwasher (6), one 9X-2027 Washer (13), and one 8T-4137 Bolt (10) .

Show/hide table



Illustration 4	g03828137
(1) 471-8263 Support As (2) 471-8264 Clamp As (5) 471-8267 Position Sensor (9) 8T-0389 Locknut (11) 8T-4185 Bolt (13) 9X-2027 Washer

3. Assemble 471-8267 Position Sensor (5) into 471-8264 Clamp As (2) previously installed on support (1) using one 8T-4185 Bolt (11), one 9X-2027 Washer (13), and one 8T-0389 Locknut (9) .

Show/hide table



Illustration 5	g03828167
(A) Assembly from Step 2 and 3 (B) Step 1 (10) 8T-4137 Bolt

4. Assemble the sonic sensor group from Steps 2 and 3 (A) onto the pre-assembly done in Step 1 (B) using one 8T-4137 Bolt (10) .

5. Repeat the assembly process Steps 1 through Step 4 a second time for the second sensor.

Show/hide table



Illustration 6	g03828191
(C) Preassemble group (D) Auger bar (9) 8T-0389 Locknut (12) 8T-5005 Bolt (13) 9X-2027 Washer

6. Install pre-assembled group (C) on auger bar (D) using one 8T-5005 Bolt (12), one 9X-2027 Washer (13), and one 8T-0389 Locknut (9) .

Show/hide table



Illustration 7	g03828439
(E) Sonic sensor left-hand connection (F) Sonic sensor right -hand connection (G) Connection to machine harness (K3) (H) Connection to ground (7) 471-8268 Cable As (8) 6V-4248 Bolt (13) 9X-2027 Washer

7. Install 471-8268 Cable As (7) onto the rear frame of the machine. Secure mounting tab of 471-8268 Cable As (7) using one 6V-4248 Bolt (8) and one 9X-2027 Washer (13) .

   Refer to Illustrations 7 and 8 for installation of ground connection (H) .

Show/hide table



Illustration 8	g03828456
(H) Ground cable (14) 8T-0642 Bolt (15) 9M-1974 Hard Washer

8. Attach ground cable (H) to the inner side of the frame (radiator side) using one 8T-0642 Bolt (14) and two 9M-1974 Hard Washers (15) .

Show/hide table



Illustration 9	g03828487
(G) K3 connection (7) 471-8268 Cable As

9. Connect 471-8268 Cable As (7) to the machine cable harness at cable K3 (G) .

Auger Sonic Sensor Installation

Required Parts

Show/hide table



Illustration 10	g03828607
(1) 471-8263 Support As (2) 471-8264 Clamp As (5) 124-7346 Lockwasher (9) 8T-4137 Bolt (12) 9X-2027 Washer

1. Pre-assemble 471-8263 Support As (1 ) with 471-8264 Clamp As (2), using one 124-7346 Lockwasher (5), one 9X-2027 Washer (12), and one 8T-4137 Bolt (9) .

Show/hide table



Illustration 11	g03828645
(1) 471-8263 Support As (2) 471-8264 Clamp As (3) 471-8267 Position Sensor (8) 8T-0389 Locknut (10) 8T-4185 Bolt (12) 9X-2027 Washer

2. Assemble 471-8267 Position Sensor (3) into 471-8264 Clamp As (2) previously installed on support (1) using one 8T-4185 Bolt (10), one 9X-2027 Washer (12), and one 8T-0389 Locknut (8) .

Show/hide table



Illustration 12	g03828671

3. Assemble the sonic sensor pre-assembly (A) onto 481-2984 Support (4) using one 8T-4137 Bolt (9) .

4. Assemble 481-2984 Support (4) to the screed end gate using the existing threaded holes using two 8T-4192 Bolts (11), and two 5P-8245 Hard Washers (6) .

   Note: If you have a machine with an S/N below S/N:D8A286 refer to Step 5, if not continue to Step 6.

Show/hide table



Illustration 13	g03828703
(4) 481-2984 Support

5. The removal of the end-gate plate circled in Illustration 13 must be done before assembling the 481-2984 support (4) onto the screed end gate.

Show/hide table



Illustration 14	g03828724
(B) Machine connection (13) 471-8269 Control Cable Gp

6. Assemble 471-8269 Control Cable Gp (13) on the connector present on the rear wall of the machine frame (B) to the connection on the 471-8267 Position Sensor (3) .

7. Repeat Steps 1 through Step 7 to complete the second sensor.