Procedure to Install Grade Sensor Mounting Brackets on Certain Asphalt Pavers and Asphalt Screeds {1408, 1439, 5645, 7000, 7050, 7220} Caterpillar

Asphalt Paver

AP1000F (S/N: AC41-UP)

AP1055F (S/N: TJ51-UP; RLM1-UP)

AP655F (S/N: 4801-UP; 4521-UP; 4531-UP; P651-UP; 6551-UP; AC61-UP; MH61-UP; ML61-UP; 4791-UP)

Asphalt Screed

SE60VT XW (S/N: E991-UP; TLW1-UP)

Introduction

This Special Instruction provides parts information and procedure to install optional grade and slope sensor mounting brackets on machines listed above.

The optional sensor mounting bracket ensures improved paving performance over a wide range of paving speeds.

Do not perform any procedure in this Special Instruction until you have read the information and you understand the information.

Reference Section

Reference: Disassembly and Assembly, UENR4559, End Gate - Remove and Install

Safety Section

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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 your Cat dealer for replacement manuals. Proper care is your responsibility.

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Improper operation, lubrication, maintenance or repair of this product can be dangerous and could result in injury or death. Do not operate or perform any lubrication, maintenance or repair on this product, until you have read and understood the operation, lubrication, maintenance and repair information.

Required Parts

Procedure to Install New Sensor Bracket on Paver

Modification of Screed Upper Frame

1. Press the extender switch to extend the screed to maximum width.

2. Safely lower the screed to and place it over wooden support.

3. Shut down the engine and disconnect main power of the machine.

4. Refer to Disassembly and Assembly, UENR4559, End Gate - Remove and Install to safely remove the end gate from the screed.
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   Illustration 1	g06249412
   Right-hand side frame plate

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   Illustration 2	g06249413
   Left-hand side frame plate

5. Mark the side plate of the right-hand side frame and left-hand side frame as highlighted in Illustration 1 and Illustration 2 respectively.

6. Clean the area around the frame plate, ensure there is no additional items or debris on the surface.
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   Illustration 3	g06249575
   (D1) 30.0 mm (1.18 inch) (D2) 51.5 mm (2.02 inch) (D3) 103.0 mm (4.05 inch) (D4) 51.0 mm (2.01 inch) (D5) 310 mm (12.2 inch) (D6) 22.0 mm (0.86 inch) (D7) 51.0 mm (2.01 inch) (D8) 103.0 mm (4.05 inch) (D9) 10.5 mm (0.41 inch)

7. Mark the location of seven holes on the left-hand side frame as per the dimensions shown in Illustration 3.

8. Use a suitable drill to drill seven holes of diameter (D9) 10.5 mm (0.41 inch) at seven locations.

9. Once drilled, thread the holes with M12 X 1.75 diameter tap tool.

10. Clean threaded section off any debris.
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    Illustration 4	g06249576
    (D9) 10.5 mm (0.41 inch) (D10) 30.0 mm (1.18 inch) (D11) 51.0 mm (2.01 inch) (D12) 51.5 mm (2.02 inch) (D13) 232.0 mm (9.13 inch) (D14) 103.0 mm (4.05 inch) (D15) 51.0 mm (2.01 inch) (D16) 30.0 mm (1.18 inch) (D17) 103.0 mm (4.05 inch)

11. Mark the location of six holes on the right-hand side frame as per the dimensions shown in Illustration 4.

12. Use a suitable drill to drill six holes of diameter (D9) 10.5 mm (0.41 inch) at six locations.

13. Once drilled, thread the holes with M12 X 1.75 diameter tap tool.

Pre Assembly of the Double Extending Bracket

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Illustration 5	g06249417
(1) 533-4154 Mount As (2) 533-4155 Tube As

1. Completely insert 533-4155 Tube As (2) in 533-4154 Mount As (1) as shown in Illustration 5.
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   Illustration 6	g06249482
   (2) 533-4155 Tube As (3) 533-4157 Guide (4) 8T-7547 Bolt (5) 5P-4116 Hard Washer

2. Secure 533-4157 Guide (3) from the back end of 533-4155 Tube As (2) using 8T-7547 Bolt (4) and 5P-4116 Hard Washer (5) as shown in Illustration 6.
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   Illustration 7	g06249483
   (1) 533-4154 Mount As (6) 7X-2542 Bolt (7) 477-0471 Clamp As (8) 3T-0852 Locknut (9) 8T-4224 Hard Washers

3. Mount 477-0471 Clamp As (7) on 533-4154 Mount As (1) using 7X-2542 Bolt (6), 3T-0852 Locknut (8), and 8T-4224 Hard Washers (9) as shown in Illustration 7.
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   Illustration 8	g06249420
   (4) 8T-7547 Bolt (5) 5P-4116 Hard Washer (10) 477-9126 Guide (11) 533-4156 Guide (12) 459-6768 Tube As

4. Insert 533-4156 Guide (11) on to 459-6768 Tube As (12) and install 477-9126 Guide (10) on the other end of the rod using 8T-7547 Bolt (4) and 5P-4116 Hard Washer (5) as shown in Illustration 8.
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   Illustration 9	g06249421
   (12) 459-6768 Tube As

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   Illustration 10	g06249422
   (2) 533-4155 Tube As (11) 533-4156 Guide (12) 459-6768 Tube As (13) 8T-4136 Bolt (14) 8T-4121 Hard Washer

5. Insert 459-6768 Tube As (12) into the pre-assembled bracket in Step 3 as shown in Illustration 9. Secure 533-4156 Guide (11) to 533-4155 Tube As (2) using 8T-4136 Bolt (13) and 8T-4121 Hard Washer (14). Refer to Illustration 10.
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   Illustration 11	g06249423
   (8) 3T-0852 Locknut (9) 8T-4224 Hard Washers (15) 477-0307 Clamp (16) 8T-4177 Bolt (17) 459-6769 Mount As

6. Assemble 477-0307 Clamp (15) to 459-6769 Mount As (17) using 8T-4177 Bolt (16), 3T-0852 Locknut (8), and 8T-4224 Hard Washers (9) as shown in Illustration 11.
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   Illustration 12	g06249424
   (12) 459-6768 Tube As (14) 8T-4121 Hard Washer (17) 459-6769 Mount As (18) 330-5646 Mount (19) 344-5675 Nut

7. Assemble pre-assembled 459-6769 Mount As (17) to 459-6768 Tube As (12) using 330-5646 Mount (18), 344-5675 Nut (19), and 8T-4121 Hard Washer (14) as shown in Illustration 12.

Installation of the Bracket

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Illustration 13	g06249460
(20) 533-4153 Mount As (21) 8T-4956 Bolts (22) 8T-4223 Hard Washers

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Illustration 14	g06249461
(20) 533-4153 Mount As (A) Support Bracket

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Illustration 15	g06249463
Tall end gate jack

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Illustration 16	g06249465
Single handle and new 45 degrees jack

1. Install the 533-4153 Mount As (20) on left side using three 8T-4956 Bolts (21) and 8T-4223 Hard Washers (22) as shown in Illustration 13.

   Note: If the machine is installed with extension packages, install the vertical support height adjustment bracket (A) before the assembly of 533-4153 Mount As (20). Ensure the vertical support bracket (A) and 533-4153 Mount As (20) do not have interference and moves freely during extender height adjustment. In case of an interference, loosen mounting bolt and adjust position of the mount till no interference is noticed for height adjustment bracket. Refer Illustration 14.

   Note: Check the type of end gate jacks installed on the machine and choose the mounting (upper or lower) location accordingly. For tall end gate jack, use the lower mounting holes as shown in Illustration 15. For single handle jacks and new 45 degrees jack, use the upper mounting holes as shown in Illustration 16.

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   Illustration 17	g06249466
   (21) 8T-4956 Bolts

2. Tighten 8T-4956 Bolts (21) to 100 ± 20 N·m (74 ± 15 lb ft) as shown in Illustration 17.
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   Illustration 18	g06249467
   (20) 533-4153 Mount As

3. Install the pre-assembled bracket assembly to 533-4153 Mount As (20) as shown in Illustration 18.
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   Illustration 19	g06249468
   (23) 495-5599 Handles

4. Secure the assembly by tightening the 495-5599 Handles (23) mounted over the guides and clamp assembly as shown in Illustration 19.

5. Repeat above Step 1 in "Pre Assembly of the Double Extending Bracket" to Step 4 in "Installation of the Bracket" for right-hand side assembly.