Caterpillar AP-1055D BG-2455D Asphalt Paver Workshop Repair Manual PDF - MCATAP1055DBG2455D.zip

Full-service repair guides featuring complete electrical wiring schematics for the Caterpillar ASPHALT PAVERS AP-1055D and BG-2455D, containing every piece of workshop data needed to service, troubleshoot, fix, and rebuild these machines.

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