Caterpillar AP655C BG-2255C Asphalt Paver Workshop Repair Service Manual PDF AYP CDG CKR - MCATAP655CBG2255C.zip

Caterpillar ASPHALT PAVERS AP655C, BG-2255C Repair Service Manuals (AYP/CDG/CKR)

These are full-coverage service and repair manuals featuring electrical wiring schematics for the Caterpillar ASPHALT PAVERS AP655C and BG-2255C, containing every piece of workshop documentation needed to service, troubleshoot, fix, and rebuild these machines.

Caterpillar ASPHALT PAVERS AP655C, BG-2255C 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.

MANUAL LIST

KENR5021 - Schematic (AP-655C Asphalt Paver Electrical System 244-5495-01).pdf

KENR5024 - Schematic (Caterpillar AP-655C and Barber Greene, BG-2255C Asphalt Paver Hydraulic System 245-0849).pdf

KENR5029 - Specifications (AP-655C and BG-2255C Asphalt Pavers Attachments).pdf

KENR5027 - Specifications (AP-655C and BG-2255C Asphalt Pavers Drag Conveyor and Auger Conveyor Systems).pdf

KENR5028 - Specifications (AP-655C and BG-2255C Asphalt Pavers Machine Systems).pdf

KENR5026 - Specifications (AP-655C and BG-2255C Asphalt Pavers Propel System).pdf

KENR5028 - Testing and Adjusting (AP-655C and BG-2255C Asphalt Pavers Machine Systems).pdf

KENR5025 - Disassembly and Assembly (AP-655C and BG-2255C Asphalt Pavers).pdf

KENR5029 - Systems Operation (AP-655C and BG-2255C Asphalt Pavers Attachments).pdf

KENR5029 - Testing and Adjusting (AP-655C and BG-2255C Asphalt Pavers Attachments).pdf

KENR5027 - Testing and Adjusting (AP-655C and BG-2255C Asphalt Pavers Drag Conveyor and Auger Conveyor Systems).pdf

KENR5027 - Systems Operation (AP-655C and BG-2255C Asphalt Pavers Drag Conveyor and Auger Conveyor Systems).pdf

KENR5026 - Systems Operation (AP-655C and BG-2255C Asphalt Pavers Propel System).pdf

KENR5026 - Testing and Adjusting (AP-655C and BG-2255C Asphalt Pavers Propel System).pdf

KENR5028 - Systems Operation (AP-655C and BG-2255C Asphalt Pavers Machine Systems).pdf

KENR5033 - Disassembly and Assembly (AP-655C and BG-2255C Asphalt Pavers Machine Systems).pdf

AP-655C ASPHALT PAVER AYP

AP-655C ASPHALT PAVER CDG

BG-2255C ASPHALT PAVER CKR

Total Pages: 1,773 pages

File Format: PDF (bookmarked, ToC, Searchable, Printable, high quality)

Manual Type: Disassembly & Assembly, Testing & Adjusting, Specifications, Systems Operation, Electrical Schematic, Troubleshooting...

Language: English

TABLE OF CONTENTS

KENR5021 - Schematic (AP-655C Asphalt Paver Electrical System 244-5495-01)......2

Collage......3

Main......35

KENR5024 - Schematic (Caterpillar AP-655C and Barber Greene, BG-2255C Asphalt Paver Hydraulic System 245-0849)......37

Collage......38

Main......53

KENR5025 - Disassembly and Assembly (AP-655C and BG-2255C Asphalt Pavers)......55

Air Cleaner - Remove and Install......56

Alternator - Remove and Install......61

Control Valve (Fan Drive) - Remove and Install......65

Electric Starting Motor - Remove and Install......68

Engine - Install......73

Engine - Remove......80

Engine Oil Filter and Oil Filter Base - Remove and Install......88

Exhaust (Muffler) - Remove and Install......92

Fuel Filter (Secondary) and Fuel Filter Base - Remove and Install......94

Gear Motor (Fan Drive) - Assemble......97

Gear Motor (Fan Drive) - Disassemble......102

Gear Motor (Fan Drive) - Install......107

Gear Motor (Fan Drive) - Remove......110

Gear Pump (Fan Drive) - Assemble......114

Gear Pump (Fan Drive) - Disassemble......119

Gear Pump (Fan Drive) - Install......124

Gear Pump (Fan Drive) - Remove......126

Radiator, Air Cooler, and Hydraulic Oil Cooler - Install......129

Radiator, Air Cooler, and Hydraulic Oil Cooler - Remove......133

Water Separator (Fuel Priming Pump and Primary Fuel Filter) - Assemble......138

Water Separator (Fuel Priming Pump and Primary Fuel Filter) - Disassemble......141

Water Separator (Fuel Priming Pump and Primary Fuel Filter) - Install......144

Water Separator (Fuel Priming Pump and Primary Fuel Filter) - Remove......145

KENR5026 - Specifications (AP-655C and BG-2255C Asphalt Pavers Propel System)......147

Accumulator (Track Tension)......148

Cooler Bypass Valve......150

Final Drive Planetary......152

Frame (Undercarriage)......156

Hydraulic Cylinder (Track Tension)......163

Hydraulic Oil Filter (Charge Pump)......165

Hydraulic Oil Filter (Return)......167

Hydraulic Tank......168

Piston Pump (Propel)......169

Pressure Control Valve (Parking Brake Release)......171

Pressure Switch (Track Tension)......172

Suction Strainer......174

Tensioner Group......176

KENR5026 - Systems Operation (AP-655C and BG-2255C Asphalt Pavers Propel System)......178

Accumulator (Track Tension)......179

Cooler Bypass Valve......181

Electrical Input Components......183

Electrical Output Components......192

Electrical Schematic......196

Electronic Control Module......198

Features......204

Final Drive Planetary......205

Frame (Undercarriage)......209

Hydraulic Cylinder (Track Tension)......216

Hydraulic Oil Filter (Charge Pump)......218

Hydraulic Oil Filter (Return)......220

Hydraulic Schematics......221

Hydraulic Tank......225

Introduction (Propel System)......226

Introduction......234

Location of Electrical Components......236

Location of Hydraulic Components......248

Multifunction Valves......266

Piston Motor (Propel)......276

Piston Pump (Propel) ......284

Piston Pump (Propel)......295

Pressure Control Valve (Parking Brake Release)......297

Pressure Switch (Track Tension)......298

Propel System......300

Suction Strainer......308

Tensioner Group......310

KENR5026 - Testing and Adjusting (AP-655C and BG-2255C Asphalt Pavers Propel System)......312

Accumulator - Test and Charge......313

Belt Alignment - Test and Adjust......322

Harness (Speed Potentiometer) and Electronic Sensor - Test......335

Lever (Propel Control) and Electronic Sensor - Test......344

Piston Motor Case Drain Flow - Test......353

Piston Pump Case Drain Flow - Test......361

Piston Pump Flow - Test......374

Piston Pump Neutral - Test and Adjust......381

Pressure Limiter Valve - Test and Adjust......391

Pump Synchronization - Test and Adjust......403

Relief Valve (Charge) - Test and Adjust......412

Rotary Position Sensor (Brake Pedal) - Test and Adjust......422

Rotary Position Sensor (Steering) - Test and Adjust......434

Seal Leakage for Final Drive Planetary - Test......448

Speed Sensor (Propel Motor) - Check and Adjust......458

Track Tension - Release......465

KENR5027 - Specifications (AP-655C and BG-2255C Asphalt Pavers Drag Conveyor and Auger Conveyor Systems)......467

Auger Conveyor......468

Auger Extension......469

Conveyor Planetary Drive (Drag)......470

Drag Conveyor......471

Footshaft......474

Gear Pump (Charge)......475

Hydraulic Oil Filter (Charge Pump)......476

Hydraulic Tank......477

Piston Motor......479

Piston Pump......482

Position Sensor (Paddle)......484

Position Sensor (Sonic)......486

KENR5027 - Systems Operation (AP-655C and BG-2255C Asphalt Pavers Drag Conveyor and Auger Conveyor Systems)......487

Auger Conveyor System......488

Charge Filter......498

Charge Pump......501

Control Valve (Auger Conveyor)......505

Control Valve (Drag Conveyor)......511

Drag Conveyor System......515

Electrical Input Components of Auger Conveyor System......525

Electrical Input Components of Drag Conveyor System......532

Electrical Output Components of Auger Conveyor System......535

Electrical Output Components of Drag Conveyor System......537

Electrical Schematic (Auger Conveyor)......538

Electrical Schematic (Drag Conveyor)......541

Features of the Auger Conveyor System......544

Features of the Drag Conveyor System......549

Hydraulic Schematic (Drag Conveyor)......554

Introduction (Auger Conveyor)......558

Introduction (Drag Conveyor)......561

Introduction......563

Location of Electrical Components (Auger Conveyor)......566

Location of Electrical Components (Drag Conveyor)......567

Location of Hydraulic Components (Auger Conveyor)......570

Location of Hydraulic Components (Drag Conveyor)......579

Piston Motor (Auger Conveyor)......587

Piston Motor (Drag Conveyor)......591

Piston Pump (Auger Conveyor)......596

Piston Pump (Drag Conveyor)......604

Planetary Drive (Auger Conveyor)......611

Planetary Drive (Drag Conveyor)......613

KENR5027 - Testing and Adjusting (AP-655C and BG-2255C Asphalt Pavers Drag Conveyor and Auger Conveyor Systems)......617

Conveyor Chain (Drag) - Check and Adjust......618

Conveyor Drive Chain (Auger) - Check and Adjust......620

Conveyor Drive Chain (Drag) - Check and Adjust......622

Conveyor Speed - Test and Adjust......624

Hydraulic Oil Contamination - Test......626

Machine Preparation for Testing and Adjusting......628

Piston Motor Case Drain Flow - Test......634

Piston Pump Case Drain Flow - Test......643

Piston Pump Flow - Test - Upper and Lower Pump Stacks......651

Piston Pump Neutral - Test and Adjust......664

Relief Valve (Charge) - Test and Adjust......679

Relief Valve - Test - Upper and Lower Pump Stacks......693

Visual Inspection......710

KENR5028 - Specifications (AP-655C and BG-2255C Asphalt Pavers Machine Systems)......714

Bank Valve - Auxiliary......715

Bank Valve - Cooling Fan......717

Cooler Bypass Valve......718

Gear Motor - Cooling Fan......720

Gear Pump (Vibratory)......721

Gear Pump - Cooling Fan......723

Hydraulic Cylinder (Auger Hoist) - Right Cylinder......724

Hydraulic Cylinder (Hopper Hoist)......725

Hydraulic Cylinder (Screed Hoist)......726

Hydraulic Cylinder (Tow Point)......727

Hydraulic Filter (Vibratory)......729

Hydraulic Oil Filter (Return) - Main......730

Hydraulic Tank......732

Manifold Valve (Screed Counterbalance)......733

Piston Pump (Auxiliary)......734

Suction Strainer......735

KENR5028 - Systems Operation (AP-655C and BG-2255C Asphalt Pavers Machine Systems)......737

Auger Lift......738

Auxiliary System......745

Bank Valve (Auxiliary)......753

Cooler Bypass Valve......762

Cooling Fan......765

Electrical Components (Cooling Fan)......775

Electrical Components (Hopper Lift)......777

Electrical Components (Screed)......780

Electrical Components (Vibratory)......787

Electrical Schematic (Auxiliary Systems)......790

Electrical Schematic (Vibratory System)......796

Hopper Lift......797

Hydraulic Schematic (Auxiliary Systems)......802

Hydraulic Schematic (Vibratory System)......808

Introduction (Auxiliary System)......810

Introduction (Vibratory System)......815

Introduction......821

Location of Electrical Components (Auxiliary Systems)......823

Location of Electrical Components (Vibratory System)......835

Location of Hydraulic Components (Auxiliary Systems)......837

Location of Hydraulic Components (Vibratory System)......855

Manifold Valve (Screed Counterbalance)......866

Piston Pump (Auxiliary)......871

Tow Point Control......877

Vibratory System......884

KENR5028 - Testing and Adjusting (AP-655C and BG-2255C Asphalt Pavers Machine Systems)......890

Gear Pump Flow - Test - Cooling Fan......891

Gear Pump Flow - Test - Vibratory......898

Piston Pump Flow - Test and Adjust - Auxiliary......904

Pressure Reducing Valve - Test and Adjust......911

Pump Control Valve (Auxiliary) - Test and Adjust......917

Relief Valve (Screed Counterbalance) - Test and Adjust......920

Relief Valve (Vibratory) - Test and Adjust......925

KENR5029 - Specifications (AP-655C and BG-2255C Asphalt Pavers Attachments)......935

Control Valve (Generator)......936

Control Valve (Truck Hitch)......938

Gear Motor (Generator) - 8 kW......940

Gear Motor (Ventilation System)......942

Hydraulic Filter (Return)......944

Piston Motor (Generator) - 23 kW......945

Piston Pump (Generator)......946

Truck Hitch......948

Washdown Group......950

KENR5029 - Systems Operation (AP-655C and BG-2255C Asphalt Pavers Attachments)......952

Control Valve (Generator) - 23 kW......953

Control Valve (Generator) - 8 kW......955

Control Valve (Truck Hitch)......960

Electrical Components (Generator) - 8 kW......966

Electrical Components (Truck Hitch)......969

Electrical Schematic......971

Flow Control Valve (Ventilation)......975

Gear Motor (Generator) - 8 kW......977

Gear Motor (Ventilation)......980

Generator Drive System - 23 kW Generator......982

Generator Drive System - 8 kW......987

Hydraulic Schematic......990

Introduction......996

Location of Electrical Components......998

Location of Hydraulic Components......1002

Piston Motor (Generator) - 23 kW......1011

Piston Pump (Generator) - 23 kW......1012

Piston Pump (Generator)......1014

Truck Hitch System......1020

Ventilation System......1022

KENR5029 - Testing and Adjusting (AP-655C and BG-2255C Asphalt Pavers Attachments)......1025

Control Valve (Truck Hitch) - Test and Adjust......1026

Fan Speed (Ventilation) - Test......1032

Gear Motor Case Drain Flow - Test - 8 kW Generator......1036

Generator Set - Test and Adjust - 8 kW Generator......1042

Piston Pump Case Drain Flow - Test - 8 kW Generator......1047

Piston Pump Control - Test and Adjust - 8 kW Generator......1053

Piston Pump Flow - Test - 8 kW Generator......1065

Piston Pump Flow - Test and Adjust......1074

Pump Control Valve - Test and Adjust - 23 kW Generator......1080

KENR5033 - Disassembly and Assembly (AP-655C and BG-2255C Asphalt Pavers Machine Systems)......1093

Accumulator (Belt Tensioner) - Remove and Install......1099

Accumulator Charging Valve (Belt Tensioner) - Assemble......1102

Accumulator Charging Valve (Belt Tensioner) - Disassemble......1104

Accumulator Charging Valve (Belt Tensioner) - Install......1106

Accumulator Charging Valve (Belt Tensioner) - Remove......1107

Auger - Assemble......1109

Auger - Disassemble......1111

Auger - Install......1113

Auger - Remove......1116

Auger Conveyor - Remove and Install......1119

Battery and Battery Cable - Separate and Connect......1124

Belt - Install......1126

Belt - Remove......1129

Belt Tensioner - Assemble......1133

Belt Tensioner - Disassemble......1138

Belt Tensioner - Install......1142

Belt Tensioner - Remove......1144

Bogie (Front) - Install......1146

Bogie (Front) - Remove......1148

Bogie (Rear) - Install......1149

Bogie (Rear) - Remove......1151

Bogie - Assemble......1152

Bogie - Disassemble......1156

Brake Pump and Valve - Assemble......1159

Brake Pump and Valve - Disassemble......1161