Conveyor Systems on Certain Asphalt Pavers Have Failed to Operate Due to a Loss of Charge Pressure to Conveyor Pumps{5073} Caterpillar

Asphalt Paver:

AP1000E (S/N: T1F1-268)

AP1055E (S/N: TJF1-407)

BG1000E (S/N: RTT1-102)

Introduction

The problem that is identified below does not have a permanent solution. Until a permanent solution is available, use the solution that is identified below.

Problem

The conveyor system on certain Asphalt Pavers may cease to operate due to loss of charge pressure. The following procedure is intended to supply the conveyor pumps with alternate charge pressure in order to remove asphalt from the machine. The charge pump is not providing flow to the feeder pumps. The spline degrades enough to prevent the pump from rotating and providing oil. This failure typically occurs at the end or just after the first full year of use on the paver.

Note: This procedure is intended for machine clean out only. This procedure is not intended for continual machine operation. If the machine is operated continually with this procedure applied, severe damage can occur to the conveyor hydraulic system.

Solution

To remove the asphalt from the machine, supply conveyor pumps with charge alternate pressure.

Note: Service technicians contact your dealer technical communicator (TC). When this failure occurs, TCs contact Steve Mark Johnson at phone number 763-493-6025 to provide detailed failure information. Email: Johnson_Steve_M@cat.com

ReferenceSpecial Instruction, REHS9173, "Relocation of Auxiliary Charge Pump on Certain Asphalt Pavers{5070, 5073}" for instructions to relocate the auxiliary charge pump.

Recommended part numbers and quantities for O-ring face seal (ORFS) and Straight thread O-ring (STOR) connectors are as follows:

• Quantity of four 8T-9041 Connectors

• Quantity of four 8T-1779 Connectors

• Quantity of four 6V-8636 Connectors

• Quantity of four 7E-9898 Connectors

• Quantity of two dash six hydraulic hoses

Note: Dash six hydraulic hoses should be at least 800 mm (31.5 inch) in length. Pressures from pumps will be between 2586 kPa (375 psi) and 2930 kPa (425 psi).

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Illustration 1	g03675127
(A) Left Propel Pump charge port (B) Conveyor Pump Charge port (C) Conveyor Pump Charge Port (D) Right Propel Pump Charge Port (E) Dash six Hoses

Note: One hose (E) should connect Left Propel Pump charge port (A) to Conveyor Pump Charge port (B). One hose (E) should be used to connect Conveyor Pump Charge Port (C) to Right Propel Pump Charge Port (D) .

1. Verify that there is no charge pressure at the conveyor charge filter. Refer to Illustration 1.

   Note: The recommended charge pressure is 2586 kPa (375 psi) to 3275 kPa (475 psi). If the recommended charge pressure is observed, then the cause of the failure is not the charge pump. Disregard this technical information bulletin if correct charge pressure is observed.

2. Remove the hydraulic tank cap to allow tank pressure to vent.

3. Clean charge pressure quick disconnects with brake or contact cleaner.

4. Remove charge pressure quick disconnects from propel pump port M3.

5. Install ORFS connector to STOR connectors in place of charge pressure quick disconnects.

6. Install two hoses (E) to connectors. Refer to Illustration 1.

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Illustration 2	g03675450
Lower port of conveyor pump (F) Connector

7. Remove charge pressure disconnects from bottom of conveyor pumps port.

8. Install ORFS to STOR connectors to charge pressure quick disconnects

9. Connect Left propel pump charge port (A) to Conveyor pump charge port (B) using dash six hoses (E). Connect Conveyor pump charge port (C) to Right propel charge port (D) using dash six hoses (E) .

10. Disconnect dash 12 hose from conveyor charge filter.

11. Install cap (1) on charge filter and plug (2) to hose.

    Note: Installation of cap (1) on charge filter and plug (2) to hose will prevent charge pressure from back feeding into failed conveyor charge pump.

12. Start machine and operate conveyors in manual to allow asphalt to be cleared from the machine.

13. Turn off machine after asphalt has been cleared from machine.

14. Remove dash six hoses and install all previously removed connectors to all ports.

    Note: Machine will need to be removed from the job site and repaired.