Usage:
NOTE: This Program can only be administered after a failure occurs. The decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS5685" as the Part Number and "7755" as the Group Number. Use "96" as the Warranty Claim Description Code and use "Z" as the SIMS Description Code.
NOTE: This Revised Service Letter replaces the July 22, 1999 (Revised November 1999) Service Letter. Changes have been made to the TERMINATION DATE, Affected Product, Parts Needed, Service Claim Allowances, Group 1 Rework Procedure, Group 2 Rework Procedure, and the Group 3 Rework Procedure.
NOTE: When applicable this program should be implemented at the same time as the April 5, 2000 Service Letter PS40165.
Termination Date
April 30, 2002Problem
Heavy duty hopper hinge pins and associated hardware can be installed on certain AP-650B, AP-800C, AP-1000B, AP-1050B, and AP-1055B Asphalt Pavers; and on certain Barber-Greene BG-225C, BG-230, BG-245C, BG-260C, and BG-2455C Asphalt Pavers Manufactured by Caterpillar. These heavy duty hinge pins have a longer service life.
Affected Product
Model & Identification Number
Group 1
AP-1000B (7HN1-242)
AP-1050B (6ZN1-195)
AP-1055B (ABB1-210, 8BM1-427)
BG-245C (4XN1-123)
BG-260C (8GN1-545)
BG-2455C (ACM1-250, 6TN1-142)
Group 2
AP-650 (9DN1-390)
BG-225C (5GN1-476)
Group 3
AP-800C (1PM1-727)
BG-230 (9AL1-275)
Parts Needed
Group 1
- 2 - 9B7237 BOLT
- 2 - 7R7963 PLATE AS
- 10 - 8T4167 WASHER
- 2 - 7W9738 WASHER
- 2 - 1061242 SPACER
- 2 - 1668785 PIN AS
- 8 - 1668786 TUBE
- 10 - 1668787 TUBE
- 4 - 1713680 BAR
- 6 - 1713681 BAR
- 2 - 1731156 PLATE
- 4 - 1731157 PLATE
- 2 - 7R7963 PLATE AS
Group 2
- 2 - 9B7237 BOLT
- 2 - 7R7963 PLATE AS
- 10 - 8T4167 WASHER
- 2 - 7W9738 WASHER
- 2 - 1061242 SPACER
- 10 - 1668787 TUBE
- 2 - 1713075 PLATE
- 6 - 1713681 BAR
- 8 - 1714772 TUBE
- 4 - 1723903 BAR
- 2 - 1723993 PIN AS
- 2 - 1731159 PLATE
- 2 - 1744376 PLATE
- 2 - 7R7963 PLATE AS
Group 3
- 2 - 9B7237 BOLT
- 2 - 7R7963 PLATE AS
- 10 - 8T4167 WASHER
- 2 - 7W9738 WASHER
- 2 - 1061242 SPACER
- 2 - 1668785 PIN AS
- 10 - 1668787 TUBE
- 6 - 1713681 BAR
- 8 - 1715476 TUBE
- 4 - 1723902 BAR
- 4 - 1731158 PLATE
- 2 - 1744375 PLATE
- 2 - 7R7963 PLATE AS
Service Claim Allowances
Parts Disposition
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
Attach.
- (1-Group 1 Rework Procedure)
- (2-Group 2 Rework Procedure)
- (3-Group 3 Rework Procedure)
- (2-Group 2 Rework Procedure)
Group 1 Rework Procedure
Hopper hinge pin rework procedure for AP-1055B/BG-2455C, AP-1050B/BG-245C, and AP-1000B/BG-260C asphalt pavers.
NOTE: PS40165 dated April 5, 2000 on AP1000B/BG260C machines should be performed while the hoppers are removed from the machine for this program.
Procedure:
1. Disconnect hopper cylinders from left and right hopper wings.
2. Attach overhead crane to the lift hole located at the top center of the hopper wing.
3. Lift hopper until hopper hinge pin is loose. Remove hopper hinge pin. Remove hopper wing and set off to the side.
4. Block the hopper wing so that the hopper hinge tubes are on top.
5. Cut the hinge tubes off the hopper wing taking care not to damage the hopper wings. Cut the hinge tube supports off the hopper wings as shown in the photo below. Clean any excess metal left by the hinge tubes and supports off the hopper wing.
6. Use the drawing below to mark the hinge tube location along the length of the hopper wing. Each hopper wing requires two 166-8787 short tubes and two 166-8786 long tubes.
7. Locate the hinge tubes 7mm below the bottom edge of the hopper wing as shown in the picture below.
8. Tack weld the tubes to the hopper wing. Use a straight edge along the bottom of the tubes to correct any misalignment. Verify the hopper hinge pin slides freely through the hinge pin tubes. Weld the hinge pin tubes to the hopper wing.
9. Position the small tube hopper plate 173-1156 and two long tube hopper plates 173-1157 so they are in full contact with the hopper wing and also make contact with the hopper hinge pin tubes. Weld the plates to the hopper wing and hopper hinge tubes. If needed grind the ends of the plates so they do not extend past the outer diameter of the hinge pin tubes.
10. Using a hand grinder chamfer the hopper wing between the hopper hinge tubes. This will create clearance for the machine frame hinge tubes.
11. Repeat steps 2 through 10 for the remaining hopper wing.
12. Remove the hinge pin tubes and angle supports from the machine frame.
13. Tack six short support bars 171-3681 to six short tubes 166-8787 as shown below. Also tack four long support bars 171-3680 to four long tubes 166-8786 as shown below. Lengthwise the bars should be centered on the tubes.
14. Use the drawing on the next page to mark the hinge tube location along the length of the main frame.
15. On the left side of the machine use a grinder or torch to remove the truck hitch lines mounting brackets.
16. Tack weld the hinge tubes to the machine frame so both the hinge tubes and the support bars are contacting the frame. The centerline of the hinge tubes should be even with the top of the machine frame as shown in the photo below.
17. Place a straight edge along the top of the tubes and correct any misalignment. Verify the hinge pin runs freely through the tubes.
18. Tack weld the support plates to the machine frame as shown in the photo below.
19. Using a grinder remove the tack welds between the hinge tubes and machine frame and also between the hinge tubes and support brackets. Remove the hinge tubes.
NOTE: On wheeled machines, or if the tracks are off the machine it is not necessary to remove the hinge tubes to weld the support brackets to the frame. On wheeled machines or with the tracks off weld along the bottom of the support brackets.
20. Weld the support brackets to the machine frame as shown in the photo below.
21. Relocate the hinge tubes. Tack weld the hinge tubes to the machine frame. Use a straight edge along the top of the hinge tubes to correct their alignment. Verify the hinge pin runs freely through the tubes.
22. Weld the hinge tubes to the machine frame and also to the support brackets.
23. Using a hand grinder chamfer the machine frame between the machine frame hinge tubes. This will create clearance for the hopper wing hinge tubes.
24. Position the new truck hitch lines mounting brackets 7R-7963 so that the lines clear the new hinge pin tubes. Weld the brackets in place and bolt down the truck hitch lines if available.
25. Position the left hopper wing on the machine so that the hinge pin can be inserted in both the machine and hopper wing. Insert the hinge pin 166-8785 placing washers 8T-4167 as needed between the hinge pin tubes in two locations so that the hopper wing cannot move forward or backward on the machine frame.
26. Reconnect the left hopper wing cylinder.
27. Repeat steps 25 and 26 for the right hopper wing.
28. Remove the truck push rollers. Rotate the hinge pins so the slotted plate is hanging down at 8 o'clock on the left side and 4 o'clock on the right side. Verify the slotted plate clears the hopper wings when they are down and also clears the steering guide tubes when they are installed. Drill an " hole into the 2" thick front plate 25mm deep located in the center of the slot on each of the hinge pins. Tap the holes with a - 16 tap. First place washer 7W-9738 followed by spacer 106-1242 onto bolt 9B-7237 and thread into newly tapped holes. Tighten bolts.
Group 2 Rework Procedure
Hopper hinge pin rework procedure for AP-650B/BG-225C asphalt pavers.
Procedure:
1. Disconnect hopper cylinders from left and right hopper wings.
2. Attach overhead crane to the lift hole located at the top center of the hopper wing.
3. Lift hopper until hopper hinge pin is loose. Remove hopper hinge pin. Remove hopper wing and set off to the side.
4. Block the hopper wing so that the hopper hinge tubes are on top.
5. Cut the hinge tubes off the hopper wing taking care not to damage the hopper wings. Cut the hinge tube supports off the hopper wings as shown in the photo below. Clean any excess metal left by the hinge tubes and supports off the hopper wing.
6. Use the drawing below to mark the hinge tube location along the length of the hopper wing. Each hopper wing requires two 166-8787 short tubes and two 171-4772 long tubes.
7. Locate the hinge tubes 7mm below the bottom edge of the hopper wing as shown in the picture below.
8. Tack weld the tubes to the hopper wing. Use a straight edge along the bottom of the tubes to correct any misalignment. Verify the hopper hinge pin slides freely through the hinge pin tubes. Weld the hinge pin tubes to the hopper wing.
9. Position the small tube hopper plate 174-4376, one middle tube hopper plate 173-1159, and one front tube hopper plate 171-3075 so they are in full contact with the hopper wing and also make contact with the hopper hinge pin tubes. Weld the plates to the hopper wing and hopper hinge tubes. If needed grind the ends of the plates so they do not extend past the outer diameter of the hinge pin tubes.
10. Using a hand grinder chamfer the hopper wing between the hopper hinge tubes. This will create clearance for the machine frame hinge tubes.
11. Repeat steps 2 through 10 for the remaining hopper wing.
12. Remove the hinge pin tubes and angle supports from the machine frame.
13. Tack six short support bars 171-3681 to six short tubes 166-8787 as shown below. Also tack four long support bars 172-3903 to four long tubes 171-4772 as shown below. Lengthwise the bars should be centered on the tubes.
14. Use the drawing on the next page to mark the hinge tube location along the length of the main frame.
15. On the left side of the machine use a grinder or torch to remove the truck hitch lines mounting brackets.
16. Tack weld the hinge tubes to the machine frame so both the hinge tubes and the support bars are contacting the frame. The centerline of the hinge tubes should be even with the top of the machine frame as shown in the photo below.
17. Place a straight edge along the top of the tubes and correct any misalignment. Verify the hinge pin runs freely through the tubes.
18. Tack weld the support plates to the machine frame as shown in the photo below.
19. Using a grinder remove the tack welds between the hinge tubes and machine frame and also between the hinge tubes and support brackets. Remove the hinge tubes.
NOTE: If the tracks are off the machine it is not necessary to remove the hinge tubes to weld the support brackets to the frame. With the tracks off weld along the bottom of the support brackets.
20. Weld the support brackets to the machine frame as shown in the photo below.
21. Relocate the hinge tubes. Tack weld the hinge tubes to the machine frame. Use a straight edge along the top of the hinge tubes to correct their alignment. Verify the hinge pin runs freely through the tubes.
22. Weld the hinge tubes to the machine frame and also to the support brackets.23. Using a hand grinder chamfer the machine frame between the machine frame hinge tubes. This will create clearance for the hopper wing hinge tubes.
24. Position the new truck hitch lines mounting brackets 7R-7963 so that the lines clear the new hinge pin tubes. Weld the brackets in place and bolt down the truck hitch lines if available.
25. Position the left hopper wing on the machine so that the hinge pin can be inserted in both the machine and hopper wing. Insert the hinge pin 172-3993 placing washers 8T-4167 as needed between the hinge pin tubes in two locations so that the hopper wing cannot move forward or backward on the machine frame.
26. Reconnect the left hopper wing cylinder.
27. Repeat steps 25 and 26 for the right hopper wing.
28. Place washer 7W-9738 followed by spacer 106-1242 onto bolt 9B-7237 and thread into the hinge pin retaining bolt hole on left and right hinge pins. Tighten bolts.
Group 3 Rework Procedure
Hopper hinge pin rework procedure for AP-800C/BG-230 asphalt pavers.
Procedure:
1. Disconnect hopper cylinders from left and right hopper wings.
2. Attach overhead crane to the lift hole located at the top center of the hopper wing.
3. Lift hopper until hopper hinge pin is loose. Remove hopper hinge pin. Remove hopper wing and set off to the side.
4. Block the hopper wing so that the hopper hinge tubes are on top.
5. Cut the hinge tubes off the hopper wing taking care not to damage the hopper wings. Cut the hinge tube supports off the hopper wings as shown in the photo below. Clean any excess metal left by the hinge tubes and supports off the hopper wing.
6. Use the drawing below to mark the hinge tube location along the length of the hopper wing. Each hopper wing requires two 166-8787 short tubes and two 171-5476 long tubes.
7. Locate the hinge tubes 7mm below the bottom edge of the hopper wing as shown in the picture below.
8. Tack weld the tubes to the hopper wing. Use a straight edge along the bottom of the tubes to correct any misalignment. Verify the hopper hinge pin slides freely through the hinge pin tubes. Weld the hinge pin tubes to the hopper wing.
9. Position the small tube hopper plate 174-4375 and two long tube hopper plates 173-1158 so they are in full contact with the hopper wing and also make contact with the hopper hinge pin tubes. Weld the plates to the hopper wing and hopper hinge tubes. If needed grind the ends of the plates so they do not extend past the outer diameter of the hinge pin tubes.
10. Using a hand grinder chamfer the hopper wing between the hopper hinge tubes. This will create clearance for the machine frame hinge tubes.
11. Repeat steps 2 through 10 for the remaining hopper wing.
12. Remove the hinge pin tubes and angle supports from the machine frame.
13. Tack six short support bars 171-3681 to six short tubes 166-8787 as shown below. Also tack four long support bars 172-3902 to four long tubes 171-5476 as shown below. Lengthwise the bars should be centered on the tubes.
14. Use the drawing on the next page to mark the hinge tube location along the length of the main frame.
15. On the left side of the machine use a grinder or torch to remove the truck hitch lines mounting brackets.
16. Tack weld the hinge tubes to the machine frame so both the hinge tubes and the support bars are contacting the frame. The centerline of the hinge tubes should be even with the top of the machine frame as shown in the photo below.
17. Place a straight edge along the top of the tubes and correct any misalignment. Verify the hinge pin runs freely through the tubes.
18. Weld the hinge tubes to the machine frame and also to the support brackets. Weld support brackets to machine frame. It may be necessary to remove the steering linkages.
19. Using a hand grinder chamfer the machine frame between the machine frame hinge tubes. This will create clearance for the hopper wing hinge tubes.
20. Position the new truck hitch lines mounting brackets 7R-7963 so that the lines clear the new hinge pin tubes. Weld the brackets in place and bolt down the truck hitch lines if available.
21. Position the left hopper wing on the machine so that the hinge pin can be inserted in both the machine and hopper wing. Insert the hinge pin 166-8785 placing washers 8T-4167 as needed between the hinge pin tubes in two locations so that the hopper wing cannot move forward or backward on the machine frame.
22. Reconnect the left hopper wing cylinder.
23. Repeat steps 21 and 22 for the right hopper wing.
24. Place washer 7W-9738 followed by spacer 106-1242 onto bolt 9B-7237 and thread into the hinge pin retaining bolt hole on left and right hinge.