PRODUCT SUPPORT PROGRAM FOR REWORKING THE ACCESSORY POWER INVERTER FAN WIRING AND UPDATING THE SOFTWARE ON CERTAIN AP500F, AP555F, AP600F, AP655F, AP1000F, AND AP1055F ASPHALT PAVERS Caterpillar

PRODUCT SUPPORT PROGRAM FOR REWORKING THE ACCESSORY POWER INVERTER FAN WIRING AND UPDATING THE SOFTWARE ON CERTAIN AP500F, AP555F, AP600F, AP655F, AP1000F, AND AP1055F ASPHALT PAVERS

Usage:

TEBE4787-01

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22Jun2016

(Revised 20Dec2016)

U-324

A-244

D-284

O-282

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Before/After	PRODUCT SUPPORT PROGRAM FOR REWORKING THE ACCESSORY POWER INVERTER FAN WIRING AND UPDATING THE SOFTWARE ON CERTAIN AP500F, AP555F, AP600F, AP655F, AP1000F, AND AP1055F ASPHALT PAVERS
1421		PS45125

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NOTE:

Caterpillar’s obligations under this Service Letter are subject to, and shall not apply in contravention of, the laws, rules, regulations, directives, ordinances, orders, or statutes of the United States, or of any other applicable jurisdiction, without recourse or liability with respect to Caterpillar.

NOTE:

This Program must be administered either before or after failure. In either case the decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS45125" as the Part Number and "7755" as the Group Number. If administered before failure, use "56" as the Warranty Claim Description Code and "T" as the SIMS Description code. If administered after failure, use "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.

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NOTE:

The information supplied in this service letter may not be valid after the termination date of this program. Do not perform the work outlined in this Service Letter after the termination date without first contacting your Caterpillar product analyst.

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NOTE:	This Revised Service Letter replaces the 22Jun2016 Service Letter. Changes have been made to the Action Required.

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TERMINATION DATE

30Jun2018

PROBLEM

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Faults may occur from the accessory power inverter including 4634-3(2) Accessory Power Inverter Start-up Fault and/or 4632-6(2), 1095-6(2) or 4388-14(2) Fan Overcurrent Faults on certain AP500F, AP555F, AP600F, AP655F, AP1000F, and AP1055F Asphalt Pavers.

AFFECTED PRODUCT

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Model	Identification Number
AP1000F	AC400101-00141, 143-181, 184-208, 210-233, 235-241, 243-248
AP1055F	RLM00101-00102, 104-105 TJ500100-00104, 117-118, 120, 132-133, 135, 143-150, 152, 155-156, 158-161, 163-169, 171-174, 177-186, 188-190, 192, 194-199, 202, 205-206, 208-220, 223-240, 246-259, 261-280, 282-283, 285-288, 295-303, 305-306, 308, 311, 314-315, 327-330, 336-342, 344, 346-355, 359-361, 367-378, 380-393, 397, 399-436, 438-451
AP500F	44900100, 103, 108
AP555F	AP500101-00108, 112, 115-119, 124, 126-128
AP600F	AP600100-00104, 106-108, 110-112, 114-123, 125-127, 129-131
AP655F	47900100, 108 MH600101-00143, 146-150, 152-172, 177-188, 190-197 ML600100 P6500100, 102, 104

PARTS NEEDED

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Qty	Part Number	Description
2	3S2093	STRAP-CABLE
1	5083236	SFWR GP-A3000
1	5089365	HARNESS AS
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 22% of dealership population. This is an initial order recommendation only, and the ultimate responsibility for ordering the total number of parts needed to satisfy the program lies with the dealer.

ACTION REQUIRED

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4634-3(2) Accessory Power Inverter Start-up Fault

This fault is likely the result of outdated machine software on the Machine ECM. Please ensure that 508-3236 Machine Software or the latest software is installed. Clear all logged faults from the paver.

4632-6(2),1095-6(2), or 4388-14(2) Fan Overcurrent Faults

These faults indicate that the fan is drawing more power than the accessory power inverter is expecting. The exact fault code varies with the version of software that is on the machine ECM. Please ensure that 508-3236 Machine Software or the latest software is installed. Clear all logged faults from the paver.

NOTE: To prevent fault codes, review the machine's history folder and check for outstanding programs for installing other software if applicable.

Refer to the attached Rework Procedure to add the 508-9365 Harness As to the fan circuit.

Note: Newer accessory power inverters with part numbers of 506-9431, 506-9432, or 506-9433 contain internal changes that do not require and will not benefit from the addition of 508-9365 Harness As. Adding the Harness As to these newer accessory power inverter is not needed. The accessory power inverter part number can be seen near the outlets and is accessed through the outlet access door.

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SERVICE CLAIM ALLOWANCES

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Product smu/age whichever comes first	Caterpillar		Dealer Suggested		Customer Suggested
Product smu/age whichever comes first	Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
0-2400 hrs, 0-24 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%
2401-4800 hrs, 25-48 mo	33.0%	50.0%	0.0%	0.0%	50.0%	50.0%

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NOTE: This is a 1.0-hour job

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PARTS DISPOSITION

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Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.

Rework Procedure

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Refer to Troubleshooting, UENR3864, "Electrical Shutdown and Voltage Discharge", before performing any procedures.

1. Remove the 10 screws shown in Image1.1.1 using a T-20 drive tool.

Image1.1.1

2. Tip the fan down to expose the fan?s electrical connection to the accessory power inverter. Cut and remove the cable tie used to secure the 2 pin connector to the existing harnesses. Disconnect the electrical connector. Refer to Image1.2.1.

Image1.2.1

3. Install Resistor Assembly 508-9365 to the cooling fins of the inverter as shown in Image1.3.1. Connect the connector lead from the fan to the left connector on the resistor assembly and connect the right side of the resistor assembly to the accessory power inverter.

4. Arrange wires and connectors to prevent rubbing on sharp surfaces, and secure with tie strap 3S-2093 as shown. Additional straps can be used if needed.