PRODUCT SUPPORT PROGRAM FOR REPLACING THE EXISTING GENERATOR BELT TENSIONING SYSTEM ON CERTAIN AP300D ASPHALT PAVERS Caterpillar

PRODUCT SUPPORT PROGRAM FOR REPLACING THE EXISTING GENERATOR BELT TENSIONING SYSTEM ON CERTAIN AP300D ASPHALT PAVERS

Usage:

TEBE3983-00

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08Mar2016

U-122

A-96

D-111

O-106

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Before/After	PRODUCT SUPPORT PROGRAM FOR REPLACING THE EXISTING GENERATOR BELT TENSIONING SYSTEM ON CERTAIN AP300D ASPHALT PAVERS
4450 1358		PS45015

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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 "PS45015" 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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TERMINATION DATE

31Mar2018

PROBLEM

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The existing generator belt tensioning system, on certain AP300D Asphalt Pavers, may fail resulting in a belt crack or a jumping off issue.

AFFECTED PRODUCT

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Model	Identification Number
AP300D	TEN00101-00222

PARTS NEEDED

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Qty	Part Number	Description
2	6V5683	BOLT-HEAD
2	7X0584	WASHER-HARD
4	8T4121	WASHER-HARD
3	8T4196	BOLT-HEX HEAD
2	8T4200	BOLT-HEX HEAD
2	8T4224	WASHER-HARD
1	1729966	BOLT-HEX HEAD
1	2808912	BOLT-HEX HEAD
1	4830194	PLATE
1	4830198	TENSIONER GP
1	4914346	SUPPORT
1	4914347	ROLLER AS
1	4914351	BELT
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 13% 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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Refer to the attached Rework Procedure.

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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%
0-2000 hrs, 0-24 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%
2001-3000 hrs, 25-48 mo	53.0%	50.0%	0.0%	0.0%	35.0%	50.0%

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NOTE: This is a 8.0-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 the Service Manual if/as necessary.

Machine Preparation
1. Park the machine in a smooth surface and extend both the extenders and screed drop off on the ground.
2. Put the paver on jack stands and remove the screed with its long arm.

Image1.1.1

Installation Procedure
1. Remove the existing 426-0426 Tensioner (1).

Image1.2.1

2. Remove the 450-2396 Pulley (2) from the 426-0426 Tensioner and keep it.

Image1.3.1

3. Grinding away the 426-0398 Bracket profile (3) from the 421-1030 Mount AS (4) in order to create room for the new design.

Image1.4.1

4. Using a straight bar edge, ensure the alignment between generator and engine pulleys (5) and (6).

Image1.5.1

5. Install the 483-0194 Plate (7) to the generator case, using 8T-4196 Bolts (8) and 8T-4121 Washers (9).

Image1.6.1

6. Install the 450-2396 Pulley (9b) to the 483-0198 Tensioner (10) using 172-9966 Bolt (10a) and 7X-0584 Washer (10b).

Image1.7.1

7. Install the 483-0198 Tensioner (10c) to the 483-0194 Plate (7) using the 280-8912 Bolt (11) and 8T-4121 Washer (13).

Image1.8.1

8. Install the 491-4346 Plate (13), equipped with the 491-4347 Roller (14), to the 483-0194 Plate (7), using 8T-4200 Bolts (15) and 8T-4224 Washers (16).

Image1.9.1

9. Install the 491-4351 Belt (17) to the drive belt system.

Image1.10.1

10. Install the 6V-5683 Bolt (18) in order to set the tensioner
Note: as first installation, install the 6V-5683 Bolt in order to align the hole 2 of the 483-0194 Plate to the 2nd hole (looking at the holes pattern in counterclockwise) on the 483-0198 Tensioner (see below for reference B).
Note: Measure the belt tension (measured on side A): 32-33.5 Hz

Image1.11.1

Image1.11.2

Image1.11.3

11. Install fenders, wheel and screed in order to restore the machine.
12. Start the machine couple of times in order to set the drive belt system.
13. Cut off the engine.
14. Check the belt tension in order to ensure the setting value.
15. Start the machine and run the heating system until all section are activated.
16. Shut down the heating system
17. Cut off the engine.
18. Check the belt tension in order to ensure the tension belt value is not decreased.