PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE INVERTER ON CERTAIN AP600F, AP655F, AP1000F, AND AP1055F ASPHALT PAVERS Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE INVERTER ON CERTAIN AP600F, AP655F, AP1000F, AND AP1055F ASPHALT PAVERS

Usage:

TEBE4367-05

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29Feb2016

(Revised 30Jun2016)

O-113

U-107

A-103

D-119

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Priority Parts stock action needed	PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE INVERTER ON CERTAIN AP600F, AP655F, AP1000F, AND AP1055F ASPHALT PAVERS
4822 7750		PI32611

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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 as soon as possible. When reporting the repair, use "PI32611" as the Part Number and "7751" as the Group Number, "56" as the Warranty Claim Description Code and "T" as the SIMS Description code. Exception: If the repair is done after failure, use "PI32611" as the Part Number, "7751" as the Group Number, "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.

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NOTE:

When submitting claim for Parts Stock Action, Use the appropriate 99Z as the s/n, the appropriate Service Letter Program Number as the Part number in the Part Causing Failure field, "7751" as the Group Number, "56" as the 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 29Feb2016 (Revised 23Jun2016) Service Letter. Changes have been made to the Rework Procedure.

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COMPLETION DATE	TERMINATION DATE
31Aug2016	28Feb2017

PROBLEM

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The failure of 448-9287 Power Inverter Group will prevent operation of the electric screed heat and auxiliary power panel. Inverter internal connector is failing.
The internal cable that connects to the 70 pin connector can lose continuity.

AFFECTED PRODUCT

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Model	Identification Number
*****Group 1*****
AP1000F	AC400103-00104, 106, 108-111, 113, 115, 117-123, 125, 127, 130-131, 133-134, 136-137, 140, 142, 144, 146-147, 149-155, 157, 162, 165-166, 171, 173, 176-177, 180, 185, 187
AP1055F	RLM00100-00105 TJ500100-00101, 107-108, 112-114, 119-121, 124-125, 128, 131, 137-138, 147-148, 150-152, 154, 156, 159, 162, 167-169, 172-181, 184-185, 187-188, 192, 197, 199, 202-203, 209, 213, 217-222, 224, 231, 235-241, 244-245, 253-254, 258-261, 264, 266-267, 270, 274-279, 281-283, 285-294, 296-299, 302-304
AP600F	AP600101, 103, 106-108, 110-111, 113-114 LR600100-00102
AP655F	MH600102, 104, 119, 124-126, 136 ML600100-00102 P6500100-00106, 108-109

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*****Group 2*****
AP1000F	AC400189-00194, 196-199, 201, 203-204
AP1055F	TJ500307-00334
AP600F	AP600115-00117
AP655F	47900104 MH600103, 106, 111, 118, 122, 128, 130-133, 135, 138, 141, 144, 146-147, 149-153, 155-162

PARTS NEEDED

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Qty	Part Number	Description
*****Group 1*****
1	1261774	ENDBELL-CONN
1	4992622	INVERTER GP-PWR
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 37% 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.
*****Group 2*****
1	4992622	INVERTER GP-PWR
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 42% 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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****Parts Stock ****

Remove all 448-9287 Power Inverters with a serial number of JF300625 (625 is the indicator) and lower from dealer parts stock.

Send the inverters back as quickly as possible. Refer to the Parts Disposition.

****Affected Product****

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Note: If a machine in the Affected Product is equipped with an inverter with a serial number containing "RJF300XXX", then no further action is necessary.

NOTE: Parts are on a parts freeze/hold and will be released for machines that are contained within this program.

To help expedite the shipping of the Inverter - Place an "Emergency Order" for the 499-2622 Inverter on the Service Letter. After placing the order, call Customer Service with the following information:
Model
Serial number of the Paver
Ask to have the Order released

Refer to the attached Rework Procedure.

Send the inverter back as quickly as possible. Refer to the Parts Disposition.

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OWNER NOTIFICATION

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Owners in the following countries will receive the attached Owner Notification:
US
Canada

SERVICE CLAIM ALLOWANCES

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****Parts Stock****

Submit one claim for all parts removed from dealer parts stock.

****Affected Product****

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Caterpillar		Dealer Suggested		Customer Suggested
Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
*****Group 1*****
100%	100%	0%	0%	0%	0%

NOTE: This is a 4.0-hour job for Group 1

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Caterpillar		Dealer Suggested		Customer Suggested
Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
*****Group 2*****
100%	100%	0%	0%	0%	0%

NOTE: This is a 4.0-hour job for Group 2

PARTS DISPOSITION

****Parts Stock****

NACD:

Hold the inverters removed from dealer parts stock for a Parts Return Request. To expedite the return of the inverters before a claim is submitted, contact Jim Moore (Moore_James_E@cat.com) for a Parts Return Request. A Parts Return Request will be issued to you through the Send-It-Back process after the claim is submitted. Make sure to list the service letter program number on the packing slip and include the closed work order paperwork, invoice, the and B/L (Bill Of Lading). On the return, state that there is "No Commercial Value" for any of the inverters.

EAME, LACD, and APD:

Hold the inverters removed from dealer parts stock for a possible Parts Return Request. Contact Jim Moore (Moore_James_E@cat.com) for a possible Parts Return Request. Make sure to list the service letter program number on the packing slip and include the closed work order paperwork, invoice, the and B/L (Bill Of Lading). On the return, state that there is "No Commercial Value" for any of the inverters. If a Parts Return Request is not issued to you after 30 days through the Send-It-Back process, handle the parts in accordance with your warranty bulletin on warranty parts handling.

****Affected Product****

NACD:

Hold the inverter removed from the Affected Product for a Parts Return Request. To expedite the return of the inverters before a claim is submitted, contact Jim Moore (Moore_James_E@cat.com) for a Parts Return Request. A Parts Return Request will be issued to you through the Send-It-Back process after the claim is submitted. Make sure to list the service letter program number on the packing slip and include the closed work order paperwork, invoice, the and B/L (Bill Of Lading). On the return, state that there is "No Commercial Value" for any of the inverters.

EAME, LACD, and APD:

Hold the inverter removed from the Affected Product for a possible Parts Return Request. Contact Jim Moore (Moore_James_E@cat.com) for a possible Parts Return Request. Make sure to list the service letter program number on the packing slip and include the closed work order paperwork, invoice, the and B/L (Bill Of Lading). On the return, state that there is "No Commercial Value" for any of the inverters. If a Parts Return Request is not issued to you after 30 days through the Send-It-Back process, handle the parts in accordance with your warranty bulletin on warranty parts handling.

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EXAMPLE COPY OF OWNER NOTIFICATION

XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999

PRIORITY - PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE INVERTER

MODELS INVOLVED - CERTAIN AP600F, AP655F, AP1000F, AND AP1055F ASPHALT PAVERS

Dear Cat Product Owner:

The inverter needs to be replaced on the products listed below. The existing inverter can prevent operation of the electric screed heat. You will not be charged for the service performed.

Contact your local Cat dealer immediately to schedule this service. The dealer will advise you of the time required to complete this service.

If you are no longer the owner of this product(s), please contact your local Cat dealer so that our records can be updated. Please refer the dealer to their Service Letter dated 29Feb2016 when scheduling this service.

We regret the inconvenience this may cause you, and urge you to have this service performed as soon as possible to prevent unscheduled downtime.

Caterpillar Inc.

Identification #(s)

Attached to 29Feb2016 Service Letter

Rework Procedure

Note: If a machine in the Affected Product is equipped with an inverter with a serial number containing "RJF300XXX", then no further action is necessary.

TOOLS REQUIRED
Tools required for electrical fittings
Remove and Replace
? Lock wire 5P-6025
? Wrench-strap 459-0233
? Diagonal Cutter 314-8478

ACTION REQUIRED

NOTE: Parts are on a parts freeze/hold and will be released for machines that are contained within this program.

To help expedite the shipping of the Inverter - Place an "Emergency Order" for the 499-2622 Inverter on the Service Letter. After placing the order, call Customer Service with the following information:
Model
Serial number of the Paver
Ask to have the Order released

Note: Ensure that all safety information, warnings, and instructions are read and understood before any operation or any maintenance procedures are performed. Refer to the Operation and Maintenance Manual, "Safety Section".

NOTE: If you have a wheeled paver, access will be tighter, but this procedure can be done without removing the wheel.

Refer to Troubleshooting, UENR3864, "Electrical Shutdown and Voltage Discharge" or Troubleshooting, UENR5500, "Electrical Shutdown and Voltage Discharge" procedure prior to starting rework.

DO NOT PERFORM ANY TYPE OF PROCEDURE ON THE ELECTRIC SCREED HEAT SYSTEM COMPONENTS OR THE ACCESSORY POWER INVERTER COMPONENTS WHEN THE ENGINE IS IN OPERATION. REGARDLESS OF THE GENERATOR ENABLEMENT.

REWORK PROCEDURE

1. For wheeled machines, lower right side fender

Image1.3.1

2. Make sure that there are no red lights (1) on power inverter (2)

Image1.4.1

3. Remove twenty-four screws (3) and three inverter access plates (4)

Image1.5.1

4. Remove bolts (5) for power Inverter to generator wires. Remove all six bolts.
Back off Grommet (6) and rubber washer. Unscrew ferrule to inverter (7). Remove power inverter to generator wires (8). Note their locations so you can reinstall in the correct locations

Image1.6.1

5. Cut lock wire (9) and disconnect screed to Inverter harness (10) and if equipped (9) AC Power Panel to inverter HV cable. Unplug 70 pin connector. Unplug FAN! Take six bolts (11) out holding inverter. Assembly is in reverse order of disassembly. Connect the harness connectors. Use tool (B) to tighten the harness connectors to a torque of 10.5+/- 0.3 Nm (7.7 +/- 0.2 lb ft). Use tool (D) to replace any lock wire cut by the tool (C).

Image1.7.1

Image1.7.2

Image1.7.3

6. Remove Inverter. Inverter weighs approximately 65 pounds. Transfer ground straps from old to new inverter

Image1.8.1

NOTE: For Group 1 machines
1. Install 126-1774 End Bell on to the harness

2. Install new 499-2622 Inverter and reverse steps shown above. Use Illustration for a guide to the Generator Phase Cables.

3. Ensure 70 Pin Connector is installed correctly by using the following procedure:

Image1.9.1

Image1.9.2

Image1.9.3

70 Pin Connector Proper Assembly
The 70 pin connector of the Control Harness As (Inverter Harness) at the Power Inverter Module may be misaligned during assembly. The jack screw of the 70 pin connector can be cross threaded, and not allowing full engagement of the connector plug to the receptacle bulkhead. This may cause intermittent fault codes. If any of these codes are associated with the Power inverter, then check the 70 Pin Harness connection. This also may result in damage or corrosion to connector pins and sockets.

Solution
Perform the following test procedure to check for proper installation of the Control Harness As (Inverter Harness) :

Test Procedure
Use the following test procedure to check for proper installation of the 70 pin connector of the Control Harness As (Inverter Harness) onto the Power Inverter Module:

Image1.11.1

Inverter with ECM and Inverter Harness
(1) Connector
(2) Location of Jack screw on ECM

1. Remove the harness bolt and washer (2) on the Control Harness As (Inverter Harness) (1) .
2. Check for proper assembly of the Control Harness As (Inverter Harness) (1) to the inverter. If the connector at the location of Jack screw (2) can be removed within five complete 360 degree turns or less of backing off the jack screw, then the jack screw was not fully engaged.

Inverter Not Properly Assembled
If the inverter is not properly assembled, perform the following procedure:
1. Remove the harness at the location of jack screws (2) and connector (1) completely.
2. Inspect harness plug and header receptacle at the location of jack screw (2) for pin damage, corrosion, debris, fluids, or cross thread damage to the jack screw and brass nut.
3. Clean/Repair as necessary.
a. In case of corrosion or pin damage, replace affected parts.
b. Check the threads on the jack screw for damage. If the threads are damaged, then the harness will need to be scrapped and a new harness will have to be used.
c. If the threads are in good condition, then make sure that there is no debris embedded in the threads. Clean out any debris for making sure that none of the debris falls into the sockets of the connector. If needed, tap the brass nut out using a 6 mm (0.24 inch) diameter with 1 mm (0.04 inch) thread pitch tap.
Note: Clean all metal flakes and debris out of inverter connector, both where the pins are and inside the nut.
This should be done by using CLEAN DRY compressed air to blow out the debris. Make sure that no debris falls back into the connector.
4. Reinstall the harness starting at jack screw at (2). Carefully reattach the connectors to make sure that the jack screw at (2) is not cross threaded again.
Note: There should be at least six complete 360 degree turns of engagement of the jack screw prior to reaching torque specification 5 N.m (3.7 lb ft) to 7.5 N.m (5.5 lb ft).
5. If the machine still presents faults, follow the normal troubleshooting procedures as specified in Service Manual.

Inverter Properly Assembled
If the inverter is properly assembled, perform the following procedure:
1. Retorque the Jack screw (2) to torque specification 5 N.m (3.7 lb ft) to 7.5 N.m (5.5 lb ft).
2. Reinstall the harness bolt and washer (2) .
3. Follow the normal troubleshooting procedures as specified in Service Manual.