PRODUCT IMPROVEMENT PROGRAM FOR CHECKING THE SETTINGS ON THE ELECTRIC SCREED GENERATOR ON CERTAIN AP-1000D, AP-1055D, AP-600D, AP-655D, AND AP-800D ASPHALT PAVERS; AND ON CERTAIN BARBER-GREENE, BG-2455D, AND BG-260D ASPHALT PAVERS MANUFACTURED BY CAT Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR CHECKING THE SETTINGS ON THE ELECTRIC SCREED GENERATOR ON CERTAIN AP-1000D, AP-1055D, AP-600D, AP-655D, AND AP-800D ASPHALT PAVERS; AND ON CERTAIN BARBER-GREENE, BG-2455D, AND BG-260D ASPHALT PAVERS MANUFACTURED BY CAT

Usage:

REBE4468-00

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15Oct2008

U-527

A-437

D-444

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*Priority*	PRODUCT IMPROVEMENT PROGRAM FOR CHECKING THE SETTINGS ON THE ELECTRIC SCREED GENERATOR ON CERTAIN AP-1000D, AP-1055D, AP-600D, AP-655D, AND AP-800D ASPHALT PAVERS; AND ON CERTAIN BARBER-GREENE, BG-2455D, AND BG-260D ASPHALT PAVERS MANUFACTURED BY CATERPILLAR
4450		PI31567

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NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI31567" 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 "PI31567" 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:

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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COMPLETION DATE	TERMINATION DATE
30Apr2009	31Oct2009

PROBLEM

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The generator needs to be inspected on certain AP-1000D, AP-1055D, AP-600D, AP-655D, AP-800D Asphalt Pavers; and on certain Barber-Greene BG-2455D and BG-260D Asphalt Pavers manufactured by Caterpillar. The existing generator adjustment settings can be incorrect.

AFFECTED PRODUCT

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Model	Identification Number
AP-1000D	EAD00230-00231, 233-255, 259-265, 267-268, 272-291, 293
AP-1055D	A6P00119-00121 FAC00527, 533, 538-561, 563, 565-579, 581-592, 596-606, 609-611, 614-634, 636-637, 639, 642-645, 647-650, 652
AP-600D	TFZ00201-00211
AP-655D	GNZ00216-00217, 219-221, 223-229, 231-248, 251-266 MAT00204
AP-800D	A5P00215, 220, 223-224, 230-231, 234-235
BG-2455D	BXW00102
BG-260D	BPW00125-00126, 128-130

PARTS NEEDED

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No parts needed for this program

ACTION REQUIRED

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Refer to the attached Rework Procedure.

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OWNER NOTIFICATION

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U.S. and Canadian owners will receive the attached Owner Notification.

SERVICE CLAIM ALLOWANCES

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Caterpillar		Dealer Suggested		Customer Suggested
Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
100%	100%	0%	0%	0%	0%

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NOTE: This is a 2.0-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.

MAKE EVERY EFFORT TO COMPLETE THIS PROGRAM AS SOON AS POSSIBLE.

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COPY OF OWNER NOTIFICATION FOR U.S. AND CANADIAN OWNERS

XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999

PRIORITY - PRODUCT IMPROVEMENT PROGRAM FOR CHECKING THE SETTINGS ON THE ELECTRIC SCREED GENERATOR ON CERTAIN AP-1000D, AP-1055D, AP-600D, AP-655D, AND AP-800D ASPHALT PAVERS; AND ON CERTAIN BARBER-GREENE, BG-2455D, AND BG-260D ASPHALT PAVERS MANUFACTURED BY CATERPILLAR

MODELS INVOLVED - AP-1000D, AP-1055D, AP-600D, AP-655D, AP-800D, BG-2455D, and BG-260D ASPHALT PAVERS.

Dear Caterpillar Product Owner:

The generator needs to be inspected on the products listed below. The existing generator adjustment settings can be incorrect. You will not be charged for the service performed.

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

Please refer the dealer to their Service Letter dated 15Oct2008 when scheduling this service.

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

Caterpillar Inc.

Identification #(s)

Attached to 15Oct2008 Service Letter

Rework Procedure

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Image1.1.1

Warning: Stop the engine before any service to the electric power generation equipment is begun. Remove the ignition key. Place the battery disconnect switch in the OFF position.

1. Do not start the machine.

Image1.2.1

2. Locate generator and remove six bolts (1) and top cover (2).

Image1.3.1

Image1.3.2

3. Use compressed air in order to remove any dust from the voltage regulator.

4. Inspect the voltage regulator in order to determine if it is a Type R230 or a Type R250 (Refer to illustrations).

5. If the voltage regulator is a Type R230 no adjustment is required. Install the top generator cover (2). The rework is complete. If the voltage regulator is a Type R250 proceed to Step 6.

6. Note the position of the adjustment screw (4).

Image1.4.1

7. Use Tool (A) to set adjustment screw (4) to "3-OFF" position (6).

8. Install the top generator cover (2).

9. Start the engine. Run the machine until the hydraulic oil reaches a temperature of 40? +/- 3? C (105? +/- 5? F).

10. Stop the engine.

Image1.5.1

11. Open the door on the auxiliary electrical panel (7) if equipped. If the machine is not equipped with an auxiliary electrical panel (7), the rework is complete.

12. Install Tool (B) in "240 V" receptacles (8) on the auxiliary electrical panel in order to measure the hertz and voltage performance of the generator.

Image1.6.1

13. Start the engine and set the throttle to full speed.

14. Start the generator.

15. Switch Tool (B) to volts and check the voltage reading. Tool (B) should read approximately 240 volts.

16. Turn the heaters for the screed plates to the ON position.

17. Switch Tool (B) to hertz and check the reading. Tool (B) should read 61 +/-1 hertz. If the hertz setting is correct the rework is complete. If the hertz setting is not correct, proceed to Step 18.

18. If the hertz reading is either too low or too high adjust the speed of the generator per the section of the testing and adjusting service manual titled "Generator frequency test and adjust".

Note: The service manual instruction may indicate that the generator frequency should be adjusted with the screed plate heaters turned OFF. When performing this generator frequency test the screed plate heaters should be turned ON. The service manuals will be updated to reflect this change.