Procedure to Install New EP Control on the Asphalt Compactors{1408, 3065, 4294, 4801, 5070, 7451} Caterpillar

Paving Compactor:

CB-534D (S/N: FGH320-321,323-324,326-326,328-329,343-343,436-438,440-442,444-446,452-452,458-459)

Introduction

The following installation instruction is required to install an improved control system for the propel pump on the CB-534D Asphalt Compactors.

Removal of the ECM and Additional Electrical Components

Note: Cleanliness is an important factor. Before you begin the removal procedure, the exterior of the components should be thoroughly cleaned. This will help to prevent dirt from entering the internal mechanism.

Note: Ensure that all of the latest updates to the machine have been performed prior to performing the instructions for the rework.

To determine that the latest updates to the machine have been performed, verify that the following components have been installed:

• Verify that the speed control potentiometer part number is 270-8384 Potentiometer As .

• Verify that the 285-3591 Auxiliary Valve and Mounting Gp is installed.

• Verify that the 282-9461 Rear Wiring Gp is installed.

• Verify that the 283-8438 Sensor is installed on propel handle. Make sure that the propel handle is properly adjusted. Refer to Special Instruction, REHS3271, "The Procedure to Adjust the Neutral Sensor for the Propel System on Paving Compactors".

Note: If any of the components need to be installed, contact DSN for assistance before performing the updates.

1. Place the machine on stands so both drums are suspended at least 51 mm (2 inch) off the ground.

2. Place the battery disconnect switch in the OFF position.

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Illustration 1	g01278516

3. Remove cover (1) from the side panel of the machine.

4. Inspect if the 283-4450 Console Wiring Gp is installed. If the 283-4450 Console Wiring Gp is installed, go to Step 5. If 283-4450 Console Wiring Gp has not been installed, go to Step 18.

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Illustration 2	g01278520

5. Disconnect harness assembly (2). This harness assembly will have the label "Limit Switch".

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Illustration 3	g01278531

6. Remove the cable strap that secures timer (3) to the existing console harness assembly. The wires that lead to the base for the timer are labelled "Timer Relay".

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Illustration 4	g01278533

7. Remove the cable strap that secures harness assembly (4) to the main console. Harness assembly (4) will be labelled "Edge Cutter".

8. Disconnect harness assembly (4) .

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Illustration 5	g01278543

9. Remove cable straps and disconnect PK wire (5) from fault alarm (7) .

10. Remove cable straps and disconnect GY wire (6) from fault alarm (7) .

11. Remove fault alarm (7) from clip (8). Discard fault alarm (7) .

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Illustration 6	g01278554

Note: Note the position of relays before removing relays.

Note: On some machines, the relays may face toward the inside of the console. To assist with removal of the bolt on these machines, separate the bottom two bases for the relays from the top two bases for the relays and rotate the top two bases for the relays in order to expose the bolt head.

12. Remove bolt (9) that secures the four bases for the relays to the side console.

13. Separate the three bases for the relays, that are part of the console add on harness, from the base on the main console harness. The base for the relay that is part of the main console contains 200-BK wire, 537-GN wire, and 115-PK wire.

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Illustration 7	g01278556

14. Install bolt (9) and the single base for the relay (10) to the console. The single base for the relay (10) is part of the console harness.

    Note: The single base for relay (10) will contain a flasher if the machine is configured with the option for the Roading Lights. If the machine is not equipped with the option for the Roading Lights, the single base for relay (10) will be empty.

15. Remove the B765-BR wire from terminal 2 of the switch for the parking brake. The B765-BR wire is part of the console add on harness.

16. Disconnect B765-BR wires of the existing console harness for terminal 2 on the bottom block of the switch for the parking brake. Cover the terminal with 35 mm (1.4 inch) of 125-7874 Heat Shrink Tube . Tie the wire back to the console harness with a cable strap.

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NOTICE
Make sure the battery disconnect switch is in the OFF position. If the battery disconnect switch is in the ON position the 330-YL wire will be powered.

Note: On newer machines, the 330-YL wire may be connected from the main console harness to the add on console harness through the connector with a "Edge Cutter" label. In this situation, the 330-YL wire would not be cut.

17. If the 330-YL wire of the add on harness is spliced into the main console harness, cut the 330-YL wire of the add on harness 50 mm (2 inch) from the splice. Cover the end of the 330-YL wire that is attached to the main console harness with 30 mm (1.2 inch) of 125-7874 Heat Shrink Tube .

18. At this point, all the add on harness connections should be loose from the machine and the main console harness. Remove any additional cable straps that secured the add on harness to the console or the console harness. Remove the add on harness and discard the add on harness.

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Illustration 8	g01278793

19. Disconnect connector (11) from the existing ECM.

20. Remove the screws and the ECM from the console.

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Illustration 9	g01278815

21. Remove cover (12) from the fuse panel on the right side of the console.

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Illustration 10	g01278905

22. Remove screws (13) that hold the fuse panel to the console.

23. Remove the base for top relay (14) in order to expose the wiring on the back side.

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Illustration 11	g01278918

24. Cut the C720-BU wire and cover each end of the cut wire with 25 mm (1 inch) of 125-7874 Heat Shrink Tube .

25. Install the base for relay (14). Install the fuse panel and bolts (13) .

Update Machine Wiring

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Illustration 12	g01278793

1. Remove the 200-BK wire from location "29" of connector (11) .

2. Connect 200 mm (7.9 inch) of BU-18 gauge wire to the 135-BU wire. The 135-BU wire is installed in location" 28" of connector (11) .

3. Install a socket onto the new 135-BU wire.

4. Install the new wire into location "29". there should now be a blue wire in location "28" and a blue wire in location 29.

Install the Harness and Route the Harness for the Conversion

1. Remove the seat from the seat base.

2. Remove the cover assembly from the seat base.

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Illustration 13	g01278942

3. Remove cable straps (1) that secure existing console harness assembly (2) to the seat base.

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Illustration 14	g01278948

4. Pull existing console harness (2) away from the seat base. Route plug (3) for the ECM of the 290-6094 Console Harness Assembly (4) through the opening in the seat base. Console harness assembly (4) should route above console harness (2) .

   Note: Routing plug (3) for the ECM and console harness assembly (4) through the opening in the seat base will be tight. If necessary, remove edging (5) in order to provide clearance. Replace edging (5) after plug (3) for the ECM and console harness (4) has been routed through the opening in the seat base.

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Illustration 15	g01278956

5. Remove the 135-BU wire from position "5" of connector (6) on the handle for the propel control. Cover the exposed socket on the 135-BU wire with 35 mm (1.5 inch) of 125-7874 Heat Shrink Tube . Secure the 135-BU wire to the existing console harness.

6. Install 135-YL wire of console harness assembly (4) into position "5" of connector (6). Connect connector (6) to the plug on the propel control handle.

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Illustration 16	g01278960

7. Route the connector with the "J-C9" label on 290-6094 Console Harness Assembly behind the existing console harness. Connect the connector with the "J-C9" label to connector (8) on the existing console harness.

8. Route the connector with the "Edge Cutter" label on 290-6094 Console Harness Assembly behind the existing console harness. Connect the connector with the "Edge Cutter" label to connector (7) on the existing console harness. Connector (7) was connected to the add-on harness plug with the "Edge Cutter" label.

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Illustration 17	g01279222

9. Connect connector (9) with the "Propel Handle" label on the 290-6094 Console Harness Assembly to connector (10) for the proximity switch for the propel control handle.

   Note: Route the wires for this connection in a location that will relieve stress from the wires and protect the wires from damage. Secure the wires in place.

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Illustration 18	g01279239

10. Install 134-2540 Connector Receptacle (11) onto connector (12) with the "Can Resistor" label on the 290-6094 Console Harness Assembly .

    Note: Connector (12) should have a blue cover plate.

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Illustration 19	g01279267

11. Install 172-9200 Arc Suppressor (13) onto connector (14) with the "Diode Pack" label on the 290-6094 Console Harness As .

12. Disconnect the 419-YL wire of the existing console harness for terminal "4" on the bottom block of the switch for the parking brake. Cover the terminal with 35 mm (1.5 inch) of 125-7875 Heat Shrink Tube and tie the terminal back to the harness. Use a 3S-2093 Cable Strap to hold the terminal in place.

13. Connect the U735-GY wire of the 290-6094 Console Harness As to terminal "2" on the bottom block of the switch for the parking brake. Bend the spade terminal in order to match the other switch wires for the parking brake.

14. Connect the U734-GN wire of the 290-6094 Console Harness As to terminal "4" on the bottom block of the switch for the parking brake. Bend the spade terminal in order to match the routing of the other switch wires for the parking brake.

15. Connect the 419-YL wire of the 290-6094 Console Harness As to terminal "X1" on the top block of the switch for the parking brake. Bend the spade terminal in order to match the routing of the other switch wires for the parking brake.

    Note: Refer to table 1 for correct wiring connections.

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    Table 1

    Top Block
    Item	Location	To	Wire
    1	Terminal X1 (Oriented Inboard)	To	419-YL
    2	Terminal X1 (Oriented Inboard)	To	200-BK

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    Table 2

    Bottom Block
    Item	Location	To	Wire
    3	Terminal 1 (Oriented Outboard)	To	155-PK (2 wires)
    4	Terminal 3 (Oriented Outboard)	To	155-PK (2 wires)
    5	Terminal 2 (Oriented Inboard)	To	U735-GY
    6	Terminal 4 (Oriented Inboard)	To	U734-GN

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Illustration 20	g01279542

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Illustration 21	g01279615
Configuration for machine with the option for drum offset

16. Determine if the machine is configured with the option for the drum offset. If the machine is configured with the option for the drum offset, perform the following procedure. Disconnect jumper plug (21) from the connector with the "Engine Hi Idle" label and attach jumper plug (21) to cap (22) with the "Offset Config" label. If the machine is not equipped with the option for the drum offset, leave connector (21) installed on the connector with the "Engine Hi Idle" label and cap (22) on the connector with the "Offset Config" label.

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Illustration 22	g01279701

17. Secure all loose wires and connectors to the harness with 7K-1181 Cable Straps and 3S-2093 Cable Straps .

    Note: Secure connector (23) labelled "Test Mode" and connector (24) Labelled "Can Port" to the existing console harness. Place connector (23) and connector (24) in an accessible position behind the fuse cover.

Installation of the New ECM for the Propel System

1. Move steering hoses out of the way to allow access to the mounting location for the new ECM.

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Illustration 23	g01279722

2. Inspect the mounting location for the ECM for tapped mounting holes (1). If mounting holes (1) are present proceed to Step 6.

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Illustration 24	g01279727
(A) 10 ± 2 mm (.4 ± .08 inch) (B) 15 mm (.6 inch)

3. Weld 290-7915 Plate (2) into the seat base. Use the dimensions in Illustration 24. Weld a fillet around holes (3) to secure plate (2) to the seat base.

   Note: Make sure that the battery disconnect switch is in the OFF position. Connect the ground as close as possible to the weld.

4. Apply a coat of 4C-4198 Black Paint to the area that was welded in Step 3.

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Illustration 25	g01279749

5. Connect the plug from the 290-6094 Console Harness As to the 290-7906 Controller . 25.

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Illustration 26	g01279751

6. Secure 290-7906 Controller (5) and 266-3310 Cover Plate Assembly (8) to the mounting holes with 7X-2535 Bolts (6). Apply 40 mm (1.6 inch) of 7X-7877 Edge Strip (7). Tighten bolts (6) to a torque of 12 ± 3 N·m (9 ± 2 lb ft).

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Illustration 27	g01279857

7. Place steering hoses (9) back into the seat base, as shown.

8. Install the cover assembly onto the seat base.

9. Install the seat onto the seat base.

Test and Adjust for the Proximity Switch for the Propel Control Handle

Table 3

Required Tools
Tool	Part Number	Part Description	Qty
A	212-2160	Digital Multimeter	1
	9U-7330	Digital Multimeter	1
	7X-1908	Probe	1
	7X-1909	Probe	1

Note: The proximity switch needs to be properly adjusted in order to prevent the machine from detecting a neutral fault and disabling the propel system.

1. Attach Tooling (A) to the ground wire for the position sensor for the propel control handle. The ground wire is a 200-BK wire. The other probe should be connected to the K708-BU signal wire in position 3 for the position sensor.

2. Set the multimeter to report the percent duty cycle.

3. Press the parking brake switch.

4. Turn the ignition key to the ON position. Do not start the engine.

5. Wait until the switch for the parking brake illuminates.

6. Release the parking brake.

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Illustration 28	g01279946

7. Move the handle for the propel system to the FULL FORWARD position. In this position, yellow indicator light (1) for the proximity switch on the handle for the propel system should be ON.

   Note: On newer machines, yellow indicator light (1) on the proximity switch will be covered with a thin metal bracket. The yellow indicator light is also visible from the opposite side indicator of the proximity switch. The use of a mirror will help improve the visibility to the light.

8. Slowly move the handle for the propel system toward the NEUTRAL position and verify that indicator light for proximity switch (1) turns off between 57% and 63% of the duty cycle.

   Note: Certain multimeters may report numbers of approximately 40% for this direction. Incorrect readings indicate that the multimeter is registering a negative duty rather than a positive duty. This can be corrected by changing a setting on the multimeter. Consult the manual for the multimeter for instructions.

9. Move the handle for the propel system to the full REVERSE position.

10. Slowly move the handle for the propel system toward the NEUTRAL position and verify that the indicator light for proximity switch (1) turns off between the 37% and 43% of the duty cycle.

11. If the conditions in Step 8 and in Step 10 are met, proceed to Step 19. If either condition in Step 8 or 10 is not met, the screw for the proximity switch requires adjustment. Proceed to Step 12.

    Note: If the proximity switch requires adjustment, it is likely that a Code "52 NEUTRAL FAULT" will occur during the adjustment. Continue the adjustment procedure if the Code "52 NEUTRAL FAULT" appears. Clear the fault after completing the adjustment procedure by cycling power with the ignition key.

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Illustration 29	g01280057

12. Loosen jam nut (2) for the screw for the proximity switch (3) and remove the screw for the proximity switch (3) from the plate for the handle.

13. Clean the screw for proximity switch (3) and remove the screw for the proximity switch from the plate for the propel control handle. Apply 9S-3263 Thread Lock Compound to the screw for the proximity switch (3) and jam nut (2) .

14. Place the propel control handle in the NEUTRAL detent position. Install the screw for proximity switch (3) and jam nut (2). There should be a .8 mm (.03 inch) gap between the end of the screw and the proximity switch. Do not tighten the jam nut.

15. Repeat Step 8 through Step 10.

16. If the conditions in Step 8 and Step 10 are met, proceed to Step 19. If the conditions in Step 8 and Step 18 are not met, make the following adjustments:

    1. If the reverse duty cycle is greater than 37% and/or the forward duty cycle is greater than 63%. Turn the screw counterclockwise for one half of a turn.

    2. If the reverse duty cycle is greater than 43% and/or the forward duty cycle is greater than 57%, turn the screw clockwise for one half turn.

17. Repeat Step 15 and Step 16 until both conditions are met.

18. Tighten jam nut (2) on the screw for proximity switch (3) .

19. Apply the parking brake and turn the ignition key to the OFF position.

20. Remove the multimeter and probes.

Calibrate the Propel Control Handle and Automatic Speed Control

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Illustration 30	g01280270

1. Place the system in test mode by removing plug (3) from the pigtail for the harness. Containing 135-BU wire (1) and T970-GY wire (2) with the "Test Mode" label. Make sure that the parking brake is in the ON position.

2. Turn the key to the ON position. Do not start the engine.

3. If there are any fault codes, do not proceed to the next step. A series of long flashes and short flashes of the light for the parking brake will indicate fault codes. Refer to Table 5 for the fault codes.

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Illustration 31	g01280289
(A) Squeeze Tabs in order to Release the Connector.

4. Disconnect the sensor for the propel control handle from harness (4) and connect harness (4) within 5 seconds. This will initiate calibration of the propel control handle.

5. Move the propel control handle to the Full Forward position.

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Illustration 32	g01280296

6. Press button (5) .

7. Move the propel control handle to the full REVERSE position.

8. Press button (5) .

9. Move the propel control handle to the NEUTRAL position.

10. Press button (5) .

11. The light for the parking brake switch will flash twice in order to confirm that the calibration was accepted.

    Note: If calibration is not successful a fault code will be displayed on the light for the parking brake switch. If the calibration is not successful, cycle the power with the key and attempt the calibration again.

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    Table 4

    Accepted Calibration Values
    FORWARD position	90% ± 5%
    REVERSE position	10% ± 5%
    NEUTRAL position	50% ± 5%
    NEUTRAL DETENT position	50% ± 2%

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Illustration 33	g01280308

12. Disconnect automatic speed control potentiometer (6) from harness (7) and connect automatic speed control potentiometer (6) within five seconds. This will initiate automatic speed control potentiometer (6) for calibration.

13. Rotate automatic speed control potentiometer (6) clockwise to the maximum position.

14. Press button (5) .

15. Rotate automatic speed control potentiometer (6) counterclockwise to the minimum position.

16. Press button (5) .

17. The light for the parking brake switch will flash twice in order to confirm that the calibration was accepted.

    Note: If calibration is not successful, a fault code will be displayed on the light for the parking brake switch. If the calibration is not successful, cycle power with the key and attempt the calibration again.

18. Connect plug (3) to the connector with the "Test Mode" label.

    Note: Recycle the power in order to end the "Test Mode".

Procedure to Remove the Orifices From the Propel Pump

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Illustration 34	g01280327

1. Thoroughly clean the propel pump in order to remove all dirt and debris near the EDC for the propel pump and ports (1) with the "X1" label and "X2" label.

2. Remove the pressure taps from ports (1) with the "X1" label and "X2" label on the pump.

3. Remove the threaded orifice plugs from each port.

4. Thoroughly clean the pressure taps that were removed from ports (1) on the pump. Install the pressure tap "X1" and pressure tap "X2" on the pump.

Exercise the Machine for Ten Minutes.

Note: Do not remove the machine from the stands for this procedure. Verify that neither drum is touching the ground.

1. Make sure that the parking brake is applied. Start the engine. Set the engine in the LOW IDLE position.

2. Set the propel speed range control in the LOW position.

3. Set the variable speed control to the MAXIMUM setting.

4. Release the parking brake.

5. Place the propel lever in the FULL FORWARD position and allow the drum to rotate for 15 seconds.

6. Place the propel lever in the NEUTRAL position for 5 seconds.

7. Place the propel lever in the FULL REVERSE position and allow the drum to rotate for 15 seconds.

8. Place the propel lever in NEUTRAL position for 5 seconds.

9. Repeat Steps 5 through 8 for 10 minutes.

10. Apply the parking brake and stop the engine.

Removal of the EDC

1. Wash the area and dry the area that surrounds the propel pump.

2. Place a suitable drain pan under the pump area.

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Illustration 35	g01261420
This photograph is a bottom view of the propel pump.

3. Disconnect harness assembly (1) from the EDC.

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Illustration 36	g01261432

4. Disconnect hose assembly (2) from the "T2" port. Cap the hose assembly and "T2" port.

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Illustration 37	g01261439

5. Disconnect hose assembly (3) or disconnect hose assembly (4) from the dump valve. Only one hose assembly needs to be disconnected. Plug the hose assembly and cap the fitting on the dump valve.

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Illustration 38	g01261451

6. Remove hose assembly (5) from distribution block (6). Plug the hose assembly and cap the fitting on the dump valve.

7. Remove distribution block (6) .

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Illustration 39	g01261522

8. Remove bolts (7) from EDC (10) .

9. Remove EDC (10), gasket (11), plate assembly (8), and gasket (9) from pump (12) .

   Note: Gasket (11) is a transparent gasket.

Installation of the New EDC on the Propel Pump

Illustration 40	g01261550

The following parts are part of 290-0725 Pump Control Valve Gp : Gasket (13), EDC (14), Gasket (15), Plate assembly (16), Bolts (17), O-ring seal (18) and Dowel Pins 19.

1. Check plate assembly (16) in order to make sure that O-ring (18) is in place. If O-ring seal (18) is not in place, install O-ring seal (18) in plate assembly (16). Use 1U-6396 O-Ring Assembly Compound .

   Note: Do not use the O-ring seal from the old EDC. Obtain a new O-ring seal (18), if necessary.

2. If the old dowel pins remain in pump (12) from the old EDC, reuse the existing dowel pins with new EDC (14). Replace dowel pins that come out of pump (12) with new dowel pins.

3. Install gasket (13) between pump (12) and EDC (14). Gasket (13) should be positioned with the raised blue sealant toward EDC (14) .

4. Assemble gasket (13), EDC (14), gasket (15), plate assembly (16), and bolts (17) .

5. EDC (14) and plate assembly (16) are secured in two directions with bolts (17). Place the assembled pump control valve on pump (12). Hand tighten bolts (17). Start with the bolt that fastens plate assembly (16) to pump (12) .

6. Tighten bolts (17) to a torque of 10.4 N·m (7.7 lb ft). Start with the bolt that fastens plate assembly (16) to pump (12). Torque bolts (17) twice. Use the same tightening sequence.

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Illustration 41	g01261451
This photograph is a bottom view of the propel pump.

7. Install distribution block (6). Install the clip that secures the electrical connector.

8. Connect hose assembly (5) to distribution block (6) .

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Illustration 42	g01261432

9. Connect hose assembly (2) to the "T2" port.

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Illustration 43	g01261439

10. Leave hose assembly (3) or hose assembly (4) disconnected from the dump valve at this time.

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Illustration 44	g01261420

11. Connect harness assembly (1) to the EDC.

Test and Adjust the New EDC

1. Do not remove the machine from the jack stands for the test procedure. Make sure that the hydraulic oil is at the proper level in the hydraulic oil reservoir.

   Note: Verify that neither drum is touching the ground.

   Note: Verify that one of the hoses is disconnected from the dump valve.

2. Make sure that the parking brake is applied. Start the engine. Set the engine to LOW idle.

3. Set the propel speed range control in the LOW position.

4. Set the variable speed control to the MAXIMUM setting.

5. Release the parking brake.

6. Verify that neither drum is rotating in the NEUTRAL position.

7. Place the propel lever in the full FORWARD position and allow the drums to rotate for 15 seconds.

8. Place the propel lever in the NEUTRAL position. Neither drum should rotate in the NEUTRAL position.

9. Place the propel lever in the full REVERSE position. Allow the drums to rotate for 15 seconds.

10. Place the propel lever in the NEUTRAL position. Neither drum should rotate in the NEUTRAL position.

11. Repeat Steps 6 through 9 for 10 minutes.

12. Perform the EDC neutral adjustment. Refer to Testing and Adjusting, "Pump Control (Electronic Displacement Control) - Test and Adjust".

    Note: Verify that neither drum is touching the ground.

    Note: One of the hoses must be disconnected from the dump valve in order to properly perform the neutral adjustment procedure for the EDC. Do not reconnect the hose to the dump valve until completing Step 13.

    Note: Be sure to remove the hose assemblies for the brake and cap the brake supply lines. The front brakes and rear brakes must remain applied during the neutral adjustment procedure for the EDC.

13. Repeat the procedure in Steps 2 through 11. Neither drum should rotate when the control lever is placed in the NEUTRAL position. If no movement is detected, the test procedure is complete. If drum movement is detected with the propel lever in NEUTRAL at any point in the additional 10 minutes of operation, go back to Step 12.

14. Reconnect the hose to the dump valve that was disconnected in Step 5 of ""Removal of the EDC " " of the procedure.

15. Remove the machine from stands.

Calibrate the Currents for the Propel Pump

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NOTICE
Both the FORWARD and REVERSE proportional solenoid threshold currents need to be calibrated.

Note: The calibration of current should be performed on a hard, level surface.

Note: The tank for the water spray system should be empty.

Note: Prior to conducting the calibration of current, run the machine in order to ensure that the hydraulic temperature reaches 38 °C (100 °F).

Note: Do not activate the Steering wheel or the offset switch during the current calibration sequence. Activating these functions during the calibration can affect the calibration values and lead to undesirable machine performance.

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Illustration 45	g01280270

1. Place the system in test mode by removing plug (3) from the harness with the "Test Mode" label. Make sure that the Parking Brake is ON.

2. Turn the key to the ON position.

3. Start the engine. Calibration should be made in "HI" idle. Release the parking brake.

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Illustration 46	g01281185

4. Set automatic speed control potentiometer (5) near the mid-position.

5. Select LOW propel range on the speed switch for propel control (6) .

6. Move the propel control handle to the full FORWARD position.

7. When the machine just begins to move, press button (4) for the water spray in order to calibrate the forward current. Approximately one minute is required to calibrate the forward current. The light for the parking brake switch will flash twice in order to confirm that the calibration was accepted.

   Note: The light for the parking brake switch must flash twice in order to indicate successful calibration of the forward current. Failure to wait for a confirmation can cause the reverse calibration of the threshold to fail.

8. Return the propel control handle to the NEUTRAL position.

9. Move the propel control handle to the full REVERSE position.

10. When the machine just begins to move, press button (4) for the water spray in order to calibrate the Reverse current. Approximately one minute is required to complete calibration of the reverse current. The light for the parking brake switch will flash twice in order to confirm that the calibration was accepted.

11. Return the propel control handle to the NEUTRAL position.

12. Engage the parking brake, and turn the engine to the OFF position.

13. Connect plug (3) to the connector with the "Test Mode" label.

    Note: If the operator does not detect motion after 60 seconds a fault code will be displayed and the calibration sequence will be aborted. A fault code will be displayed and the calibration sequence will be aborted if the water spray button is pushed after the electrical current reaches the upper calibration limit of the pump solenoid.

    Note: If Calibration is not successful a fault code will be displayed on the light for the parking brake switch. Verify that the potentiometer for the automatic speed control is set near the mid-position if calibration is not successful. If the calibration procedure is not successful, cycle power with the key and attempt the calibration procedure again.

14. Check all the machine functions for proper operation.

15. Install the plastic cover on the side console.

Fault Codes Table.

Fault codes are indicated on the machine through a sequence of flashes from the parking brake light. Each fault code will be indicated by a series of long flashes that are followed by a series of short flashes. The first digit of the fault code is the number of long flashes and the second digit of the fault code is the number of short flashes. Neutral Fault number fifty two would be indicated by five long flashes then two short flashes by the light that is for the parking brake switch.

Table 5

Fault Code	Fault Code
11	Brake Switch
12	Propel Control Handle
13	Speed Control
14	Solenoid for the Forward EDC
15	Solenoid for the Reverse EDC
16	Calibration of the Propel Control Handle
17	Calibration of the Speed Control
18	Calibration of the Forward EDC
19	Calibration of the Reverse EDC
22	Offset Switch
28	CCW Offset
29	CW Offset
31	Brake Solenoid
32	Solenoid of the Valve for the Shunt
51	Propel Mode
52	Neutral Fault
53	Machine Type
54	Backup Alarm
91	Sensor Power