MPC-10 Propel Module Needs To Be Updated On Certain AP-650B, AP-1000B, AP-1050B, And AP-1055B Asphalt Pavers; And On Certain Barber-greene BG-225C, BG-245C, BG-260C, And BG-2455C Asphalt Pavers Manufactured By Caterpillar Caterpillar

NOTE: This Program must be administered as soon as possible. When reporting the repair, use "PI3245" as the Part Number, "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 "PI3245" as the Part Number, "7751" as the Group Number, "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.

NOTE: This Revised Service Letter replaces the February 24, 1999 Service Letter. Changes have been made to the Parts Needed and Rework Procedure.

NOTE: If PI3245 has already been completed there is no requirement to rework the machine.

Completion Date

Termination Date

Problem

The propel software needs to be updated on certain AP-650B, AP-1000B, AP-1050B, and AP-1055B Asphalt Pavers; and on certain Barber-Greene BG-225C, BG-245C, BG-260C, and BG-2455C Asphalt Pavers manufactured by Caterpillar to improve steering response and other software enhancements. The propel enable valves and plumbing must be removed in conjunction with this rework.

Affected Product
Model & Identification Number

Group 1

AP-650B (9DN1-380)

AP-1050B (6ZN1-194)

AP-1055B (8BM1-390, 8BM394-396, 8BM398, 8BM414-)

BG-225C (5GN1-471)

BG-245C (4XN1-122)

BG-2455C (6TN1-140)

Group 2

AP-1000B (7HN1-228)

BG-260C (8GN1-541)

Parts Needed

Dealers will need to order parts for this Program.

Group 1

4 - 3J7354 SEAL-O-RING

1 - 8L8413 STRAP-CABLE

4 - 9S4182 PLUG-O-RING

1 - 1491336 FILM-IDENT

1 - See Note CIRCUIT AS-P

Group 2

4 - 3J7354 SEAL-O-RING

1 - 8L8413 STRAP-CABLE

4 - 9S4182 PLUG-O-RING

1 - See Note CIRCUIT AS-P

1 - 1725331 FILM

NOTE: The Circuit Assembly is available by contacting Kathy Wiebusch of CPPI Paving Machinery at (612) 493-1496. Parts will be shipped to the dealer.

Action Required

See the attached procedure.

Owners Notification

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

Service Claim Allowances

NOTE: This is a 3-hour job.

NOTE: U.S. and Canadian Dealers Only - This Program does not qualify for a Type 2 SIMS Report.

Parts Disposition

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

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

Attach.

(1-Owner Notification)

(2-Rework Procedure)

Copy Of Owner Notification For U.S. And Canadian Owners

Rework Procedure

PROPEL ELECTRONIC CONTROL MODULE GROUP #1 & GROUP #2 MACHINES

Parts Required

(1) E-Prom 173-3929 (See note to order this part)

(1) 8L-8413 Tie Wrap

(1) 149-1336 (rev.01) Service Code Decal (GROUP #1 MACHINES ONLY)

(1) 172-5331 Service Code Decal (GROUP #2 MACHINES ONLY)

(4) 9S4182 7/16-20 O-Ring Plug

(4) 3J7354 O-ring Seal

NOTE: Rework the control module in a dust, moisture, and static free environment.

Remove all jewelry from your hands.

Use of a ground strap is highly recommended.

To clean the viewing glass use Alcohol. Do Not use Brake Cleaner or solvent on the control module.

1. Turn the key switch and disconnect switch off.

2. Remove 40-pin connector from the Propel control module with a 4.0 mm hex wrench.

3. Remove the control module by removing four 6V8185 retaining nuts, eight 8C5607 mounts, four 8C5608 spacers. Retain all parts.

4. Remove the sixteen Propel control cover mounting hex head bolts (1) using a in socket/wrench.

Illustration 1.

5. Slowly separate the back cover from the front cover. Three internal connectors must be disconnected before the two pieces can be separated from one another

Disconnect the 24 pin connector (2).

Disconnect the 12 pin connector (3).

Disconnect the 4 pin power connector (4).

Illustration 2 Propel Control Module -

(2) 24 Pin Connector

(3) 12 Pin Connector

(4) Pin Power Connector

6. Lay the back cover on a flat surface with the circuit board facing up.

NOTE: The service person should be grounded before removing or installing the EPROM by touching a metal table, metal stand, etc.

7. Using a cutter, cut 8L8413 plastic tie wrap that is holding the EPROM chip in the socket. Remove the plastic tie wrap and discard.

Illustration 3.

EPROM socket is located below the digital display when the cover is on the module.

(5) EPROM

(6) O-ring seal 3E8716

8. Note the direction in which the notch on the EPROM is pointing.

NOTE: The notch on the PC-board socket is not always pointing in the correct direction. Insure that notch on the EPROM is pointing in the same direction as noted in step 9.

9. Using a small screwdriver, gently pry upward on both ends of the EPROM until it is free from the socket. Retain the old EPROM until the new EPROM is installed .

10. Take the new EPROM and arrange the chip over the socket making sure that the notch is pointing in the proper direction as illustrated and the pins are lined up with the corresponding holes. The EPROM pins may need to be bent at a right angle to the EPROM body in order to install.

11. Push the EPROM into the socket, make sure it is pushed in all the way.

12. Slide a new 8L8413 plastic tie wrap between the EPROM socket and the circuit board. Clamp the tie wrap securely making sure not to over tighten. Remove excess tie wrap with a cutter.

13. Reconnect the 3 internal connectors making sure they are pushed all the way in.

Reconnect the 4 pin power connector (4).

Reconnect the 12 pin connector (3).

Reconnect the 24 pin connector (2).

14. Inspect the 3E8716 o-ring. Install a new 3E8716 o-ring if cut or damaged. Insert the sixteen hex head bolts finger tight. Check that the O-ring is properly seated before proceeding.

15. Tighten each bolt to 12 N·m (9ft-lb)

16. Reinstall the Propel control module into the machine. Tighten the 6V8185 retaining nuts to 12 N·m.

17. Connect the 40 pin connector using a 4.0mm hex wrench.

18. Remove the two propel enable valves and plumbing, disconnect the electrical connector and plug the pump ports with the four 7/16-20 O-Ring plugs P/N 9S4182 and seals P/N 3J7354. These valves are located above and to the left of the propel pumps with two hoses connected to the pump servo ports from the valves.

19. Install the service code decal p/n 149-1336 inside the left hand service door AP-650, BG-225C, AP-1050B, BG245C, AP-1055B & BG2455. Install the service code decal p/n xx-xxx inside the left hand service AP-1000B & BG-260C.

20. Turn on the disconnect and key start switches. The controller LED should be green. If no lights are on, check the Propel control module internal connections. If a red LED is flashing, repeat the EPROM change procedure.

21. Recalibrate the Propel control module according to the Propel Electronic Control System Service Manual (KENR2949)

22. Clear all inactive fault codes

23. Scribe the new part number (173-0579) on the box and grind out the old part number to identify that the module has been reworked and updated.