Usage:
NOTE: This Program can be administered either before or after a failure. In either case the decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS4763" as the Part Number and "7755" as the Group Number. If administered before failure, use "56" as the Warranty Claim Description Code and use "T" as the SIMS Description Code. If administered after failure, use "96" as the Warranty Claim Description Code and use "Z" as the SIMS Description Code.
Termination Date
April 30, 2000Problem
The material module software 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 has been revised and provides improved sonic sensor performance and an additional calibration that allows adjustment of the maximum auger speed.
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
Group 1
Group 2
Action Required
See the attached procedure.
Service Claim Allowances
NOTE: This is a 2-hour job.
Parts Disposition
Handle the parts in accordance with your Warranty Bulletin on w35arranty parts handling.
Attach.
- (1-Rework Procedure)
Rework Procedure
MATERIAL ELECTRONIC CONTROL MODULE GROUP #1 & GROUP #2 MACHINES
Parts Required
- (1) 174-2939 Feeder E-Prom
- (1) 8L8413Tie Wrap
- (1) 172-5331 Service Code Decal ( GROUP #2 MACHINES ONLY)
- (1) 8L8413Tie Wrap
NOTE: The decal is required only if the correct decal is not present.
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 Material 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 7/16 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 -
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.
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 and replace 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 Material 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. Install a new service code decal inside the left hand service door if not equipped.
19. Turn on the disconnect and key start switches. The controller LED should be green. If no lights are on, check the Material control module internal connections. If a red LED is flashing, repeat the EPROM change procedure.
20. Recalibrate the Material control module according to the Material Electronic Control System Service Manual (KENR2861)
NOTE: The service code decal indicates additional required calibration steps that are not shown in the service manual.
21. Clear all inactive fault codes
22. Scribe the new part number (174-2937) on the box and grind out the old part number to identify that the module has been reworked and updated.