PRODUCT IMPROVEMENT PROGRAM FOR REWORKING THE PROPEL CONTROL SYSTEM ON CERTAIN CB-434D AND CB-534D ASPHALT COMPACTORS Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR REWORKING THE PROPEL CONTROL SYSTEM ON CERTAIN CB-434D AND CB-534D ASPHALT COMPACTORS

Usage:

SEBE9455-01

January 13, 2006
(Revised April 2006)
O-20

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*Safety*	PRODUCT IMPROVEMENT PROGRAM FOR REWORKING THE PROPEL CONTROL SYSTEM ON CERTAIN CB-434D AND CB-534D ASPHALT COMPACTORS
5412 5910 7620		PI10441

NOTE: This Program must be administered as soon as possible. When reporting the repair, use "PI10441" 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 "PI10441" 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 January 13, 2006 Service Letter. Changes have been made to the Affected Product.

PROBLEM

Caterpillar recently requested removal of certain CB-434D and CB-534D Asphalt Compactors from service. The propel control system needs to be reworked on each of these Asphalt Compactors. After the propel control system is reworked by implementing this program the Asphalt Compactor can be returned to service.

AFFECTED PRODUCT

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Model	Identification Number
*** Group 1 ***
CB-534	C2B00173, C2B00189, C2B00190
CB-534DXW	EAA00246
CB-534DXW	C4B00203

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Model	Identification Number
*** Group 2 ***
CB-434D	CNH000322, CNH394, CNH396, CNH398-399

PARTS NEEDED

Dealers will need to order parts for this Program.

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Quantity	Part Number	Description
*** Group 1 - CB-534/D***
1	5C2890	NUT
2	8C8451	BOLT
3	6D4246	CLIP
3	3J1907	SEAL-O-RING
1	3K0360	SEAL-O-RING
5	7K1181	STRAP-CABLE
2	4P7581	CLIP-LADDER
2	5P4115	WASHER-HARD
2	5P4116	WASHER-HARD
2	8T6869	BOLT
3	6V8397	SEAL-O-RING
2	6V8398	SEAL-O-RING
1	1160118	CLIP
1	1388737	HOSE AS
1	1765505	CONNECTOR
1	2829626	HOSE AS.
1	2836929	KIT-REWORK (See Note)
2.5 m	5P5677	WIRE
Note: The 283-6929 KIT-REWORK contains two, 282-8453, .9mm orifices. These orifices are not required for this program so please discard the orifices and do not use in the completion of this program
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*	2838325	ORIFICE ? 2.1mm
*	Sauer	Service Tool Kit
* Note: One 285-7320 Orifice will be required to complete the rework for each CB-534D Asphalt Compactor. These orifices will be supplied along with the Sauer Service Tool Kit to be supplied to the dealer directly by Caterpillar Prodotti Stradali. One kit will be supplied per dealer. Contact Mauro Monti at phone 3905-1660-7431, or Monti_Mauro @ cat.com by e-mail to obtain the Sauer Service Tool Kit (including all required orifices).

Dealers will need to order parts for this Program.

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Quantity	Part Number	Description
*** Group 2 - CB-434D ***
1	5C2890	NUT
3	5C7261	NUT
3	3J1907	SEAL-O-RING
5	7K1181	STRAP-CABLE
2	4P7581	CLIP-LADDER
2	5P4116	WASHER-HARD
2	8T3647	BOLT
2	8T6870	BOLT
3	6V8397	SEAL-O-RING
2	6V8398	SEAL-O-RING
2	6V8724	ELBOW-FACE SEAL
1	6V9837	TEE-SWIVEL
1	1160118	CLIP
1	1765505	CONNECTOR-
1	2357155	HOSE AS.
1	2834948	HOSE AS.
1	2838199	KIT-REWORK
2.5 m	5P-5677	WIRE
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*	2857320	ORIFICE ? 1.4mm
*	2838325	ORIFICE ? 2.1mm
*	Sauer	Service Tool Kit
* Note: One 285-7320 Orifice and one 283-8325 Orifice will be required to complete the rework for each CB-434D Asphalt Compactor. These orifices will be supplied along with the Sauer Service Tool Kit to be supplied to the dealer directly by Caterpillar Prodotti Stradali. One kit will be supplied per dealer. Contact Mauro Monti at phone 3905-1660-7431, or Monti_Mauro @ cat.com by e-mail to obtain the Sauer Service Tool Kit (including all required orifices).

ACTION REQUIRED

***** Group 1 - CB-534D Asphalt Compactors *****

Perform the following procedures to rework the propel control system.

----CB-534D Rework Procedure

----Propel Handle Rework

----Flash New Software Into Control Group

NOTE: Flashing new software into the Control Group will require the new software files. The required PLUS+1 GUIDE computer program, ECM software file and required cable connectors are part of the Sauer Service Tool Kit and should be obtained from Caterpillar Prodotti Stradali. ----Installation of Valve Control Circuitry Note: The valve control circuitry and propel handle portions can be completed while the hydraulic tank is draining. ----Return To Service Check

***** Group 2 - CB-434D Asphalt Compactors *****

Perform the following procedures to rework the propel control system.

----CB-434D Rework Procedure

----Propel Handle Rework

----Flash New Software Into Control Group

OWNER NOTIFICATION

An example of an Owner Notification Letter is attached.

SERVICE CLAIM ALLOWANCES

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Caterpillar		Dealer Suggested		Customer Suggested
Parts	Labor Hrs.	Parts	Labor Hrs.	Parts	Labor Hrs.
*** Group 1 - CB-534D Asphalt Compactors ***
100%	9.5	0	0	0	0
NOTE: This is a 9.5-hour job.

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Caterpillar		Dealer Suggested		Customer Suggested
Parts	Labor Hrs.	Parts	Labor Hrs.	Parts	Labor Hrs.
*** Group 2 - CB-434D Asphalt Compactors ***
100%	9.5	0	0	0	0
NOTE: This is a 9.5-hour job.

PARTS DISPOSITION

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

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

Attach. (1- Example Of An Owner Notification Letter)
        (2-CB-434D Rework Procedure)
        (2-CB-534D Rework Procedure)
        (3-Propel Handle Rework)
        (4-Flash New Software Into Control Group)
        (5-Installation of Valve Control Circuitry)
        (6-Return To Service Check)

EXAMPLE OF AN OWNER NOTIFICATION LETTER

XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999 SAFETY - PRODUCT IMPROVEMENT PROGRAM FOR REWORKING THE PROPEL CONTROL SYSTEM ON CERTAIN CB-434D AND CB-534D ASPHALT COMPACTORS MODELS INVOLVED - CB-434D AND CB-534D ASPHALT COMPACTORS

Dear Caterpillar Product Owner:

Caterpillar recently requested removal of the products listed below from service.

Caterpillar has recently investigated reports of CB-434D and CB-534D Asphalt Compactors allegedly failing to properly respond to propel control commands. Failure of the machines to properly respond to a propel command may happen unexpectedly at any time during machine operation and may result in personal injury or death.

After the propel control system is reworked by implementing this program the Asphalt Compactor can be returned to service.

If an operator experiences a loss of control over this machine, the operator should immediately actuate the "Parking Brake" switch, located near the base of the propel control handle and shut off the machine.

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 January 13, 2006 when scheduling this service. You will not be charged for the service performed.

We regret the inconvenience this may cause you, but urge you to have this service performed for your added safety and satisfaction.

Caterpillar Inc.

Identification #(s)

Attached to January 13, 2006 Service Letter

CB-434D REWORK PROCEDURE

Procedure to add drain valve, hoses and wire harness to engine compartment NOTE: Turn off electrical disconnect switch before starting this procedure. 1. Install the 6V-8397 O-ring Seals and 3J-1907 O-ring Seals onto the 6V-8724 Elbows. Install the elbows into the 279-6525 Valve. (See illustration 3 below under step 6)

2. Attach the 279-6525 Valve Gp. to the 283-1116 Plate using the 8T-6870 Bolts, 5P-4116 Washers and 5C-7261 Nuts. Install the 116-0118 Clip onto the 8T-6870 Bolt as shown in illustration 1. Install the 189-3158 Arc Suppressor into the 116-0118 Clip. (Also see ill 3 for orientation of the elbows.)

3. Locate the hydraulic return manifold, on the left hand side of the engine compartment, in front of the hydraulic tank. Remove and discard bolts attaching the 162-2453 return manifold to its mounting bracket. Install the new 283-1116 Plate with the valve attached, between the return manifold and the mounting bracket using the 8T-3647 Bolt and the existing washers and nuts. Install a 4P-7581 Clip-Ladder to the right hand bolt when reinstalling bolt to attach the return manifold. (See ill 1.)

4. Drain the Hydraulic tank if a hydraulic tank vacuum is not available.

5. Remove hose A from the connector in the hydraulic tank. Install the new 6V-9837 Tee fitting and 6V-8398 Seals. Reconnect hose A. (See ill 2)

6. Connect the 283-4948 Hose from the 279-6525 Valve to the 6V-9837 Tee in the hydraulic tank. (See ill 3)

7. Install a 6V-8397 O-ring Seal, a 3J-1907 O-ring Seal, and a 283-8325 Orifice onto the 176-5505 Connector. Install the 176-5505 Connector into the PS port on the top side of the propel pump. Install the 235-7155 hose between the 279-6525 Valve and the 176-5505 Connector in the PS port of the propel pump. (See ill 3)

8. Remove the pressure taps from the X1 & X2 ports on the propel pump. Check to see if orifices were installed in the pump. If there are no orifices in the X1 & X2 ports, install the pressure taps back into the ports. If there are orifices in the X1 & X2 ports, remove and discard the orifices and re-install the pressure taps into the pump.

9. Remove the plug located next to the "G" port on the top side, of the head of the propel pump. Remove the existing orifice located under the plug. Install the new 285-7320 1.4mm orifice and install the plug. (See illustration 4).

10. Check to ensure all fittings and hoses are tight and that the new hoses installed do not rub on existing hoses or other components. Refill the hydraulic tank to the proper level. Refer to the OMM for recommended hydraulic oil and quantity.

11. Install the 282-9084 Harness, with the end containing two connectors on the left side of the engine compartment at the 279-6525 Valve, routing it along side existing electrical harnesses inside the front of the engine compartment. (See ill 5) Connect one connector to the solenoid on the 279-6525 Valve and the other connector to the 189-3158 Arc Suppressor installed in Step 3. Secure the harness to the ladder clip installed in Step 2 using a 7K-1181 strap. Connect the single connector on the opposite end of the harness to the unused connector, on the right hand side of the engine compartment, labeled "Joint Cutter Up". (The wire #s for the "Joint Cutter Up" should be C729 BU and 200 BK.) Secure the 282-9084 Harness to existing electrical harnesses using the seven 177-2215 Dual Straps. Do not allow the harness to lie on any sharp metal edges. Do not secure the 282-9084 Harness to any hydraulic hoses.

On CNH00388-400 and up, the "joint cutter up" (729 BU and 200 BK) is on the front right side of the engine compartment.

CB-534D REWORK PROCEDURE

Add Drain valve, hoses and wire harness to engine compartment 1. Drain the Hydraulic tank. Remove the hose "A" from the 6V-8639 Connector, and remove the 6V-8639 Connector from the Hydraulic tank. Install the 6V-8398 Seal O-Rings and the 3K-0360 Seal O-Ring onto the 6V-8782 Tee and install the tee into the hydraulic tank. Reconnect the hose to the bottom fitting on the Tee. (See ill 1.)

2. Locate, drill and tap two holes in the frame on the left hand side of the engine compartment. Hole should be tapped to M8 X 1.25 - G6. (See ill 2 & 3)

3. Install the 6V-8397 O-ring Seals and 3J-1907 O-ring Seals onto the 6V-8724 Elbows. Install the elbows into the 279-6525 Valve. Install the new 279-6525 Valve Gp. to the frame using the 8T-6869 Bolts and 5P-4116 Washers. Install the 116-0118 Clip onto the 8T-6869 Bolt as shown in illustration 3. Install the 189-3158 Arc Suppressor into the 116-0118 Clip.

4. Install a 283-8325 2.1mm Orifice, a 6V-8397 Seal and a 3J-1907 Seal onto the 176-5505 Connector, and install the 176-5505 Connector into the "PS" port in the top side of the propel pump. Remove the pressure taps from the X1 & X2 ports on the propel pump. Check to see if orifices were installed in the pump. If there are no orifices in the X1 & X2 ports, install the pressure taps back into the ports. If there are orifices in the X1 & X2 ports, remove and discard the orifices and re-install the pressure taps into the pump. (See ill 4)

5. Install the 136-8737 Hose between the 279-6525 Valve and the 176-5505 Connector in the PS port of the propel pump. Install the 282-9626 Hose from the 279-6525 Valve to the 6V-9837 Tee in the hydraulic tank. See ill 5.
NOTE: Move existing waterline to the outside (closer to the frame), and place the hydraulic hose to the inside (closer to the engine).

6. Remove the existing 8C-8451 Stauff Clamp bolts and 7V-5628 Plate (see ill 5 & 6, location "5-6-7"). Install two new 196-4205 Stacking Bolts, and a 7V-7954 Lock Plate. Install the new 7V-5626 Clamp halves around the hose and secure with the 7V-5628 Plate and 8C-8451 Bolts previously removed. Secure the rest of the 282-9626 Hose using the 177-2215 Straps and 6D-4246 Clips. (Use existing hardware from the Stauff Clamp and Hood Latch to attach the 6D-4246 Clips in place. Remove one bolt, add Clip and reinstall bolt.) (See ill 5 & 6. Note: Callouts in illustration 6 are the same as illustration 5. Add (1) 5P-4115 Washer to bolt as shown in ill 6.)

7. Check to ensure all fittings and hoses are tight and that the new hoses installed do not rub on existing hoses or other components. Refill the hydraulic tank to the proper level. Refer to the OMM for recommended hydraulic oil and quantity.

8. Remove one bolt from the shift valve and one bolt from the manual brake release valve. Install one 4P-7581 Ladder clip on each bolt and reinstall the bolts. Install the 282-9084 Harness, with the end containing two connectors on the left side of the engine compartment at the 279-6525 Valve, routing it along side existing electrical harnesses inside the front of the engine compartment. (See ill 7) Connect one connector to the solenoid on the 279-6525 Valve and the other to the 189-3158 Arc Suppressor installed in Step 3. Connect the single connector on the opposite end of the harness to the unused connector, on the right hand side of the engine compartment, labeled "Joint Cutter Up". (The wire #s should be C729 BU and 200 BK.) Secure the 282-9084 harness to the two ladder clips using the 7K-1171 Straps. Secure the 282-9084 Harness to existing electrical harnesses using the seven 177-2215 Dual Straps. Do not allow the harness to lie on any sharp metal edges.

NOTE: For those machines that may be equipped with the Joint cutter, a new harness for the "Joint Cutter Up" circuit will need to be fabricated and installed for the joint cutter option. Use an appropriate length of 18ga wire and new Duetch connector components.

INSTALLATION OF VALVE CONTROL CIRCUITRY

Groups 1 & 2 Note: It is recommended that the procedure for "Flash New Software Into Control Group" be completed before this procedure, as access to the ECM communication port will be easier. Install the new 283-4434 Harness. 1. Remove the plastic Propel Console Cover. Remove and discard the cap plug "B" from the "Joint Cutter" connector "A" in the existing harness. Connect the 8 pin connector Labeled "Edge Cutter", on the 283-4434 Harness, to connector "A" labeled "JOINT CUTTER." Strap the plug back to the existing harness in the same location. (See ill 1). Note: On certain machines the "Joint Cutter" connector may be located in the Instrument Console near the Steer Pump - Metering. The 284-1637 harness is required to connect the 283-4434 harness to the "Joint Cutter" connector. The affected machines are estimated to be FGH00001-196 and EAA00001-156. For these machines it will be necessary to remove the seat and the covers from the bottom of the operator station and from the lower portion of the front console base, in order to route the additional 284-1637 harness.

2. Attach the B765 BR wire in the 283-4434 Harness to Terminal 2 on the brake switch base. (See ill 2.) Note: Inspect the wiring of the parking brake switch and confirm that the following connections are made. Reorient the switch contact block and/or rewire the parking brake switch, if necessary. It is necessary to connect the U735 GY on the parking brake switch with the 765 BR with the 283-4434 Harness. Switch Orientation: Terminals 2 and 4 are oriented outboard (toward right side of machine.)

Wire Connections:

Terminal 1 and 3 = 155 PK

Terminal 2 = U735 GY

Terminal 4 = U734 GN

X1 = 419 YL

Terminal X2 = 200 BK

3. Splice the bare 330 YL in the 283-4434 Harness into 330 YL wire near machine ECM. The splice must be soldered and heat shrink wrapped.(see ill 3.) Note: The 330 YL is located at the control module, under the seat. It will be necessary to remove the operator seat, and the cover plate under the seat to access the control module and 330YL wire to make the splice. It will be necessary to add an extension wire of 250 mm of a 5P-5677 Wire to the 283-4434 harness to reach the 330YL wire located at pin #35 of the connector at the control module. 4. Run a 7K-1181 Strap through a 4P-7581 Ladder Clip and bolt to the console stud using a 5C-2890 nut and 5P-4115 Washer. Install the 232-1792 alarm to the ladder clip. (See ill 4)

5. Attach the P789 PK the 283-4434 Harness to the positive terminal on alarm. Attach the N781 GY the 283-4434 Harness to negative terminal on alarm. Note: There are two P789 PK leads, and two N781 GY leads. Use the ones with the largest connectors. The alarm has a tag on the bottom indicating the + & - Terminals. 6. Install the 3E-9362 relays into the "Park Brake Relay" base and "Neutral Relay" base. Remove the screw and washer attaching the existing relay base "A" to the side of the console. Clip the "Park Brake Relay" base, and the "Neutral Relay" base together. Clip the existing relay base "A" and the "Solid State Driver" base together. Install the screw and washer removed from relay base "A" into the hole of the "Solid State Driver" base, and install the bank of two relay bases back onto the side console. Rotate the relay back to an angle equal to the edge of the console, with the wires to the outside and tighten the screw. Clip the "Park Brake Relay" base, and the "Neutral Relay" base to the "Solid State Driver" base of the 283-4434 Harness. Install the 2780461/">278-0461 Driver -Solid State into the relay base that has the F877 WH, 175 PK, K792 GN wire combination. (See ill 5) Note: This device can be easily confused with the other standard relays; verify part number and location with proper wire combination.

Note: The existing relay base is for an option and may be empty on certain machines.

7. Connect the "Limit Switch" connector plug "A" from 283-4434 Harness, to the switch connector socket "B", from the 283-8438 Sensor previously installed in the propel control. (See ill 6).

8. Install the 189-4920 Timer Relay into the Timer relay base of the 283-4434 Harness. Tuck the relay into the console. Tie the new 283-4434 Harness securely to the existing harness using 7K-1811 Straps. (See ill 7).

9. Attach the 283-4321 Film to the propel control panel. Center the film between the screw heads as shown. Make sure the "N" on the film is centered with the propel handle neutral detent.

10. Test the circuit using the procedure outlined below. After verifying the system is functioning properly, replace the Propel console side cover.

11. After verifying the alarm is functioning properly, reinstall the plastic console side cover. (See test procedure below)

Testing

Test of Alarm

1. Temporarily disconnect the three-pin connector for the switch.

2. Make a short a jumper wire, and connect pin A to pin B on the machine harness.

3. Position the propel handle in the neutral position.

4. Turn the ignition key to the ON position, but do not start the engine.

5. The neutral switch fault alarm should sound in approximately 9 seconds.

6. Move the handle out of neutral the alarm should shut off.

7. Return the handle to the neutral position.

8. The alarm should sound in approximately 9 seconds.

9. Test Complete.

Alarm Troubleshooting:

Problem: Alarm does not sound after 9 seconds with propel handle in neutral and jumper is installed as described above.

===========

Check 1: Verify the P789PK is on the "+" terminal and the N781 GY is on the "-" terminal of alarm.

No: Swap wire and recheck.

Yes: Continue

===========

Check 2: Verify there is 12V on P789PK on the + terminal ground on - terminal of alarm.

Yes: Replace alarm

No: If P789 is not at 12V continue to check 3, if P789 is at 12V go to check 6.

===========

Check 3: Verify there is 12V on 175PK on 2780461 Relay.

No: Check fuse, wiring.

Yes: Continue

===========

Check 4: Verify there is 12V on K792 GN on 2780461 Relay.

No: Verify there is a 0-1V on F877 WH and 12V on 175 PK on 2780461 Relay. No: Check jumper, wiring, switch adjustment (light should be OFF.)

Yes: Replace 2780461/">278-0461 Relay

Yes: Continue ===========

Check 5: Verify there is 12V on P789 PK on relay with 200 BK, 330YL, P789 PK, C706 OR wire combination.

No: Verify there is 12Von 330YL and ground on 200 BK on the relay No: Check splice, wiring, 330YL output directly at ECM.

Yes: Replace relay.

Yes: Continue ===========

Check 6: Verify there N781 GY is at ground on 189-4920 Relay - Timed

No: Verify there is 0-1V on F877 WH, 12V on P789 PK, ground on 200BK No: Check wiring, switch adjustment (light should be OFF.)

Yes: Replace 189-4920 Relay.

Yes: Replace Alarm Test for proper valve actuation signal.

---------------------------------------

1. After verifying alarm circuit above, verify that the neutral switch connector is reconnected to the harness.

2. Position the propel handle in the neutral position.

3. Release the parking brake.

4. Turn the ignition to ON, but do not start the engine.

5. Move the handle to the full forward position.

6. There should be 12V on C729 BU. (Check directly at valve.)

7. Move the handle to neutral, verify that the neutral light illuminates on the dash.

8. The 12V signal on C729 BU should no longer be present.

9. Move the handle to the full forward position.

10. There should be 12V on C729 BU. (Check directly at valve.)

11. Apply the parking brake.

12. The 12V signal on C729 BU should no longer be present.

13. Test Complete.

PROPEL HANDLE REWORK

Propel Handle Rework (Sensor Install, Tension Adjust.)

Tools/Supplies Needed:

212-2160 or 9U-7330 Multimeter

7X-1708 Probe, Red

7X-1709 Probe, Black

9S-3263 (or 4C-4030) Thread Lock

169-5464 Quick Cure Primer

4C-9506 (or 4C-9507) Compound - High Strength

Test Harness (Parts and Instructions listed at end of section.)

Portable drill press and vice.

Carbide Drill Bit (4.3mm diameter)

M5-Cobalt Tap

Install neutral detection switch into the propel handle as shown in Illustration 1.

1. Remove handle from machine.

2. Drill and tap the hole in the detent cam plate, D, as shown in Illustration 2.

Note: Do not disassemble the handle. Do not remove the lever arm, C.

Note: The cam plate is case hardened. It is recommended that this operation be done using a carbide drill bit installed in a drill press or vertical mill and the handle assembly fixtured in vice. A cobalt tap is recommended. A straight tap handle will interfere with the handle, so a T-handle tap wrench will be needed.

Alternative drilling method: Break surface using 1/4" (6.35 mm) carbide spot drill. Carbide tools are easily chipped - do not apply excessive pressure when using the spot drill. Drill hole with HSS cobalt drill. Note: Make sure all metal chips are completely cleared off handle before actuating handle to prevent contamination of friction disk.

3. Drill one hole in handle base, E, using dimensions given in Illustration 3. Note: Make sure all metal chips are completely cleared off handle before actuating handle to prevent contamination of friction disk.

4. Connect test harness to the propel handle position sensor, F. (Instruction for making the test harness are at the end of this section.)

5. Apply power and ground to test harness leads.

6. Connect a multimeter capable of measuring duty cycle (212-2160 or 9U-7330) to position sensor ground (F, Position 2) and the position sensor signal wire (F, Position 3.) Do not attempt to pick up ground from frame of handle.

7. Set the meter to report % duty cycle.

8. Position the handle such that the duty cycle is 50 +/-0.2%. Do not move the handle from the position until all the remaining hardware is installed.

9. Install the 8T-4127 Screw and 5C-2874 Nut. Apply the medium strength thread locker (9S-3263) to the screw. Do not fully thread or lock the nut, yet.

10. Apply 169-5464 Quick Cure Primer to the bottom of the 283-8438 sensor and to the mounting location on the propel handle frame. Allow the primer to dry for 1 minute. Apply one drop of the high strength, retaining compound (4C-9506 or 4C-9507) on the bottom of the sensor. Note: Inspect the sensor closely for a target symbol on the end opposite the screw hole. This target symbol must point upward. A counter sink for the screw will also be pointing upward along with the target symbol. 11. Install the 283-8438 sensor with 234-4982 screw and 9N-7446 Nut into hole drilled into frame in Step 0.

12. Position the 283-8438 sensor such that the target marks on the sensor are centered under the target screw and tighten the 234-4982 screw and 9N-7446 Nut using standard torque.

Note: Verify that the sensor is not touching the friction disk. A 1mm gap between sensor and friction disk is desired. It may be necessary to move the sensor away from the friction disk. Only move the sensor along line A-A in order to keep sensor trip points centered (symmetrical.) (Illustration 4.)

Illustration 4: Sensor Alignment

13. Turn the 8T-4127 screw until it just touches the sensor, then turn the screw out 1 turn (0.8mm gap.)

14. Tighten the 5C-2874 Jam Nut on the 8T-4127 Target Screw.

15. Connect the 283-8438 sensor to the test harness.

16. With the handle positioned such that the position sensor reads 50% duty, verify that the orange light on the sensor is not illuminated.

17. Slowly push the handle forward until the switch light just illuminates. Note the handle duty cycle output. It should be between 59% and 63%

Note: If the reading is over 63%, then nudge sensor in the counter clockwise direction. If the reading is under 59% nudge the sensor in the clockwise direction. 18. Slowly push the handle to the rearward direction until the switch light just illuminates. Note the handle duty cycle output. It should be between 37% and 41%. Note: If the reading is over 41%, then nudge sensor in the clockwise direction. If the reading is under 37% nudge the sensor in the counter clockwise direction. 19. Repeat adjustments until Steps 17 and 18 are satisfied.

Adjust the friction level on the handle.

Note: The friction of the handle is dependent upon the spring washer compression and the detent spring force. Reducing the spring washer compression as defined in the procedure will improve detent latching. Set the propel handle force required to exit the neutral detent to 4lb +/-1lb. (1.82kg) 1. Fixture the handle in a vice such that the when the handle is in the neutral detent position that it points parallel with the ground. See Illustration 5.

Illustration 5: Handle Friction Adjustment

2. Attach a pair of zip ties over the top handle as shown in Illustration 5.

3. Strap together a 7X-2579 bolt and 7X-2465 bolt. This assembly weights about 3.62lbs (1.64kg.)

4. Attach the bolts to the top of the propel handle.

Note: If the handle begins to move at this point, stop and tighten the pivot bolt slightly. 5. Very slowly loosen the pivot bolt until the handle just drops out of the neutral detent position.

6. Inspect the spring washers and bearing that attached to the pivot bolt and verify that they are not loose.

7. Remove the weight and strap.

8. Rework of handle is complete.

Test Harness

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Table 2: Test Harness Parts
Item	Qty	Part Number	Part Name
1	1	180-0050	Plug Kit
2	5	186-3736	Socket
3	2	8T-8737	Plug
4	1	155-2260	Plug Kit
5	12 dm	5P-3075	Wire - BK
6	12 dm	5P-9073	Wire - RD
7	0.5 dm	6V-2648	Wire - WH
8	1 (optional)	179-5434	Plug As ? Power Port

1. Cut one red and one black wire, each 100mm (4in) long.

2. Cut one red and one black wire, each 200mm (8in) long.

3. Splice the 100mm and 200mm red wires to one end of the remaining length of red wire.

4. Splice the 100mm and 200mm black wires to one end of the remaining length of black wire.

5. Cover the splices with heat shrink or electrical tape.

6. Install a 186-3736 socket onto one end of the white wire and cover the other end with heat shrink.

7. Install 186-3736 sockets onto the ends of the 100mm and 200mm wires.

8. Insert the 100mm red wire into Postion1 on the 180-0050 connector.

9. Insert the 100mm black wire into Position 2 on the 180-0050 connector.

10. Insert the white wire into Position 3 on the 180-0050 connector.

11. Insert an 8T-8737 plug into Position 4 on the 180-0050 connector.

12. Install the 180-0050 wedge (173-3049) with the keying feature over the Position 1.

13. Insert the 200mm black wire into Position A on the 155-2260 connector.

14. Insert an 8T-8737 plug into Position B on the 155-2260 connector.

15. Insert the 200mm red wire into Position C on the 155-2260 connector.

16. Install terminals on the unfinished ends of the red and black wires. The terminals should be suitable for connection to local +12V source and it's ground. (Battery clips, power port plug, etc.)

Illustration 6: Test Harness Schematic

FLASH NEW SOFTWARE INTO CONTROL GROUP

NOTE: In order to install and use the Plus 1 GUIDE Service and Diagnostic Tool, you will need to have administrative rights to your computer. 1. Install Service Tool Software on PC

2. Insert the CD sent with the Sauer Service tool into your computer. This CD contains the software required to re-flash the control module.

3. Copy the files from the CD enclosed in the Sauer Service Tool Kit sent to the dealership, onto the harddrive.

4. Click to launch the "Plus 1 Guide Service Tool Set Up" File

5. The application will open and an error screen will appear stating "No Active License", Click "OK."

6. The "License Manager" window will appear.

7. Select "Get License."

8. Fill out Questionnaire.

Note: In the " License Type" dialog box, select "Guide Service Tool".
9. In the "What was your order number?" entry box, type "No Charge Service Tool License". 10. In the "Where did you buy your license from?" entry box, type "NA"

11. After completing the Questionnaire, Click "Generate File." You will be prompted to save the file to a location. Select a location and save the file.

NOTE: Before clicking the "Generate File" button, note the email address at the bottom of the form. This will be the address you will need to send the generated file to.

12. As instructed at the bottom of the "Get License." Window, attach the generated, saved file, to an e-mail message and send to the address given at the bottom of the questionnaire. ( plus1license @ sauer-danfoss.com )

13. A message will be sent back, containing the license file. Save the license file to your hard drive as instructed.

14. Follow the instruction in the e-mail to activate the license.

15. Save the attached license file to your local hard drive.

16. Open Plus 1 GUIDE Service and Diagnostic Tool.

17. The "License Manager" window will open. Click the Add License button.

18. Browse to locate the license file on your local hard drive and click Open. This will add the new license to your list of available licenses.

19. Click on the license file in the License Manager dialog box to select it.

20. Click the Make Active button.

Select "NO"

Note: Do not enable password protection. [The GUIDE Tools will now run,]

Flash Controller - Software Flashing

1. Connect the computer to the Sauer Danfoss Can Gateway using a USB cable supplied with the Sauer kit.

2. Connect Sauer Danfoss Can Gateway to the machine using the cable, with the three pin connector, supplied with the Sauer kit. Connect the 3-pin connector to the "Com Port" plug, located behind the fuse cover on the propel side console.

3. Turn the ignition key to on but do not start the engine.

4. Double click on the CB564D.P1D file previously saved to your computer.

5. Click the File menu from the top left.

6. Select File Download.

7. On the left side click the controller you want to flash. There will only be 1

8. Select the CBX34_MAIN_CONTROLLER.lhx from wherever you saved it.

9. Click "Start Download"

10. An error dialog box will pop up. Click "Ignore".

11. On the left side, click on the CB564D under parameter function.

12. Click the upload button

13. Only the "DefaultsCheck" should be visible under the "Signal Name" column. Change the parameters in "Value" column from 555 to 0. Hit the enter

14. Click the download Button. Electrical Calibration

The Electrical calibration should be performed at the Operator Station Assembly.

The Electrical calibration has two types, one with the Key ON and Engine OFF, used for the Propel Handle Calibration, the Water Timer POT Calibration and the Automatic Speed control calibration; and the other one with the Engine ON, either at LOW or HI idle, used for the Propel PUMP Threshold Currents Calibration. HI idle is recommended, however Hi or Low idle will work.

Propel Handle Calibration:

1. Place the system in test mode. Remove the machine fuse panel cover. There should be 4 plugs in the compartment. Disconnect the "Model Config" plug.

2. Depress the Parking Brake switch to make sure the Parking Brake is ON. Turn the Key to the ON position. (Do not Start the engine)

3. Disconnect the Propel Handle Sensor from the Harness.(wait 5 seconds)

4. Re-connect the Propel Handel Sensor to the Harness.

5. Move the Propel Handle to the full forward position.

6. Press the Water Spray ON/OFF button.

7. Move the Propel Handle to the full reverse position.

8. Press the Water Spray ON/OFF button.

9. Move the Propel Handle to the NEUTRAL position.

10. Press the Water Spray ON/OFF button.

11. The system warning Brake light will flash twice (2) to confirm good calibration.

NOTE: Both the light in the Brake switch and on the dash panel should light/flash. If Calibration is not successful, a fault code will be displayed on the System warning Brake light. Automatic Speed Control Calibration: 1. Place the system in test mode. Remove the machine fuse panel cover. There should be 4 plugs in the compartment. Disconnect the "Model Config" plug.

2. Turn the Key to the ON position. (Do not start the engine)

3. Disconnect the ASC POT from the Harness. (Wait 5 seconds)

4. Re-connect the ASC POT to the Harness.

5. Rotate the ASC POT Clockwise to the Maximum position.

6. Press the Water Spray ON/OFF button.

7. Rotate the ASC POT Counter Clockwise to the Minimum position.

8. Press the Water Spray ON/OFF button.

9. The system warning Brake light will flash twice (2) to confirm good calibration.

NOTE: If Calibration is not successful a fault code will be displayed on the System warning Brake light. Water Timer POT Calibration: 1. Place the system in test mode. Remove the machine fuse panel cover. There should be 4 plugs in the compartment. Disconnect the "Model Config" plug.

2. Turn the Key to the ON position. (Do not Start the engine)

3. Disconnect the Water Timer POT from the Harness. (wait 5 seconds)

4. Re-connect the Water Timer POT to the Harness.

5. Rotate the Water Timer POT Clockwise to the Maximum position.

6. Press the Water Spray ON/OFF button.

7. Rotate the Water Timer POT Counter Clockwise to the Minimum position.

8. Press the Water Spray ON/OFF button.

9. The system warning Brake light will flash twice (2) to confirm good calibration.

NOTE: If Calibration is not successful a fault code will be displayed on the System warning Brake light. Propel PUMP Threshold Currents Calibration: NOTE: Both the FORWARD and REVERSE Proportional Solenoids Threshold Currents need to be Calibrated. This test is best performed after the Hydraulic Oil has been brought up to operating temperature, but it is not required to have the machine at operating temperature. 1. Place the system in test mode. Remove the machine fuse panel cover. There should be 4 plugs in the compartment. Disconnect the "Model Config" plug.

2. Turn the Key to the ON position.

3. Start the Engine. Calibration can be made in HI idle. Deactivate the Parking Brake.

4. Move the Propel Handle in the FORWARD position.

5. Press the water spray ON/OFF button once the machine starts moving.

6. This may take up to 2 minutes.

7. Return the Propel Handle to the NEUTRAL position.

8. Move the Propel Handle in the REVERSE position.

9. Press the water spray ON/OFF button once the machine starts moving.

10. This may take up to 2 minutes.

11. Return the Propel Handle to the NEUTRAL position.

12. Activate the PARKING BRAKE, and turn OFF the Engine.

13. The system warning Brake light will flash twice (2) to confirm good calibration.

NOTE: If Calibration is not successful a fault code will be displayed on the System warning Brake light. If the Operator Does not detect motion after 60 seconds or does not push the Water Spray ON/OFF button after the pump solenoid current reaches the upper allowable upper limit, a fault code is displayed and CALIBRATION sequence is aborted.

FAULT CODES BLINK DECODING SEQUENCE:

The first digit is the LONG sequence; the second digit is the short sequence.

Example:

Steer wheel FAULT (STEER_WHEEL_FLT=======FAULT_2_5)

Will have 2 long blinks and 5 short blinks.

14. Reconnect the "Model Config" plug, replace the cap on the "Com Port", and replace the fuse cover.

15. Proceed to test section.

Testing

The following test is intended to verify proper propel function after flashing the control group.

Check the electronic neutral range.

Note: Use a multimeter capable of measuring duty cycle (i.e. 212-2160 or 9U-7330 Multimeter) A. Place the propel handle in the neutral position.

B. Place the automatic speed control (ASC) knob in the full clockwise position.

C. Place the transmission selector in turtle.

D. Apply the parking brake.

E. Turn the ignition key to ON, but do not start the engine.

F. Release the parking brake.

G. Verify that the neutral symbol is illuminated.

A. Hook the multi-meter up to the ground and the K708BU signal wire of the propel handle position sensor. Set the multimeter to read duty cycle.

I. With the handle centered in the detent, the reading should be between 48% and 52%. Record the measurement.

J. Slowly move the handle forward until the neutral light just goes out. The reading should be between 9% and 11% higher than the reading recorded in step I in neutral.

K. Return the handle to the neutral position.

L. Slowly move the handle rearward until the neutral light just goes out. The reading should be between 9% and 11% lower than the reading recorded in step I in neutral.

If the incorrect response is found in steps j or l of this test or step k of the previous test, attempt to re-flash the control group. If that is unsuccessful, contact DSN