A Process is Available to Replace the Propel Lever Group{3209, 5462} Caterpillar

Paving Compactor:

CP-323C (S/N: 6DM1-UP)

CP-433C (S/N: 1ZN1-UP; 2JM1-UP; 4JZ1-UP)

CP-533 (S/N: 3ZL1-UP; 5AL1-UP)

CP-533C (S/N: 3XN1-UP; 3YN1-UP)

CP-563 (S/N: 1YJ1-UP; 5AJ1-UP)

CP-563C (S/N: 5JN1-UP; 5KN1-UP)

CS-323C (S/N: 1EN1-UP)

CS-431C (S/N: 3WZ1-UP; 6EN1-UP; 9XL1-UP)

CS-433C (S/N: 1FS1-UP; 1XZ1-UP; 2TN1-UP; 3TM1-UP; 5BZ1-UP)

CS-531 (S/N: 3WM1-UP; 4KM1-UP)

CS-531C (S/N: 5ZN1-UP; 9RN1-UP)

CS-533 (S/N: 3BL1-UP; 4HL1-UP)

CS-533C (S/N: 2WN1-UP; 2XN1-UP)

CS-563 (S/N: 7GG1-UP; 8XF1-UP)

CS-563C (S/N: 4KN1-UP; 4LN1-UP)

CS-573 (S/N: 8PK1-UP)

CS-573C (S/N: 6LN1-UP)

CS-583 (S/N: 1EL1-UP; 8YJ1-UP)

CS-583C (S/N: 7MN1-UP; 7NN1-UP)

Introduction

This Special Instruction provides the information that is required to replace the Propel Lever Group.

Parts That Are Required

Note: The parts in Table 2 are only required for the following machines: CP-533 (S/N: 3ZL1-UP; 5AL1-UP), CP-563 (S/N: 1YJ1-UP; 5AJ1-UP), CS-531 (S/N: 3WM1-UP; 4KM1-UP), CS-533 (S/N: 3BL1-UP; 4HL1-UP), CS-563 (S/N: 7GG1-UP; 8XF1-UP), CS-573 (S/N: 8PK1-UP) and CS-583 (S/N: 1EL1-UP; 8YJ1-UP)

Rework Procedure

Illustration 1	g00833851

1. Remove four bolts that secure control panel (A) to the platform for the operator. Do not discard the bolts. Remove panel (A) .

2. Disconnect the propel cable from lever group (E) .

3. Disconnect the electrical connectors for the vibratory ON/OFF switch (B). Remove the electrical connectors for the switch (B) for the back up alarm.

4. Remove handle (C) and discard handle (C) from the existing lever group (E) .

5. Disconnect the leveling blade control from the propel lever group on machines that are equipped with an optional leveling blade attachment. You must remove the two bolts that connect the leveling blade control to the propel lever group.

6. Remove the two bolts that connect the existing leveling blade control to control panel (A). Do not discard the bolts.

7. Remove the bolts that connect the existing propel lever group (E) to panel (A). Do not discard the bolts.

8. Remove the existing propel lever group and discard the existing propel lever group.

9. Remove existing boot (D) .

Note: The following machines have harnesses with round electrical connectors.The round electrical connectors will not plug into the new assembly for the propel lever: CP-533 (S/N: 3ZL1-UP; 5AL1-UP), CP-563 (S/N: 1YJ1-UP; 5AJ1-UP), CS-531 (S/N: 3WM1-UP; 4KM1-UP), CS-533 (S/N: 3BL1-UP; 4HL1-UP), CS-563 (S/N: 7GG1-UP; 8XF1-UP), CS-573 (S/N: 8PK1-UP) and CS-583 (S/N: 1EL1-UP; 8YJ1-UP).

10. Inspect the electrical connectors that were disconnected in Step 3. Determine if the electrical connectors that were disconnected in Step 3 are round connectors or square connectors. Replace the round electrical connectors with the square electrical connectors. Use the parts that are listed in Table 2 in order to rework the electrical connections.

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Illustration 2	g00833853
(1) Lever group (2) Plug

11. Use 152-9155 Adhesive to install boot (G) on panel (A) .

12. Use hardware (I) to connect the existing housing for the propel cable to the new lever group.

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Illustration 3	g00833855
View of Pump Area (3) Hole in the pump lever (4) Clevis pin (5) Pump lever (6) Propel cable clevis

Note: Assemble the cable in the new lever group. The cable, the linkage for the pump and the new lever group must be in the NEUTRAL position. Failure to comply could result in the improper adjustment of the neutral start system. Failure to comply could result in the improper adjustment of the back up alarm system. Refer to illustration 3.

13. Connect the end of the cable to the new lever group (1). Refer to illustration 2.

14. When the cable has been assembled to the new lever group, the pin on the bottom end of the cable must be in the center of the hole in the pump lever. Refer to illustration 3.

15. Use the existing hardware in order to assemble lever group (1) to panel (A). Refer to illustration 1.

16. Install handle (F) in lever group (1). Refer to illustration 2.

17. Make sure that clearance exists between harness (H) in illustration 2 and the moving parts on the control mechanism throughout the range of movement. You must have the correct clearance between harness (H) and the control mechanism. You should tie the harness again if you have any interference. Refer to illustration 2.

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Illustration 4	g00833979

18. Use bolts (7) and use locknuts (8) to connect bracket (9) to the blade on machines that are equipped with an optional leveling blade attachment.

19. Use existing hardware to attach bracket (9) to panel (A) .

20. Install plugs (2) in the unused holes in panel (A). Refer to illustration 2.

21. Install panel (A) on the operator platform.

22. Check the operation of the backup alarm. Make sure that the backup alarm operates properly. Start the engine. Release the parking brake. Slowly move the control lever to the REVERSE position. Slowly move the control lever to the NEUTRAL position. When the control lever is moved in the reverse direction, the alarm should sound prior to movement of the machine. The alarm should turn off when the control lever is moved to the NEUTRAL position. Refer to step 12 if the adjustment of the alarm is incorrect.

23. Make sure that the neutral start switch operates properly. Apply the parking brake. Move the control lever to the REVERSE position and back to the NEUTRAL position. Make sure that the machine will start.

24. Deactivate the parking brake. Set the engine speed at low idle. Move the control lever to the FORWARD position. Turn the key switch to the START position. Slowly move the control lever toward the NEUTRAL position until the engine starts. When the machine starts, hold the control lever in position. After the machine is started, the machine should not move in a forward direction. If the neutral start adjustment is incorrect, refer to step 12. If the neutral start adjustment is incorrect, check the adjustment of the neutral start switch in the propel pump.

25. Deactivate the parking brake. Set the engine speed at low idle. Move the control lever to the REVERSE position. Turn the key switch to the START position. Slowly move the control lever toward the NEUTRAL position until the engine starts. When the machine starts, hold the control lever in position. After the machine is started, the machine should not move in a reverse direction. If the neutral start adjustment is incorrect, refer to step 12. If the neutral start adjustment is incorrect, check the adjustment of the neutral start switch in the propel pump.

26. Check the functions of the vibration system. Make sure that you can shut off the system. Make sure that you can turn on the system.

The Special Instruction is available through the normal literature distribution system. The publication can also be found on the Caterpillar Information System (SIS).