Installation
1. Remove pump cover
a. Drill pump cover to allow controller to be installed
2. Remove “+” wire on backup alarm
3. Remove old wiring harness with selector switch, box leads and pump leads
4. Peel back loom from mainframe harness (behind toe board and engine
muffler)
a. Cut white/blue, orange/black and yellow wires inside mainframe harness
b. Yellow wire (backup) cut back and insulate (not used)
c. White/blue and orange/black wires cut back and insulate (not used)
5. Remove ground (in front of left motor mount)
6. Remove old harness
7. Remove both steering boxes (retain mounting hardware for use later)
8. Controller installation
a. Install controller onto pump cover
b. Install red status light
c. Cut wire labeled “status light” at loom and connect to light
d. Disassemble Deutsch connectors from dash harness
9. Remove control panel and multipin connector
a. Lay box upside down on deck
b. Drill 7/8” hole in bottom of box ( see illustration 1)
c. Install weather tight fitting
i. Locknut LN1010
ii. ½” watertight fitting 3200DI
d. On black relay in the upper left hand side of box
i. Pull white/blue wire out and cut
10. Tie mainframe harness and install loom
11. Install controller and new harness
a. Remove cover support
b. Connect backup alarm wire
c. Run steering box wires behind the battery under motor mounts (long
cable for left hand box)
d. Run dash cable into the box
i. Status light wire cut and remove
ii. Separate power (red) and vibrate relay wires
iii. Install vibrate relay wire onto black relay onto black relay terminal
wire removed in step 9.d.i.
iv. Install red wire with an inline fuse (5A) and connect into the
bottom of terminal pin 8 of terminal board
v. Connect ground wire to the bottom of terminal O of terminal
board
vi. Connect engine enable (white with no end) wire to top of terminal
6 of terminal board
vii. Deutsch C8 pin 1 Cal, pin 2 Opt
viii. C7 high output pin 1
ix. C11 Black wire high output pin 1
x. C9 Black wire optimize pin 2
xi. C10 black wire cal pin 1
e. Connect C7 and C11
f. Connect C8 into “Y” adaptor
12. Reinstall panel
13. Connect harness to steering boxes
14. Install grounds to battery negative terminal
15. Connect 2 optimize connectors into dash
16. Turn on ignition key, status light should blink
17. On left box push both joysticks full forward for 5 seconds
18. Push both joysticks full reverse for 5 seconds
19. Repeat steps 17 and 18 for right box
20. Perform steering calibration
Description of Operation
Startup
When the key is turned on the status light will come on for approximately 3
second while the Plus One powers up. The status light will turn off when the
machine is ready to start. If the light stays on this means that the joystick(s) in
the control box are not in neutral and the Plus One will not allow the engine to
start. Placing the joystick(s) in neutral will turn off this light and allow the engine
to start. If the light starts to blink see the Fault Code table in section IV of this
manual.
High Current Pump Selection
If High Current pumps are being used (either Rexroth or Sauer-Danfoss H1) then
the correct parameters for these pumps should be chosen via the instructions
below:
1. Turn OFF power to the control system (Key in Stop/Off position)
2. Connect at least one Steering Wheel or Dual Joystick control box
3. Turn all RUN / STOP switches on the control box(or boxes) to STOP
4. Open the control panel and install the Y-adapter that allows connecting
the Optimize and Calibrate plugs at the same time
5. Connect the High Current plug to the High Current connection
6. Connect the Optimize plug to the Y-adapter (ensure that the wires In and
Out match)
7. Connect the Calibrate plug to the Y-adapter (ensure that the wires In and
Out match)
8. Turn ON the power to the control system (Key in ON position)
9. Wait for the Status Light on the control panel to go out (indicates waiting
for commands / running OK)
10. Move the Left Joystick on either Dual Joystick box (if more than one is
installed) or the Speed/Direction Joystick on either Steering Box (if more
than one is installed) to one of the following positions to choose which
parameters to load:
a. All the way Forward – loads the Sauer H1 parameters
b. All the way Reverse – loads the Rexroth parameters
11. If both Left Joysticks (Dual Joystick boxes) or both Speed/Direction
Joysticks (Steering boxes) are moved then NO parameters will be
changed; user can only move one Left Joystick or Speed/Direction
Joystick
12. Toggle the RUN / STOP switch on the box with the positioned Left
Joystick (or Speed/Direction Joystick) to RUN
13. If Parameter Change is successful, the Status Light will flash very rapidly
14. Toggle the RUN / STOP switch used in step 12 to STOP (the Status Light
will stop flashing)
15. Turn OFF the power to the control system (Key in OFF position)
Disconnect the Optimize and Calibrate plugs from the Y-adapter
After a Parameter Change routine is completed, all Optimize and Calibrate values
are reset to default values. Optimize and Calibrate routines will have to be
processed again if they were already done before the Parameter Change.
Optimization
After installing this software the steering control box(s) will require optimization
as well as calibration (which will be discussed in the next section).
The software will automatically recognize which type of steering control (Dual
Joystick or Steering Wheel with Forward/Neutral/Reverse Joystick) is installed
and if there is one or two boxes connected. On machines with two boxes; the
Plus One will only operate if both boxes are of the same type.
Plus One will not allow the Engine Enable to come on until the Optimization
procedure has been done.
To optimize the Dual Joystick Steering Control Box:
1. Turn the machine off. Open the dash board panel and locate the
Optimize/Calibrate connector and plug it into the Optimize receptacle.
2. Place all joysticks in the center position and move the Run/Stop switch(s)
into the Stop position.
3. Turn the power key to the on position (power to the Plus One controller).
Outputs are disabled. The status light will blink a slow continuous blink to
indicate Optimize Mode.
4. Wait 5 seconds for the Plus One to capture the joysticks in center
position.
5. Push joysticks full forward for 5 seconds.
6. Push joysticks full reverse for 5 seconds.
7. If a second control box is present optimize it in the same manner.
8. The status light will stop blinking. Unplug the Optimize/Calibrate
connector from the Optimize receptacle and turn off the power key.
To Optimize the Steering Wheel with Forward/Neutral/Reverse
Joystick Control Box:
1. Turn the machine off. Open the dash board panel and locate the
Optimize/Calibrate connector and plug it into the Optimize receptacle.
2. Place all steering wheels and joysticks in the center position and move
the Run/Stop switch(s) into the Stop position.
3. Turn the power key to the on position (power to the Plus One controller).
Outputs are disabled. The status light will blink slowly with no pauses to
indicate Optimize Mode.
4. Wait 5 seconds for the Plus One to capture the steering wheel center
position.
5. Turn the steering wheel full right and push the FNR joystick full forward
for 5 seconds.
6. Turn the steering wheel full left and the FNR joystick full reverse for 5
seconds.
7. If a second control box is present optimize it in the same manner.
8. The status light will stop blinking. Unplug the Optimize/Calibrate
connector from the Optimize receptacle and turn off the power key.
Calibration
Calibration (also called straight line tracking) involves 4 steps: Threshold, low,
mid and high speed setting. There are separate procedure for calibrating
machines with Dual Joystick steering control and Steering wheel with FNR
Joystick steering control. On machines with two steering control boxes the
calibration will only need to be done with one box.
To Calibrate the Dual Joystick Steering Control Box:
Turn the machine off. Open the dash board panel and locate the
Optimize/Calibrate connector and plug it into the Calibrate receptacle.
Place all joysticks in the center position and move the Run/Stop switch into the
Run position. If two control boxes are present place the other Run/Stop switch to
the stop position.
Turn machine on and the status light will blink rapidly with no pauses to indicate
Calibration Mode.
Setting the threshold:
1. Start the engine and run at ½ throttle
2. Move left joystick forward until machine begins to move slightly, then toggle
run/stop switch from run to stop and back to run. Return joystick to neutral.
3. Move left joystick reverse until machine begins to move slightly, then toggle
run/stop switch from run to stop and back to run. Return joystick to neutral
4. Move right joystick forward until machine begins to move slightly, then toggle
run/stop switch from run to stop and back to run. Return joystick to neutral.
5. Move right joystick reverse until machine begins to move slightly, then toggle
run/stop switch from run to stop and back to run. Return joystick to neutral.
Setting the straight line tracking:
1. Move joysticks forward until machine begins to move forward slowly, adjust
Right Joystick forward or reverse as necessary to make sure machine is
traveling straight. Toggle Run/Stop switch from Run to stop and back to run
2. Move Left Joystick to approximately 1/2 joystick position, adjust Right
Joystick forward or reverse as necessary to make sure machine is traveling
straight. Toggle Run/Stop switch from Run to stop and back to run.
3. Move Left Joystick to full forward, adjust the Right Joystick forward or
reverse as necessary to make sure machine is traveling straight. When the
machine has achieved full speed, reduce joystick position until the machine
slows slightly. Toggle Run/Stop switch from Run to stop and back to run.
4. Repeat for reverse.
5. Bring both joysticks to neutral.
6. Keeping power to the Plus One, unplug the Optimize/Calibrate connector
from the Calibrate receptacle (this will write the calibration values to
memory).
7. Turn off and restart machine. Run machine to verify acceptable operation.
Machine will now operate in typical dual joystick mode with speed and
direction of each track controlled by the respective joystick.
To Calibrate the Steering Wheel with Forward/Neutral/Reverse
Joystick Control Box:
Turn the machine off. Open the dash board panel and locate the
Optimize/Calibrate connector and plug it into the Calibrate receptacle.
Place all steering wheels and joysticks in the center position and move the
Run/Stop switch into the Run position. If two control boxes are present place the
other Run/Stop switch to the stop position. Turn machine on and the status light
will blink rapidly with no pauses to indicate Calibration Mode.
Setting the threshold:
1. Start the engine and run at ½ throttle
2. Turn the steering wheel full left; Move FNR joystick forward until machine
begins to move slightly, then toggle run/stop switch from run to stop and
back to run. Return joystick to neutral.
3. With steering wheel still at full left; Move FNR joystick reverse until machine
begins to move slightly, then toggle run/stop switch from run to stop and
back to run. Return joystick to neutral
4. Turn the steering wheel full right. Move FNR joystick forward until machine
begins to move slightly, then toggle run/stop switch from run to stop and
back to run. Return joystick to neutral.
5. With steering wheel still at full right; Move FNR joystick reverse until machine
begins to move slightly, then toggle run/stop switch from run to stop and
back to run. Return joystick to neutral.
Setting the straight line tracking:
1. Move FNR joysticks forward until machine begins to move forward slowly,
adjust the steering wheel as necessary to make sure machine is traveling
straight. Toggle Run/Stop switch from Run to stop and back to run
2. Move FNR Joystick to approximately 1/2 joystick position, adjust the steering
wheel as necessary to make sure machine is traveling straight. Toggle
Run/Stop switch from Run to stop and back to run.
3. Move FNR Joystick to full forward. When the machine has achieved full
speed, reduce joystick position until the machine slows slightly. Adjust the
steering wheel as necessary to make sure machine is traveling straight.
Toggle Run/Stop switch from Run to stop and back to run.
4. Repeat for reverse.
5. Bring the FNR joystick to neutral and center the steering wheel.
6. Keeping power to the Plus One, unplug the Optimize/Calibrate connector
from the Calibrate receptacle (this will write the calibration values to
memory).
7. Turn off and restart machine. Run machine to verify acceptable operation.
Steering/Acceleration and Deceleration
Steering the machine is done by slowing the left or right track.
When a steering wheel with FNR joystick control box is used there is a 75%
maximum differential is built into the Plus One. This limits the ability to counterrotate
the tracks at high speeds. If the FNR joystick is at 100% forward and the
steering wheel was turned full right the right track would only slow to 25%
forward (75% differential). If the FNR joystick is at 50% forward the right track
would counter-rotate at 25% reverse. You can achieve full counter-rotation up to
approximately 3/8 of the joystick range. The counter-rotating track can never
exceed the speed of the forward track. The percentage of differential is controlled by the Steer Authority setting and can be adjusted with the Service
Tool.
Each joystick and steering wheel has been setup with individual profile and
ramping to give smooth control.
Ramping for acceleration and deceleration is proportional to the amount of
movement of the joystick. This will provide a quicker ramp for direction changes
and a slower ramp if the joysticks are moved to neutral. These profiles can be
adjusted with the Service Tool.
The steering wheel profile has been setup to give a finer degree of control when
the wheel is moved a small amount and more aggressive steering as the wheel is
turned more. These profiles can be adjusted with the Service Tool.
The Steering wheel has a center position dead band separate from the joysticks.
This dead band is less than that used by the joystick controller and reduces the
amount of “play” in the steering wheel. This dead band can be set with the
service tool.
Steering Box Control Selection
The Plus One will only assign control of the machine to a steering control box if
all joysticks are in neutral, the steering wheels are centered and the Run/Stop
switches are in the Stop position.
The Plus One will assign control to the first box that is switched to the Run
position.
If at anytime the Run/Stop switch is set to the Stop position the machine will
decelerate to stop and set the brake after 3 seconds. At anytime during
operation if the Run/Stop switch on the second control box is set to the Run
position the machine will decelerate to stop and set the brake after 3 seconds.
Control will be restored to the operator when this switch is set back to Stop (the
machine will ramp back to the setting of the operator’s controls). This purpose of
this is to allow personnel on the opposite side of the machine to pause the
machine and then return control to the operator by flipping the Run/Stop switch
back to Stop.
Machine control can be switched to the second steering control box by setting all
joysticks in neutral, centering the steering wheels, switching both Run/Stop
switches to the Stop position and then switching the second box to Run.
Neutral Safety Lockout
If at anytime the machine is in Neutral with the Run/Stop switch in the Run
position, the Plus One will disable the control box, set the brake and turn on the
status light after 10 seconds. The operator will be required to switch from Run to
Stop and back to Run to regain control. This is provided as a safety in the event
that the operator leaves his station with the control box still active. When
activated; the joysticks can’t cause the machine to accidentally move without
someone at the controls. The length of time until lockout activates can be
adjusted with the Service Tool.
Pump Control Outputs
The Plus One controller is setup to operate dual hydrostatic pumps, two options
are built in; the low current outputs for the Sauer 42 series pumps and high
current outputs for the Sauer H1 series pumps. The low current output is the
default setting.
If the H1 pumps are used you must switch the Plus One to high current outputs
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