The Procedure to Adjust the Neutral Sensor for the Propel System on Paving Compactors {5705, 5737} Caterpillar

Asphalt Compactor

CB-534D (S/N: EAA1-UP; FEA1-UP; GCA1-UP; C2B1-UP; C4B1-UP; FGH1-UP; B5M1-UP; C8M1-UP)

CB-564D (S/N: C6D1-UP; D4M1-UP)

Paving Compactor

CB-434D (S/N: CNH1-UP)

CB-634D (S/N: CDF1-UP)

Introduction

This special instruction provides the necessary information in order to install a 283-8438 Sensor on Paving Compactors. Proper installation and adjustment of the sensor will eliminate fault code "52" for the propel system on the CB-434D Paving Compactors, CB-534D Paving Compactors, and CB-634D Paving Compactors. Proper installation and adjustment of the sensor will also eliminate fault code "55" for the propel system on the CB-434D Paving Compactors and CB-534D Paving Compactors with the Italian roading homologation. Proper installation and adjustment of the sensor will also eliminate fault code "55" for the propel system on the CB-564D Paving Compactors.

Note: Machines reworked to special instruction REHS4763 "Procedure To Install a Rotary Position Sensor and Flash New Software on All D Series Paving Compactors" should disregard this instruction and refer to that instruction instead. The specifications for the neutral switch activation is changed after REHS4763 is applied.

Identification of Propel Control

Illustration 1	g01288953
Type "A" propel control. (A) This switch is held in place with a compound.

Illustration 2	g01288954
Type "B" propel control. (B) This switch is held in place with a metal clip.

Two different types of propel controls were used on the affected Paving Compactors. Refer to Illustration 1 in order to identify the propel control (A). The switch is held in place with a compound on propel control (A). Refer to Illustration 2 in order to identify the propel control (B). The switch is held in place with a metal clip on propel control (B).

Installation and Adjustment of the Sensor on the Type "A" Propel Controls for Switches Retained by compound

Note: This section provides the adjustment procedure with a multimeter. To use the Plus+1 Service Tool for Caterpillar (P1STC) software to adjust the sensor, refer to Section "Procedure to Use P1STC Software to Adjust the Sensor".

Illustration 3	g01436314
(1) Sensor (2) Screw (3) Locknut (4) Screw (5) Locknut (10) Frame for the handle (11) Cam plate (12) Pin (13) Lever arm (14) Position sensor

Center the Handle for the Propel System

1. Connect Tooling (6) to the ground, which is position 2 on sensor (14) and to signal wire which is position 3 on sensor (14). Do not attempt to pick up ground from the frame of the handle.

2. Set Tooling (6) to report a percent duty cycle.

3. Position the handle so the duty cycle is 50 percent ± 2 percent. Do not move the handle from the position until all the remaining hardware is installed.

Install the Sensor

1. Apply Tooling (7) to the bottom of sensor (1) and to the mounting location on the frame for the propel control handle. Allow Tooling (7) to dry for one minute. Apply one drop of Tooling (8) on the bottom of sensor (1).

   Note: Inspect sensor (1) carefully for a target on the end opposite the screw hole. The target and a countersink for the screw will be pointing upward.

2. Install sensor (1), screw (2), and locknut (3) into the mounting hole for the sensor on the frame for the propel control handle.

Center the Sensor

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Illustration 4	g01288025
(A) Centerline (B) Screw (4) centered over the target on sensor (1). (C) Swing arc of screw (4). (D) Pivot for the disc

1. Position sensor (1) so the mark on sensor (1) is centered under screw (4). Tighten screw (2) and nut (3) to standard torque.

   Note: Verify that sensor (1) is not touching the retaining washer. A 1 mm (.04 inch) gap between sensor (1) and the friction disc is desired. It may be necessary to move sensor (1) away from the friction disc. Only move sensor (1) along centerline (A). Keep the trip points for sensor (1) centered. Refer to Illustration 4.

2. Move the engine start switch to the ON position.

   Note: The settings of sensor (1) may be outside allowable limits. This may cause the ECM to register faults while sensor (1) is being centered. Ignore the faults until all of the adjustments have been completed. After sensor (1) has been centered clear the history of the faults in the ECM. Refer to KENR8650 Troubleshooting, Resetting of Fault History, Timers, Calibration Values.

3. Position the propel control handle so position sensor (14) reads 80%. The orange light on sensor (1) should be illuminated.

4. Slowly move the propel control handle toward neutral until the orange light on sensor (1) just goes out. Note the duty cycle output of position sensor (14). This is the forward setting of sensor (1).

5. Position the propel control handle so position sensor (14) reads 30%. The orange light on sensor (1) should be illuminated.

6. Slowly move the propel control handle toward neutral until the orange light on sensor (1) just goes out. Note the duty cycle output of position sensor (14). This is the reverse setting of sensor (1).

7. The forward range is found by subtracting 50 from forward setting . The reverse range is found by subtracting reverse setting from 50.

8. Proceed to Step "Verify That the Sensor is Within Specifications" if the difference between the forward range and the reverse range is less than 1.

9. If the forward range is greater than the reverse range, nudge sensor (1) counterclockwise and then repeat Step 1 through Step 8.

10. If the reverse range is greater than the forward range, nudge sensor (1) clockwise and repeat Step 1 through Step 8.

Verify That the Sensor is Within Specifications

Note: When P1STC software is used, the reading on the ECM will be about 1% higher than the reading on a multimeter.

1. The reading on the ECM for the forward duty cycle should be between 62% and 58%. The reading on the multimeter for the forward duty cycle should be between 61% and 57%.

2. The reading on the ECM for the reverse duty cycle should be between 38% and 42%. The reading on the multimeter for the reverse duty cycle should be between 37% and 41%.

   Note: It is recommended to set sensor (1) so that there is at least a 0.5% margin between the respective limits and the settings.

3. Adjust screw (4) in order to obtain the recommended setting.

   1. Turning screw (4) counterclockwise will decrease the forward setting (A). Turning screw (4) counterclockwise will also increase the reverse setting (B).

   2. Turning screw (4) clockwise will increase forward setting (A). Turning screw (4) clockwise will also decrease reverse setting (B).

   Note: If it is necessary to adjust screw (4), refer to "Install the Target Screw (As Required)".

4. Verify that no faults occur when the propel control handle is held at the FORWARD setting position for sensor (1).

5. Verify that no faults occur when the propel control handle is held at the REVERSE setting position for sensor (1).

6. Clear the fault history of the ECM. Refer to Special Instruction, REHS3302.

Install the Target Screw (As Required)

1. Loosen the screw and remove old thread lock compound.

2. Install screw (4) and nut (5). Apply Tooling (9) to screw (4). Do not tighten screw (4) or locknut (5).

3. Turn screw (4) clockwise until screw (4) touches sensor (1). Turn screw (4) counterclockwise for one complete turn. This distance will be approximately .8 mm (.03 inch).

4. Tighten locknut (5) on screw (4).

Installation and Adjustment of the Sensor on the Type "B" Propel Control for Switches Retained by a Clip

Illustration 5	g01289317
(1) Sensor (2) Screw (3) Locknut (4) Screw (5) Locknut (8) Frame for the Handle (9) Cam Plate (10) Pin (11) Lever Arm (12) Position Sensor (13) Metal Clip (14) Screw (15) Lockwasher (16) Washer

Note: This section provides the adjustment procedure with a multimeter. To use the Plus+1 Service Tool for Caterpillar (P1STC) software to adjust the sensor, refer to Section "Procedure to Use P1STC Software to Adjust the Sensor".

Install the Sensor

Note: Inspect sensor (1) carefully for a target on the end opposite the screw hole. The target and a countersink for the screw will be pointing upward.

1. Install sensor (1), screw (2), locknut (3), and metal clip (13) into the mounting hole for the sensor on the frame for the propel control handle.

   Note: Make sure that the sensor is held by the clip. There should not be any clearance between the tabs on the clip and the sensor.

2. Position sensor (1) so the mark on sensor (1) is centered under screw (4). Tighten screw (2) and nut (3) to standard torque.
   Show/hide table

   Illustration 6	g01288025
   (A) Centerline (B) Screw (4) centered over the target on sensor (1). (C) Swing arc of screw (4). (D) Pivot for the disc

3. Apply Tooling (7) and install screw (14), locknut (15), and washer (16). Tighten screw (14).

   Note: Verify that sensor (1) is not touching the retaining washer. A 1 mm (.04 inch) gap between sensor (1) and the friction disc is desired. It may be necessary to move sensor (1) away from the friction disc. Only move sensor (1) along centerline (A). Keep the trip points for the sensor centered. Refer to Illustration 6.

Install the Target Screw (As Required)

Note: Follow this process in order to reapply thread lock compound if screw (4) and nut (5) are loosened in order to adjust the settings of the sensor.

1. Loosen screw (4) and remove old thread lock compound.

2. Apply Tooling (7) to screw (4) and install screw (4) and nut (5) . Do not tighten locknut (5).

3. Turn screw (4) clockwise until screw (4) touches sensor (1). Turn screw (4) counterclockwise for one complete turn. This distance will be approximately .8 mm (.03 inch).

4. Tighten locknut (5) on screw (4).

5. Connect sensor (1) to the machine harness.

Connect Tooling

1. Connect Tooling (6) to the ground, which is in position 2 on sensor (12) and to the signal wire which is position (3) on sensor (12).

   Note: Do not attempt to pick up ground from the frame of the handle.

2. Set Tooling (6) to report a percent duty cycle.

Verify that the Sensor is Centered

Note: The position of sensor (1) is fixed by metal clip (13). Do not use the procedure to center the sensor on the "A" handle on the "B" handle. The use of clip (13) is intended to make centering adjustments unnecessary.

Verify that the Settings for the Sensor are Within Specifications

1. Place the ignition switch in the ON position.

2. Position the propel control handle so position sensor (14) reads 80%. The orange light on sensor (1) should be illuminated.

   Note: The metal clip covers the light on the near side. Use a mirror to view the light from the far side of the metal clip.

3. Slowly move the propel control handle toward neutral until the orange light on the sensor (1) goes out. Note the duty cycle output of position sensor (14). This is the forward setting of sensor (1).

4. Position the propel control handle so position sensor (14) reads 30%. The orange light on sensor (1) should be illuminated.

5. Slowly move the propel control handle forward until the orange light on the sensor (1) goes out. Note the duty cycle output of position sensor (14). This is the reverse setting of sensor (1).

6. The forward range is found by subtracting 50 from forward setting . The reverse range is found by subtracting reverse setting from 50.

Verify That the Sensor is Within Specifications

Note: When P1STC software is used, the reading on the ECM will be about 1% higher than the reading on a multimeter.

1. The reading on the ECM for the forward duty cycle should be between 62% and 58%. The reading on the multimeter for the forward duty cycle should be between 61% and 57%.

2. The reading on the ECM for the reverse duty cycle should be between 38% and 42%. The reading on the multimeter for the reverse duty cycle should be between 37% and 41%.

3. Adjust screw (4) in order to obtain the recommended setting.

   1. Turning screw (4) counterclockwise will decrease the forward setting (A). Turning screw (4) counterclockwise will also increase the reverse setting (B).

   2. Turning screw (4) clockwise will increase forward setting (A). Turning screw (4) clockwise will also decrease reverse setting (B).

   Note: If it is necessary to adjust screw (4), refer to "Install the Target Screw (As Required)".

4. Verify that no faults occur when the propel control handle is held at the FORWARD setting position for sensor (1).

5. Verify that no faults occur when the propel control handle is held at the REVERSE setting position for sensor (1).

6. Clear the fault history of the ECM. Refer to KENR8650 Troubleshooting, Resetting of Fault History, Timers, Calibration Values.

Procedure to Use P1STC Software to Adjust the Sensor

A procedure for checking the setting of sensor (1) with the Plus+1 Service Tool for Caterpillar (P1STC) software is provided in this section. Refer to Special Instruction, REHS7696 for installation, tools, and use of the P1STC software.

Illustration 7	g01433681
(1) Duty cycle reading (2) "PROX_SW" indicator (3) "PROPEL" text

Start the P1STC program and follow the instructions to establish communication between the machine ECM and personal computer. Click on the "PROPEL" text (3).

Note duty cycle reading (1) for the position sensor of the propel control handle . To obtain the duty cycle value, divide the indicated value by 100. Duty cycle reading (1) reads "5757". Divide duty cycle reading (1) by 100 in order to get a duty cycle value of 57.57%.

Move the propel lever to the forward direction until the duty cycle reads about 80%. Slowly return the handle toward the NEUTRAL position. When "PROX_SW" indicator (2) turns from red to green check duty cycle reading (1). The ECM will accept 63% to 57%. However, in order to provide an additional margin to allow for variation of the signal, use the limits that were provided in the previous sections.

Note: The reading on the ECM is about 1% higher than the reading on a multimeter. The acceptable range of the duty cycle on a multimeter is 62% to 56%. However, in order to provide an additional margin to allow for variation of the signal, use the limits that were provided in the previous sections.

Move the propel lever to the reverse direction until the duty cycle reads about 30%. Slowly return the handle toward the NEUTRAL position. When "PROX_SW" turns from red to green check duty cycle reading (1). The ECM will accept 37% to 43%. However, in order to provide an additional margin to allow for variation of the signal, use the limits that were provided in the previous sections.

Note: The reading on the ECM is about 1% higher than the reading on a multimeter. The acceptable range of the duty cycle on a multimeter is 36% to 42%. However, in order to provide an additional margin to allow for variation of the signal, use the limits that were provided in the previous sections.

If the settings are not within specifications, readjust the sensor.