Procedure to Install a Rotary Position Sensor and Flash New Software on All D Series Paving Compactors {5705, 7620} 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

An improved 40° rotary position sensor for the propel control handle and new machine control software is available for Paving Compactors. The improved rotary position sensor and new machine control software provide an improved calibration process, improved neutral switch limits, and improved automatic vibratory functions.

Proper installation, calibration, and adjustment of the rotary position sensor and neutral position sensor will eliminate fault code 52 for the propel system on the CB-434D, CB-534D, and CB-634D Paving Compactors. These improvements will also eliminate fault code 55 for the propel system on the CB-434D, CB-534D, and CB-634D Paving Compactors with the Italian Road Homologation (IRH) attachment and the CB-564D Paving Compactor propel system.

This Special Instruction provides the information that is needed to update the rotary position sensor and flash the new software. The new software can only be used with the Required Parts listed in the Table below.

The new rotary position sensor contains an electrical connector configuration that is different from the previous electrical connector. The rotary position sensor connector on the machine electrical harness will need to be changed.

Read and understand the following instructions thoroughly, before performing this procedure.

Instructions for Replacing the Rotary Position Sensor and Connector Plug

1. Remove and retain the screws and cover from the right side operator console.
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   Illustration 1	g06052558
   View showing right side operator console with cover removed (A) Connector plug assembly (B) Rotary position sensor (C) Screws

2. Disconnect connector plug assembly (A) from rotary position sensor (B).

3. Remove and retain screws (C) that secure rotary position sensor (B). Remove rotary position sensor (B).
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   Illustration 2	g06054813
   View showing handle control group on right side operator console (parts removed for clarity) (1) 351-6944 Position Sensor Gp (2) 281-8803 Connector Plug As (C) Screws

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   Illustration 3	g06052535
   Original rotary position sensor with 4-pin connector

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   Illustration 4	g06052545
   New rotary position sensor with 3-pin connector for an IRH equipped machine. Non-IRH equipped machines use wire K708 BU at position 3.

   Note: Connector plug assembly (A) for the propel system rotary position sensor will need to be replaced. The original sensor used a 4-pin connector with no connection on terminal 4, or a 3-pin connector with a #1 key. The new connector plug assembly is a 3-pin connector with a #3 key. The wire locations of the new connector plug assembly will correspond to the same three positions as the previous connector plug assembly. Refer to Illustration 4 for wire placement to plug location.

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   Illustration 5	g06053126

   Note: The neutral position sensor should not be confused with the propel system rotary position sensor.

4. Replace connector plug assembly (A) using 281-8803 Connector Plug As (2).

5. Install 351-6944 Position Sensor Gp (1), using retained screws (C).

6. Assemble connector plug assembly (2) to position sensor group (1).

7. Using the retained screws, install the right side operator console cover.

Instructions for Software Installation

The original control groups have been replaced and may not be available for service. If the original control group (ECM) fails, the new control group must be used and flashed with the new software. Refer to table above for new control group software (flash files). New control group software is not compatible with original control groups. Original control group software is not compatible with new control groups.

The ECM part number must be identified visually or with P1STC in the following instructions to determine the required flash from Table 2 or 3.

Italian Road Homologation - (IRH)

The "New P1STC Diagnostic File" listed in table above is now used for all Series D Asphalt Compactors.

Reference: Special Instruction, REHS7696, "Software Installation Instructions of the Plus+1 Service Tool for Caterpillar Paving Products"

Illustration 6	g06271209
(A) Software part number (B) Control group part number

A decal with the part number will be attached to the control group housing. The control group can also be identified using the Plus+1 Service Tool For Caterpillar (P1STC).

1. Obtain and install the latest Plus+1 Service Tool for Caterpillar (P1STC) software to a portable computer.

   To download the applicable Flash File from SIS web:

   • Select "Service Software Files"

   • Select "Flash Files" and enter the software number in the "Flash Filename" search field

   • Select the software number that appears to start the download process to your computer

   • Note the location of the saved file

   Note: The first use of Communication Cable (CG-150) Tool (1) may start a driver installation for the USB port being used. Allow the computer to install the driver if prompted

2. Connect Communication Cable (1) and Communication Cable As (2) together and attach the USB connector to a portable computer.
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   Illustration 7	g06052994
   View showing connections near the fuse/relay panel (D) Test Mode/Model Config plug (calibration) (E) Diagnostic connector (F) CAN resistor (G) Vibratory Configuration plug (IRH & CB564D)

3. Attach the 3-pin Deutsch connector receptacle to machine 3-pin diagnostic connector (E) (located near the fuse/relay panel, on the main harness that leads to the machine controller).

   Diagnostic connector (E) includes wires F711 GN, F712 GY, and A249 BK.

4. Turn the engine start switch to the "Run" position, and leave the engine off.

5. Start the P1STC program on the portable computer.
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   Illustration 8	g06271249
   View showing "Plus+1 Service Tool for Caterpillar" (P1STC) default window (H) Status (J) Menu (K) Select Gateway (Communication Cable Menu) (L) Scan System (M) Navigation Panel On (N) Navigation Panel Off (P) P1D Help (Cross Reference Document) (Q) Open Folder (R) Connection Status (S) Gateway/Communication Cable Selected (T) Online Mode

6. From the P1STC default window, select the tab for "Select Gateway" (K) .
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   Illustration 9	g06271549
   View showing Available Gateways and Channels screen

7. Select the "CG150" gateway.
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   Illustration 10	g06271555
   View showing "Select Sauer-Danfoss CG150 Channel" screen

8. Select the "CG150 #0 (Channel 0)" channel and "Change" under the "Current Selection".

9. Select "Set to Online Mode" if P1STC was last used in off-line mode. If the icon is grayed out, it is already set to Online Mode.
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   Illustration 11	g06053183
   Typical view of "Diagnostic Navigator" (M) Navigation Panel On (Q) "Open"

10. Select "Navigation Panel On" tab (M).

11. Select the "Open folder" tab (Q) for the diagnostic file folder.

    The path to the diagnostic file is "C:\PLUS+1\CAT Diagnostic Files".

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    Illustration 12	g06053188
    View showing "Open" screen with "CAT Diagnostic Files" folder selected

12. Select and open the "Cat Diagnostic Files" folder.
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    Illustration 13	g06053191
    View showing "ACOM_D_SERIES.P1D" diagnostic file selected on "Open" screen

13. Select and Open the "ACOM_D_SERIES.P1D" diagnostic file. Allow P1STC to refresh.
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    Illustration 14	g06053637
    View showing "PLUS+1 GUIDE Service Tool" screen with "File Download" selected

14. Select "File" from the menu bar, then select "File Download". A new window will open.
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    Illustration 15	g06053196
    View showing "Open" window to select the specific flash file

15. Locate and open the new flash file.
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    Illustration 16	g06053200
    View showing "Download File to ECU - Select Download Files" window

16. From the "Download File to ECU - Select Download Files" window, read the warning message and select "Next" to continue.
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    Illustration 17	g06053207
    View showing "Download File to ECU - Confirm" window

17. Select "Confirm" located under the "App/File Type" column. A new window will open.
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    Illustration 18	g06053210
    View showing "Caution" pop-up window

18. Refer to the "Required Software Flash File for Original (and New) Control Group" tables, then enter the application type that matches the new software.

    Note: Only numbers are allowed in this field.

19. Select "OK" to proceed to "Download File to ECU - Ready" window.
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    Illustration 19	g06053262
    View showing "Download File to ECU - Ready" window

20. Select "Start Download" to continue.
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    Illustration 20	g06053263
    View showing typical download in progress

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    Illustration 21	g06053264
    View showing "Download File to ECU - Download Report" window

21. After the download is complete, "Download successful" appears. Select "Close" to continue.
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    Illustration 22	g06053266
    View showing Plus+1 Service Tool for Caterpillar screen (T) "New System" (U) "Parameter Functions" (V) "Defaults" (W) "Edit Value" column (X) "Download"

22. Refer to the "Diagnostic Navigator" in "P1STC" screen and notice the check-box next to each reference.

    • Select "New System" (T)

    • Select "Parameter Functions" (U)

    • Select "Defaults" (V)

    • Select the field in "Edit Value" column (W) for each row and change value "555" to value "0"

    • Select "Download" (X) (green arrow pointing down) to set the new values

    The error message can be ignored and closed.

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    Illustration 23	g06053267
    Typical error message window after resetting each "Edit Value" to "0"

    Note: This software will require that calibrations be performed to clear a calibration fault condition that occurs after flashing the new software. The test plug connector must be disconnected from the machine harness to continue. Refer to Testing and Adjusting for your machine, then perform each of the calibration procedures listed.

    Note: The Test Mode or Model Configuration connector used for calibrations contains wires; A990 BU, 135 BU, and 200 BK for three pin connectors and T970 GY and 135 BU for machines with a two pin connector.

23. Disconnect the test plug connector from the machine harness and perform the following calibrations:

    • Calibrate the propel system rotary control position sensor. Refer to Testing and Adjusting , "Propel Control - Calibrate".

    • Calibrate the propel speed control sensor. Refer to Testing and Adjusting , "Speed Control - Calibrate".

    • Calibrate the forward propel solenoid. Refer to Testing and Adjusting , "Solenoid Valve (Forward Propel) - Calibrate".

    • Calibrate the reverse propel solenoid. Refer to Testing and Adjusting , "Solenoid Valve (Reverse Propel) - Calibrate".

    • Calibrate the water spray timer control sensor for the CB-564D, CB-434D IRH, and CB-534D IRH machines only. Refer to Testing and Adjusting , KENR3617, "Water Spray Timer - Calibrate".

    After performing the calibrations, the machine should be clear of faults.

24. Reconnect the test plug connector to the machine harness.

Instructions to Verify New Propel Position Sensor

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Illustration 24	g06271570
Propel handle in neutral position.

1. Start P1STC and load the proper diagnostic file. Navigate to the "Propel Handle" tab (A).

   The top bar graph (B) illustrates the propel rotary position sensor duty cycle. Divide the value by 100 to obtain the actual duty cycle percentage.

2. Move the propel handle to the neutral detent position. The duty cycle should not exceed 51 ± 3%.
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   Illustration 25	g06271572
   Propel handle in forward position.

3. Move the propel handle fully to the forward position. The duty cycle (B) should be 80 - 85%. The proximity value (C) should change from "ON" to "OFF".
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   Illustration 26	g06271575
   Propel handle in reverse position.

4. Move the propel handle fully to the reverse position. The duty cycle (B) should be 17 - 22%.

5. If the duty cycle is incorrect for any of the positions, verify the propel handle is in good working order. If the propel handle is worn, replace as necessary.

   If the duty cycle range is between 10 - 90%, the rotary position sensor is incorrect or defective.

Instructions for Checking the Neutral Switch Activation Points

1. Do a general inspection of the handle. Make sure that the neutral sensor is secure.

2. Inspect the spring washers on the pivot shaft to make sure that the spring washers are not loose.
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   Illustration 27	g01875495

3. Start Plus 1, load provided diagnostic file, select "Neutral Adjust" tab. Refer to Illustration 27.

4. Move the handle out of neutral so that the duty is about 10% beyond the respective activation points.

5. Slowly return the handle to neutral and note the "Prox_Sw_Adjustment" value (A).

   Note: The handle must be moved slowly to get good readings.

   Note: Divide the "Prox_Sw_Adjustment" value (A) by 100 to obtain the actual duty cycle percentage.

6. Repeat the process to make sure that the value is stable.

7. Forward activation point should be between 56% to 59%.

8. Reverse activation point should be between 43% to 46%.

   Note: The switch response is affected slightly by ambient temperature. Follow the guidelines given below when Testing and Adjusting the switch.

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   Table 6

   Direction	Ambient 4° - 32° C (39° - 90° F)	Ambient < 4° C (39° F)	Ambient > 32° C (90° F)
   Forward	56% - 59%	55.5% - 58.5%	56.5% - 59.5%
   Reverse	43% - 46%	43.5% - 46.5%	42.5% - 45.5%

9. If outside the range, the target screw on the propel handle can be adjusted.

10. To help the testing process, remove the detent spring.

11. Loosen the jam nut on the target screw. Turn the target screw in to increase the forward transition point and reduce the reverse transition point.

    Note: 9S-3263 Thread Lock Compound may be applied to the screw, if adjustment is required.

12. Turn out the screw for the opposite effect.

13. Adjust as required until both forward and reverse translation points are within specifications.

14. Lock the screw with the jam nut.

    Note: Adjustment of the neutral switch may be necessary if both points cannot be brought to within specifications.

15. If adjustment of the proximity switch position is necessary, the recommended process is described below.

    Note: The neutral switch on some machines may be held in place with adhesive, whereas other machines use a metal clip. If the switch is held in place with adhesive and requires adjustment, perform the process to reapply adhesive before proceeding. Refer to "Procedure to Apply Adhesive on Certain Neutral Safety Switches."

    1. Adjust the target screw until the difference between the forward and reverse activation points is 13%. Lock the target screw with the jam nut.

    2. Loosen the neutral switch only enough to allow the switch to rotate. Keep the switch snug during the check in the following step. A loose switch may give irregular readings.

    3. Rotate the switch until the forward activation point is found to be in the center of the specified range.

    4. Tighten the switch mounting screws.

    5. The reverse activation point should now be within specifications. Confirm both forward and reverse settings are within specifications.

16. Reinstall the detent spring. Set detent spring so the handle position sensor reads 50 ± 2% when detent roller is firmly engaged in the cam detent.

17. Recalibrate the propel handle position sensor.

18. Clear the faults history and reset the timers. Refer to Troubleshooting, KENR3568, "Resetting of Fault History, Timers, Calibration Values".

Procedure to Apply Adhesive on Certain Neutral Safety Switches

1. Some neutral switches may be fixed with an adhesive. Some neutral switches may be fixed with a metal clip. This procedure applies to switches secured with adhesive that require adjustment per the above instructions.

   1. Remove the mounting screw.

   2. Carefully remove the switch from the frame. Do not bend the switch.

   3. Remove loose adhesive from the switch.

   4. Apply 169-5464 Quick Cure Primer to the bottom of the 283-8438 Sensor and to the mounting location on the propel handle frame.

   5. Allow the primer to dry for 1 minute.

   6. Apply one drop of 4C-9507 Retaining Compound on the bottom of the sensor.

   7. Install the sensor and the screw.

   8. Proceed with adjustment procedure described above.