Cat® Compaction Control Setup and Configuration Procedure for Certain Asphalt and Soil Compactors {1408, 7490, 7494, 7610} Caterpillar

Asphalt Compactor

CB64B (S/N: C561-UP; 4771-UP)

CB66B (S/N: 4751-UP; B661-UP)

CB68B (S/N: 4961-UP; C681-UP)

CD10 (S/N: J6B1-UP)

Paving Compactor

CB10 (S/N: MS21-UP; NPP1-UP; P8P1-UP)

CB7 (S/N: AT51-UP; EL51-UP; NLJ1-UP)

Vibratory Asphalt Compactor

CB13 (S/N: LP91-UP; PWP1-UP)

CB15 (S/N: M941-UP; NPB1-UP)

CB16 (S/N: HP51-UP; KHC1-UP)

CB8 (S/N: JL41-UP; B461-UP; CB81-UP)

CD44B (S/N: 3981-UP; JXE1-UP)

CD54B (S/N: GRT1-UP; J9T1-UP)

CD8 (S/N: RH41-UP)

Vibratory Soil Compactor

CP54B (S/N: 4831-UP; P541-UP; GP51-UP; PM51-UP; 5061-UP; 5461-UP; P5F1-UP; PFM1-UP; CPX1-UP)

CP56 (S/N: C5P1-UP; FCP1-UP)

CP56B (S/N: 4851-UP; MP61-UP; P561-UP; 4381-UP; 5081-UP; LHC1-UP; M5P1-UP)

CP68B (S/N: 5101-UP; 6841-UP; CM61-UP; P681-UP; 4891-UP; LCF1-UP; SDT1-UP)

CP74 (S/N: P8F1-UP)

CP74B (S/N: 4911-UP; 5121-UP; P741-UP; 7441-UP; CP71-UP; L7B1-UP; M7B1-UP)

CP76 (S/N: JCP1-UP)

CS44B (S/N: CS31-UP; 4G31-UP)

CS54B (S/N: G541-UP; 5M41-UP; 5051-UP)

CS64 (S/N: C7F1-UP; C6S1-UP; WSW1-UP)

CS64B (S/N: C641-UP; CW61-UP; DH61-UP; TF61-UP; 4861-UP; 5181-UP)

CS68B (S/N: CS81-UP; M681-UP; 4881-UP; 4391-UP; 5091-UP; MBF1-UP; MMS1-UP)

CS74 (S/N: C8F1-UP; C8S1-UP)

CS74B (S/N: 4901-UP; 4411-UP; C741-UP; CS41-UP; LCB1-UP; E7E1-UP; B7M1-UP)

CS76 XT (S/N: JCS1-UP; CYX1-UP)

CS76B (S/N: 4921-UP; CB71-UP; L9H1-UP)

CS78B (S/N: 4431-UP; 4931-UP; 5131-UP; M781-UP; S781-UP; L8C1-UP; M8M1-UP)

Introduction

This Special Instruction will aid in theCat^® Compaction Control Configuration and Setup Procedure for certain Asphalt Compactors.

Important Safety Information

Do not perform any procedure in this Special Instruction until the information in this Special Instruction has been fully read and understood. Use only proper tools and observe all precautions that pertain to the use of those tools. Failure to follow these procedures can result in personal injury. The following procedures should be observed.

Work safely. Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs.

A person must be alert to potential hazards. This person should also have the necessary training, skills, and tools to perform these functions properly.

Safety precautions and warnings are provided in this instruction and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons. Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard.

Therefore, the warnings in this publication and the warnings that are on the product are not all inclusive. Ensure that any tool, procedure, work method, or operating technique you use that is not recommended by Caterpillar is safe.

Ensure that the product will not be damaged or the product will not be made unsafe by the operation, lubrication, maintenance, or repair procedures used.

Note: Caterpillar recommends that each customer conducts a risk assessment for remote control operation and establish layers of protection in and around the area of the remote controlled machine and establish safe job site procedures. Examples may include personnel training, warning signs, and barricades.

Note: Prior to operation of the machine read the Operation and Maintenance Manual.

Before starting installation and in addition to the normal safety precautions that are taken in the day to day maintenance of heavy machinery, the following preliminary steps are recommended:

1. Move the machine to a smooth, level location, and away from other working machines and personnel.

2. Ground all implements.

3. Engage the parking brake for the machine.

4. Stop the engine.

5. Move the hydraulic control levers to all positions to release the pressure in the hydraulic system.

6. Turn the battery disconnect switch to the OFF position. Remove the key for the battery disconnect switch. Use a secure padlock to lock the battery compartment access door.

7. Place a lockout tag on the disconnect switch.

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Be sure all personnel are clear of the equipment while the equipment is being lowered. Failure to stay clear of the equipment while the equipment is being lowered may result in personal injury.

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Do not operate or work on this machine unless you have read and understand the instructions and warnings in the Operation and Maintenance Manual. Failure to follow the instructions or heed the warnings could result in injury or death. Contact any Caterpillar dealer for replacement manuals. Proper care is your responsibility.

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Improper operation of an access platform could result in injury or death. Operators must carry out their duties properly and follow all instructions and guidelines given for the machine and access platform.

• Only mount the machine and dismount the machine at locations that have steps and/or handholds.

• Inspect the steps and the handholds before mounting and dismounting. Clean the steps and the handholds, if necessary. Repair the steps and the handholds, if necessary.

Illustration 1	g00037367

• Face the machine when you are mounting and dismounting.

• Maintain a three-point contact with the steps and the handholds. Three-point contact is maintained when two feet and one hand are in contact or one foot and two hands are in contact.

• Never get on a moving machine or off a moving machine.

• Never jump off the machine.

• Do not try to climb on the machine or climb off the machine when you are carrying tools or supplies. Use a hand line to pull equipment up to the operator platform.

• Do not use any of the controls as handholds as you are climbing into the machine or exiting the machine .

Note: Prior to operation of the machine read theOperation and Maintenance Manual .

Required Tools

• 7.6 m (25.00 ft) tape measure

• 1 m (4.0 ft) level

• 15 m (50.0ft) tape measure

• Chalk line

Cat Compaction Control System for Asphalt Compactors (Mapping System)

The factory designed and integrated mapping system for the Asphalt compactors is offered with two levels of accuracy:

• Satellite-Based Augmentation System (SBAS) level of accuracy requires no off-board infrastructure and delivers only pass count mapping

• RTK level of accuracy that requires a corrections source (base station, IBSS, VRS) and data radio, an RTK level of accuracy delivers pass count mapping and CCA (Cat Compaction Algorithm) mapping. Contact your Cat Dealer Technology Representative to order a base station and/or data radio

Note: Outside of North America and Europe, SBAS is not available in all regions. The Compaction Control System on the CB460 display will have two operating modes:

Operator Mode - Operator mode allows the operator to navigate through the system and implement some changes to the system functionality and configurations. Adjusting the system functionality and configurations ensure the best performance and benefits of the mapping system without impacting the system accuracy or the system setting. The operator mode will also have some menu items and softkeys disabled.

Manager Mode - Manager mode allows the user to accomplish a permanent system settings changes when any changes are needed.

Note: Use extreme care when the compaction control system is in the manager mode to prevent any accidental changes of the system settings. Accidental changes to the system setting may affect the system functionality or the system accuracy.

Machine Settings

Follow the below steps for machine settings.

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Illustration 2	g06367964
Display (1) "OK" button (2) Power button (8) Arrow buttons

1. Ensure that the CB460 operating system is in the "manager mode".

2. To enter the "manager mode" on the display system:

   1. Turn off the display.

   2. Press and hold the "OK" button (1) on the display then press the Power button (2) on the display while still holding the "OK" button (1) until the system begins to initiate on the display screen.
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   Illustration 3	g06367870
   Display (1) "OK" button (3) Main menu button (4) F1 softkey button (5) F2 softkey button (6) F6 softkey button

3. Press the Main menu button (3) from the design screen.
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   Illustration 4	g06367646
   "Setup Menu - Configuration" screen

4. Press the F2 softkey button (5) next to "Installation" on the "Setup Menu - Configuration" screen.
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   Illustration 5	g06367659
   "Setup Menu - Installation" screen

5. Select "Machine Settings" from the "Setup Menu – Installation" screen using the Arrow buttons (8).

6. Press the "OK" button (1).

Machine Settings Menu

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Illustration 6	g06367660
"Machine Settings" screen

1. Press the F6 softkey button (6) next to "Edit Machine" on the "Machine Settings" screen to edit machine options.
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   Illustration 7	g06367662
   "Machine Settings - Name" screen

2. Enter the desired "Machine Name" using the Arrow buttons (8) on the display. Press the F6 softkey button (6).
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   Illustration 8	g06367666
   "Machine Settings - Machine Type" screen

3. Use the arrow buttons on the display to highlight "Asphalt Compactor" from the "Machine Type" screen. Press the F6 softkey button (6).
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   Illustration 9	g06367668
   "Machine Settings - Compaction Sensor" screen

4. Select the desired sensor from the "Compaction Sensor" screen to be used. Press the F6 softkey button (6).
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   Illustration 10	g06367675
   "Machine Settings - 3D Sensor Position"screen

5. Select the desired sensor position from the "3D Sensor Position" screen. Press the F6 softkey button (6).
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   Illustration 11	g06367685
   "Machine Settings - 3D Sensor Mounting" screen

6. Select the mounting application on the "3D Sensor Mounting" screen. Press the F6 softkey button (6).
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   Illustration 12	g06367688
   "Machine Settings - Cab Mount Sensor" screen

7. Select appropriate sensor on the "Machine Settings - Cab Mount Sensor" screen. Press the F6 softkey button (6).
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   Illustration 13	g06367692
   "Machine Settings - Cab Mount Sensor Orientation" screen

8. Select the desired cab sensor orientation on the "Cab Mount Sensor Orientation" screen. Press the F6 softkey button (6).
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   Illustration 14	g06367694
   "Machine Settings - Temperature Sensor" screen

9. Select desired sensor on the "Temperature Sensor" screen. Press the F6 softkey button (6).
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   Illustration 15	g06367699
   "Machine Settings - Fixed Radios" screen

10. Select the desired application on the "Fixed Radios" screen to be used. Press the F6 softkey button (6).

    Press the F1 softkey button (4) next to Enablement/Disablementon icon on the screen to change the status.

    Note: A correction source (base station, IBSS, VRS) and a data radio is required to accomplish a high accuracy RTK (Real-Time Kinematics) positioning.

    When the machine is equipped with a high accuracy mapping option (RTK) and a Third-Party Radio option, an RS232 Serial Port method of communication is required.

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    Illustration 16	g06367703
    "Machine Settings - Wireless Communications" screen

11. Select the desired setting on the "Wireless Communications" screen. Press the F6 softkey button (6).
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    Illustration 17	g06367722
    "Machine Settings - Printer" screen

12. Select the printer in use on the "Printer" screen. Press the F6 softkey button (6).
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    Illustration 18	g06367726
    "Machine Settings - Lightbar" screen

13. Select desired application on the "Lightbar" screen. Press the F6 softkey button (6).
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    Illustration 19	g06367728
    "Machine Settings - Finished" screen

14. The "Machine Settings – Finished" page will display "Finished!". Press the F6 softkey button (6) to update and be returned to the "Machine Settings" screen.

Machine Dimensions

Note: Machines ordered from the factory with the mapping option installed will be pre-loaded with one of the Machine Control data (.MCH) files depending on the model with settings and dimensions.The machine dimensions file for Mapping System on any of the compactor machines with a factory installed Compaction Control System can be obtained from Caterpillar. Contact the support team through the Dealer Solution Network (DSN).The machine dimensions for the factory installed Compaction Control System will be preloaded in the machine system display CB460 from the factory for Asphalt Compactor machines.GPS mast and locations will differ between models, the GPS antenna will be on the front left, right, or both sides of the cab.

Note: Refer to Illustrations 20 and 21 to find where measurements will be taken from.

Illustration 20	g06367732
Machine measurement dimensions (A) Above bottom of front drum (B) Mast height (C) Drum height (D) Distance from the front of the machine to the center of the front drum (E) Distance between drum centers (F) Distance from the back of the machine to the center of the rear drum (G) Distance from the front of the machine to the center of the GPS mast

Illustration 21	g06368812
Machine measurement dimensions (H) Drum Width (J) In from Left Side of Drum

Field Measurement Table

Use Table 1 to enter the values that are needed during the "Machine Measurements Procedure".

Machine Measurements Procedure

Ensure that the CB460 operating system is in the manager mode.

To enter the manager mode on the display system, perform the following steps:

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Illustration 22	g06367964
Display (1) "OK" button (2) Power button (8) Arrow buttons

1. Turn off the display.

2. Press and hold the "OK" button (1) on the display then press the Power button (2) on the display while still holding the "OK" button (1) until the system starts to initiate on the display screen

Follow the next steps for machine settings.

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Illustration 23	g06367754
Display (1) "OK" button (3) Main menu button (4) F1 softkey button (5) F2 softkey button (6) F6 softkey button (7) Next button

1. Press the Main menu button (3).
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   Illustration 24	g06367774
   "Setup Menu - Configuration" screen

2. Press F2 softkey button (5) next to "Installation" on the "Setup Menu - Configuration" screen.
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   Illustration 25	g06367779
   "Setup Menu - Installation" screen

3. Select "Machine Measurements" from the "Setup Menu – Installation" screen using the Arrow buttons (8) then press the "OK" button (1).

Machine Measurements Menu

Illustration 26	g06367785
"Machine Measurements" screen

From the "Machine Measurements" menu "3D Sensor Measurements" or "Machine Measurements" can be selected.

Illustration 27	g06367790
"3D Sensor Measurements" screen

Follow the instructions on the CB460 display screen then press the F6 softkey button (6).

1. "Park the machine on a level surface."

2. "Ensure that the machine is straight, no articulation (use the articulation lock-outs, if available)."

3. "Measure to the bottom of the front drum."

4. "Measure to the left edge of the front drum."

3D Sensor Measurements

Illustration 28	g06367800
"3D Sensor Measurements" screen

Three different selections can be made to start the measure-up process. Select the appropriate tool to complete this procedure:

• Top of mast

• Measure-up tool

• Center of Universal Total Station (UTS) target

Reference: Special Instruction, M0092319, "Set-Up and Measure-Up Process of a Universal Total Station (UTS) for Cat^®Grade Control"

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Illustration 29	g06367805
"3D Sensor Measurements" screen

1. "Back from center of front drum ( - = forward)"

   1. Measure from front of machine to centerline of front drum as shown in Illustration 20 (D).

   2. Measure from front of machine to centerline of mast as shown in Illustration 20 (G).

   3. Subtract the value (D) from value (G) obtained from measurements for the "Back from center of front drum ( - = forward)" value.
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   Illustration 30	g06367817
   "3D Sensor Measurements" screen

2. "Above bottom of front drum"

   1. Measure from bottom of drum to top of mast as shown in Illustration 20 (A).

   2. This measurement can also be taken by adding drum height (C) to mast height (B) as shown in Illustration 20.
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   Illustration 31	g06367824
   "3D Sensor Measurements" screen

3. "In from left edge of front drum ( - = out)"

   1. Measure from left edge of front drum to center of mast (J) refer to Illustration 21.

"Machine Measurements"

Illustration 32	g06367828
"Machine Measurements" screen

Select "Machine Measurements" in the "Machine Measurements" screen.

Illustration 33	g06367854
"Machine Measurements" screen

Enter values in this section obtained from "Field Measurement Table" 1.

"Drum width:"

Illustration 34	g01361801
Level on top of drum

1. Place a level on the left side of the drum. The level should be pointing front to back. The level should be parallel with the edge of the drum.

   1. Move the level fore and aft to find the highest point of the drum.

   2. Ensure that the bubble in the sight glass is level.

   3. Mark the center point of the level on the drum.

2. Place the carpenters level on the right side of the drum. The level should be pointing front to back. The level should be parallel with the edge of the drum.

   1. Move the level fore and aft to find the highest point of the drum.

   2. Ensure that the bubble in the sight glass is level.

   3. Mark the center point of the level on the drum.

3. Snap a string line across the drum between the two marks that were created with a chalk line. This reference line is the center line of the drum.

4. Measure the reference line from one edge of the drum to the opposite edge of the drum. Refer to Illustration 21 and record this measurement as Drum width (H) in box 1 of Table 1.

"Drum height:"

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Illustration 35	g06368294
Drum Height (C) Drum height (9) Tape measure (10) Level

1. Place a level (10) parallel to the drum along the reference line that was created in Step 3 in ""Drum width:"".

2. Place a tape measure (9) on top of the level and measure to the ground.

   Note: Refer to Illustration 35 to ensure that the edge of the tape measure stays positioned against the yoke.

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   Illustration 36	g06368319
   Side view of compactor (C) Drum height (9) Tape measure (10) Level

   Note: Refer to Illustration 36 to ensure that the tape measure is centered on the drum.

3. Mark the location where the end of the tape measure meets the ground. This location will be used for the "Avoidance Zone" measurements.

4. Determine the measurement from the bottom of the level to the ground. Refer to Illustration 20 and record the measurement as "Drum height" (C) in box 2 of Table 1.

"Distance Between Drum Centers: (Front to Rear)"

1. Determine center line of the front and rear drum.

   Note: The location mark made from Step 3 in ""Drum height:"" can be used for the front measurement. Repeat Steps 1 through 3 in ""Drum width:"" and Steps 1 through 3 in ""Drum height:"" to obtain a measurement point for the rear drum.

2. Measure the marks between the front and rear drums and record the measurement as "Distance between drum centers" (E) as shown in Illustration 20.

"Machine Body Dimensions"

These measurements will be used to indicate the Avoidance Zone around the machine.

Illustration 37	g06367858
"Machine Measurements" screen

1. Measure from the front of the machine along the ground to the center point of the drum that was marked during Step 3 in""Drum height:"".

2. Record this measurement as "Distance from the front of the machine to the center of the drum" (D) in box 3 of Table 1 in ""Drum height:"".

1. Measure from the back of the machine along the ground to the center point of the drum that was marked during Step 3 in ""Drum height:"".

2. Record this measurement as "Distance from the back of the machine to the center of the drum" (F) in box 4 of Table 1.