Installation of the AccuGrade Electronic Components for Motor Graders{7220} Caterpillar

Motor Grader:

120H (S/N: CAF1-UP)

12H (S/N: AMZ686-UP; CBK1-UP)

135H (S/N: CBC1-UP)

140H (S/N: APM2223-UP; CCA1-UP)

143H (S/N: APN662-UP)

14H (S/N: ASE1380-UP)

160H (S/N: ASD496-UP; CCP1-UP)

163H (S/N: ARL338-UP)

16H (S/N: ATS466-UP)

Introduction

ReferenceOperation and Maintenance Manual, SEBU7811, "AccuGrade - Grade Control System"

This Special Instruction provides information for the installation of the Electronic components of the Single Mast and Dual Mast AccuGrade - Grade Control System.

The operation of the AccuGrade - Grade Control System is covered in the Operation and Maintenance Manual, SEBU7811, "AccuGrade - Grade Control System". Refer to that manual for more information.

Important Safety Information

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 in order 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. The warnings in this publication and the warnings on the product are not all inclusive. If a tool, a procedure, a work method, or an operating technique that is not specifically recommended by Caterpillar is used, you must be satisfied of your safety and the safety of other people. You should also make sure that the product will not become damaged or unsafe by the operation, the lubrication, the maintenance, or repair procedures that are chosen by you.

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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 your Caterpillar dealer for replacement manuals. Proper care is your responsibility.

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Personal injury or death can result from improper assembly procedures. Do not attempt any assembly until you have read and understand the assembly instructions.

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Movement of the transmitter could cause unexpected blade movement. Death or serious injury could occur. Turn off the transmitter before you move the transmitter or before you adjust the transmitter.

Required Tools

The following tools will be required to install the AccuGrade - Grade Control System. The list below contains the recommended Caterpillar service tools.

Table 1

Part Number	Description
9S-1748	Wrench Set (Socket) (1/2 Inch Drive)
199-6156	Metric Wrench Set (Socket) ( 1/2 Inch Drive )
194-3584	Wrench Set (Socket) (Torx screw)
1U-7230	Hand Tool Group (Screwdrivers)
8T-9293	Torque Wrench (1/2 inch Drive)
9S-3263	Thread Lock Compound
	Straight Edge 1219.2 mm (4 ft)
	Adjustable Square 609.6 mm (2 ft)
	Tape Measure 15.24 m (50 ft)

Parts List

249-7783 Display Kit

Table 2

249-7783 Display Kit
249-7785 Electronics Group (2D)
	Quantity	Part Number	Description
225-9598 Bracket	4	3L-6789	Lockwasher
	4	4E-5724	Washer
	4	149-4311	Bolt (Socket)
255-0947 Control Group	1		Display
250-0889 Harness Assembly
250-1919 Installation Group
	Quantity	Part Number	Description
294-5261 Support	1	5P-4116	Hard Washer
	1	244-1901	Plate Assembly
	1	244-1902	Support Assembly
	1	244-1903	Handle
251-9569 Wiring Group (Cab)	2	3S-2093	Cable Strap
	1	4P-7581	Clip (Ladder)
	3	5P-4115	Hard Washer
	2	5P-9299	Clip
	1	8T-4121	Hard Washer
	1	8T-4137	Bolt
	3	9X-2045	Truss Head Screw
	1	130-5300	Clip
	1	156-6175	Clip (Ladder)
	1	233-3292	Harness Assembly

Cross Slope

120H, 135H, 12H, 140H, 143H, 160H And 163H Motor Graders

Table 3

249-7788 Sensor Kit
226-9169 Power Module
249-7789 Electronics Group (Cross Slope)
	Quantity	Part Number	Description
226-9170 Angle Sensor
226-9170 Angle Sensor
244-1714 Rotation Sensor
250-2172 Bracket	2	4M-6425	Bolt
	2	8T-4224	Hard Washer
	1	270-7137	Bolt
255-0941 Bracket	3	269-3303	Screw
	3	269-3304	Spacer
250-1932 Installation Group
Kit	Quantity	Part Number	Description
247-6438 Wiring Group (Grade)	1	3S-2093	Cable Strap
	4	4K-8302	Clip
	1	7D-5962	Bolt
	1	8T-0326	Bolt
	8	8T-4121	Hard Washer
	2	8T-4133	Nut
	4	8T-4191	Bolt
	2	8T-4195	Bolt
	1	8T-4223	Hard Washer
	2	8X-5489	Sleeve
	2	9G-9154	Clip
	5	9X-8256	Washer
	2	061-6665	Machine Screw
	1	089-7960	Washer
	1	186-0359	Loop Clip
	1	236-2356	Harness Assembly
	1	243-3250	Harness Assembly
	1	251-2383	Bracket
	4	160-8500	Nut
	4	188-9644	Screw
	4	211-9032	Washer
	1	5C-2890	Nut
	1	6V-8188	Nut
	4	9X-2537	Bolt

14H And 16H Motor Graders

Table 4

250-3027 Sensor Kit
226-9169 Power Module
Kit	Quantity	Part Number	Description
249-7789 Electronics Group (Cross Slope)
Kit	Quantity	Part Number	Description
226-9170 Angle Sensor
226-9170 Angle Sensor
244-1714 Rotation Sensor
250-2172 Bracket	2	4M-6425	Bolt
	2	8T-4224	Hard Washer
	1	270-7137	Bolt
255-0941 Bracket	3	269-3303	Screw
	3	269-3304	Spacer
250-1933 Installation Group
Kit	Quantity	Part Number	Description
251-2140 Wiring Group (Grade)	1	6V-8188	Full Hex Nut
	3	4K-8302	Clip
	1	7D-5962	Bolt
	1	8T-0326	Bolt
	6	8T-4121	Hard Washer
	1	8T-4133	Nut
	4	8T-4191	Bolt
	1	8T-4195	Bolt
	1	8T-4223	Hard Washer
	2	8X-5489	Sleeve
	2	9G-9154	Clip
	5	9X-8256	Washer
	2	061-6665	Machine Screw
	1	089-7960	Washer
	1	186-0359	Loop Clip
	1	236-2356	Harness Assembly
	1	243-3250	Harness Assembly
	1	251-2383	Bracket
	4	160-8500	Nut
	4	188-9644	Screw
	4	211-9032	Washer
	1	5C-2890	Nut
	4	9X-2537	Bolt

Single Sonic Tracer

Table 5

249-7801 Kit (Single Sonic Tracer)
248-1493 Case
	Quantity	Part Number	Description
(2) 248-1484 Base Assemblies	2	5P-1076	Hard Washer
	2	5S-7385	Lockwasher
	2	6V-8188	Full Hex Nut
	2	8T-8917	Bolt
	2	8T-9389	Bolt
249-7792 Electronics Group (Sonic Tracer)
	Quantity	Part Number	Description
244-1715 Sonic Tracer
248-1487 Pole
248-1488 Bracket Assembly	2	1B-2578	Jam Nut
	1	5P-1075	Hard Washer
	1	096-4836	Cotter
248-1497 Cable (Coiled)	1
272-5450 Electronics Group (Sonic Tracer)
	Quantity	Part Number	Description
257-4153 Elec Gp - ST400	1
250-1934 Pole	2
248-1484 Bracket Assembly	2	1B-2578	Jam Nut
	1	5P-1075	Hard Washer
	1	096-4836	Cotter
256-6944 Carrying Case - Dual ST400	1
250-1934 Installation Group
	Quantity	Part Number	Description
245-7404 Mounting Group	3	4L-6454	Bolt
	1	7X-2537	Bolt
	2	8T-4224	Hard Washer
	1	8T-7547	Bolt
	1	245-7405	Bracket Assembly
	1	245-7406	Clamp
	1	245-7407	Bracket Assembly

Dual Sonic Tracer

Table 6

249-7806 Dual Sonic Tracer
248-1493 Case
	Quantity	Part Number	Description
(2) 248-1484 Base Assemblies	2	5P-1076	Hard Washer
	2	5S-7385	Lockwasher
	2	6V-8188	Full Hex Nut
	2	8T-8917	Bolt
	2	8T-9389	Bolt
249-7792 Electronics Group (Sonic Tracer)
	Quantity	Part Number	Description
244-1715 Sonic Tracer	2
248-1487 Pole	2
248-1488 Bracket Assembly	4	1B-2578	Jam Nut
	2	5P-1075	Hard Washer
	2	096-4836	Cotter
272-5451 Electronics Group (Sonic Tracer)
	Quantity	Part Number	Description
257-4153 Elec Gp - ST400	2
250-1934 Pole	2
248-1484 Bracket Assembly	2	1B-2578	Jam Nut
	1	5P-1075	Hard Washer
	1	096-4836	Cotter
256-6944 Carrying Case - Dual ST400	1
250-1934 Installation Group
	Quantity	Part Number	Description
245-7404 Mounting Group	6	4L-6454	Bolt
	2	7X-2537	Bolt
	4	8T-4224	Hard Washer
	2	8T-7547	Bolt
	2	245-7405	Bracket Assembly
	2	245-7406	Clamp
	2	245-7407	Bracket Assembly

Single Laser

Table 7

249-7795 Single Laser
235-4587 Case
(3) 237-7552 Warning Films (Laser)
248-1496 Riser
	Quantity	Part Number	Description
248-1496 Riser	1	3B-4512	Lockwasher
	1	9S-1362	Bolt
249-7793 Electronics Group (Laser)
Kit	Quantity	Part Number	Description
226-2333 Electric Mast	1
226-2334 Laser Receiver	1
226-9167 Adapter (Receiver)	1
226-9270 Cable (Coiled)	1
231-0049 Cable (Coiled)	1
234-9970 Shock Mount	1
(1) 248-1503 Bracket	4	7X-0343	Bolt
	2	7X-0366	Bolt
	4	8T-4122	Hard Washer
	2	8T-4994	Hard Washer
252-8744 Warning Film (Blade)	1

Dual Laser

Table 8

249-7804 Kit (Dual Laser)
235-4587 Case
Kit	Quantity	Part Number	Description
(3) 237-7552 Warning Films (Laser)
248-1496 Riser
	Quantity	Part Number	Description
248-1496 Riser	1	3B-4512	Lockwasher
	1	9S-1362	Bolt
249-7793 Electronics Group (Laser)
Kit	Quantity	Part Number	Description
226-2333 Electric Mast	2
226-2334 Laser Receiver	2
226-9270 Cable (Coiled)	2
231-0049 Cable (Coiled)	2
234-9970 Shock Mount	2
(2) 248-1503 Bracket	8	7X-0343	Bolt
	6	7X-0366	Bolt
	8	8T-4122	Hard Washer
	6	8T-4994	Hard Washer
252-8744 Warning Film (Blade)	2

System Components

Illustration 1	g01103119
(1) Display (2) Mainfall Sensor (3) Blade Slope Sensor (4) Rotation Sensor

Display

Illustration 2	g01135073
(10) "Left Mast Elevation/Menu Scroll" switch (11) LCD (12) "Right Mast Elevation/Menu Scroll" Switch (13) "Elevation Select" switch (14) Right Grade Indicators (15) Left Grade Indicators (16) "Blade Swap" Button (17) "ESC/Left Reset/Left Bench" Button (18) "Power/Setup" switch (19) "OK/Right Reset/Right Bench" button

The 255-0947 Display (1) allows setup and operation of the system by using the following features: grade indicators, toggle switches and push buttons. For more information on the 255-0947 Display (1), refer to the Operation and Maintenance Manual, SEBU7811, "AccuGrade - Grade Control System", "System Components" section for additional information.

Features

• The function of the switches are similar for the right side and the left side.

• The position of the blade is displayed by the LED.

• Automatic Mode and Manual Mode are displayed by the LED.

• The brightness of the LED adjusts automatically.

• The contrast of the LCD adjusts automatically.

Angle Sensors

Illustration 3	g01184100

The 276-6146 Angle Sensor (2, 3) is a highly accurate sensor that is capable of measuring up to 100 percent slopes.

In a Cross Slope system, one 276-6146 Angle Sensor (2, 3) measures the actual slope of the blade, and a second 276-6146 Angle Sensor (2, 3) measures the slope of the machine in the direction of travel.

Rotation Sensor

Illustration 4	g01184175

The 244-1714 Rotation Sensor (4) is a device that measures the change of the angle between two pivoting members. The primary application is for measuring the rotation of the blade. That measurement is used to calculate the cross slope of the blade of a machine.

Sonic Tracer

Illustration 5	g01103197
244-1715 Sonic Tracer - ST300

Illustration 6	g01354907
253-8330 Sonic Tracer - ST400

The Sonic Tracer (5) uses sound waves to determine the distance to a reference surface. References can include the following items: string line, curb and gutter. Additionally, the reference can include the previous pass. Once the device has been locked onto a reference, any change in the distance from the set point causes a correction signal to be sent to the 255-0947 Display (1) .

The Sonic Tracer (5) measures the length of time that is taken by the sound waves to travel between the transducer in the Sonic Tracer (5) and the reference surface in order to determine the elevation. Once the elevation is set, any deviations in elevation are sent to the 255-0947 Display (1). These corrections are then sent to the valve module. Then, the valve module sends the correction signals to the proportional control valve.

Laser Receiver

The Laser Receiver (6) is 100 percent weatherproof. The Laser Receiver (6) can detect a laser beam within 360 degrees of the receiver. The Light Emitting Diodes indicate to the operator if the machine is on grade. The Laser Receiver (6) can be configured through the 255-0947 Display (1) to match the tolerances of the job site.

LR400 Laser Receiver

Illustration 7	g01108194

The Laser Receiver (6) performs the following tasks:

• Detection of the laser beam

• The grade and the slope of the machine is displayed.

LR410 Laser Receiver

Illustration 8	g01354911

The Laser Receiver (6) performs the following tasks:

• Detection of the laser beam

• The grade and the slope of the machine is displayed.

Installation Procedure (Sensors)

Table 9

Tools That are Needed
Quantity	Description
1	Adjustable Square ( 600 mm (2 ft))

Rotation Sensor Installation

1. Make sure that the blade is square to the machine.

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Illustration 9	g01103304

2. Remove the bolts (48) on the swivel lid.

3. Remove bolt (47) from the frame of the circle.

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Illustration 10	g01103309

4. Remove the swivel lid (49) .

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Illustration 11	g01135610
(4) 244-1714 Rotation Sensor (51) 7D-5962 Bolt (53) 4K-8302 Clip (54) 6V-8188 Nut (56) 8T-4223 Washer (81) 243-3250 Rotation Sensor Harness Connector

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Illustration 12	g01120720

5. Replace the bolt that was taken out in Step 3 with 7D-5962 Bolt (51). Torque the bolt.

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Illustration 13	g01103309

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Illustration 14	g01108042

6. Remove the 2 seals (50) and (55) from the swivel lid.

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Illustration 15	g01108045

7. Place the seals from the swivel lid onto the 255-0941 Plate (60) .

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Illustration 16	g01102028

8. Replace the existing swivel lid with the 255-0941 Plate (60). Place the white Spacer (65) on 255-0941 Plate (60). Refer to Illustration 16.

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Illustration 17	g01184190

9. Install the 255-0941 plate (60) and face the slot (66) in the direction that is shown in Illustration 17. This will ensure that the rotation arm (70) is indexed at zero. Use the 061-6665 Bolts (64) to secure the 255-0941 plate (60) .

10. Install 061-6665 Bolts (64) and tighten in order to secure the 255-0941 plate (60) in place.

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Illustration 18	g01108055

11. Install the 244-1714 Rotation Sensor (4) onto the Plate.

    Make sure that the rotation arm (70) is seated into the slot (66). Make sure that the connector (71) of the 244-1714 Rotation Sensor faces in the direction of the rear of the machine.

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Illustration 19	g01108122

12. Install the 269-3303 Screws (75) and 269-3304 Spacers (3 places) on the sensor on the 255- 0941 Plate in order to secure the 244-1714 Rotation Sensor in place.

13. Tighten the 269-3303 Screws (75) and 269-3304 Spacers on the 255- 0941 Plate (60) .

    Note: The Rotation Sensor will continue to rotate until 250-2172 Bracket (99) is installed. Refer to Illustration 22.

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Illustration 20	g01184242
(4) 244-1714 Rotation Sensor (20) 9G-9154 Clip (21) 8T-4191 Bolt (22) 8T-4121 Washer (23) 8X-5489 Sleeve (53) 4K-8302 Clip (54) 6V-8188 Nut (56) 8T-4223 Washer (64) 061-6665 Screw (78) 4 Pin Connector of the 243-3250 Rotation Sensor Harness (79) 243-3250 Rotation Sensor Harness (80) 236-2356 Blade Slope Sensor Harness (88) 4 Pin Connector of the 236-2356 Blade Slope Sensor Harness

14. Connect the 243-3250 Harness (79) for the 244-1714 Rotation Sensor (4) to the connector (78). Refer to Illustration 20.

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Illustration 21	g01135610
(4) 244-1714 Rotation Sensor (51) 7D-5962 Bolt (53) 4K-8302 Clip (54) 6V-8188 Nut (56) 8T-4223 Washer (81) 243-3250 Rotation Sensor Harness Connector

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Illustration 22	g01184298
250-2172 Bracket and hardware

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Illustration 23	g01184324
Part A of 250-2172 Bracket

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Illustration 24	g01145760

15. Attach the 250-2172 Bracket to the 4K-8303 Bolt that was installed in Step 5. Use the 6V-8188 Nut (54) and the 8T-4223 Washer (56) .

    Note: Do not tighten the nut. There is additional hardware that will be added in the Installation of the Blade Slope Sensor section.

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Illustration 25	g01184351
Part B of 250-2172 Bracket

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Illustration 26	g01145703

16. Place the 86-0359 Clip around the 243-3250 Rotation Sensor Harness .

17. Use the bolts and washers (58) of the 250-2172 Bracket to secure part B of the 250-2172 Bracket and the 186-0359 Clip to the top of the 244-1714 Rotation Sensor (4) .

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Illustration 27	g01145744

18. Install the bolt between part A and part B of the 250-2172 Bracket . Refer to Illustration 27.

19. Install the 243-3250 Rotation Sensor Harness Connector (81) to the 244-1714 Rotation Sensor (4) .

20. Stop.

Installation of the Blade Slope Sensor

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Illustration 28	g01102023
(3) 226-9170 Angle Sensor (Blade Slope) (89) Blade Slope Sensor Connector of the 236-2356 Blade Slope Sensor Harness

1. Install the Sensor (3) .

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Illustration 29	g01135972
(3) 226-9170 Angle Sensor (Blade Slope) (57) 9X-2537 Bolt (82) 251-2383 Bracket (83) 8T-4191 Bolt (84) 8T-4121 Washer (89) Blade Slope Sensor Connector of the 236-2356 Blade Slope Sensor Harness

2. Use the 9X-2537 Bolts (57) to secure the 229-9170 Angle sensor to the mounting plate on the rear of the circle.

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Illustration 30	g01184242
(4) 244-1714 Rotation Sensor (20) 9G-9154 Clip (21) 8T-4191 Bolt (22) 8T-4121 Washer (23) 8X-5489 Sleeve (53) 4K-8302 Clip (54) 6V-8188 Nut (56) 8T-4223 Washer (64) 061-6665 Screw (78) 4 Pin Connector of the 243-3250 Rotation Sensor Harness (79) 243-3250 Rotation Sensor Harness (80) 236-2356 Blade Slope Sensor Harness (88) 4 Pin Connector of the 236-2356 Blade Slope Sensor Harness

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Illustration 31	g01145769
(20) 9G-9154 Clip (21) 8T-4191 Bolt (22) 8T-4121 Washer (23) 8X-5489 Sleeve

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Illustration 32	g01135473
(3) 226-9170 Angle Sensor (Blade Slope) (57) 9X-2537 Bolt (82) 251-2383 Bracket (83) 8T-4191 Bolt (84) 8T-4121 Washer (89) Blade Slope Sensor of the 236-2356 Blade Slope Sensor Harness

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Illustration 33	g01184654

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Illustration 34	g01184598

3. Install the 8T-4195 Bolt , 4K-8302 Clip , 8T-4121 , and 8T-4133 Nut in order to secure the 236-2356 Blade Slope Sensor Harness to the hose tray. Refer to Illustrations 33 and 34.

4. The 236-2356 Blade Slope Harness goes into the circle. Refer to the Illustrations in the following list: 32, 33 and 34

   Note: Additional information on routing the cables through the circle can be found in the Diagrams Section of this manual.

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Illustration 35	g01145922
(4) 244-1714 Rotation Sensor (20) 9G-9154 Clip (21) 8T-4191 Bolt (22) 8T-4121 Washer (23) 8X-5489 Sleeve (53) 4K-8302 Clip (54) 6V-8188 Nut (56) 8T-4223 Washer (78) 4 Pin Connector of the 243-3250 Rotation Sensor Harness (79) 243-3250 Rotation Sensor Harness (80) 236-2356 Blade Slope Sensor Harness (88) 4 Pin Connector of the 236-2356 Blade Slope Sensor Harness

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Illustration 36	g01102023
(3) 226-9170 Angle Sensor (Blade Slope) (89) Blade Slope Sensor Connector of the 236-2356 Blade Slope Sensor Harness

5. Connect the 6 pin connector of the 236-2356 Blade slope harness (89) to the connector on the 226-9170 Angle Sensor . Connect the 4 pin connector of the 236-2356 Blade slope harness to the mating connector on the right side of the circle.

   Note: Ensure that the 4-pin connector (88) of the harness for the Blade Slope Sensor is routed between the base of the sensor and the cylinder below. The round 6-pin connector (89) will not fit through the gap.

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Illustration 37	g01184660

6. Install the 8T-4191 Bolt (145), 8T-4121 Washer (146), and 4K-8302 Clip (147) in order to secure the 236-2356 Blade Slope Sensor Harness to the frame of the circle. Refer to Illustration 37.

Installing the Pointer

Illustration 38	g01108401

1. Fasten the 251-2383 Bracket (82) to the circle with 8T-4191 Bolts (83) and 8T-2121 Washers (84) .

   Note: Do not tighten the Bolts.

Installation of the Power Supply Module

Illustration 39	g01184666
(2) 226-9170 Angle Sensor (Mainfall) (9) 226-9169 Power Module (90) 9X-2537 Bolt (91) 5C-2890 Nut (148) 188-9644 Flat Head Screw (149) 211-9032 Washer (150) 160-8500 Nut

Illustration 40	g01102121
(2) 226-9170 Angle Sensor (Mainfall) (9) 226-9169 Power Module

1. Remove the 3 bolts that secure the bracket for the Mainfall sensor and the power module.

2. Remove the Implement and Valve Control ECM from the Plate.

3. Use the 188-9644 Flat Head Screw (148), 211-9032 Washer (149) and 160-8500 Nut (150) to mount the 226-9169 Power Module to the bracket.

Note: There are 2 connectors on the Power Supply Module (9). Make sure that the Power Supply Module (9) is oriented correctly with the symbol for the battery. Make sure that the cables will reach to the correct Power Supply Module connector (9). The connectors on the Power Supply Module (9) are designed so that the connection of the Power Supply Module (9) to the system will be correct.

Note: On some models, there are hydraulic hoses that are attached to the bracket.

Mainfall Sensor Installation

Illustration 41	g01184666
(2) 226-9170 Angle Sensor (Mainfall) (9) 226-9169 Power Module (90) 9X-2537 Bolt (91) 5C-2890 Nut (148) 188-9644 Flat Head Screw (149) 211-9032 Washer (150) 160-8500 Nut

Illustration 42	g01102121

Use a 9X-2537 Bolt (90) to secure the 226-9170 Angle Sensor (Mainfall) (2) to the threaded hole in the bracket. Use a 9X-2537 Bolt (90), 9X-8256 washer (103) and 5C-2890 Nut (91) to secure the 226-9170 Angle Sensor (Mainfall) (2) to the slotted hole in the bracket. Refer to Illustration 42.

The Mainfall Sensor (2) must be parallel within 25 mm (1/4 inch) to the frame.

1. Place the straight edge of the Adjustable Square (600 mm (2 ft)) on the side of the Mainfall Sensor.

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Illustration 43	g01079500

2. Verify that the second straight edge of the Adjustable Square (600 mm (2 ft)) is parallel with the edge of the cab platform. Refer to Illustration 43.

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Illustration 44	g01184666
(2) 226-9170 Angle Sensor (Mainfall) (9) 226-9169 Power Module (90) 9X-2537 Bolt (91) 5C-2890 Nut (148) 188-9644 Flat Head Screw (149) 211-9032 Washer (150) 160-8500 Nut

3. If the Mainfall Sensor is not parallel to the cab platform, then loosen the 5C-2890 Nut (91) and the 9X-2535 Bolt (90) that is to the rear of the motor grader on the sensor. Adjust the sensor until the second straight edge is parallel with the cab platform. Tighten the nut and the bolt.

   Note: The rear hole for the sensor on the mounting bracket is slotted for purposes of adjusting.

4. Once the cab platform is parallel to the second straight edge secure the Mainfall Sensor.

5. After the Mainfall Sensor has been secured, verify that the sensor is aligned correctly.

   Note: Tightening the bolts of the Mainfall Sensor can cause the Mainfall Sensor to move out of adjustment.

Installation Procedure (Laser)

Installation of the 252-8744 Films

Note: The following steps show the procedure for applying the 252-8744 Films to the 226-2333 Electric Masts (7). Repeat this procedure if your Motor Grader is equipped for Dual Laser Receivers.

Illustration 45	g01061212

Place a 252-8744 Film on the 226-2333 Electric Masts (7) that will be used with the laser. While you are standing between the machine and the blade, place the 252-8744 Film on the rear of the mast and at eye level.

Installation of the 237-7552 Films

Illustration 46	g01071800

Place a 237-7552 Film on each leg of the tripod that will be used with the laser. The 237-7552 Film must be placed in a visible location on the tripod's legs.

Installation of the Laser Receiver

Install the Adjustable Angle Bracket to the Blade (If Equipped)

Illustration 47	g01079269
248-1503 Adjustable Angle Bracket (111) 7X-0366 Bolt (112) 8T-4994 Washer (113) 7X-0343 Bolt (114) 8T-4122 Washer

Mount the 248-1503 Adjustable Angle Bracket (97) to the blade. Refer to Illustration 47.

Install the Vertical Mast Riser

Illustration 48	g01079311

Illustration 49	g01079262

The following steps will guide you in the installation of the 248-1496 Vertical Mast Riser (96) .

1. Use the 9S-1362 Bolt (100) and the 3B-4512 Washer (101) to mount the 248-1496 Vertical Mast Riser (96) to the 248-1503 Adjustable Angle Bracket (97) .

2. Tighten the 9S-1362 Bolt (100) and the 3B-4512 Washer (101) to 305 N·m (225 lb ft).

Install the Shock Mount

Illustration 50	g01079275

The following information shows the installation of the 234-9970 Shock Mounts (105) and the 226-2333 Electric Masts (7) to the left side of the blade of a Motor Grader. Repeat this procedure for the right side of the blade if your Motor Grader is equipped for Dual Laser Receivers.

1. Use the 9S-1362 Bolt (106) and the 3B-4512 Washer (107) to mount the 234-9970 Shock Mount (105) to the 248-1496 Vertical Mast Riser (96) .

2. Tighten the 9S-1362 Bolt (106) and the 3B-4512 Washer (107) to 305 N·m (225 lb ft).

Install the Laser Receiver

Note: The following steps show the procedure for mounting a 226-2334 Laser Receivers (6) to a 226-2333 Electric Mast (7) on the left side of the blade. Repeat this procedure for the right side of the blade if your Motor Grader is equipped for Dual Laser Receivers.

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To prevent possible personal injury during installation and removal of the laser receivers, lower the mast to the minimum height and use an approved access system to reach the mounting locations of the laser receivers at the top of the mast. Do not climb on the blade.

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Illustration 51	g01142983

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Illustration 52	g01142980

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Illustration 53	g01080278

1. Slide the 226-2334 Laser Receivers (6) onto the Adapter Blocks that are mounted to the 226-2333 Electric Masts (7) .

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Illustration 54	g01103062
Top view of the 226-2334 Laser Receivers on the 226-2333 Electric Masts (7)

2. Hand tighten the clamp (25) of the 226-2334 Laser Receivers (6) to the 226-2333 Electric Masts (7) .

Install the Electronic Mast (If Equipped)

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Illustration 55	g01079275

1. Remove bolts (108) and the bracket (110) .

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NOTICE
The bolts that secure the U-Bracket to the Shock Mounts are not tightened to specification. Failure to perform the following procedure may result in damage to the Electric Mast or Shock Mounts.

2. Remove the two 13 mm (1/2 inch) bolts (115) that secure the U-bracket (109) to the 234-9970 Shock Mounts (105) .

3. Apply 9S-3263 Thread Lock Compound to the two 13 mm (1/2 inch) bolts (115) .

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Illustration 56	g01080139
U-Bracket of the 234-9970 Shock Mounts

4. Install the bolt of the U-Bracket (109) to the bottom of the 226-2333 Electric Mast (7) .

   Tighten the bolt to 305 N·m (225 lb ft).

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Illustration 57	g01080146

5. Place the 226-2333 Electric Mast (7) into the 234-9970 Shock Mounts (105) .

6. Reinstall the bracket that was removed in step 1 and tighten the bolts (108) by hand.

7. Reinstall the two 13 mm (1/2 inch) bolts (115) into the U-bracket (109) and tighten the bolts to 54 N·m (40 lb ft).

8. Tighten the bolts (108) in Step 6 to 9 N·m (85 lb in).

Installation Procedure (Sonic Tracer)

Installation of the Sonic Tracers (If Equipped)

Install the 248-1484 Base Assembly for the Sonic Tracer

Illustration 58	g01103282
248-1484 Base Assembly

1. Use the 8T-8917 Bolt (125) and 5S-7385 Washer (125) to mount the 248-1484 Base Assembly (106) to the blade.

2. Torque the 8T-8917 Bolt (125) to 305 N·m (225 lb ft) .

Installing the Pole in The Mounting Bracket

Illustration 59	g01103285
(8) 248-1487 L-Pole (106) 248-1484 Base Assembly (130) Clamping bolts of the 248-1484 Base Assembly

1. Insert the short end of the 248-1487 L - Pole (8) into the 248-1484 Base Assembly (106) far enough so that the end of the longer tube is away from the end of the blade and vertical.

2. Tighten the Clamping bolts of the 248-1484 Base Assembly in order to prevent the tube from rotating in the clamp.

Install the 248-1488 Bracket Assembly onto the 248-1487 L-Pole

Illustration 60	g01103324
(8) 248-1487 L-Pole (135) 248-1488 Bracket (136) Clamping Handle of the 248-1488 Bracket

1. Slide the 248-1488 Bracket (135) onto the 248-1487 L-Pole (8) .

2. Tighten the clamping handle of the 248-1488 Bracket (136) by hand.

   Note: Do not overtighten the handle.

Install the Sonic Tracer in the Mounting Bracket

Illustration 61	g01104286
(5) 244-1715 Sonic Tracer (8) 248-1487 L-Pole (135) 248-1488 Bracket (140) Rachet Handle of the 248-1488 Bracket (141) 248-1497 Coil Cable

1. Use the Rachet Handlerachet handle of the 248-1488 Bracket (140) to attach the 244-1715 Sonic Tracer (5) to the 248-1488 Bracket (135) .

2. Hand tighten the rachet handle of the 248-1488 Bracket (140) in order to secure the 244-1715 Sonic Tracer (5) in place.

   Note: Do not overtighten the handle.

3. Connect one end of the 248-1497 coil cable (141) to the connector on the 244-1715 Sonic Tracer (5) .

4. Tighten the connector by hand.

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Illustration 62	g01184799

5. Connect the quick disconnect connector of the 248-1497 Coil Cable to the lower connector (146) or the upper connector of the knuckle bracket (145) .

   Note: The upper and lower connectors are electrically identical. Any one of the connectors may be used.

Installation Of the 245-7404 Mouting Group For Storage Of The 248-1487 L-Poles

Note: If the Motor Grader is configured with a front straight scarifier or a front V-type scarifier, then the L-Pole storage feature of the Sonic Kit is not compatible with the Motor Grader. If this is the case the Sonic Kit must be configured differently. Find a suitable mounting location for the L-Pole storage brackets that will allow the L-Pole to be stored without interfering with normal machine operation.

Illustration 63	g01126953
(116) 245-7405 Bracket , 245-7406 Clamp , 2 4L-6454 Bolts and 8T-4224 Washer (117) 245-7404 Bracket , 4L-6454 Bolt , 8T-7547 Bolt and 8T-4224 Washer

Illustration 64	g01136204
(116) 245-7405 Bracket , 245-7406 Clamp , 2 4L-6454 Bolts and 8T-4224 Washer (117) 245-7404 Bracket , 4L-6454 Bolt , 8T-7547 Bolt and 8T-4224 Washer

1. Remove the 5M-3062 Bolts from the frame. The bolts are shown in Illustration 64.

2. Attach 245-7405 Bracket (116) and 245-7407 Bracket (117) to the frame with 4L-6454 Bolts and 8T-4224 Washers .

3. Secure the 248-1487 L-Pole(s) (8) in the brackets.

Repeat 1 through 3 for Dual Sonic Tracers.

Installation Procedure (Display)

Installing the Display

Illustration 65	g01146293

1. Remove side panels (29) from the right hand side of the steering console.

2. Remove the black covers (28) from the right hand side of the steering console.

3. Remove the bolts from the right hand side of the steering console that are located under the black covers (28) .

   Note: There is a nut and a spacer that is located behind the bolt at the front end of the steering console. The nut and the spacer will fall into the steering console if care is not taken during removal of the front bolt.

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Illustration 66	g01313494

4. Use 2 8T-2501 Bolts (210) in the holes that are closest to the front of the Motor Grader in order to attach the 286-5686 Support Assembly (122) to the steering console. Additionally, use 1 0L-1351 Bolt (211) in the hole that is closest to the rear of the Motor Grader in order to attach the 286-5686 Support Assembly (122) to the steering console.

5. Reinstall the black covers (28) .

6. Reinstall the side panels (29) that were removed in Step 1.

   Note: Do not tighten screws that secure the side panels. Some of the screws will be replaced in the following procedure.

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Illustration 67	g01355665

7. Attach 255-0947 Display (1) to 294-5260 Bracket Assembly (212) with 4 149-4311 Bolts and 4 4E-5724 Washers . Tighten the bolts.

8. Attach 294-5260 Bracket Assembly (212) to 286-5686 Support Assembly (122) .

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Illustration 68	g01355687

9. Hand tighten the 292-8963 Knob (213) .

10. Reinstall the side panels (29) that were removed in Step 1.

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Illustration 69	g01146850
(34) AccuGrade 40 pin Bulkhead connector (41) 40 pin connector of the 233-3292 Display Harness (42) 12 pin plug (43) 12 pin connector of the 233-3292 Display Harness (44) 4P-7581 Ladder Clip and 32-2039 Strap (45) 8T-4137 Bolt (46) 8T-4121 Washer (61) 130-5300 Clip (62) 9X-2045 Screw (63) 5P-4115 Washer (67) Left hand switch connectors of the 233-3292 Display Harness (69) 5P-9299 Clip (93) 156-6175 Ladder Clip and 3S-2093 Strap (94) 9X-2045 Screw (95) 5P-4115 Washer

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Illustration 70	g01146300
(34) AccuGrade 40 pin Bulkhead connector

11. Connect the 40-pin connector (41) of the 233-3292 Harness Assembly to the 40-pin connector (34) in the forward bulkhead on the right hand side of the cab. Hand tighten the connector.

12. Use a 8T-4137 Bolt (45) and a 8T-4121 Washer (46) to attach a 4P-7581 Ladder Clip (44) to the boss that is located above the 40-pin connector.

13. Use the 9X-2045 Screw (94) and 5P-4115 Washer (95) to attach the 156-5300 Clip (93) to the lowest mounting screw hole for the forward panel on the right hand side of the steering console.

14. Place a 5P-9299 Clip (69) on the 233-3292 Harness Assembly above the section of the harness that attaches to the 12-pin connector.

15. Use the 9X-2045 Screw (62) and 5P-4115 Washer (63) to attach the 5P-9299 Clip (69) that was installed in Step 14 and 156-5300 Clip (61) to the middle mounting screw hole for the forward panel on the right hand side of the steering console.

16. Attach the 12-pin connector (43) of the 233-3292 Harness Assembly to the 156-5300 Clip that was installed in Step 15.

    The contacts should face upward.

17. Connect the 3-pin connector and the 4-pin connectors of the 233-3292 Harness Assembly to the 3-pin connector and the 4-pin connector of the remote switches on the right hand side of the steering console.

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Illustration 71	g01127134
(68) Left hand switch connectors of the 233-3292 Display Harness (72) 5P-9299 Clip (73) 5P-4115 Washer (74) 9X-2042 Screw

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Illustration 72	g01146304
(68) Left hand switch connectors of the 233-3292 Display Harness (72) 5P-9299 Clip (73) 5P-4115 Washer (74) 9X-2042 Screw

18. Route the other leg of the 233-3292 Harness Assembly across the front of the steering console.

19. Place a 5P-9299 Clip (72) on the 233-3292 Harness Assembly . The clip must leave enough slack in order to allow the 3 pin and 4 pin switch connectors on the left hand side of the 233-3292 Harness Assembly to reach the 3 and 4 pin connectors of the remote switches.

20. Use the 9X-2045 Screw (73) and the 5P-4115 Washer (74) to attach the 5P-9299 Clip to the middle mounting screw hole for the forward panel on the left side of the steering console.

21. Connect the 3 and 4 pin connectors of the 233-3292 Harness Assembly to the 3 and 4 pin connectors of the remote switches on the left hand side of the steering console.

22. Use the 3S-2093 Straps to secure the harness to the two ladder clips that were installed in Step 12 and Step 13.

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Illustration 73	g01079374
(1) 255-0947 Display (31) 244-1902 Support (33) Knob (35) 149-4311 Bolts (36) 3L-6789 Lock Washers (37) 4E-5724 Washers (38) 225-9598 Display Bracket (39) 255-0889 Harness (display)

23. Use the four 149-4311 Bolts (35), 3L-6789 Lock Washers (36) and 4E-5724 Washers (37) to secure the 225-9598 Display Bracket (38) to the 255-0947 Display (1) .

24. Secure the 225-9598 Display Bracket (38) to the 244-1902 Support (32) with Knob (33) .

25. Connect the two connectors of the 250-0889 Harness Assembly (39) to the 255-0947 Display (1) .

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Illustration 74	g01184890

26. Connect the 12 pin male connector (42) of the 250-0889 Harness Assembly to the 12 pin female connector (43) of the 233-3292 Harness Assembly .

Machine Measurements

Note: The measurements that are entered into the display default to zero when the machine type is changed.

Position of the Circle

Illustration 75	g01146207

Make sure that the circle is square to the machine.

• Take a measurement from the front center of the frame to the tips of the moldboard.

Note: This procedure can also be accomplished by visually making sure that the lift cylinders are vertically positioned on the machine.

The following machine dimensions are required for setting up the system:

• Spacing of the Cylinders

• Blade Length

• Length of the A-Frame

Make the following measurements and record the measurements in Table 10.

Table 10

Measurement	Dimension
Spacing of the Cylinders
Blade Length
A-Frame Length

Spacing of the Cylinders

Measure the distance between the lift cylinders.

Illustration 76	g01108387

Measure the distance between the center of the 2 knuckles on the cylinders. Record the measurement in Table 10.

Blade Length

Measure the length of the blade from one end of the cutting tip to the other end of the cutting tip. Record the measurement in the Table 10.

Length of the A-Frame

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Illustration 77	g01101488

1. Locate a point at the front of the A-frame.

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Illustration 78	g01101490

2. Measure the distance from the point in Step 1 to the center of the swivel joint. Refer to Illustration 78.

   Note: This location is the center of the rotation of the blade.

Machine Type and Geometry

To enter the dimensions that were recorded in the previous procedure, you must enter the "Installation Menu".

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Illustration 79	g01135073
(10) "Left Mast Elevation/Menu Scroll" switch (11) LCD (12) "Right Mast Elevation/Menu Scroll" Switch (13) "Elevation Select" switch (14) Right Grade Indicators (15) Left Grade Indicators (16) "Blade Swap" Button (17) "ESC/Left Reset/Left Bench" Button (18) "Power/Setup" switch (19) "OK/Right Reset/Right Bench" button

1. Turn on the Display.

2. Toggle the "Power/Setup" Switch (18) to "i" in order to access the Configuration Menu.

3. Press the following keys at the same time in order to enter the "Installation Menu":
   • "ESC/Left Reset/Left Bench" Button (17)

   • "Blade Swap" Button (16)

   • "Right Mast Elevation/Menu Scroll" Switch (12)

   Note: The "Right Mast Elevation/Menu Scroll" Switch (12) needs to be toggled downward in order to enter the menu.

4. Toggle the "Right Mast Elevation/Menu Scroll" Switch (12) downward until "Machine Setup" is highlighted.

5. Press the "OK" Button (19) in order to enter the "Machine Setup" Menu.

6. Toggle the "Right Mast Elevation/Menu Scroll" Switch (12) downward until "Machine Type and Geometry" is highlighted.

7. Press the "OK" Button (19) in order to enter the "Machine Type and Geometry" Menu.

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Illustration 80	g01146206

8. Toggle the "Right Mast Elevation/Menu Scroll" Switch (12) downward until "Motor Grader" is highlighted.

9. Press the "OK" Button (19) in order to enter the "MG" Menu.

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Illustration 81	g01114848

10. Toggle the "Right Mast Elevation/Menu Scroll" Switch (12) downward until "Cylinder Spacing" is highlighted.

11. Press the "OK" Button (19) in order to enter the "Cylinder Spacing" entry screen.

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Illustration 82	g01114849

12. Enter the measurement that was taken across the cylinders. Refer to SEBU 7811 Operation and Maintenance Manual for additional information on entering data.

13. Press the "OK" Button (19) .

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Illustration 83	g01114852

14. Toggle the "Right Mast Elevation/Menu Scroll" Switch (12) downward until "Blade Length" is highlighted.

15. Press the "OK" Button (19) in order to enter the "Blade Length" entry screen.

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Illustration 84	g01114858

16. Enter the measurement that was taken across the cylinders. Refer to SEBU 7811 Operation and Maintenance Manual for additional information on entering data.

17. Press the "OK" Button (19) .

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Illustration 85	g01114862

18. Toggle the "Right Mast Elevation/Menu Scroll" Switch (12) downward until "A-Frame Length" is highlighted.

19. Press the "OK" Button (19) in order to enter the "A-Frame Length" entry screen.

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Illustration 86	g01114863

20. Enter the measurement that was taken across the cylinders. Refer to SEBU7811 Operation and Maintenance Manual for additional information on entering data.

21. Press the "OK" Button (19) .

22. Press the "ESC" Button (17) in order to return to the "Installation" Menu.

Center the Blade

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Illustration 87	g01079442

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Illustration 88	g01101537

1. Measure the distance from each side of the moldboard for the blade to the corresponding blade beam.

2. Shift the blade to the side until the measurements are equal.

   The distance that is measured should be within 12.7 mm (0.5 inch) of each other.

Rotation of the Blade

Note: Make sure that the blade is level.

Note: Make sure that the machine is on a level surface.

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Illustration 89	g01079446

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Illustration 90	g01108390

1. Locate a point at the front of the frame that is also centered on the frame.

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Illustration 91	g01108395

2. Measure from the point that is shown in Illustration 90 to the bottom edge of the moldboard that is located on each end of the blade

3. Rotate the blade until the measurements are equal.

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Illustration 92	g01108401

4. Adjust the 251-2383 Bracket (82) of the zero alignment gauge to the lower pointer (98) .

5. Tighten the bolts.

   Note: Do not move the machine. The machine is ready to perform the system calibrations.

Configuring the Implement/Valve Control ECM

The Implement/Valve Control ECM is shipped from the factory with the status of the AccuGrade grade control system in the "Not Installed" state. Configure the Implement/Valve Control ECM to the "Installed" state before using the system. Use the following procedure to configure the Implement/Valve Control ECM.

Procedure

1. Connect the 7X-1425 Data Link Cable As between the 7X-1700 Communication Adapter Gp and the Electronic Technician.

2. Connect the 139-4166 Data Link Cable As between the 7X-1700 Communication Adapter Gp and the diagnostic connector of the machine.

3. Turn the Key Start switch to the "On" position.

4. Open up the Electronic Technician software and select the Grade/Slope Control.

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Illustration 93	g01181296

5. Select the "Configuration"option in the "Service menu".

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Illustration 94	g01181331

6. Double click on the "Accugrade System Installation Status" parameter.

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Illustration 95	g01181333

7. Change the new value to "Installed" and click the "OK" button.

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Illustration 96	g01181336

8. Click on the "Yes" button.

9. Verify that the correct sales model is selected. If the selected sales model is incorrect, repeat this procedure for the "Product Sales Model "parameter.

Calibrations

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NOTICE
Do not perform calibrations of the Implement/Valve Control ECM that are available in the Caterpillar Electronic Technician. The Calibrations Procedures will degrade the system performance of the Implement/Valve Control ECM.

Two calibrations are required to be performed prior to operating the system by the AccuGrade - Grade Control System. These calibrations are listed here:

• Sensor Calibration

• Valve Calibration

The Sensor calibration must be performed prior to the Valve Calibrations in order to allow the system to determine the position of the blade.

Calibration of the Cross Slope Sensors

Setup (Machine)

1. Select a location that provides a hard level surface before setting up the machine for calibration.

   Note: Soft surfaces or uneven surfaces will affect the accuracy of the calibration of the sensors.

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Illustration 97	g01102552

2. Ensure that the alignment of the machine is still in accordance with the Machine Alignment Procedure.
   • There is zero machine articulation.

   • Rotate the blade to a point that is perpendicular to the frame. Use the alignment arrows on the circle that were aligned during the Machine Alignment Procedure.

   • Set wheel lean to vertical.

   • Center the circle.

   • Center the blade.

   Note: The accuracy of the calibration of the Mainfall Sensor will be affected if wheel lean is changed.

Marking The Machine Position

Refer to the following steps for the procedure for marking the Machine Position.

1. Select a location that provides a flat hard surface before setting up the machine for calibration.

   Note: A soft surface or an uneven surface will affect the accuracy of the sensor calibration.

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Illustration 98	g01102828

2. Lower the Blade to the ground. Set the blade in the float position.

   Note: Make sure that the lift cylinders for the blade can be rotated by hand.

3. Mark the center of the front and the rear wheels on the surface. A line that is parallel to the wheels will help when you are repositioning the machine. Refer to Illustration 98.

4. Trace the edge of the blade on the surface. Extend the line beyond the blade to help in repositioning the blade. Refer to Illustration 98.

Full Sensor Calibration

Illustration 99	g01135073
(10) "Left Mast Elevation/Menu Scroll" switch (11) LCD (12) "Right Mast Elevation/Menu Scroll" switch (13) "Elevation Select" switch (14) Right Grade Indicators (15) Left Grade Indicators (16) "Cursor Scroll" button (17) "ESC/Left Reset/Left Bench" button (18) "Power/Setup" switch (19) "OK/Right Reset/Right Bench" button

1. Turn on the Display.

2. Toggle the "Power/Setup" Switch (18) to the "i" position in order to access the "Configuration" Menu.

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Illustration 100	g01145036

3. Toggle the "Inc/Dec" switch downward until the "Sensor Calibration" menu is highlighted.

4. Press the "OK" button (19) in order to enter the "Sensor Calibration" Menu.

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Illustration 101	g01102843

5. Toggle the "Inc/Dec" switch until the "Full Sensor Calibration" menu is highlighted.

6. Press the "OK" button (19) in order to enter the "Full Sensor Calibration" Menu.

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Illustration 102	g01131138

7. Press the "OK" button (19) in order to start the Calibration.

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Illustration 103	g01144019

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Illustration 104	g01131139

8. The screen in Illustration 103 will be displayed until the system verifies that the sensors are stable. Once the system has determined that the sensors are stable, the screen in Illustration 104 will be displayed. Press the "OK" button (19) in order to continue the calibration.

   Note: If the Blade Slope Sensor, Mainfall Sensor, or Rotation Sensor (4) are not detected or if the null values cannot be read, an error message will be displayed. Calibration of the sensors will not be allowed until the issue has been resolved.

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Illustration 105	g01102846

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Illustration 106	g01102851

9. Press the "OK" button (19) in order to continue.

   When a "Initial Position" calibration is performed the following actions take place:

   • The Rotation Sensor (4) is calibrated for the blade.

   • First reading for slope of the blade

   • First reading for the calibration of the Mainfall Sensor

   Note: If the data from the sensor is not stable the "not OK" icon will be shown on the screen.

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Illustration 107	g01102859

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Illustration 108	g01102866

10. Rotate the machine 180 degrees from the original position. Align the blade to the marks that were made at the beginning of the procedure. Refer to Illustration 108.

11. Rest the blade on the ground. Make sure that all pressure is off the blade.

    Note: Make sure that the lift cylinders for the blade can be rotated by hand.

12. Press the "OK" button (19) in order to continue.

    When a "Blade Position" calibration is performed the following action takes place:

    • Second reading for slope of the blade

    Note: If the data from the sensor is not stable the "not OK" icon will be shown on the screen.

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Illustration 109	g01131143

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Illustration 110	g01102876

13. Move the machine forward. Align the tires of the machine to the front and rear marks of the tires that were made previously. Refer to Illustration 110.

    Note: If you are calibrating on a sloped surface, alignment to the lines for the tires will be more critical for accurate calibration of the Mainfall Sensor.

14. Once the blade and the machine have been positioned, press the "OK" button (19) .

    When a "Mainfall Position" calibration is performed the following actions take place:

    • The second reading for Mainfall Sensor

    Note: If the data from the sensor is not stable the "not OK" icon will be shown on the screen.

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Illustration 111	g01131144

15. Press the "OK" button (19) in order to accept the full calibration.

    Note: If the "ESC" button is pressed, the calibration is not saved and the setting reverts to the previous saved values.

Valve Calibration

A valve calibration must be completed because most Pulse Width Modulated valves have loose manufacturing tolerances. Each valve will respond differently to a given command. A valve calibration determines the way that the valve responds to a given command. A valve calibration will determine the velocity of the blade when a command is given in order to drive the valves at a specific percent. Additionally, a valve calibration will create a curve (valve) for use in automatic tuning of the valve drives.

Note: To ensure the best performance (grading), the operator should perform a valve calibration with the hydraulic system at the operating temperature.

Note: Before you begin to grade, make sure that the machine reaches the temperature that was used during the calibration of the valves. This will ensure the proper performance of the system. Perform the following steps in order to make sure that the hydraulic system is at the operating temperature before performing any calibrations.

1. Start the engine and allow the engine to warm.

2. Cycle implements.

3. Begin warming the implement hydraulic system.

   1. After implements have been cycled, elevate engine speed and cycle the circle drive.

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   NOTICE
   It is important to not stall a very cold hydraulic system for an extended period of time to avoid thermally shocking a valve, which could damage the hydraulic system.

   2. Intermittently stall the wheel lean while you continue to cycle the circle drive.

      Note: Do not stall the wheel lean for any more than 60 seconds at a time.

      Note: When you are calibrating the valves, the warm up procedure may need to be repeated after calibrating a valve on one side of the machine and before calibrating the valve on the other side.

      Note: The machine may need to be warmed up several times during the day if the machine idles and the machine cools for extended periods of time. The following types of sensors can be used for valve calibration:

      • Cross Slope Sensors

      Note: Disconnect the Laser Receivers or Sonic Tracers when you are performing a valve calibration.

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Illustration 112	g01102552

Note: The rotation of the blade needs to be perpendicular within ± 5 degrees. Ensure that the alignment arrows on the circle are aligned.

1. Adjust both sides of the blade upward in order to allow the blade to have approximately 304.80 mm (1.00 ft) of movement.

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Illustration 113	g01135073
(10) "Left Mast Elevation/Menu Scroll" switch (11) LCD (12) "Right Mast Elevation/Menu Scroll" switch (13) "Elevation Select" switch (14) Right Grade Indicators (15) Left Grade Indicators (16) "Cursor Scroll" button (17) "ESC/Left Reset/Left Bench" button (18) "Power/Setup" switch (19) "OK/Right Reset/Right Bench" button

2. Turn on the Display.

3. Toggle to "Power/Setup" Switch (18) to the "i" position in order to access the "Configuration" Menu.

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Illustration 114	g01128112

4. Press the following keys at the same time in order to enter the "Installation Menu": "ESC" (17), "Blade Swap" (16), and "Right Inc/Dec" (12) .

   Note: The "Right Inc/Dec" (12) needs to be toggled downward in order to enter the menu.

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Illustration 115	g01145059

5. Toggle the "Inc/Dec" switch (12) until "Calibration" is highlighted.

6. Press the "OK" button (19) in order to enter the Calibration Mode.

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Illustration 116	g01145060

7. Toggle the "Inc/Dec" switch (12) until "Valve Calibration" is highlighted.

8. Press the "OK" button (19) in order to enter the "Valve Calibration" Menu.

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Illustration 117	g01145062

9. Toggle the "Inc/Dec" switch (12) until the side that needs to be calibrated is highlighted.

10. Press the "OK" button (19) in order to enter valve calibration.

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Illustration 118	g01354978

11. Move the Left side of the blade down in order to set the Lower limit.

    Note: Move the blade downward until "OK" is not circled. Refer to Illustration 118.

12. Press the "OK" button (19) in order to accept the lower position of the blade.

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Illustration 119	g01354985

13. Move the Left side of the blade upward in order to set the upper limit.

    Note: Move the blade upward until the "OK" is not circled. Refer to Illustration 119.

14. Press the "OK" button (19) in order to accept the position of the blade.

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Illustration 120	g01145063

15. Press the "OK" button (19) in order to start the calibration.

    A percentage value that shows the progress of the calibration appears. 10 minutes to 15 minutes should be allowed in order to complete the valve calibration. The blade automatically tilts to the left and right during this process.

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Illustration 121	g01145064

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Illustration 122	g01145065

16. Press the "OK" button (19) in order to accept the calibration.

    When the calibration is finished, the screen in Illustration 122 appears.

    Note: "ESC" cancels the calibration. Then, the system is restored to the previous calibration values.

Repeat the Valve Calibration for the Right Valve after the Left Valve has been successfully calibrated.

Diagrams 247-6438 Wiring Group (120H through 163H)

Illustration 123	g01184970
(4) 244-1714 Rotation Sensor (51) 8T-0326 Bolt (53) 4K-8302 Clip (54) 1F-7958 Nut (56) 8T-4523 Washer (57) 9X-2537 Bolts (64) 061-6665 Screws (81) Rotation Sensor Connector of the 243-3250 Rotation Sensor Harness (82) 251-2383 Bracket (83) 8T-4191 Bolts (84) 8T-2121 Washers (85) 4K-8303 Clip (89) Rotation Sensor Connector of the 2236-2356 Blade Slope Harness

Illustration 124	g01120308
(3) 226-9170 Blade Slope Sensor (4) 244-1714 Rotation Sensor (51) 8T-0326 Bolt (52) 089-7960 Washer (53) 4K-8302 Clip (54) 1F-7958 Nut (56) 8T-4523 Washer (78) 4 pin connector of the 243-3250 Rotation Sensor Harness (79) 243-3250 Harness (80) 236-2356 Blade Slope Harness (81) Rotation Sensor Connector of the 243-3250 Rotation Sensor Harness (82) 251-2383 Bracket (83) 8T-4191 Bolts (84) 8T-2121 Washers (85) 4K-8303 Clip (88) 4 pin connector of the 236-2356 Blade Slope Harness (89) Rotation Sensor Connector of the 236-2356 Blade Slope Harness

Illustration 125	g01184993
Diagram of 251-2140 Wiring Group (14H and 16H) (3) 226-9170 Blade Slope Sensor (4) 244-1714 Rotation Sensor (51) 8T-0326 Bolt (57) 9X-2537 Bolts (78) 4 pin connector of the 243-3250 Rotation Sensor Harness (79) 243-3250 Harness (80) 236-2356 Blade Slope Harness (81) Rotation Sensor Connector of the 243-3250 Rotation Sensor Harness (82) 251-2383 Bracket (83) 8T-4191 Bolts (84) 8T-2121 Washers (85) 4K-8303 Clip (88) 4 pin connector of the 236-2356 Blade Slope Harness (89) Rotation Sensor Connector of the 236-2356 Blade Slope Harness

Illustration 126	g01185018
(4) 244-1714 Rotation Sensor (51) 8T-0326 Bolt (53) 4K-8302 Clip (54) 1F-7958 Nut (56) 8T-4523 Washer (57) 9X-2537 Bolts (64) 061-6665 Screws (81) Rotation Sensor Connector of the 243-3250 Rotation Sensor Harness (82) 251-2383 Bracket (83) 8T-4191 Bolts (84) 8T-2121 Washers (85) 186-0359 Clip (89) Rotation Sensor Connector of the 2236-2356 Blade Slope Harness

Illustration 127	g01185085
(22) 8T-4121 Washer (44) 4P-7581 Ladder Clip (45) 8T-4137 Bolt (61) 130-5300 Clip (62) 9X-2045 Screw (63) 5P-4115 Washer (72) 5P-9299 Clip (93) 3S-2093 Strap

Illustration 128	g01185459
(62) 9X-2045 Screw (63) 5P-4115 Washer (72) 5P-9299 Clip