Procedure to Update Steering Sensor Hardware and Software for the CD54 Asphalt Compactor{1408, 430S, 7620} Caterpillar

Paving Compactor:

CD54 (S/N: J5R1-UP)

Introduction

This Special Instruction outlines the steps needed to update the software and wiring hardware for the steering sensors on certain CD54 Asphalt Compactors.

Do not perform any of the procedures contained in this document or order any parts until you have read and understand the directions in this publication.

Safety Section

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Do not operate or work on this machine or work tool unless you have read and understand the instructions and warnings in the Operation and Maintenance Manuals and Owner's Manuals. 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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Diesel engine exhaust contains products of combustion which may cause personal injury. Always start and operate the engine in a well ventilated area, and, if in an enclosed area, vent the exhaust to the outside.

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Personal injury can result from rotating and moving parts. Stay clear of all rotating and moving parts. Never attempt adjustments while the machine is moving or the engine is running unless otherwise specified. The machine must be parked on a level surface and the engine stopped. Attach a "Do Not Operate" or similar warning tag to the start switch and controls before servicing, repairing, or making adjustments to the machine.

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Shock/Electrocution Hazard! Do not work on this equipment unless you have read and understand the instructions and warnings in the Operation and Maintenance Manuals. Failure to follow the instructions or heed the warnings could result in serious injury or death.

Effectivity

There is a possibility for noise on the ground circuit of the steering sensor. The table below identifies the possible machines.

Required Parts

Rework Procedure

Software Installation

1. Obtain the new software. The software is available on Service Information System (SIS) in the Downloads. Under the Paving Products heading download "CD54_Diagnostics.zip". The heading for this file is "CD54 Flash and Diagnostic File".

2. Connect the Plus+1^TM Guide Service Tool software into the machine.

3. In the Plus+1^TM Service Tool select "File Download". Select the controller labeled with the part number "3401914" or "10107147". Refer to Troubleshooting, KENR7099, "Electronic Control Module (ECM) - Flash Program".

4. Now select software part number "4228961REV00.lhx " to flash to the controller. Refer to Troubleshooting, KENR7099, "Electronic Control Module (ECM) - Flash Program"

5. Check that machine has no fault codes, it is possible that calibrations will need to be performed. If so refer to the calibration procedures in, Test and Adjust, KENR5738, "CD54 Vibratory Asphalt Compactor Propel System", and Test and Adjust, KENR5740, "CD54 Vibratory Asphalt Compactor Machine Systems".

Harness Installation

The following are installation instructions for the 430-9969 Sensor Harness As and 430-9972 Sensor Harness As . In order to install the 430-9969 Sensor Harness As and 430-9972 Sensor Harness As the existing center 313-9067 Front Chassis Harness As and 346-7536 Rear Harness As will need to be reworked. These instructions will show you how to rework your existing center 313-9067 Front Chassis Harness As and 346-7536 Rear Harness As with out having to remove the harness from the machine.

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Illustration 1	g03340825

1. Remove side cover plate from all four corners to expose the hoses and harnesses.

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Illustration 2	g03340826

2. Remove "stauf" clamp stack closest to the harness that goes to the speed sensors. Pull the hydraulic hoses to the side. Secure hydraulic hoses using cable straps.

3. Prep folded support surface for welding. Weld one 7T-1099 Link (9) to the inside of each folded support. The following Illustrations show the right front of the machine.

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Illustration 3	g03340835
(5) 430-9972 Sensor Harness As (9) 7T-1099 Link

4. Shown is weld link (9) and 430-9972 Sensor Harness As (5) on the front right side of the machine.

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Illustration 4	g03340836
(X) 120 mm (4.7 inch)

5. Illustration 4 is the view of the folded support if viewed from the side. Dimension (X) is equal to 120 mm (4.7 inch).

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Illustration 5	g03340838
(9) 7T-1099 Link (Y) 100 mm (3.9 inch)

6. Illustration 5 shows weld link (9) viewed from the middle of the drum. Place weld link (9) approximately 100 mm (3.9 inch) at dimension (Y) from the vertical surface of the folded support.

   Note: These same dimensions can be used for the weld links on all four folded supports. The location will be similar on the side of folded support with the large hole for towing.

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Illustration 6	g03340850
(5) 430-9972 Sensor Harness As (9) 7T-1099 Link

7. Prep the surface of the hose retention plate for welding. Place weld link (9) approximately 30 mm (1.2 inch ) from the edge of the folded support and centered on the plate vertically.

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Illustration 7	g03340851

8. Cut center harness between the weld link added on the hose retention plate and the weld link on the bumper just above the plate. Remove lower portion of harness from machine.

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Illustration 8	g03340854

9. Crimp 9X-3402 Connector Socket (13) on all wires that were clipped. Add 155-2274 Connecting Plug Kit (2) to remaining portion of center harness. The table in Illustration 8 is for the Front Left/Rear Right corner that contains the propel speed sensor. Use 430-9972 Sensor Harness As (5) on the Front Left and Rear Right corners of the machine.

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Illustration 9	g03340857

10. The table in Illustration 9 is for the Front Right/Rear Left corner that contains the propel speed sensor and the vibe speed sensor. Use 430-9969 Sensor Harness As (4) on the Front Right and Rear Left corners of the machine.

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Illustration 10	g03340861

11. Attach harness to weld link that was added on the hose retention plate. Use two 3S-2093 Cable Straps (3) to attach the harness as shown in Illustration 10.

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Illustration 11	g03340862

12. Route harness along folded support and attach harness to the weld link added on the folded support. Ensure that the heat shrink on out side of the harness lands inside the weld links and 7K-1181 Cable Strap (3) is secured around the heat shrink.

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Illustration 12	g03340863

13. Route harness from the folded support to the drive plate. When routing on the Front Left/Rear Right corners add one 132-5789 Clip (1) to the drive plate using 7X-2537 Bolt (10), 5C-7261 Nut (7) and 8T-4224 Hard Washer (11). Route the portion of the harness going to the propel speed sensor as shown in Illustration 12. Use a 7K-1181 Cable Strap (3) to secure harness. Use existing ladder clip and a 7K-1181 Cable Strap (3) to secure connector for the propel speed sensor.

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Illustration 13	g03340864

14. When routing on the Front Right/Rear Left corners first move the Deutsche clip for the vibe speed sensor one hole over on the drive plate. Then, add 1 each of 4P-7581 Clip (6) and 132-5789 Clip (1) using 7X-2537 Bolt (10), 5C-7261 Nut (7) and 8T-4224 Hard Washer (11) as shown in Illustration 13. Route harness to vibe speed sensor and propel speed sensor using 7K-1181 Cable Strap (3) to secure the harness to the ladder clips. Secure the propel speed sensor connector to 4P-7581 Clip (6) and the vibe speed sensor harness to 132-5789 Clip (1) .

15. With the new jumper harnesses installed, reassemble the hoses back into the "stauf" clamps. Install cover plate over hoses and test machine functionality. Specifically perform the Test and Adjust, KENR5740, "Vibratory Frequency Test and Adjust - Two Amplitude System" and Test and Adjust, KENR5738, "Speed Sensor (Propel Motor) - Test".