- Asphalt Paver
- AP1000F (S/N: AC41-UP)
- AP1055F (S/N: TJ51-UP; RLM1-UP)
- AP500F (S/N: 5031-UP; 4491-UP)
- AP555F (S/N: AP51-UP; 5F51-UP)
- AP600F (S/N: AP61-UP; LR61-UP)
- AP655F (S/N: 4801-UP; 4521-UP; 4531-UP; P651-UP; 6551-UP; MH61-UP; ML61-UP; 4791-UP)
- AP1055F (S/N: TJ51-UP; RLM1-UP)
- Asphalt Screed
- SE50 V (S/N: J971-UP)
- SE50 VT (S/N: J6K1-UP)
- SE60 XW (S/N: JS91-UP; TLW1-UP)
- SE60 V (S/N: JJ31-UP)
- SE50 VT (S/N: J6K1-UP)
Introduction
This Special Instruction contains the required parts and procedure to install Cat® 416-2003 Grade and Slope Control Gp on certain Series F Asphalt Pavers and Series V Asphalt Screeds. This instruction is intended for use with the grade slope system assembly drawings. When ordered from the factory as a ship loose kit, this system comes with an assembly blueprint. If the assembly blueprint is missing, contact Cat Paving.
Note: Machines that are factory ordered with Cat Grade And Slope Control Group, will be equipped with the electronic control (ECM) components already installed. If the ECM components are already installed, begin this procedure at Step 2.
Important Safety Information
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Improper operation, lubrication, maintenance or repair of this product can be dangerous and could result in injury or death. Do not operate or perform any lubrication, maintenance or repair on this product, until you have read and understood the operation, lubrication, maintenance and repair information. |
Required Parts
| Required Parts | |||
|---|---|---|---|
| Item | Qty | Part Number | Description |
| 1 | 1 | Connector Receptacle As | |
| 2 | 2 | Washer | |
| 3 | 2 | Clip | |
| 4 | 3 | Cable Strap | |
| 5 | 2 | Washer | |
| 6 | 12 | Hard Washer | |
| 7 | 8 | Bolt | |
| 8 | 4 | Bolt | |
| 9 | 2 | Bolt | |
| 10 | 8 | Hard Washer | |
| 11 | 2 | Screw | |
| 12 | 8 | Bolt | |
| 13 | 12 | Seal Plug | |
| 14 | 16 | Screw | |
| 15 | 4 | Ring Nut | |
| 16 | 2 | Collar | |
| 17 | 4 | Hard Washer | |
| 18 | 2 | Receptacle As | |
| 19 | 4 | Protection Cap As | |
| 20 | 1 | Power Converter | |
| 21 | 4 | Nut | |
| 22 | 1 | Carrying Case | |
| 23 | 2 | Film | |
| 24 | 1 | Film | |
| 25 | 2 | Mount As | |
| 26 | 1 | Plate As | |
| 27 | 1 | Plate As | |
| 28 | 1 | Electronic Control (ECM) | |
| 29 | 2 | Mount As | |
| 30 | 1 | Machine Electronic Control Module (Software Group) | |
| 31 | 1 | Control Harness As | |
| 32(1) | 2 | Control Harness As | |
| 33(2) | 2 | Control Harness As | |
| 34(3) | 1 | Grade Sensor Gp (Optional) | |
| 35(4) | 1 | Strap | |
| 36(4) | 1 | Position Sensor As | |
| 37(4) | 1 | Control Harness As | |
| 38(5) | 1 | Connector Receptacle As | |
| 39(4) | 2 | Clip | |
| 40(4) | 2 | Cable Strap | |
| 41(4) | 4 | Hard Washer | |
| 42(4) | 4 | Bolt | |
| (1) | To be used for early screeds with no end gate tower, and Weiler screeds. If applicable, harness is installed on the end gate location. |
| (2) | Harness is used on early and late model screeds, and only intended to be installed on main screed body, near the screed control panel. |
| (3) | Supplied as a group |
| (4) | Part of |
| (5) | Part of |
Installation of the Hardware
- Install electronic control (28).
- Pivot the right side paver operator station to full "Out" position.
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Illustration 1 g03827784 View showing connectors below the right side operator station
(A) 40-pin plug (with jumper wires)
(B) Right operator panel harness
(C) CAN resistor - Locate 40-pin plug (with jumper wires) (A) below the right operator station.
- Remove and retain 40-pin plug (A) from connector RP-C2 of right operator panel harness (B). Do not remove CAN resistor (C).
Note: Retain 40-pin plug (A). Reinstallation will be necessary if the Cat Grade and Slope Control Group is removed.
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Illustration 2 g03827786 View showing placement of electronic control below the right operator station
(28)449-2017 Electronic Control - Position electronic control (28) below the right operator station, as shown in Illustration 2.
- Use four nuts (21) and four hard washers (17) to fasten electronic control (28).
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Illustration 3 g03827787 View showing control harness assembly connected to electronic control and right operator panel harness
(23)371-6464 Film
(28)449-2017 Electronic Control
(31)459-2971 Control Harness As
(B) Right operator panel harness
(D) 80-pin connector (RA-C2)
(E) 40-pin connector (RA-C1)
(F) 3-pin connector (RA-C6) - Connect 80-pin connector (RA-C2) (D), of control harness assembly (31), to electronic control (28).
- Connect 40-pin connector (RA-C1) (E), of control harness assembly (31), to connector (RP-C2) of right operator panel harness (B).
- Connect 3-pin connector (RA-C6) (F), of control harness assembly (31), to CAN resistor (C)
- Install film (24) (not shown) in a conspicuous location on electronic control (28).
Note: Film (24) allows for the transaction of Caterpillar Trimble Control Technologies LLC (CTCT) content (an intangible item), which is included in the machine software. Validation of enabling the software is stored in Product Software Programming System (PSPS).
- Pivot the right side paver operator station to full "Out" position.
- Reconfigure screed communication connectors.
- Locate 12-pin connector plug (MR-C16) (G) (with three pairs of twisted wires) on the right side of the right main screed. Refer to Illustration 4.
- Remove and retain 12-pin connector receptacle (with jumper wires) (H) from 12-pin connector plug (MR-C16) (F) of the right main screed harness.
Note: Reinstallation of 12-pin connector receptacle (with jumper wires) (H) will be necessary if the Cat Grade and Slope Control Group is removed.
- Install 12 seal plugs (13) into connector receptacle assembly (1).
- Install connector receptacle assembly (1) with 12 seal plugs (13) onto 12-pin connector plug (MR-C16) (G) of the right main screed harness.
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Illustration 4 g03827788 View showing 12-pin connector on right side of right main screed
(G) 12-pin connector plug (MR-C16)
(H) 12-pin connector receptacle (with jumper wires) - Install power converter (20).
- Select the correct location to install power converter (20).
Illustration 5 is an example of a location for a vertically mounted power converter found on a SE60V Asphalt Screed.
Illustration 6 is an example of a location for a horizontally mounted power converter found on an SE50, SE60VXW, or SE60VT XW Asphalt Screed.
- Using two screws (11) and two washers (2) fasten power converter (20) at the selected location on the machine.
- Install the 6-pin connector of the screed wiring harness to power converter (20).
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Illustration 5 g03827789 View showing placement of vertically mounted power converter
(20)340-7160 Power ConverterShow/hide table
Illustration 6 g03827790 View showing location to install horizontally mounted power converter
(J) Location to install horizontally mounted power converter - Select the correct location to install power converter (20).
- Install mount assemblies (optional).
- Mount assembly (25) and mount assembly (29) are to be installed as needed.
Note: Mount assemblies are used to position the sensors in optional locations. On screeds with heated endgates, remove cable cover in position where mount assembly is to be installed.
Note: Included in the parts with the Grade and Slope Control Group is 351-4477 Carrying Case (22) (not shown). Carrying case (22) is used to store grade sensors.
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Illustration 7 g03829645 View showing mount assemblies and hardware
(6)8T-4121 Hard Washer
(7)8T-4136 Bolt
(10)8T-4223 Hard Washer
(12)8T-4956 Bolt
(16)146-9410 Collar
(25)443-3733 Mount As
(29)450-9464 Mount As - Mount assembly (25) and mount assembly (29) are to be installed as needed.
- Assemble sensor ports and harness assemblies.
- Assemble control harness assemblies with sensor ports, connectors, and hardware as shown in Illustration 8.
Note: These control harnesses are only assembled to the main screed frame next to the control panels.
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Illustration 9 g03829139 View of control harness assemblies with sensor ports, connectors, and hardware, to be mounted near screed end gates
(3)4D-7388 Clip
(4)7K-1181 Cable Strap
(5)7X-7729 Washer
(9)8T-4191 Bolt
(14)103-6262 Screw
(15)132-8487 Ring Nut
(18)289-9632 Receptacle As
(19)332-6701 Protection Cap As
(32)463-8518 Control Harness As
(P) Sensor port (X1)
(Q) Sensor port (X2)
(R) 12-pin connector receptacle (X1)
(S) 12-pin connector receptacle (X2) - Assemble control harness assemblies with, sensor ports, connectors, and hardware as shown in Illustration 9.
Note: This assembly only applies to early Cat screeds without the end gate tower design, and Weiler screeds. If screed is a late model SE with the end gate tower, see Step 7.
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Illustration 8 g03827791 View showing control harness assemblies with sensor ports and connectors, for left and right main screed
(6)8T-4121 Hard Washer
(8)8T-4137 Bolt
(14)103-6262 Screw
(15)132-8487 Ring Nut
(19)332-6701 Protection Cap As
(26)446-6629 Plate As
(27)446-6630 Plate As
(33)477-6212 Control Harness As
(K) Sensor port (X3)
(L) Sensor port (X4)
(M) 12-pin connector (X3)
(N) 12-pin connector (X4) - Assemble control harness assemblies with sensor ports, connectors, and hardware as shown in Illustration 8.
- Install sensor ports and harness assemblies.
- Install the assembled components shown in Illustration 8 to main screed body, next to the thickness control screw.
- Ensure the keys in sensor port (X-3) (J) and sensor port (X-4) (K) are oriented as per the assembly drawing.
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Illustration 10 g03827792 View of sensor port, control harness, and connectors installed on left side of extender by screed end gate on a SE60V Asphalt Screed
(3)4D-7388 Clip
(18)289-9632 Receptacle As
(19)332-6701 Protection Cap As
(P) Sensor port (X1)
(R) 12-pin connector receptacle (X1)
(T) Connector plug (LE-C7) - Install the assembly containing sensor port (X-1) (N) to left side of extender by screed end gate.
Note: This installation location is important for correct CAN resistor configuration.
- Ensure the key in sensor port (X-1) (N) is oriented as per the assembly drawing.
- Connect left sensor 12-pin connector receptacle (Q) to connector plug (LE-C7) (S).
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Illustration 11 g03827793 View of sensor port, control harness, and connectors installed on right side of extender by screed end gate on a SE60V Asphalt Screed
(3)4D-7388 Clip
(18)289-9632 Receptacle As
(19)332-6701 Protection Cap As
(Q) Sensor port (X2)
(S) 12-pin connector receptacle (X2)
(U) Connector plug (RE-C7) - Install the assembly containing sensor port (X-2) (P) to right side of extender by screed endgate.
Note: This installation location is important for correct CAN resistor configuration.
- Ensure the key in sensor port (X-2) (P) is oriented as per the assembly drawing.
- Connect right sensor 12-pin connector receptacle (R) to connector plug (RE-C7) (T).
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Illustration 12 g06080843 View showing late model end gate tower design Show/hide table
Illustration 13 g06080822 View showing late model end gate tower design with cover removed
(18)289-9632 Receptacle As - Illustration 12 shows the end gate tower design on later Series SEScreeds. The sensor port harness is incorporated into the design, and there is no harness installation required.
The only part that is added when installing Cat Grade Control is 289-9632 Receptacle As (18). Refer to Illustration 13.
Note: This design does not use the following parts:
- Install grade sensor group (34) (optional).
- Place position sensor assembly (36) on transverse beam (U) between the paver and the screed.
Note: Ensure position sensor assembly (36) is placed with the arrow facing the front of the paver.
- Position two clips (39) (one shown) on the two rear mounting holes.
- Using four bolts (42) and four hard washers (41) fasten position sensor assembly (36) with two clips (39) (not shown) to transverse beam (V).
- Route harness assembly (36) along transverse beam (V) as shown in Illustration 14.
- Using one strap (35) (not shown) and two cable straps (40) secure control harness assembly (37) to transverse beam (V).
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Illustration 15 g03827795 View showing 12-pin connector on right side of right main screed
(38) Connector receptacle assembly
(G) 12-pin connector plug (MR-C16)
(W) 12-pin connector plug - Install connector receptacle assembly (38) onto 12-pin connector plug (W) on the right side of the right main screed.
Note: Connector plug (W) is located next to 12-pin connector plug (MR-C16) (G) (with three pairs of twisted wires) called out in Step 2 and Illustration 4.
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Illustration 14 g03827794 View from right side of machine showing placement of grade sensor group
(35)177-2215 Strap
(36)315-6697 Position Sensor As
(37)362-6642 Control Harness As
(39)277-1873 Clips (one shown)
(40)7K-1181 Cable Strap
(41)8T-4224 Hard Washer
(42)8T-7547 Bolt
(V) Transverse beam - Place position sensor assembly (36) on transverse beam (U) between the paver and the screed.
Installation of the Software
The software is pre-programmed into the ECM. The newest machine control software is set to detect the Cat Grade and Slope system. There is no need to change the configuration, using the Cat® Electronic Technician (Cat ET) Service Tool, as necessary in older models.
For updating the Cat Grade and Slope software, refer to M0067870.
Calibration of the System
- Prepare the machine for calibration.
- Connect 416-2006 Sonic Sensor Gp to one side of the machine.
- Place tow point in mid position.
- Place sonic sensor group behind the tow point, approximately 16 inches above the ground.
- Make sensor selection and calibrate tow point valve.
- Set the paver to the following conditions to calibrate:
- Engine idling
- In "PAVE" mode
- Parking brake ON
- Place screed in "FLOAT" mode by depressing the screed FLOAT button.
- Carefully depress the propel lever trigger and place the propel lever forward.
The calibration sequence screens will step the operator through the calibration procedure.
Grade and Slope Sensor Select
To change a sensor, press a SENSOR icon.
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| Illustration 16 | g03834822 |
The "Sensor" page will appear. Press a SENSOR and the sensor will appear on the main page and configure.
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| Illustration 17 | g03835066 |
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View showing "Sensor" page with current sensor options (A) "None" (B) "Slope" (C) "Contact Sensor" (D) "Averaging Beam Sensors (3)" (E) "Averaging Beam Sensors (2)" (F) "Single Sonic Sensor Over Ground" (G) "Single Sonic Sensor Over String Line" | |
Note: "Single Sonic Sensor Over Ground" (F) is the necessary selection to calibrate.
Grade and Slope Menus and Settings
To access "Grade and Slope" menus and change settings, press the MENU button on the top right corner of the page.
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| Illustration 18 | g03674521 |
The "Menu" page will appear.
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| Illustration 19 | g03790363 |
Operator Settings
To access "Operator Settings", press the OPERATOR SETTINGS button and the selection will highlight in yellow. The "Operator Settings" page will appear. Press and slide the scroll bar UP and DOWN to view all menu options.
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| Illustration 20 | g03790368 |
The current "Operator Settings" menu items are as follows:
- Main Screen
- USB Sync (if USB is inserted)
- Beeper
- Text Slider Bar
- Units
To access a menu item, press the item and the item will highlight in yellow. The setting page of the item's will appear. Change a setting by pressing an option. The item will highlight in yellow. Press OK to set.
Press the BACK button to return to the previous menu.
Diagnostics
To access "Diagnostics" menus, press the DIAGNOSTICS button and the "Diagnostics" menu page will appear.
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| Illustration 21 | g03790384 |
Press a "Diagnostics" item to view and the selected item will highlight in yellow. The menu page of the item will appear. To view other items within a menu page, press the item and the selected item will highlight in yellow. Another screen will appear with additional information.
Press the BACK button to return to the previous menu.
Installation
To access "Installation" menu items, press the INSTALLATION button and the selected item will highlight in yellow.
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| Illustration 22 | g03674540 |
A "Caution" screen will appear stating, "Changing some settings can make the machine inoperable". Press the OK button to continue navigation to the "Installation" menu items, or press the BACK button to return to the previous page.
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| Illustration 23 | g03790416 |
The current "Installation" settings menu items are as follows:
- Guidance Settings
- Control Settings
- Left Valve Calibration
- Right Valve Calibration
- Firmware Upgrade (if USB is inserted)
- Option Keys
Press and slide the scroll bar UP or DOWN to view menu items. To view information within the menus and submenus, press an item and the selected item will highlight in yellow. The settings page will appear.
Change settings by pressing an option. The option will highlight in yellow. Press OK to set.
Press the BACK button to return to the previous menu.
Grade and Slope Diagnostic Message
When a Grade and Slope diagnostic message appears on the screen, the diagnostic message will cover the TEXT SLIDER BAR and a beeper will sound. Press the "Mute" icon to mute the beeper. If the beeper is muted, the message will remain on the screen. Press the X to remove the message from the screen.
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| Illustration 24 | g03690717 |
Refer to Systems Operation, UENR4675, "AP300F, AP500F, AP555F, AP600F, AP655F, AP1000F, and AP1055F Asphalt Pavers Monitoring System" and Operation and Maintenance Manual, SEBU8845, "Cat® Grade & Slope v2.0 F-Series Asphalt Pavers" for more information.