Cat® Grade Control Cross Slope System for Motor Graders Caterpillar

Aligning the Machine

1. Verify that all tires have the proper air pressure, refer to the Operation and Maintenance Manual of the machine.

2. Move the machine to a smooth level surface and away from other working machines and personals.

3. Put the frame in the straight position.

4. Ensure that there is enough space ahead to turn the machine 180 degrees.

5. Ensure that all wheels are in the vertical position and there is no wheel lean (by pressing the auto wheel lean button).

6. Ensure that the machine has zero articulation by (pressing the automatic articulation button).

   Note: For higher level of accuracy the machine must have zero articulation. To ensure that the machine has no articulation, string lines can be run from the same exact points of the back axle to the same exact points on the front axle on both sides of the machine. The measurements of the string lines from both sides must be equal. A laser beam could also be used on both sides of the machine to ensure that the machine is not articulated.

7. Ensure the link bar is centered with the locking pin in the middle hole.
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   Illustration 1	g06070328

8. Visually center the circle and the blade on the machine.

9. Engage the parking break.

10. Lower the implements to the ground and stop the engine.

Center the Circle with Frame of the Machine

1. Locate the center of the slope sensor bracket by measuring the slope sensor bracket with tape measure.
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   Illustration 2	g06300217
   (1) Blade slope sensor

2. Connect the center point to the top of the circle. Normally the center point will be the welding joint between the two parts of the circle, place a square on top of the center point or mark the center point with pencil. Refer to Illustration 2.
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   Illustration 3	g06300235
   (2) Magnetic base (3) Center (4) Plumb bob string (A) Distance from one end of the frame to the center

3. Measure the part of the frame above the circle, find the center of the frame. Mark the center of the frame with pencil. Refer to Illustration 3.
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   Illustration 4	g06300236
   (2) Magnetic base (4) Plumb bob string (5) Plumb bob

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   Illustration 5	g06098625

4. Place a carpenter square on the center of the marked frame to the marked center circle and adjust the circle until the tip of the square will line with marked center of it.

   Or

   Ensure that the machine is level to get an accurate result, and place a plumb bob string (4) on the center of the frame using a magnet base (2) to secure the plumb bob string to the frame. Let the plumb bob (5) hang down. Ensure that the plumb bob (5) tip reaches the top part of the circle but not touching it, as shown Illustration 3 and Illustration 4.

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   Illustration 6	g06300238
   (4) Plumb bob string (5) Plumb bob

5. Move the circle until it gets centered to the frame by checking the plumb bob (5) or the square tip is on the center line on top of the circle as shown in Illustration 6.

Note: Using a Plumb Bob (5) could result in less than accurate result, when it is used always ensure that the machine cross angle is leveled (right to left) and the pitch angle (front to back) is level of the machine these factors will also effect where the tip the Plumb Bob will be pointing to, when it is hung down.

Centering the Blade

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Illustration 7	g06070586

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Illustration 8	g06070589

1. Measure the distance from both side of the blade tips to the sides of circle as shown in Illustration 7 and Illustration 8.
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   Illustration 9	g06300240
   (B) Distance between left end of the blade tip to the center (C) Distance between right end of the blade tip to the center

2. Sides shift the blade until both distances (B) and (C) are equal in length. Refer to Illustration 9.

Rotation of the Blade

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Illustration 10	g06070593

1. Locate the center point of the ball pivot joint on the A -frame as shown in Illustration 10.
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   Illustration 11	g06070595

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   Illustration 12	g06070598

2. Measure the distance between the center of the ball pivot joint on the A-frame to both the left and the right side of the moldboard (blade). Refer to Illustration 11 and Illustration 12.

   Note: The lower or the upper corners of the blade can be used to obtain the measurements, but it has to be the same point in both sides of the blade the (right and left).

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   Illustration 13	g06300242
   (6) Center line (D) Distance between left corner of the blade to the center (E) Distance between right corner of the blade to the center

3. Move the blade from the side that is bigger to the side that is smaller until both sides are equals in lengths ( (D) should be equal to (E)) as shown in the Illustration 14.

   Note: The measurement has to be within 12.7 mm (0.50 inch).

Adjusting the Zero Alignment Gauge

1. The machine alignment, circle alignment, A-frame with machine frame alignment, and the centering and the rotation of the blade must be done before proceeding to the below steps.
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   Illustration 14	g06300244
   (7) Bolt

2. Loosen the bolt (7) on the lower part of rear end of the circle to adjust the bolt, as shown in Illustration 14.

3. Line up the pointers.

4. Tighten the bolt.

Machine Dimension

Note: The machine dimensions will be pre-populated in the machine from factory, this instruction is included in this document to show how to obtain this dimension in the case of modification of the blade, sensors, or the A frame of the machine.

A-Frame Measurement

Illustration 15	g06300246
(F) Distance between lift (Lift cylinders) (G) The height of the blade (Top to Bottom) (H) The width of the blade (Left to Right)

Measure and record the distance between the lift cylinders (F) Illustration 15.

Measure and record the height of the blade (G) as shown in Illustration 15.

Measure and record the distance between the lower tips of the blade, the right lower corner to the left lower corner (H) as shown in Illustration 15. Measure the length of the A-frame of the machine by performing the following steps:

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Illustration 16	g06070606

1. Locate the ball pivot at the center of the A- frame

2. Locate the center point on top of the rotation sensor and mark the center point with pencil
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   Illustration 17	g06070607

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   Illustration 18	g06300247
   (8) Blade rotation sensor

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   Illustration 19	g06300249
   (8) Blade rotation sensor (9) Top center of the rotation sensor

3. Measure and record the distance between the center fronts of the A-frame to the center of the rotation sensor, Refer to Illustration 17, Illustration 18, Illustration 19.

Cross Slope Sensors Alignment

The following steps must be completed before starting sensor alignments:

1. The machine must be on smooth level surface away from working machines and personnel, lower the blade to the ground, engage the parking break, and turn off the engine.

2. The machine, circle, and the blade must be rested and aligned.

The Inclination (Main-fall) Sensor

Illustration 20	g06300250
(10) Inclination (Main-fall) sensor

Note: Ensure proper installation of the Inclination (main-fall) sensor (10), when the sensor is replaced or reinstalled on the machine (the sensor can be installed backwards inverted 180 degrees causing accuracy problems to the system).

1. Loosen the bolts and nuts which secure the main-fall sensors, to allow a little movement of the sensor for the adjustments.
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   Illustration 21	g06300251
   (10) Inclination (Main-fall) sensor (11) Level

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   Illustration 22	g06300252
   (11) Level (12) Square

2. Disconnect the sensor connector from the machine harness connector.

3. Use a combination of square (12) and level (11) to ensure that the sensor is square to the machine frame. As shown in Illustration 21 and Illustration 22.

4. Tighten the nuts and bolts of the sensor to the bracket to secure the sensor.

5. Repeat Step 3 to ensure that the sensor is properly aligned to the frame and it did not move while securing the sensor to the bracket.

6. Connect the machine harness connector to the sensor connector.

Blade Slope Sensor Alignment

Illustration 23	g06300253
(1) Blade slope sensor

Note: The blade slope sensor must be within 0.3 degrees of being parallel to the cutting edge. Follow the below steps to align the blade slope sensor.

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Illustration 24	g06300255
(1) Blade slope sensor (13) The cutting edge of the blade (J) The left side of the blade measurement (K) The right side of the blade measurement

1. Place one end of the 1219 mm (4 ft) straight edge against the vertical edge of the blade slope sensor.
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   Illustration 25	g06300256
   (4) plumb bob string (5) plumb bob

2. Hang a plumb bob (5) from the circle down to the front cutting edge of the blade Illustration 25.
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   Illustration 26	g06300257
   (4) Plumb bob string

3. Use the measuring tape to measure the distance between the edge of the 1219 mm (4 ft) level and the plumb bob string (4) line.

4. Repeat Step 1 through Step 3 for the other side of the blade. Make sure that the distance is equal or within the acceptable limitation, if not loosen the sensor bolts and rotate the sensor, so that the sensor measurements for both sides of the blade become equal.

Blade Rotation Sensor

Illustration 27	g06300259
(8) Blade rotation sensor

Note: To calibrate the rotation sensor, the sensor reading has to be within 32 degrees. If the sensor reading is greater than that a hardware adjustment of the rotation sensor is needed.

Before calibrations, ensure that the rotation sensor is within the 32 degrees by following the steps below:

With the key switchon go to the "Configuration" menu, press the arrow key until the "Diagnostic" is highlighted on the LCD screen, then press the "Ok" key. The diagnostic menu will appear, then press the arrow keys until "sensor data" is highlighted on the LCD screen, press the "Ok" key. The data screen will appear, press the key arrow to select the rotation sensor, then press "Ok" to view the rotation sensor value. Ensure that the rotation sensor reading is within ±32 degrees from zero.

Note: If the value of the rotation sensor is not within the limitation (±32 degrees) sensor hardware adjustments is needed, and if the value within the limitation you proceed to the sensor calibration.

Rotation Sensor Adjustment Procedure

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Illustration 28	g06300261
(8) Blade rotation sensor

1. Ensure that the machine is in safe condition to be serviced. The machine must be on a smooth leveled surface and away from the working personals, the implements (blade) is lowered to the ground and perpendicular with the machine, and the parking break is engaged,

   Note: Do not disconnect the sensor connector while you adjust the sensor hardware. Remove the rotation sensor from the mounting plat.

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   Illustration 29	g06300263
   (8) Blade rotation sensor (14) Allen head screw

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   Illustration 30	g06300264
   (8) Blade rotation sensor (14) Allen head screw

2. Loosen the Allen head screw for the Bracket Kit.
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   Illustration 31	g06300265
   (8) Blade rotation sensor (14) Allen head screw (15) Screwdriver (16) Folded paper

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   Illustration 32	g06300266
   (8) Blade rotation sensor (14) Allen head screw (15) Screwdriver (16) Folded paper

3. Place a piece of folded paper or a spacer under the drive arm.

4. Position the drive arm for the sensor, so that it covers the seal screw. Use a small flat head screwdriver to rotate the shaft until the display reads zero.

5. Tighten the Allen head screw on the drive arm for the sensor. Recheck the reading value from the LCD screen on the machine display.

6. Repeat Step 2 through Step 5, until the sensor is adjusted to ±32 degrees.

7. Reattach the rotation sensor to the swivel lid.

8. If the rotation sensor value within the limitation (32 degrees) the sensor is ready to be calibrated.