21/5/2021 SIS 2.

2017/10/09 Position Sensor (Body) - Calibrate (KENR8396)

SMCS - 7250 i07175167

793F Body Position Sensor Calibration

Illustration 1 g02451337
Typical rod linkage
(1) Rod end
(2) Nut
(3) Rod
(4) Body position sensor
(5) Center of the rod ends
The calibration procedure for body position sensor (4) must be performed when one or more of the following conditions occur:

A new truck is being assembled.

A new position sensor is installed.

The Electronic Control Module (ECM) is replaced.

The body is replaced.

Body position sensor (4) is located near the pivot pin for the body. A lever is attached between the sensor and the body. When the body is raised or
lowered, the lever rotates the sensor. This action changes the Pulse Width Modulation (PWM) signal that is sent to the "Chassis" ECM.

If the expected PWM signal does not occur, then the "Chassis" ECM generates an event code. The code is logged toVIMSTM.

Full Lower Calibration

Required Conditions
The following conditions must be met for 12 seconds:

The engine is running with no ground speed.

The payload is zero.

The hoist control lever must be in FLOAT mode.

The duty cycle output is within the range of 3 to 30 percent.

Note: The recommended duty cycle output is within the range of 14 to 19 percent.

The following occurs when all the conditions are met for 12 seconds:

The calibration value will be the average of the values that were recorded during that 12 seconds.

Expected Values
When the bed is fully lowered, the "Chassis" ECM expects a value that is greater than 1 percent PWM.

If the expected PWM value is not obtained, then an FMI 04 will be logged. If this event occurs, then perform the "Rod Adjustment" in the "Body
Position Sensor - Adjust" section.

Tolerance Range
The standard range for the calibration limits is plus or minus 2 percent of the last calibration point. If the tolerance range is not exceeded, then the
lower calibration point will not change.

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If the tolerance range is exceeded, then the upper calibration point will default to a 50 percent duty cycle until the upper calibration is performed.
The lower calibration point will change to the average value over the last 12 seconds.

This change occurs because there has been a mechanical change in the system that measures the output of the sensor. For example, a change
could occur under any of the following conditions:

The nuts that secure the adjustment rod are loose.

There is excessive wear on the body pins.

The adjustment rod is bent or damaged.

The sensor is damaged.

Any of these conditions could affect the duty cycle of the full lower calibration.

Full Raise Calibration

Required Conditions
The following conditions must be met for 500 milliseconds:

The engine is running with no ground speed.

The duty cycle output is in a range of 50 to 95 percent.

The current full up duty cycle must be greater than the previous full up duty cycle.

The hoist control lever must be in RAISE mode or in HOLD mode.

Note: When the bed has reached the maximum height, the operator should move the hoist lever from the RAISE position to the HOLD position.
Five seconds after the hoist lever is in position the calibration will begin.

The following occurs when all the conditions are met for 500 milliseconds:

The calibration value will be the average of the values that were recorded during the 500 milliseconds.

If the current upper calibration value is less than the previous upper calibration value, then the value will not change.

Expected Values
When the bed is fully raised, the Chassis ECM expects a value of less than 96 percent PWM.

If the expected PWM value is not obtained, then an FMI 03 will be logged. If this event occurs, then perform the "Rod Adjustment" in the "Body
Position Sensor - Adjust" section.

Known Issues
The following issues could prevent calibration of the position sensor. The issues could cause sensor diagnostics to be logged.

Wear on the Body Pins

Wear on the body pins could cause the position sensor to provide an incorrect value. This value could cause diagnostic faults to register against
the sensor.

If the body pins are worn, perform the "Rod Adjustment" in the "Body Position Sensor - Adjust". Verify that the angle of the body is less than 7
degrees when the body is fully lowered.

The Body Does Not Drop Fully

If the body does not drop fully to the frame rails, perform the following:

1. Adjust the "Hoist Lower Valve Adjustment Status" value with Cat® Electronic Technician (Cat® ET).

2. Perform a body up/ body down cycle.

3. Continue to adjust the "Hoist Lower Valve Adjustment Status" value until the desired snubbing is obtained.

Body Position Sensor - Adjust

Rod Adjustment
The following adjustment may be required for the "Chassis" ECM to calibrate the position sensor:

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1. Disconnect rod (3) from the body.

2. Loosen nut (2) on rod (3).

3. Twist the rod (3) to get a distance of 360 ± 3 mm (14.2 ± 0.1 inch) between the centers of the rod ends (5).

4. Tighten nut (2).

5. Reattach rod (3) to the body.

Angle Verification
Verify that the angle of the body is within tolerance when any of the following components are replaced:

A Sensor

A Body

An ECM

Note: If the angle is not within tolerance, then the "Chassis" ECM cannot correctly calibrate the position sensor.

Lower the body to the frame rails. If the value is less than 7 degrees, the software in the "Chassis" ECM calibrates the sensor. The calibration is
performed automatically by the "Chassis" ECM when the body is raised and lowered. If the value is not less than 7 degrees, then perform the "Rod
Adjustment" in the "Body Position Sensor - Adjust" section.

797F Body Position Sensor Calibration

Illustration 2 g02451016
(6) Rod end
(7) Nut
(8) Rod
(9) Body position sensor
(10) Centers of the rod ends
Body position sensor (9) is located on the frame near the left pivot pin for the body. Rod (8) is connected between the body position sensor (9) and
the body. When the body is raised, rod (8) rotates body position sensor (9). This action changes the PWM signal that is sent to the "Chassis" ECM.
The adjustment of the rod between the sensor and the body is important. See the below "Body Position Sensor - Adjust" for the proper adjustment
procedure.

The "Chassis" ECM is constantly checking for the need to calibrate body position sensor (9). Body position sensor (9) is calibrated by the "Chassis"
ECM when all of the following conditions exist for 30 seconds:

The engine is operating with no ground speed.

The hoist control has been placed in the HOLD position before being placed in the FLOAT position.

The duty cycle from the position sensor for the body is stable.

The duty cycle from the position sensor for the body is within the specified range for the LOWER position.

The signal from the body position sensor is also used for the following items:

Limit the top gear when the body is up.

Snubbing for the body

Starting a cycle for the Truck Payload Measurement System

Signal a new load count. (The hoist control must be in the RAISE position for 10 seconds.)

Illuminate the dash lamp that indicates that the body is not against the frame.

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Allow VIMS to provide warnings when the body is up.

Body position sensor (9) is used to limit the top gear while the body is UP. The "Chassis" ECM comes from the factory with the top gear value that
is set to FIRST gear. The transmission will not shift past FIRST gear until the body is DOWN. The top gear value is configurable and can be
changed using Cat ET). The top gear value can be changed to SECOND gear or THIRD gear.

The signal from body position sensor (9) is also used to control the SNUB position of the hoist control valve. The "Chassis" ECM will signal the
proportioning solenoids to move the hoist control valve to the SNUB position when the body nears the frame. The speed in FLOAT is reduced in
the SNUB position to prevent the body from contacting the frame too hard.

Known Issues
The following issues could prevent calibration of the position sensor. The issues could cause sensor diagnostics to be logged.

Wear on the Body Pins

Wear on the body pins could cause the position sensor to provide an incorrect value. This value could cause diagnostic faults to register against
the sensor.

If the body pins are worn, perform the "Body Position Sensor - Adjust" procedure. Verify that the angle of the body is less than 7 degrees when the
body is fully lowered.

The Body Does Not Drop Fully

If the body does not drop fully to the frame rails, perform the following:

1. Adjust the "HLVAS" value using Cat ET.

2. Perform a BODY UP/BODY DOWN cycle.

3. Continue to adjust the "HLVAS" value until the desired snubbing is obtained.

Body Position Sensor - Adjust

Note: The body position sensor must be adjusted correctly for the proper gear limit operation when the body is raised. Also, the body position
sensor is used to control the SNUB position of the hoist control valve.

The distance between the centers of the rod ends (10) must be 423 ± 3 mm (16.7 ± 0.1 inch).

Rod Adjustment
Perform the following to adjust the rod:

1. Disconnect rod (8) from the body.

2. Loosen nut (7) on rod (8).

3. Adjust rod end (6) to get a distance of 423 ± 3 mm (16.7 ± 0.1 inch) between the centers of the rod ends.

4. Tighten nut (7).

5. Reattach rod (8) to the body.

D3T1-UP, LAJ1-UP, LTZ1-UP, RB41-UP, RBT1-UP, SND1-UP, SSP1-UP, SXP1-UP, WSP1-UP

PSP-00043039
2021/05/21
13:21:50-05:00
i03881814
© 2021 Caterpillar Inc.
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