Operator'S Manual: Cat Accugrade Grade and Slope System For Asphalt Pavers

OPERATOR’S MANUAL
®
Cat AccuGrade Grade and Slope System
TM
for Asphalt Pavers
Version 1.10
Revision A
Part Number xxxxx-00-ENG
June 2009
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This is the June 2009 release (Revision A) of the AccuGrade Grade and Software or any packaging and related materials without the prior
Slope System for Asphalt Pavers Operator’s Manual, part number written approval of an authorized representative of CTCT.
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2 AccuGrade Grade and Slope System for Asphalt Pavers Operator’s Manual
11. Applicable Law: This Agreement shall be construed, interpreted, Canada
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This Class B digital apparatus complies with Canadian ICES-003.
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Notices Australia and New Zealand
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communication. However, there is no guarantee that interference will Taiwanese regulations require that waste batteries are recycled.
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measures: Recycling in Europe: To recycle Trimble WEEE (Waste
– Reorient or relocate the receiving antenna. Electrical and Electronic Equipment, products that run on
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equipment under Federal Communications Commission rules. 5521 DZ Eersel, NL
AccuGrade Grade and Slope System for Asphalt Pavers Operator’s Manual 3
Safety Information
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 to perform these functions properly.
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.
Safety precautions and warnings are provided in this manual and on the product. If
these hazard warnings are not heeded, bodily injury or death could occur to you or to
other persons.
The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal
Word” such as “DANGER”, “WARNING” or “CAUTION”. The Safety Alert
“WARNING” label is shown below.
C WARNING – This alert warns of a potential hazard which, if not avoided, can cause severe
injury.
The meaning of this safety alert symbol is as follows:

Attention! Become Alert! Your Safety is Involved.
The message that appears under the warning explains the hazard and can be either
written or pictorially presented.
Operations that may cause product damage are identified by “NOTICE” labels on the
product and in this publication.
Caterpillar cannot anticipate every possible circumstance that might involve a

potential hazard. The warnings in this publication and on the product are, therefore,
not all inclusive. If a tool, procedure, work method or operating technique that is not
specifically recommended by Caterpillar is used, you must satisfy yourself that it is
safe for you and for others. You should also ensure that the product will not be
damaged or be made unsafe by the operation, lubrication, maintenance or repair
procedures that you choose.
The information, specifications, and illustrations in this publication are on the basis of
information that was available at the time that the publication was written. The
specifications, torques, pressures, measurements, adjustments, illustrations, and other
items can change at any time. These changes can affect the service that is given to the
product. Obtain the complete and most current information before you start any job.
Caterpillar dealers have the most current information available.
C WARNING – When replacement parts are required for this product Caterpillar recommends
using Caterpillar replacement parts or parts with equivalent specifications including, but not
limited to, physical dimensions, type, strength and material.
Failure to heed this warning can lead to premature failures, product damage, personal injury or
death.
Warnings
C WARNING – Do not operate this system unless you are fully trained and qualified to use this
equipment and the end-use equipment.
Never leave the system in automatic mode while the system is unattended.
Always place the screed on the ground when the screed is not in use.
Maintenance of hydraulic hoses, fittings, and valves must be done by qualified service
personnel only.
C WARNING – The screed may move without warning when automatic controls are on. Always
put the system in Manual and engage the machine’s park brake when you leave the cab or
when somebody is working near the screed.
C WARNING – The screed may move abruptly during hydraulic valve calibration. To avoid injury,
make sure the machine's park brake is engaged, and that the calibrations are supervised by an
operator in the machine cab. Maintain adequate clearance from people and objects during the
hydraulic valve calibration.
C WARNING – The screed may move abruptly during hydraulic valve tuning. To avoid injury,
make sure the machine's park brake is engaged, and that the tuning is supervised by an
hydraulic valve tuning.
Contents
Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1 Using the Control Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.1 Control box basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.2 Working with control box information. . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.2.1 Working with the guidance screen . . . . . . . . . . . . . . . . . . . . . . . 7
1.2.2 Understanding grade indicator information . . . . . . . . . . . . . . . . . . 12
1.2.3 Working with menus and dialogs . . . . . . . . . . . . . . . . . . . . . . . 13
1.3 Beeper patterns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2 Machine Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.1 Installing the control box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.2 Installing the removable sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.2.1 Mounting a sonic tracer for use over a surface or stringline . . . . . . . . . 21
2.2.2 Mounting a CS200C contact sensor for use on a surface or stringline . . . . 23
2.2.3 Multiple sonic tracers on an averaging ski . . . . . . . . . . . . . . . . . . 23
3 Preparing to Work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
3.1 Power up checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3.2 System configuration checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3.2.1 Configure the display setup . . . . . . . . . . . . . . . . . . . . . . . . . . 27
3.2.2 Check sensor setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
3.2.3 Elevation control window. . . . . . . . . . . . . . . . . . . . . . . . . . . 32
4 Working With the System in the Field . . . . . . . . . . . . . . . . . . 33

4.1 Pre-run setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
4.1.1 Set a side for cross slope control . . . . . . . . . . . . . . . . . . . . . . . 34
4.1.2 Bench (Null) the sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
4.1.3 Edit the displayed elevation runtime number . . . . . . . . . . . . . . . . . 37
4.1.4 Turn on automatic controls . . . . . . . . . . . . . . . . . . . . . . . . . . 38
4.1.5 Calibrate the cross slope sensor . . . . . . . . . . . . . . . . . . . . . . . . 38
4.2 Making a paving run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
4.2.1 Adjusting the mat thickness and/or cross slope . . . . . . . . . . . . . . . . 39
4.2.2 Keeping a sonic tracer over a stringline. . . . . . . . . . . . . . . . . . . . 39
4.2.3 Manual control with measured values . . . . . . . . . . . . . . . . . . . . 41
4.2.4 Check for material spills . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
4.2.5 Use the screed crank to gain ram travel. . . . . . . . . . . . . . . . . . . . 42
4.2.6 Switching to manual control . . . . . . . . . . . . . . . . . . . . . . . . . 42
5 Troubleshooting in the Field. . . . . . . . . . . . . . . . . . . . . . . . 43

5.1 System troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
5.1.1 Control box does not power up . . . . . . . . . . . . . . . . . . . . . . . . 44
5.1.2 Automatic controls are unstable . . . . . . . . . . . . . . . . . . . . . . . 44
5.1.3 Control box shows a gray sensor icon . . . . . . . . . . . . . . . . . . . . 44
Conte nts
5.1.4 Dialogs display in wrong language . . . . . . . . . . . . . . . . . . . . . . 45

5.2 Fault messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
5.2.1 Additional display detected . . . . . . . . . . . . . . . . . . . . . . . . . . 45
5.2.2 Valve module (VMxx) fault codes . . . . . . . . . . . . . . . . . . . . . . 46
5.2.3 Control box (CBxx) fault codes. . . . . . . . . . . . . . . . . . . . . . . . 47
5.3 Running diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
5.3.1 Checking sensor connections . . . . . . . . . . . . . . . . . . . . . . . . . 50
5.3.2 Testing valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
5.3.3 Viewing operating hours . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
5.3.4 Checking firmware versions . . . . . . . . . . . . . . . . . . . . . . . . . 52
5.3.5 Checking sensor data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
5.3.6 Viewing system fault history . . . . . . . . . . . . . . . . . . . . . . . . . 54
5.3.7 Checking the system power . . . . . . . . . . . . . . . . . . . . . . . . . . 54
5.3.8 Checking the control box grade indicators and softkeys . . . . . . . . . . . 55
5.4 System maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
5.5 Machine maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
6 Advanced Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . 59
6.1 Control box configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
6.1.1 Setting units of measure. . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
6.1.2 Setting beeper volume and triggers . . . . . . . . . . . . . . . . . . . . . . 62
6.1.3 Setting the control box and grade indicator brightness . . . . . . . . . . . . 64
6.1.4 Setting the control box contrast . . . . . . . . . . . . . . . . . . . . . . . . 65
6.2 Firmware maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
6.2.1 View current firmware information . . . . . . . . . . . . . . . . . . . . . . 66
6.2.2 Manage access to menus and sub-menus . . . . . . . . . . . . . . . . . . . 66
6.2.3 Enter service agreement key . . . . . . . . . . . . . . . . . . . . . . . . . 69
6.3 Basic controls tuning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
6.3.1 Deadband adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
6.3.2 Cross coupling adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
CHAPTER
1
Using the Control Box 1
In this chapter: As you work with the AccuGrade Grade and

Slope System, you need to set up and control the
Q Control box basics guidance system and understand the guidance
Q Working with control box information the system is giving you.
information
You control the guidance system with, and are
Q Beeper patterns given guidance information by the CD625
control box, with integrated grade indicators,
and an audible alarm, or beeper.
The system includes add-on support for 3D
elevation and slope. This is achieved by adding a
3D system to the AccuGrade Grade and Slope
System.
This chapter describes, in general terms, how the
CD625 control box is used.
For more information on these components,
refer to the AccuGrade Grade and Slope System
for Asphalt Pavers Reference Manual.
1 Using the Control Box
1.1 Control box basics

The CD625 control box is a computer that runs the system software. The control box
has a black and white LCD screen to display guidance and other information, and
push button controls to operate the system. See Figure 1.1, and the following table
that describes the items in the figure.
LCD screen
Integrated softkeys (push buttons) / grade indicators
Figure 1.1 The CD625 control box - the guidance screen of the left control box of a dual
control box system
Description Function
LCD screen Displays guidance and control information
Softkey labels See Softkeys and softkey labels, page 8
Softkey/grade indicators See Softkeys and softkey labels, page 8, and 1.2.2 Understanding
grade indicator information
Beeper See 1.3 Beeper patterns
To turn on the control box and the system, turn the machine power on.
To turn off the control box, turn the machine power off. You can turn off the system
when the control box is displaying any screen or dialog.
1.2 Working with control box information

When you work with the control box, you use a mix of softkeys, menus, dialogs, and
guidance screens. The availability of many of these items is determined by the
following factors:
• The sensors installed on the machine. For example, some configuration screens
are available only when particular sensors are installed.
• The guidance configuration of the system. Your selection of guidance method
affects:
– the guidance information available on the control box
– the guidance configuration options available
1.2.1 Working with the guidance screen

While you work, you read guidance information from the system. Guidance screens
display a mix of text and graphics that give you information such as the slope or
elevation of the screed.
The availability of each screen, and the information the screen contains, changes with
the following configuration items:
• The sensors installed on the machine
• The guidance configuration of the system
Guidance screen components

Figure 1.2 shows the main components of the guidance screen.
Sensor settings
Softkey labels Softkey labels
Guidance
area
Automatic controls settings
Figure 1.2 Guidance screen components – left side control box
The main areas of a guidance screen are:

• The softkey label area. See Softkeys and softkey labels, page 8.
• The guidance settings area. See, Guidance area, page 9.
• The sensor settings area. See Sensor settings, page 10.
• The automatic controls settings area. See Automatic controls settings, page 11.
Softkeys and softkey labels

Softkeys (push buttons) are the ten physical keys, five each immediately to the left
and right of the control box screen. The function of these physical keys depends on
the information displayed on the screen, and is identified by the softkey label beside
the softkey.
Table 1.1 describes the possible softkey labels visible on the control box screen.
Table 1.1 Softkey labels
Softkey label Function
Save settings and return to previous menu
Return to previous menu without changing settings
Increment value
Decrement value
Move cursor to right
• When elevation is being monitored or controlled, press briefly and release to

edit the reference elevation. Otherwise, when cross slope is being monitored
or controlled, press briefly and release to edit the cross slope calibration value
or the elevation runtime value, or;
• Press and hold to swap between cross slope and elevation guidance for the
control box’s side of the screed
• Press briefly and release to swap between automatic and manual control of
the control box’s side of the screed, or;
• Press and hold to swap between the display of the target elevation or cross
slope value, and the display of the measured elevation error or cross slope
value
Press and hold to bench (null) the sensor giving guidance to the left side of the
screed
Table 1.1 Softkey labels (Continued)

Softkey label Function
In the guidance screen, press to view the configuration menu. In a menu or dialog,
press to display the guidance screen
Press and hold to bench (null) the sensor giving guidance to the right side of the
screed
Menu access restrictions applied
Menu access restrictions can be set
If a softkey has no function in a screen or dialog, the softkey label is blank.

By convention, this manual refers to a softkey/function combination by softkey label.
Guidance area
The guidance area is used to display the runtime number (typically the benched
(nulled) elevation sensor error value or the benched (nulled) cross slope value), or the
actual elevation error value or cross slope value. These values are displayed in the
configured units.
In addition, if the control box is giving guidance to elevation using a sonic tracer over
a string line, then a steering indicator will be displayed.
The following table lists the icons that may appear in the guidance settings area.
Table 1.2 Guidance icons
Icon Description
Level cross slope set
Positive cross slope set (right side of screed high)
Negative cross slope set (left side of screed high)
Sonic tracer centered over string line
Table 1.2 Guidance icons (Continued)

Icon Description
Sonic tracer offset to the left of the stringline
Sonic tracer offset to the right of the stringline
Sonic tracer offset to the far left of the stringline
Sonic tracer offset to the far right of the stringline
A second control box is configured but is not found
Displayed data is the currently measured value, not the target value
Note – If you are operating a sonic tracer over a stringline, and no stringline
guidance icon is displayed, then the sonic tracer is not tracking the stringline.
Sensor settings
The sensor settings area is used to display the sensors providing guidance data to the
control box. The icons in the sensor settings area may also display the configuration
of a sensor and its current connection state.
In addition, the side the control box and sensors are mounted on is indicated by
positioning the sensor and control box icons in relation to an icon depicting a view of
the screed from the rear.
Table 1.3 lists the icons that may appear in the sensor settings area.
Table 1.3 2D sensor settings icons
Icon Description
Control box icon
Cross slope sensor icon
Single sonic tracer configured to track a string line
Single sonic tracer configured to track a surface
Table 1.3 2D sensor settings icons (Continued)

Icon Description
Two sonic tracers configured to track a surface
Three sonic tracers configured to track a surface
Contact sensor (typically, a profiling ski)
Table 1.4 lists additional sensor setting icons that are only available when using the
system with an additional 3D system.
Table 1.4 3D system sensor setting icons
Icon Description
3D cross slope sensor icon
3D elevation sensor icon
If a sensor was detected and configured after power up, but is later disconnected, then
the sensor’s icon will be displayed grayed out, as shown in the example below.
Automatic controls settings

The automatic controls settings area is used to display the state of the automatic
controls for each side of the screed.
The following table lists the icons that may appear in the automatic controls settings
area:
Icon Description
Manual control is selected
Automatic control is selected
Inactive Automatic control (Automatic control is selected, but is currently

inactive)
1.2.2 Understanding grade indicator information

The system uses ten grade indicator LEDs, integrated into the softkeys on each side of
the CD625 control box, to provide the operator with guidance information.
On each side of the control box there are five LEDs in two colors, as shown in
Figure 1.3.
Amber LEDs
Green LED
Amber LEDs
Figure 1.3 CD625 control box grade indicator LEDs – left side
When the screed is within the on-grade tolerance, the central green LED is lit. If any
LED, other than a green LED is lit, the screed is off-grade.
The following table describes possible LED patterns that may be displayed.
Table 1.5 LED patterns
LED pattern Description
All LEDs off No sensor data, invalid sensor data, or a configured sensor is
missing.
Top and bottom amber LEDs Elevation sensor is beyond the Elevation Control Window and is
flashing not currently giving guidance.
Two upper amber LEDS flashing Elevation sensor data is more than 13 mm (0.5 inches) above
the benched (nulled) distance, or slope sensor data is more than
0.7% negative cross slope off the benched (nulled) slope.a
Two upper amber LEDS on solid Elevation sensor data is between 6 mm (0.25 inches) and
13 mm (0.5 inches) above the benched (nulled) distance, or
slope sensor data is between 0.3% and 0.7% negative cross
slope off the benched (nulled) slope.a
Center green LED and upper Elevation sensor data is between 3 mm (0.12 inches) and 6 mm
amber LED on solid (0.25 inches) above the benched (nulled) distance, or slope
sensor data is between 0.04% and 0.3% negative cross slope off
the benched (nulled) slope.a
Table 1.5 LED patterns (Continued)

LED pattern Description
Center green LED on solid On-grade. Elevation sensor data is within ±3 mm (±0.12 inches)
of the benched (nulled) distance, or slope sensor data is within
0.3% of the benched (nulled) slope.a
Center green LED and lower Elevation sensor data is between 3 mm (0.12 inches) and 6 mm
amber LED on solid (0.25 inches) below the benched (nulled) distance, or slope
sensor data is between 0.04% and 0.3% positive cross slope off
the benched (nulled) slope.a
Two lower amber LEDs on solid Elevation sensor data is between 6 mm (0.25 inches) and
13 mm (0.5 inches) below the benched (nulled) distance, or
slope sensor data is between 0.3% and 0.7% positive cross
slope off the benched (nulled) slope.a
Two lower amber LEDs flashing Elevation sensor data is more than 13 mm (0.5 inches) below
the benched (nulled) distance, or slope sensor data is more than
0.7% positive cross slope off the benched (nulled) slope.a
a
The values for the LED patterns are default deadband distances. If the deadband is increased or
decreased, the distances will change respectively.
1.2.3 Working with menus and dialogs

Before you can begin work, you must enter configuration and set-up information into
the system, and view the current system state. You do this by working with screens
called menus and dialogs. Menus let you select a dialog. Dialogs let you specify
set-up and configuration information, or view information about the state of system
components.
Note – The AccuGrade Grade and Slope System can support one or two CD625
control boxes. Each installed control box can configure the settings for, and control,
one or both sides of the screed. To simplify the description of configuration
procedures, this manual describes configuration procedures as they are performed on
a control box controlling one side of the screed only. If the control box controls both
sides of the screed, an additional menu may be displayed to determine which side of
the screed the settings should be applied. In this case, a menu similar to the following
appears:
Menus
Menus let you choose another menu or dialog from a list. To move up or down the list
of menu items use the ! or # keys. Once you highlight the item you want to view,
press ) to select the item.
Indicates this menu has

one or more sub-menus
Highlighted menu item.

When you press ),
this item is selected.
Indicates that more menu items

can be viewed by scrolling down
Figure 1.4 Example menu – the Diagnostics menu
To leave a menu without making a selection, and return to the previous screen, press
*. To leave a menu without making a selection, and return to the guidance screen,
press (.
Dialogs
Dialogs let you enter data into the system. Dialogs can contain any of the following
items:
• Editable data fields. Editable data fields let you enter alphanumeric values,
such as a service agreement key.
• Rolling number fields. Rolling number fields let you enter numeric values,
such as the calibrated cross slope.
• Sliders. Sliders let you enter numeric values, such as valve speed.
• Lists. Lists let you select a single item from a list of items, such as a list of
available sensors.
To enter data into a editable number field, use the arrow keys as follows:
• % selects the next character to the right. If the current character is the
rightmost editable character, the cursor wraps around to select the leftmost
editable character.
In fields that allow spaces, press % twice to insert a space.
• For the selected character, press ! or # to scroll through the numbers
(0 through 9) and then the first six upper case alphabetical characters
(A through F) and back to 0.
Note – Available values depend on the type of field that is selected. For
example, the only values available for number fields are 0 through 9. In
addition, you cannot enter a value outside the maximum or minimum value in
fields which have an upper or lower limit.
If the cursor is in a position that precedes the first numeral, then pressing ! or
# will swap between a blank character and the minus (–) sign.
When you change a character in a field, the keys ! and # start stepping from
the existing character.
Data field
– individually editable characters
Press % to move to the

next character in the field
Figure 1.5 Example of a dialog with an editable data field
Once you have set the correct value, press ) to save the setting and return to
the previous screen.
To enter data into a rolling number field, press ! or # to increment or decrement
the value of the field in units of the least significant digit.
Number field
– rolling value
Figure 1.6 Example of a guidance screen with a rolling number field
Note – In the above example, press & to highlight the number field prior to editing.
Once you have set the correct value, press ) to save the setting and return to the
previous screen.
To enter data using a slider, press ! or # to move the slider bar to the right
(increase) or left (decrease).
Slider bar
Figure 1.7 Example of a dialog with a slider
Once you have set the correct value, press ) to save the setting and return to the
previous screen. Otherwise, press * to return the setting to its original value.
To select an item from a list, press ! or # to highlight the item you want to select.
When you press ),

this item is selected
Figure 1.8 An example of a list in a dialog
Once you selected the correct item, press ) to save the setting and return to the
previous screen.
To leave a dialog without saving a setting, and return to the previous screen, press *.
To leave a dialog without saving a setting, and return to the guidance screen, press (.
1.3 Beeper patterns

In addition to the control box, the system also alerts you to changes and events using
the system’s beeper.
The beeper will sound for the following events:
• when an error message is displayed
• when a sensor has completed a bench (null)
• when a sensor measures an off-grade condition
• when a button is pressed
CHAPTER
2
Machine Setup 2
In this chapter: This chapter describes how to select and install

the removable system components that are
Q Installing the control box required for the paving job.
Q Installing the removable sensors
2 Machine Setup
2.1 Installing the control box

The control box and beeper are mounted to a steel bracket. The bracket also carries a
16-pin bayonet connector to connect the control box to the system harness, and a
rotation arm mount (RAM) to mount the control box onto the mounting post. Most
installations use two control boxes, one for each side of the screed. A control box
assembly is shown in the following picture.
To install a control box:

1. Use the RAM mount to mount the control box assembly to the post.
2. Plug the 16-socket connector on the control box cable (P/N 65602-xxx) into
the connector on the rear of the control box assembly, and secure.
2.2 Installing the removable sensors

The system supports a number of different sensors and sensor configurations. In most
installations the cross slope sensor is permanently installed onto the screed transverse
beam, so in this manual it is not treated as a removable sensor. For this reason, this
section describes only the brackets and cables used to mount the elevation sensors
available with the system.
Table 2.1 lists possible 2D elevation sensor configurations you may use when paving.
Table 2.1 2D system sensor configurations
Sensor configuration Typical use See ...
Sonic tracer over surface Joint matching 2.2.1 Mounting a sonic tracer for use
over a surface or stringline.
Sonic tracer over stringline Controlling elevation to 2.2.1 Mounting a sonic tracer for use
a stringline reference over a surface or stringline.
Machine Setup 2
Table 2.1 2D system sensor configurations (Continued)

Contact sensor on surface Joint matching 2.2.2 Mounting a CS200C contact
sensor for use on a surface or
stringline.
Contact sensor on stringline Controlling elevation to 2.2.2 Mounting a CS200C contact
a stringline reference sensor for use on a surface or
stringline.
Averaging beam (multiple sonic Joint matching and/or 2.2.3 Multiple sonic tracers on an
tracers over a surface or paving using an averaging ski.
travelling stringline) irregular reference
surface
Table 2.2 lists an additional sensor configuration that is only available when using the
system with an additional 3D system.
Table 2.2 3D system sensor configuration
3D elevation sensor Controlling elevation to Sensor selection, page 29.
a 3D design
All sensor configurations use either one or two swing arms to support the sensors.
The scissor arms are mounted to the tow arms using brackets. The brackets are
permanently fixed to each tow arm; one at the rear near the screed lift ram, and one at
the front near the tow point ram. The two brackets are shown in Figure 2.1.
Rear bracket Front bracket

Figure 2.1 Swing arm mounting brackets
2 Machine Setup
A scissor arm is made up of two swing arms (P/N 65614) shown in Figure 2.2.
Figure 2.2 Swing arm
The square tube of the inner swing arm is mounted onto the scissor arm mounting
bracket. The square tube of the outer swing arm is mounted onto the round tube of the
inner swing arm.
A sensor is attached to the scissor arm using a swing arm adaptor (P/N 65648) and a
sensor mounting post (P/N 65612) shown in Figure 2.3.
Figure 2.3 Swing arm adaptor and sensor mounting post
The swing arm adaptor is mounted onto the round tube of the outer swing arm, and
the sensor mounting post is clamped into the free tube of the adaptor.
Machine Setup 2
Sensor cables attach to the screed end of the harness on the machine using quick
disconnect connectors and strain relief brackets.
There is one quick disconnect connector and strain relief bracket mounted
permanently on each side of the body of the tractor or screed.
2.2.1 Mounting a sonic tracer for use over a surface or stringline

To mount a single sonic tracer for use over a surface or stringline:
1. Mount the scissor arm assembly onto either the front or the rear tow arm
bracket.
2. Attach the sonic tracer to the support tube, and tighten the clamp so the sonic
tracer is securely held in the collar of the tube. The sonic tracer is oriented in
the following way:
– For use over a surface, with the cable connector to the rear of the machine.
– For use over a stringline, with the cable connector to the left when looking
in the direction of travel of the machine.
3. Plug the 10-pin quick disconnect connector on the coil cable (P/N 68182) into
the quick disconnect connector, and attach the strain relief boot to the bracket
for that side of the machine.
4. Plug the 7-socket connector on the coil cable into the connector on the sonic
tracer, and secure.
2 Machine Setup
The following picture shows a typical installation for using a sonic tracer over a
surface.
The following picture shows a typical installation for using a sonic tracer over a
stringline.
Consider the following points when setting up a sonic tracer over a stringline:
• Set up the sonic tracer so there is enough weight to hold the sensing tube on the
string without flexing the string.
• Make sure that the weight on the string is not so light that it won't follow the
string.
• During operation, watch the sensor to make sure it doesn’t fall off the string
and balance in space inside the elevation control window.
Machine Setup 2
2.2.2 Mounting a CS200C contact sensor for use on a surface or stringline

To mount a single CS200C contact sensor for use over a surface or on a stringline:
1. Mount the scissor arm assembly onto either the front or the rear tow arm
bracket.
2. Attach the contact sensor to the support tube, and tighten the clamp so the
sensor is securely held in the collar of the tube. The contact sensor is mounted
with the cable connector toward the front of the machine.
3. Plug the 10-pin quick disconnect connector on the coil cable (P/N 68182) into
the quick disconnect connector, and attach the strain relief boot to the bracket
for that side of the machine.
4. Plug the 7-socket connector on the coil cable into the connector on the contact
sensor, and secure.
The following picture shows a typical installation for using a contact sensor with a
profiling ski on a surface.
2.2.3 Multiple sonic tracers on an averaging ski

You can use one, two, or three sonic tracers on an averaging beam to form an
averaging ski. Valid combinations are:
• One sonic tracer in the center (second) position on the beam
• Two sonic tracers, one in the front (first) position and one in the back (third)
position on the beam
• Three sonic tracers, one in each position on the beam.
2 Machine Setup
European ski harness assembly

For more information on assembly, refer to the European Sonic Averaging Ski
Assembly Instructions (P/N 69419-00-ENG).
North American ski harness assembly

1. Mount the front scissor arm assembly (a scissor arm is comprised of two swing
arms (P/N 65614)) on the front tow arm bracket.
2. Mount the rear scissor arm assembly on the rear tow arm bracket.
3. Assemble the beam, lower the beam onto the beam support tubes on the scissor
arms, and tighten the lock nuts.
4. Insert the required sensor support tubes into the appropriate holes in the beam
and tighten the lock nuts.
5. Attach the required sonic tracers to the support tubes, and tighten the clamps so
the tracers are securely held in the collars of the tubes. The sonic tracers are
oriented with the sonic tracer parallel to the machine.
6. Attach the ski harness (P/N 68335) to the beam by connecting the snap links on
the harness to the corresponding loops on the beam.
Note – The ski harness has a portion on either side of the quick disconnect
connector branch:
– the front portion has two sonic tracer connectors and five snap links
– the rear portion has a single sonic tracer connector and three snap links
7. Plug the 10-pin quick disconnect connector on the ski harness into the quick
disconnect connector for that side of the machine.
8. Plug the 8-pin Deutsch connectors on the jumper cables (P/N 69457) into the
8-socket Deutsch connectors on the ski harness.
9. Plug the 7-socket connectors on the jumper cables (P/N 69457) into the
connectors on the sonic tracers, and secure.
The following picture shows a typical installation using an averaging beam to mount
multiple sonic tracers for use over a surface.
CHAPTER
3
Preparing to Work 3
In this chapter: This chapter describes control box and system

configuration checks that should be carried out
Q Power up checks after power up and prior to using the system for
Q System configuration checks paving guidance.
3 Preparing to Work
3.1 Power up checks

When power is supplied to the system the grade indicators will flash in tandem from
top to bottom twice. During this period, a splash screen is displayed.
When power up is completed, the guidance screen is displayed.
The following problems may occur when you power up the control box and the
system.
Problem Action
Control box does not start up Check that the master disconnect switch and machine power
switch are on.
Check the tow point cable (ignition switched power supply)
connections.
Start-up completes but an error The system has detected an error. See 5.2 Fault messages.
message appears
3.2 System configuration checks

The following table lists common tasks that you may need to perform to check the
system configuration.
Task When To learn how, see ...

Check the display mode Every time you start the 3.2.1 Configure the display
system setup
Check the sensor configuration Every time you start the 3.2.2 Check sensor setup
system, or whenever you
change sensors
To check these configuration items, start from the Configuration menu. To access the
Configuration menu, press (. The Configuration menu appears.
Note – When you leave the guidance screen and enter the Configuration menu, if
automatic control of the screed was turned on, it is turned off. You must turn the
automatic controls back on, when you return to the guidance screen.
Preparing to Work 3
If you have a system that uses a single control box, some menu items may have an
additional sub-menu that enables you to choose the side of the machine that you want
to configure. An example of this type of sub-menu is shown below:
Unless otherwise noted, this manual assumes a dual control box system.
3.2.1 Configure the display setup

Note – If you are operating with a single display system in dual side control mode and
another control box is added to the system later, the first control box will restart and
automatically reconfigure in single side control mode.
After power up completes, observe the control box, and check that the correct display
mode for your job has been selected.
For jobs with two screed operators, both control boxes are typically set to Single Side
display mode. In this mode each control box configures and displays sensor and
guidance information for one side of the screed only. A typical Single Side display
mode guidance screen is shown below:
3 Preparing to Work
For jobs where one screed operator is controlling the system, one or both control
boxes can be set to Dual Side display mode. In this mode a control box can configure
guidance settings, and display sensor and guidance information for both sides of the
screed. A typical Dual Side display mode guidance screen is shown below:
If the display mode is incorrect on one or both control boxes, complete the following
steps to correctly set the display mode (on one or both control boxes):
1. From the Configuration – Customize menu, select Display Setup.
2. Select Single Side or Dual Side.

3. To confirm the settings, press ); to exit without saving changes, press ( or
*.
Note – If changing from a two display system to a single display system, you must
configure the single display to control both sides of the screed, known as Dual Side
Control Mode.
3.2.2 Check sensor setup

Check the current sensor setup by observing the icons in the sensor settings area.
These icons are described in Table 1.3 on page 10. Check that the sensor setup
matches the sensors you have attached, and matches the way in which you intend to
use them, by checking the following items:
• Sensor selection. Are the correct type and number of sensors selected? If not,
see Sensor selection, page 29.
• Sonic tracer mode. If you are using one or more sonic tracers, are they
appropriately configured for surface or stringline operation? If not, see Sonic
tracer operating setting, page 31.
Preparing to Work 3
Sensor selection
If the sensor selection is incorrect for one or both sides, use the following procedure
to select the correct sensors:
1. From the Configuration menu, select Sensor Selection.
2. Select Elevation, or to configure slope go to Step 6. If you selected Elevation,

the following sub-menu appears:
3. Select Single Sensor, or to configure multiple sonic tracers for an averaging

application go to Step 9. If you select Single Sensor, the following menu
appears:
Select 3D Elevation when using

the system with an additional 3D system
Figure 3.1 Single sensor dialog
4. Select one of the following options:

– ST200C – sets the elevation sensor as a sonic tracer(s)
– CS200C – sets the elevation sensor as a contact sensor
– 3D Elevation – sets elevation to be controlled by a 3D system.
3 Preparing to Work
5. To confirm the settings, press ); to exit without saving changes, press *.

Note – Selecting 3D Elevation (only available with a 3D system) disables the
bench (null) elevation icon, as shown in Figure 3.2.
3D elevation icon is only available

when an additional 3D system is
connected to the system
Disabled bench (null) elevation icon
Figure 3.2 Bench (Null) elevation icon disabled (grayed out)
6. To configure how slope is controlled, select Slope from the Sensor Selection
menu:
3D slope is only available when

an additional 3D system is
connected to the system
Figure 3.3 Sensor selection - slope menu

– To allow the operator to manually enter/adjust the desired target slope,
select 2D Slope.
– To allow an additional 3D system to automatically adjust the desired target
slope to match the underlying slope of the 3D design surface, select 3D
Slope.
8. To confirm the settings, press); to exit without saving changes, press ( or
*.
Preparing to Work 3
9. To use multiple sonic tracers in an averaging application, select Averaging Ski.

– All ST200C – use grade data from all three sonic tracers
– Center Only – use grade data from the center sonic tracer only
– Front and Back – use grade data from the front and back sonic tracers only
Note – Make sure the position of the installed sonic tracers corresponds with
the averaging ski setting.
11. To confirm the settings, press); to exit without saving changes, press ( or
*.
Sonic tracer operating setting

If the sonic tracer setting is incorrect for one or both sides of the machine, use the
following procedure to select the correct setting:
1. From the Configuration menu, select ST200C Configuration.

– String Line – set the sonic tracer(s) to work over a string line
– Surface – set the sonic tracer(s) to work over a surface
*.
3 Preparing to Work
3.2.3 Elevation control window

Use this dialog to change the Elevation Control Window setting to a value between
20 mm (0.8 inches) and 200 mm (8 inches). The default value is 50 mm (2 inches).
If the reported sensor deviation falls outside the Elevation Control Window value, the
screed elevation will be locked into its current position (this means that no valve
commands are issued). This guards against large, sudden changes in screed elevation
movement and helps to maintain mat smoothness.
Sudden changes in sensor deviation may caused by any of the following conditions:
• rough terrain below the sensor
• obstacles lying on the surface, for example, a rock, a shovel, or a piece of wood
• the sensor slipping off a curb being used as a reference surface
• accidental movement of the sensor from its mounting
• an operator’s boot moving between the sensor and the reference surface
Note – Caterpillar recommends to increase the default value to 100 mm (4 inches)
when using a sonic averaging ski.
The Elevation Control Window setting does not affect slope sensors, however it does
affect the following elevation sensors:
• CS200C contact sensor
• ST200C sonic tracer(s)
• 3D elevation sensor(s)
To change the default value:
1. From the Configuration – Customize menu, select Elevation Control Window.
2. Press ! or # to increase or decrease the setting. The above dialog shows the
value set at 100 mm (4 inches).
3. To confirm the setting, press ); to exit without saving changes, press ( or
*.
CHAPTER
4
Working With the System in the Field 4
In this chapter: This chapter explains how to bench (null) the

screed for elevation and cross slope, and make a
Q Pre-run setup paving run.
Q Making a paving run
4 Working With the System in the Field
4.1 Pre-run setup

Common tasks that you may need to perform before you begin a paving run are listed
in the following table:

Set side for cross slope Every time you begin a run 4.1.1 Set a side for cross slope
when one side of the screed will control
be controlled to maintain cross
slope
Bench (Null) the sensors Every time you begin a run 4.1.2 Bench (Null) the sensors
Edit the displayed runtime Optionally, every time you begin 4.1.3 Edit the displayed elevation
number a run runtime number
Enable automatic controls Every time you begin a run 4.1.4 Turn on automatic controls
Calibrate the cross slope When you first install the sensor, 4.1.5 Calibrate the cross slope
sensor and when you reinstall the sensor
sensor or change screeds.
4.1.1 Set a side for cross slope control

To control the elevation of one side of the screed to maintain a constant cross slope,
on the corresponding control box press and hold &. After approximately three
seconds the elevation sensor icon, if present in the sensor settings area, is replaced by
either a 2D cross slope icon or a 3D cross slope icon, depending on the configuration
of the slope sensor for the associated side.
If the opposite side of the screed was previously controlled for cross slope, then
control will revert to the elevation sensor, if one is attached.
Note – You can only use this feature if automatic controls are turned off. If automatic
controls are turned on, the & softkey label will be grayed out, and pressing and
holding the softkey will have no effect.
4.1.2 Bench (Null) the sensors

Prior to beginning a paving run you must put the elevation sensors in their working
position, and bench (null) the sensor readings.
Set up the screed

To set up the screed prior to benching (nulling) the sensors:
1. Move the machine into position for the start of the run.
Note – When using a 3D system, additional steps may be required to ensure the
screed is at the desired starting height relative to the design surface to be built.
For more information, refer to your 3D system operations manual.
2. Place starter boards under the screed, and adjust the starter boards so that when
the screed is sitting on the starter boards it is at the correct mat thickness and
cross slope. The more accurately the starter boards are set up the more accurate
the mat thickness and cross slope.
B Tip – Soak the starter boards in a drum of water overnight. The screed will pull off the starter
boards more easily when the boards are wet.
3. On each side of the machine, use the controls on the machine to center the tow
point ram to the middle of the ram stroke.
4. Lower the screed onto the starter boards, and pull forward a few inches to
remove any slack from the tow arms.
B Tip – Measure the length of the ram stroke. If the scale is missing, mark the center point of the
stroke for future reference.
Note – Step 5 and Step 6 only apply to North American screeds. European screeds do
not have screed cranks.
5. On each side of the machine, use the screed cranks to bench (null) the screed
angle of attack (pitch). This is the point at which little or no resistance is felt
when turning the screed crank.
6. Turn the screed crank, in the direction indicated by the arrow on the crank, to
increase the angle of attack until resistance is felt, then add one full turn. This
sets the screed angle of attack.
B Tip – For detailed information about benching (nulling) and setting the screed angle of attack,
refer to the machine manufacturer’s operating manual.
Position an elevation sensor

To correctly position an elevation sensor for a run, consider the following points:
• Sonic tracers:
– When following a surface, mount the sonic tracers parallel to the direction
of the run.
Or, when following a string line, mount the sonic tracer at right angles to
the direction of the run with the connector facing to the left when looking
in the direction of travel.
– For one or more sonic tracers following a surface, adjust the distance
between the sonic tracer and the machine to be as close as possible,
bearing in mind spills from the hopper during refilling.
– For a single sonic tracer, position the sonic tracer closer to the screed for a
quick response to an elevation change, making sure that the trailing edge
of the sonic tracer is no further rearward than the center line of the augers.
This configuration is typical of applications where joint matching or
accuracy is critical.
Or, position the single sonic tracer closer to the tow point for a slower
response to an elevation change, making sure that the leading edge of the
sonic tracer is no further forward than the tow point ram. This
configuration is typical of applications where smoothness is critical. See
Figure 4.1.
Furthest forward position Furthest rearward position

Figure 4.1 Single sonic tracer positions
– Adjust the height of each sonic tracer so that it is approximately 35 cm

(14 inches) above the string line or surface.
– For multiple sonic tracers on an averaging ski, make sure the averaging
beam is approximately level and parallel to the machine. The center sonic
tracer should be in the middle third of the tow arm cylinder and the auger.
B Tip – For improved smoothness results using the averaging ski, position the rear sonic tracer
behind the screed over the newly laid mat.
• Contact sensors:
– For a contact sensor following a surface, adjust the distance between the
contact sensor and the machine to be as close as possible, bearing in mind
spills from the hopper during refilling.
Or, for a contact sensor following a string line, adjust the contact sensor so
that it is over the string line.
– Position the contact sensor closer to the screed for a quick response to an
elevation change, making sure that the trailing edge of the contact sensor
is no further rearward than the center line of the augers. This configuration
is typical of applications where joint matching is critical.
Or, position the contact sensor closer to the tow point for a slower
response to an elevation change, making sure that the leading edge of the
contact sensor is no further forward than the tow point ram. This
configuration is typical of applications where smoothness is critical.
– Position the contact sensor so that the swing arm is parallel to, and
trailing, the direction of the paving run.
– Adjust the height of the contact sensor so that the swing arm has an
optimum amount of movement.
– When the contact sensor is following a surface, the angle of the swing arm
should be about 45°.
Or, when the contact sensor is following a string line, the angle of the
swing arm should be about 45°.
– Adjust the swing arm counter weight so that the profiling ski or wand
follows the surface or string line reliably.
– When using a wand on a string line, make sure the wand does not distort
the string line.
• Tighten all lock nuts securely to minimize movement of the sensors.
Bench (Null) sensor readings

Benching (Nulling) the sensors has the following outcomes:
• the target elevation error is set to zero (the sensor output is set to zero)
• the 2D target cross slope is set to the measured cross slope of the screed
Note – When using a 3D system to control cross slope, the Bench (Null) button is
disabled. See Figure 3.2 on page 30.
To bench (null) the sensor controlling the left or right side of the screed, press and
hold . or / for about 3 seconds. Benching (Nulling) is completed when the green
grade indicator illuminates, and the beeper sounds.
4.1.3 Edit the displayed elevation runtime number

The runtime number displayed on the control box equals the value of the elevation
when the system is in manual and is not displaying measured values. The elevation
runtime number is typically used to remind the screed operator of the target mat
thickness.
Note – When the elevation runtime number is modified in the following way, it has no
effect on guidance.
To change the runtime number:
1. At the guidance screen of the control box displaying the elevation runtime
number, briefly press &. The elevation runtime number field is highlighted.
2. Use ! and # to increment or decrement the value of the elevation runtime
number.
B Tip – Press ! and # simultaneously to set the runtime number to zero.
3. To confirm the setting, press &.

When you bench (null) the sensors, the elevation runtime number displayed on the
guidance screen remains unchanged.
You can change the elevation runtime number for a paving run to any arbitrary value
between 9.999 m (32.8 ft) and –9.999 m (–32.8 ft).
4.1.4 Turn on automatic controls

To turn on automatic controls for one and/or both sides of the screed, press + on the
control box for the required side. The icon in the automatic controls settings area
changes to the Auto indicator.
C WARNING – The screed may move without warning when automatic controls are on. Always
put the system in Manual and engage the machine’s park brake when you leave the cab or
when somebody is working near the screed.
4.1.5 Calibrate the cross slope sensor

To calibrate the cross slope sensor:
1. Use a smart digital level to calibrate the slope sensor. Place the level on the
AS200C cross slope sensor, located on the transverse beam, and record the
smart digital level reading.
2. Calibrate the AS200C cross slope sensor using the reading recorded in Step 1.
3. Bench (Null) the AS200C cross slope sensor. See Bench (Null) sensor
readings, page 37.
4. Turn on Automatic controls and begin paving.
5. Use either a smart digital level, a traditional level and string, or another method
and record the slope of the freshly laid mat.
6. Re-calibrate the AS200C cross slope sensor using the reading recorded in
Step 5.
4.2 Making a paving run

Once you have completed all the tasks in 4.1 Pre-run setup, you are ready to pull off
the starter boards and begin your paving run.
Table 4.1 lists common tasks that you may need to perform during a paving run.
Table 4.1 Common paving run tasks
Adjust the mat thickness and/or When the mat thickness 4.2.1 Adjusting the mat thickness
cross slope during the run and/or cross slope is and/or cross slope
measured during the run
and needs to be adjusted
Keep a sonic tracer over a string When using a sonic tracer 4.2.2 Keeping a sonic tracer over
line over a stringline a stringline
Table 4.1 Common paving run tasks (Continued)

Manually control the screed When you need to manually 4.2.3 Manual control with
using measured values for control the screed measured values
elevation and slope
Check for material spills that When using a sensor over a 4.2.4 Check for material spills
may affect a sensor working surface
over a surface
Manually adjust the screed When a tow point ram is 4.2.5 Use the screed crank to gain
angle of attack while using reaching the limit of its range ram travel
automatic controls
Switch control to manual At the end of a run, or 4.2.6 Switching to manual control
whenever manual control is
required
4.2.1 Adjusting the mat thickness and/or cross slope

It may be necessary to adjust the mat thickness or cross slope during a run.
To adjust the mat thickness or cross slope during a run, use ! or # to increment or
decrement the runtime number in units of its least significant digit.
When the runtime number is modified in this way, it causes the system to drive the
end of the screed up or down by the amount the runtime number was incremented or
decremented.
Note – You can use ! or # to adjust the mat thickness during a run, even if the
automatic controls are set to Manual, however the runtime number will not change
when the system is adjusted in Manual. Also, if the mat thickness or cross slope is
modified while in manual, you must bench (null) the screed before returning to
Automatic in order to maintain the current elevation or cross slope.
4.2.2 Keeping a sonic tracer over a stringline

When you are working with a sonic tracer over a stringline you must keep the sonic
tracer centered over the string. In most cases the tractor driver will try and follow the
stringline as closely as possible using the machine’s guide chain, however the driver
may not have the fine control required to center the sonic tracer over the string, or the
string line may be curved. In this case, you will have to adjust the swing arm to
position the sonic tracer over the stringline, or move the screed extensions in or out to
keep the sonic tracer centered above the string.
To help you adjust the sonic tracer position, the system provides horizontal guidance
to the stringline.
Figure 4.2 shows the guidance screen when a sonic tracer is centered over the
stringline.
Stringline guidance icon

- sonic tracer centered over stringline
Figure 4.2 Stringline guidance – sonic tracer centered over stringline
If the sonic tracer moves off center of the stringline, then the horizontal guidance icon
changes to indicate the direction in which the sonic tracer position should be adjusted.
Figure 4.3 shows the guidance screen when the center of the left sonic tracer is
slightly to the left of the stringline.

- sonic tracer center
to the left of stringline
Figure 4.3 Stringline guidance – move sonic tracer right
If the center of the sonic tracer moves too far off the center of the stringline, then the
horizontal guidance icon is highlighted as well as indicating the direction in which the
sonic tracer position should be adjusted. Figure 4.4 shows the guidance screen when
the center of the left sonic tracer is to the far right of the stringline.

- sonic tracer center
to the far right of stringline
Figure 4.4 Stringline guidance – move sonic tracer left
4.2.3 Manual control with measured values

When the system is set for manual control you can choose to view, in the guidance
screen, either:
• the target elevation offset and/or cross slope
• the currently measured value for the elevation error and/or cross slope.
This feature is useful for situations where you want to manually guide the screed to a
designed elevation or cross slope, using ! or #; for example when you are paving a
super elevated curve.
To select which information is displayed, from the guidance screen and with the
system in manual, press and hold +. The control box screen changes to show the
measured value indicator and the current value of the elevation error and/or cross
slope. See Figure 4.5.
Measured value
indicator
Current elevation
deviation
Figure 4.5 Manual guidance screen showing elevation error
To display the target elevation offset and/or cross slope again, press and hold +.
To turn on automatic controls from the measured value screen, briefly press +.
Automatic controls are turned on, and the currently measured elevation offset and/or
cross slope is used as the new target. The target elevation offset and/or cross slope is
displayed.
4.2.4 Check for material spills

When the tractor hopper is being refilled, there may be material that is spilt on either
side of the machine. If the spill lies in the path of a sensor working over a surface,
then the sensor may report incorrect guidance information as it passes over the spill,
resulting in a defect in the mat.
You must be aware of the possible effects of spills, and be prepared to remove
material from the path of a sensor if a spill occurs.
4.2.5 Use the screed crank to gain ram travel

Note – As European screeds do not have thickness screws on the screed and have
longer tow point cylinders (rams), the following procedure may not be necessary for
European customers.
If a tow point ram is nearing the end of its travel range, an adjustment to the screed
angle of attack is necessary.
If the ram is fully retracted, use the screed control cranks to slowly increase the
screed’s angle of attack until the automatic controls drive the ram down to near the
center of its travel.
Similarly, if the ram is fully extended, slowly decrease the screed pitch until the
automatic controls drive the ram up to near the center of its travel.
4.2.6 Switching to manual control

When you reach the end of the run when using automatic controls, before the tractor
driver raises the screed, turn off automatic controls. You may also be required to
switch to manual control at other times during the run.
To turn off the automatic controls for one side of the screed, press + on the control
box for that side. The icon in the automatic controls settings area changes to the
Manual indicator, as shown below:
CHAPTER
5
Troubleshooting in the Field 5
In this chapter: This chapter describes the immediate actions

you can take to resolve system faults and
Q System troubleshooting performance issues.
Q Fault messages
Q Running diagnostics
Q System maintenance
Q Machine maintenance
5 Troubleshooting in the Field
5.1 System troubleshooting

Occasionally, problems will occur. Good troubleshooting techniques can significantly
reduce the time it takes to isolate the problem and, ultimately, the length of downtime.
Try to isolate the problem. Accumulate all relevant information. The more
information you can provide for the support personnel, the less time it will take them
to solve your problem.
5.1.1 Control box does not power up

• Check to make sure the ignition is turned on. The CD625 control box(es) are
typically powered by an ignition switched power supply.
• Check the cable and connections into the control box. Tighten all connections
and replace any cable that is cut or that has bare wires showing.
• Check the fuses on the tow point connector cables.
• Stop the machine, and then restart it. If the control box still does not power up,
call your Caterpillar dealer.
• If you have two control boxes installed, stop the machine, and disconnect the
faulty control box. Re-configure the remaining control box to allow both sides
of the screed to be monitored and controlled from a single control box.
5.1.2 Automatic controls are unstable

• Put the system in manual control and set the screed on the ground. If the grade
indicators for one or both sides of the screed are still erratic, check the stability
of the appropriate sensor outputs. For more information, see 5.3.5 Checking
sensor data.
• Recalibrate and re-tune the valves and control system. To learn about valve
calibration and tuning, refer to the AccuGrade Grade and Slope System for
Asphalt Pavers Installation Manual.
C WARNING – The screed may move abruptly during hydraulic valve tuning. To avoid injury,
make sure the machine's park brake is engaged, and that the tuning is supervised by an
hydraulic valve tuning.
• If the problem persists call your Caterpillar dealer.
5.1.3 Control box shows a gray sensor icon

• Check that the sensor is connected into the system. For more information, see
5.3.1 Checking sensor connections.
• Check all the cables and connections from the sensor. Tighten all connections
and replace any cable that is cut or that has bare wires showing.
• If the sensor still does not operate and the icon is still gray, call your Caterpillar
dealer.
5.1.4 Dialogs display in wrong language

Select the correct language from the Language dialog. To access the Language
dialog, press and hold both the bottom right and bottom left soft keys while powering
up the control box. The Language dialog opens immediately.
5.2 Fault messages

The system provides fault codes and fault messages to help you troubleshoot any
system problems.
When a fault is detected, a message appears on the control box. There are two kinds
of faults:
• A function has been initiated but the function cannot be carried out.
• A fatal error where something must be repaired or replaced.
Figure 5.1 shows an example of a fault message.
Location
(left or right)
Device code
Fault number
Time stamp
(operating hours) Brief description
Figure 5.1 Example of a CB71 fault reported by the left control box
To clear a fault message, press * or ).

The system stores the last five fault messages generated. For more information, see
5.3.6 Viewing system fault history.
5.2.1 Additional display detected

This message is briefly displayed when a single control box system detects that an
additional control box has been added. The message is displayed by the control box
initially connected to the harness, and indicates that the control box is about to
shutdown and restart in a new configuration suitable for a dual control box system.
5.2.2 Valve module (VMxx) fault codes

Table 5.1 lists faults that can be generated by the valve module during configuration
of the system, or while the automatic controls system is driving the valves.
Table 5.1 Valve module fault codes
Number Message Description Action
1 Memory Fault. Set Valve Type Internal failure. Set correct valve type and then
& Recalibrate recalibrate valves. If the error
persists, replace valve module.
2 Memory Fault, Service Internal failure. Replace valve module.
3 Serial Number Fault, Service Internal failure. Replace valve module.
4 Serial Number Fault, Service Internal failure. Replace valve module.
5 Internal Fault, Service Internal failure. Replace valve module if problem
persists.
7 Communication Fault, Service The valve module has been sent Check the cable to the valve
an invalid command. module for proper installation.
Check the function instance lines
in the cable to verify there are no
shorts or opens on these lines.
10 <-Valve Hardware Fault, The valve driver is over Check the cable to the valve
Service temperature and in current module for proper installation.
regulation or an overcurrent is Check the harness to make sure it
detected. Overcurrent is at is wired correctly.
5 amps.
11 Valve Hardware Fault ->, The valve driver is over Check the cable to the valve
Service temperature and in current module for proper installation.
regulation or an overcurrent is Check the harness to make sure it
detected. Overcurrent is at is wired correctly.
5 amps.
12 Multiple VM Detected, Service More than one valve module has Check for multiple valve modules.
been detected on the CAN bus.
13 Communication Fault, Service The valve module has been sent A device on the CAN bus is
an invalid command. sending illegal valve drive
commands.
Check the cable to the valve
module for proper installation.
14 Internal Fault, Service Internal failure. Replace valve module if problem
persists.
15 Too Many Devices in the Valve module initialization failed. Check the cable to the valve
Network, Service module for proper installation.
Replace valve module if problem
persists.
16 Memory Fault, Cycle Power Internal failure. Cycle power. If problem persists,
replace the valve module.
17 Valve Drive Fault, Service Internal failure. Cycle power. If problem persists,
Table 5.1 Valve module fault codes (Continued)

21 Function Instance Fault, State of function instance pins Check the cable to the valve
Service have changed during operation. module for proper installation.
Replace valve module if problem
persists.
23 Control Signal Shorted, The control signal line is shorted. Check the cable between the valve
Service module and the valve.
24 Memory Fault, Cycle Power Internal failure. Cycle power. If problem persists,
27 Serial Number Fault, Service PCB SN Checksum Failure. The Replace device.
PCB serial number has never
been programmed into the
device or the PCB serial number
memory has been corrupted
28 Serial Number Fault, Service Device SN Checksum Failure. Replace device.
The Device serial number has
never been programmed into the
device or the Device serial
number memory has been
corrupted.
5.2.3 Control box (CBxx) fault codes

Table 5.2 lists faults that can be generated by the control box during configuration of
the system, or while sensor data is being processed to provide guidance.
Table 5.2 Control box fault codes
1 Set Limits Fault The screed has moved out of the Reset limits to a wider span and
calibration limits during recalibrate.
calibration.
2 No Sensor Data, Check The sensor data is not being Check the sensor or harness
Harness seen by the control box. connection.
4 Calibration Fault, Check Valve There is a problem with the valve Recalibrate the valve module. If
calibration. the problem persists, service the
valve.
5 Calibration Fault, Restart Internal failure. Replace valve module upon
repeated occurrences.
6 Wrong Screed Motion, Check The hydraulics and/or valve Check the connection to the valve
Valve wiring are reversed. module, and recalibrate.
Table 5.2 Control box fault codes (Continued)

7 Calibration Fault, Restart Internal Failure. Replace valve module upon
repeated occurrences.
8 No Movement, Check Valve The control box requested screed Verify valve operation by following
movement but it took too long for the procedure in 5.3.2 Testing
it to get to the desired position. valves.
10 Set Limits Fault, Restart The calibration limits were Reset the limits and recalibrate the
incorrectly set. system.
12 System Hours Lost, Continue The operational hours have been Frequent occurrence of this fault
lost from the non-volatile indicates a faulty control box.
memory.
13 Valve Calibration Lost, The valve calibration data in the It is acceptable for this to occur
Recalibrate non-volatile memory was after installing new firmware. Any
corrupted. other occurrence indicates a faulty
control box.
14 Memory Fault, Recalibrate The valve tuning data in the It is acceptable for this to occur
Valves non-volatile memory was after installing new firmware. Any
corrupted. other occurrence indicates a faulty
control box.
15 Memory Fault, Service The program in the flash memory It is acceptable for this to occur
was corrupted. after installing new firmware. Any
other occurrence indicates a faulty
control box.
17 Network Fault, Service Possible damage to the CAN bus Check cables and bus termination.
to control box connection.
19 Network Fault, Service Possible damage to the CAN bus Check cables and bus termination.
to control box connection.
22 VM Missing, Service Valve module not detected. Check cables and bus termination
23 Unsupported Device. Cycle A device has reported a function Verify function instances on
Power instance that is outside the valid harness for all devices.
range for that device.
24 Duplicate Left/Right Device, Duplicate function instance Check harness left/right coding.
Service detected.
25 <-Elevation Limit, Check A sensor on the left has reached Re-bench (null).
Bench its end-of-travel, or the operator
has attempted to move the
setpoint (slope or elevation) past
its limits.
26 Elevation Limit ->, Check A sensor on the right has Re-bench (null).
Bench reached its end-of-travel, or the
operator has attempted to move
the setpoint (slope or elevation)
past its limits.
29 VM Intermittent, Check The connection to the valve Check cables and bus termination.
Connection module is intermittent.
32 ECM Disconnected, Service ECM not detected. Check cables and bus termination.
33 VM Fault, Service Faulty device. Service.
34 VM Fault, Service Faulty device. Service.
41 Control Latency, Cycle Power Left control box fault. Cycle power to control box.
Table 5.2 Control box fault codes (Continued)

42 Control Latency, Cycle Power Left control box fault. Cycle power to control box.
47 Device Missing, Check Check if the necessary sensor Check cables and bus termination.
Harness has a poor or intermittent
connection.
48 Invalid Password Service agreement password is Contact your dealer.
incorrect at power up, or when
entered.
50 Serial Number Fault, Service Device serial number verification Contact your dealer.
failed.
52 Sensor Not Supported, Sensor is detected that is not Check sensors.
Reconfigure appropriate for the present
machine type and configuration.
56 Reference Target Not Found, The ST200C Reference Target Service sensor.
Service has not been found.
58 Valve Interface Mismatch, Valve module fault. Service the valve module.
Service
59 Screed Control Not Allowed Operator desires to run a valve Check that the machine is in
calibration, but screed control is service mode.
not allowed by the valve control
unit.
61 Service Agreement Expired The service agreement password Contact your dealer.
has expired.
62 VM Fault, Service Valve module fault. Service the valve module.
63 Calibration Fault, Check Setup Valve calibration or auto-tuning Check that the cylinder ram is not
timed out. at the limit of its travel.
Check cables.
66 Device Config Error Error when configuring grade or Check sensor/harness.
angle sensor.
67 Device Config Timeout Timeout when configuring grade Check sensor/harness.
or angle sensor.
68 Valve Calibration In Process The ram on the opposite side of Do not try and drive a tow point
screed is being calibrated. ram while a calibration is taking
place.
69 Incorrect Password Invalid password entered during Re-enter password.
menu lock or unlock.
70 String Line Not Allowed Sonic tracer is in “sonic over Change to “sonic over surface”
stringline” configuration during configuration. See Sonic tracer
valve calibration. operating setting, page 31.
72 Valve Calibration Required The valve has never been Calibrate the valve.
calibrated by the control box, or
the calibration is invalid.
73 Valve Type Selection Required Valve type selection required. Select valve type.
74 VM, Service. Invalid Firmware The version of firmware on the Replace the valve module or
Version VM200 valve module is not contact your dealer.
supported.
5.3 Running diagnostics

To access the Diagnostics menu, from the Configuration menu, select Diagnostics.
Note – To learn how to access the Configuration menu, see 3.2 System configuration
checks.
The options in the Diagnostics menu let you perform the following tasks.
Task See ...

Check sensors 5.3.1 Checking sensor connections
Check valve drive 5.3.2 Testing valves
View operating hours 5.3.3 Viewing operating hours
Check component firmware 5.3.4 Checking firmware versions
Check sensor outputs 5.3.5 Checking sensor data
Check past faults 5.3.6 Viewing system fault history
Check machine power supply 5.3.7 Checking the system power
Check control box grade indicators and 5.3.8 Checking the control box grade indicators
softkeys (push buttons) and softkeys
5.3.1 Checking sensor connections

To check the sensors detected by the system:
1. From the Diagnostics menu of either control box, select Sensor Connectivity.
2. The Sensor Connectivity dialog shows a simplified plan view of the machine,
and indicates the presence of sensors using the icons in Table 1.3 on page 10. If
a sensor was connected and detected at startup, and has subsequently become
disconnected, then the icon will be grayed out, as shown in Figure 5.2.
Missing sensor
Figure 5.2 Missing sensor
3. Press ), *, or ( to exit.
5.3.2 Testing valves

The system provides an interface that allows you to use the valve module to drive the
automatic control valves.
To test drive the valves:
1. From the Diagnostics menu of either control box, select Test Valves.
2. Use the following tools to test the valve module and valves:
– Press the left ! and # softkeys to drive the left towpoint cylinder valve.
– Press the right ! and # softkeys to drive the right towpoint cylinder
valve.
– Press % to edit the magnitude of the drive command sent to the valve
module. By default, the maximum valve drive command (100%) will be
sent to the valve module.
5.3.3 Viewing operating hours

You can view the total number of hours a control box has been operating since it was
manufactured (operating hours). In addition, you can also view the number of hours
the control box has been operating with automatic controls enabled (control hours).
To view operating and control hours:
1. From the Diagnostics menu of the control box, select Hour Meter.
5.3.4 Checking firmware versions

You can view the version numbers of the firmware currently loaded into the control
box(es), valve module, and sensors currently connected to the system.
Control boxes are identified by an arrow indicating the side they are on. Other devices
are identified by a number, referred to as a function instance. The function instance
for each device/location combination is shown in Figure 5.3.
FI = 2 FI = 3
Single
Sonic Tracer or
FI = 0 Contact Sensor
FI = 1
FI = 4 FI = 5
Up to three Sonic Tracers
FI = 6 FI = 7
AS200C FI = 0 FI = Function Instance
Figure 5.3 Device function instances
To view version numbers:

1. From the Diagnostics menu of either control box, select Software Versions.
5.3.5 Checking sensor data

You can view the data reported by the sensors connected to the system, and monitor
the stability of that data.
When there is only a single elevation sensor on a side, then the elevation sensor is
identified by an arrow indicating the side it is on. If there is more than one elevation
sensor on a side, then each elevation sensor is identified by a number, referred to as a
function instance. Slope sensors are identified by function instance. The function
instance for each device/location combination is shown in Figure 5.3.
Elevation data is reported as a deviation from the benched (nulled) elevation. Slope
data is reported as a deviation from horizontal, with a negative value indicating that
the sensor is sloping down to the right.
The data reporting interval is also displayed.
To view sensor data:
1. From the Diagnostics menu of either control box, select Sensor Data.
Sensor type
Side
Function instance Reporting interval

Data
Figure 5.4 The Sensor Data dialog
5.3.6 Viewing system fault history

The system stores the last five fault messages generated. For more information on
fault codes, see 5.2 Fault messages.
To view fault codes:
1. From the Diagnostics menu of either control box, select Fault History.
2. To view details of a fault, select the fault and press ).
The information in the dialog is the same as that described in Figure 5.1, with
the exception of the number in brackets after the fault code. This number
indicates the total number of times the fault has occurred in the lifetime of the
device.
5.3.7 Checking the system power

The system lets you view the power supply voltage. The power supply must provide
between 11V and 30V DC, with all equipment operating.
To view the system power:

1. From the Diagnostics menu of either control box, select Machine Voltage.
5.3.8 Checking the control box grade indicators and softkeys

The system lets you check that all the grade indicator LEDs (Light Emitting Diodes)
are working, and that all softkeys (push buttons) are being read correctly
To run a softkey and LED test:
1. From the Diagnostics menu of the control box, select Test Control Box. The
grade indicator LEDs on both sides of the control box are repeatedly
illuminated in sequence from top to bottom, and the Test Control Box dialog
appears:
2. Press each softkey in turn and observe the control box.
A switch that ... is represented by a flashing identifier and ...

has a short to power the “+” symbol
has a short to ground the “–” symbol
is not detected by the system the “?” symbol
The following table describes the control box entries:
Key Entry
! left P1:
# left P1:
Blank first left P2:
Blank second left P3:
* – Note: You will return to the Diagnostics menu when this key is P4:
released
! right P5:
# right P5:
( – Note: You will return to the guidance screen when this key is P3:
released
Blank right P6:
) – Note: You will return to the Diagnostics menu when this key is P7:
released
3. Test that the complete display screen is working by performing the following
steps:
a. Simultaneously press both up arrow keys to turn on all the display screen
pixels.
The display momentarily turns black.
b. Simultaneously press both down arrow keys to turn off all the display
screen pixels.
The display momentarily turns white.
5.4 System maintenance

The system requires little maintenance. Occasionally, however, adjustments are
necessary.
The common maintenance issues involved with the system are as follows:
• Whenever the hydraulic system is serviced, adjusted, or has components
replaced, a valve calibration must be carried out. To learn about valve
calibration, refer to the AccuGrade Grade and Slope System for Asphalt Pavers
Installation Manual.
B Tip – As a minimum, valve calibrations should be carried out every 12 months.
C WARNING – The screed may move abruptly during hydraulic valve calibration. To avoid injury,
make sure the machine's park brake is engaged, and that the calibrations are supervised by an
hydraulic valve calibration.
• Inspect the cables daily to make sure the cables are not cut or pulled during
operation. Repair or replace the cables as required.
• Periodically inspect the drain holes for clogging.
• Routinely check the machine sensor calibration to ensure accurate slope
control. See 4.1.5 Calibrate the cross slope sensor.
5.5 Machine maintenance

Some of the machine maintenance problems that may affect control system accuracy
are:
• slop in the screed ram pins
• power supply problems
Always perform regularly scheduled maintenance to keep the machine tight and
operating at peak performance.
CHAPTER
6
Advanced Configuration 6
In this chapter: The system provides interfaces to let you

configure the control box menus and dialogs,
Q Control box configuration and refine the response of the automatic
Q Firmware maintenance controls.
Q Basic controls tuning This chapter describes these interfaces.
6 Advanced Configuration
6.1 Control box configuration

The system provides an interface that enables you to configure the control box to suit
your working needs.
Common control box configuration tasks that you may need to perform are listed in
the following table:

Set units for the display of Optionally, when you are 6.1.1 Setting units of measure
elevation and slope data working to a design with
different units than the
current setting
Set beeper volume and triggers Optionally, to suit the job 6.1.2 Setting beeper volume and
and site conditions triggers
Set control box brightness Optionally, to suit the job 6.1.3 Setting the control box and
and site conditions grade indicator brightness
Set control box contrast Optionally, to suit the job 6.1.4 Setting the control box
and site conditions contrast
Less common control box configuration tasks are listed in the following table:

Configure on-grade deadband The tow point cylinders are 6.3.1 Deadband adjustment
not being driven effectively
Configure the elevation control You need to guard against 3.2.3 Elevation control window
window large, sudden changes in
screed elevation movement
and to help maintain mat
smoothness
Configure the display setup One control box fails in a 3.2.1 Configure the display setup
dual control box system
Configure cross coupling Changes in elevation cause 6.3.2 Cross coupling adjustment
the screed slope to vary
To configure the control box, select Customize from the Configuration menu:
6.1.1 Setting units of measure

The system lets you select:
• the units of measure used to display elevation data
• the number of decimal places (precision) used to display slope data
Note – Slope data is always displayed as the ratio of elevation gain to distance
travelled (“rise over run”), expressed as a percentage.
To set the units of measure for elevation and slope, select Units of Measure from the
Customize menu:
Setting elevation units

To set the units used to display elevation data:
1. From the Units of Measure menu, select Elevation:

– Decimal Feet
– Meters
– Decimal Inches
*.
Setting slope precision

To set the precision used to display slope data:
1. From the Units of Measure menu, select Slope.

– 0.1 Percent – slope is displayed with a precision of one decimal point
– 0.01 Percent – slope is displayed with a precision of two decimal points
*.
6.1.2 Setting beeper volume and triggers

To configure the beeper, select Audio from the Customize menu:
Setting beeper volume

To set the beeper volume:
1. From the Audio menu, select Audio Volume:
2. Use ! or # to increase or decrease the volume setting.

*.
Setting beeper triggers

To enable or disable the beeper for off-grade alerts:
1. From the Audio menu, select one of the following options:
– Elevation Alert
– Slope Alert
If, for example, you select Elevation Alert, the Elevation Alert dialog appears:
Note – The Slope Alert dialog uses On/Off options similar to the Elevation
Alert dialog.
– On – enable the alert
– Off – disable the alert
*.
6.1.3 Setting the control box and grade indicator brightness

To adjust the brightness of the control box and/or the grade indicators:
1. Select Brightness from the Customize menu.

– Push Button – adjust the brightness of the grade indicators
– Screen – adjust the brightness of the control box
If, for example, you select Screen, the Screen dialog appears:
Note – If you select Push Button all the grade indicators will be turned on until
you leave the dialog. The Push Button Brightness dialog uses a slider similar
to the Screen Brightness dialog.
3. Use ! or # to increase or decrease the brightness setting.
*.
6.1.4 Setting the control box contrast

To adjust the control box contrast:
1. Select Contrast from the Customize menu.
2. Use ! or # to increase or decrease the contrast setting.

*.
6.2 Firmware maintenance

The system provides an interface that enables you to view firmware version
information, manage operator access to menus, and enter your system’s service
agreement key.
To access the firmware maintenance menu items, select Advanced Option from the
Configuration menu.
Common tasks that you may need to perform to maintain your system are listed in the
following table:

View firmware version Before talking to your 6.2.1 View current firmware
information Caterpillar dealer or information
Caterpillar support staff
Restrict operator access to When you setup a system 6.2.2 Manage access to menus
some menus for a new operator and sub-menus
Enter a new firmware service When you purchase an 6.2.3 Enter service agreement
agreement key updated service agreement, key
or when you upgrade the
system firmware
6.2.1 View current firmware information

To view information about the currently installed system firmware, select About from
the Advanced Option menu.
The following information is shown in the About dialog:

• The product name and version number of the installed firmware.
• The serial number of the CD625 control box.
• The date on which the firmware service agreement option key expires. For
more information, see 6.2.3 Enter service agreement key.
6.2.2 Manage access to menus and sub-menus

In some situations, you may want to restrict an operator’s access to one or more
Configuration menu items or items in sub-menus. The system allows you enable a
factory-defined password to manage access to individual menus and sub-menus.
Menu access management is a two step process:
1. Enable password access to the menu management feature.
2. Select the menu items and sub-menu items you want to restrict access to.
These steps are described in detail in the following sections.
Turning on the password protection feature

To turn on the password protection feature:
1. Select Supervisor Password from the Advanced Option menu. The first screen
of the Supervisor Password wizard appears:
2. Select Enable. The second screen of the Supervisor Password wizard appears:
B Tip – To move the cursor to the next character position, press %.
3. Enter the supervisor password. The supervisor password is the four digit
number “8024”. Press ). The Advanced Option menu appears, with the 1
softkey label displayed:
Selecting restricted access items

Once you have enabled password restrictions, you must select the menu, or menus, to
which the restrictions will be applied.
To restrict operator access to one or more Configuration or sub-menu items:
1. From any menu or sub-menu, press and hold 1. The Supervisor Password
password entry dialog appears:
Tip – To move the cursor to the next character position, press %.
number “8024”. Press ). The original menu you were in appears, and the 1
softkey label is replaced with the 0 softkey label:
3. Move through the menu and sub-menus. Whenever you need to restrict access
to a menu item, press and release 0. A small lock icon appears beside the
menu item, as shown below:
Pressing and releasing 0 toggles the state of a menu item between locked and
unlocked.
4. Once all the menu items you need to restrict access to are marked for locking,
press and hold 0. This locks all the menu items that you selected.
Clearing menu item access restrictions

To reset all menu items to their unlocked state:
1. Select Supervisor Password from the Advanced Option menu.
2. Select Disable. The second screen of the Supervisor Password wizard appears.
number “8024”. Press ). The Advanced Option menu appears.
6.2.3 Enter service agreement key

To begin using automatic controls, you must enter a service agreement option key
into the control box. This key is supplied by your Caterpillar dealer, and is unique to a
specific control box.
The key also has a date associated with it. You will not be able to upgrade your
control box with new software manufactured after this date. To learn how to view the
option key expiry date, see 6.2.1 View current firmware information.
Once you have obtained a service agreement option key, to enter the key into the
control box:
1. Select Service Agreement Password from the Advanced Option menu.
B Tip – To move the cursor to the next character position, press %.
2. Enter the supplied service agreement password, and press ).
6.3 Basic controls tuning

The system provides interfaces that enable you to adjust automatic controls system
parameters.
Common controls tuning tasks that you may need to perform are listed in the
following table:

Adjust the automatic controls The tow point cylinders are 6.3.1 Deadband adjustment
deadband not being driven effectively.
Adjust the feedback from the Changes in elevation are 6.3.2 Cross coupling adjustment
side controlled for elevation to causing the screed slope to
the side controlled for slope vary.
The controls tuning menu items are in the Customize menu. To learn how to access
the Customize menu, see 6.1 Control box configuration.
6.3.1 Deadband adjustment

The on-grade deadband setting allows you to modify the amount of error the system
will tolerate before valve drive commands are generated.
If the on-grade deadband is too narrow, the valves will be driven in response to noise
in the elevation or slope sensors, and will “chatter”.
If the on-grade deadband is too wide, the system will fail to drive the valves in
response to real errors, and defects may appear in the mat.
To adjust the on-grade deadband:
1. Select On Grade Deadband from the Customize menu.

– Elevation – adjust the elevation deadband
The default setting for elevation is 3 mm (0.12 inches), which provides a
3 mm display deadband for the on-grade LED indicators and a 3 mm
control deadband for the automatic hydraulic valve control. This setting
suits most applications.
– Slope – adjust the slope deadband
The default setting for slope is 0.05%, which provides a 0.05% display
deadband for the on-grade LED indicators and a 0.05% control deadband
for the automatic hydraulic valve control. This setting suits most
applications.
If, for example, you select Elevation, the Elevation dialog appears:
Note – The Slope dialog uses a sliding scale similar to the Elevation dialog.
3. Use ! or # to increase or decrease the deadband setting.
*.
6.3.2 Cross coupling adjustment

The cross coupling setting adjusts the amount by which the system will attempt to
predict, and then compensate for, errors in screed slope caused by movement of the
elevation-controlled side of the screed.
The cross coupling setting communicates corrections from one side of the screed to
the other side of the screed. Use this setting to ensure that the screed raises and lowers
without delays. Removing the delays will smooth out the movement of the screed and
prevent the opposite side of the screed from digging into the desired grade.
If the system determines that the elevation side must be raised to maintain mat depth,
the system will automatically raise the slope side to maintain the desired cross slope.
If cross coupling is set to 0%, the slope side will not move until the system senses that
the slope sensor is not at the desired slope.
Note – Cross coupling can be adjusted to zero in order to stabilize the system during
heavy passes.
1. Select Cross Coupling from the Customize menu.
2. Use ! or # to increase or decrease the cross coupling value. A value of

100% sets the maximum amount of cross coupling available.
*.
Index
A Configuration menu
accessing 26
About dialog 66 dialog 26
adaptor, swing arm 20 Contrast dialog 65
adjusting mat thickness or cross slope 39 control box
Advanced Option menu 65 controls icons 8
audible alarm, see beeper controls settings 11
Audio menu 62 dialogs 14
Audio Volume dialog 63 fault codes 47
automatic controls guidance area 9
settings 11 guidance icons 9
troubleshooting 44 guidance screen 7
turn off 42 information overview 7
turn on 38 installation 18
Averaging Ski dialog 31 keys 6
menus 14
power 6
B sensor icons 10
beeper sensor settings 10
configuration 62 softkey labels 8
using 16 softkeys 8
volume 63 troubleshooting 44
benching (nulling) the sensors 34 using 6
brightness settings 64 controls icons 8
controls settings 11
cross coupling
C adjustment 71
dialog 72
CD625 control box, see control box cross slope
checking adjusting 39
automatic valves 51 sensor calibration 38
fault history 54 Customize menu 60
firmware versions 52
operating hours 52
power 54 D
push buttons and LED indicators 55
sensor connections 50 deadband adjustment 70
sensor data 53 diagnostics 50
softkeys and LED indicators 55 check automatic valves 51
configuration check fault history 54
cross slope guidance 34 check firmware versions 52
Display Setup 27 check power 54
elevation control window 32 check push buttons and LED indicators 55
sensor type 29 check sensor connections 50
sensors 28 check sensor data 53
sonic tracer mode 31 check softkeys and LED indicators 55
checking operating hours 52
menu 50 Display Setup
dialogs dialog 28
About 66 dual side control mode 27
Audio Volume 63 setting 27
Averaging Ski 31 single side control mode 27
Contrast 65
Cross Coupling 72
Display Setup 28 E
Elevation 61
Elevation Alert 63 Elevation Alert dialog 63
Elevation Control Window 32 elevation alerts 63
Elevation deadband 71 Elevation Control Window dialog 32
Fault History 54 elevation control window settings 32
Hour Meter 52 Elevation deadband dialog 71
Language 45 Elevation dialog 61
Machine Voltage 55 elevation units of measure 61
Push Button 64 error messages 45
Screen 64
Sensor Connectivity 50
Sensor Data 53 F
Service Agreement Password 69 fault codes 45
Single Sensor 29 Fault History
Slope 62 dialog 54
Slope Alert 63 menu 54
Slope deadband 71 firmware
Software Versions 53 service agreement 66
ST200C Configuration 31 version 66
Supervisor Password viewing information 66
enable 67
enable lock set 68
enter password 67 G
Test Control Box 55
Test Valves 51 grade indicators, using 12
using 14 guidance area 9
display guidance icons 9
controls icons 8 guidance screen, using 7
controls settings 11
dialogs 14
guidance area 9 H
guidance icons 9 horizontal guidance to stringline 39
guidance screen 7 Hour Meter dialog 52
information overview 7 How To
installation 18 access the Advanced Options menu 65
keys 6 access the Customize menu 60
menus 14 adjust cross coupling 71
power 6 adjust deadband 70
sensor icons 10 adjust mat thickness or cross slope 39
sensor settings 10 bench (null) the sensors 34
softkey labels 8 calibrate the cross slope sensor 38
softkeys 8 check firmware versions 52
troubleshooting 44 check power 54
using 6
check push buttons and LED indicators 55 M
check sensor connections 50
check sensor data 53 Machine Voltage dialog 55
check softkeys and LED indicators 55 maintenance
configure the beeper 62 machine 57
edit the elevation runtime number 37 system 57
enable alerts 63 mat thickness, adjusting 39
enable supervisor password 66 measure mode 41
keep horizontal guidance to stringline 39 menus
manage menu access 66 Advanced Option 65
select cross slope guidance 34 Audio 62
select sensor type 29 Brightness 64
select sonic tracer mode 31 Configuration 26
set beeper volume 63 Customize 60
set control box and grade indicator Diagnostics 50
brightness 64 Fault History 54
set Display Setup 27 lock access 68
set elevation units 61 On Grade Deadband 70
set slope precision 62 restricting access 66
set the control box contrast 65 Sensor Selection 29
set the Elevation Control Window 32 Sensor Selection, Elevation 29
set the service agreement option key 69 Sensor Selection, Slope 30
set units 61 Units of Measure 61
set up sensors 28 unlock access 69
test automatic valves 51 using 14
turn off automatic controls 42 mounting post, sensor 20
turn on automatic controls 38
view fault history 54
view firmware information 66 O
view operating hours 52 On Grade Deadband menu 70
I P
icons power the control box 6
controls 8 Push Button dialog 64
guidance 9
sensor 10
install R
control box 18
sensors 18 restrict menu access 68
runtime number, setting elevation 37
K
S
keys, control box 6
scissor arm mounting brackets 19
Screen dialog 64
L Sensor Connectivity dialog 50
Sensor Data dialog 53
Language dialog 45 Sensor Selection menu 29
sensors set up over string 31
bench (null) 34 set up over surface 31
calibrating cross slope 38 ST200C Configuration dialog 31
icons 10 Supervisor Password dialog
installation 18 enable and disable 67
mounting post 20 enable lock set 68
select cross slope 34 enter password 67
select sonic tracer mode 31 password 67
select type 29 supervisor password, enabling 66
setting up 28 swing arm 20
settings 10
troubleshooting 44
service agreement T
expiry 66
setting the option key 69 Test Control Box dialog 55
Service Agreement Password dialog 69 Test Valves dialog 51
setting troubleshooting
alerts 63 automatic controls 44
beeper configuration 62 control box 44
beeper volume 63 control box fault codes 47
control box and grade indicator brightness 64 display 44
control box contrast 65 error messages 45
cross coupling 71 fault messages 45
cross slope guidance 34 machine maintenance 57
deadband 70 running diagnostics 50
Display Setup 27 sensors 44
elevation control window 32 system 44
elevation runtime number 37 system maintenance 57
elevation units 61 valve module fault codes 46
language 45
menu locks 68
sensor type 29 U
sensors 28 units of measure 61
service agreement option key 69 Units of Measure menu 61
slope precision 62 unlock menus 69
sonic tracer mode 31
units 61
Single Sensor dialog 29 V
slope
alerts 63 valve module fault codes 46
precision 62
Slope Alert dialog 63
Slope deadband dialog 71 W
Slope dialog 62 wizards, manage menu access 67
softkeys
labels 8
using 8
Software Versions dialog 53
sonic tracers
averaging 29
keep horizontal guidance to stringline 39
material spills 41

Operator'S Manual: Cat Accugrade Grade and Slope System For Asphalt Pavers

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OPERATOR’S MANUAL

for Asphalt Pavers

The meaning of this safety alert symbol is as follows:

Caterpillar cannot anticipate every possible circumstance that might involve a

4 Working With the System in the Field . . . . . . . . . . . . . . . . . . 33

5 Troubleshooting in the Field. . . . . . . . . . . . . . . . . . . . . . . . 43

5.1.4 Dialogs display in wrong language . . . . . . . . . . . . . . . . . . . . . . 45

In this chapter: As you work with the AccuGrade Grade and

1.1 Control box basics

Integrated softkeys (push buttons) / grade indicators

1.2 Working with control box information

1.2.1 Working with the guidance screen

Guidance screen components

Softkey labels Softkey labels

Automatic controls settings

Figure 1.2 Guidance screen components – left side control box

The main areas of a guidance screen are:

Softkeys and softkey labels

Save settings and return to previous menu

Return to previous menu without changing settings

Move cursor to right

• When elevation is being monitored or controlled, press briefly and release to

Table 1.1 Softkey labels (Continued)

Menu access restrictions applied

Menu access restrictions can be set

If a softkey has no function in a screen or dialog, the softkey label is blank.

Level cross slope set

Positive cross slope set (right side of screed high)

Negative cross slope set (left side of screed high)

Sonic tracer centered over string line

Table 1.2 Guidance icons (Continued)

Sonic tracer offset to the left of the stringline

Sonic tracer offset to the right of the stringline

Sonic tracer offset to the far left of the stringline

Sonic tracer offset to the far right of the stringline

A second control box is configured but is not found

Control box icon

Cross slope sensor icon

Single sonic tracer configured to track a string line

Single sonic tracer configured to track a surface

Table 1.3 2D sensor settings icons (Continued)

Two sonic tracers configured to track a surface

Three sonic tracers configured to track a surface

Contact sensor (typically, a profiling ski)

3D cross slope sensor icon

3D elevation sensor icon

Automatic controls settings

Manual control is selected

Automatic control is selected

Inactive Automatic control (Automatic control is selected, but is currently

1.2.2 Understanding grade indicator information

Table 1.5 LED patterns (Continued)

1.2.3 Working with menus and dialogs

Indicates this menu has

Highlighted menu item.

Indicates that more menu items

Figure 1.4 Example menu – the Diagnostics menu

Press % to move to the

Figure 1.5 Example of a dialog with an editable data field

Figure 1.6 Example of a guidance screen with a rolling number field

Figure 1.7 Example of a dialog with a slider

When you press ),

Figure 1.8 An example of a list in a dialog