Workshop Manual

W3026EN4.pdf
System Applications And Calibrations
Vibratory Vibratory Pneumatic
Rollers Rollers Rollers
CC224-624HF CA1500-6500 CP224/274

Serial number: Serial number: Serial number:

*284x00001* - *100001XXx0A007867*- *224x00001* -
*384x00001* - *274x00001* -
*100003XXx0X000001-* *1000050Xx0B001387-*

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Introduction .............................................................................................................................. 1
How to connect ........................................................................................................................ 5
Download a system application file.......................................................................................... 9
Parameter file - Master ECU for CC, CA and CP .................................................................. 17
Download Parameter Files - For CP rollers ........................................................................... 21
Calibration - FNR lever .......................................................................................................... 27
Calibration of throttle and brake pedal on CP rollers ............................................................. 33
Download a control board application.................................................................................... 39
Download a traffic light controller application......................................................................... 43
Use the diagnostic file............................................................................................................ 47
Error codes and symbols (Only CA) ...................................................................................... 55

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Introduction

Introduction

The purpose with this manual is to give you a quick guide of how to install and/or
upgrade the software applications on CC224-624HF, CA1500-6500 and CP224/274
machines.

To be able to connected to the software system of the machine you need the following:

- Service tool Plus1 installed to your PC

- Can/USB gateway interface communicator CG150 (P/N 4700792584)
- Diagnostic file (P1D) corresponding to the machine software version.

PC-system requierments:

- PC with Pentium 3 CPU, 1.0 GHz processor

- Microsoft Windows XP, Vista 32 bit, Windows 7
- Local Administrator Access
- 1 GByte of RAM or higher
- 125 MB of available hard-disk space
- Super VGA (1024 x 768) or higher resolution graphics card/monitor with 16 bit color
- USB 2.0 for use with CAN/USB gateway
- Access to E-mail for license registration

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Introduction

The electronic system contains of several parts, depending on how the machine is
equipped. Pictures on the next page show the major differences between the system of
the rollers. Certain options could also make differences in the systems, but those are not
considered here.
For location of the different units, please see instruction manual.

System Nod ID Unit

0,2 Control unit propulsion pump - CP
0,3 - When connected to CAN Open Master ECU - CA, CC, CP
0,12 Inclination Sensor - CA
0,16 Display - CA, CC, CP
1,3 - When connected to J1939 Master ECU - CP
0,8 I/O card - CA, CC, CP
0,9 Master ECU without Dynapac software - CA, CC, CP
0,22 DCO Controller - CA
0,24 Traffic light controller - CC
0,35 DCA - Compaction analyzer - CA
0,52 DCI - Compaction indicator - CA

- All systems consist of a master ECU, an I/O control card and a display. On the CP
rollers there are always two ECU´s, where one is handling the features of the machine
whilst the other one is handling most of the safety and propulsion functions. On the
CC rollers only one ECU is in control of all the machine functions.
- The ECU´s are run and controlled by software, which we in this manual will call
system application.
- There is also another software installed to the ECU, we will call it the parameter file in
this manual. The parameter file set the parameters critical to different markets,
different options, and different setups.
- Inside the FNR lever control box there is an I/O control board, which handles the
signals from switches and potentiometer movements. Also this I/O control board is
run by a specific software application.
- CC Machines equipped with traffic light exist in two versions. One version is
equipped with a traffic light controller (ECU), a specific software application is
installed to run that controller. The other version is a traditional type of installation,
with relays and traditional wiring.
- Be aware that the display of the machine is not accessable to program via the
software tool described in this manaul.

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Introduction

Fig. Both CC and CP Fig.

ECU revealed behind rear cover in Can Open and CAN J1939 connectors.
drivers platform. Note: Only CP have two connectors located here.

Fig.
Second CAN Bus
connector on CA

Fig.
Only CP

The propulsion pump ECU on the CP rollers

does, just as the ECU in the driver platform,
contain both a system application and parameter
file. On the CP rollers propulsion pump ECU the
system application is preinstalled from the
supplier of the pump, only the parameter file is
controlled by Dynapac. Fig. Only CP
ECU on the propulsion pump, uses J1939
connector for communication.

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Introduction

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How to connect

How to connect

1.

Fig. 1

1. For CC and CP, remove the cover (4 screws (1)), located on the right hand
side behind the drivers seat, to reveal the controller and the CAN Open and
CAN J1939 (J1939, only for CP) connector/s.
CA machines are slightly different, which have two seperate CAN Open
conntectors. One is located on the rear side of the FNR-lever control box
and the other one is located behind the small fuse box cover located on the
left hand side of the rear cover.
2. NOTE: On the CP rollers there are two connectors behind the rear cover,
one for each system, J1939 and CAN Open.
The connectors are tagged with J1939 or CAN Open
J1939 is used for communication with the hydraulic propulsion pump.
CAN Open is used for communication with the rest of the system i.e.
sprinkler, controls etc.

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How to connect

1.

Fig. 2

1. Connect the communication gateway cable to the 9-pin D-sub (1) for
whichever system intended to connect to, J1939 or CanOpen.
2. Connect the USB connector from the gateway cable to your PC.
3. If this is the first time the gateway cable is connected to the PC, you will
have to install required driver to make the gateway cable to run properly.
As soon as the gateway is connected to the PC the reqiured drivers to run
the gateway will be installed.
As soon as you insert the gateway USB connector to the PC, the
installation procedure starts. Follow the instructions on screen.
4. Turn on the ignition.

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How to connect

1.

2.

3.
4.

Fig. 3

1. Start Plus1 service tool

2. Click on "Communication" (1), chose "Gateway" (2), chose "CG150" (3)
and chose "Sauer-Danfoss CG150" (4). This is to make sure that the
correct communication interface is selected.

PWR, green solid light.

CAN, orange solid light.

Fig. 4
CANBus gateway P/N 4700792581

Make sure that gateway PWR LED have a solid green light and CAN LED have
a solid orange light when service tool is running.

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How to connect

1.

Fig. 5

1. Make sure that the "Connect"-symbol (1) is green.

2. Connection with the system is now established.
3. Click "File" and select "Scan System" or press F8 to scan the system.

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Download a system application file

Download a system application file

Before you start downloading a new system application file to the roller you should keep in mind
that changes/settings, other than factory default, that has been made to the software might get
lost when installning a new system application.
Changes might have been done to meet an operators demand in regards of propulsion
smothness, vibration properties e.t.c.
NOTE: If the ECU previously have been running with an application intended for another
machine type (eg. previously running with CP and now changed to CC) a certain function in the
diagnostic file have to be activated. The function is called "Set Default Values" and the procedure
is described by figure 16.

To proceed with the download process, continue at figure 6.

3.

1.

2.

Fig. 6

1. Connected to the system as per figure 1-5.

2. Start your Plus1 service tool.
3. If the "Confirm" (1) screen appears, chose "Yes" (2) to scan the system.
4. Otherwise press "F8" or "File" (3) and chose "Scan system" from the menu
to scan the system.

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Download a system application file

2.

1.

Fig. 7

The currently installed software version (1) will now show in the "Diagnostic
Window" (2).

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Download a system application file

1.

2.

Fig. 8

Press "Ctrl" + "D" or click "File" (1) and chose "File Download" (2), below
screen will appear.

1.

2.

Fig. 9

Highlight the row for the 0,3 / Controller Application (1) and click "OK" (2)
NOTE:
If a completely new master ECU is to be installed, the identification (Node ID) name
of the ECU will most likely not be 0,3, as shown in above picture, but instead 0,9. The
identification name of the ECU can therefore also be used as a checkup, to
determine whether the download was successful or not. If a new master ECU still,
after having downloaded a new system application file, hold the same identification
name 0,9. The download was most likely not successful or not accepted by the ECU.

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Download a system application file

1.

2.

Fig. 10

1. Browse for the correct system application file, corresponding to the

machine model.
2. Select/highlight the correct system application file (1).
3. Click "Open" (2)

1.

Fig. 11

When/if this warning screen appears, always chose "Auto Fix" (1).

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Download a system application file

1.

Fig. 12

1. Click "Start Download" (1)

NOTE: You may be forced to enter a system application confirmation code,
a kind of password, to proceed.
Enter the correct system application code and press "Enter" to
continue.
For CC rollers the code is “CC”, for CP rollers the code is
“CP224 274” and for CA rollers the code is "CA".
2. Download starts.

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Download a system application file

Fig. 13

NOTE: During download, make sure not to disconnect powersupply!

When download is completed there will be an automatic scan of the system.

Done, system application file is downloaded.
NOTE: DO NOT TURN OFF IGNITION!

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Download a system application file

1.

Fig. 14

If the new downloaded system application have added or deleted any parameters,
a diaglog box will appear on screen. This dialog box display which parameters
now are added to or deleted from the system.
In this example there was four new parameters added to the system.

1. Click "OK" (1) to continue.

1.

Fig. 15

When/if, this dialog box appears, click "Cancel" (1).

The reason for this dialog box to show is depending on how the previously connected
system was configured e.g. which units were present in that system. If your current
system does not hold the same configuration this dialog box will show, however
always select "Cancel".

When download is completed there will be an automatic scan of the system.

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Download a system application file

2.

3.

1.

Fig. 16

To set the default parameters of the installed application, select the matching machine
type diagnostic file and choose "D. Set Default Values" (1). This procedure is only
applicable to CP- and CC roller applications. For CA roller applications see page 20.

- Each grey box concern a specific number of parameters, which ae

explained next to it.
- Press "Upload parameters from ECU" (2). The upload will uncheck all
grey boxes.
- Enter digit "1" in the boxes where it is desired to set default values,
press "Enter"-key. By pressing "Enter"-key, the box will be checked. In
cases were there have been a change in application type (from CC to
CP or vice versa) all grey boxes shall be entered with a "1".
- When all boxes have been checked and "1" is entered, press "Download
parameters to ECU" (3). Default parameters will now be written to the
ECU.
- Press "Upload parameters from ECU" (2).

When finished, wait at least 30 seconds until you turn off ignition to make sure
that the ECU memory has saved all new data.

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Parameter file - Master ECU for CC, CA and CP

Parameter file - Master ECU for CC, CA

and CP

To download a parameter file to the master ECU, follow the steps in figure 16-20 and 21.
Figure 21 is only for CA machines.

1.

Fig. 17

1. Make sure you are connected to the ECU / controller as per fig. 1-6 in previous
chapters.
2. Click "Download File To ECU" (1).

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Parameter file - Master ECU for CC, CA and CP

1.

2.

Fig. 18

1. Highlight "Read Only Parameter" row (1).

2. Click "OK" (2). A new window appear.
It is highly important that the correct/intended parameter file is installed.

1.

Fig. 19

1. Browse the parameter file intended for the ECU / controller, select and click
"Open" (1).

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Parameter file - Master ECU for CC, CA and CP

1.

Fig. 20

1. Click "Start Download" (1).

Fig. 21

NOTE: When download starts, make sure not to disconnect powersupply.

When download is completed the system will make an automatic scan of

the system.
Parameter file is now downloaded / installled.

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Parameter file - Master ECU for CC, CA and CP

1.

2.

Fig. 22

NOTE: For CA machines only!!!

When a parameter file for CA machines have been installed, you will have to
use a function in the diagnostic file called "I. Initiate All New Parameters" (1)
and then press the button "Initiate All New Parameters" (2) . This have to be
done in order to activate all the new parameters from the installed parameter
file!

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Download Parameter Files - For CP rollers

Download Parameter Files - For CP

rollers

On the CP rollers the propulsion pump is controlled by an additional ECU, other than
the master ECU. This ECU contain a software system application and four different
parameter files. Those parameter files, XLM files, have to be installed to and
activated in the propulsion pump ECU in order to make the pump run correct and
correspond to specifications of different markets. Make sure to be connected to CAN
J1939 to be able to communicate with the propulsion pump ECU.

2.

1.

Fig. 23

-Open the diagnostic file intended for the CP-rollers.

-Select "Parameter/Costumer Settings" (1) as in above picture.
-Click "Import Values From A Data Parameter File" (2)
- A new window appear, browse the Costumer Settings XML-file given to you for this
specific machine. Click "OK".

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Download Parameter Files - For CP rollers

1.

Fig. 24

-The values from the Costumer Settings XML-file are now ready to be downloaded to
the system. Click "Download Parameters To ECU" (1).

2.

1.

Fig. 25

-Select "Parameter/Costumer Calibration" (1) as in above picture.

-Click "Import Values From A Data Parameter File" (2)
- A new window appear, browse the Costumer Calibration XML-file given to you for
this specific machine. Click "OK".

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Download Parameter Files - For CP rollers

1.

Fig. 26

-The values from the Costumer Calibration XML-file are now ready to be downloaded
to the system. Click "Download Parameters To ECU" (1).

2.

1.
Fig. 27

-Select "Factory Parameter/Pump Settings" (1) as in above picture.

-Click "Import Values From A Data Parameter File" (2)
- A new window appear, browse the Pump Settings XML-file given to you for this
specific machine. Click "OK".

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Download Parameter Files - For CP rollers

1.

Fig. 28

-The values from the Pump Settings XML-file are now ready to be downloaded to the
system. Click "Download Parameters To ECU" (1).

2.

1.
Fig. 29

-Select "Factory Parameter/Pump Calibration" (1) as in above picture.

-Click "Import Values From A Data Parameter File" (2)
- A new window appear, browse the Pump Calibration XML-file given to you for this
specific machine.

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Download Parameter Files - For CP rollers

1.

Fig. 30

-The values from the Pump Calibration XML-file are now ready to be downloaded to
the system. Click "Download Parameters To ECU" (1).

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Download Parameter Files - For CP rollers

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Calibration - FNR lever

Calibration - FNR lever

Calibration of the FNR-lever potentiometer for
CA1500-6500
and CC224-624

Calibration Instruction

To calibrate the joystick, ignition has to be switched on and the diesel engine shall not be started,
calibration is not allowed with the diesel engine running and calibration menu will not be
accessible.

1.

Fig. 31

Press twice on the button below the tool image (1) to go to Main Menu.

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Calibration - FNR lever

1.

2.

Fig. 32

From Main Menu , choose Service. Use arrow down (1) and press Enter (2).

1.

Fig. 33

From Service Menu, choose Adjustment. Press Enter (1).

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Calibration - FNR lever

1.

2.

Fig. 34

From Adjustments, choose Calibration. Use arrow down (1) and press Enter (2).

Fig. 35

Enter Pin Code appears in the display.

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Calibration - FNR lever

Fig. 36

Enter the Pin Code, supplied by Dynapac Service, on the keypad to continue.
There is no display feedback from the keypad when pressing the digits.

It is important that the PIN Code is used only by Dynapac Service

Personal.

1.

Fig. 37

When the correct Pin Code is entered, following menu appears.

Choose EDC Calibration, press Enter (1).

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Calibration - FNR lever

Use these two buttons at the

same time to confirm value

Fig. 38

EDC Calibration appears. Calibration mode is now active.

- Push joystick maximum forward to calibrate new values. It is normal that the
two last digits in each box (F, N, R, H, L) is fluctuating, pay no attention to this.
- When joystick is in max forward position, push the two black buttons on
joystick at the same time for two seconds.
- When buttons are released the calibrated value will be shown in the
F(forward) square and calibration will jump to N(neutral).
- If buttons is not pushed for two seconds the calibration stays in forward
calibration and you have to make a new try.
- Neutral and Reverse is calibrated in the same way. Support the joystick with
one hand when you are calibrating neutral and reverse, if not the values can be
incorrect.
- When this is done the calibration will continue down a row to calibrate
potentiometer for speed limit. Calibration starts with H (Max) position, turn the
potentiometer to max right position and push the black joystick buttons for 2
seconds.
- Repeat the same procedure with L (Min) position.

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Calibration - FNR lever

1.

2.

Fig. 39

Now the calibration is done and the values will be shown in the display.
Press Save (1) and your new calibration will be active. Return to Main Menu by
using backstep (2) button.

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Calibration of throttle and brake pedal on CP rollers

Calibration of throttle and brake pedal

on CP rollers

To calibrate the throttle pedal you have to enter calibration mode for the system. It
might be that you already are in calibration mode when you enter the system. This is
determined by looking at what is displayed by the “Throttle Pedal Status” parameter.
Chose "Parameter Functions / Throttle Pedal" in the diagnostic navigator window and
look for the parameter called "Throttle Pedal Status" in the logging screen (to the
right). If the parameter status is "Press Pedal", the system is in calibration mode.

Fig. 40

-If the parameter "Throttle Pedal Status" already is displayed as "Press Pedal", go to
fig. 42, otherwise follow instruction in fig. 41 to set the system in calibration mode.

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Calibration of throttle and brake pedal on CP rollers

1.

2.

Fig. 41

-To enter calibration mode, enter "1" in the parameter box for "Calibrate Throttle
Pedal" (1) by using the digit on the numpad of your PC and press enter key.
-Press "Download Parameter To ECU" (2).
-The parameter "Throttle Pedal Status" should now be displayed as "Press Pedal".

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Calibration of throttle and brake pedal on CP rollers

1.

Fig. 42

When in calibration mode.

-Press the throttle pedal as far down as possible and hold until the parameter
"Throttle Pedal Status" (1) changes status to "Release Pedal".

1.

Fig. 43

When the pedal is released and the calibration is accepted by the system the
parameter "Throttle Pedal Status" (1) will change text to "Calibrated" and the color
will change to green.

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Calibration of throttle and brake pedal on CP rollers

Proceed and repeat the same procedure to calibrate the brake pedal.

To calibrate the brake pedal you have to enter calibration mode for the system. It
might be that you already are in calibration mode when you enter the system. This is
determined by looking at what is displayed by the “Brake Pedal Status” parameter.
Chose "Parameter Functions / Brake Pedal" in the diagnostic navigator window and
look for the parameter called "Brake Pedal Status" in the logging screen (to the right).
If the parameter status is "Press Pedal", the system is in calibration mode.

Fig. 44

-If the parameter "Brake Pedal Status" already is displayed as "Press Pedal", go to
fig. 46, otherwise follow instruction in fig. 45

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Calibration of throttle and brake pedal on CP rollers

1.

2.

Fig. 45

-To enter calibration mode, enter "1" in the parameter box for "Calibrate Brake Pedal"
(1) by using number one digit on the numpad of your PC and then press enter key.
-Press "Download Parameter To ECU" (2).
-The parameter "Brake Pedal Status" should now be displayed as "Press Pedal".

1.

Fig. 46

When in calibration mode.

-Press the brake pedal as far down as possible and hold until the parameter "Brake
Pedal Status" (1) changes status to "Release Pedal".

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Calibration of throttle and brake pedal on CP rollers

1.

Fig. 47

When the pedal is released and the calibration is accepted by the system the
parameter "Brake Pedal Status" (1) will change text to "Calibrated" and the color will
change to green.
Done!

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Download a control board application

Download a control board application

Fig.
Control board location.

To download a control board application, follow the steps in figure 47-50.

1.

Fig. 48

1. Make sure you are connected to the ECU / controller as per fig. 1-6 from the
first chapters.
2. Click "Download File To ECU" (1).

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Download a control board application

2.
1.

Fig. 49

1. Select the "Controller Application" (1) row for ECU 0,8. (ECU 0,8 is the
control board inside of the forward and reverse control box).
2. Click "OK" (2). A new window appears.
3. Browse the system application file intended for the control board and
machine model, select and click "Open".

1.

Fig. 50

1. Click "Start Download" (1).

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Download a control board application

Fig. 51

When download is completed there will be an automatic scan of the system.

Control board application is now downloaded / installed.

NOTE: When download starts, make sure not to disconnect powersupply.

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Download a control board application

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Download a traffic light controller application

Download a traffic light controller

application

Fig.
Traffic light ECU location.

Traffic light controller is only used on CC rollers manufactured during 2007-2009 and
to some extension 2010.

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Download a traffic light controller application

To download a traffic light controller application, follow the steps in figure

51-54.

1.

Fig. 52

1. Make sure you are connected to the system as per fig. 1-6, from the first
chapter.
2. Click "Download File To ECU" (1).

2.
1.

Fig. 53

1. Select the "Controller Application" (1) row for ECU 0,24. (ECU 0,24 is the traffic
light controller)
2. Click "OK" (2). A new window appears.
3. Browse the system application file intended for the traffic light controller, select
and and click "Open".

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Download a traffic light controller application

1.

Fig. 54

1. Click "Start Download" (1).

Fig. 55

When download is completed there will be an automatic scan of the system.

Traffic light controller application is downloaded.

NOTE: When download starts, make sure not to disconnect powersupply.

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Download a traffic light controller application

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Use the diagnostic file

Use the diagnostic file

How to navigate in the diagnostic file

3.

1.

2.

Fig. 56
Diagnostic file layout

1. Diagnostic Navigator window. This is where you chose which function you would
like to monitor.
2. Monitoring window. This window display actions and monitor the selected function.
3. Diagnostic Navigator Window button. A useful function to hide and unhide the
navigator window. It allows you to view a bigger monitoring window.

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Use the diagnostic file

1.

Fig. 57
Navigate in the diagnostic file

Select 1. FNR and Keypad test (1) and the window in picture 58 will appear.

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Use the diagnostic file

1.

2.

Fig. 58
FNR and Keypad testing screen.

-In this picture the Diagostic Navigator button (1) has been activated in order to have
a bigger monitoring window available.
-To run the monitoring you have to make sure that the logging is active, press "Play"
(2). (in some versions of the service tool "Play" is activated automatically.)
-Run the test by pressing corresponding switches, moving controls forth and back to
make sure of functionality.

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Use the diagnostic file

1.

Fig. 59
Navigate in the diagnostic file

Depending on which function you have chosen, the layout is a bit different. In this
example "Start Diesel Engine" (1) is to be chosen.

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Use the diagnostic file

Fig. 60
Start Diesel Engine - Schematic layout

In this monitoring screen logging of all parameters and signals significant for starting
the diesel engine is available.

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Use the diagnostic file

1.

Fig. 61
Navigate in the diagnostic file

Select "Start Diesel Engine Flow" (1) and the screen in fig. 62 will appear.

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Use the diagnostic file

Fig. 62
Start Diesel Engine - Flowchart layout

When having chosen one of the flow chart layouts it will explain the criteras needed
to fullfill the action, in this case to start the engine, and also shows the flow of signals
which will then make it easier to find out what is missing if an event do not occur.

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Use the diagnostic file

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Error codes and symbols (Only CA)

Error codes and symbols (Only CA)

Describtion Display Display Symbols Buzzer Yellow Red Alarm Comment

Status Pop-up LED LED list
Clogged air X X X X
filter /
Warning
Clogged X X X X
hydraulic
filter /
Warning
Diesel engine X X X X
low oil
pressure /
Warning
High diesel X X X X X Warning
enigne based on
temperature coolant
temperature
High X X X X X
hydraulic fluid
temperature /
Warning
No charging X X X X

Low fuel level X X X X Yellow

/ Warning LED for 2
min
Diesel engine X X X X
stop lamp
Diesel enigne X X X
warning lamp
Low coolant X X (X) (X) (X) X Red and
level buzzer or
yellow
depening
om
serverity
from
diesel
eninge
Water in fuel X X (X) (X) (X) X Red and
/ Warning buzzer or
yellow
depening
om
serverity
from
diesel
eninge

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Error codes and symbols (Only CA)

Describtion Display Display Symbols Buzzer Yellow Red Alarm Comment

Status Pop-up LED LED list
Dynapac X X
SubSystem /
Warning
(DSS)

(X) = Stage 3B / Tier 4 diesel engines

Dynapac SubSystem Error codes (DSS)

DSS Code Description Note

1 Speedsensor front Option (TC)
2 Speedsensor rear (AVC, TC)
3 Inclination sensor Option
4 DCM Option
5 IO-Card
6 Cooling fan speed sensor
7 Vibration frequency meter Option, supervision only active if
adjustable frequency or ECO is available
8 Power group 1
9 Power group 2
10 Power group 3
11 Power group 4

Dynapac SubSystem Error codes (DFC)

DFC Code Description

00 Data availabel but above normal operating range (most severe)
01 Data availabel but below normal operating range (most severe)
02 Data erratic, intermittent or incorrect
03 Voltage above normal
04 Voltage below normal
05 Current below normal
06 Current above normal
07 Mechanical system not responding properly
08 Abnormal frequency, pluse or width period

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Error codes and symbols (Only CA)

DFC Code Description

09 Abnormal update rate
10 Abnormal rate of change
11 Failure mode not identifiable
12 Bad device or component
13 Out of calibration
14 Special instruction
15 Data valid but above normal operating range (least servere)
16 Data valid but above normal operating range (moderate servere)
17 Data valid but below normal operating range (least servere)
18 Data valid but below normal operating range (moderate servere)
19 Recived network data in error
20 Data drifted high

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Dynapac Compaction Equipment AB
Box 504, SE-371 23 Karlskrona, Sweden
Dynapac Compaction Equipment AB
Box 504, SE-371 23 Karlskrona, Sweden