When a problem is experienced, first look at the setting/message display. Inspect the display in order to determine if the problem is self-diagnosed. If the display has a fault or an error message, refer to "Diagnostic Messages and Troubleshooting Flowcharts". If no message appears, consult the list below for the symptom.
No electrical power
- Check the wiring, the connectors and the circuit breaker in the control's power lines. Check for breaks or openings.
- Replace the operator console.
No cylinder movement
- Check the settings for the propel control's handle and the maximum pave speed knob. In order to obtain the sufficient motion that trips the motion switch, both settings must be greater than 50%.
- Check the time delay relay in the junction box.
- Check for hydraulic pressure with a gauge or by moving the manual operator on the valves.
- Check in order to determine that any locking pins in the rams are removed.
- Replace the operator console.
The machine cycles up and down.
- Adjust the sensitivity lower.
- Lower the adjustment of the valve step. Use the dealer's access in order to make the adjustment.
- Check for the proper orifice in the hydraulic supply.
- Replace the control valve.
The control for the ram is sluggish.
- Check for adequate hydraulic pressure or check for a restricted orifice. Check by actuating the toggle switch with the control in MANUAL, or check by actuating the valve's manual operator.
- Adjust the sensitivity higher.
- Raise the adjustment of the valve step. Use the dealer's access in order to adjust the valve step.
- Replace the control valve.
The control will not hold the grade.
- Move the grade sensor closer to the auger.
- Check for adequate hydraulic pressure with a gauge.
- Raise the adjustment of the valve step. Use the dealer's access in order to adjust the valve step.
- Lower the adjustment of the sensor's error deadband for the sonic sensor.
- Set the auto/manual switch to the AUTO mode. Simultaneously, observe the setting/message display and move the sensor's position in order to check for a sensor's malfunction.
- Replace the operator console.
The screed's position does not match the display.
- Use the sensor's sequence for setup in order to recalibrate the sensors with the display.
- Set the auto/manual switch to the AUTO mode. Simultaneously, observe the setting/message display and move the sensor's position in order to check for a sensor's malfunction.
The sonic sensor's error light is on.
- Adjust the sensor's elevation in order to obtain the proper height for operation. A proper working height is
355.6 ± 12.7 mm (14 ± 0.5 inch) from the target surface. - Replace the transducer element in the sonic sensor.
- Replace the sonic sensor.
- Check the cable and the cable connections.
The grade control quickly extends the tow point's cylinder. The tow point's cylinder is extended to the lowest position.
- The thickness of the material that is under the screed's plate is too thin. The aggregate in the mix will not allow the screed to lower to the desired grade. The only solution is increasing the mat's depth.
- The endgates of the extensions are stuck. The endgates cannot move freely upward and the endgatescannot move freely downward. The endgate will then carry that side of the screed and the towpoint will not be able to lower the screed.
Replacement of the Control Console
A control console may be moved from one side of the screed to the other side of the screed. After the control console has been relocated, fasten the bolts and the harness connector in accordance to the original setup. After the paver is powered up, the control console will prompt the operator to reset the configurations' variables. Push the setup switch on the relocated control console in order to recover the original values for the new location.
Note: Verify that both bolts of the cable connector are present and that the bolts are in good condition during the replacement. Tighten the bolts to
Note: During the replacement of a control console with a new control console, pay attention to the software version. The left control console must always have the newer software version in order to have communication between the two control consoles.
Diagnostic Messages and Troubleshooting Flowcharts
The control console can recognize many of the faults or errors which may potentially occur in the sensors, valves, operator's console or wiring. The control console will report the condition to one or both displays. The control console will sound the alarm and may shut down the control if a fault in the paver's operation is possible.
When the control operates in "auto" mode, a fault may inhibit valve's driving. When the control operates in "manual" mode, a fault will not inhibit the driving of the valve. Faults will be cleared when the cause is repaired or eliminated.
Errors result from internal problems within the control console. The errors will prevent the operation of the control console. In order to test for a continuous error, turn off the power to the control console and then turn on the power to the control console. If the error persists, replace the operator console.
Following is a series of fault messages that can be displayed by the setting/message display. A troubleshooting flowchart for each fault is provided to the operator. For faults which do not turn off the valve drive, the displayed fault message alternates with the normal operating information.
Note: Some messages are more than eight characters in length and the messages are too big for the screen. Scroll across the screen in order to read the entire message.
"FAULT: NETWORK RIGHT CONTROLLER"
Note: This fault occurs when the controllers can no longer communicate with each other due to a problem with the wiring, a sensor or a controller.
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| Illustration 1 | g00946926 |
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Troubleshooting flowchart for the "NETWORK RIGHT CONTROLLER" fault message | |
"FAULT: NETWORK LEFT CONTROLLER"
Note: This fault occurs when the controllers can no longer communicate with each other due to a problem with the wiring, a sensor or a controller.
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| Illustration 2 | g00947212 |
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Troubleshooting flowchart for the "NETWORK LEFT CONTROLLER" fault message | |
Note: This fault occurs in "auto" mode, when a grade or a slope sensor has exceeded the limit that is set for the sensor. This could be caused by a misaligned sensor or the set value in the controller adjusted too low.
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| Illustration 3 | g00947183 |
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Troubleshooting flowchart for the "CONTROL OUT OF RANGE" fault message | |
Note: This fault normally occurs when a sonic sensor is out of the working range, or the sonic sensor is faulty.
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| Illustration 4 | g00946729 |
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Troubleshooting flowchart for the "SENSOR ERROR" fault message | |
This fault appears in both "auto" and "manual" modes.
Note: This problem is usually caused by a short between a wire harness and the positive terminal of the battery, or the problem is caused by a short between the sensor and the positive terminal of the battery.
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| Illustration 5 | g00946474 |
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Troubleshooting flowchart for the "SENSOR POWER HIGH" fault message | |
Note: This fault occurs whenever pin 22, pin 23, or pin 24 is pulled under 4.6 Volts of direct current. The normal value is 5 volts of direct current. Pin 22, pin 23, and pin 24 are located on the rear of the controller. This fault is normally caused by a shorted battery, a shorted sensor ground, or a shorted machine frame. The fault can also be caused by a faulty sensor.
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| Illustration 6 | g00946676 |
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Troubleshooting flowchart for the "SENSOR POWER LOW" fault message | |
Note: This fault is normally caused by a sensor that is adjusted to the far limit of the working range or by a problem in the wire harness.
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| Illustration 7 | g00946041 |
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Troubleshooting flowchart for the "SENSOR HIGH" fault message | |
Note: This fault is normally caused by a sensor that is adjusted to the far limit of the working range or by a problem in the wire harness. This fault appears in the "auto" mode.
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| Illustration 8 | g00946041 |
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Troubleshooting flowchart for the "SENSOR LOW" fault message | |
"FAULT: RAISE VALVE SHORTED HI"
This fault occurs in both "auto"mode and "manual" mode, but the fault only occurs when the valve is not driven by the controller.
Note: This fault is usually caused by a short between the wire harness and the positive terminal of the battery. This is generally accompanied by the raise valve going to FULL ON position.
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| Illustration 9 | g00947263 |
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Troubleshooting flowchart for the "RAISE VALVE SHORTED HI" fault message | |
"FAULT: RAISE VALVE SHORTED LO"
The fault occurs in both "auto" and "manual", but the fault only occurs when the controller is driving the valves.
Note: This fault is usually caused by a short in the wire harness to ground. This is generally accompanied by the fact that theraise valve will not function.
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| Illustration 10 | g00947307 |
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Troubleshooting flowchart for the "RAISE VALVE SHORTED LO" fault message | |
"FAULT: LOWER VALVE SHORTED HI"
The fault occurs in both "auto" mode and "manual"mode, but the fault only occurs when the valve is not driven by the controller.
Note: This fault is usually caused by a short between the wire harness and the positive terminal of the battery. This is generally accompanied by the fact that the raise valve goes to FULL ON position.
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| Illustration 11 | g00947317 |
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Troubleshooting flowchart for the "LOWER VALVE SHORTED HI" fault message | |
"FAULT: LOWER VALVE SHORTED LO"
The fault occurs in both "auto" mode and "manual" mode, but the fault only occurs when the controller drives the valves.
Note: This fault is usually caused by a short between the wire harness and the ground. This is generally accompanied by the fact that the raise valve will not function.
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| Illustration 12 | g00947327 |
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Troubleshooting flowchart for the "LOWER VALVE SHORTED LO" fault message | |
Note: This problem is caused by a low supply voltage from the battery. Low supply voltage occurs when the voltage drops below 16.5 Volts of direct current. The problem is normally due to a fault in the machine's charging system.
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| Illustration 13 | g00947328 |
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Troubleshooting flowchart for the "BATTERY LOW" fault message | |
Note: This problem is caused by a high supply voltage from the battery. High supply voltage occurs when the voltage rises above 32 Volts of direct current. This is normally due to a fault in the machine's charging system.
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| Illustration 14 | g00947459 |
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Troubleshooting flowchart for the "BATTERY HIGH" fault message | |
Note: This problem is caused by a very high supply voltage from the battery. A very high supply voltage occurs when the voltage rises above 35 Volts of direct current. This is normally due to a fault in the machine's charging system. This problem could lead to serious damage to the machine's components if the problem is not corrected promptly.
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| Illustration 15 | g00947467 |
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Troubleshooting flowchart for the "BATTERY VERY HIGH" fault message | |
Note: This fault occurs when the controllers can no longer communicate with each other due to a problem with the wiring, or a controller.
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| Illustration 16 | g00947475 |
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Troubleshooting flowchart for the "ADDRESS" fault message | |
Note: This fault occurs when the controllers can no longer communicate with each other due to a problem with the software or the controller.
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| Illustration 17 | g00947555 |
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Troubleshooting flowchart for the "DFLT CHECKSUM" fault message | |
Auto Grade Control System's Ladder Diagrams
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| Illustration 18 | g00949924 |
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| Illustration 19 | g00950092 |
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| Illustration 20 | g00950093 |