924K, 930K, 938K, 950G II, 950H, 950K, 950L, 950M, 950M Z, 962G II, 962H, 962K, 962L, 962M, 962M Z, 966G II, 966H, 966K, 966L, 966M, 966M XE, 972G II, 972H, 972K, 972L, 972M, 972M XE, 980G II, 980H, 980K, 980L, 980M and 982M Wheel Loaders Automatic L Caterpillar

Automatic Lubrication System Troubleshooting

Usage:

972M A8P

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Table 1
Error Codes
Error Code	Cause	Solution
SPN 5521 FMI 11	Error code not used	Error code not used
SPN 5522 FMI 7	The pressure switch did not close during a greasing cycle in primary line-A. Possible causes (A) Broken/damaged primary line-A (B) Metering unit causes internal bypass (C) Air trapped in pump and or primary line-A	(A) Check condition of primary lines and connectors. Replace or repair when necessary (B) Refer to Testing and Adjusting, "Electrical System - Test" "Check for an Internal System Leak." (C1) Refill reservoir until reservoir is bled. See Testing and Adjusting, "Automatic Lubrication System - Adjust". (C2) Purge the pump and primary lines. See Testing and Adjusting, "Automatic Lubrication System - Adjust".
SPN 5523 FMI 7	The pressure switch did not close during a greasing cycle in primary line-B. Possible causes (A) Broken/damaged primary line-B (B) Metering unit causes internal by pass. (C) Air trapped into pump and or primary line-B.	(A) Check condition of primary lines and connectors. Replace or repair when necessary (B) Refer to Testing and Adjusting, "Electrical System - Test" "Check for an Internal System Leak.". (C1) Refill reservoir until reservoir is bled. See Testing and Adjusting, "Automatic Lubrication System - Adjust" (C2) Purge the pump and primary lines. See Testing and Adjusting, "Automatic Lubrication System - Adjust"
SPN 5524 FMI 7	The pressure switch was still closed at the outset of a cycle in primary line-A Possible causes (A) Damaged pressure switch wiring harness to where wires are joined (B) 5/2-way valve did not operate correctly (C) Pressure switch failed/broken	(A) Check wiring and connectors. Replace or repair when necessary (B) Check 5/2-way valve, see Testing and Adjusting, "Electrical System - Test" "Check for the Pump and the 5/2 Magnetic Valve", and operate manually with the use of PC-GINA. Replace or repair when necessary (C) Check and or replace pressure switch (valve)
SPN 5525 FMI 7	The pressure switch was still closed at the outset of a cycle in primary line-B Possible causes (A) Interrupted pressure switch wiring harness to where wires are joined (B) 5/2-way valve did not operate correctly (C) Pressure switch failed/broken	(A) Check wiring and connectors. Replace or repair when necessary (B) Check 5/2-way valve, see Testing and Adjusting, "Electrical System - Test" "Check for the Pump and the 5/2 Magnetic Valve", and operate manually with the use of PC-GINA. Replace or repair when necessary (C) Check and or replace pressure switch (valve).
SPN 5519 FMI 18	Cycles that have not been performed, due to grease reservoir running empty and disabling the pump, caused by: (A) Max. number of cycles with an activated low-level switch exceeded (with pump low-level stop activation). (B) A combination of an activated low-level switch and initial "no pressure line-A or -B" error, indicating the pump ran out of grease.	(A) Refill the reservoir. See Testing and Adjusting, "Automatic Lubrication System - Adjust" (A) Refill the reservoir. See Testing and Adjusting, "Automatic Lubrication System - Adjust"
SPN 3597 FMI 4	Aborted cycles, control unit encountered successive power dips in attempt to initiate pump motor, caused by: (A) Faulty battery (vehicle) (B) Faulty wiring (ground wire) (C) Corroded pin-contact in connector	(A) Charge or replace battery (B) Check wiring. Replace or repair when necessary (C) Check connections and replace or repair when necessary.
SPN 5526 FMI 11	Pressure switch did not close during greasing cycle in primary line-A or -B while control unit noticed deviant resistance over the pressure switch circuit. Caused by: (A) Faulty wiring or connectors (B) Defective pressure switch	(A) Check wiring/connectors. Replace or repair when necessary. (B) Replace pressure switch.
SPN 5527 FMI 5	Control unit detected too low current draw to pump motor, in combination with initial "no pressure line- A or B" error, caused by: (A) Interrupted wiring (B) Defective motor (C) Defective control unit.	(A) Check wiring. Replace or repair when necessary (B) Check motor for faulty wiring, check the resistance of the motor. Replace when necessary (C) Check control unit. Replace or repair when necessary
SPN 5527 FMI 6	Control unit detected too high current draw to pump motor and aborted the attempted cycle. Caused by: (A) Short circuit in wiring of motor (B) Short circuit in motor. (C) Drive shaft blocked (D) Extreme low working temperature in combination with a grease not suitable for conditions. (E) The "pump motor current limit" setting not suitable for the low working temperature	(A) Check the wiring of motor. Replace or repair when necessary. (B) Check motor for faulty wiring, check the resistance of the motor. Replace when necessary (C) Check the drive shaft. Replace or repair when necessary. (D) Replace the grease in the reservoir and purge the system with a suitable grease for the working conditions. (E) Increase the "pump motor current limit" parameter setting but only after checking whether the vehicle wiring and fuse can handle a higher setting
SPN 5528 FMI 5	Control unit detected too low current draw to first coil of the 5/2- way valve. This error was detected in combination with initial "system on pressure before cycle" error. Caused by: (A) Interrupted wiring of the coil (B) Defective coil	(A) Check wiring. Replace or repair when necessary. (B) Check for faulty wiring on coil, check the resistance of the coil. Replace or repair when necessary
SPN 5528 FMI 6	Control unit detected too high current draw to 5/2-way valve in combination with initial "system on pressure before cycle" error. Caused by: (A) Short circuit in wiring of the coil (B) Defective coil	(A) Check wiring. Replace or repair when necessary (B) Check for faulty wiring on coil, check the resistance of the coil. Replace or repair when necessary
SPN 5529 FMI 5	Control unit detected too low current draw to first coil of the 5/2-way valve in combination with initial "system on pressure before cycle" error. Caused by: (A) Interrupted wiring of the coil (B) Defective coil	(A) Check wiring. Replace or repair when necessary. (B) Check for faulty wiring on coil, check the resistance of the coil. Replace or repair when necessary.
SPN 5529 FMI 6	Control unit detected a too high current draw to 5/2-way valve in combination with initial "system on pressure before cycle" error, caused by: (A) Short circuit in wiring of the coil (B) Defective coil	(A) Check wiring. Replace or repair when necessary. (B) Check for faulty wiring on coil, check the resistance of the coil. Replace or repair when necessary.
SPN 5530 FMI 11	Error code currently not used	Error code currently not used
SPN 628 FMI 12	Control unit encountered corrupted parameters during power up and restored the production default settings.	Replace control unit
SPN 5531 FMI 4	Real-time clock battery low (2.2 V) at the control unit.	Replace control unit
SPN 629 FMI 12	Control unit encountered a corrupted real-time clock causing the events and errors to be stored with in accurate time & dates caused by: a. RTC battery empty	a. Replace control unit.

Problem 1

The pump will stop pumping when the number of successive errors are exceeded. The standard is ten times but can be changed.

Probable cause

The pump turned off because the pressure switch did not turn on during a sequence of successive cycles.

Note: The pump is looking at the change of signal of the pressure switch. The pump is not looking at the switch status.

Solution

The switch for the grease pressure did not turn on due to one of the following reasons:

The primary grease line contains a leak.
1. External problem to check
  (i) Broken primary grease line "(A or B)"
  (ii) An O-ring is damaged or missing causing a leak at one of the following:
  - The metering unit
  - The switch for the grease pressure
  - The blind plug
2. Internal problem to check
  (i) There is an internal leak in the metering unit or in the switch for the grease pressure.
Air is in the system. Automatic Lubrication System Air - Purge, "Purging the Lubrication Lines for the Automatic Lubrication System"
There is a wiring defect between the pressure switch and the pump.
The pressure switch is broken. Electrical System - Test, "Check for the Lube Pressure Switch"
The 5/2 solenoid valve is broken. Electrical System - Test, "Check for the Pump and the 5/2 Magnetic Valve". If a fault is found in either the pressure switch or the solenoid valve, replace the entire pump.
The viscosity of the grease is wrong or the surrounding temperature is too low.

Problem 2

There is no lubricant at the grease points and no reports regarding malfunctions have been given.

Probable cause

Problem with the voltage supply for the pump
There is a problem with supply to pin (3) on the pump control or with the "Command Signal Inverted (CSI)" setting.
1. Information for operator
  - Pin (3) on the autolube pump is supplying the command signal to the pump.
  - The operator has a "Command Signal Inverted (CSI)" setting which can be modified with the TWIN GINA software.
  - The pump control has an interval timer. The interval timer counts down to the next grease interval:
  - - Pin (3) is powered and "CSI" setting equals "0 or NO".
  - - Pin (3) is not powered and "CSI" setting equals 1 or YES.
  - The "Command Signal Inverted (CSI)" setting equals Yes or 1 for Articulated Truck because pin (3) is not powered.
  - The "Command Signal Inverted (CSI)" setting equals NO or 0 for the Medium Wheel Loaders because pin (3) is powered.
Installed new pump
- The "Command Signal Inverted (CSI)" setting equals No or 0 for Medium Wheel Loader.
- The "Command Signal Inverted (CSI)" setting equals Yes or 1 for Articulated Truck.

Solution

Check if supply voltage does not drop immediately after the start of the grease interval. Voltage drop could be related to voltage drops over cables, connections, or low battery voltage.
Check the "Command Signal Inverted (CSI)" setting to verify the setting. If the setting is in error, change the setting.
- The "Command Signal Inverted (CSI)" setting equals NO or 0 for Medium Wheel Loader.
- The "Command Signal Inverted (CSI)" setting equals Yes or 1 for Articulated Truck.
Same as the previous point

Problem 3

There is insufficient lubricant at all grease points and no reports regarding malfunctions have been given.

Probable Cause

The grease interval is too long.

Solution

Switch the mode of the cycle to "HEAVY DUTY" or adjust cycle times through the TWIN GINA software.
Shorten the preset grease intervals behind the modes with the diagnostic tool.

Problem 4

There is too much lubricant at the grease points.

All grease points contain an excessive amount of grease.

Probable Cause

The grease interval is too short.

Solution

Change the mode of the cycle to "LIGHT DUTY".
Lengthen the preset grease intervals behind the duty modes with the diagnostic tool.

Problem 5

No supply of grease to some points

One or more greasing points contain no grease while the other points receive sufficient grease.

Probable Cause

One or more greasing points or lines were not filled with grease previously.
The secondary grease lines are broken or the lines are squeezed.
The output of grease for the metering unit is too low.
A metering unit has malfunctioned.

Solution

Disconnect the secondary grease line and fill the grease points manually.
Check the affected secondary grease line. Replace the line, if necessary.
Mount the metering unit with a larger output of grease.
Remove the metering unit and clean the metering unit. Mount a new metering unit, if necessary.

Completed with issues of the software