E890- Autolube System Cannot Operate
Each machine is assigned a specific “Stroke” count ( proximity sensor reading of main distributor valve piston) that must be achieved during every grease cycle. If a single stroke is not detected within 12 minutes of pump operation, the ECM will generate the E890 error code. This code can only be cleared by successfully completing the machine specified stroke count during “Single Test” or "Continuous Test Mode".
If problem root cause has been repaired (follow specific instructions for system charging), successful operating conditions can be achieved in as little as 5 minutes of operating in single test mode. If cause is not repaired during service, error will remain until cause is addressed.
Note: If the root cause is not found, the fault code quickly reappears.
If blockage occurs down stream of valves, the flow will be restricted and pressure will build in the system. The pressure will eventually build to the point of stopping flow through the main distributor valve. The proximity sensor on the main distributor valve will then no longer see movement of valve spool. If system is opened during repair, pressure will purge off. After repair, and before initiating a Single Test, be sure to "re-build" the pressure in the repaired line using a manual grease gun and the valve inlet adapter on the nearest upstream valve. If this pressure is not "re-built," the Single Test may not deliver a sufficient amount of grease to pressurize the line and detect a potential "unfixed" issue (see Table 3).
Causes: See Table 1.
E863 - Autolube System Operation Abnormal.
Each machine is assigned a specific "Stroke" count (valve proximity sensor reading of Main Valve piston) that must be achieved during every grease cycle. If this stroke count is not achieved during the allotted cycle time (based on duty cycle selection in cab – High/Medium/Low), and the E890 code is not active, the system will start counting how many cycles are completed with this issue present. Upon completing three cycles in a row where the allotted strokes were not achieved, the system generates the E863 error. Pump will run continuously until issue is addressed or until reservoir is emptied.
Note: E890 and E863 are independent codes. Either code can be triggered before the other.
The reservoir contains a capacitance sensor that indicates a low level of grease. If the grease level drops below the sensor (no reading), the pump will continue operating until the reservoir is empty.
Causes: See Table 3
Causes: See Table 4.
| Code E890 Auto Lube System Cannot Operate | ||
|---|---|---|
| Cause | Resolution | How To: |
| Blockage at pin joint | Inspect/Repair Joint | Pump grease into joint.
If no flow, repair pin joint and repeat step. If flow achieved, see "Blockage in Secondary Valve" |
| Blockage in secondary valve | Achieve flow through rear secondary valve | Check flow at inlet of valve.
If no flow, replace valve. If slight flow, see "Blockage at Pin Joint" If flow achieved, see "Blockage in Main Distributor Valve" Note: Manual grease gun is able to exert higher pressures than the relief pressure of pump. This higher pressure will produce a slight flow to the blocked line as the hose material continues to expand.” |
| Blockage in main distributor valve | Achieve flow through the main distributor valve | Check flow at inlet of valve.
If no flow, replace valve. If slight flow, see "Blockage in Secondary Valve" If flow achieved, issue resolved. Blockage has been cleared. |
| Broken supply line | Repair hose | Check for leaks along entire length of supply hose.
If no leaks visible, disconnect hose from valve and check flow while in "Single Test" mode. If no flow, replace hose. If flow achieved, hose integrity is normal. No issue. If leaks found, repair hose. |
| Incorrect assembly of supply hose | Rebuild supply hose | Step 1: Check for abnormal (Balloon) hose size near couplings.
If abnormal size seen, replace hose. If no abnormal size is seen, see Step 2. Step 2: Check for loose bulk hose material at coupling connection. If bulk hose material is loose or out of coupling, rebuild hose. If no loose bulk hose material is seen, hose integrity is normal. No issue. NOTE: Ensure proper assembly of coupling to hose bulk. Refer to Special Instruction , M0074815 , "Cat Autolube Hose Assembly Instructions for Medium Wheel Loaders". |
| Loose supply connector | Tighten loose fittings | Check for leaks on all supply hose connectors.
If leaks found, tighten connectors. If no leaks found, connector integrity normal. No issue. |
| Valve sensor (damage/electrical connection) | 1. Make electrical connection
2. Replace sensor 3. Repair wiring harness |
Step 1: Ensure that sensor is properly connected to wiring harness.
If not connected, make connection. If connected, see Step 2. Step 2: Ensure that sensor operation is normal. If LED indicator light on sensor does not turn on and off (or sensor voltage does not clearly change from high to low) with each stoke during Single Test mode, replace sensor (ensure no other issue with valve is present before replacing sensor). If LED indicator light on sensor turns on and off (or sensor voltage clearly changes from high to low) with each stoke during Single Test mode, sensor integrity normal. No issue. Step 3: Check continuity of wiring harness. If no continuity, make needed repairs to harness. If continuity achieved, harness integrity normal. No issue. NOTE: During "Single Test" or "Continuous Test" mode, the voltage should clearly increase and decrease as the internal spool moves slowly back and forth. Ifin "Single Test" mode, the voltage cycle (High to Low cycle = One “Stroke”) cycles should match the number shown in the "stroke count" CAT ET parameter. |
| Incorrectly assembled pumping element | Reassemble pumping element | Ensure that the pumping element is properly assembled to pump.
If flow achieved (remove hose from pump during "Single Test" mode.), pumping element assembled correctly. No issue. If no flow, reassemble pumping element using instructions on pump label. NOTE: If piston is not assembled to cam, pumping element will not pump. |
| Warn pumping element | Replace pumping element | Ensure that pumping element produces correct pressure.
If no flow through the return-to-tank hose, replace pumping element. If flow achieved, pumping element integrity normal. No issue. NOTE: Pump equipped with over pressure relief valve and return-to tank-hose. To check if pumping element produces correct pressure, disconnect return to tank hose and completely block pump outlet. Pressure should exceed relief pressure and both an audible "clicking" will be heard and flow through return-to-tank hose will begin during "Single Test" mode. As an alternative to checking pumping element output, block the return to tank line and attach pressure gauge to pump outlet. Pressure should reach |
| Pump electrical connection | Make connection at pump base
Repair wiring harness Replace pump motor |
Step 1: Ensure that pump connector is properly inserted into pump base.
If connection is not properly assembled, make connection. If connection is properly assembled, check pump functionality Step 2: Ensure that wiring harness is free of damage. If damaged, make repair. If not damaged, check continuity. Step 3: Consider replacing pump motor. NOTE: Pump is equipped with reservoir stirrer. This stirrer is assembled to the same shaft as the pumping element. If stirrer is rotating counter-clockwise (from top down) and pumping element is operating correctly, pump can be considered to be working properly. |
| Improper system charging after repair | Charge system with grease after repair | Step 1: Ensure that grease gun tool is free of dirt/debris.
Step 2: Charged system with grease using grease fittings at the inlet of each valve (5-7 pumps) after each blockage repair. Step 3: Clear code by selecting "Single Test" mode within cab display. NOTE: In the event of a system blockage, up-stream hoses will pressurize and swell until flow is restricted. When repairs are made, this pressure will be relieved. If system is not charged with grease after repair, it is possible that one full cycle could be completed with issue still present (in the event that blockage was not addresses during repair). |
| Bad fuse or relay | Replace 10A fuse or relay in the fuse panel. | Check for blown fuse or bad relay |
| Low Grease Level(1) | Fill reservoir | Fill reservoir using grease fittings provided |
| (1) | The E890 error code can become active while the E234 error code is active, due to the reservoir being low or out of grease. |
Note: Error code cannot be cleared until "Single Test" mode is successfully executed. Be sure to review "Improper System Charging after Repair" before selecting "single Test" mode within machine display or Caterpillar ET.
| E863, Autolube System Operation Abnormal | ||
|---|---|---|
| Cause | Resolution | How To |
| Slow leak in main supply line | 1. Repair supply hose
2. Tighten loose connectors |
Step 1: Ensure that supply line does not contain damage.
If damage found, replace hose If no damage found, see Step 2. Step 2: Ensure that all connectors are properly tightened. If leaks found, tighten connectors If no leaks found, hose integrity normal. No Issue. |
| Extreme low temperatures | Replace grease with low temperature grease | If operating temperature is below |
| Wear on pumping element | See "Worn Pumping Element" | See "Worn Pumping Element" |
Note: Error code cannot be cleared until "Single Test" mode is successfully executed. Be sure to review "Improper System Charging after Repair" before selecting "single Test" mode within machine display or Caterpillar ET.
| E234, Autolube Reservoir Low | ||
|---|---|---|
| Cause | Resolution | How To |
| Low grease level | Fill reservoir | Fill reservoir using grease fittings provided. |
| Sensor connection | 1. Make Sensor Connection
2. Repair Damaged Wiring Harness 3. Replace Lid (Sensor within) |
Step 1: Ensure connector to pump lid is properly connected.
If not connected, make connection. If properly connected, see Step 2. Step 2: Ensure no damage to wiring harness (check continuity) If damage found, repair/replace harness. If no damage found, see Step 3. Step 3: Ensure that pump lid or connector is not damaged If damaged, replace Lid |
Note: Upon addressing below potential issues, E234 will Automatically clear. No need to run "Single Test" mode.
| Non-Error Code Issues | |||
|---|---|---|---|
| Machine Over or Under Greased | |||
| Issue | Cause | Resolution | How To |
| Machine Under Greased | 1. Incorrect duty cycle selected
2. Incorrect stoke count per cycle |
1. Select higher duty cycle (Medium or High)
2. Raise stroke count per cycle within CAT ET |
Step 1: Ensure proper duty cycle selected for machine application.
Step 2: Using the CAT ET tool, adjust the amount of "strokes" per cycle to increase the overall grease delivery rate to machine. |
| Machine Over Greased | 1. Incorrect duty cycle selected
2. Incorrect stoke count per cycle |
1. Select lower duty cycle (Medium or Low)
2. Lower stroke count per cycle within CAT ET |
Step 1: Ensure proper duty cycle selected for machine application.
Step 2: Using the CAT ET tool, adjust the amount of "strokes" per cycle to reduce the overall grease delivery rate to machine. |
Over Greasing: What is known as a "grease collar" is normal for pin joints. A grease collar is a ring around a pin joint that is exposed to atmosphere where old/used grease has collected. This is normal and is a sign of "healthy" pin lubrication. If grease collars on most pins are excessively large, there is a possibility that the machine is being over greased for given application.
Under Greasing: As described above, a grease collar at pin joints is both normal and a sign of "healthy" pin lubrication. If this collar is nonexistent or minimal on most machine pins, there is a possibility that the machine is being under greased for the given application.
Note: Changing duty cycle in cab display/CAT ET or stroke count within CAT ET only changes the greasing "amplitude" of the entire system. Pins cannot be adjusted independently.
Cat Electronic Technician Parameter Adjustments
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| Illustration 1 | g06119375 |
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Example of the Caterpillar ET interface | |
| CAT ET Verbiage | Interpretation | Factory Setting |
|---|---|---|
| Auto Lube System Installation Status
Installed/Not Installed |
Installed | |
| Auto Lube System Configuration Code
1 or 2 |
(1= Legacy System, 2= Cat System) | 2 |
| Auto Lube Cycle Configuration
5-40 |
Main Valve Stroke Count per Lube Cycle or "strokes" | Standard
950-972 = 14 980-982 = 25 Steel Mill 950-972 = 6 980 = 16 |
| Lubrication Cycle Set Command
Cycle Mode #1 Cycle Mode #2 Cycle Mode #3 |
Cycle Mode #1 = Low
Cycle Mode #2 = Medium Cycle Mode #3 = High |
Cycle Mode #2 |
| Lubrication Operation Mode Set Command
Automatic Mode Test #1 Mode Test #2 Mode |
Automatic Mode = Auto
Test #1 = Single Test Test #2 = Continuous Test |
Automatic Mode |