1996/02/26 Caterpillar

New Troubleshooting Guide Is Needed To Test The Grade/Slope System{7219,7569}

Usage:

PM-565 (3TK) Cold Planer

Reference: Operation & Maintenance Manual, KEBU6664, PM-565 Cold Planer.

A new troubleshooting guide is not available in the Operation & Maintenance Manual for the Grade/Slope System in the PM-565 Cold Planer. To provide testing instructions for controllers that may malfunction, use the following Troubleshooting Guide for the -Grade/Slope Controller.

Troubleshooting Guide For The Grade/Slope Controller

Instrument face of the sonic sensors and the central Grade/Slope controller. (A) LCD display. (B) Sonic sensor. (C) Central controller. (D) Rotary adjustable knobs.

Grade/Slope Controller Error Codes

NOTE: Error codes will be shown on the LCD displays of the central controller at the operator's station. The display will sequence between "ERR" and then the "XX" error code number. The displays on the sonic sensors will display "ERR" only.

NOTE: Refer to the following part numbers for the error code decal.

118-2736 Film (English)

118-2737 Film (French)

118-2738 Film (Spanish)

118-2739 Film (German)

118-2740 Film (Italian)

01 -- Left Side Failure To Return To Grade Within 10 Seconds

This error code is to alert the operator that the Automatic control of the left leg is not working as it should. The error code is active only in the AUTO grade or slope mode. If the central Grade/Slope controller detects that the left leg does not raise or lower the machine to the ON GRADE position (flashing on grade bar) within 10 seconds of its last on grade position, the Grade/Slope controller left LCD will flash error code "01". The error code will remain until either:

1. ON GRADE is reached,

2. the set point is adjusted with the rotary knob,

3. the left side is put into the manual mode,

4. the opposite mode, grade or slope, is selected for that side.

Possible Causes

The rear of the machine has not been lowered from the interlock position, which prevents the front legs from lowering. An open circuit to the left raise/lower solenoid valve exists. A failed or sticky solenoid valve. The leg cylinder is sticking from lack of grease. Low hydraulic pressure to the left leg. The GAIN is set to low on the Grade/Slope controller for slope, grade, or both. The solenoid valve offsets are not set correctly.

Quick Check-Repair (Key On - Engine Running)

With the Grade/Slope controller turned off or in the manual mode, raise and lower the left front leg using one of the manual toggle switches. If the leg functions correctly; the hydraulics, the leg cylinder, and the electrical connections are functional. Next, with the system in the manual mode, turn the rotary adjustment knob clockwise to lower the machine about three inches. If this works correctly, the output drivers and electrical wiring is functional from the central Grade/Slope controller. If the error code comes on intermittently, the GAIN may need to be increased to speed up the system. Recalibrating the solenoid valve offsets using the auto offset mode (AUT OFS) may also help the system response.

02 -- Right Side Failure To Return To Grade Within 10 Seconds

This error code is to alert the operator that the Automatic control of the right leg is not working as it should. The error code is active only in the AUTO grade or slope mode. If the central Grade/Slope controller detects that the right leg does not raise or lower the machine to the ON GRADE position (flashing on grade bar) within 10 seconds of its last on grade position, the Grade/Slope controller right LCD will flash error code "02". The error code will remain until either:

1. ON GRADE is reached,

2. the set point is adjusted with the rotary knob,

3. the right side is put into the manual mode,

4. the opposite mode, grade or slope, is selected for that side.

Possible Causes

The rear of the machine has not been lowered from the interlock position, which prevents the front legs from lowering. An open circuit to the right raise/lower solenoid valve exists. A failed or sticky solenoid valve. The leg cylinder is sticking from lack of grease. Low hydraulic pressure to the right leg. The GAIN is set to low on the Grade/Slope controller for slope, grade, or both. The solenoid valve offsets are not set correctly.

Quick Check-Repair (Key On - Engine Running)

With the Grade/Slope controller turned off or in the manual mode, raise and lower the right front leg using one of the manual toggle switches. If the leg functions correctly; the hydraulics, the leg cylinder, and the electrical connections are functional. Next, with the system in the manual mode, turn the rotary adjustment knob clockwise to lower the machine about three inches. If this works correctly, the output drivers and electrical wiring is functional from the central Grade/Slope controller. If the error code comes on intermittently, the GAIN may need to be increased to speed up the system. Recalibrating the solenoid valve offsets using the auto offset mode (AUT OFS) may also help the system response.

03 -- Communication Error Of Left Sonic Sensor

This error code is to alert the operator that the left sonic sensor is not communicating through the harness to the Grade/Slope controller on the console. The error code "03" will be flashed in the left LCD display and will remain until communication is made or slope mode is selected for the left side. The error code is active in both the AUTO and MANUAL grade modes.

Possible Causes

The most likely cause is a faulty or corroded connection at the connectors or an open circuit to BOTH communication wires caused by a cut in the coil cord. A faulty sonic sensor connector or internal hardware failure will also produce the error code.

Quick Check-Repair (Key On - Engine Off)

Remove and inspect the coil cord connectors for cuts. Clean the coil cord connectors at the sensor and at the console with a good quality electrical cleaner. Check to see that the display and the lights are working on the sonic sensor. This will indicate that the sensor has power and ground. If the sonic sensor powers up and the error code is still present, swap sonic sensors from the left to the right side. If the fault code follows the sensor to the right side, the sensor or connector has failed. If the fault code remains on the left side, both of the communication wires C769-OR and C761-PK are open or corroded. Remove the coil cord and test all wires with a continuity tester for open circuits.

04 -- Communication Error Of Right Sonic Sensor

This error code is to alert the operator that the right sonic sensor is not communicating through the harness to the Grade/Slope controller on the console. The error code "04" will be flashed in the right LCD display and will remain until communication is made or slope mode is selected for the right side. The error code is active in both the AUTO and MANUAL grade modes.

Possible Causes

Quick Check-Repair (Key On - Engine Off)

Remove and inspect the coil cord connectors for cuts. Clean the coil cord connectors at the sensor and at the console with a good quality electrical cleaner. Check to see that the display and the lights are working on the sonic sensor. This will indicate that the sensor has power and ground. If the sonic sensor powers up and the error code is still present, swap sonic sensors from the right to the left side. If the fault code follows the sensor to the left side, the sensor or connector has failed. If the fault code remains on the right side, both of the communication wires C769-OR and C761-PK are open or corroded. Remove the coil cord and test all wires with a continuity tester for open circuits.

05 -- Communication Error Of Slope Sensor

This error code is to alert the operator that the slope sensor is not communicating through the harness to the Grade/Slope controller on the console. The error code is active in both AUTO and MANUAL slope modes. The error code "05" will be flashed on the LCD display on the side that has been selected for operation. Error code "05" will remain until communication is made or until the slope mode is turned off.

Possible Causes

The most likely cause is a faulty or corroded connection at the connectors or an open circuit to BOTH communication wires caused by a cut in the harness. A faulty slope sensor connector or an internal hardware failure will also produce the error code.

Quick Check-Repair (Key On - Engine Off)

Remove and clean the harness connectors at the sensor and at the console with a good quality electrical cleaner. With the key ON and the engine OFF, turn the slope off and run in grade for both the left and the right sides. Remove the RIGHT sonic grade sensor and plug it into the harness connector for the slope sensor. Check to see that the lights and the display on the sonic sensor are functional. If not, the power or ground wires are open or shorted. If no error codes start flashing, then the harness and connectors are in working order and the slope sensor or sensor connector is defective. If "05" communication error appears, then there is a problem with the harness or the connectors. Test both of the communication wires C769-OR and C761-PK for open or corroded connections.

06 -- Communication Error Of All Sensors

This error code is to alert the operator that the data link between the slope sensor, both sonic sensors, and the central Grade/Slope controller is non-functional. The entire system will not function correctly in MANUAL or AUTO. The "06" error code will flash on BOTH the left and the right LCD displays.

Possible Causes

A short on one or both of the communication wires C769-OR and C761-PK leading into the central Grade/Slope controller is possible; however, it is more likely that one of the wires is shorted to ground in a coil cord. The wires could also be shorted to positive, or possibly one of the sensors or the controller is malfunctioning.

Quick Check-Repair (Key On - Engine Off)

The coil cords that attach the grade sensors are the likely candidates for being pinched or cut. Disconnect and remove one at a time at the console bottom to see if the error code changes. If error code "06" is still flashing, then also disconnect the slope sensor harness from the bottom of the console. The control console is now isolated from all other sensors and a continuing "06" error code would indicate a faulty console harness or a failed central Grade/Slope controller. Disconnect the Grade/Slope control and check for a short between communication wires C769-OR and C761-PK. If none are found, install a different Grade/Slope controller.

07 -- Grade/Slope System Powered Up In AUTO

Error code "07" will flash on the LCD displays whenever the Grade/Slope system is turned ON while in the AUTO mode. Along with the code, the AUTO red indicator will flash on the central Grade/Slope controller. The system will not function until both sides are put into the manual mode to reset. This error code is active in both grade or slope mode.

08 -- Erratic Readings Being Reported By Left Sonic Sensor

This error code is to alert the operator that the sonic sensor on the left side is measuring large differences in depth in a short period of time. Automatic control will not function correctly, nor will the displayed measurement be correct in the manual mode. Error code "08" will be flashed on the left LCD display of the central Grade/Slope controller and will remain until the measurements stabilize or until the slope mode is selected for the left side. This code is active in both the AUTO and MANUAL grade modes.

Possible Causes

The most likely cause is that the sonic sensor is positioned in such a way that it is sensing multiple targets which are at different heights. Some of the more common positioning mistakes are:

1. The sonic sensor is placed too close to the side of the machine, causing the sensor to read the side plate and the pavement;

2. the sonic sensor is placed over a string line that is too small in diameter or too smooth;

3. the sonic sensor is placed over the top of a curb where the sensor reads both the top and the bottom of the curb.

Moisture or dirt on the transducer or the transducer filter may cause the error code to be flashed. Also, the error code might be triggered if the sensor is mounted too close or too far from it's reference target. A failed sonic sensor transducer will also cause the error code to be activated.

Quick Check-Repair (Key On - Engine Off)

The first thing to check is the position of the sensor. Move the sensor to several different locations to see if the error code stops. Keep in mind that the sound waves from the sensor are in a cone shape with the small end of the cone at the sensor. The greater the distance between the sensor and the target, the larger the target area of the cone. Check to see that the sensor transducer and the transducer filter are dry and clean, and the connectors at both ends of the coil cord are fastened securely. In general, if an erratic error code is appearing more often for longer durations, it indicates a sensor transducer is failing. If the error code continues, swap the left and the right side sonic sensors to see if the error code follows the sensor. If the error codes follow ("09" for right side), then the sensor is malfunctioning and should be sent in for repair. If the error code does not follow the sensor and remains on the same side of the machine, then it is likely that the sensor is mounted incorrectly.

09 -- Erratic Readings Being Reported By Right Sonic Sensor

This error code is to alert the operator that the sonic sensor on the right side is measuring large differences in depth in a short period of time. Automatic control will not function correctly, nor will the displayed measurement be correct in the manual mode. Error code "09" will be flashed on the right LCD display of the central Grade/Slope controller and will remain until the measurements stabilize or the slope mode is selected for the right side. This code is active in both the AUTO and MANUAL grade modes.

Possible Causes

The most likely cause is that the sonic sensor is positioned in such a way that it is sensing multiple targets which are at different heights. Some of the more common positioning mistakes are:

1. The sonic sensor is placed too close to the side of the machine, causing the sensor to read the side plate and the pavement;

2. the sonic sensor is placed over a string line that is too small in diameter or too smooth;

3. the sonic sensor is placed over the top of a curb where the sensor reads both the top and the bottom of the curb.

Moisture or dirt on the transducer or transducer filter may cause the error code to be flashed. Also, the error code might be triggered if the sensor is mounted too close or too far from it's reference target. A failed sonic sensor transducer will also cause the error code to be activated.

Quick Check-Repair (Key On - Engine Off)

The first thing to check is the position of the sensor. Move the sensor to several different locations to see if the error code stops. Keep in mind that the sound waves from the sensor are in a cone shape with the small end of the cone at the sensor. The greater the distance between the sensor and the target, the larger the target area of the cone. Check to see that the sensor transducer and the transducer filter are dry and clean, and the connectors at both ends of the coil cord are fastened securely. In general, if an erratic error code is appearing more often for longer durations, it indicates a sensor transducer is failing. If the error code continues, swap the left and the right side sonic sensors to see if the error code follows the sensor. If the error codes follows ("08" for left side), then the sensor is malfunctioning and should be sent in for repair. If the error code does not follow the sensor and remains on the same side of the machine, then it is likely that the sensor is mounted incorrectly.

10 -- Erratic Readings Being Reported By Slope Sensor

This error code is to alert the operator that large differences in slope angles are being measured in a short period of time. Error code "10" will remain until the measurements stabilize or until the slope mode is turned off. This code is active in both the AUTO and MANUAL slope modes and will appear in the LCD display on the side that has been selected for operation.

Possible Causes

An internal failure of the sensor is the most likely cause to activate error code "10".

Quick Check-Repair (Key On - Engine Off)

Check to see that the sensor is securely mounted. With slope in the manual mode in either right or left side, watch to see if the LCD displays a stable slope reading. If it is erratic or the error code continues, the slope sensor should be sent in for repair.

11 -- Left Front Leg RAISE Solenoid Valve Shorted To Ground

This error code is to alert the operator that the positive output circuit of the central Grade/Slope controller is detecting a short to battery negative. The error code will appear on the left LCD display and will remain until the short is corrected or until the Grade/Slope system is turned off. This code is active in all modes of operation. The error code is only displayed when a RAISE command is activated.

Possible Causes

The console or front chassis harness that contains wire number C753-PU is either shorted to the frame or to a ground wire. Also, the coil on the solenoid valve may have failed because of shorted windings.

Quick Check-Repair (Key On - Engine Off)

Disconnect the harness from the LEFT RAISE solenoid coil and reset the breaker if it is tripped. With the Grade/Slope controller switched off, select the RAISE position with one of the manual toggle switches. If the breaker trips, then the harness is shorted to a ground wire or to the frame. If the breaker does not trip, re-connect the LEFT RAISE solenoid coil and again select the RAISE position with the manual toggle switch. The solenoid coil has failed by a short if the breaker trips again.

12 -- Left Front Leg LOWER Solenoid Valve Shorted To Ground

Possible Causes

The console or front chassis harness that contains wire number C752-PK or E760-PU is either shorted to the frame or to a ground wire. Also, the coil on the solenoid may have failed because of shorted windings.

Quick Check-Repair (Key On - Engine Off)

Disconnect the harness from the LEFT LOWER solenoid coil and reset the breaker if it is tripped. With the Grade/Slope controller switched off, select the LOWER position with one of the manual toggle switches. If the breaker trips, then the harness is shorted to a ground wire or to the frame. If the breaker does not trip, re-connect the LEFT LOWER solenoid coil and select the LOWER position again with the manual toggle switch. The solenoid coil has failed by a short if the breaker trips again.

13 -- Right Front Leg RAISE Solenoid Valve Shorted To Ground

This error code is to alert the operator that the positive output circuit of the central Grade/Slope controller is detecting a short to battery negative. The error code will appear on the right LCD display and will remain until the short is corrected or until the Grade/Slope system is turned off. This code is active in all modes of operation. The error code is only displayed when a RAISE command is activated.

Possible Causes

The console or front chassis harness that contains wire number C758-GY is either shorted to the frame or to a ground wire. Also, the coil on the solenoid may have failed because of shorted windings.

Quick Check-Repair (Key On - Engine Off)

Disconnect the harness from the RIGHT RAISE solenoid coil and reset the breaker if it is tripped. With the Grade/Slope controller switched off, select the RAISE position with one of the manual toggle switches. If the breaker trips, then the harness is shorted to a ground wire or to the frame. If the breaker does not trip, re-connect the RIGHT RAISE solenoid coil and select the RAISE position again with the manual toggle switch. The solenoid coil has failed by a short if the breaker trips again.

14 -- Right Front Leg LOWER Solenoid Valve Shorted To Ground

This error code is to alert the operator that the positive output circuit of the central Grade/Slope controller is detecting a short to the battery negative. The error code will appear on the right LCD display and will remain until the short is corrected or until the Grade/Slope system is turned off. This code is active in all modes of operation. The error code is only displayed when a LOWER command is activated.

Possible Causes

The console or front chassis harness that contains wire number C757-BR or E761-BR is either shorted to the frame or to a ground wire. Also, the coil on the solenoid may have failed because of shorted windings.

Quick Check-Repair (Key On - Engine Off)

Disconnect the harness from the RIGHT LOWER solenoid coil and reset the breaker if it is tripped. With the Grade/Slope controller switched off, select the LOWER position with one of the manual toggle switches. If the breaker trips, then the harness is shorted to a ground wire or to the frame. If the breaker does not trip, re-connect the RIGHT LOWER solenoid coil and select the LOWER position again with the manual toggle switch. The solenoid coil has failed by a short if the breaker trips again.