Wittke Pendulum Service manual

SERVICE MANUAL SUPPLEMENT
Automated Side Loader
Crocodile
with CAT Operating System
STRONGER ALL AROUND
Crocodile CAT Electronic System Troubleshooting
Automated Side Loader
Crocodile
with Caterpillar electronic system
Supplement Manual
TROUBLESHOOTING
Index
Section
Page
1.
Introduction…………………………………………………………...
3
2.
Reference……………………………………………………………..
4
3.
Exit/Entry Conditions………………………………………………...
4
4.
Pump Control…………………………………………………………
5
5.
Allison Transmission Program Parameters……………………….
6
6.
Hoist Control………………...………………………………….…….
7
7.
Tailgate Open/Close Control……………………………………….
8
8.
Manual Pack/Return Control…………………..…………………..
9
9.
Autopack Control……………………………………………………
10
10.
Electronic Joystick Operational Requirements………………....
11
11.
Joystick Manual Arm Control Loading…………………………….
11
12.
Joystick Manual Arm Control Return to Home…………………..
12
13.
Joystick Auto Dump Arm Control…………………………..……..
13
14.
Joystick Auto Return to Home Control…………….……….…….
14
15.
Indicator Non Hydraulic Output Control…………………….……
15
16.
Arm Lift Calibration Routine……………………………….……..
16
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Index (cont.)
Section
Page
17.
Diagnostic Flash Code Values…...………………………………...
18
18.
Visual Diagnostic Display - Messenger……….…………………..
20
19.
Switch Input Verification……...………………………………….....
24
20.
Connectors……………………………………………………...……
36
21.
Troubleshooting Charts……………………….…………………....
41
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1. Introduction
Troubleshooting is an organized study of the problem and a planned method
of investigation and correction.
Think about the following before proceeding:
Quiz the operator
What were the warning signs prior to failure?
Ensure components and wiring are installed per factory specifications
Do not rule out previous failed attempts
Work through troubleshooting charts methodically
Check the obvious things first. Keep it simple
Many problems can be traced not to one part alone, but to the relationship of one part to
another
For multiple electrical faults, check the common ground locations, common harnesses and
power supply
Learn to read the schematics
Identify hydraulic system heat build-up using an infra red sensor
Carry out flow, vacuum and pressure test to hydraulic systems before removing components
Use the Troubleshooting Guide as a reference only; it may not contain all the answers
Keep to Maintenance Schedules
Important Safety Information
!
CAUTION
Read and understand this entire manual before repairing or adjusting this
equipment. Consult Maintenance and Operation Manual for additional
information.
Correct lockout and tagout procedures must be followed when servicing or
repairing this equipment. Consult OSHA and ANSI guidelines. Technicians
must be trained and familiar with the product.
Some of the troubleshooting tests described here require the hydraulic system
to be active. In these instances, the truck should be placed in a safe location
with the area cordoned off. Warn other personnel that the units is active and
being worked on.
?
INFO
Many tests can be conducted with the engine shut off, but with the ignition
switch left in the ON position.
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2. Reference:
Operation and Maintenance Manual 105355
Schematics: AP8-E022; AP8-E023 Rev.3
Overview: AP8-E024 Rev.5
Tool requirements:
Multi meter with Hz % feature
Testing ‘spoons’ Leach Part # 723688 and 723705; Caterpillar Part # 7X-1708 and 7X-1709
(Leach Part # 972214 includes 723688 and 723705)
Deutsch pin puller Leach Part # 723937; Caterpillar part # 151-6320
Test site:
ECM plugs J1 and J2 (see page 33)
3. Entry/Exit Conditions
The first consideration in troubleshooting electronic system faults is to ensure that all Entry
Conditions are met. If one of the Entry Conditions are not met or, if one of the Exit Conditions
exist, the system will not function as intended.
Entry Condition:
System is within electronic and operational parameters. Must meet all Entry
Conditions simultaneously before entry
Note: all Entry Conditions expect ignition to be on, pump switch on
Exit Condition:
System has experienced a condition that will limit operation. Any Exit
Condition will force exit
The following pages detail each operational basic functionality in turn and contains tables of entry
and exit conditions for each operation.
?
INFO
Prior to embarking upon in depth troubleshooting, technicians
should verify that each of the entry conditions are met and
none of the exit conditions exist
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4. Pump Control
Basic Functionality
Activate pumps with pump switch on the Control Panel as long as the minimum safe
conditions are met. Will switch pump off if a short to battery is detected on any hydraulic
solenoid.
Notes: Joystick or switch states that are requesting hydraulic motion will not affect pumpon entry. The logic is that each individual circuit will have its own state machine
forcing the operator to re-center the joystick/switch after pump on, before any
commands will be allowed.
Pump switch must be cycled to recover from previous forced exit
ENTRY CONDITIONS
EXIT CONDITIONS
Pump switch ON
Pump switch OFF
Access ladder stowed
Access ladder down
No fault on pump solenoid
Fault detected on pump solenoid
No short-to-battery faults on any functions
Short-to-battery on any function
Engine RPM below 900
Engine RPM above 1900
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5. Allison Transmission Program Parameters
The following parameters have been programmed into the transmission ECU at factory.
PARAMETER NAME
RPM
Maximum engine speed for PTO engagement
900
Maximum engine speed for PTO operation
1,900
Maximum output speed for PTO engagement
2,000
Maximum output speed for PTO operation
4,000
Maximum output speed for auto neutral
60
Speed to turn on output speed interlock
250-300 (7-10mph)
Speed to turn off output speed interlock
250-300 (7-10mph)
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6. Hoist Control
Basic Functionality
Raise/lower body when proper conditions are met and operator is pressing the switch in
the desired direction
Notes: Hoist raise/lower logic is identical to tailgate control logic
Switches must be re-centered if out of neutral at pump-on or after forced exit
condition
ENTRY CONDITIONS
EXIT CONDITIONS
Pump switch ON
Pump switch OFF
Raise/Lower switch activated and held
Raise/Lower switch released
No fault hoist raise/lower solenoid (raise only)
Fault on hoist raise/lower solenoid (raise only)
No fault hoist lower solenoid (lower only)
Fault on hoist lower solenoid (lower only)
Arm home
Arm not home
Transmission gear selected
Transmission in neutral
Not in lift autocalibration mode
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7. Tailgate Open/Close Control
Basic Functionality
Open/close tailgate when proper conditions are met and operator is pressing the switch in
the desired direction
Notes: Tailgate open/close logic is identical to hoist control logic
Switches must be re-centered if out of neutral at pump-on or after forced exit
condition
ENTRY CONDITIONS
EXIT CONDITIONS
Pump switch ON
Pump switch OFF
Open/Close switch activated and held
Open/Close switch released
No fault tailgate open/close solenoid (open only)
Fault on tailgate open/close solenoid (open only)
No fault tailgate close solenoid (close only)
Fault on close solenoid (close only)
Arm home
Arm not home
Transmission in neutral
Transmission gear selected
Not in lift autocalibration mode
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8. Manual Pack/Return Control
Basic Functionality
Extend the pendulum when the proper conditions are met and the operator is holding
down the pack button. Retract the pendulum when the proper conditions are met and the
operator is holding down the return button.
Notes: Switch must be re-pressed after forced exit condition
ENTRY CONDITIONS
EXIT CONDITIONS
Pump switch ON
Pump switch OFF
No fault on any pack solenoid
Fault on any pack solenoid
Pack/return switch pressed and held
Pack/return switch released
Any control switch pressed
No other control switch pressed
Top doors open (if equipped)
Top doors closed (if equipped)
Tailgate closed and locked
Tailgate ajar and not fully open
(Tailgate ajar and fully open OK for unload)
Not in lift autocalibration mode
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9. Autopack Control
Basic Functionality
In autopack mode, cycle the pendulum continuously
Notes: Illuminates Autopack lamp when cycle is active
Switch must be re-pressed after forced exit condition
ENTRY CONDITIONS
EXIT CONDITIONS
Pump switch ON
Pump switch OFF
No fault on any pack solenoid
Fault on any pack solenoid
Autopack switch pressed
Autopack stop switch pressed
No other control switch pressed
Any control switch pressed
Tailgate closed and locked
Tailgate ajar and not fully open
Top doors open (if equipped)
Top doors closed (if equipped)
Not in lift autocalibration mode
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10. Electronic Joystick Operational Requirements
Joystick selector switch on Control Panel:
must be set to ‘ENABLE’
Auto trigger on joystick:
must be triggered prior to first operational input
must be re-triggered to recover from a forced exit
(for example: should the vehicle speed exceed 7mph 11kmph after
loading, the joystick will need to be re-triggered)
11. Joystick - Manual Arm Control - Loading
Basic Functionality
move arm functions when proper conditions are met
the most functions state is “loading OK” where any motion within the operating zone is
permitted provided that Entry Conditions are satisfied
semi-functional state is manual return to home where only Lift Lower, Slide Retract, and
Grab Open are allowed should any Exit Conditions exist
fully locked out state permits no motion
Note: joystick out of center at neutral condition will never allow arm to enter loading state
ENTRY CONDITIONS
EXIT CONDITIONS
Pump switch ON
Pump switch OFF
Joystick centered, trigger toggled
Fault detected in joystick
Vehicle speed less than 7mph (11kmph)
Vehicle speed exceeds 7mph (11kmph)
Brake pedal depressed
Brake pedal not depressed
Tailgate not ajar or fully open
Tailgate ajar or fully open
No fault on any arm solenoid or lift position sensor
Fault detected on any arm solenoid
Top door(s) open (if equipped)
Top door(s) close (if equipped)
All return to home conditions OK
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12. Joystick - Manual Arm Control - Return to Home
Basic Functionality
move arm functions when proper conditions are met
the most functions state is “loading OK” where any motion within the operating zone is
permitted provided that Entry Conditions are satisfied
semi-functional state is manual return to home where only Lift Lower, Slide Retract, and
Grab Open are allowed should any Exit Conditions exist
fully locked out state permits no motion
ENTRY CONDITIONS
EXIT CONDITIONS
Pump switch ON
Pump switch OFF
No fault in lift lower, slide retract, grab
open solenoids
Fault on return to home solenoid
No fault on any joystick axis
Fault on joystick axis
Not in lift autocalibration mode
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13. Joystick - Automatic Dump Arm Control
Basic Functionality
provide automated arm control when proper conditions are met
automatically dump can previously gripped by operator and return can to the point at which
autodump was initially triggered
once successfully engaged, autodump will:
- apply a small grip command and lift to the top of the load zone
- retract slide fully
- raise to dump can; briefly shake can
- wait for a toggle of the autodump switch state (operator input)
- lower to the top of the load zone
- slide out to original slide extension (where autodump was initiated)
- lower can to the original lift position (where autodump was initiated)
- operator input required to release can (manually or using return to home
function)
Note: joystick out of center at neutral condition will never allow arm to enter loading state
Autodump parameter must be enabled
Timeout of any part of the autodump operation (default times set approx. 3 times normal
operating time for respective condition)
ENTRY CONDITIONS
EXIT CONDITIONS
Pump switch ON
Pump switch OFF
Joystick centered, trigger toggled
Fault detected in joystick
Vehicle speed less than 7mph (11kmph)
Vehicle speed exceeds 7mph (11kmph)
Brake pedal depressed
Brake pedal not depressed
Autodump button pressed and held
Autodump button released
Lift below the load zone height
Lift above the load zone height
Grip not fully open
Grip fully open
Body not raised, tailgate not ajar
Body raised, tailgate ajar
No fault on any arm solenoid or lift position sensor
Fault detected on any arm solenoid
Tailgate not ajar or fully open
Tailgate ajar or fully open
Top door(s) open (if equipped)
Top door(s) close (if equipped)
Any large joystick motion (>50%)
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14. Joystick - Automatic Return to Home (RTH) Arm Control
Basic Functionality
provide automated arm control to return arm fully home (lift fully lowered, slide fully retracted,
grip open) when proper conditions are met
triggered by top joystick thumb button, dead-man control (must be held)
will continue to try to retract arm as long as button is held (no logic to turn off commands
when arm is home)
once engaged, RTH will retract grip cylinder, slide cylinder, arm lift cylinder in turn
Note: can still activate Return to Home if main joystick is disabled
vehicle speeds in excess of 7mph 11kmph does NOT lockout Return to Home
RTH parameter must be enabled
ENTRY CONDITIONS
EXIT CONDITIONS
Pump switch ON
Pump switch OFF
Autostow button pressed and held
Autostow button released
Lift below the load zone height
Lift above the load zone height
No fault on any joystick axis
No fault on any joystick axis
No fault on any arm solenoid
Fault detected on any arm solenoid
No fault on lift position sensor
Fault on lift position sensor
Body not raised, tailgate not ajar
Body raised, tailgate ajar
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15. Indicator/Non-Hydraulic Output Control
Basic Functionality
Arm not home indicator: illuminates control panel warning lamp if grip not fully
open, slide not fully retracted, lift position not fully down or when lift position sensor
fault present
Arm not home and speed exceeds 7mph (11kmph): illuminates control panel
warning lamp and sounds alarm if grip not fully open, slide not fully retracted, lift
position not fully down or when lift position sensor fault present AND speed exceeds
7mph (11kmph)
System warning light blinks warning codes when present: see Flash Code
Values Table
Tailgate ajar indicator: illuminates control panel warning lamp, sounds in-cab
alarm and back-up alarm when tailgate unlocked
Body raised indicator: illuminates control panel warning lamp, sounds in-cab
alarm when body is raised
Autopack indicator: illuminates Autopack switch warning lamp when Autopack
active
Access ladder down: illuminates control panel warning lamp, sounds in-cab alarm
when access ladder is down. Will cause exit condition for pump control
Packer blade stall warning lamp: illuminates control panel warning lamp
whenever pendulum stalls against refuse, activating the pack pressure switch
Bin counter: advances the counter 0.6 seconds after arm leaves the load zone
Hydraulic oil cooler relay: turn on relay when oil temperature switch is active
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16. Arm Lift Calibration Routine
This routine is provided to automatically calibrate the initiation currents for the lift raise and lift
lower functions. It uses cylinder position information to determine the current level at
which motion in either direction begins. It is intended for periodic use by trained maintenance
technicians only in order to reset the pre-programmed operating cushions at the top and
bottom ends of lift motion. It is designed to be initiated through a sequence of button presses.
The calibration routine should be used when the machine has reached normal operating
temperature (90*C). After the routine has executed, the calibration values will automatically
be updated and the arm will be ready to use for normal operation. All other hydraulic circuits
will be locked out during calibration.
?
INFO
!
CAUTION
If the ECM is ever washed after a calibration routine has been
performed, the calibration values will revert to their default values and
the calibration routine will have to be re-run.
If the lift arm position sensing cylinder is replaced, it is advisable to run
a calibration routine as this will calibrate the new cylinder.
The routine will move the lift cylinder without warning.
Be sure to leave enough space for the arm to operate and cordon off
the area to avoid inadvertent contact.
Warn other shop personnel that the calibration is being conducted.
Turning off the pump switch or un-centering the joystick at any time
will stop the routine.
Minimum Operating Conditions
(must be met during entire calibration
sequence)
Pump ON
Joystick centered
Transmission in neutral
Start Condition
(must be met before and during button
press)
Arm home
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Calibration Sequence
1. Simultaneously press and hold manual pack, manual return and autopack buttons for
more than 3 seconds
2. While maintaining hold on the autopack button, release manual pack and manual return
buttons
3. Maintain autopack button depressed for additional 3+ seconds after releasing other
buttons. Once the auto-calibration routine has started, autopack button can be released
4. Lift cylinder motion indicates calibration routine has successfully started
5. Arm will rise to a center position, rise slightly further, lower slightly, rise slightly, lower
slightly, and then it will travel a full stroke
6. The arm will travel up and down 5 times. After this has been completed, and the arm is at
the home position, turn the ignition key off
7. After 10 seconds, turn the ignition key back on and start the vehicle. This ensures that the
calibration is complete.
Use the pump OFF switch or un-center the joystick as an
emergency stop to end the auto-calibration early if necessary
?
INFO
During the entire calibration sequence, the system warning alarm will
sound
No calibration values will be updated unless the entire calibration
completes successfully
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17. Diagnostic Flash Code Values
The Caterpillar electronic control module monitors certain components in the system for
faults. The valve solenoids, joystick and position sensing cylinder are all monitored by the
controller. If the control module detects a fault in these systems, it will initiate a series
of warning flashes in sequence to aid in diagnosing the fault quickly. The red system warning
light mounted into the control panel will flash in a series of three numerical sets. Once
this sequence of flashes is complete, the warning light will extinguish briefly and then the
sequence begins again. The technician must count this sequence of flashes and refer to the
chart below to determine the faulty circuit/component.
For example:
the system warning light flashes 6 times, pauses, flashes 3 times, pauses,
flashes 2 times, pauses for longer, then repeats;
this sequence is 6.3.2 indicating a problem with Lift arm grabber open
solenoid.
?
Outputs
INFO
Upon ignition start up, the system warning completes
a self test by issuing a 6.5.4 sequence. This is normal
FAULT DESCRIPTION
FLASH CODE
Lift arm raise solenoid
6.3.4
Lift arm lower solenoid
6.3.5
Lift arm slide extend solenoid
6.3.6
Lift arm slide retract solenoid
6.3.7
Lift arm grabber close solenoid
6.3.3
Lift arm grabber open solenoid
6.3.2
Pendulum extend solenoid
6.3.8
Pendulum retract solenoid
6.3.9
Tailgate raise solenoid
6.4.2
Tailgate lower solenoid
6.4.1
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Outputs (cont)
FAULT DESCRIPTION
FLASH CODE
Body raise solenoid
6.4.5
Body lower solenoid
6.4.6
Bin counter
6.4.7
Pump on output (to coil)
6.4.9
Inputs
FAULT DESCRIPTION
FLASH CODE
Lift arm cylinder position sensor
6.1.1
Joystick X-Axis (slide)
6.5.4
Joystick Y-Axis (lift)
6.5.5
Joystick thumbwheel (grabber)
6.5.6
Miscellaneous System Issues
FAULT DESCRIPTION
FLASH CODE
Harness code invalid
4.1.2
System voltage
5.1.1
8v sensor supply
5.1.7
5v sensor supply
5.1.6
The flash codes will alert the technician to a failure in the circuit indicated. The cause may be a
failed component such as a joystick or position sensing cylinder, or as simple as a loose
connector or broken wire. Flash codes mean that an exit condition exists and the related
function will not operate.
The cause of the flash code should be investigated first by a visual check of the components
related to that function.
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18. Visual Diagnostic Display - Messenger
Included with the Caterpillar loading control system is a diagnostic LCD display unit that has
the ability to monitor the vehicle and engine information (certain chassis wiring interface
connections are required for these features). Potentially serious engine problems are
displayed automatically and engine diagnostic codes may be accessed by the driver.
When connected, data links are used to provide
performance and operating information to Messenger.
The system has the capability to display and record
fuel usage, average miles per gallon, oil pressure,
coolant temperature and more on an LCD display.
Drivers can also monitor their performance in achieving
fuel economy goals.
!
Do not attempt to manipulate the display while the
vehicle is moving. This could divert attention from driving
and result in personal injury or equipment damage
CAUTION
?
INFO
Further information is available from your Caterpillar
dealer by requesting manual REHS1413
The Messenger system displays diagnostic codes for
the body systems monitored by the ECM. Faults
displayed as a series of flashes on the Control Panel
System Warning light are also displayed on the LCD
display.
The fault is displayed on the screen as a ‘Diagnostic
Event’, along with a brief description such, as ‘Body
Lift Sol Open’
Users have the ability to adjust select arm operational
settings through the Messenger. In order to do this,
the Service Mode must be enabled.
Using the simple navigation keys, toggle through the
Main Menu until ‘Service Mode’ is displayed.
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Select ‘Service Mode ENABLED’ and use the ‘back’
key to return to the Main Menu
?
The default setting for Service Mode is DISABLED.
It will revert to disabled when the ignition key is
INFO switched off
Use the up/down toggles to select ‘Settings’
Press ‘OK’
Use the up/down toggles to select ‘Config Parameters’
Press ‘OK’
Within the CONFIG PARAMETERS menu select arm operational settings can be adjusted
as follows:
AUTO STOW
enables or disables the arms’ ability to Return to Home with a
single joystick button press
AUTO DUMP
enables or disables the arms’ ability to dump a container with a
single joystick button press
AUX JOYSTICK STATUS
joystick
-
if equipped, enables or disables the secondary
LOAD ZONE DISPLACEMENT gives the operator the ability to adjust the
maximum height to which the arm raises while the slide is extended
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Settings: Config Parameters
Auto Stow Status
Settings: Config Parameters
Auto Dump Status
OK
OK
Auto Stow Disabled
Press OK to Enable
Auto Dump Disabled
Press OK to Enable
OK
OK
Auto Stow ENABLED
Press OK to Disable
Auto Dump ENABLED
Press OK to Disable
Settings: Config Parameters
Aux. Joystick Status
OK
Aux. Joystick Not Installed
Press OK to Install
OK
Aux. Joystick INSTALLED
Press OK to Uninstall
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Settings: Config Parameters
Load Zone Displacement
OK
Load Zone Interlock Pct Displacement
Press OK to Edit
35.0%
OK
Load Zone Interlock Pct Displacement
Toggle to adjust to desired setting
Press OK to set
?
INFO
The lower the percentage value set for Load Zone Interlock,
the lower the height interlock engages when the slide is
deployed
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19. Switch Input Verification
Switch Input Verification aims to pinpoint faults by identifying individual wires at the Electronic
Control Module, and testing through the connector to verify voltage readings.
Using an Ohm meter set to the VOLT function, technicians may test the relevant pins to
determine if voltages are correct at the ECM. Most circuits are tested for a 0v condition or a
12v condition; the joystick circuits are tested for Hz% duty cycle and voltage.
The pin to pin identification charts allow the technician to make continuity checks of the
harnesses between the ECM and the relevant in cab control or valve solenoid etc.
Use the following charts for reference.
1. Pump on enable
2. Slide extend proximity switch
3. Grabber close proximity switch
4. Tailgate ajar
5. Access ladder down
6. Tailgate open switch
7. Tailgate close switch
8. Autopack
9. Manual pack
10. Manual return
11. Pack toggle
12. Pack reset
13. Pack pressure switch
14. Body raised limit switch
15. Autodump
16. Return to home
17. Hydraulic oil temperature switch
18. Top doors open switch
19. Top doors close switch
20. Front top door open limit switch
21. Rear top door open limit switch
22. Neutral indicator
23. Speed above 7mph (11kmph)
24. Main joystick trigger
25. Aux joystick trigger
26. Body raise switch
27. Body lower switch
28. Indicator non hydraulic voltage chart
29. Solenoid voltage/resistance chart
30. Digital Joystick Input Verification
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Switch Input Verification
FUNCTION
1
2
3
4
5
6
Pump ON
enable
Slide Extend
Proximity
Grabber Close
Proximity
Tailgate Ajar
Access
Ladder
Tailgate Open
Switch
CURRENT
USED
Y
Y
Y
Y
Y
Y
LOCATION
TEST
CONVENTION
J1 14
12v
Pump is OK to
turn on
0v
Pump is not
OK to turn on
12v
Slide is not
extended
0v
Slide is
extended
12v
Grabber fully
open
0v
Grabber is not
fully open
12v
Tailgate not
ajar
0v
Tailgate is ajar
12v
Access ladder
is down
0v
Access ladder
is stowed
12v
Tailgate open
switch is not
active
0v
Tailgate open
switch is active
J1 24
J1 25
J1 27
J1 28
J1 32
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FUNCTION
7
8
9
10
Tailgate Close
Switch
Autopack
Manual
Pack
Manual
Return
CURRENT
USED
Y
Y
Y
Y
LOCATION
TEST
J1 34
12v
J1 33
J1 35
J1 40
Pack Toggle
Y
J1 41
Tailgate close
switch is active
12v
Autopack is not
active
0v
Autopack is
active
12v
Manual pack is
not active
0v
Manual pack is
active
12v
Manual return
is not active
12v
0v
12
Pack Reset
Y
J1 43
12v
0v
26
Tailgate close
switch is not
active
0v
0v
11
CONVENTION
Manual return
is active
Pendulum is
not fully
extended
Pendulum is
fully extended
Pendulum is
not fully
retracted
Pendulum is
fully retracted
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FUNCTION
13
14
15
Pack Pressure
Switch
Body Raised
Limit Switch
Autodump
CURRENT
USED
Y
Y
Y
LOCATION
TEST
J1 63
12v
Pendulum not
at max
pressure
0v
Pendulum at
max pressure
12v
Body is not
raised
0v
Body is raised
12v
Autodump
button is not
active.
J1 64
J2 23
0v
16
17
Return to
Home
Hydraulic Oil
Temperature
Switch
Y
Y
J2 28
J2 29
Top Doors
Open Switch
Y
RTH button is
not active
0v
RTH button is
active
12v
J2 36
12v
0v
27
Autodump
button is active
12v
0v
18
CONVENTION
Temperature
switch is
inactive
Temperature
switch is
activated
Top doors
open switch
not active
Top doors
open switch is
active
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Crocodile CAT Electronic System Troubleshooting
FUNCTION
19
20
21
Top Doors
Close Switch
Front Top
Door Open
Limit Switch
Rear Top Door
Open Limit
Switch
CURRENT
USED
Y
Y
Y
LOCATION
TEST
J2 37
12v
Top doors
close switch
not active
0v
Top doors
close switch
active
12v
Front top door
is open
0v
Front top door
is not open
12v
Rear top door
is open
J2 39
J2 44
0v
22
23
Neutral Indicator
(from
transmission)
Speed above
7mph (from
transmission)
Y
Y
J2 46
J2 47
Main Joystick
Trigger
Y
Trans is not in
neutral
0v
Trans is in
neutral
12v
J2 52
12v
0v
28
Rear top door
is not open
12v
0v
24
CONVENTION
Vehicle is not
traveling above
7mph
Vehicle is
traveling at or
above 7mph
Joystick trigger
is not active
Joystick trigger
is active
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Crocodile CAT Electronic System Troubleshooting
FUNCTION
25
26
27
Aux Joystick
Trigger
Body Raise
Switch
Body Lower
Switch
CURRENT
USED
Y
Y
Y
LOCATION
J2 53
J2 54
J2 58
TEST
CONVENTION
12v
Aux joystick
trigger is not
active
0v
Aux joystick
trigger is active
12v
Body raise switch
is not active
0v
Body raise switch
is active
12v
Body lower
switch is not
active
0v
29
Body lower
switch is active
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Crocodile CAT Electronic System Troubleshooting
28
Indicator non hydraulic voltage chart
PIN #
ACTIVE
VOLTAGE
INACTIVE
VOLTAGE
Arm not home indicator lamp
J2 09
0v
12v
N/A
Arm not home and >7mph
J2 10
0v
12v
N/A
System warning indicator
J2 11
0v
12v
N/A
Pendulum stall indicator
J2 12
0v
12v
N/A
Body up indicator
J2 13
0v
12v
N/A
Tailgate ajar indicator
J2 19
0v
12v
N/A
Autopack lamp indicator
J2 20
0v
12v
N/A
Access ladder indicator
J2 21
0v
12v
N/A
Bin counter
J2 03
12v
0v
N/A
Pump on output (to coil)
J2 05
0v
12v
N/A
Hydraulic oil cooler relay
J2 06
0v
12v
N/A
DESCRIPTION
30
NORMAL COIL
RESISTANCE
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Crocodile CAT Electronic System Troubleshooting
29
Solenoid voltage/resistance chart
PIN #
ACTIVE
VOLTAGE
INACTIVE
VOLTAGE
Top doors open solenoid
J2 07
12v
0v
Top doors close solenoid
J2 112
12v
0v
Lift arm raise solenoid
J1 48
0v
5.3Ohms
Lift arm lower solenoid
J1 49
0v
5.3Ohms
Slide extend solenoid
J1 51
0v
5.3Ohms
Slide retract solenoid
J1 52
0v
5.3Ohms
Grabber close solenoid
J1 58
0v
5.3Ohms
Grabber open solenoid
J1 59
0v
5.3Ohms
Pendulum extend solenoid
J1 61
0v
5.3Ohms
Pendulum retract solenoid
J1 62
0v
5.3Ohms
Tailgate raise solenoid
J1 65
0v
5.3Ohms
Tailgate lower solenoid
J1 66
0v
5.3Ohms
Body raise solenoid
J1 667
0v
5.3Ohms
Body lower solenoid
J1 68
0v
5.3Ohms
DESCRIPTION
31
NORMAL COIL
RESISTANCE
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Crocodile CAT Electronic System Troubleshooting
30
Electronic Joystick Input Verification
The electronic joystick operates using Pulse Width Modulation (PWM) outputs for the slide,
arm and grab functions, as well as fixed output voltage for the push button functions autodump, auto-stow.
PWM is an output signal characterized by a change in the duty cycle of a square wave. This
is measured as a Hz% on the multi-meter. When the joystick is inactive (neutral position) the
multi-meter Hz% is approx. 50%. The range of acceptable values is between 5%-95% when
the joystick slide, lift or grab functions are operated to their maximum position.
The electronic joystick can be tested for failure condition using a multi-meter to record
readings at the relevant pin connections. Readings outside the parameters detailed here may
indicate a failure in the joystick.
?
The electronic joystick sensor is designed so that it does not fail with
an acceptable output
INFO
The main cab connector is a convenient location for
conducting the joystick verification tests. The technician is
able to operate the joystick and observe the meter readings at
the same time and remain clear of the arm assembly.
Remove the covers to expose the 70 pin connector in the cab
footwell.
Refer to overview drawing AP8-E024 rev 5 for connector and
pin locations.
i
The first test is to ensure the joystick is receiving a power supply
WIRE #
PIN CONNECTOR #
J144 Power
Insert Pos +
spoon
10
J145 Ground
Insert Neg spoon
11
METER READING
8v
32
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Crocodile CAT Electronic System Troubleshooting
ii
Neutral joystick position @ 50%+Note: any one of the following functions will show a 50% duty cycle when
the joystick is in neutral:
Slide extend/retract wire 224
Arm raise/lower wire 225
Grabber open/close wire 226
Insert only the Pos+ meter wire into the connector - there is no requirement
for the meter to be grounded for %duty cycle tests
WIRE #
PIN CONNECTOR #
J224 Slide Extend Retract
J225 Arm Raise/Lower
J226 Grabber Open/Close
iii
METER READING
45
46
47
50%+-
Joystick Slide/Extend duty cycle
Note: Insert only the Pos+ meter wire into the connector - there is no
requirement for the meter to be grounded for %duty cycle tests
The maximum range of acceptable values is 5%-95%
WIRE #
PIN CONNECTOR #
JOYSTICK
OPERATION
METER READING
J224 Slide
Extend Retract
45
Slide Extend
20%+-
J224 Slide
Extend Retract
45
Slide Retract
80%+-
33
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Crocodile CAT Electronic System Troubleshooting
iv
Joystick Arm Raise/Lower duty cycle
Note: Insert only the Pos+ meter wire into the connector - there is no
requirement for the meter to be grounded for %duty cycle tests
The maximum range of acceptable values is 5%-95%
WIRE #
PIN CONNECTOR #
JOYSTICK
METER READING
OPERATION
J225 Arm Raise
Lower
46
Arm Raise
20%+-
J225 Arm Raise
Lower
46
Arm Lower
80%+-
v
Joystick (thumbwheel) Grabber Open/Close duty cycle
Note: Insert only the Pos+ meter wire into the connector - there is no
requirement for the meter to be grounded for %duty cycle tests
The maximum range of acceptable values is 5%-95%
WIRE #
PIN CONNECTOR #
JOYSTICK
OPERATION
METER READING
J226 Grabber
Open Close
47
Grabber
Close
20%+-
J226 Grabber
Open Close
47
Grabber
Open
80%+-
34
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Crocodile CAT Electronic System Troubleshooting
vi
Joystick Auto Dump (single button push)
Joystick Auto Stow (single button push)
Joystick Trigger (single toggle)
Note: Insert the Pos+ meter wire into the connector pin
Insert black cable into connector pin # 11 ground wire #145
WIRE #
PIN CONNECTOR #
JOYSTICK
OPERATION
METER READING
J223 Arm Auto
Dump
22
Auto Dump
button NOT
pressed
J223 Arm Auto
Dump
22
Auto Dump
button
pressed
J228 Arm Auto
Stow
49
Auto Stow
button NOT
pressed
12.9V
J228 Arm Auto
Stow
49
Auto Stow
button
pressed
0v
J252 Main
Joystick Trigger
63
Trigger
NOT
pressed
12.9V
J252 Main
Joystick Trigger
63
Trigger
pressed
35
12.9V
0v
0v
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Crocodile CAT Electronic System Troubleshooting
20. Connectors
The Caterpillar control system uses sealed Deutsch connectors to connect wiring harnesses
to major control components. It is critical to maintain integrity of connectors, pins, seals and
wires to ensure the system continues to function correctly. Special tools are required to
service Deutsch connectors.
?
INFO
The Caterpillar Position Sensing Cylinder (PSC) uses a pulse
modulation system that requires gold contacts to be used in the cylinder
communication connectors. If a cable requires replacement in the field,
gold contacts will have to be used.
Common symptoms are erratic or total loss of the cylinder operation.
Normal resistance or continuity checks will show the harness in good
condition and directs the solution to be the replacement of the cylinder.
Caterpillar Electronic Control Module
The Caterpillar system is controlled through the
ECM mounted underneath the main valve.
Two harnesses connect to the ECM via Deutsch
connectors into the ECM multi-pin plugs.
Each connector is keyed differently and cannot be
misassembled. Uses a standard 4mm allen bolt and
the seal is provided by a blue rubber gasket in the
harness plug.
J2
?
INFO
J1
The harness plugs are identified as J1 and J2.
The plug closest to the prominent bulge in the ECM
is J1
It is not necessary to disconnect plugs in order to conduct system
troubleshooting via Input Verification tests. Unnecessary disruption of
plugs may lead to damage of pins and seals.
To gain easier access to the plugs, dismount the ECM and suspend it
from the valve table using tie-wraps. (Ensure the ground strap
remains connected)
36
6/27/2005
Crocodile CAT Electronic System Troubleshooting
Connectors
The ECM plugs secure the harness connectors to
the ECM pins. Not all of the available spaces are
used. Unused spaces must be fitted with sealing
plugs.
Refer to Pin out charts page 39-40 for correct pin
placement.
Switch input verification test locations refer to this
numbered location in the plug to take the readings
During switch input verification tests, special
‘spoons’ are required to contact the pin inside the
sealed plug in order to take readings. The wire from
the spoon is connected to the test meter.
It is critical to maintain effective
sealing at this plug.
?
INFO
Ingress of contamination will
seriously damage the ECM
No other tools are to be used in
this application
37
6/27/2005
Crocodile CAT Electronic System Troubleshooting
Connectors
If the need arises, wires may be pulled from the
Deutsch connector using a special pin puller shown
at left
Clip the pin puller onto the wire casing and gently
insert the pin puller into the connector.
Feel the wire release as the terminal is unlocked
from the connector
Pull the wire out of the connector, followed by the
pin puller.
To replace the wire, simply reinsert the terminal into
the connector and push in until a click is felt as the
terminal is retained by the connector
38
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Crocodile CAT Electronic System Troubleshooting
39
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Crocodile CAT Electronic System Troubleshooting
40
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Crocodile CAT Electronic System Troubleshooting
21. Troubleshooting Charts
The following pages detail the steps necessary to investigate common faults with the Caterpillar
electronic control system.
Indicates a step
to be taken
?
INFO
!
CAUTION
Contains notes
and reminders
Conclusion
Technical support and further troubleshooting advice is available by
calling the FSDepot call center toll-free (877) 800.1111
The main operating hydraulic valves are equipped for use with manual
handles. These are supplied loose with the unit. Handles are for use by
qualified maintenance personnel only and should not be left fitted to an
operational unit. Use of the handles for system troubleshooting and
verification will bypass all electrical lockouts, safety interlocks and
operational cushions.
The handles can be used to quickly identify which part of the system is at
fault, hydraulic or electrical. For example a handle may be fitted to the work
section of the function in question. With the pump on, operate the handle
and if the function is operating, then the fault lies in the electrical system.
Troubleshooting Charts
1. No functions at all
2. No joystick functions or limited joystick functions
3. Arm does not dump
4. Pendulum will not pack
5. Pendulum will not return
41
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Crocodile CAT Electronic System Troubleshooting
1
Check main power
supply to Main Power
Solenoid in Relay Box
No functions
at all
Ensure all Entry conditions are
met and no Exit conditions exist
- Pump Control p.5
- Program Parameters p.6
12v
0v
Start engine
and wait 1.5
secs
Check 50A fuse from
Batt + post
Check continuity to ground
from Main Power Solenoid
in Relay Box
Test for 12v at
Start Interrupt
Timer T1
0v
12v
Check for 12v on wire
#J101 at ECM connector
J1 #01 with Footbrake
depressed
Test Start Interrupt
Relay 4 is operating
Replace Relay
Test Start Interrupt
Timer is operating
Replace Timer
0v
Check battery supply
to ECM connection at
J131
Check ground wire #17
continuity to ground
Check continuity wire
#65 and contacts at
Footbrake switch
Check continuity wire
J131 from ECM to
battery connection
42
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Crocodile CAT Electronic System Troubleshooting
2
No joystick functions
or
Limited joystick
functions
Is the red system warning
light flashing a Diagnostic
Flash Code or Messenger
displaying a fault
Ensure all Entry conditions are met and
no Exit conditions exist
- Electronic joystick p.811/12/13/14
Check Joystick
Enable switch set
to ON
No
Complete Switch Input
Verification check #24
page 28
Yes
Read Diagnostic
Flash Code Value
per page 18-19
Check plug in
connector is tight and
wiring connections to
joystick terminals tight
Note: The possible Flash codes illuminated in
the system warning light (or Messenger) will
indicate that either the lift or slide axis is out
of range. In this case, some of the functions
on the joystick may be operating
Check for 8v sensor
power on wire J144
pin #1 at 6 pin joystick
plug
Complete Switch Input
Verification page 32-35
Check continuity of wire
J144 from joystick to ECM
J1 connector pin 44
Check continuity of wire
J145 from joystick to ECM
J1 connector pin 45
All Switch Input
Verification and
continuity checks
OK
Flash Code Value
6.5.4
Joystick X-Axis
(Slide) out of range
Replace
joystick
Replace
Joystick
Check the harness
and plug to the
joystick
Flash Code Value
6.5.5
Joystick Y-Axis (Lift)
out of range
Replace
Joystick
43
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Crocodile CAT Electronic System Troubleshooting
3
Arm does not
Dump
Does the arm
travel part of the
way up and stop
Retract the slide completely
home and check that the
slide home proximity tab is
correctly set (3/8" from
proximity face)
Yes
Arm raises to
dump
Ensure all Entry conditions are
met and no Exit conditions exist
- Electronic joystick p.11
Check proximity switch
has power (wire J124)
and ground (wire 17)
in the harness
No, arm does
not move at all
Check
harness/plugs
No
Replace
proximity switch
Yes
Check continuity
through switch when
tripped wire 18 to
J1-24
Is the red system
warning light flashing
a Diagnostic Flash
Code
No
No
Check Joystick
Enable switch set
to ON
Note: Also refer to
joystick troubleshooting
chart page 32-35
Check plug in
connector is tight and
wiring connections to
joystick terminals tight
Complete Switch Input
Verification check #24
page 28
Yes
Flash Code Value
6.3.4
Lift arm raise
solenoid
Replace
Solenoid
Check the harness
and plug to the raise
solenoid/lift cylinder
Read Diagnostic
Flash Code Value
per page 18-19
Flash Code Value
6.1.1
Lift arm cylinder
position sensor
44
Replace lift
cylinder
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Crocodile CAT Electronic System Troubleshooting
4
Pendulum
will not pack
Is the red system
warning light flashing
a Diagnostic Flash
Code
Ensure all Entry conditions are met and no
Exit conditions exist
- Manual pack control p.9
Autopack Control p.10
Re-check top doors
are open, arm
down, tailgate
locked
No
Check top doors limit
switches
Check tailgate tilt
switch
Yes
Read Diagnostic
Flash Code Value
per page 18-19
As many as 5 Switch input verification tests may
be conducted during this troubleshooting. Faults
in any one of these circuits would contribute to
the failure of the packing operation
Flash Code Value
6.3.8
Pendulum extend
solenoid
Complete Switch Input Verification
checks page 26
- tests # 8, 9, 10, 11, 12
Replace
solenoid
Check the harness
and plug to the
solenoids
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Crocodile CAT Electronic System Troubleshooting
5
Pendulum will
not return
Is the red system
warning light flashing
a Diagnostic Flash
Code
Ensure all Entry conditions are met and no Exit
conditions exist
- Manual pack/return control p.9
Autopack control p.10
Re-check top doors
are open, arm
down, tailgate
locked
No
Check top doors limit
switches
Check tailgate tilt
switch
Yes
As many as 5 Switch input verification tests may
be conducted during this troubleshooting. Faults
in any one of these circuits would contribute to
the failure of the packing operation
Complete Switch Input Verification
checks page 26
- tests # 8, 9, 10, 11, 12
Read Diagnostic
Flash Code Value
per page 18-19
Flash Code Value
6.3.9
Pendulum retract
Solenoid
Replace
Solenoid
Check the harness
and plug to the
solenoids
46
6/27/2005
FSDepot
54 Park Place
Suite 925
Appleton, WI 54914
Ph. (877) 800-1111
www.fsdepot.com
June 27, 2005
Part Number 105356