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……………………………………….
Crocodile CAT Electronic System Troubleshooting 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……………………….…………………....
Crocodile CAT Electronic System Troubleshooting 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.
Crocodile CAT Electronic System Troubleshooting 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.
Crocodile CAT Electronic System Troubleshooting 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.
Crocodile CAT Electronic System Troubleshooting 5. Allison Transmission Program Parameters The following parameters have been programmed into the transmission ECU at factory.
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Crocodile CAT Electronic System Troubleshooting 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.
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Crocodile CAT Electronic System Troubleshooting 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.
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Crocodile CAT Electronic System Troubleshooting 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.
Crocodile CAT Electronic System Troubleshooting 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.
Crocodile CAT Electronic System Troubleshooting 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.
Crocodile CAT Electronic System Troubleshooting 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.
Crocodile CAT Electronic System Troubleshooting 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.
Crocodile CAT Electronic System Troubleshooting Select ‘Service Mode ENABLED’ and use the ‘back’ key to return to the Main Menu ? The default setting for Service Mode is DISABLED.
Crocodile CAT Electronic System Troubleshooting 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.
Crocodile CAT Electronic System Troubleshooting Settings: Config Parameters Load Zone Displacement OK Load Zone Interlock Pct Displacement Press OK to Edit 35.
Crocodile CAT Electronic System Troubleshooting 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.
Crocodile CAT Electronic System Troubleshooting 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 la
Crocodile CAT Electronic System Troubleshooting 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 CONVEN
Crocodile CAT Electronic System Troubleshooting 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.
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 Trig
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 6/27/2005
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
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.
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%.
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 READIN
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 i
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.
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.
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.
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.
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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.
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.
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.
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.
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.
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.
FSDepot 54 Park Place Suite 925 Appleton, WI 54914 Ph. (877) 800-1111 www.fsdepot.
