Visio-Wittke ASL wCAT Troubleshooting Jan 05 UNFINISHED
Contents
1. Ov rocker not pressed Grip close rocker pressed 2 3 2005 2 ASL Electronic System Troubleshooting Analog Joystick Input Verification The joystick can be tested for failure condition by recording the voltage present at the relevant pins in the ECM plug Using an Ohm meter set to the VOLT function test the relevant pins to determine voltages as the joystick is operated see chart below Readings outside of those listed indicate a faulty joystick RANGE Voltage must never leave range at extremes of travel INFO INFO CENTER Voltage must fall into center range when the joystick is in neutral FUNCTION LOCATION RANGE CENTER CONVENTION 9V Power 1 3 620 488 54 Supply Lift Raise 2 35V Joystick Lower voltages Lower ooo 285 back RAISE Joystick 17 voltages LOWER Slide 2 35 Higher Extend C7 37 gt 0 2V 4 8V 2 85V Joystick left voltages Retract SLIDE IN Joystick right Lower voltages SLIDE OUT If the joystick fails outside of the voltage ranges shown here it will also flash a diagnostic code on the system warning light For example should the slide axis2. 18 12v gt X button not pressed Joystick not enabled Ov Trigger not down Joystick enabled Trigger on 2 3 2005 FUNCTION Autopack Mode ASL Electronic System Troubleshooting Speed Lockout TEST Half Pack Pressure 12v CONVENTION v Ov Intelli pack v Tailgate Fully Open 12v Multi pack Speed lockout Ov not on Speed lockout Grip Open Rocker 12v on Not at pack Ov or pack press At 12 pack or at pack Grip Close Rocker 12v pressure Tailgate not Ov fully open Tailgate fully TYPE LOCATION Ground C7 42 Ground C7 43 Ground gt C7 64 Ground gt C8 23 Ground gt C7 30 Ground gt C7 31 12v open Grip open rocker not Ov pressed Grip open 19 12v rocker pressed Grip close
3. Footbrake Slide proximity Grip proximity Pump on off Tailgate ajar Packer blade Hopper cover Autopack start Autopack stop 10 Manual pack 11 Manual return 12 Joystick trigger 13 Autopack mode 14 Speed lockout 15 Half pack pressure switch 16 Tailgate fully open 17 Grip open rocker 18 Grip close rocker 0 1 5 0 Analog Joystick Input Verification 1 5v power supply 2 Lift raise lower 3 Slide extend retract 16 2 3 2005 E ASL Electronic System Troubleshooting Switch Input Verification FUNCTION Footbrake Slide Proximity CONVENTION Brake on Brake not on Grip Proximity Slide home Slide not home Pump On Off v LEEEEL Tailgate Ajar Packer Blade Tailgate ajar TYPE LOCATION TEST Battery gt C7 14 12v Ov Battery gt C7 24 12 Ov Battery C7 25 12v Ov Ground gt C7 26 12 Ov Ground gt C7 27 12 Ov Ground gt C7 28 12
4. Ld SERVICE MANUAL SUPPLEMENT AUTOMATED SIDE LOADER WITH CAT SYSTEM UPGRADE ASL Electronic System Troubleshooting Wittke Automated Side Loader with Caterpillar electronic system Supplement Manual TROUBLESHOOTING Section Page 1 8 Uc 2 2 FIC TCT CIC ws 3 3 EXIVEMthy 3 4 211112 OOM EP 4 9 Allison Transmission Program Parameters 5 6 Manual Pack Return 20 2 2 6 7 AUtopack GOhIOL 7 8 Electronic Joystick Operational Requirements 8 9 Joystick Manual Arm Control Loading 8 10 Joystick Manual Return to 9 11 Tailgate Open Close 10 12 Indicator Non Hydraulic Output Control 11 13 Arm Lift Calibration 2022 22 12 14 Diagnostic Flash Code 14 15 SWITCH sec E 16 16 COMME ENS UT UT 21 17 Troubleshooting 6 0 2 21 26 1 2 3 2005 ASL Electronic System Troubleshooting 1 Introduction Troubleshooting is an organized stu
5. Check main power at all T 1 1 1 1 Ensure all Entry conditions are met and no Exit conditions exist Pump Control p 4 Program Parameters p 5 Start engine and wait 1 5 secs y Test for 12v at Start Interrupt Timer T6 Check 50A fuse from Batt post 12v y Check for 12v on wire 64 at ECM connector C C7 supply to Main Power Solenoid in Relay Box 12v 4 Ov p gt Ov v Check continuity to ground from Main Power Solenoid in Relay Box Test Start Interrupt Relay is operating Check ground wire 17 continuity to alternator ground Test Start Interrupt Timer is operating Replace Relay 14 with Footbrake depressed 27 Replace Timer Check continuity wire 65 and contacts at Footbrake switch 2 3 2005 ASL Electronic System Troubleshooting c No joystick functions or Limited joystick functions Is the red system warning light flashin 2 Ing gn 97 gt Enable switch set a Diagnostic Flash to ON Code Yes Note The possible Flash codes illuminated in the system warning light will Read Diagnostic indicate that either the lift or slide axis is Flash Code Valu
6. Solenoid v Check the harness and plug to the raise solenoid lift cylinder Replace lift 29 cylinder 2 3 2005 ASL Electronic System Troubleshooting Ensure all Entry conditions are Packer blade met and no Exit conditions exist will not pack Hg EN v Is the red system Re check hopper warning light flashing No cover is open arm Check hopper cover a Diagnostic Flash down tailgate limit switch Code locked Check tailgate tilt switch v Yes As many as 9 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 v Y Complete Switch Input Verification Note the packing operation will run checks pages 17 18 19 Read Diagnostic at 50 speed if one of the pack tests 5 6 7 8 9 10 13 15 Flash Code Value extend solenoids is faulty 16 per page 14 15 E Flash Code Value 6 3 8 Replace Packer blade extend solenoid solenoid 1 Check the harness gt and plug to the solenoids Flash Code Value 6 4 2 Replace Packer blade extend solenoid solenoid 2 30 2 3 2005 5 ASL Electroni
7. ASL Electronic System Troubleshooting Inputs FAULT DESCRIPTION FLASH CODE Lift arm cylinder position sensor 6 1 1 Joystick X Axis slide Joystick Y Axis lift Miscellaneous System Issues FAULT DESCRIPTION FLASH CODE Harness code invalid System voltage 8v sensor supply 5v sensor supply 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 15 2 3 2005 ASL Electronic System Troubleshooting 15 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 Ov condition or a 12v condition the joystick circuits are tested for a voltage range 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
8. Ov 17 Grip open Grip not open Pump switch off Pump switch on LE Tailgate closed Packer blade not home Packer blade home 2 3 2005 FUNCTION Hopper Cover Autopack ASL Electronic System Troubleshooting Start Autopack TEST Stop Manual 12v CONVENTION Hopper cover Ov open Hopper cover Pack Manual 12v closed Autopack start gt X button not Ov pressed Autopack start Return Joystick 12v button pressed Autopack stop Ov button pressed Autpoack stop gt button not Trigger 12v pressed Manual pack button not Ov pressed Manual pack TYPE LOCATION Ground C7 32 Ground C7 33 Ground C7 34 Ground C7 35 Ground C7 40 Ground C7 41 12v button pressed Manual return Ov button pressed Manual return
9. close solenoid open only Fault on close solenoid close only Arm not home Transmission gear selected Not in lift autocalibration mode 10 2 3 2005 ASL Electronic System Troubleshooting 12 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 sound 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 mph 11kmph System warning light blinks warning codes when present see Flash Code Values Table Tailgate ajar indicator illuminates control panel warning lamp sound in cab alarm and back up alarm when tailgate unlocked Autopack indicator illuminates Autopack switch warning lamp when Autopack active Access door open illuminates control panel warning lamp sound in cab alarm when access door is open 11 2 3 2005 ASL Electronic System Troubleshooting 13 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
10. fail outside of 0 2v 4 8v flash code 4 3 3 will illuminate If the joystick fails completely it will not flash a code Refer to troubleshooting chart 2 to make power and ground checks 20 2 3 2005 ASL Electronic System Troubleshooting 16 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 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 The harness plugs are identified as C C7 and the plug closest to the prominent bulge in the ECM is C C7 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 INFO 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 21 2 3 2005 ASL Electronic System Troublesho
11. 4 aedy emo 2 3 2005 ASL Electronic System Troubleshooting 17 Troubleshooting Charts The following pages detail the steps necessary to investigate common faults with the Caterpillar electronic control system Indicates a step Contains notes Conclusion to be taken and reminders 2 Technical support and further troubleshooting advice is available by INFO 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 N qualified maintenance personnel only and should not be left fitted to an operational unit Use of the handles for system troubleshooting and CAUTION 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 Packer blade will not pack 5 Packer blade will not return 26 2 3 2005 ASL Electronic System Troubleshooting No functions
12. OFF No fault on pump solenoid Fault detected on pump solenoid No short to battery faults on any functions Short to battery on any function 4 2 3 2005 ASL Electronic System Troubleshooting 5 Allison Transmission Program Parameters The following parameters have been programmed into the transmission ECU at factory Note Brake pedal and joystick trigger must both be depressed for 50 to engage Throttle pedal is disabled while this condition exists Maximum engine speed for PTO engagement Maximum engine speed for PTO operation Maximum output speed for PTO engagement Maximum output speed for PTO operation Speed to turn on output speed interlock 250 300 7 10mph Speed to turn off output speed interlock 250 300 7 10mph Throttle soeed up 750 5 2 3 2005 ASL Electronic System Troubleshooting 6 Manual Pack Return Control Basic Functionality Extend packer blade when proper conditions are met and the operator 15 holding down the pack button Retract packer blade when proper conditions are met and the operator is holding down the return button Notes Switch must be re pressed after forced exit condition Tailgate ajar and fully open OK for unload 6 2 3 2005 ASL Electronic System Troubleshooting 7 Autopack Control Basic Functionality In multi mode cycle the packer blade a pre programmed number of cycles 3 and then stop In intelli mode cycle the packer blade once every pre progra
13. 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 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 0 If the is ever washed after a calibration routine has been INE performed the calibration values will revert to their default values and the calibration routine will have to be re run 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 CAUTION Warn other shop personnel that the calibration is being conducted Turning off the pump 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 12 2 3 2005 ASL Electronic System Troubleshooting Calibration Sequence 1 Simultaneously press and hold manual pack manual return and autopack butions for more than 3 seconds 2 While maintaining hold on the autopack button release manual pack and
14. c System Troubleshooting Packer blade will not return y 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 6 COMMENT c Yes v Re check hopper cover is open arm down tailgate locked As many as 9 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 CM NEN Read Diagnostic Flash Code Value per page 14 15 Note the return operation will run at 5096 speed if one of the pack extend solenoids is faulty CUM 775 Flash Code Value 6 3 9 Packer blade retract solenoid 1 Check hopper cover limit switch y tests Complete Switch Input Verification checks pages 17 18 19 5 6 7 8 9 11 13 15 16 Flash Code Value 6 4 1 Packer blade retract solenoid 2 v Replace Solenoid Check the harness and plug to the solenoids Replace solenoid 2 3 2005 z A FEDERAL SIGNAL COMPANY r d Ld gt j r d Ld fS Depot 2737 Harrison Street Oshkosh WI 54901 Tel 877 800 1111 Please visit our website www fsdepo
15. dy of the problem and a planned method of investigation and correction Think about the following before proceeding e Quiz the operator What were the warning signs prior to failure Ensure components and wiring are installed per factory specifications e 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 e Use the Troubleshooting Guide as a reference only it may not contain all the answers e Keep to Maintenance Schedules 2 2 3 2005 ASL Electronic System Troubleshooting 2 Reference Operation and Maintenance Manual schematics AL8 E015 Overview AL8 E014 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 C C7 C C8 3 Entry Exit Conditions The first consideration in troubleshooting electronic system
16. e gt out of range In this case some of the per page 14 15 v Flash Code Value 4 3 3 Ensure all Entry conditions are met and no Exit conditions exist Electronic joystick p 8 9 CON Check plug in connector is tight and functions on the joystick may be operating v wiring connections to joystick terminals tight Complete Switch Input Verification check 1 page 20 Check for sensor power on wire 5 at joystick plug Complete Switch Input Verification check 12 page 18 Check for ground on wire 17C at joystick plug Check continuity of wire 5 from joystick to splice with wire 7 from pump switch circuit Switch Input Verification and continuity checks OK Check continuity of wire 17C from joystick to ECM C7 19 Replace joystick Joystick X Axis Slide out of range Flash Code Value 4 3 2 Check the harness and plug to the joystick Replace Joystick Y Axis Lift out of range 28 Joystick Replace Joystick 2 3 2005 ASL Electronic System Troubleshooting Arm does not Dump Does the arm m travel part of the way up and stop X En
17. 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 oystem 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 oystem 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 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 ASL 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 pump on 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
18. 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 While the arm is on its way down from a full stroke returning to home press and hold the autopack button again for 3 seconds 7 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 8 After 10 seconds turn the ignition key back on and start the vehicle This ensures that the calibration is complete P Use the pump OFF switch or un center the joystick as an emergency stop to end the auto calibration early if necessary INFO No calibration values will be updated unless the entire calibration completes successfully 13 2 3 2005 ASL Electronic System Troubleshooting 14 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 quickl
19. mmed number of container dumps 4 Notes IIluminates Autopack lamp when cycle is active Switch must be re pressed after a forced exit condition The pre programmed values are not adjustable by field technicians a NN 7 2 3 2005 ASL Electronic System Troubleshooting 8 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 9 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 Grip Open are allowed should any Exit Conditions exist e 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 Joystick centered trigger toggled Pump switched off 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 Hopper cover open Hopper cover close All return
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21. oting 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 24 25 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 Ingress of contamination will seriously damage the ECM No other tools are to be used In this application 22 2 3 2005 ASL 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 23 2 3 2005 ASL Electronic System Troubleshooting punoiD apo 558 WJ3 911498 SUR 18400 1193 aule Jamod 193 91128 msu
22. sure all Entry conditions are met and no Exit conditions exist Electronic joystick p 8 9 CMM NEM No arm does not move at all v Is the red system warning light flashing a Diagnostic Flash Code No Retract the slide completely home and check that the Yes slide home proximity tabis correctly set 3 8 from proximity face Arm raises to dump Check proximity switch has power wire 390 and ground wire 17 in the harness Yes Check continuity through switch when tripped wire 219 to C7 24 v Yes y Check Joystick Enable switch set L Check harness plugs Replace proximity switch Check plug in connector is tight and to ON wiring connections to joystick terminals tight Complete Switch Input Verification check 2 page Note Also refer to joystick troubleshooting chart page 27 Flash Code Value 6 3 4 Read Diagnostic Flash Code Value per page 14 15 Lift arm raise solenoid 20 Complete Switch Input Verification check 12 page 18 Replace Flash Code Value 6 1 1 Lift arm cylinder position sensor
23. t com February 11 2005 Part Number 105367
24. to home conditions OK Fault detected on any arm solenoid Fault detected in joystick 8 2 3 2005 ASL Electronic System Troubleshooting 10 Joystick Manual Arm Control Return to Home Basic Functionality e 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 Grip Open are allowed should any Exit Conditions exist fully locked out state permits no motion ENTRY CONDITIONS EXIT CONDITIONS Pump ON Pump OFF No fault in lift lower slide retract grip open solenoids No fault on any joystick axis Fault on joystick axis 9 2 3 2005 ASL Electronic System Troubleshooting 11 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 body control logic Switches must be re centered if out of neutral at pump on or after forced exit condition ENTRY CONDITIONS Pump ON Open Close switch activated and held No fault tailgate open close solenoid open only No fault tailgate close solenoid close only Arm home Transmission in neutral EXIT CONDITIONS Pump OFF Open Close switch released Fault on tailgate open
25. y The red system warning light mounted onto the control panel rear 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 system warning light flashes 6 times pauses flashes 3 times pauses flashes 2 times pauses for longer then repeats this sequence 15 6 3 2 indicating a problem with Lift arm grabber open solenoid The yellow warning light mounted onto the control panel front indicates that P the system has failed completely and has shutdown This may be accompanied by a flash sequence the system warning light INFO Note functions not directly controlled by the Caterpillar controller such as the tailgate and the hopper cover will not initiate a flash sequence or indicate system failure in the event of a fault Outputs FAULT DESCRIPTION FLASH CODE Lift arm raise solenoid 6 3 4 Lift arm lower solenoid 6 3 5 Lift arm slide extend solenoid 3 Lift arm slide retract solenoid 6 3 7 Lift arm grabber close solenoid 6 3 3 Lift arm grabber open solenoid 6 3 2 Packer blade extend solenoid 1 3 Packer blade retract solenoid 1 6 3 9 Packer blade extend solenoid 2 6 4 2 Packer blade retract solenoid 2 6 4 1 DA 2 3 2005
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