Cat Grade Control Errors on Certain F Series Asphalt Pavers {7610, 7620} Caterpillar

Asphalt Paver

AP1000F (S/N: AC41-UP)

AP1055F (S/N: TJ51-UP; RLM1-UP)

AP500F (S/N: 5031-UP; 4491-UP)

AP555F (S/N: AP51-UP; M451-UP; 5F51-UP; RBM1-UP)

AP600F (S/N: AP61-UP; LR61-UP)

AP655F (S/N: 4801-UP; 4521-UP; 4531-UP; P651-UP; 6551-UP; MH61-UP; ML61-UP; 4791-UP)

Introduction

The problem listed below does not have a known permanent solution. Until a permanent solution is identified, use the steps listed below to diagnose and repair your machine.

Problem

Fault codes and malfunctioning of Cat Grade and Slope have been reported on the listed Asphalt Pavers.

Reported symptoms include:

• The padlock icon appears in middle of the grade control screen when no other screen is interacting with the same function.

• The tow point cylinder fully extends or retracts without command.

• "Grade and Slope ECM Disconnected" messages appear.

• "Check Machine ECM" messages appear.

• The measured value on screen is replaced by "-" and system shows sensor as disconnected in diagnostic menu.

To investigate and diagnose the faults, diagnostic data must be captured just after the event or error occurs. Information about operating conditions leading up to the event or error is also important for investigation.

Solution

To diagnose Cat Grade Control errors or malfunctions, work with your dealer Technical Communicator (TC) using the following approach:

• Recognize whether a true problem exists.

• Collect and analyze information about symptoms and operating conditions.

Note: Cat Grade Control diagnostic information is separate from the machine ECM and is not retrieved with Cat Electronic Technician (Cat ET). When a grade control error occurs, a yellow banner will appear on the screen. There are no code numbers associated with the yellow banner error messages. Errors from the machine are indicated by a wider yellow message, with associated error code numbers.

Determine the Existence of a True Problem

After an error is indicated, take note of the following:

• Surrounding operating conditions prior to the error or malfunction.

• Sensors must be set up correctly.

• Sensor connections must be tight and dry.

• Erratic behavior of the crew prior to the error or malfunction.

• Understand the repeatability of the error or malfunction.

• Observe how often the error or malfunction occurs.

Gather Information for Analysis

Initiate a Dealer Solution Network (DSN) ticket through your dealer TC. Collect and provide information to the DSN as follows:

• Record the exact date and time of occurrence.

• Record the exact yellow banner message on the grade control screen. Take a photo if possible.

• Initiate a "Z Snap" within 1 minute of the error occurrence. See "Z Snap Process" below.

• Retrieve and compress the diagnostic files collected by "Z Snap". See "Retrieving Diagnostic Files" and "Compressing (Zipping) Diagnostic Files" below.

• Provide the machine serial number, sensor configuration, and any additional photos or information.

E-mail your dealer TC (or DSN contact) the information listed above. Attach the compressed diagnostic information files.

Z Snap Process

The "Z Snap" is obtained by swiping a finger from the LOWER RIGHT corner to the UPPER RIGHT corner of the main grade control screen. A camera symbol will appear in the center of the screen. A "Diagnostics Recorded – Changed to Manual" message may appear, indicating the grade system diagnostic data is being stored. Do not touch the screen or any buttons when the camera symbol is present. If the grade system was in AUTO when the "Z Snap" was initiated, the grade system will enter manual mode.

The system can be reset or placed back into automatic mode after the camera symbol is gone. The stored diagnostic files can be retrieved with a USB memory device.

Retrieving Diagnostic Files

Insert a known good USB memory device into the port next to the ignition key switch. From the left paver operator station, perform a "USB Sync".

Navigate from the Main grade control screen, touch the gray Menu icon. Select "Operator Settings". Select "USB Sync". Select "To USB". Touch the right-facing arrow to start the process. A message on the screen will ask for the USB device to be removed when the process is complete.

If the USB process is not working, contact your dealer TC to initiate a DSN request. Ask for the request to be sent to the product group in Minneapolis. Further instruction can be given to retrieve the diagnostic files.

Compressing (Zipping) Diagnostic Files

The diagnostic file must be compressed (zipped) before sending through e-mail.

Illustration 1	g06114058
Z Snap recordings will be saved in a file folder on the USB device.

Illustration 2	g06114067
Compress the file folder into a zipped file for e-mail transfer. Right-click the file name, hover over "Send to", select "Compressed (zipped) folder".

Illustration 3	g06114384
The compressed folder will populate in the same location as the file folder.

Insert the USB device into a computer to access the files. Enter "Windows Explorer" and find the USB device. Locate the "Machine Control Data" file that was stored during the "USB Sync" process.

Right-click the "Machine Control Data" folder. Highlight "Send to", navigate to "Compressed (zipped) folder". The compressed folder icon will look like a file with a zipper on it. The compressed file is the file to send to your TC (or DSN contact).