Automation Creation Ltd Electronic Control System

Troubleshooting

Electronics trouble shooting:

1. The Control Panel remains blank after power is switch on:

- Check Control Panel power cables are connected to the battery
- Check that the battery has adequate charge (Try starting the vehicle)
- Check 5 amp fuse in the cable junction box.  If the fuse has blown, try a new fuse.
If the fuses continue to blow try the following...
a. Unplug the sensor lead from the cable junction and pump control box and try again 
b. Contact Automation Creation by completing the FAX.
 

2. The Control Panel Display Indicates "E 1" or "E 0" when power is applied:

- This indicates an error with the calibration values. Pressing a height control key
should allow the system to complete the power up sequence. When the display indicates
"0 0" try altering the range or zero settings then switch the control panel on and off again. 

- If the problem persists, the EEPROM circuit requires attention or the EEPROM requires
changing.  "E 0" or "E 1" will always be displayed when using an EEPROM for the first time
that has not yet been programmed.

3. The Control Panel Displays the correct information and allow values to be changed and the
pump starts but the height will not increase:

- Check the cable between the pump and the control panel has been secured correctly.
- Check the 5 amp fuses in the pump control box.  These fuses control the valves.
- Check the indication lamps on the pump valves.  If the lamp on the raise valve(s)
are illuminated then check that the pump has sufficient hydraulic oil.

- If a service has been performed on the Skid Car and the oil line between the Accumulator
and the RAM has been adjusted or more nitrogen has been added to the cylinder, the
accumulator system may be providing too much opposing pressure to allow the frame to rise.
Bleed out either oil or nitrogen until the frame can raise to its heighest point on the ram
without too much effort.

- The cable between the control panel and the cable junction box may be defective and will
require changing.  (D25 male to female 2 m all pins wired straight through)

4. The control panel seems to display the correct information and allow values to be
changed, but the pump does not start when the height setting is increased:

- Check the pump control box.  Ensure that all plugs are secured firmly.
- Check cable between the cable junction box and the control panel is secured firmly.
  Replace if a fault is suspected  with this cable.
- Check 5 amp fuses in the pump control box.
- Check indication lamps on pump valves.  If the raise valve(s) are illuminated, then
the 90 amp pump starting relay (solenoid) may not be operating correctly. 

Checking the Pump Starting Relay:

To check the pump starting relay, ensure that the raise valves on the pump are on.
(Use the control box and increase any of the height settings.)  The pump starter relay
should activated. 

Use a voltmeter set to DC volts and check that there is approximately 12 volts on the
coil of the start relay.  If the voltage is absent then there is check the 8 pin pump
plug and ensure all the connections are making contact.

If there is voltage on the relay coil, use the voltmeter set to DC volts and check the
voltage on both sides of the relay pump contacts.  (Place the red lead to the relay
terminal and the other lead to the chassis of the vehicle.)  The readings should be
12 volts on both sides of the relay contacts.  If the side of the relay supplying the
pump does not read the same voltage as the other side of the relay, the relay requires
changing. 

- Both the RED and GREEN LED's should be illuminated in the pump control box with the
control panel switched on.

LED indicator definition:

RED LED: When on, it indicates that the electronics on the valve saver circuit board are
functioning correctly.  If the Red Led is extinguished, the valve saver circuit board may
require changing.

GREEN LED: When on, it indicates that the relay in the pump control box is operating
correctly.  If the RED Led is on but the GREEN Led is off, the relay may be defective 
or one of the relay wires may have pulled out of its connection.

5. The height of the Skid Car does not decrease when the control panel height is
decreased or when the emergency lower is pressed:

- Check the 5 amp fuses in the pump control box.
- Check the pump cables are securely

6. The control panel flashed "E E" and will not reset when a height control button
is pressed:

- Locate the cable junction box.  Ensure that the link between the negative and
centre terminal on the 3 terminal connector is fitted.
- Ensure that cable between the control panel and the cable junction box is fitted
correctly.  Replace if suspect cable failure.

7: When system is first switched on, the front and/or rear of the Skid Car travels
to maximum height and the pump runs on continuously:

- Check that the sensors have been plugged in. If they have not, remove the red power
cable, supplying the electronics, from the battery before plugging in the sensors.

- Check that the cable between the control panel and pump control box is secured
correctly. Replace is necessary i.e. after testing sensors and sensor strip.

- Identify which end of the frame is malfunctioning.  Go to the sensor assembly on the
ram of the end that is malfunctioning and do the following...

i  Check that the sensor strip is running within the sensor block.  If the strip has
come away, ensure that the bolt hold the sensor strip bracket is not tight and re align
the sensor bracket.

ii Check that the sensor strip is clean and not damaged.  Replace if damaged.

iii Clean the sensor using the methods in the maintenance section of this manual.

iv Change the sensor itself.  A sensor may be damaged by being plugged into the system
when power is fully connected.

8: Height Control is Erratic:

- Check all sensor cable connections.
- Clean or replace the sensor strips and clean the sensors.