Professional Documents
Culture Documents
CAT 16H Service Manual PDF
CAT 16H Service Manual PDF
CAT 16H Service Manual PDF
November 2003
Systems Operation
Troubleshooting
Testing and Adjusting
120H, 12H, 135H, 140H, 143H, 14H,
160H, 163H and 16H Motor Graders
Caterpillar Monitoring System
1241-Up (Machine)
1251-Up (Machine)
1261-Up (Machine)
CCA1-Up (Machine)
CBC1-Up (Machine)
ASD1-Up (Machine)
ASE1-Up (Machine)
CAF1-Up (Machine)
CBK1-Up (Machine)
ARL1-Up (Machine)
APM1-Up (Machine)
APN1-Up (Machine)
CCP1-Up (Machine)
ATS1-Up (Machine)
AMX1-Up (Machine)
ALZ1-Up (Machine)
AMZ1-Up (Machine)
i01658146
General Information
SMCS Code: 7490
Introduction
g00944992
Illustration 1
Caterpillar Monitoring System for the 140H, 143H, 160H and 163H
The quad gauge module and the speedometer/tachometer module are optional components.
5
Systems Operation Section
g00863307
Illustration 2
Caterpillar Monitoring System for the 14H and 16H
The quad gauge module and the speedometer/tachometer module are optional components.
6
Systems Operation Section
g00945076
Illustration 3
Caterpillar Monitoring System for the 12H, 120H and 135H
The quad gauge module and the speedometer/tachometer module are optional components.
7
Systems Operation Section
Speedometer/Tachometer Module
• One tachometer gauge (6) shows the information
on the engine speed (RPM).
8
Systems Operation Section
• One three digit display area (7) shows the The operator modes are accessible by using the
information on the ground speed. The speed is selector switch for the operator mode that is located
displayed in “MPH” and “km/h”. in the operator’s compartment. The following table
shows the available modes. See the Operation and
• Information on the transmission gear and the Maintenance Manual of the machine that is being
direction are shown on a two digit gear readout (8). serviced for specific information on the operator
mode.
Quad Gauge Module
When power is applied, the Caterpillar Monitoring
• The four gauges (5) show the condition of System performs the self test. After the self test is
the machine. The quad gauge will display the complete the Caterpillar Monitoring System enters
following information: engine coolant temperature, the Normal Mode. Normal Mode is service mode 0.
articulation angle, system voltage, and fuel level. Normal Mode contains the operator modes. In order
to enter the other service modes, the service and
According to the application, the type and the clear inputs must be grounded at the same time.
quantity of indications that are used in the display Access to the service and clear inputs is provided
areas varies. All of the indications are not used on with the service connector. The service connector is
the machine. The quantity of quad gauge modules located within the operator compartment. Information
and speedometer/tachometer modules may vary on the location of the service connector is in the
with each machine. An action lamp and an action Electrical System Schematic for the machine that is
alarm indicate the severity (warning category) of a being serviced.
problem. To determine the functions that are used
on a particular machine, see the corresponding When the service and clear inputs are grounded, the
Operation and Maintenance Manual. service mode numbers scroll sequentially on the six
digit display area of the main display module.
Table 1 i01856906
Table 2
12H, 14H, 16H, 120H, 135H, 140H, 143H,
160H And 163H
Service Modes
Service Mode Mode Number
Harness Code 1
Parameter Display 2
Diagnostic Service 3
Tattletale 4
Digital Tattletale 4
Units 5
Calibration (Articulation Gauge) 6
Calibration (Transmission Control) 7 g00789331
Illustration 6
Calibration (Transmission Control) 8 Caterpillar Monitoring System Display Components
Calibration (All Wheel Drive Control) 9 (1) (1) Quad gauge module
(143H, 163H) (2) Speedometer/tachometer module
(3) Main display module
Setup 9 (4) Alert indicators
(5) Gauges
Setup (143H, 163H) 10 (6) Tachometer
(7) Ground speed readout
(1) This mode is not operational at this time. This mode is reserved (8) Transmission gear readout
for future use. (9) Display area
• The main display module continuously watches The default condition is shown on the six digit display
machine systems. If the gauges are available, the area when the main display module enters normal
gauges in the quad gauge module show a value mode. This condition is normally the service meter.
in a normal range. Ground speed readout (7) is See System Operation, “Service Meter Mode” for
shown as a numeric value and the transmission more information.
gear readout (8) on the module shows numeric
values. The value for a condition may also be The six digit display area scrolls through the available
shown in the display area. operator modes when the operator switch input
is grounded. Opening the switch input will stop
• The main display can show a problem with the the scrolling on the currently shown mode. Mode
machine. The main display module continuously numbers are not displayed when operator modes are
monitors machine systems. When an abnormal scrolling.
condition (problem) exists, the corresponding alert
indicator (4) FLASHES. As the severity of the See the topic with the corresponding name on the
problem increases, the action lamp FLASHES and following pages for a more detailed explanation of
the action alarm SOUNDS. See System Operation, each mode.
“Warning Operation”.
Optional Machine Conditions
Note: The main display module may notify the
operator when a diagnostic code exists in other The display area may be used to show other
electronic systems. This is done in different ways. information on the condition of the machine. For
The following example is of a diagnostic code that example, the display area may be used as a gear
occurs in the engine electronic system. The service readout when the speedometer/tachometer module
code indicator will show “SERV CODE” and the is not used. The following situation occurs in order
alert indicator for “check engine” FLASHES. See the to function as a gear readout. The six digit display
Operation And Maintenance Manual for the machine area changes from the default condition to the gear
that is being serviced for more specific information readout when the parking brake is DISENGAGED.
on the machine. The symbol for the service meter turns OFF and the
information on the transmission gear is shown on the
Operator Modes six digit display area.
The main display module keeps track of the total The engine RPM is shown on the six digit display
number of engine hours. The total machine operating area when the main display module is in tachometer
hours are shown on the six digit display area when mode. The indicator for the units shows “RPM”. The
you are in service meter mode. The symbol for the main display module can calculate engine speed with
service meter is ON in order to indicate when the a frequency sensor. The main display module may
display is functioning as a service meter. The value is also receive information from a frequency sensor
continuously updated when the engine is operating. from another electronic control module. This can be
done by way of the CAT data link.
The main display module monitors the following
electrical inputs in order to determine when the
i01456960
machine engine is operating: the engine speed,
terminal for alternator “R”, and the engine oil
pressure. The main display module starts the service
Scrolling Mode
meter for the machine when one of these inputs is SMCS Code: 7490
in the normal range.
i01461542
Odometer Mode
SMCS Code: 7490
g00298418
Illustration 8
Display Area
Table 4 g00299479
Illustration 12
Machine Codes
Display Area
Sales Model Machine Code
Numeric readout mode is always mode 2. Numeric
14H 14 readout mode assists service personnel with
140H 40 troubleshooting of sensor inputs. The inputs supply
information for the gauges in the quad gauge
143H 43 modules. Numeric readout mode more accurately
160H 60 shows the same information that is shown on the
gauges in normal mode. The system identifier and
163H 63 the numeric value for the system scrolls on the six
120H 20 digit display area. The system identifier identifies the
system that is currently shown on the six digit display
135H 35 area. See table 5 for “System Identification” and
12H 12 illustration 13 in order to match the system identifier
to the appropriate gauge.
16H 16
13
Systems Operation Section
i01525238
g00299481
Illustration 14 g00298101
Illustration 15
This is an illustration of the display area on the Main Display
Module that is showing an example of a system identifier. Display Area
Service Mode
SMCS Code: 7490
g00298418
Illustration 16
Display Area
Service personnel can see the diagnostic codes and Component Identifier (CID) – The components that
service personnel can troubleshoot the diagnostic are faulty are noted by the CID. These components
codes when the main display module has detected are examples: transmission oil temperature sensor,
a fault. All detected faults are shown in the display speed sensor, action lamp, and boost pressure
area as a diagnostic code. The diagnostic codes can sensor. The CID is a four digit code that is shown on
be placed on hold and the diagnostic codes can be the six digit display area. The CID and the FMI are
cleared while the main display module is in service shown together after the MID has been displayed.
mode. See the table “Diagnostic Codes For Caterpillar
Monitoring System” in Testing And Adjusting,
Note: Diagnostic codes from other machine systems “Troubleshooting Diagnostic Codes”. This will show a
under electronic control are shown in the display list of CID codes for the main display module.
area of the main display module when the main
display module is in Service Mode. The CAT data Failure Mode Identifier (FMI) – The FMI tells the
link allows the transfer of diagnostic information from type of failure that has occurred. The following
other electronic control modules to the main display situations are examples: voltage above normal,
module. This diagnostic information is then shown current below normal, and abnormal frequency.
when the main display module is in service mode. The FMI is a two digit code that is shown on the
The diagnostic code for faults from other electronic six digit display area. The CID and the FMI are
control modules has a MID that is unique to the shown after the MID is displayed. The CID and the
control. These diagnostic codes can scroll similarly to FMI are separated by a decimal point “.”. See the
the diagnostic codes from the Caterpillar Monitoring table “Diagnostic Codes For Caterpillar Monitoring
System. See the following description of Module System” in Testing And Adjusting, “Troubleshooting
Identifier (MID). Diagnostic Codes”. This table will show a list of failure
mode identifiers for the main display module.
The diagnostics of the Caterpillar Monitoring System
are available to assist with the troubleshooting of When the main display module enters the service
diagnostic codes when the main display module is mode, the MID, the CID, and the FMI are shown. At
placed in service mode. A diagnostic code is used this time, the diagnostic code that is shown is on hold.
to specify each fault. The diagnostic code is made The display area continuously changes between
up of three identifiers (MID, CID and FMI). These the following identifiers when the diagnostic code is
identifiers are shown in the display area. The display on hold: MID, CID, and FMI. This is maintained as
area continuously changes between the following long as the service and clear inputs remain open.
identifiers when the diagnostic code is on hold: Troubleshooting is performed while the diagnostic
code is on hold.
Module Identifier (MID) – The MID is a three-digit
code that is shown on the display area. The MID Note: The display shows “- - -” when the main display
is shown for approximately one second before the module has no diagnostic codes.
diagnostic code that is shown in the same area. The
electronic control module that has diagnosed the All diagnostic codes are shown one at a time in
diagnostic code is logged by the MID. The following the display area when the diagnostic codes are
examples are of some MID. scrolling. Grounding the service input causes the
display to scroll when the main display module is
Caterpillar Monitoring System ...................... 030 in service mode. This will momentarily show the
Engine Control (ADEM) ................................ 036 MID. The display will show the CID and the FMI that
Power Train Electronic Control System ........ 081 corresponds. Removing ground from the service
All Wheel Drive Electronic Control System ... 075 input stops the scrolling when the diagnostic code
that is desired is shown. The diagnostic code that
See the table for the Module Identifier (MID) on is shown is now on hold.
the Electrical System Schematic for the machine
that is being serviced for the most complete list. Note: The diagnostic codes from other electronic
To troubleshoot diagnostic codes, use the service control modules can be shown on the display. Use
manual for the control that detected the code. the same procedure in order to place the diagnostic
codes on hold.
16
Systems Operation Section
Diagnostics are provided in order to assist service Illustration 19 shows a main display module that is
personnel during troubleshooting of intermittent currently receiving a signal. This signal is from the
faults. The service code indicator “SERV CODE” is transmission oil temperature sensor and the signal
shown when the diagnostic code is present. This is out of range.
can aid in troubleshooting of intermittent faults. The
service code indicator changes from “SERV CODE” Detailed Explanation
that is OFF to “SERV CODE” that is ON. This will
occur when the fault changes status. The action MID (3) – “030”. This code concerns the Caterpillar
alarm SOUNDS briefly during the change of status Monitoring System. The Caterpillar Monitoring
when the diagnostic code is on hold for a fault. System service manual should be used to
These diagnostics signal the service personnel while troubleshoot the diagnostic code. If the MID that was
inspections are performed. These diagnostics assist shown was “081”, the diagnostic code would concern
in troubleshooting intermittent faults by one service the power train electronic control. The service module
person. for the power train electronic control should be used
to troubleshoot the diagnostic code.
A diagnostic code is removed from the memory of
the main display module when the diagnostic code CID (5) – “0110”. This code means that a fault has
has been cleared. When a fault is corrected, it is occurred in the sensor circuit for the engine coolant
necessary to remove the corresponding diagnostic temperature of MID “030”. See the table for Detected
code from the memory of the main display module. Faults in Testing And Adjusting, “Troubleshooting
In order to remove the diagnostic code from the Diagnostic Codes”. This will show a list of CID codes
memory, place the diagnostic code on hold and for the Caterpillar Monitoring System.
ground the clear input. The memory of the main
display module saves a diagnostic code until the FMI (6) – “08”. This identifier means that a signal
code is cleared. The main display module does not of abnormal frequency, pulse width or period is
allow clearing of a diagnostic code that corresponds being received concerning CID “0110”. See the
to a fault which is present. table for Detected Faults in Testing And Adjusting,
“Troubleshooting Diagnostic Codes”. This table will
Note: The diagnostic codes from other electronic show a list of FMI codes for the Caterpillar Monitoring
control modules should be cleared by using the main System.
display module.
Service code indicator (4) is ON in Illustration 19.
When the main display module is in service mode,
the service code indicator (4) functions as a fault
present indicator. Therefore, the CID “0110” fault is
present. The service code indicator changes from ON
to OFF when the CID “0110” fault changes status.
Also, the action alarm sounds when the CID “0110”
fault changes status. This action will take place while
the main display module is in service mode.
i01520269
Tattletale Mode
SMCS Code: 7490
g00427558
Illustration 19
Diagnostic Example
g00301362
(1) First display. (2) Second display. (3) Module identifier (MID). (4) Illustration 20
Service code indicator (“SERV CODE”). (5) Component identifier Display Area
(CID). (6) Failure Mode identifier (FMI).
Brief Explanation
17
Systems Operation Section
Example
Units Mode
SMCS Code: 7490
g01019884
Illustration 23
Display Area
Calibration Mode 7 and Calibration Mode 8 include The error codes indicate that the inching pedal
submodes in order to extend the diagnostic position sensor may be adjusted improperly.
capabilities. After you have entered mode 7 or mode Perform the Testing and Adjusting, “Inching Pedal
8, use the service switch in order to scroll through - Adjust” procedure in this manual and then repeat
the submodes. the calibration procedure.
Submode 7.29 / 8.29 (Calibration Of The 6. Exit submode number 29 by scrolling to the next
submode number by using the “SCROLL” switch
Inching Pedal Position Sensor ) or by exiting the “Power Train Calibration” mode
by using the “Mode” Switch.
This procedure allows the calibration of the travel
limits of the inching pedal position sensor. The inching
pedal must be calibrated if any of the conditions that Calibration Of The Engagement Pressure
are listed below have occurred: For The Transmission Clutch
• The power train ECM has been replaced. Incorrect transmission clutch pressure adversely
affects the life of the transmission. Submodes 31
• New software has been flashed into the power through 33 are used in order to set the transmission
train ECM and a diagnostic code of CID 0573 FMI clutch pressure of the direction clutches (No. 1
13 is active. through No. 3). In this process, the service technician
adjusts the electrical current that is sent to the
• The position sensor for the inching pedal has been transmission solenoid valve in order to obtain the
replaced. specified pressure for the transmission clutch. The
calibration of the transmission clutch pressure must
• The linkage for the inching pedal has been be performed prior to the transmission clutch fill
adjusted. calibration (submode 40).
1. Connect the 4C-8195 Control Service Tool to the The transmission system must be calibrated if any of
service tool connector. the following conditions have occurred:
2. Use the 4C-8195 Control Service Tool in order • A transmission solenoid valve has been replaced
to enter the “Power Train Calibration” Mode (7) or cleaned.
via the “MODE” switch. Then use the “SCROLL”
switch to enter submode number 29. • A different power train ECM has been installed.
3. Ensure that the inching pedal is not pressed. Use • New flash software has been flashed into the ECM.
the “INCREMENT (+)” position of the “CLEAR”
switch to start the calibration. The display on the • A transmission clutch has been rebuilt.
4C-8195 Control Service Tool will change to
“C01”. • The transmission clutch does not shift correctly.
4. Press and hold the inching pedal to the down limit.
Select “INCREMENT (+)” position of the “CLEAR”
switch. The display on the 4C-8195 Control
Service Tool will change to “C02”.
g00795884
Illustration 24
Transmission Clutch Solenoid Valves
(1) Transmission solenoid valve (No. 3) (4) Transmission solenoid valve (No. 8) (7) Transmission solenoid valve (No. 5)
(2) Transmission solenoid valve (No. 1) (5) Transmission solenoid valve (No. 4) (8) Transmission solenoid valve (No. 7)
(3) Transmission solenoid valve (No. 2) (6) Transmission solenoid valve (No. 6)
Table 8
Error Codes for the Calibration of the
Transmission Clutch Fill
The Clutch Solenoid or the Speed Sensor
E01
has an Active Failure.
E04 The Transmission is Not in the Park Position.
The Temperature of the Transmission Oil
E05 is Below the Fault Threshold.
(68 °C (154 °F))
The Engine Speed is Below the Fault
E06
Threshold of 1800 rpm.
E09 Machine Speed Is Not Zero.
Calibration of the Engagement Pressure
E11
Is Not Completed.
E21 Number 1 Clutch at a Limit
E22 Number 2 Clutch at a Limit
E23 Number 3 Clutch at a Limit
g00795884
Illustration 25
Transmission Solenoid Valves
(1) Transmission solenoid valve (No. 3) (5) Transmission solenoid valve (No. 4)
(2) Transmission solenoid valve (No. 1) (6) Transmission solenoid valve (No. 6)
(3) Transmission solenoid valve (No. 2) (7) Transmission solenoid valve (No. 5)
(4) Transmission solenoid valve (No. 8) (8) Transmission solenoid valve (No. 7)
g00794045
Illustration 26
Display Area (Mode 6)
g00530894
Illustration 27
Up Stop Display
g00531227
Illustration 28
Down Stop Display
i01862466
Warning Operation
SMCS Code: 7490
Table 9
WARNING OPERATION
Warning Indications (1)
g00427600
Illustration 30
Speedometer/Tachometer Module
(3) Tachometer
(4) Pictograph symbol
(5) Ground speed readout
(6) Transmission gear readout
g00789595
Illustration 29
Quad Gauge Module
(1) Gauge warning area
(2) Pictograph symbol
25
Systems Operation Section
g00923072 g00923075
Illustration 33 Illustration 34
Alert Indicators For 140H, 160H, 12H, 120H And 135H Alert Indicators For 14H And 16H
(1) Hydraulic Oil Temperature (1) Hydraulic Oil Temperature
(2) Parking Brake Status (2) Parking Brake Status
(3) Charging System Status (3) Charging System Status
(4) Unused (4) Unused
(5) Check Engine Status (5) Check Engine Status
(6) Engine Coolant Temperature (6) Engine Coolant Temperature
(7) Steering System Status (7) Steering System Status
(8) Engine Oil Pressure (8) Engine Oil Pressure
(9) Brake Air Pressure (9) Brake Air Pressure
(10) Transmission System Status (10) Unused
i01855060
Charging System Status – The light
indicates that battery voltage is outside the Main Display Module
range of 24.8 to 29.5 DCV. While the engine
is running, the light also turns on when the alternator SMCS Code: 7490
frequency is below 90 Hz. In addition to the lighting
of the indicator, the action lamp and the action alarm
will also activate when the battery voltage rises
above 32 DCV.
Low Engine Oil Pressure – This light (1) Alert Indicators. (2) Display area.
indicates that the engine oil pressure is low.
This signal is received by the Caterpillar The main display module continuously monitors all
Monitoring System from the engine ECM via the CAT machine systems. The main display module makes
data link. The indicator lights when the switch voltage decisions that are based upon the input from the
is high or the switch voltage is floating. machine systems or other electronic control modules.
The main display module sends information to other
electronic controls on the machine. The input and
Transmission System Status – The light output of this information takes place over the CAT
indicates that the transmission conditions data link. The outputs on the main display module
are not working properly. The information notify the operator and the service person of the
is received from the power train ECM via the CAT status of the machine systems. The following outputs
data link. are on the Caterpillar Monitoring System: the quad
gauge, the speedometer/tachometer module, the
main display module, the action lamp, and the action
i01862477
alarm. A connector with 40 contacts is located on
Component Description the rear of the module. This connector connects
the necessary harness wiring to the inputs and
SMCS Code: 7490 outputs. For a complete description of the connector,
see Testing And Adjusting, “Connector Contact
This arrangement of the Caterpillar Monitoring Description of Main Display Module”.
System will work on the current Motor Graders.
Three modules constitute the Caterpillar Monitoring Inputs/Outputs
System: main display module, quad gauge module,
and speedometer/tachometer module. All of the CAT Data Link
following electrical components are not present on
every machine. The main display module recognizes The CAT data link (connector contacts 5 and 14) is
the machine and the components that are present. used to communicate with other electronic control
For the location of the electrical components, see the modules on the machine. The CAT data link is
Electrical System Schematic in the Service Manual bidirectional. This allows the modules to input the
for the machine. information. Also, the modules can output the
information. This permits sharing of information
such as engine oil pressure, harness codes and
diagnostics.
28
Systems Operation Section
The inputs from the harness code switch tell the main
display module the machine model. Information of the
model is necessary because of the differences in the
machines. Information from the machine is necessary
for the main display module to make decisions.
29
Systems Operation Section
Switch Inputs - Service At the input for the alternator terminal “R” (connector
contact 30), the terminal “R” of the alternator provides
The inputs from the service switches (connector an AC signal to the main display module. The
contacts 23 and 33) control the setup, the mode main display module determines the speed of the
of operation, and certain diagnostic functions. alternator by measuring the frequency (Hz) of the AC
Grounding the service input (connector contact 23) signal. The alternator R terminal helps determine the
and the clear input (connector contact 33) at the same condition of the electrical charging system. Harness
time will initiate a change in the monitoring system wiring directly connects the alternator terminal
mode of operation. Removing ground from these two “R” to the sensor input for the alternator “R”. The
inputs locks the main display module in the selected information on the alternator terminal “R” is used with
mode. Other diagnostic functions are also performed other inputs (engine oil pressure, engine speed, etc)
when the service inputs are grounded and/or opened in order to determine when the engine is running.
at the proper time. For more information, see System
Operation, “Modes Of Operation”. Sender Input - 0- 240 Ohm
Sensor Inputs - PWM Each 0-240 ohm sender input (connector contacts 9
and 18) may be programmed in order to operate as
Each PWM sensor input (connector contacts 7, 17, either a sender input or a switch input.
27 and 37) may be programmed in order to operate
as either a sensor input or a switch input. A sender input measures a resistance value in order
to determine the condition of the system. A resistive
A PWM signal is present when the sensor input is fuel level sender (or a component with a similar
programmed to operate as a PWM sensor input. A output signal) provides this information. The output
PWM signal represents the condition of a machine resistance of the fuel level sender corresponds to the
system. As the condition of the machine changes, the depth of fuel within the tank. The main display module
duty cycle of the signal changes. The duty cycle is the measures the resistance value. The information is
percentage of time that the signal is ON compared then sent to the quad gauge in order to be shown on
to the time the signal is OFF. The frequency of one of the gauges.
the signal is constant. The following examples are
conditions that are monitored: temperature, pressure, Note: See “Switch Input - Uncommitted” for input
and level. The main display module measures the operation when the 0-240 ohm sender input is
duty cycle of the output for the PWM sensor. The programmed to operate as a switch input. Use the
information is then sent to the quad gauge in order Electrical System Schematic of the machine that is
to be shown on one of the gauges. being serviced in order to determine the inputs that
are programmed.
Note: See “Switch Input - Uncommitted” for
input operation when the PWM sensor input is Note: The 0-240 ohm sender input may be
programmed to operate as a switch input. Use the programmed to operate a gauge or an alarm
Electrical System Schematic of the machine that is indicator. The sensor can also be programmed to
being serviced in order to determine the inputs that operate both a gauge and an alarm indicator.
are programmed.
Sender Input - 70-800 Ohm
Note: The input from the PWM sensor may be
programmed to operate a gauge or an alarm Each 70-800 ohm sender input (connector contacts
indicator. The sensor can also be programmed to 8, 10, 28 and 38) may be programmed in order to
operate both a gauge and an alarm indicator. operate as a sender input, a PWM sensor input or
a switch input.
Sensor Input - Frequency
The 70-800 ohm sender input measures a resistance
At each frequency sensor input (connector contacts value in order to read the condition of the system. The
26, 30 and 36), an AC signal is present. The temperature sender (or a component with a similar
signal represents the speed of a machine system. output signal) provides this information. The output
Frequency sensors for engine speed and machine resistance of the temperature sender corresponds to
speed provide an AC signal to the main display the temperature of the fluid that is being measured.
module. The main display module measures the Oil, coolant and hydraulic temperature are examples
frequency (Hz) of the AC signals. The information is of fluid temperatures that are measured. The main
then sent to the speedometer/tachometer module. display module measures the resistance value. The
information is then sent to the quad gauge in order
to be shown on one of the gauges.
30
Systems Operation Section
Category 1 – The frequency for the terminal “R” The alert indicators notify the operator of abnormal
from the alternator is less than 90 Hz or the system conditions with the machine. The main display
voltage is greater than 29.5 volts for at least 2 module uses the status of the uncommitted switch
seconds. The system voltage is less than 24.8 volts inputs, sender inputs and/or sensor inputs in
for a least 2 seconds. order to determine when an abnormal condition is
present. The main display module then FLASHES
Category 3 – The system voltage is less than 23.0 the appropriate alert indicator. The symbol of the
volts for at least 2 seconds or the system voltage is FLASHING alert indicator identifies the responsible
greater than 32.0 volts for at least 2 seconds. machine system. When an alert indicator FLASHES,
an abnormal condition exists. For more information,
see System Operation, “Warning Operation”.
The display area has various symbols that show the Table 10
condition of the machine systems. The symbols also Contact Description Of Display Components
show information for service and setup. The type of Connector
information that is shown on the display depends
on the operating mode. For more information about No. Function Type
the display area, see System Operation, “Modes of 1 +9 DCV Input
Operation”.
2 Ground Ground
Action Lamp 3 Display Clock Input
i01521112
Display Components
SMCS Code: 7450
g00789595
Illustration 37
An Example Of A Quad Gauge Module
(1) Gauge warning area. (2) Pictograph symbol.
32
Systems Operation Section
The quad gauge module shows the following Note: The input is received from the fuel level sender.
information: engine coolant temperature, articulation The warning level for this gauge is a Level I.
angle, system voltage, and fuel level. The main
display module uses the information from sensor
i01020517
inputs or the CAT data link in order to calculate the
values that are shown on the gauges. Pictograph
symbol (2) identifies the parameter for the machine
Speedometer/Tachometer
system which is shown on each gauge. Abnormal Module
values are shown by the gauge warning area (1).
SMCS Code: 7450
Table 11
Engine Coolant Temperature Gauge
Minimum Displayed Value 40 °C (104 °F)
Midpoint Value 82 °C (179 °F)
Red Zone Value 107 °C (224 °F)
Table 14
Switches
Fuel Level Gauge SMCS Code: 1435; 7332
Minimum Displayed Value 5%
Switches provide information (input) to the main
Midpoint Value 50% display module. Switches are two state devices. The
two states of the switches are open and closed.
Red Zone Value 10%
Maximum Displayed Value 95% Closed – The switch connects the control input to
frame ground.
33
Systems Operation Section
Open – The switch connects the control input to Pressure Switch (RH Brake System)
nothing. (The input is floating.)
g00304432
Illustration 39
Temperature Switch (Hydraulic Oil)
(1) Switch. (2) Schematic symbol. g00303717
Illustration 41
Level Sender (Fuel)
During normal operation, temperature switch (1)
(1) Sender
is closed to ground. The switch opens when the (2) Schematic symbol
temperature of the fluid system is greater than the
specified value. The open switch tells the main Fuel level sender (1) provides fuel level sensing. A
display module that there is a high temperature. The resistive signal which corresponds to the depth of
switch is closed when the switch is off the machine. fuel within the fuel tank is sent from the sender to the
main display module. Typically, there are two possible
Pressure Switch types of senders: 0 to 90 ohms and 33 to 240 ohms.
The main display module measures the resistance
Pressure Switch (Parking Brake) value in order to determine the fuel that is remaining
in the tank. Typical gauge readings for the fuel level:
Pressure Switch (LH Brake System)
34
Systems Operation Section
• When the fuel tank is at 4% of capacity, the gauge Position Sender (Articulation
shows that the tank is empty.
Angle)
• When the fuel tank is at 14% of capacity, the gauge
shows the needle at the red zone on the gauge.
Temperature Sender
g00793324
Illustration 43
Position Sender (Articulation Angle)
(1) Schematic symbol
(2) Sender
i01060965
Temperature sender (2) provides a method for
sensing fluid temperature. The temperature sender
produces a resistive signal which corresponds to
Sensors
the temperature of the fluid that is being monitored. SMCS Code: 1408-NS
Typically, the resistance range of the sender is
from 70 ohms at 110°C (230°F) to 3000 ohms at
25°C (77°F). The main display module measures General Information
the resistance value in order to determine the fluid
temperature. Sensors provide information (input) to the main
display module about changing conditions. The
sensor signal changes in a proportional manner in
order to reflect the changing condition. The main
display module shows the information from the
sensors on the gauges. The main display module
recognizes two types of sensor signals.
Frequency Sensors
Frequency sensors produce an AC signal. The
frequency (Hz) varies as the condition changes.
35
Systems Operation Section
g00304924
Illustration 44
Speed Sensor
(1) Sensor. (2) Schematic symbol.
g00304926
Illustration 46
Typical PWM Sensor Schematic
Action Lamp
SMCS Code: 1408-LMP; 7400-LMP
g00304970
Illustration 49
Action Lamp Symbol
g00304927
Illustration 47 The action lamp connects to an output of the main
Temperature Sensor display module. The action lamp is an LED that
(1) Schematic symbol. (2) Sensor. is located within the operator’s viewing area. The
FLASHING of the action lamp tells the operator that a
Temperature sensor (2) reacts to the temperature of condition exists. The condition will require changing
fluids. Examples of the fluids are hydraulic oil, power the operation of the machine. The action lamp is
train oil, and engine coolant. The sensor receives located on the main display module. The action
operating power from the main display module (8 lamp will FLASH whenever a warning category 2,
DCV) or from the battery (24 DCV). The sensor sends a warning category “2S”, or a warning category 3
the main display module a PWM signal. The signal problem exists.
changes as the fluid temperature changes. The main
display module measures the duty cycle of the sensor
i01940097
signal in order to determine the fluid temperature.
Action Alarm
Pressure Sensor
SMCS Code: 7407
g00304929
Illustration 48
g00307223
Pressure Sensor Illustration 50
(1) Schematic symbol. (2) Sensor. Action Alarm
(1) Schematic symbol. (2) Action alarm.
Pressure sensor (2) reacts to the pressure of fluids.
The sensor receives operating power from the main The action alarm connects to an output of the main
display module (8 DCV) or from the battery (24 DCV). display module. When the action alarm is audible, the
The sensor sends the main display module a PWM machine needs immediate attention. A safe machine
signal. The signal changes as the fluid pressure shutdown is required. The main display module will
changes. The main display module measures the sound the action alarm whenever a warning category
duty cycle of the sensor signal in order to determine 3 problem exists. An alarm for a warning category
the fluid pressure. 3 is a pulsating sound. The alarm for a warning
category 2S is a continuous tone.
37
Systems Operation Section
i00703569
Related Components
SMCS Code: 1408; 7450
Alternator
The R terminal of the alternator is connected to an
input of the main display module. The main display
module monitors the frequency at the R terminal of
the alternator. This tells the main display module if
the alternator is rotating.
Service Tools
Introduction SMCS Code: 0785
g00309227
Illustration 57
End view of service connectors
i01671837
Diagnostic Capabilities
SMCS Code: 7490
g00777826
Illustration 58
The Caterpillar Electronic Technician (ET) is a • Program the ECM (Flash). This is done with the
software program that is used to access data. The “WINflash” program. See Testing and Adjusting,
service technician can use the Caterpillar Electronic “Electronic Control Module (ECM) - Flash
Technician in order to perform maintenance work on Program”.
the machine. Some of the options that are available
with the Caterpillar Electronic Technician are listed • Print reports.
below:
The following list contains some of the diagnostic
• View Diagnostic codes. See Troubleshooting, functions and programming functions that are
“Using the Caterpillar Electronic Technician to performed by the service tools.
Determine Diagnostic Codes”.
• The failures of the ECM system are displayed.
• View the status of parameters.
• The status of most of the inputs and the outputs
• Clear active diagnostic codes and clear logged are displayed.
diagnostic codes
• The settings for the ECM are displayed.
• Perform calibration of machine systems.
• Display the status of the input and output
parameters in real time.
43
Troubleshooting Section
g00867289
Illustration 59
Typical ET Status Screen
44
Troubleshooting Section
i01782268
g00859671
Illustration 61
Typical Cat ET screen for active diagnostic codes
g00859762
Illustration 62
Typical Cat ET screen for logged diagnostic codes
g00866484
Illustration 63
Schematic for the ground speed sensor
49
Troubleshooting Section
This diagnostic code is associated with the ground B. Disconnect the J1 machine harness connector
speed sensor. The FMI 08 means that the main from the main display module.
display module has determined that the signal
frequency or the signal pulse width is not within the C. The sensor remains disconnected.
expected range.
D. At the machine harness connector for the sensor,
The possible causes of this diagnostic code are listed measure the resistance from the signal contact
below: 3 (wire C913-BU) and ground contact 2 (wire
210-BK).
• The sensor has failed.
E. At the machine harness connector for the sensor,
• Intermittent connections or poor connections measure the resistance from the signal contact
3 (wire C913-BU) and + battery contact 1 (wire
• Mechanical devices are loose. 113-OR).
Repair: It is unlikely that the main display module Test Step 1. CHECK THE CONTROL AND
has failed. Exit this procedure and perform this THE HARNESS.
procedure again. If the cause of the diagnostic
code is not found, replace the main display module. A. Turn the disconnect switch and the key start
See Testing and Adjusting, “Module - Replace”. switch to the ON position.
STOP.
The resistance is greater than 5000 ohms. The possible causes of this failure are listed here:
Repair: It is unlikely that an ECM has failed. Exit • The main display module has failed. This is
this procedure. Perform this CID 0096 FMI 03 unlikely.
procedure again. If the failure is not found, replace
the main display module. Refer to the Testing and This failure causes the fuel gauge to always
Adjusting, “Module - Replace”. indicate an empty fuel tank or the fuel gauge may
intermittently indicate an empty fuel tank.
STOP.
Test Step 1. CHECK THE SENDER.
• NOT OK – The resistance is less than 5000 ohms.
The machine harness has failed. There is a short A. Disconnect the machine harness from the sender.
between the +battery circuit and the signal circuit
in the machine harness. Expected Result:
Repair: Repair the machine harness or replace the The diagnostic code changes from CID 0096 FMI
machine harness. 04 to CID 0096 FMI 03.
STOP. Results:
STOP.
B. Turn the disconnect switch and the key start Service Notes: Ensure that the desired code (CID
switch to the OFF position. and FMI) is on hold. Ensure that the diagnostic code
indicator shows “SERV CODE”. The schematic that
C. Disconnect the J1 machine harness connector is shown above represents a typical installation of
from the main display module. the component. Verify the connector contact and wire
numbers by using the Electrical System Schematic
D. At the machine harness connector for the sender, for the machine that is being serviced.
measure the resistance between the signal
contact 1 (wire 447-PK) and frame ground. Note: See Troubleshooting, “Sensor Signal Voltage”
in order to troubleshoot this component.
Expected Result:
Perform the following diagnostic procedure: “Sensor
The resistance is greater than 5000 ohms. Signal Voltage ”
Results: Results:
STOP. g00530708
Illustration 67
Schematic for the Caterpillar data link
i01916153
This diagnostic code is recorded when the
MID 030 - CID 0096 - FMI 08 main display module does not receive expected
information. The following example shows a possible
SMCS Code: 1273-038-UN diagnostic code. The information from the actual gear
status is not being received from other electronic
Conditions Which Generate This Code: control modules through the CAT data link. The
information from the CAT data link indicates the
abnormal values in the readout. The possible causes
of this diagnostic code are listed below. The causes
are listed in order of probability:
Note: An electronic control module which uses the B. Disconnect the machine harness from all the
CAT data link may have lost power or an electronic electronic control modules that use the CAT data
control may have failed. This is unlikely. If the main link.
display module was recently replaced, see Testing
and Adjusting, “Main Display Module Initialization - C. At the machine harness connector for the main
Adjust”. display module, measure the resistance between
frame ground and the CAT data link circuits
Service Notes: Ensure that the desired diagnostic (contacts 5 and 14).
code (CID and FMI) is on hold. Ensure that the
service code indicator shows “SERV CODE”. Expected Result:
Test Step 1. CHECK FOR OTHER CODES. The resistance that is measured is less than 5000
ohms.
A. Check other electronic control modules for a
similar diagnostic code. If a similar diagnostic code Results:
is found, exit this test. Perform the corresponding
procedures for the other diagnostic codes that are • YES – The resistance is less than 5000 ohms.
shown. The machine harness has failed. There is a short
between the frame ground and the CAT data link
Expected Result: circuit in the machine harness.
There are other diagnostic codes that are showing. Repair: Repair the machine harness or replace the
machine harness.
Results:
STOP.
• YES – Exit this procedure and perform the other
procedures for the diagnostic codes that are • NO – The resistance is greater than 5000 ohms.
shown. STOP. The harness circuit resistance is correct. Proceed
to test step 4.
• NO – There are not any other diagnostic codes
that are shown. Proceed to test step 2. Test Step 4. CHECK FOR A SHORT TO
THE +BATTERY.
Test Step 2. INSPECT THE HARNESS
CONNECTORS. A. The disconnect switch remains OFF.
A. Turn the disconnect switch to the OFF position. B. All related control modules remain disconnected
from the machine harness.
B. Inspect the connections for the machine harness
that are related to the CAT data link. C. At the machine harness connector for the main
display module, measure the resistance between
C. Make sure that connectors are clean and tight. the +battery (contact 1) and the CAT data link
circuits (contacts 5 and 14).
Expected Result:
Expected Result:
The machine harness is correct.
The resistance is greater than 5000 ohms.
Results:
Results:
• OK – The machine harness is correct. Proceed
to test step 3. • OK – The resistance is greater than 5000 ohms.
The harness circuit resistance is correct. Proceed
• NOT OK – The machine harness is not correct. to test step 5.
Repair: Repair the machine harness or replace the • NOT OK – The resistance is less than 5000 ohms.
machine harness. The machine harness has failed. There is a short
between the +battery and the CAT data link circuit
STOP. in the machine harness.
Test Step 3. CHECK FOR A SHORT TO Repair: Repair the machine harness or replace the
GROUND. machine harness.
The resistance is less than 5 ohms. This diagnostic code is recorded when the main
display module reads an above normal sensor supply
Results: voltage (+24 DCV).
• YES – The resistance is less than 5 ohms. The Note: The procedures that are used to troubleshoot
CAT data link circuit in the machine harness is this diagnostic code may cause additional diagnostic
correct. codes to be logged. Find the cause and repair the
cause of this diagnostic code before you troubleshoot
Repair: It is unlikely that the main display module any new diagnostic codes.
has failed. Exit this procedure and perform this
procedure again. Also, recheck if the diagnostic Test Step 1. CHECK THE VOLTAGE AT
code indicator is illuminated for this diagnostic THE MAIN DISPLAY MODULE.
code. If the cause of the diagnostic code is not
found, replace the main display module. See A. Use the 7X-1710 Multimeter Probe in order to
Testing and Adjusting, “Module - Replace”. check the voltage at the connector for the main
display module. Measure the voltage from the
STOP. contact 1 to the contact 2 (ground). DO NOT
disconnect the harness from the module.
• NO – The resistance is greater than 5 ohms. The
machine harness has failed. The CAT data link Expected Result:
circuit is open in the machine harness.
The supply voltage that is measured is 24.0 ± 0.5
Repair: Repair the machine harness or replace the DCV.
machine harness.
Results:
STOP.
• YES – The voltage is 24.0 ± 0.5 DCV. The sensor
supply voltage is correct. Verify that the diagnostic
code is still present. If the diagnostic code is still
present the main display module has failed.
STOP.
55
Troubleshooting Section
• NO – The voltage is NOT 24.0 ± 0.5 DCV. The Repair: Replace the sensor.
sensor supply voltage is NOT correct. Proceed to
test step 2. STOP.
Test Step 2. CHECK THE HARNESS FOR • NO – The voltage is NOT approximately 0 DCV.
A SHORT TO THE +BATTERY CIRCUIT. The harness or a sensor has failed. Repeat
this test. The machine harness is shorted to
A. Disconnect the machine harness from the main the +battery circuit if all the sensors have been
display module. disconnected from the machine harness and the
voltage is NOT approximately 0 DCV.
B. At the machine harness connector for the main
display module, measure the voltage from the Repair: Repair the harness or replace the harness.
connector contact 1 to 2 (ground).
STOP.
Expected Result:
i01440283
The voltage that is measured should be approximately
0 DCV. MID 030 - CID 0263 - FMI 04
Results: SMCS Code: 7490-038-NS
• YES – The voltage is approximately 0 DCV. The Conditions Which Generate This Code:
voltage is correct.
• NO – The voltage is NOT approximately 0 DCV. This diagnostic code is recorded when the main
The harness or a sensor has failed. Proceed to display module reads the signal voltage. The voltage
test step 3. from the sensor is too low.
A. Disconnect one of the sensors that are connected A. Use the 7X-1710 Multimeter Probe in order to
to the +24 DCV sensor supply of the main display check the voltage at the connector for the main
module from the machine harness. display module. Measure the voltage from contact
1 to contact 2 (ground). DO NOT disconnect the
B. After you disconnect the sensor, measure the harness from the module.
voltage from the connector contact 2 (ground) to
contact 1 of the machine harness connector for Expected Result:
the main display module.
The voltage measures 24.0 ± 0.5 DCV.
Expected Result:
Results:
The voltage that is measured should be approximately
0 DCV. • YES – The voltage is 24.0 ± 0.5 DCV. The sensor
supply voltage is correct. Verify that the diagnostic
Results: code exists.
STOP.
Test Step 3. CHECK FOR A SHORT TO Schematic for the alarm (action)
GROUND.
This diagnostic code is recorded when the main
A. Turn the disconnect switch and the key start display module reads the voltage of the circuit for
switch to the OFF position. the action alarm as above normal. The result of this
diagnostic code is the continuous sounding of the
B. The sensors remain disconnected. action alarm. The schematic that is shown above
represents a typical installation of the component.
C. Disconnect the machine harness from the main Verify the connector contact and wire numbers
display module. by using the Electrical System Schematic for the
machine that is being serviced.
D. At the machine harness connector for the main
display module, measure the resistance between
the frame ground and the sensor supply circuit
(connector contact 1).
57
Troubleshooting Section
CHECK THE ALARM CIRCUIT. This diagnostic code is recorded when the main
display module reads the current of the action alarm.
A. Turn the disconnect switch and the key start The current for the action alarm is below normal.
switch to the OFF position. The action alarm does not SOUND as a result of this
diagnostic code. The schematic that is shown above
B. Disconnect the machine harness from the main represents a typical installation of the component.
display module. Verify the connector contact and wire numbers
by using the Electrical System Schematic for the
C. Turn the disconnect switch to the ON position. machine that is being serviced.
D. Listen for the SOUNDING of the action alarm. Test Step 1. CHECK THE ALARM.
E. Turn the key start switch to the ON position. A. Disconnect the machine harness from the alarm.
Repair: Repair the harness or replace the harness. • YES – The CID 0271 FMI 05 remains present. The
action alarm is not causing the diagnostic code.
STOP. Verify that the action alarm is correct. The correct
resistance for a good alarm is 200 ± 100 ohms.
• NO – The alarm does NOT SOUND. The main Proceed to test step 2.
display module has failed.
• NO – The CID 0271 FMI 05 is NO longer present.
Repair: It is unlikely that the main display module The alarm is open.
has failed. Exit this procedure and perform this
procedure again. Also, recheck if the diagnostic Repair: Replace the action alarm. Verify that the
code indicator is illuminated for this diagnostic action alarm is open. The correct resistance for a
code. If the cause of the diagnostic code is not good alarm is 200 ±100 ohms.
found, replace the main display module. See
Testing and Adjusting, “Module - Replace”. STOP.
Expected Result:
g00544121
Illustration 71
The resistance is greater than 300 ohms.
Schematic for the alarm (action)
Results:
• NOT OK – The resistance is less than 300 ohms. • NO – The diagnostic code is NO longer active.
The harness circuit resistance is correct. Proceed The diagnostic code does not exist at this time.
to test step 4. The initial diagnostic code was probably caused by
a poor electrical connection or a short at one of
Test Step 3. CHECK THE HARNESS. the harness connectors that was disconnected and
reconnected. Resume normal machine operation.
A. Disconnect the machine harness from the alarm. STOP.
Expected Result:
Results:
STOP.
59
Troubleshooting Section
Test Step 2. CHECK THE HARNESS. • NOT OK – The diagnostic code is NO longer
active. The diagnostic code does not exist at this
A. Turn the disconnect switch to the OFF position. time. The initial diagnostic code was probably
caused by a poor electrical connection or a
B. The alarm remains disconnected from the short at one of the harness connectors that was
machine harness. disconnected and reconnected. Resume normal
machine operation. STOP.
C. Disconnect the machine harness from the main
display module.
i01394739
Results:
Repair: Repair the machine harness or replace the This diagnostic code is recorded when the main
machine harness. display module reads the voltage of the circuit for the
action lamp as above normal. The action lamp is
STOP. ON CONTINUOUSLY as a result of this diagnostic
code. The schematic that is shown above represents
Test Step 3. CHECK THE MODULE. a typical installation of the component. Verify the
connector contact and wire numbers by using the
A. Remove contact 4 from the machine harness Electrical System Schematic for the machine that is
connector for the main display module by using being serviced.
the correct service tools.
CHECK THE LAMP CIRCUIT.
B. Reconnect the machine harness connector to the
module. A. Turn the disconnect switch and the key start
switch to the OFF position.
C. Turn the disconnect switch and the key start
switch to the ON position. B. Disconnect the machine harness from the main
display module.
D. Place the same diagnostic code on hold and
check the service code indicator. C. Turn the disconnect switch to the ON position.
The CID 0271 FMI 06 is present. E. Turn the key start switch to the ON position.
• OK – The CID 0271 FMI 06 remains present. The The action lamp is ON.
main display module has failed.
Results:
Repair: It is unlikely that the module has failed.
Exit this procedure and perform this diagnostic • OK – The action lamp is ON. The harness circuit
code procedure again. If the problem has not been 411-PK is shorted to the +battery.
found, then replace the main display module. See
Testing and Adjusting, “Module - Replace”. Repair: Repair the harness or replace the harness.
STOP. STOP.
60
Troubleshooting Section
• NOT OK – The action lamp is OFF. The module • NOT OK – The CID 0324 FMI 05 is present. The
has failed. action lamp is not causing the diagnostic code.
Proceed to test step 2.
Repair: It is unlikely that the main display module
has failed. Exit this procedure and perform this Test Step 2. CHECK THE HARNESS.
procedure again. Also, recheck if the diagnostic
code indicator is illuminated for this diagnostic A. Turn the disconnect switch and the key start
code. If the cause of the diagnostic code is not switch to the OFF position.
found, replace the main display module. See
Testing and Adjusting, “Module - Replace”. B. Remove the jumper from wire 411-PK to frame
ground. Make sure that the action lamp is
STOP. connected to the machine harness.
Results:
STOP.
61
Troubleshooting Section
• NOT OK – The circuits are NOT correct. B. Wire 411-PK remains disconnected from the
action lamp.
Repair: Repair the harness or replace the harness.
C. Disconnect the machine harness from the main
STOP. display module.
Conditions Which Generate This Code: The resistance is greater than 5000 ohms.
Results:
STOP.
62
Troubleshooting Section
STOP.
Illustration 76
g00528295 • The signal circuit in the machine harness is open
or the sender is disconnected.
Schematic for the pressure sensor (brake air)
Expected Result: • 6.0 ± 0.5 DCV – The voltage is 6.0 ± 0.5 DCV. The
voltage is correct. Verify that the diagnostic code
The diagnostic code indicator remains ON. is still present.
• YES – The resistance is 5 ohms or less. Proceed Repair: Repair the harness or replace the harness.
to test step 3. Exit this procedure and perform this procedure
again. Also, recheck if the diagnostic code
• NO – The resistance is greater than 5 ohms. The indicator is illuminated for this diagnostic code. It
ground wire for the harness is open. is unlikely that the main display module has failed.
If the cause of the diagnostic code is not found,
Repair: Repair the ground wire or replace the replace the main display module. See Testing and
ground wire for the sender. Adjusting, “Module - Replace”.
STOP. STOP.
Expected Result:
• The main display module has failed. The voltage that is measured is within one of the
following specifications.
Note: The main display module is unable to
determine when a sender is open. Also, the main Results:
display module is unable to determine when a sender
signal harness is open. This condition is recognized • 6.0 ± 0.5 DCV – The voltage is 6.0 ± 0.5 DCV. The
when the gauge constantly indicates a value at the voltage is correct. Verify that the diagnostic code
far left side of the scale. remains.
Service Notes: Ensure that the desired diagnostic Repair: It is unlikely that the main display module
code is on hold. Ensure that the diagnostic code has failed. Exit this procedure and perform this
indicator shows “SERV CODE”. The schematic that procedure again. Also, recheck if the diagnostic
is shown above represents a typical installation of code indicator is illuminated for this diagnostic
the component. Verify the connector contact and wire code. If the cause of the diagnostic code is not
numbers by using the Electrical System Schematic found, replace the main display module. See
for the machine that is being serviced. Testing and Adjusting, “Module - Replace”.
STOP.
STOP.
i01944181
g00737908
Illustration 79
Schematic for the display power supply
66
Troubleshooting Section
This diagnostic code is recorded when the B. Disconnect the harness from the main display
main display module does not receive expected module.
information. When the main display module sends
information to a display component, the display C. Disconnect the machine harness connectors from
component sends a signal back to the main display all of the display components.
module. The signal confirms correct information.
When the main display module does not receive D. At the harness connectors for the main display
expected information, the diagnostic code is logged. module, measure the resistance between the
As a result of this diagnostic code, the main display contacts that are listed below:
module may not respond to the information that is
received. Gauges and readouts could be incorrect • Connector contact 1 (wire 113-OR) and the
when the main display module is in normal mode. Display Data Link circuit contact 4 (wire
Check the connections for the display data link. C413-YL).
Check for opens or shorts in the harness wiring for
the display data link. • Connector contact 1 (wire 113-OR) and the
Display Data Link circuit contact 5 (wire
Test Step 1. INSPECT THE HARNESS C414-BU).
CONNECTIONS.
• Connector contact 1 (wire 113-OR) and
A. Turn the disconnect switch to the OFF position. the Display Data Link circuit contact 3 (wire
E708-PK).
B. Inspect the harness connections that are related
to the display data link. Make sure that the Expected Result:
connectors are clean and tight.
The resistance is greater than 5000 ohms.
C. Check the mating of the harness connectors.
Results:
D. Check wires at the connector.
• OK – The resistance is greater than 5000 ohms.
E. Check each wire for nicks or signs of abrasion in Proceed to test step 3.
the insulation.
• NOT OK – The resistance is less than 5 ohms.
F. Check for moisture at the connector. The machine harness has failed.
G. Check for dirty contacts or corroded contacts. Repair: There is a short between the +battery and
the circuits of the display data link in the machine
H. Check each pin and each socket. harness. Replace the machine harness or repair
the machine harness.
Expected Result:
STOP.
The machine harness connectors are tight and free
of corrosion. Test Step 3. CHECK FOR AN OPEN
HARNESS.
Results:
A. The disconnect switch and the key start switch
• OK – The machine harness connectors are tight remain in the OFF position.
and free of corrosion. Proceed to test step 2.
B. All the display modules remain disconnected from
• NOT OK – The machine harness connectors are the machine harness.
NOT tight and free of corrosion.
C. Measure the resistance of the circuits of the
Repair: Repair the machine harness or replace the display data link that are listed below:
machine harness.
• Measure the resistance between connector
STOP. contact 35 (wire C413-YL) to connector contact
4 (wire C413-YL) of the message center
Test Step 2. CHECK FOR A SHORT TO module.
+BATTERY.
A. Turn the key start switch and the disconnect
switch to the OFF position.
67
Troubleshooting Section
• Measure the resistance between connector Test Step 5. CHECK FOR + 12 DCV
contact 15 (wire C414-BU) to connector contact
5 (wire C414-BU) of the message center A. Reconnect all modules to the machine harness.
module.
B. Turn the disconnect switch and the key start
• Measure the resistance between connector switch to the ON position.
contact 25 (wire E708-PK) to connector contact
3 (wire E708-PK) of the message center C. Use the 7X-1710 Cable probes to check the
module. voltage at the contact 1 (wire E707-GN) to contact
2 (wire 201-BK) of the message center module.
Expected Result:
Expected Result:
The resistance is less than 5 ohms.
The voltage is 9.0 ± 0.5 DCV.
Results:
Results:
• OK – The resistance is less than 5 ohms. The
circuit resistance is correct. Proceed to test step 4. • OK – The voltage is 9.0 ± 0.5 DCV.
• – The resistance is greater than 5000 ohms. Repair: Replace the message center module.
Expected Result:
Results:
STOP.
68
Troubleshooting Section
i01395272
g00737908
Illustration 80
Schematic for the display power supply
B. DO NOT disconnect the harness from the module. • NOT OK – The voltage is NOT 9.0 ± 0.5 DCV.
The display power supply voltage is NOT correct.
C. The correct voltage should measure 9.0 ± 0.5 Proceed to test step 2.
DCV.
Test Step 2. CHECK THE HARNESS FOR
Expected Result: A SHORT TO +BATTERY.
The voltage that is measured is 9.0 ± 0.5 DCV. A. Disconnect the machine harness from the main
display module.
69
Troubleshooting Section
Expected Result:
Results:
STOP.
STOP.
i01487073
g00737908
Illustration 81
Schematic for the display power supply
70
Troubleshooting Section
Test Step 1. CHECK THE VOLTAGE AT Repair: Replace the module that was
THE MAIN DISPLAY MODULE. disconnected.
B. Use the 7X-1710 Multimeter Probe Group. Check • NOT OK – The voltage is NOT 9.0 ± 0.5 DCV.
the voltage at the connector for the main display The display power supply voltage is not correct.
module. Measure the voltage from contact 34 to Repeat this test step again. All the modules have
contact 2 (ground). been disconnected from the machine harness and
the voltage is NOT 9.0 ± 0.5 DCV. Proceed to test
Expected Result: step 3.
The voltage measures 9.0 ± 0.5 DCV. Test Step 3. CHECK FOR A SHORT TO
GROUND.
Results:
A. Turn the disconnect switch and the key start
• OK – The voltage is 9.0 ± 0.5 DCV. The display switch to the OFF position.
power supply voltage is correct. Check the main
display module for the same diagnostic code. If the B. Disconnect the machine harness from the main
service code indicator is still ON, the main display display module.
module has failed.
C. At the machine harness connector for the main
Repair: It is unlikely that the main display module display module, measure the resistance. Measure
has failed. Exit this procedure and perform this the resistance between harness connector contact
procedure again. Also, recheck if the diagnostic 34 and harness connector contact 2.
code indicator is illuminated for this diagnostic
code. If the cause of the diagnostic code is not Expected Result:
found, replace the main display module. See
Testing and Adjusting, “Module - Replace”. The resistance that is measured is greater than 5000
ohms.
STOP.
Results:
• NOT OK – The voltage is NOT 9.0 ± 0.5 DCV.
The display power supply voltage is NOT correct. • OK – The resistance is greater than 5000 ohms.
Proceed to test step 2. STOP.
Test Step 2. DISCONNECT THE • NOT OK – The resistance is less than 5000 ohms.
MODULES. The harness has failed.
A. Use the 7X-1710 Multimeter Probe Group. Check Repair: Repair the harness or replace the harness.
the voltage at the connector for the main display
module. Measure the voltage from contact 34 to STOP.
contact 2 (ground).
Diagnostic System B. Place a jumper wire from the signal wire to the
ground wire. (If a ground wire is not present,
Procedures connect the signal wire to frame ground.)
Expected Result:
i01432657
Flashing Results:
This procedure is for the parameter that has the • NO – The alert indicator stops FLASHING. The
alert indicator which is FLASHING constantly. This circuit is operating correctly. The switch has failed.
condition is caused by an undesired open circuit or a
failed main display module. Repair: Check or replace the switch.
A. Locate the switch which corresponds to the The resistance is greater than 5.0 ohms.
parameter that always FLASHES the alert
indicator. (If necessary, use the Electrical System Results:
Schematic in order to assist in locating the switch.)
• YES – The resistance is greater than 5 ohms.
Expected Result:
Repair: Repair the harness or replace the harness.
The appropriate switch is located.
STOP.
Results:
• NO – The resistance is less than 5 ohms. The
• OK – The appropriate switch is located. Proceed harness is not causing the problem. The main
to test step 2. display module has failed.
A. Locate the switch for the alert indicator that never The resistance is greater than 5000 ohms.
flashes. (If necessary, use the Electrical System
Schematic to assist in locating the switch.) Results:
STOP.
73
Troubleshooting Section
STOP.
i01398181
Harness Code
SMCS Code: 1408-038
S/N: ASD1-Up
S/N: ARL1-Up
S/N: APM1-Up
S/N: APN1-Up
Table 18
Harness Code Troubleshooting(1)
Main Display Module 31 3 12 22 16 6
Connector Contact
Wire Identification 270-BK 271-BK 272-BK 273-BK 274-BK 275-BK
Harness Code Plug Contact(2) 1 2 3 4 5 6
Before you perform this procedure, determine the C. Check for continuity between the connector
proper machine code. The main display module contacts that are grounded contacts and contact
must have the correct part number for the particular 2 (ground). Check for continuity at the machine
machine. If the machine code is not shown correctly, harness connector for the main display module.
this procedure determines the component that is
malfunctioning. This failure could be caused by a Expected Result:
failure in the main display module, a wrong harness
code plug or a harness that has failed. The resistance measures 5.0 Ohms or less.
Note: The harness code and the machine code are Results:
similar terms. The codes describe the particular
machine. The harness code is the status (open or • YES – The resistance is 5.0 Ohms or less. The
ground) of the six harness code inputs (connector circuit for the harness code is not open. No defect
contacts 3, 6, 12, 16, 22 and 31). The main display was found in the ground circuits for the harness
module assigns a number to a machine. This code. Proceed to test step 2.
number is the machine code. The machine code
is shown during harness code mode. Each sales • NO – The resistance is greater than 5.0 Ohms.
model has a specific harness code. Therefore, each The circuit for the harness code is open. Check
sales model also has a specific machine code. The the harness code plug on so equipped machines.
specific machine code is listed in Systems Operation, Record the open contact of the machine harness
“Harness Code Mode”. The specific harness code is connector.
given in the Electrical System Schematic.
Repair: Repair the open circuits for the harness
Note: The following procedure checks for incorrect code that is found or replace the machine harness.
harness codes on the inputs for the main display
module. Compare the status of the harness code that If conditions are not resolved, proceed to test step
is found in the test “Determine the machine code” to 2.
the status at the inputs for the main display module.
The table identifies the connector contacts and wire Test Step 2. CHECK FOR SHORTS
identification of the harness code circuits. Contacts
that are specified as grounded contacts should be A. The disconnect switch remains in the OFF
checked for opens in the harness. Contacts that are position. The machine harness to the main display
specified as open contacts should be checked for module remains disconnected.
shorts in the harness.
B. Measure the resistance between the connector
Test Step 1. CHECK FOR OPENS contacts that are specified as open contacts and
contact 2 (ground). Measure the resistance at the
A. Turn the disconnect switch to the OFF position. machine harness connector for the main display
module.
B. Disconnect the machine harness from the main
display module.
76
Troubleshooting Section
The resistance measures 5000 Ohms or more. Pulse Width Modulated Sensor
Results: SMCS Code: 7490-038-NS
• The ground contact is contact “B”. Repair: If the sensor and the harness are correct,
it is likely that the main display module has failed.
• The signal wire is wire number 443. Replace the main display module. See Testing and
Adjusting, “Module - Replace”.
• The signal contact is contact “C”.
STOP.
Table 19
Tools Needed
i01916286
9U-7330 Multimeter 1
Sensor Signal Voltage
7X-1710 Multimeter Probe Group 1
SMCS Code: 7490-038-NS
Test Step 1. TROUBLESHOOT THE
SENSORS. System Operation Description:
Troubleshoot sensor circuits in the following order. Note: The main display module is connected.
Table 20
A. Perform the Troubleshooting, “Sensor Signal
Voltage” procedure. This procedure checks the Sensor Voltage Specifications
sensor voltages at the sensor while the circuits For The Sensor Voltage Test
remain connected. DISCONNECT NOTHING. 100-3055 Temperature Sensor And 131-0427
Troubleshoot “as is” before disconnecting any Temperature Sensor
circuits. Disconnecting circuits first may alter a
poor connection. Proving the original cause of a Temperature Signal Voltage(1) Duty Cycle
problem may be difficult or impossible. −20 to 0°C 1.1 to 1.4 DCV 11 to 15%
(−4 to 32°F)
Expected Result:
0 to 20°C 1.4 to 2.0 DCV 15 to 23%
(32 to 68°F)
The Troubleshooting, “Sensor Signal Voltage”
procedure has determined the cause of the problem. 20 to 40°C 2.0 to 3.1 DCV 23 to 37%
(68 to 104°F)
Results:
40 to 60°C 3.1 to 4.5 DCV 37 to 55%
• OK – This test step has determined the cause of (104 to 140°F)
the problem. STOP.
60 to 80°C 4.5 to 5.7 DCV 55 to 71%
• NOT OK – This test step has NOT determined the (140 to 176°F)
cause of the problem. Proceed to test step 2. 80 to 100°C 5.7 to 6.6 DCV 71 to 82%
(176 to 212°F)
Test Step 2. TROUBLESHOOT THE
SENSORS 100 to 120°C 6.6 to 7.2 DCV 82 to 89%
(212 to 248°F)
A. Perform the Troubleshooting, “Sensor Dynamic 120 to 140°C 7.2 to 7.4 DCV 89 to 93%
Operation” procedure. This is an additional test. (248 to 275°F)
This will test the sensor during actual operating (1) These voltages are guidelines for troubleshooting and are not
conditions. considered exact. The tolerance is ± 10%, depending on the
condition of the harness. Most important is that the output
Expected Result: voltage changes smoothly as the temperature changes.
Results:
Table 21 Results:
Sensor Voltage Specifications
For Sensor Voltage Test • YES – The voltage is between 7.5 and 8.5 DCV.
The system voltage is present. Proceed to test
3E-5370 Temperature Sensor Group And step 2.
131-0784 Temperature Sensor
Temperature Signal Voltage(1) Duty Cycle • NO – The voltage is not between 7.5 and 8.5 DCV.
There is an open circuit. Trace the +V and ground
−40 to 20°C 0.8 to 1.5 DCV 4 to 11% circuits in the machine harness.
(−40 to −4°F)
−20 to 0°C 1.5 to 2.5 DCV 11 to 22% Repair: Repair the machine harness or replace the
(−4 to 32°F) machine harness.
0 to 20°C 2.5 to 3.7 DCV 22 to 34% STOP.
(32 to 68°F)
20 to 40°C 3.7 to 4.8 DCV 34 to 46% Test Step 2. CHECK THE SIGNAL
(68 to 104°F) VOLTAGE.
40 to 60°C 4.8 to 6.0 DCV 46 to 59%
(104 to 140°F) A. At the sensor connector, identify the signal and
ground circuits.
60 to 80°C 6.0 to 7.2 DCV 59 to 71%
(140 to 176°F) B. Push the 7X-1710 Cable Probes in the back of
80 to 100°C 7.2 to 8.1 DCV 71 to 81% the sensor connector along side of the signal and
(176 to 212°F) the ground circuit wires.
100 to 120°C 8.1 to 8.8 DCV 81 to 87% C. Measure the signal voltage and record the signal
(212 to 248°F) voltage.
120 to 140°C 8.8 to 9.2 DCV 87 to 92%
(248 to 275°F) Note: If a precise signal voltage is necessary, use the
(1) These voltages are guidelines for troubleshooting and are not
specifications that are listed in the provided tables.
considered exact. The tolerance is ± 10%, depending on the
condition of the harness. Most important is that the output Expected Result:
voltage changes smoothly as the temperature changes.
The measured signal voltage is approximately
Locate the suspect sensor. Identify the sensor wires between 1.0 and 7.0 DCV. The measured signal
and connector contacts. See Troubleshooting, “Pulse voltage is approximately between 1.0 and 9.0 DCV
Width Modulated (PWM) Sensor - Test”. DO NOT when using the 3E-5370 Temperature Sensor
DISCONNECT ANY HARNESS CONNECTORS Group.
AT THIS TIME. Turn the key start switch to the ON
position. DO NOT START THE ENGINE. Results:
Test Step 1. CHECK THE SENSOR • FROM 1.0 TO 7.0 (9.0) DCV – The voltage is
POWER. between approximately 1.0 and 7.0 DCV (9.0 DCV
for 3E-5370 Temperature Sensor Group). The
A. At the sensor connector, identify the +V and signal voltage at the sensor is correct.
ground circuits.
Repair: The harness and the main display module
B. Push the 7X-1710 Cable Probes in the back of are working properly. The voltage that is measured
the sensor connector along side of the +V and is correct. The sensor has failed. Replace the
ground circuit wires. sensor.
Repair: Repair the machine harness or replace the Repair: Repair the machine harness or replace the
machine harness. Repeat this test step in order machine harness.
to verify that the problem has been corrected. If
the problem has not been corrected replace the STOP.
main display module. See Testing and Adjusting,
“Module - Replace”. Test Step 4.
STOP. Perform the following diagnostic procedure: “Sensor
Dynamic Operation”
• LESS THAN 1.0 DCV – The voltage is less than
1.0 DCV. The signal voltage is not correct. The Results:
signal circuit of the machine harness is shorted
to ground. • OK – STOP.
Repair: Repair the machine harness or replace the • REPAIRED, OK – STOP.
machine harness. Repeat this test step in order
to verify that the problem has been corrected. If
the problem has not been corrected replace the i01396902
main display module. See Testing and Adjusting,
“Module - Replace”. Sensor Dynamic Operation
STOP. SMCS Code: 7490-038-NS
Expected Result:
Results:
Table 22 Table 23
Sensor Voltage Specifications (1) Sensor Voltage Specifications (1)
Test Step 1. CHECK THE INITIAL SIGNAL B. At the machine harness connector for the main
VOLTAGE. display module, measure the voltage (DCV)
between the signal contact and frame ground.
A. The engine coolant and the temperature sensors
should be below operating temperature. C. For the correct operation, the voltage (DCV) is
greater (and increases smoothly without step
B. Ensure that the engine coolant and temperature increases) than the voltage that was recorded in
sensors are below normal. Ensure that the key the previous test “Check the initial signal voltage”.
switch is OFF and that the sensor is connected
to the machine harness. Note: The larger the change in the system that is
being monitored, the greater the difference between
C. Turn the key switch to the ON position. DO NOT the voltages of this test “Check the signal voltage
START THE ENGINE. with new conditions” and the previous test “Check
the initial signal voltage”.
D. At the machine harness connector for the main
display module, measure the voltage and record Expected Result:
the voltage (DCV) between the signal contact
and frame ground. For correct operation, the The voltage increases during the test procedure.
approximate voltage is between 1.0 and 7.0 DCV.
For the 3E-5370 and 131-0784 Temperature Results:
Sensor Groups the approximate voltage is
between 1.0 and 9.0 DCV. • OK – The voltage increase during the test
procedure and the sensor operates smoothly. The
Note: When precise specifications for the signal sensor has not failed. STOP.
voltage are necessary, use the specifications that are
listed in the provided tables. • NOT OK – The voltage does not increase during
the test procedure. The probable cause is a failed
Expected Result: sensor.
The voltage that is measured is within the Repair: The sensor has failed. Replace the sensor.
specifications.
STOP.
Results:
i01397975
• YES – The approximate voltage is between 1.0
and 7.0 DCV. For the 3E-5370 and 131-0784
Temperature Sensor Groups the approximate
Fuel Level Sender
voltage is between 1.0 and 9.0 DCV. The signal SMCS Code: 1273-038-UN
voltage to the main display module is correct.
Proceed to test step 2. System Operation Description:
• NO – The approximate voltage is NOT between For the most accurate specifications for the sender,
1.0 and 7.0 DCV. For the 3E-5370 and 131-0784 see the table “Resistor, Solenoid And Sender
Temperature Sensor Groups the approximate Specification”. This table is located in the Electrical
voltage is NOT between 1.0 and 9.0 DCV. The System Schematic for the machine that is being
signal voltage to the main display module is not serviced.
correct. The probable cause is a failed sensor.
CHECK THE SENDER
Repair: The sensor has failed. Replace the sensor.
A. Disconnect the sender from the machine harness.
STOP.
B. Measure the resistance between the two contacts
Test Step 2. CHECK THE SIGNAL of the sender.
VOLTAGE WITH THE NEW CONDITIONS.
The following data is the correct approximate
A. Increase the temperature, the pressure or the resistance:
fuel level of the system that is being tested.
The following procedures are examples: run the 106-3535 Level Sender Assembly and
engine in order to increase the engine coolant 134-3033 Fuel Level Sender
temperature, operate the implement controls in
order to increase the hydraulic oil temperature, Empty tank ................................. 240 to 260 Ω
and add fuel in order to increase the fuel level. Half tank ....................................... 97 to 118 Ω
Full tank ......................................... 27 to 40 Ω
82
Troubleshooting Section
104-5546 Level Sender Assembly, 115-2086 Test Step 1. CHECK FOR AN OPEN IN
Fuel Level Sender, 121-3174 Fuel Level Sender, THE HARNESS
136-1617 Fuel Level Sender, 137-5156 Fuel
Level Sender, 150-2995 Fuel Sender, and A. Locate the switch that corresponds to the alert
151-1399 Sender indicator that is located on the main display
module. (If necessary, use the Electrical System
Empty tank ..................................... 92 to 98 Ω Schematic to assist in locating the switch.)
Full tank .......................................... 0 to 3.5 Ω
B. Disconnect the signal wire from the switch.
9X-4942 Fuel Level Sender
Empty tank ..................................... 80 to 85 Ω C. Place a jumper wire from the signal wire to the
Half tank ......................................... 40 to 43 Ω ground wire.
Full tank ............................................. 0 to 2 Ω
Expected Result:
C. Actuate the sender by hand while you are
measuring the resistance. The alert indicator is no longer active on the main
display module.
D. The resistance should change as the sender is
actuated through the empty range to the full range. Results:
Test Step 3. CHECK THE SIGNAL Repair: The machine harness is not the cause
CIRCUIT OF THE HARNESS. of the failure. The ECM has failed. It is unlikely
that the ECM has failed. Exit this procedure
A. Turn the key start switch and the disconnect and perform this procedure again. If the fault is
switch to the OFF position. not found, replace the ECM. See Testing and
Adjusting, “Module - Replace”.
B. Use the Electrical System Schematic to trace the
signal wire from the switch back to the ECM. STOP.
C. Determine the signal contact (connector contact) • NOT OK – The resistance is greater than 5.0
of the machine harness at the ECM. ohms.
D. Disconnect the machine harness connectors J1 Repair: The machine harness has failed. Repair
and J2 from the ECM. the machine harness or replace the machine
harness.
E. At the machine harness connector for the ECM,
measure the resistance between the signal STOP.
contact and contact 2 of the switch.
i01428111
Expected Result:
• OK – The resistance is less than 5 ohms. The possible causes of these failures are listed
below:
• The switch has failed. Repair: The voltage is correct. The ECM has
failed. It is unlikely that the ECM has failed. Exit
• The ECM has failed. this procedure and perform this procedure again.
If the fault is not found, replace the ECM. See
Test Step 1. CHECK FOR AN OPEN IN Testing and Adjusting, “Module - Replace”.
THE HARNESS
STOP.
A. Locate the switch that corresponds to the alert
indicator that is located on the main display • NOT OK – The voltage is NOT 8 ± 0.5 volts.
module. (If necessary, use the Electrical System Proceed to test step 3.
Schematic to assist in locating the switch.)
Test Step 3. CHECK THE SIGNAL
B. Disconnect the signal wire from the switch. CIRCUIT OF THE HARNESS.
C. Place a jumper wire from the signal wire to the A. Turn the key start switch and the disconnect
ground wire. switch to the OFF position.
• NOT OK – The alert indicator remains on the main The resistance is less than 5 ohms.
display module. The machine harness is open or
the ECM has failed. Proceed to test step 2. Results:
Test Step 2. CHECK THE VOLTAGE OF • OK – The resistance is less than 5 ohms. The
THE ECM. signal circuit of the harness is correct. Proceed to
test step 4.
A. Remove the jumper that was used in the previous
test step. • NOT OK – The resistance is greater than 5.0
ohms.
B. The signal wire remains disconnected.
Repair: The signal circuit of the harness is not
C. Measure the pull-up voltage from the signal wire correct. Repair the machine harness or replace the
to the ground wire with a digital multimeter. machine harness.
Expected Result:
Results:
Illustration 83
g00496660 • VOLTAGE HIGHER – The voltage measurement
Special wire probe technique for G3B, Y3A, and L3A alternators.
is greater than the voltage that was observed in the
previous test step “Check The System Voltage”.
C. Read the voltage that is shown on the multimeter. The voltage is also less than the maximum voltage
that is listed in the specifications for the alternator.
Expected Result: The alternator is partially charging the battery.
Proceed to test step 6.
The voltage measurement is within .5 volts of the
battery voltage. • VOLTGE TOO HIGH – The voltage measurement
is greater than the voltage that was observed in the
Results: previous test step “Check The System Voltage”.
The voltage is also greater than the maximum
voltage that is listed in the specifications for the
• YES – The voltage reads battery voltage. The alternator. The alternator is over charging. Proceed
excitation circuit is correct. 4.
to test step 19.
• NO – The voltage that is measured is more than
a .5 volt less than the battery voltage. There is a • VOLTAGE LOWER – The voltage is not higher
problem in the wiring harness to the alternator or than the voltage that was observed in the previous
there is a poor electrical connection. Correct the test step. Proceed to test step 7.
problem and operate the machine. Watch for a
recurrence of the problem. STOP. Test Step 6. TEST THE ALTERNATOR
OUTPUT.
Test Step 4. CHECK THE SYSTEM
VOLTAGE. Note: For the proper output current, refer to table 24.
A. Before you start the machine, connect a voltmeter A. Ensure that the batteries are NOT fully charged.
between the “B+” terminal and the case of the
alternator. Turn OFF all electrical loads. Note: A fully charged battery may have open circuit
voltage above 12.5 volts on 12 volt systems. 24 volt
B. Turn the key to the ON position but do not start systems may be as high as 25 volts.
the engine. Read the voltage on the voltmeter.
Make a note of the voltage that was measured. B. If the batteries are fully charged, then crank the
engine for 30 seconds. This action reduces the
Expected Result: battery voltage. Operate the lights for 10 minutes
while the engine is off as an alternative.
This voltage should be approximately system voltage.
C. Connect the 9U-5795 Current Probe or 8T-0900
Results: Ammeter to a DMM (digital multimeter). The
multimeter must have a peak hold feature. Clamp
the probe around the alternator output wire “B+”.
• YES – The voltage is approximately system Before you clamp the probe around the wire,
voltage. Proceed to test step 5.
ensure that the probe is “zeroed”.
88
Troubleshooting Section
D. Set the digital multimeter to “peak hold” or “max Test Step 8. TEST THE CHARGING
mode” on the “mV” scale. CIRCUIT.
E. Turn on all electrical accessories: lights, air A. Verify that the nut on the “B+” alternator terminal
conditioning, and radio. is tight. Also, verify that the wire has a good
connection to the “B+” terminal.
F. Start the machine, and immediately set the throttle
to at least 75%. The peak current will appear on B. Many Caterpillar machines are equipped with a
the voltmeter in “peak hold” or “max” mode. connector for the 6V-2150 Starting/Charging
Analyzer. Use of this tester replaces the remainder
Expected Result: of this test step. To operate the analyzer, refer to
Tool Operating Manual, SEHS7768, “Using the
The current reading should be at least 90% of the 6V-2150”.
specified peak output.
C. Start the engine and set the throttle to at least 75
Results: percent. Turn ON all electrical accessories for the
remainder of this test step. Allow the engine to run
• YES – The current is at least 90% of the specified for at least 3 minutes before continuing.
peak output. Proceed to test step 13.
D. Measure the voltage between the “B+” alternator
• NO – The current is less than 90% of the specified terminal and the alternator case ground. Make a
peak output. Proceed to test step 7. note of the measured voltage. Perform the next
measurement immediately.
Test Step 7. CHECK THE DRIVE SYSTEM
OF THE ALTERNATOR. E. Measure the voltage across the battery. Put the
red lead on the battery positive terminal, and put
A. Check the condition of the alternator drive belt. the black lead on the battery negative terminal.
Clean the pulley and replace the drive belt if the Make a note of the voltage that was measured.
drive belt is oily. Dry the drive belt if the belt is wet.
Replace the drive belt, if the belt is worn. Expected Result:
B. Check the tension of the alternator drive belt. The voltage at the battery should be less than the
Adjust the drive belt to the correct tension. voltage at the alternator. The difference in voltages
should not be more than 1 volt on 12 volt systems.
C. Check the nut on the alternator pulley. Tighten the The difference should not be more than 2 volts on
nut if the nut is loose. 24 volt systems.
The drive system of the alternator is functioning • YES – The voltage at the battery is less than the
correctly. No corrections to the drive system were voltage at the alternator. Also, the difference in
necessary. voltages is less than 1 volt for 12 volt systems
and the difference is less than 2 volts for 24 volt
Results: systems. The wiring that is related to the alternator
is correct at this time.
• YES – The drive system of the alternator
is functioning correctly. No corrections were Repair: There is an internal problem with the
necessary. Proceed to test step 8. alternator. Repair or replace the alternator.
Test Step 9. TEST THE POSITIVE SIDE Repair: There is high resistance in the negative
OF THE CHARGING CIRCUIT. side of the charging circuit that is caused by one of
the following conditions:
A. Measure the voltage between the frame ground
and the “B+” alternator terminal. Make a note of • An electrical connection has loosened.
the voltage that was measured. Perform the next
measurement immediately. • The alternator ground has loosened.
B. Measure the voltage between the frame ground • The engine ground has opened.
and the + battery post. Make a note of the voltage
that was measured. Repair the problem or replace any component
that has failed. Exit this procedure and retest the
Expected Result: alternator charging system.
Repair the problem or replace any component • NO – The voltage rises and the alternator begins
that has failed. Exit this procedure and retest the charging.
alternator charging system.
Repair: The wire to the “R” terminal is shorted.
STOP. Repair the wiring or replace the wiring. Exit this
procedure and retest the alternator charging
Test Step 10. TEST THE NEGATIVE SIDE system.
OF THE CHARGING CIRCUIT.
STOP.
A. Check the voltage between the negative battery
post and the alternator case ground. Test Step 12. RESTORE THE RESIDUAL
MAGNETISM OF THE ROTOR.
Expected Result:
A. Connect one end of a jumper wire to the “B+”
The voltage does not exceed 1 volt on 24 volt terminal (D+ terminal for K1, N1, and N3) of the
systems or 0.5 volts on 12 volt systems. alternator.
• NO – The voltage output does not rise. Note: The standard acceptable current draw is 50
milliamperes. A current draw above 50 milliamperes
Repair: There is an internal problem with the usually indicates a problem. However, some large
alternator. Repair or replace the alternator. machines with multiple electronic control modules
have a higher acceptable limit. For more information,
STOP. contact a Caterpillar dealer or contact the business
unit that produces the machine.
Test Step 13. TEST FOR UNDESIRABLE
CURRENT FLOW IN THE ALTERNATOR Expected Result:
CHARGING SYSTEM.
The current is below 0.050 amperes (50
A. Turn off all of the accessories. Turn the keyswitch milliamperes).
to the OFF position.
Results:
B. Clamp a 9U-5795 Current Probe or 8T-0900
Ammeter around the main ground cable. Clamp • YES – The current is below 0.050 amperes. The
the tool with the positive side away from the charging system is functioning properly at this time.
battery. Reset the probe (zero) before you clamp The failure is possibly an intermittent draw in the
the probe around the wire. Read the current on system. The batteries may have failed. Ensure
the meter. Make a note of the current that was that NO accessories were ON during the test. Exit
measured. this procedure and retest the alternator charging
system. STOP.
Expected Result:
• NO – The current is above 0.050 amperes. There
The current is below 2 amperes. The “YES” selection is a draw in the system. Proceed to test step 16.
is dependent on the presence of a main disconnect
switch on the machine that is being tested. Test Step 15. MEASURE THE CURRENT
OF THE SYSTEM BY REMOVING THE
Results: NEGATIVE BATTERY CABLE.
• YES - WITH DISCONNECT SWITCH – The A. Disconnect the ground cable from the negative
current is below 2 amperes. For machines with a battery post. There may be more than one battery
main disconnect switch, proceed to test step 14. that is connected to ground. Disconnect all of the
batteries that are connected to ground. Do not
• YES - WITHOUT DISCONNECT SWITCH – The disconnect cables that are between batteries that
current is below 2 amperes. For machines without are connected in series.
a main disconnect switch, proceed to test step 15.
B. Connect an ammeter between the disconnected
• NO – The current is above 2 amperes. There is a battery ground cable and one of the negative
current draw in the system. Proceed to test step 16. battery terminals. Connect the red positive lead
of the ammeter to the cable. The negative lead
Test Step 14. MEASURE THE CURRENT should be connected to the battery terminal. If a
OF THE SYSTEM BY USING THE MAIN multimeter is being utilized for this test, use the 10
DISCONNECT SWITCH. ampere connections in order to avoid damage.
Note: The standard acceptable current draw is 50 Test Step 17. TEST THE OUTPUT
milliamperes. A current draw above 50 milliamperes CURRENT OF THE ALTERNATOR
usually indicates a problem. However, some large BELOW 0.015 AMPERES.
machines with multiple electronic control modules
have a higher acceptable limit. For more information, A. Disconnect the wire from the “B+” terminal of
contact a Caterpillar dealer or contact the business the alternator. Set the multimeter on the 10 amp
unit that produces the machine. scale. Connect the red lead of the multimeter to
the wire that was disconnected. Connect the black
Expected Result: lead of the multimeter to the “B+” terminal of the
alternator. Make a note of the current that was
The current is below .050 amperes (50 milliamperes). measured.
• YES – The current is below 0.050 amperes. The The current is less than 0.015 amperes.
charging system is currently good. The problem is
a possible intermittent current draw in the system. Results:
The batteries may have failed. Check that NO
accessories were ON during the test. STOP. • YES – The current is under 0.015 amperes. The
alternator is operating correctly. There may be a
• NO – The current is above 0.050 amperes. There current draw on the machine. Proceed to test step
is excessive current flow in the system. Proceed 18.
to test step 16.
• NO – The current is over 0.015 amperes.
Test Step 16. TEST THE CURRENT OF
THE ALTERNATOR OUTPUT BELOW 2 Repair: There is an internal problem with the
AMPERES. alternator. Repair or replace the alternator.
B. Connect the 9U-5795 Current Probe or 8T-0900 Test Step 18. IDENTIFY THE SOURCE OF
Ammeter to a DMM (digital multimeter). Clamp EXCESSIVE CURRENT DRAW.
the probe around the “B+” wire of the alternator.
Before you clamp the probe around the wire, A. Make sure that every electrical component is
ensure that the probe is “zeroed”. turned OFF. Make sure that the keyswitch is turned
OFF. Make sure that the dome lights are OFF.
C. Read the current on the meter. Make a note of the
current that was measured. B. Clamp a 9U-5795 Current Probe or 8T-0900
Ammeter around the main ground cable. Clamp
Expected Result: the tool with the positive side away from the
battery. Reset the probe (zero) before clamping
The current is under 2 amperes. the probe around the wire. Use the current probe if
the draw is above approximately 2 amperes. Use
Results: the Ammeter if the draw is below approximately
2 amperes.
• YES – The current is under 2 amperes. Proceed
to test step17. C. Remove the fuses or open the circuit breakers
one at a time. Check the current after each fuse
• NO – The current is over 2 amperes. has been removed or each circuit breaker has
been opened. After observing the current, reinstall
Repair: There is an internal problem with the the fuse or close the circuit breaker. Start with the
alternator. Repair or Replace the alternator. main circuits first, and proceed to smaller circuits.
F. All of the components in the circuit should be D. Measure the voltage between the “B+” terminal of
disconnected. If the problem still exists, then the alternator and the case of the alternator. Make
check the wiring in the circuit. There may be a note of the voltage that was measured. Perform
circuit leakage through corrosion or circuit leakage the next measurement immediately.
through a short.
E. Measure the voltage across the battery. Put the
Note: The standard acceptable current draw is 50 red lead on the positive terminal of the battery,
milliamperes. A current draw above 50 milliamperes and put the black lead on the negative terminal of
usually indicates a problem. However, some large the battery. Make a note of the voltage that was
machines with multiple electronic control modules measured.
have a higher acceptable limit. For more information,
contact a Caterpillar dealer or contact the business Expected Result:
unit that produces the machine.
The voltage at the battery should be less than the
Expected Result: voltage at the alternator. On systems that are 12 volt,
the difference in voltages should not be more than
The source of the excessive current draw was 1 volt. On systems that are 24 volt, the difference
determined. should not be more than 2 volts.
Results: Results:
• YES – The source of the excessive current draw • YES – The voltage at the battery is less than the
was determined. voltage at the alternator. Also, the difference in
voltages is less than 1 volt for 12 volt systems
Repair: Repair the problem or replace any and the difference is less than 2 volts for 24 volt
component that has failed. Exit this procedure and systems. The wiring that is related to the alternator
retest the alternator charging system. is correct at this time.
Repair: Exit this procedure and retest the • NO – The voltage at the battery is less than the
alternator charging system. voltage at the alternator. However, the difference in
voltages is greater than 1 volt for 12 volt systems
STOP. and the difference is greater than 2 volts for 24 volt
systems. Proceed to test step 20.
Test Step 19. TEST FOR AN
OVERCHARGING CONDITION FROM THE Test Step 20. TEST THE POSITIVE SIDE
ALTERNATOR. OF THE CHARGING CIRCUIT.
A. Verify that the nut on the “B+” alternator terminal A. Measure the voltage between the frame of the
is tight. Also, verify that the wire has a good machine and the “B+” terminal of the alternator.
connection to the “B+” terminal. Make a note of the voltage that was measured.
Perform the next measurement immediately.
B. Many Caterpillar machines are equipped with a
connector for the 6V-2150 Starting/Charging B. Measure the voltage between the frame of the
Analyzer. Use of this tester replaces the remainder machine and the positive terminal of the battery.
of this test step. To operate the analyzer, refer to Make a note of the voltage that was measured.
Tool Operating Manual, SEHS7768, “Using the
6V-2150”. Expected Result:
C. Start the engine and set the throttle to at least 75 The voltage difference does not exceed 1 volt on 24
percent. Turn ON all electrical accessories for the volt systems or 0.5 volts on 12 volt systems.
remainder of this test step. Allow the engine to run
for at least 3 minutes before continuing. Results:
STOP.
STOP.
Expected Result:
Results:
Testing and Adjusting • The test for the LCD segments for rpm, gear and
direction (8) will turn on every segment of the
Section display. The readout looks like a “0” with an “X” and
a “+”. There should be twelve of these symbols
next to each other on the lamp/gear module.
Testing and Adjusting • The alert indicators (3) and the mode indicators (7)
for the lamp/gear module will turn ON.
i01916579
• Tachometer gauge (6) and gauges (5) jump to
System Self Test half scale. The gauges go to zero. The gauges
then go to full scale. After reaching full scale, the
SMCS Code: 7490-038 tachometer and the gauges return to the current
machine values.
1. Identify the connectors and the wire numbers of 2. Turn the key start switch and the disconnect
the suspect circuits. Use the Electrical System switch to the OFF position.
Schematic of the machine to identify the circuits.
3. Disconnect the component and the ECM from the
2. Turn the key start switch and the disconnect wiring harness.
switch to the OFF position.
4. At the machine harness connector for the ECM,
3. Disconnect the component and the ECM from the place one of the multimeter probes on the contact
wiring harness. of the suspect wire.
4. At one of the disconnected harness connections, 5. Use the other multimeter probe to check the
place a jumper wire from the contact of the resistance across all other contacts in the
suspect wire to frame ground. connector(s) of the ECM and frame ground.
5. At the other connector of the machine harness, Expected Result: The resistance is greater than
use the multimeter probes to measure the 5000 ohms for all the measurements.
resistance from the contact of the suspect wire to
frame ground. OK – The resistance is greater than 5000 ohms
for all the measurements. The harness circuits
Expected Result: The resistance is less than 5 are correct.
ohms.
Stop.
OK – The resistance is less than 5 ohms. The
harness circuit is correct. NOT OK – The resistance is less than 5 ohms.
There is a short in the machine harness. The short
Stop. is between the suspected wire and the wire with
the lowest resistance measurement.
NOT OK – The resistance is greater than 5000
ohms. There is an open in the machine harness. Repair: Repair the machine harness or replace
the machine harness.
Repair: Repair the machine harness or replace
the machine harness. Stop.
Stop.
i01547498
• If the wires enter the connector at an angle, Expected Result: The module has been
there may not be a good seal between the successfully replaced and the module has
connector and the wire insulation. completed the self test.
Prior to replacement of a module, ensure that Note: Once the module has been replaced
replacement is absolutely necessary. A diagnostic successfully, see Testing and Adjusting, “Main
code is seldom caused by the module. Always ensure Display Module-Flash Program”.
that the machine code is correct for the machine.
Also ensure that the power is available to the main i01104167
display module. The system voltage is required
between the contacts 1 and 2 of the connector for the Main Display Module
main display module. To check the machine code,
see System Operation, “Harness Code Mode”.
Initialization - Adjust
SMCS Code: 7490-025
Procedure
The initialization is an internal process within the
1. Replace the module. main display module. During the initialization, the
main display module listens to the CAT data link and
a. Turn the key start switch to the OFF position. the harness code inputs. From this information, the
module learns about the machine. For example, the
b. Disconnect the machine harness from the module learns that the information for the engine oil
module. pressure is coming from an engine ECM.
c. Ensure that the module that is replacing the old Normally, the initialization occurs when the main
module has the correct part number. display module is replaced. Also, the initialization
occurs when there is a change in the harness code.
d. Install the new module. However, when a previously used main display
module is used as a replacement, initialization could
Note: If the main display module that is replacing the be necessary. Faults that can not be explained with
old module was previously removed from service, the CAT data link can occur if the main display
see Testing and Adjusting, “Main Display Module module is not initialized correctly. The service
Initialization - Adjust”. person must activate the initialization when the
main display module has been previously used.
e. Connect the machine harness to the module. Initialization is used if the module was taken out
On so equipped machines, make sure that the of an application that had the same machine code
harness code plug is installed. as the main display module that is to be removed.
b. Various indicators in the Caterpillar Monitoring d. Use WinFlash in order to load the software.
System display area will illuminate. Wait 10
seconds. Note: Flash programming is not allowed if the engine
is running, or the machine is moving.
c. Turn the key switch to the OFF position.
99
Testing and Adjusting Section
Indicator – An indicator is any of the items within Pulse Width Modulation (PWM) – The PWM
the Caterpillar Monitoring System display area which is a signal that consists of variable pulse widths
operate in an ON, FLASHING or OFF manner in at fixed intervals. The duty cycle can be varied.
order to bring attention to a machine condition. The frequency of a PWM signal is constant. The
Caterpillar Monitoring System has sensors which
Jumper – A jumper is a piece of wire that is used to provide a PWM signal to the main display module.
make an electrical connection during troubleshooting.
Scroll – When you scroll through information in
Key Start Switch – This is an automotive type key the display area, all available sets of diagnostic
start that provides engine cranking/starting . information are shown by one set at a time. A set of
diagnostic information is shown briefly. Then, the
Lamp – This is a component of the machine display automatically advances to the next set. After
electrical system that emits light by converting all sets have been shown, the sets are repeated.
electrical energy into light.
Sender – This is a device that changes resistance
Light Emitting Diode (LED) – This is a solid state according to a physical condition. The sender then
device. The device emits light that is visible to the sends a signal to a gauge. A single connection
human eye when an electrical current is passed provides the signal and the power.
through the device. The LED is used as a lamp
in electronic controls because the device is very Sensor – This is a device that monitors the physical
reliable. condition of a machine system. The sensors can
monitor the conditions that are listed here: pressure,
Liquid Crystal Display (LCD) – This is a type temperature, flow, and mechanical movement. The
of solid state display that uses a liquid crystalline sensors convert the condition into an electrical signal
material. The material is sealed between two glass that can be understood by an electronic control.
sheets. An electrical signal causes segments of the
crystal material to be visible to the eye. Service Code – This is a type of maintenance code
that describes a condition that has been identified
Machine Service Connector – This is a harness by an electronic control system. The code indicates
connector for the machine or for engine electrical when service is required. This code is stored in the
systems. The harness connector will allow the control for the service technician. This term was
connection of a service tool for diagnostics. previously referred to as a fault code. This code is
now referred to as a service type of maintenance
Module Identifier (MID) – An MID is a diagnostic event.
code that identifies the electronic control module
which diagnosed the diagnostic code. The two-digit Service Tool – This is a tool that is used in order to
code is displayed in the display area when the service Caterpillar machines. This term most often
machine is in the service mode. refers to the service equipment that is listed here:
Electronic Control Analyzer Programmer (ECAP),
Open Circuit – This is a condition that exists when Caterpillar Electronic Technician (ET), a digital
an electrical circuit is broken. multimeter, and laptop computer This may also refer
to any other dedicated service equipment.
Pressure Sensor – This is a device that generates
a signal that is proportional to the pressure that is Short Circuit – A connection between two points in
sensed. a circuit that is normally unwanted.
Problem – This refers to the presence of an Show – This pertains to information that is within
abnormal machine condition. When a problem exists, the Caterpillar Monitoring System display area that is
warning operation is activated and the main display viewed by the operator or a service person.
module notifies the operator.
Signal – This is the changing voltage that is used
Pounds per square inch (psi) – This is an English to carry information. A signal is typically sent from a
unit of pressure measurement. The measurement sensor to an electronic control. For example, a signal
represents the force that is applied to one square is sent from the transmission output speed sensor
inch. The value is measured in pounds. 6.89 kPa (TOS) to the transmission control.
(1 psi)
Signal Wire – This is the harness wire that carries
Pull up Voltage – This is the voltage that is the signal voltage to the electronic control. The signal
measured on the input of an electronic control. The is sent by any of the components that are listed here:
measurement is taken when an input device (sensor a sensor, a switch, and any other similar components.
or switch) has been disconnected.
101
Testing and Adjusting Section
i01857510
Table 25
Contact Description Of Main Module Connector
12H, 120H, 135H, 140H, 143H, 160H And 163H
No. Function Type Description
1 + Battery Input - Voltage (Power) 28 VDC
2 Ground Ground 0 VDC
3 Harness Code 1 Switch Input - Programming Programming Switch(1)
4 Action Alarm Output Alarm Driver
5 CAT Data Link + Input/Output - Data Link Driver/Receiver (+)
6 Harness Code 5 Switch Input - Programming Programming Switch(1)
7 PWM/Switch 1 Sensor Or Switch Input Unassigned
8 PWM/Switch/Sender 5 Sensor, Switch Or Sender Input Unassigned
9 Switch /Sender 10 Switch Or Sender Input Fuel Level
(continued)
102
Testing and Adjusting Section
Table 26
Contact Description Of Main Module Connector
14H, And 16H
No. Function Type Description
1 + Battery Input - Voltage (Power) 28 VDC
2 Ground Ground 0 VDC
3 Harness Code 1 Switch Input - Programming Unassigned
4 Action Alarm Output Alarm Driver
5 CAT Data Link + Input/Output - Data Link Driver/Receiver (+)
6 Harness Code 5 Switch Input - Programming Unassigned
7 PWM/Switch 1 Sensor Or Switch Input Unassigned
8 PWM/Switch/Sender 5 Sensor, Switch Or Sender Input Unassigned
9 Switch /Sender 10 Switch Or Sender Input Fuel Level
10 PWM/Switch/Sender 6 Sensor, Switch Or Input Unassigned
11 Switch 7 Switch Input Neutral Start Switch
12 Harness Code 2 Switch Input - Programming Unassigned
13 Action Lamp Output Lamp Driver
14 CAT Data Link - Input/Output - Data Link Driver/Receiver (-)
15 Display Module Load Output Driver for Gauge Module
16 Harness Code 4 Switch Input - Programming Unassigned
17 PWM/Switch 2 Sensor Or Switch Input Reverse/Backup Alarm Switch
18 Switch/Sender 9 Switch Or Sender Input Articulation Angle Sender
19 Switch 1 Switch Input Brake System Pressure Switch
20 Switch 4 Switch Input Operator Mode Switch
21 Switch 8 Switch Input Unassigned
22 Harness Code 3 Switch Input - Programming Unassigned
23 Service Switch Input Scroll Switch
24 Sensor Power Supply Output Unassigned
25 Display Module Clock Output Driver for Gauge Sequencing
26 Frequency 1 Sensor Input - Frequency Ground Speed Sensor
27 PWM/Switch 4 Sensor or Switch Input Unassigned
28 PWM/Switch/Sender 7 Sensor, Switch Or Sender Input Unassigned
29 Switch 2 Switch Input Park Brake
30 Alternator R terminal Sensor Input - Frequency Alternator Frequency
31 Harness Code 0 Switch Input - Programming Unassigned
32 Switch 6 Switch Input Hydraulic Temperature
33 Clear Switch Input Clear Switch
34 Display Module Power Supply Output 9 VDC
35 Display Module Data Input/Output Data for Gauge Module
36 Frequency 2 Sensor Input - Frequency Unassigned
37 PWM/Switch 3 Sensor Or Switch Input Unassigned
(continued)
104
Testing and Adjusting Section
i01857839
System Schematic
SMCS Code: 7566
g00947079
Illustration 85
106
Testing and Adjusting Section
14H
g00865621
Illustration 86
107
Testing and Adjusting Section
16H
g00947028
Illustration 87
108
Testing and Adjusting Section
g00947030
Illustration 88
109
Index Section
Index
A I
F
O
Fuel Level Sender ................................................. 81
Odometer Mode...................................................... 11
G
P
General Information........................................... 4, 38
Introduction .......................................................... 4 Pulse Width Modulated Sensor ............................. 76
Glossary of Terms.................................................. 99
Q
H
Quad Gauge Module ............................................. 31
Harness Code........................................................ 73
Harness Code Mode.............................................. 12
110
Index Section
R W
Scrolling Mode........................................................ 11
Senders ................................................................. 33
Level Sender (Fuel) ........................................... 33
Position Sender (Articulation Angle) .................. 34
Temperature Sender .......................................... 34
Sensor Dynamic Operation ................................... 79
Sensor Signal Voltage ........................................... 77
Sensors ................................................................. 34
Frequency Sensors............................................ 34
General Information ........................................... 34
Pulse Width Modulated (PWM) Sensors............ 35
Service Meter Mode .............................................. 10
Service Mode......................................................... 14
Service Tools ......................................................... 38
4C-8195 Control Service Tool........................... 40
Changing Modes................................................ 40
Service Switches................................................ 39
Setup Mode ........................................................... 18
Speedometer/Tachometer Module ........................ 32
Switch Circuits ................................................. 82–83
Switches ................................................................ 32
Pressure Switch ................................................. 33
Rocker Switch (Operator Mode Selector) .......... 33
Temperature Switch (Hydraulic Oil) ................... 33
System Schematic............................................... 104
12H, 120H, 135H, 140H, 143, 160H, And
163H............................................................... 108
140H, 143H, 160H And 163H ......................... 105
14H .................................................................. 106
16H .................................................................. 107
System Self Test.................................................... 94
Systems Operation Section ..................................... 4
Table of Contents..................................................... 3
Tachometer Mode................................................... 11
Tattletale Mode ...................................................... 16
Testing and Adjusting ............................................ 94
Testing and Adjusting Section ............................... 94
Troubleshooting Section ........................................ 38