Service Training SEGV3004

Course Module July 1997

TECHNICAL PRESENTATION

TRUE RMS MULTIMETER

FLUKE 87
AUTO DC

0 0 00
0 1 2 3 4 5 6 7 8 9 0
V

± 4
CATERPILLAR
MIN MAX RANGE HOLD

REL ∆

MACHINE
Hz
Peak Min Max

Ω
---
mV

---
V mA
A
ELECTRONICS
~V
µA

OFF
COURSE
A mA µA COM V-Ω

400mA MAX
FUSED

10A MAX 1000V MAX

FUSED

MODULE FOUR: ELECTRICAL

SCHEMATICS
SEGV3004 -2- Module Four
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TABLE OF CONTENTS

COURSE DESCRIPTION............................................................................................................3

MODULE DESCRIPTION/OBJECTIVES..................................................................................4

LESSON PLAN ............................................................................................................................5

SCHEMATICS..............................................................................................................................7

FEATURES ON FRONT OF SCHEMATIC ................................................................................8

FEATURES ON BACK OF SCHEMATIC ................................................................................14

MODULE FOUR QUIZ USING SCHEMATIC SENR5919 .....................................................19

MODULE FOUR QUIZ USING SCHEMATIC SENR5672 .....................................................25

SEGV3004 -3- Module Four
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COURSE DESCRIPTION

This module is a review of the basic electrical and electronic principles needed by a technician to
understand and maintain the complex machine systems installed in Caterpillar products. The modules
do not teach specific machine systems unless otherwise stated in the lesson description.

Each module contains a quiz/skill test to measure the student's electrical/electronic skills and
knowledge. It is recommended that the pretest be completed prior to scheduling training. The pretest is
designed to evaluate each module of the course and may be used as a "skills/knowledge inventory" for
the evaluation of each student.

Suggest the following procedure:

Pretest
• Administer the pretest.
• Do not answer questions regarding pretest content.
• Collect pretest, do not review or discuss test with students.
• Grade the pretest, but do not pass out scores.
• Use the pretest to evaluate each students knowledge prior to receiving instruction.

Posttest
• Each module lesson quiz/skill test will serve as a posttest for the individual modules.
• Have students exchange tests and review and discuss each question.
• Have students mark the incorrect responses.
• Collect all copies of the quizzes/skill tests and file for future reference.

The course is designed as several modules. The current modules are:

Module 1: Basic Electrical and Electronic Principles (SEGV3001)

Module 2: Electronic Components (SEGV3002)
Module 3: Wire Maintenance (SEGV3003)
Module 4: Electrical Schematics (SEGV3004)
Module 5: Machine Electrical and Electronic Systems, Diagnostic Tooling and Troubleshooting
Procedures (SEGV3005)
Additional Support Information:
List of Acronyms and Glossary of Electrical/Electronic Terms (SEKV3001)
Machine Electronic Course Pretest (SEBV3001)
Machine Electronic Course Pretest Answers (SEEV3001)

Each module contains the following:

A module description
A module objective
A module plan
A list of reference materials or job aids needed to present the module
A student handout section (if applicable)
A student quiz and a master copy of the quiz for the instructor (with answers)
SEGV3004 -4- Module Four
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Module Four MODULE FOUR: ELECTRICAL SCHEMATICS

Module Four Description

Time: 2 hours The electrical schematic lesson provides the student with a description
and explanation of all the information that is available to help the
technician in diagnosing and troubleshooting electrical and electronic
systems.

Presentation Methods The module may be presented in two different ways:

Method One: Give each student a specific machine schematic

and a copy of a quiz specifically designed for the schematic being
used. Have each student answer the questions using only the
schematic as a reference. Do not deliver slide presentation.

Method Two: Deliver the slide presentation explaining all the

features depicted on both the front and rear of the schematic and
then pass out a copy of the quiz and have the students answer the
questions.

Objective Module Four Objective

Given a specific machine electrical schematic and a quiz, demonstrate an

ability to read and interpret the schematic information.

Module Four Reference Materials

Order a schematic for Schematic--950F Series II Wheel Loader Electrical System SENR5919
each student
or

Schematic--785B Truck Electrical Schematic SENR5672

Pick appropriate Select the appropriate schematic quiz from the student materials section
schematic of this course and duplicate a copy for each student.

Duplicate Quiz Module Four Quizzes located at the end of the presentation.

Suggestion: The reference schematics and their associated quizzes have been
selected to provide a broadbased example of Caterpillar product. If a
dealer trainer desires, the reference materials can be easily adapted to
another product by ordering a machine specific schematic and then
tailoring the quiz to match the schematic.
SEGV3004 -5- Module Four
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Module Four Module Four Lesson Plan

Method One Choose a method for delivering module four. If Method One is used,
conduct the exercise is the following manner.

Complete quiz before 1. Pass out copies of appropriate electrical schematic and quiz.
presenting slides
2. Instruct each student to work independently.

3. Allow students ample room to spread out (open) the schematic for
easier viewing. Allow approximately 45 - 60 minutes to complete
the quiz.

4. Treat quiz as an "open book" exercise (all the requested

information is documented on the schematic).

5. Do not grade the quiz. Encourage each student to "mark" their

incorrect responses, and more importantly, participate in a class
discussion of the correct response. When a disagreement occurs
on a particular response, have that student locate the correct
response on their schematic and explain their response. This
ensures that everyone knows the correct response.

6. Exercise completed.

If Method Two is used, conduct the exercise in the following manner.

Method Two Slide Presentation (Slides 1 through 7)

Lecture A. Electrical Schematics

1. Pass out copies of appropriate electrical schematic.

2. Slide presentation. Using slides and the electrical schematic,

explain the features depicted on the front and rear of the
schematic.

B. Administer Quiz

1. Instruct each student to work independently.

2. Allow students ample room to spread out (open) the

schematic for easier viewing. Allow approximately 45 - 60
minutes to complete the quiz.

➥
SEGV3004 -6- Module Four
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3. Treat quiz as an "open book" exercise (all the requested

information is documented on the schematic).

4. Do not grade the quiz. Encourage each student to "mark" their

incorrect responses, and more importantly, participate in a
class discussion of the correct response. When a disagreement
occurs on a particular response, have that student locate the
correct response on their schematic and explain their response.
This ensures that everyone knows the correct response.

5. Lesson completed.
SEGV3004 -7- Module Four
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ELECTRICAL
SCHEMATICS

Schematics Schematics

Schematics are basically line drawings that explain how a system works
by using symbols and connecting lines. Symbols are used to represent
devices or components of both simple and complex electrical and
electronic systems.

Schematics are used by technicians to determine how a system works and

to assist in the repair of a system that has failed.

Schematic symbols present a great deal of information in a small amount

of space and the reading of schematic symbols requires highly developed
skills and practice. A logical, step-by-step approach to using schematic
diagrams for troubleshooting begins with the technician's understanding
of the complete system.

Caterpillar electrical schematics contain very valuable information. The

information is printed both on the front and reverse side of the schematic.
The technician needs to become very skilled in reading and interpreting
all the information contained on both sides of the schematic.
SEGV3004 -8- Module Four
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FEATURES
On The Front

Color Codes for Circuit Identification

Grid Design for Location
Machine Silhouette Layout
Component Part Numbers
Symbol Descriptions
Wiring Harness Information

Front Side Features Features on the Front of the Schematic

Some of the features contained on the front side are:

• Color codes for circuit identification (top center)

• Color abbreviation codes (right side)

• Symbol descriptions (right side)

• Wiring harness information (right side)

• Schematic notes and conditions (lower right side)

• Grid design for component location (outside margins)

• Component part numbers (next to each component)

➥
SEGV3004 -9- Module Four
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The dash lines on Explain the various types of dashed lines on electrical schematics. The
schematics are following is a recommendation for clearing up the confusion associated
confusing. Ensure with dashed lines:
the students
understand the • Dashed "colored" lines represent attachment circuits. Use the
different applications. color identification code located in the top center of the schematic
Use the schematic to determine the circuit.
classroom exercise to
measure this section. • The heavy "double-dashed" lines identify the circuitry and
components located in the operator station.

• A dashed (thin black) line is used to identify an attachment, wire,

cable or component. (See symbol description on right side of
schematic).
SEGV3004 - 10 - Module Four
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OLD FORMAT

COLOR CODE WIRE SIZE

WIRE LABEL

169 - PK - 18

NEW FORMAT COLOR CODE

WIRE LABEL WIRE SIZE

169 - H5 PK - 18

WIRE #5 in HARNESS "H"

PRO/E Format Machine Electrical Schematics with New Format

Some Caterpillar machines use a new format for electrical system

schematics. The new format is called PRO/E and provides additional
information for wire, connector, component and splice symbol. The
following information describes the new format.

Wire Identification Labels

This slide shows the new wire identification format. The label includes
the circuit identification wire label number (169), harness identification
code (H), the wire number in the harness (5), color code (PK) and the wire
size (18).

NOTE: The codes shown are examples of the new identification system.
Consult the appropriate electrical schematic for more detailed and
accurate information.
SEGV3004 - 11 - Module Four
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OLD FORMAT
CONNECTOR LABEL CONNECTOR LABEL
H G

CONNECTOR LABEL
NEW FORMAT
CONNECTOR LABEL
H-C7 G-C1
3E3382 3E3379

"H" is the harness identification, "C" stands for connector,

"7" is the connector number in the harness,
and 3E3382 is the receptacle connector part number

Connectors

The new connector identification format includes the harness

identification code (H), identifies the assembly as a connector (C),
identifies the number of the connector within the harness (7), and lists the
connector part number (3E3382).

NOTE: The codes shown are examples of the new identification system.
Consult the appropriate electrical schematic for more detailed and
accurate information.
SEGV3004 - 12 - Module Four
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OLD FORMAT
FUSE
113-8490
10 A

NEW FORMAT

H-P12
113-8490
10 A

Components

The previous method of component labeling on a schematic shows the

descriptive name and the component part number. The schematics drawn
in PRO/E format contain a harness identification letter (H), a serializing
code (P-12) where "P" stands for part and "12" stands for harness position
(number "12" part in harness "H", and the component part number (113-
8490).

NOTE: The codes shown are examples of the new identification system.
Consult the appropriate electrical schematic for more detailed and
accurate information.
SEGV3004 - 13 - Module Four
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OLD FORMAT
10 A 405-GY-16
Splice

405-GY-16

NEW FORMAT
10 A 405-G9 GY-16
Splice

405-G7 GY-16
Splice

405-G14 GY-16

Splices

The PRO/E format for splices uses two connection points to indicate
which side a given wire exits. The previous splice symbol used a simple
filled-in dot to indicate a splice.

The new format shows that in harness "G", wire 405-G9 GY-16 is spliced
into two wires, "405-G7 GY-16" and "405-G14 GY-16."

NOTE: The codes shown are examples of the new identification system.
Consult the appropriate electrical schematic for more detailed and
accurate information.
SEGV3004 - 14 - Module Four
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FEATURES
On The Back

Harness and Wire Electrical Symbols

Electrical Schematic Symbols and Definitions
Machine Harness Connector and Component Locations
Off Machine Switch Specifications
Resistor and Solenoid Specifications
CID, FMI and Flash Code Information

Reverse Side Features on the Back of the Schematic

Features
Some of the features on the reverse side are:

• Harness and wire electrical schematic symbols and identification

(lower right side)

• Electrical schematic symbols and definitions (lower right side)

• Wire description chart (top right center)

• Related electrical service manuals (below wire description chart)

• Harness connector location chart (top center)

• Off machine switch specifications (below harness connector chart)

➥
SEGV3004 - 15 - Module Four
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• Machine harness connector and component locations, identified as

a machine silhouette (top left center)

• Component Identifier (CID) list and flash code conversion (below

silhouette)

• Component location chart (top left side)

• Resistor and solenoid specifications (below component location

chart)

• Failure Mode Identifier (FMI) list (below resistor and solenoid

chart)
SEGV3004 - 16 - Module Four
7/97 Schematic Quiz 1
Instructor Copy

Schematic Quiz

Directions: Using electrical schematic SENR5919 for a 950F Wheel Loader, complete the following
quiz. Fill in the blanks and/or circle the correct answer.

1. Locate the hydraulic temperature sensor on the schematic. List the schematic grid location and
the machine silhouette.
A-3 grid location
15 machine location (silhouette)

2. What is the part number of the hydraulic temperature sensor? 3E-5370

3. Is the part of the connector attached to the hydraulic temperature sensor, a plug or receptacle?
plug

4. What does the above part in question 3 have?

a. pins only
b. sockets only
c. combination of pins and sockets
d. none of the above

5. What gauge wires are attached to the sensor in question 3?

a. 14 gauge
b. 16 gauge
c. 18 gauge
d. 20 gauge

6. What is the part number of the machine harness assembly for the sensor in question 3?
9U-2771

7. On the sensor in question 3, where is the ground circuit connected?

a. to engine ground
b. to cab ground
c. to CMS control
d. none of the above

8. Locate the start aid switch on the schematic. List the schematic grid location and the
machine silhouette.
E-8 grid location
C machine location (silhouette)

9. How many wires are attached to the switch in question 8?

a. 2
b. 3
c. 4
d. 5
SEGV3004 - 17 - Module Four
7/97 Schematic Quiz 1
Instructor Copy

10. What type of connection(s) are used to attach the switch in question 8 to the machine wiring
harness?
a. Sure-Seal connector
b. Deutsch connector
c. Hard wire connections
d. other (explain) blade, spade, ring or screw

11. Briefly explain what a solid red line represents on the schematic.
Wires that have voltage when the key start switch is off.

12. Briefly explain what a colored dash line represents on the schematic. They are attachments.

13. What symbol represents attach wire, cable, and component on the schematic? Dashed line

14. Locate the transmission speed sensor on the schematic. List the schematic grid location and
the machine silhouette.
C-13 grid location
18 machine location (silhouette)

15. What is the part number of the sensor connector in question 14?
a. 8X-2419
b. 8W-3843
c. 3X-2419
d. none of the above

16. What is the part number of the machine harness assembly for the sensor in question 14?
103-6030

17. What does the sensor receptacle in question 14 have?

a. pins only
b. sockets only
c. combination of pins and sockets
d. none of the above

18. What is the part number of the wiring harness attached to the payload measurement control?
103-4735

19. What gauge wire is used in the payload monitor harness? 18

20. The Computerized Monitoring System displays a MID of 81. The probable malfunction is in the
a. computerized monitoring system
b. engine RPM sensor
c. electronic transmission control
d. secondary brake pressure switch

21. The Computerized Monitoring System displays a FMI of 4. Explain the failure
description. Voltage below normal, or shorted low
SEGV3004 - 18 - Module Four
7/97 Schematic Quiz 1
Instructor Copy

22. At what pressure does the transmission neutralizer switch open?

103 .0 ± 20 kPa (15.0 ± 3.0 psi)

23. Locate the fuel level sender on the schematic. What does the dashed
ground symbol represent? (explain) internal electrical connection to the surface
of the component

24. What is the color of the wire that connects the CMS control to the above sender? Pink

25. What does the letter "C" represent on the machine location (silhouette)?
Component located in right console

26. What is the form number of the service manual for the Electronic Transmission Control
System? SENR5922

27. What are all the possible wire numbers for the basic machine circuit?
301, 302, 304, 306, 307, 308, 310, 311, 321, 322, 326

28. While visually inspecting a machine wiring harness, the mechanic discovers a wire cut in
two. The wire number on the conductor is labeled 976-OR. What machine circuit is controlled
by this wire? Ride control solenoid
SEGV3004 - 19 - Module Four
7/97 Schematic Quiz 1
Student Copy

Schematic Quiz

Directions: Using electrical schematic SENR5919 for a 950F Wheel Loader, complete the following
quiz. Fill in the blanks and/or circle the correct answer.

1. Locate the hydraulic temperature sensor on the schematic. List the schematic grid location and
the machine silhouette.
____ grid location
____ machine location (silhouette)

2. What is the part number of the hydraulic temperature sensor? ______

3. Is the part of the connector attached to the hydraulic temperature sensor, a plug or receptacle?
_____________

4. What does the above part in question 3 have?

a. pins only
b. sockets only
c. combination of pins and sockets
d. none of the above

5. What gauge wires are attached to the sensor in question 3?

a. 14 gauge
b. 16 gauge
c. 18 gauge
d. 20 gauge

6. What is the part number of the machine harness assembly for the sensor in question 3?
________

7. On the sensor in question 3, where is the ground circuit connected?

a. to engine ground
b. to cab ground
c. to CMS control
d. none of the above

8. Locate the start aid switch on the schematic. List the schematic grid location and the
machine silhouette.
____ grid location
____ machine location (silhouette)

9. How many wires are attached to the switch in question 8?

a. 2
b. 3
c. 4
d. 5
SEGV3004 - 20 - Module Four
7/97 Schematic Quiz 1
Student Copy

10. What type of connection(s) are used to attach the switch in question 8 to the machine wiring
harness?
a. Sure-Seal connector
b. Deutsch connector
c. Hard wire connections
d. other (explain) ______________________________________

11. Briefly explain what a solid red line represents on the schematic.
__________________________________________________________________

12. Briefly explain what a colored dash line represents on the schematic. _________________

13. What symbol represents attach wire, cable, and component on the schematic? ___________

14. Locate the transmission speed sensor on the schematic. List the schematic grid location and
the machine silhouette.
______ grid location
______ machine location (silhouette)

15. What is the part number of the sensor connector in question 14?
a. 8X-2419
b. 8W-3843
c. 3X-2419
d. none of the above

16. What is the part number of the machine harness assembly for the sensor in question 14?
__________

17. What does the sensor receptacle in question 14 have?

a. pins only
b. sockets only
c. combination of pins and sockets
d. none of the above

18. What is the part number of the wiring harness attached to the payload measurement control?
_____________

19. What gauge wire is used in the payload monitor harness? ____

20. The Computerized Monitoring System displays a MID of 81. The probable malfunction is in the
a. computerized monitoring system
b. engine RPM sensor
c. electronic transmission control
d. secondary brake pressure switch

21. The Computerized Monitoring System displays a FMI of 4. Explain the failure
description. _____________________________________
SEGV3004 - 21 - Module Four
7/97 Schematic Quiz 1
Student Copy

22. At what pressure does the transmission neutralizer switch open?

_______________________________

23. Locate the fuel level sender on the schematic. What does the dashed
ground symbol represent? (explain) ____________________________________________
________________________________

24. What is the color of the wire that connects the CMS control to the above sender? ______

25. What does the letter "C" represent on the machine location (silhouette)?
_________________________________

26. What is the form number of the service manual for the Electronic Transmission Control
System? __________________

27. What are all the possible wire numbers for the basic machine circuit?
_______________________________________________

28. While visually inspecting a machine wiring harness, the mechanic discovers a wire cut in
two. The wire number on the conductor is labeled 976-OR. What machine circuit is controlled
by this wire? _____________________________
SEGV3004 - 22 - Module Four
7/97 Schematic Quiz 2
Instructor Copy

Schematic Quiz

Directions: Using electrical schematic SENR5672 for a 785B Truck, complete the following quiz. Fill in
the blanks and/or circle the correct answer.

1. Locate the engine coolant temperature sensor on the schematic. List the schematic grid
location and the machine silhouette.
B-4 grid location
19 machine location (silhouette)

2. What is the part number of the engine coolant temperature sensor? 6V-1923

3. Is the part of the connector attached to the engine coolant temperature sensor, a plug or
receptacle? receptacle

4. What does the part in question 3 have?

a. pins only
b. sockets only
c. combination of pins and sockets
d. none of the above

5. What gauge wires are attached to the sensor in question 3?

a. 14 gauge
b. 16 gauge
c. 18 gauge
d. 20 gauge

6. What is the part number of the machine harness assembly for the sensor in question 3? 7E-6361

7. On the sensor in question 3, the analog return circuit is connected to the

a. engine ground
b. machine ground
c. engine control
d. none of the above

8. Locate the start aid switch on the schematic. List the schematic grid location and the machine
silhouette.
D-15 grid location
C machine location (silhouette)

9. How many wires are attached to the switch in question 8?

a. 2
b. 3
c. 4
d. 5
SEGV3004 - 23 - Module Four
7/97 Schematic Quiz 2
Instructor Copy

10. What type of connection(s) are used to attach the switch in question 8 to the machine wiring
harness?
a. Sure-Seal connector
b. Deutsch connector
c. Hard wire connections
d. other (explain) blade, spade, ring, or screw terminal

11. Briefly explain what a solid red line represents on the schematic.
Wires that have battery voltage when the key switch is off.

12. Briefly explain what a colored dash line represents on the schematic. They are attachments.

13. What symbol represents attach wire, cable, and component on the schematic? Dashed line

14. Locate the transmission speed sender on the schematic. List the schematic grid location and the
machine silhouette.
A-13 grid location
20 machine location (silhouette)

15. What is the part number of the sender connector in question 14?
a. 8X-2419
b. 8W-3843
c. 3X-2419
d. none of the above

16. What is the part number of the machine harness assembly for the sender in question 14?
102-9095

17. What does the sender receptacle in question 14 have?

a. pins only
b. sockets only
c. combination of pins and sockets
d. none of the above

18. What is the part number of the harness connector attached to the payload monitor control?
2A-7132

19. What gauge wire is used in the payload monitor harness? 16

20. The automatic retarder control displays a CID of 627. The probable malfunction is in the
a. throttle position sensor
b. engine RPM sensor
c. auto retarder pressure switch
d. secondary brake pressure switch
SEGV3004 - 24 - Module Four
7/97 Schematic Quiz 2
Instructor Copy

21. If the electronic engine control displays a FMI of 4. Explain

the failure description. voltage below normal, or shorted low

22. At what temperature does the power train oil temperature switch actuate? 51.7°C (125°F)

23. Locate the coolant temperature sender on the schematic. What does the dashed ground
symbol represent? (explain) internal electrical connection to surface of component

24. On the sender in question 23, what is the color of the wire that connects to the temperature
gauge? Orange

25. The engine diagnostic lamp is flashing code 76. What are the CID and FMI codes? 006, 05, 06

26. What does the letter "G" represent on the machine silhouette? components located in
overhead console

27. What is the resistance of the air start solenoid coil? 42 ohms

28. What is the form number of the service manual for the automatic retarder control system?
SENR5683

29. What are all the possible wire numbers for the machine accessory circuits?
513, 515, 516, 517, 521, 522, 537, 539, 540

30. While visually inspecting a machine wiring harness, the mechanic discovers a wire cut in two.
The wire number on the wire is labeled 999-WH. What machine circuit is controlled by this
wire? EUI engine speed signal
SEGV3004 - 25 - Module Four
7/97 Schematic Quiz 2
Student Copy

Schematic Quiz

Directions: Using electrical schematic SENR5672 for a 785B Truck, complete the following quiz. Fill
in the blanks and/or circle the correct answer.

1. Locate the engine coolant temperature sensor on the schematic. List the schematic grid
location and the machine silhouette.
____ grid location
____ machine location (silhouette)

2. What is the part number of the engine coolant temperature sensor? ______________

3. Is the part of the connector attached to the engine coolant temperature sensor, a plug or
receptacle? _______________

4. What does the part in question 3 have?

a. pins only
b. sockets only
c. combination of pins and sockets
d. none of the above

5. What gauge wires are attached to the sensor in question 3?

a. 14 gauge
b. 16 gauge
c. 18 gauge
d. 20 gauge

6. What is the part number of the machine harness assembly for the sensor in question 3? _______

7. On the sensor in question 3, the analog return circuit is connected to the

a. engine ground
b. machine ground
c. engine control
d. none of the above

8. Locate the start aid switch on the schematic. List the schematic grid location and the machine
silhouette.
____ grid location
____ machine location (silhouette)

9. How many wires are attached to the switch in question 8?

a. 2
b. 3
c. 4
d. 5
SEGV3004 - 26 - Module Four
7/97 Schematic Quiz 2
Student Copy

10. What type of connection(s) are used to attach the switch in question 8 to the machine wiring
harness?
a. Sure-Seal connector
b. Deutsch connector
c. Hard wire connections
d. other (explain) ___________________________

11. Briefly explain what a solid red line represents on the schematic. ____________________
____________________________________________

12. Briefly explain what a colored dash line represents on the schematic. ___________________

13. What symbol represents attach wire, cable, and component on the schematic? _____________

14. Locate the transmission speed sender on the schematic. List the schematic grid location and the
machine silhouette.
____ grid location
____ machine location (silhouette)

15. What is the part number of the sender connector in question 14?
a. 8X-2419
b. 8W-3843
c. 3X-2419
d. none of the above

16. What is the part number of the machine harness assembly for the sender in question 14?
________________

17. What does the sender receptacle in question 14 have?

a. pins only
b. sockets only
c. combination of pins and sockets
d. none of the above

18. What is the part number of the harness connector attached to the payload monitor control?
_____________

19. What gauge wire is used in the payload monitor harness? ____

20. If the automatic retarder control displays a CID of 627. The probable malfunction is in the
a. throttle position sensor
b. engine RPM sensor
c. auto retarder pressure switch
d. secondary brake pressure switch
SEGV3004 - 27 - Module Four
7/97 Schematic Quiz 2
Student Copy

21. If the electronic engine control displays a FMI of 4. Explain

the failure description. ___________________________________

22. At what temperature does the power train oil temperature switch actuate? _______________

23. Locate the coolant temperature sender on the schematic. What does the dashed ground
symbol represent? (explain) _____________________________________________________

24. On the sender in question 23, what is the color of the wire that connects to the temperature
gauge? ____________

25. The engine diagnostic lamp is flashing code 76. What are the CID and FMI codes? _________

26. What does the letter "G" represent on the machine silhouette? _________________________
_________________________________

27. What is the resistance of the air start solenoid coil? _______________

28. What is the form number of the service manual for the automatic retarder control system?
________________

29. What are all the possible wire numbers for the machine accessory circuits?
________________________________________

30. While visually inspecting a machine wiring harness, the mechanic discovers a wire cut in two.
The wire number on the wire is labeled 999-WH. What machine circuit is controlled by this
wire? _____________________________