Documenti di Didattica
Documenti di Professioni
Documenti di Cultura
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
3
Table of Contents
Table of Contents
Systems Operation Section
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62
62
64
65
68
69
71
72
73
76
77
79
81
82
83
85
Troubleshooting Section
Index Section
Introduction
General Information ..............................................
Service Tools ........................................................
Electrical Component and Connector Locations ...
Diagnostic Capabilities .........................................
4
Systems Operation Section
General Information
SMCS Code: 7490
Introduction
Illustration 1
Caterpillar Monitoring System for the 140H, 143H, 160H and 163H
The quad gauge module and the speedometer/tachometer module are optional components.
g00944992
5
Systems Operation Section
Illustration 2
Caterpillar Monitoring System for the 14H and 16H
The quad gauge module and the speedometer/tachometer module are optional components.
g00863307
6
Systems Operation Section
Illustration 3
Caterpillar Monitoring System for the 12H, 120H and 135H
The quad gauge module and the speedometer/tachometer module are optional components.
g00945076
7
Systems Operation Section
Illustration 4
g00789331
Typical Example
Caterpillar Monitoring System Display Components
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
Speedometer/Tachometer Module
One tachometer gauge (6) shows the information
on the engine speed (RPM).
8
Systems Operation Section
Modes of Operation
SMCS Code: 7490
Illustration 5
g00297408
9
Systems Operation Section
Table 1
i01856906
Normal Mode
SMCS Code: 7490
Operator Modes
Mode Number
Operator Mode
Service Meter
Odometer
Digital Tachometer
Diagnostic Scrolling
Cumulative Fuel
Trip Odometer
Trip Fuel
Table 2
Mode Number
Harness Code
Parameter Display
Diagnostic Service
Tattletale
Digital Tattletale
Units
(1)
Setup
10
(1)
Illustration 6
g00789331
10
Systems Operation Section
Mode Number
Service Meter
Odometer
Digital Tachometer
Diagnostic Scrolling
Cumulative Fuel
Trip Odometer
Trip Fuel
i00971876
Illustration 7
Display Area
g00298101
11
Systems Operation Section
Scrolling Mode
SMCS Code: 7490
i01461542
Odometer Mode
SMCS Code: 7490
Illustration 8
g00298418
Display Area
Illustration 10
g00495188
(1) First display. (2) Second display. (3) Module identifier (MID). (4)
Service code indicator SERV CODE. (5) Component identifier
(CID). (6) Failure mode identifier (FMI).
i01518524
Tachometer Mode
SMCS Code: 7490
Illustration 9
Display Area
g00298698
12
Systems Operation Section
i01996543
g00298918
Illustration 11
Display Area
i01804895
Illustration 12
Machine Codes
Sales Model
g00299479
Display Area
Machine Code
14H
14
140H
40
143H
43
160H
60
163H
63
120H
20
135H
35
12H
12
16H
16
13
Systems Operation Section
Illustration 13
g00299481
Illustration 14
System Identification
System Identifier
Gauge (System)
GA-1
GA-2
GA-3
GA-4
Table 6
Units
Condition
Temperature
Angle
Voltage
Level
Units of Measurement
C
0.1 volts
% full
Illustration 15
g00298101
Display Area
14
Systems Operation Section
i01520209
Service Mode
SMCS Code: 7490
Illustration 16
g00298418
Display Area
g00427558
Diagnostic Example
(1) First display. (2) Second display. (3) Module identifier (MID). (4)
Service code indicator (SERV CODE). (5) Component identifier
(CID). (6) Failure Mode identifier (FMI).
Illustration 17
g00678891
Display Area
15
Systems Operation Section
030
036
081
075
16
Systems Operation Section
Tattletale Mode
SMCS Code: 7490
Illustration 19
g00427558
Diagnostic Example
(1) First display. (2) Second display. (3) Module identifier (MID). (4)
Service code indicator (SERV CODE). (5) Component identifier
(CID). (6) Failure Mode identifier (FMI).
Brief Explanation
Illustration 20
Display Area
g00301362
17
Systems Operation Section
Illustration 21
g00789331
18
Systems Operation Section
i01963289
Setup Mode
SMCS Code: 7490
i01041208
Units Mode
SMCS Code: 7490
Illustration 23
g01019884
Display Area
Illustration 22
g00301504
Calibration Mode
SMCS Code: 7490
Calibration Mode 7 and Calibration Mode 8 are
associated with the power train ECM. Calibration
Mode 7 and Calibration Mode 8 are identical. Both
modes contain the same submodes and perform the
same calibrations. Calibration Mode is used on some
machines in order to perform special functions of
calibration. The operation of the Calibration Mode will
vary depending on the machine and the system that
is being calibrated. The Service Manual Module for
the controls that require the Calibration Mode should
be used in order to determine the operation.
19
Systems Operation Section
Submodes
or cleaned.
20
Systems Operation Section
g00795884
Illustration 24
Transmission Clutch Solenoid Valves
(1) Transmission solenoid valve (No. 3)
(2) Transmission solenoid valve (No. 1)
(3) Transmission solenoid valve (No. 2)
Table 7
E02
E03
E04
E05
E06
E09
21
Systems Operation Section
Table 8
E04
E05
E06
E09
E11
E21
E22
E23
22
Systems Operation Section
g00795884
Illustration 25
Transmission Solenoid Valves
(1) Transmission solenoid valve (No. 3)
(2) Transmission solenoid valve (No. 1)
(3) Transmission solenoid valve (No. 2)
(4) Transmission solenoid valve (No. 8)
i01529536
23
Systems Operation Section
Illustration 26
g00794045
Illustration 27
g00530894
Up Stop Display
Illustration 28
g00531227
24
Systems Operation Section
i01862466
Warning Operation
SMCS Code: 7490
Table 9
WARNING OPERATION
Warning Indications
Warning
Category
Alert
Indicator
Flashes (3)
(4)
2-S
(4)
(4)
(1)
(2)
(3)
(4)
(5)
(6)
Action
Lamp
Flashes(4)
(1)
Action
Alarm
Sounds
No harmful effects or no
damaging effects.
Severe damage to
components can occur.
(5)
(6)
Illustration 30
Speedometer/Tachometer Module
(3)
(4)
(5)
(6)
Illustration 29
Quad Gauge Module
(1) Gauge warning area
(2) Pictograph symbol
g00789595
Tachometer
Pictograph symbol
Ground speed readout
Transmission gear readout
g00427600
25
Systems Operation Section
g00302085
i01854075
Illustration 32
Alert Indicators For 143H And 163H
(1) Hydraulic Oil Temperature
(2) Parking Brake Status
(3) Charging System Status
(4) All Wheel Drive Status
(5) Check Engine Status
(6) Engine Coolant Temperature
(7) Steering System Status
(8) Engine Oil Pressure
(9) Brake Air Pressure
(10) Transmission System Status
g00789816
26
Systems Operation Section
Illustration 33
g00923072
Illustration 34
g00923075
27
Systems Operation Section
i01855060
data link.
Illustration 35
g00297407
Component Description
SMCS Code: 7490
This arrangement of the Caterpillar Monitoring
System will work on the current Motor Graders.
Three modules constitute the Caterpillar Monitoring
System: main display module, quad gauge module,
and speedometer/tachometer module. All of the
following electrical components are not present on
every machine. The main display module recognizes
the machine and the components that are present.
For the location of the electrical components, see the
Electrical System Schematic in the Service Manual
for the machine.
Inputs/Outputs
CAT Data Link
The CAT data link (connector contacts 5 and 14) is
used to communicate with other electronic control
modules on the machine. The CAT data link is
bidirectional. This allows the modules to input the
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
Inputs
The operation and the status of the machine is
transferred from the inputs to the main display
module. Three types of inputs exist: switch type
input, sensor type input, and sender type input.
Switches and harness wiring provide a ground
or an open signal to the switch inputs. Sensors
provide a changing signal to the sensor inputs of the
main display module. Senders provide a changing
resistance to the sender inputs of the main display
module.
Some inputs are multipurpose (switch, sensor or
sender). The following examples are of multipurpose
inputs: connector contacts 7, 17, 27 and 37 may be
either switch inputs or PWM sensor inputs, connector
contacts 9 and 18 may be either switch inputs or
0-240 ohm sender inputs, and connector contacts 8,
10, 28 and 38 may be switch inputs, PWM sensor
inputs or 70-800 ohm sender inputs. These inputs
are programmed at the time of installation in order to
define the components that are monitored. In order
to determine the inputs on the main display module
that are programmed, see the Electrical System
Schematic in the Service Manual.
29
Systems Operation Section
30
Systems Operation Section
Outputs
Input - Voltage
The input for battery voltage (connector contact 1
and 2) provides the main display module with power.
The voltage input is also used by the main display
module to monitor the machine electrical system.
This information from the voltage helps determine the
condition of the electrical system.
When an alert indicator is used in order to indicate
the voltage of the machine system, the battery signal
is combined with the signal for the terminal R
within the main display module. When an electrical
system fault occurs, there are two possible warning
categories. The category is set by the type of fault.
Category 1 The frequency for the terminal R
from the alternator is less than 90 Hz or the system
voltage is greater than 29.5 volts for at least 2
seconds. The system voltage is less than 24.8 volts
for a least 2 seconds.
Category 3 The system voltage is less than 23.0
volts for at least 2 seconds or the system voltage is
greater than 32.0 volts for at least 2 seconds.
Illustration 36
g00297407
31
Systems Operation Section
Table 10
Function
Type
+9 DCV
Input
Ground
Ground
Action Lamp
Display Clock
Input
Display Data
Input
Display Load
Input
Harness Code
Open(1)
Action Alarm
When a critical abnormal condition exists, the
main display module activates the output for the
action alarm (connector contact 4) and the action
alarm SOUNDS. For more information, see System
Operation, Warning Operation.
(1)
Display Components
SMCS Code: 7450
The following table shows the contact description for
all the display components.
Illustration 37
An Example Of A Quad Gauge Module
(1) Gauge warning area. (2) Pictograph symbol.
g00789595
32
Systems Operation Section
Speedometer/Tachometer
Module
SMCS Code: 7450
Table 11
40 C (104 F)
Midpoint Value
82 C (179 F)
107 C (224 F)
140 C (284 F)
Table 12
g00357114
Speedometer/Tachometer module
20 C (4 F)
Midpoint Value
0 C (32 F)
20 C (68 F)
22 V
Midpoint Value
26.2 V
23.8 V
28.5 V
31 V
Switches
SMCS Code: 1435; 7332
5%
Midpoint Value
50%
10%
95%
33
Systems Operation Section
Illustration 40
g00793486
Pressure Switch
(1) Schematic symbol
(2) Switch
Senders
SMCS Code: 1408-UN
Illustration 39
g00304432
Pressure Switch
Pressure Switch (Parking Brake)
Pressure Switch (LH Brake System)
Illustration 41
g00303717
34
Systems Operation Section
Temperature Sender
Illustration 43
g00793324
Illustration 42
g00303718
Temperature Sender
(1) Schematic symbol
(2) Sender
Sensors
SMCS Code: 1408-NS
General Information
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 The sensor produces an AC signal.
The frequency (Hz) varies as the condition changes.
Pulse Width Modulated (PWM) The sensor
produces a digital signal. The duty cycle varies as
the condition changes. The frequency of this signal
is constant.
Frequency Sensors
Frequency sensors produce an AC signal. The
frequency (Hz) varies as the condition changes.
35
Systems Operation Section
Speed Sensor
Illustration 44
g00304924
Speed Sensor
(1) Sensor. (2) Schematic symbol.
Illustration 45
g00304925
Illustration 46
g00304926
36
Systems Operation Section
Temperature Sensor
i01679184
Action Lamp
SMCS Code: 1408-LMP; 7400-LMP
Illustration 49
g00304970
g00304927
Temperature Sensor
(1) Schematic symbol. (2) Sensor.
Pressure Sensor
Illustration 48
Action Alarm
SMCS Code: 7407
g00304929
Pressure Sensor
Illustration 50
Action Alarm
g00307223
37
Systems Operation Section
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.
38
Troubleshooting Section
Troubleshooting Section
Introduction
i01966052
Service Tools
SMCS Code: 0785
i01400224
General Information
Service Tools
Part
CAT Electronic Technician
6V-7070
9U-7330
Digital Multimeter
8T-3224
7X-1710
8T-8726
6V-3000
9U-7246
4C-3406
4C-8195
Illustration 51
g00280782
39
Troubleshooting Section
Illustration 52
g00774942
Cable
171-4400 Communication Adapter II
Service diagnostic cable.
Current version of Caterpillar Electronic Technician software
and an IBM-COMPATIBLE personal computer
Service Switches
During troubleshooting, it is necessary for the service
person to use the diagnostic operations of Caterpillar
Monitoring System. Service personnel use the
service switches in order to access the different
display modes of diagnostic operation.
The switches are the momentary type of switch. The
service personnel activate the switches by pressing
and holding. Pressing the clear switch grounds the
clear input (contact 33) of the monitor. Pressing the
set switch grounds the service switch (contact 23)
of the monitor. The location of the service switches
will vary depending on the machine that is being
serviced. Not all machines are equipped with service
switches. For a more accurate location of the service
switches, see the Electrical System Schematic in the
Service Manual for the machine.
40
Troubleshooting Section
Changing Modes
Table 16
Service
Contact(1)
Clear Contact(1)
To Scroll
Ground
Ground
To Hold
Open
Open
To Scroll
Ground
Open
To Hold
Open(2)
Open
Open
Ground
Open
Ground
Changing Modes:
Service Modes:
Illustration 53
g00743610
To
Clear(3)
Tattletale Mode:
To Clear
(1)
(2)
(3)
Illustration 54
g00743652
To Scroll
Ground
Open
To Hold
Open
Open
i01398954
General Information
The Electrical System Schematic, Parts Manual and
Operation and Maintenance Manual for the machine
that is being serviced should be used to locate
electrical components and connectors.
The following information is a guide to reading
the tables on the back of the Electrical System
Schematic.
41
Troubleshooting Section
g00309224
Illustration 57
g00309227
Illustration 55
g00309228
Service Connector
The service connector provides access to the
service and clear inputs of the main display module.
Connector contact 1 is the service input and contact
2 is the clear input. Contacts 3 and 4 could be any
wire from the 200 family. The service connector
is usually located under the dashboard within the
operator compartment. The service connector is a
DT type of connector. For a more accurate location
of the service connector, see the Electrical System
Schematic in the Service Manual.
42
Troubleshooting Section
i01671837
Diagnostic Capabilities
SMCS Code: 7490
g00777826
Illustration 58
Print reports.
The following list contains some of the diagnostic
functions and programming functions that are
performed by the service tools.
43
Troubleshooting Section
Illustration 59
Typical ET Status Screen
g00867289
44
Troubleshooting Section
Diagnostic Code
Procedures
(1)
Table 17
CID/FMI
Signal is abnormal
FMI 04
FMI 08
Signal is abnormal
FMI 04
FMI 05
FMI 06
FMI 05
FMI 06
Description
FMI 03
FMI 04
FMI 04
Notice that the second and third above items are the
same warning indications that are activated if the
engine overheats.
45
Troubleshooting Section
i01672648
Procedure
Illustration 60
g00429460
Display Area
(1) First display. (2) Second display. (3) Module identifier (MID). (4)
service code indicator (SERV CODE). (5) Component identifier
(CID). (6) Failure mode identifier (FMI).
46
Troubleshooting Section
47
Troubleshooting Section
Illustration 61
Typical Cat ET screen for active diagnostic codes
g00859671
48
Troubleshooting Section
g00859762
Illustration 62
Typical Cat ET screen for logged diagnostic codes
i01802609
Illustration 63
Schematic for the ground speed sensor
g00866484
49
Troubleshooting Section
Expected Result:
unlikely.
Results:
STOP.
50
Troubleshooting Section
STOP.
STOP.
Results:
Illustration 64
g00866238
System Response:
This failure causes the fuel gauge to always
indicate an empty fuel tank or the fuel gauge may
intermittently indicate an empty fuel tank.
51
Troubleshooting Section
i01678452
Illustration 65
g00866238
Expected Result:
Results:
to ground.
STOP.
Results:
Expected Result:
52
Troubleshooting Section
Results:
Results:
OK STOP.
REPAIRED, OK STOP.
i01858627
STOP.
Illustration 67
g00530708
Illustration 66
Schematic for the fuel level sender
g00866238
53
Troubleshooting Section
STOP.
54
Troubleshooting Section
i01440228
g00754378
Expected Result:
Results:
55
Troubleshooting Section
Expected Result:
The voltage that is measured should be approximately
0 DCV.
i01440283
Results:
voltage is correct.
Illustration 69
g00754378
Expected Result:
The voltage measures 24.0 0.5 DCV.
Results:
56
Troubleshooting Section
Expected Result:
The resistance that is measured is greater than 5000
ohms.
Results:
i01394484
STOP.
Illustration 70
g00544121
57
Troubleshooting Section
Expected Result:
Expected Result:
Results:
Results:
STOP.
STOP.
i01394545
Illustration 71
Schematic for the alarm (action)
g00544121
58
Troubleshooting Section
Expected Result:
The machine harness is correct.
Results:
Illustration 72
g00544121
Expected Result:
Expected Result:
Results:
Results:
59
Troubleshooting Section
Expected Result:
Illustration 73
g00544436
STOP.
Expected Result:
Results:
Expected Result:
Results:
60
Troubleshooting Section
Illustration 74
g00544436
61
Troubleshooting Section
Results:
Expected Result:
g00544436
Expected Result:
STOP.
Expected Result:
The CID 0324 FMI 06 is present.
Results:
62
Troubleshooting Section
i01528712
STOP.
Illustration 77
g00793582
Illustration 76
g00528295
OK STOP.
REPAIRED, OK STOP.
63
Troubleshooting Section
Results:
Expected Result:
STOP.
STOP.
to test step 3.
64
Troubleshooting Section
i01528825
Expected Result:
Results:
g00793582
STOP.
STOP.
65
Troubleshooting Section
Illustration 79
Schematic for the display power supply
g00737908
66
Troubleshooting Section
Expected Result:
The resistance is greater than 5000 ohms.
Results:
67
Troubleshooting Section
Expected Result:
The resistance is less than 5 ohms.
Results:
68
Troubleshooting Section
i01395272
g00737908
Illustration 80
Schematic for the display power supply
Results:
69
Troubleshooting Section
Illustration 81
Schematic for the display power supply
g00737908
70
Troubleshooting Section
Expected Result:
The voltage that is measured is 9.0 0.5 DCV.
Results:
STOP.
71
Troubleshooting Section
Diagnostic System
Procedures
Expected Result:
Results:
The machine harness is open or the main display
module has failed. Proceed to test step 3.
Expected Result:
Expected Result:
The appropriate switch is located.
Results:
Results:
72
Troubleshooting Section
Expected Result:
The alert indicator is FLASHING.
Results:
STOP.
Expected Result:
Expected Result:
Results:
The harness is not causing the failure. The main
display module has failed.
73
Troubleshooting Section
Harness Code
SMCS Code: 1408-038
S/N: ASD1-Up
S/N: ARL1-Up
S/N: APM1-Up
S/N: APN1-Up
System Operation Description:
Table 18
31
12
22
16
Wire Identification
270-BK
271-BK
272-BK
273-BK
274-BK
275-BK
Machine Code
Specified Status
01
O(3)
G(4)
02
03
04
05
06
07
08
09
10
11
12
13
14
15
16
17
18
G
(continued)
74
Troubleshooting Section
31
12
22
16
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
O
(continued)
75
Troubleshooting Section
(1)
(2)
(3)
(4)
31
12
22
16
55
56
57
58
59
60
61
62
Results:
Expected Result:
The resistance measures 5.0 Ohms or less.
76
Troubleshooting Section
Expected Result:
i01916278
Results:
Illustration 82
g00315944
77
Troubleshooting Section
STOP.
Table 19
Tools Needed
i01916286
9U-7330
Multimeter
7X-1710
Table 20
Signal Voltage(1)
20 to 0C
(4 to 32F)
11 to 15%
0 to 20C
(32 to 68F)
15 to 23%
20 to 40C
(68 to 104F)
23 to 37%
40 to 60C
(104 to 140F)
37 to 55%
60 to 80C
(140 to 176F)
55 to 71%
80 to 100C
(176 to 212F)
71 to 82%
100 to 120C
(212 to 248F)
82 to 89%
120 to 140C
(248 to 275F)
89 to 93%
Expected Result:
The Troubleshooting, Sensor Signal Voltage
procedure has determined the cause of the problem.
Duty Cycle
Results:
the problem. STOP.
(1)
78
Troubleshooting Section
Results:
Table 21
Signal Voltage(1)
Duty Cycle
40 to 20C
(40 to 4F)
4 to 11%
20 to 0C
(4 to 32F)
11 to 22%
0 to 20C
(32 to 68F)
22 to 34%
STOP.
20 to 40C
(68 to 104F)
34 to 46%
40 to 60C
(104 to 140F)
46 to 59%
60 to 80C
(140 to 176F)
59 to 71%
80 to 100C
(176 to 212F)
71 to 81%
100 to 120C
(212 to 248F)
81 to 87%
120 to 140C
(248 to 275F)
87 to 92%
(1)
Expected Result:
The voltage that is measured is between 7.5 and 8.5
DCV.
79
Troubleshooting Section
Test Step 4.
Perform the following diagnostic procedure: Sensor
Dynamic Operation
Results:
REPAIRED, OK STOP.
STOP.
OK STOP.
i01396902
80
Troubleshooting Section
Table 22
Table 23
(1)
Signal Voltage(2)
(1)
Duty
Cycle
Temperature
Signal
Voltage(2)
Duty
Cycle
10 to
11%
4 to
11%
20 to 0C (4 to 32F)
11 to
15%
20 to 0C (4 to 32F)
11 to
22%
15 to
23%
22 to
34%
23 to
37%
34 to
46%
37 to
55%
46 to
59%
55 to
71%
59 to
71%
71 to
82%
71 to
81%
100 to 120C
(212 to 248F)
82 to
89%
100 to 120C
(212 to 248F)
81 to
87%
120 to 140C
(248 to 275F)
89 to
93%
120 to 140C
(248 to 275F)
87 to
92%
(1)
(2)
(1)
(2)
81
Troubleshooting Section
Expected Result:
The voltage that is measured is within the
specifications.
Expected Result:
The voltage increases during the test procedure.
Results:
procedure and the sensor operates smoothly. The
sensor has not failed. STOP.
the test procedure. The probable cause is a failed
sensor.
Repair: The sensor has failed. Replace the sensor.
STOP.
Results:
i01397975
82
Troubleshooting Section
Results:
Expected Result:
STOP.
STOP.
i01968414
Switch Circuits
SMCS Code: 1435-038; 7332-038
System Operation Description:
When a filter has been replaced and the bypass
switch continues to indicate that a problem exists,
further troubleshooting is necessary to isolate the
fault. Refer to the Systems Operations, Switches
section for additional information on the individual
switches.
The possible causes of these failures are listed
below:
83
Troubleshooting Section
Switch Circuits
SMCS Code: 1435-038; 7332-038
S/N: 1241-Up
S/N: 1251-Up
S/N: 1261-Up
S/N: CCA1-Up
S/N: CBC1-Up
S/N: ASD1-Up
STOP.
S/N: CBK1-Up
S/N: CAF1-Up
S/N: ARL1-Up
S/N: APN1-Up
S/N: APM1-Up
S/N: CCP1-Up
S/N: AMX1-Up
S/N: ALZ1-Up
S/N: AMZ1-Up
System Operation Description:
When a filter has been replaced and the bypass
switch continues to indicate that a problem exists,
further troubleshooting is necessary to isolate the
fault. Refer to the Systems Operations, Switches
section for additional information on the individual
switches.
The possible causes of these failures are listed
below:
84
Troubleshooting Section
Expected Result:
STOP.
Expected Result:
Expected Result:
STOP.
85
Troubleshooting Section
Table 24
Alternator Specifications
Expected Result:
Peak
Current
Rating
(Amps)
Minimum
Peak
Current
(Amps)
Results:
12 Volt Alternators
8C-5535
32
28
7N-4784, OR-5201
40
36
51
46
9W-2648, 9W-2949,
8T-9700, 105-2811(IG),
OR-4327(IG), 105-2812(IG),
OR-9273(IG), 34-3268,
68-4139, 3E-7295(D+),
7T-2876(D+), 100-8223
55
49
7G-7889
60
54
8C-5510(I), OR5200
61
55
8N-2268
75
68
3E-7892, OR-3616
85
77
105-2813(IG), OR-9274(IG),
105-2814(IG), OR-4328(IG),
149-2064(REG),
OR-9410(REG),
9X-0341(D+)
90
81
8C-6163, OR-1699,
107-2519
105
95
167-7816
110
99
9X-6796, 9X-9096,
121-4134, 121-4136,
OR-3527
115
104
3E-8827, 121-4135,
117-1379(I)
130
117
152-8746
135
122
125-9597, OR-8332
145
131
200-2232
67.5
26
169-3345
50
30
200-8281
67.5
26
2P-1204, 3Y-8200
19
17
2Y-8310
21
19
33
30
35
32
5N-5692, OR-2698
45
41
5S-9088, 100-5047,
112-5041, 3E-7578,
OR-5206, OR-3667,
OR-3668
50
45
Charging System
SMCS Code: 1406-038
System Operation Description:
Often when problems with the charging system
are being investigated, the alternator is not the
problem. If a low battery condition is present test the
batteries first. See Special Instruction, SEHS7633,
Battery Test Procedure for more information. If the
engine cranks slowly, then test the starting system.
See Service Magazine, SEPD0020, Testing The
Starter On The Engine for more information. If a
warning indicator for the charging system is ON, see
Service Magazine, SEBD1751, Difference Between
Alternator Indicator In Electronic Monitoring System
(EMS) And Low Voltage Indicator In Operating
Monitoring System (OMS).
Note: Severely discharged batteries can cause low
system voltage. This can occur even while the engine
is running above idle, and the alternator is working
properly. Proper low engine idle is also important.
24 Volt Alternators
(continued)
86
Troubleshooting Section
Results:
Alternator Specifications
Peak
Current
Rating
(Amps)
Minimum
Peak
Current
(Amps)
109-2362, 9W-3043
, OR-3652(D+), 112-8032
55
50
3E-7772(IG), OR-9437(IG),
105-3132(IG), 4N-3986,
OR-5203
60
54
155-7434, 132-2156(I),
107-7977(I), OR-8279(I)
70
63
169-4319, 167-7812
75
67.5
107-7976, 114-2401,
OR-8997, 3E-7577, OR-3615
75
68
165-5140
100
90
9X-7803, OR-3749
100
90
Expected Result:
6T-1193
18
16
40
36
6T-1195
42
38
Results:
7X-1340
45
41
9G-6079, 6T-1194
63
57
40
36
87
Troubleshooting Section
g00496660
Special wire probe technique for G3B, Y3A, and L3A alternators.
88
Troubleshooting Section
Expected Result:
Results:
Results:
89
Troubleshooting Section
90
Troubleshooting Section
Results:
91
Troubleshooting Section
Results:
Expected Result:
Expected Result:
Results:
STOP.
92
Troubleshooting Section
Results:
Results:
Expected Result:
was determined.
93
Troubleshooting Section
94
Testing and Adjusting Section
The test for the LCD segments for rpm, gear and
i01916579
g00296905
95
Testing and Adjusting Section
96
Testing and Adjusting Section
i01744672
S/N: APM1-Up
S/N: APN1-Up
S/N: ATS1-Up
A short circuit is a failure of an electrical circuit that
results in undesired electrical current. Usually, a
short circuit is a bypass of the circuit across a load.
For example, a short across the wires in a circuit for
a lamp produces too much current in the wires but
no current is felt at the lamp. The lamp is shorted
out. The resistance in a normal circuit can vary, but
the resistance between a particular circuit and other
unrelated circuits is always greater than 5000 ohms.
The following procedure explains the test for a short
circuit:
Reference: For a complete electrical schematic,
refer to Electrical System Schematic for the machine
that is being serviced.
TEST FOR A SHORT CIRCUIT.
1. Identify the connectors and the wire numbers of
the suspect circuits. Use the Electrical System
Schematic of the machine to identify the circuits.
i01205456
Stop.
connector seals.
97
Testing and Adjusting Section
Results:
i01855646
Module - Replace
SMCS Code: 7490-510
Prior to replacement of a module, ensure that
replacement is absolutely necessary. A diagnostic
code is seldom caused by the module. Always ensure
that the machine code is correct for the machine.
Also ensure that the power is available to the main
display module. The system voltage is required
between the contacts 1 and 2 of the connector for the
main display module. To check the machine code,
see System Operation, Harness Code Mode.
Procedure
1. Replace the module.
a. Turn the key start switch to the OFF position.
b. Disconnect the machine harness from the
module.
c. Ensure that the module that is replacing the old
module has the correct part number.
d. Install the new module.
Note: If the main display module that is replacing the
old module was previously removed from service,
see Testing and Adjusting, Main Display Module
Initialization - Adjust.
e. Connect the machine harness to the module.
On so equipped machines, make sure that the
harness code plug is installed.
f. Turn the disconnect switch and the key start
switches to the ON position. Make sure that the
module successfully completes the self test:
see Testing and Adjusting, System Self Test.
2. Setup
a. Set up the optional display modules, see
Systems Operation, Setup Mode.
b. Set the desired units (English or Metric), see
System Operation, Units Mode.
Note: Once the module has been replaced
successfully, see Testing and Adjusting, Main
Display Module-Flash Program.
i01104167
98
Testing and Adjusting Section
Results:
Results:
completed the self test. STOP.
CONTINUE - Proceed to 3.
3. Reconnection and verification.
a. Turn the disconnect switch and the key start
switches to the ON position.
b. Various indicators in the Caterpillar Monitoring
System display area will illuminate. Wait 10
seconds.
c. Turn the key switch to the OFF position.
i01519504
99
Testing and Adjusting Section
i01425096
Glossary of Terms
SMCS Code: 7490
Abnormal This means a condition that is not
normal. The presence of an abnormal condition or an
abnormal signal indicates the existence of a problem.
A warning is activated in order to alert the operator.
Alert Indicator An alert indicator is a red indicator
lamp that is located on the top portion of the main
display module. The alert indicator notifies the
operator of an abnormal condition.
+Battery This pertains to any of the harness
wiring which is part of the circuit that connects to the
positive battery post. +Battery voltage is also referred
to as system voltage.
Caterpillar Electronic Technician (ET) This is
a Windows based program, that is used to service
Caterpillar products. The software operates on a
service tool (personal computer).
Component Identifier (CID) The CID is a
diagnostic code that informs the operator of
component or the system that has failed. The CID is
a four digit code, that is located in the digital display
area when the main display module is in service
mode.
100
Testing and Adjusting Section
101
Testing and Adjusting Section
Function
Type
Description
+ Battery
28 VDC
Ground
Ground
0 VDC
Harness Code 1
Programming Switch(1)
Action Alarm
Output
Alarm Driver
Driver/Receiver (+)
Harness Code 5
Programming Switch(1)
PWM/Switch 1
Unassigned
PWM/Switch/Sender 5
Unassigned
Switch /Sender 10
Fuel Level
(continued)
102
Testing and Adjusting Section
(1)
Function
Type
Description
10
PWM/Switch/Sender 6
Unassigned
11
Switch 7
Switch Input
Unassigned
12
Harness Code 2
Programming Switch(1)
13
Action Lamp
Output
Lamp Driver
14
Driver/Receiver (-)
15
Output
16
Harness Code 4
Programming Switch(1)
17
PWM/Switch 2
Unassigned
18
Switch/Sender 9
19
Switch 1
Switch Input
20
Switch 4
Switch Input
21
Switch 8
Switch Input
Unassigned
22
Harness Code 3
Programming Switch(1)
23
Service
Switch Input
Scroll Switch
24
Output
Unassigned
25
Output
26
Frequency 1
Unassigned
27
PWM/Switch 4
Unassigned
28
PWM/Switch/Sender 7
Unassigned
29
Switch 2
Switch Input
Park Brake
30
Alternator R terminal
Alternator Frequency
31
Harness Code 0
Programming Switch(1)
32
Switch 6
Switch Input
Hydraulic Temperature
33
Clear
Switch Input
Clear Switch
34
Output
9 VDC
35
Input/Output
36
Frequency 2
Unassigned
37
PWM/Switch 3
Unassigned
38
PWM/Switch/Sender 8
Unassigned
39
Switch 3
Switch Input
Unassigned
40
Switch 5
Switch Input
This pin is only used on early model machines for the 140H, 143H, 160H, And 163H. Newer machines use flash software to program the
harness code.
103
Testing and Adjusting Section
Table 26
Function
Type
Description
+ Battery
28 VDC
Ground
Ground
0 VDC
Harness Code 1
Unassigned
Action Alarm
Output
Alarm Driver
Driver/Receiver (+)
Harness Code 5
Unassigned
PWM/Switch 1
Unassigned
PWM/Switch/Sender 5
Unassigned
Switch /Sender 10
Fuel Level
10
PWM/Switch/Sender 6
Unassigned
11
Switch 7
Switch Input
12
Harness Code 2
Unassigned
13
Action Lamp
Output
Lamp Driver
14
Driver/Receiver (-)
15
Output
16
Harness Code 4
Unassigned
17
PWM/Switch 2
18
Switch/Sender 9
19
Switch 1
Switch Input
20
Switch 4
Switch Input
21
Switch 8
Switch Input
Unassigned
22
Harness Code 3
Unassigned
23
Service
Switch Input
Scroll Switch
24
Output
Unassigned
25
Output
26
Frequency 1
27
PWM/Switch 4
Unassigned
28
PWM/Switch/Sender 7
Unassigned
29
Switch 2
Switch Input
Park Brake
30
Alternator R terminal
Alternator Frequency
31
Harness Code 0
Unassigned
32
Switch 6
Switch Input
Hydraulic Temperature
33
Clear
Switch Input
Clear Switch
34
Output
9 VDC
35
Input/Output
36
Frequency 2
Unassigned
37
PWM/Switch 3
Unassigned
(continued)
104
Testing and Adjusting Section
Function
Type
Description
38
PWM/Switch/Sender 8
Unassigned
39
Switch 3
Switch Input
Unassigned
40
Switch 5
Switch Input
i01857839
System Schematic
SMCS Code: 7566
These schematics are typical Caterpillar Monitoring
System schematics, that show possible inputs and
outputs. On some machines, certain sensors are
not part of the system. However, the main display
module receives the sensor information over the
CAT data link from other electronic controls. For an
accurate schematic of a particular machine, always
see the Electrical System Schematic in the machine
Service Manual.
105
Testing and Adjusting Section
Illustration 85
g00947079
106
Testing and Adjusting Section
14H
Illustration 86
g00865621
107
Testing and Adjusting Section
16H
Illustration 87
g00947028
108
Testing and Adjusting Section
Illustration 88
g00947030
109
Index Section
Index
A
Action Alarm ..........................................................
Action Lamp...........................................................
Additional Operator Modes....................................
Trip Fuel Consumption Mode.............................
Trip Hourmeter Mode .........................................
Trip Odometer Mode ..........................................
Alert Indicator Description .....................................
Alert Indicator Is Always Flashing..........................
Alert Indicator Never Flashes ................................
Articulation Gauge Calibration Mode.....................
I
36
36
13
14
13
14
25
71
72
22
C
Calibration Mode ................................................... 18
Submodes.......................................................... 19
Charging System ................................................... 85
Component Description ......................................... 27
Connector Contact Description of Main Display
Module ............................................................... 101
D
Diagnostic Capabilities ..........................................
The Caterpillar Electronic Technician (ET).........
Diagnostic Code List..............................................
Diagnostic Code Procedures.................................
Diagnostic System Procedures .............................
Display Components .............................................
42
42
44
44
71
31
E
Electrical Component and Connector Locations ... 40
Connector Contact Numbers for the Main Display
Module ............................................................. 41
General Information ........................................... 40
Service Connector ............................................. 41
Electrical Connector - Inspect................................ 96
F
Fuel Level Sender ................................................. 81
G
General Information........................................... 4, 38
Introduction .......................................................... 4
Glossary of Terms.................................................. 99
H
Harness Code........................................................ 73
Harness Code Mode.............................................. 12
110
Index Section
Related Components............................................. 37
Alternator ........................................................... 37
Other Electronic Controls................................... 37
S
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 ................................................. 8283
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
T
Table of Contents..................................................... 3
Tachometer Mode................................................... 11
Tattletale Mode ...................................................... 16
Testing and Adjusting ............................................ 94
Testing and Adjusting Section ............................... 94
Troubleshooting Section ........................................ 38
U
Units Mode ............................................................ 18
Using Caterpillar Electronic Technician to Determine
Diagnostic Codes................................................. 46
Using Caterpillar Monitoring System to Determine
Diagnostic Codes................................................. 45
Procedure .......................................................... 45
111
Index Section
2003 Caterpillar
All Rights Reserved
Printed in U.S.A.