You are on page 1of 53

966F Series II Wheel Loader 1SL00507-UP (MACHINE) POWERED BY 3306 Engin...

Pgina 1 de 53

Cerrar SIS
Pantalla anterior
Producto: WHEEL LOADER
Modelo: 966F II WHEEL LOADER 1SL01330
Configuracin: 966F Series II Wheel Loader 1SL00507-UP (MACHINE) POWERED BY 3306 Engine

Pruebas y Ajustes
COMPUTERIZED MONITORING SYSTEM (CMS) WITH VFD CIRCULAR GAUGE
Nmero de medio -SENR5247-03

Fecha de publicacin -29/12/1995

Fecha de actualizacin -11/10/2001

Testing And Adjusting

Introduction
Reference: For machine specific operation information, see the Operation And Maintenance Manual
for the machine being serviced.
Reference: For machine specific electrical circuit information, see the Electrical System Schematic
module for the machine being serviced.

https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb... 20/02/2015

966F Series II Wheel Loader 1SL00507-UP (MACHINE) POWERED BY 3306 Engin... Pgina 2 de 53

The troubleshooting of the CMS system requires additional information from the machine Service
Manual. The Electrical System Schematic and the Operation & Maintenance Manual are required
support material.
As a guide, a Typical CMS Schematic is at the end of this manual. For an accurate representation of
the machine being diagnosed, see the Electrical System Schematic in the machine Service Manual.
When the troubleshooting procedure instructs to REPAIR THE HARNESS, use the Electrical System
Schematic in the machine Service Manual to trace the circuit. Perform continuity checks at connectors
to locate harness failures. At component connectors, always check the ground circuit. Less than five
ohms of resistance is required between the connector ground contacts and frame ground. Excessive
ground resistance, greater than five ohms, can cause incorrect diagnosing of problems.
During troubleshooting, inspect all component and harness connections before any component is
replaced. If these connections are not clean and tight they can cause electrical problems, either

https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb... 20/02/2015

966F Series II Wheel Loader 1SL00507-UP (MACHINE) POWERED BY 3306 Engin... Pgina 3 de 53

permanent or intermittent (come and go). Make sure the connections are tight before other tests are
made.
Failure of an electrical component can cause, or be caused by the failure of one or more other
components. Always attempt to find and correct the cause of electrical system failure before making
replacement of a component.

Harness Connector Inspection


Intermittent electrical problems are often caused by poor connections at harness connectors. Use the
following checks as a guide for inspecting connectors.
CHECK Connector Mating:
* Ensure locking rings lock into place.
* Ensure that locking clips are used on Sure Seal connectors.
* Ensure that the screw is tight in the center of DRC connectors.
* Ensure that the connector contacts (pins and sockets) align properly.
CHECK Wires At The Connector:
* Ensure that the wires enter the back of the connector straight not at an angle.
* Ensure that each wire is properly crimped into the proper connector contact.
* Ensure that each connector contact is properly locked into the connector body. When locked
properly, the contact (or wire) cannot be pulled out of the connector body without excessive
force.
CHECK Each Wire For Nicks Or Signs Of Abrasion In The Insulation.
CHECK For Dirty Or Corroded Contacts (Pins And Sockets):
Clean contacts (pins and sockets) with a cotton swab or a soft brush and denatured alcohol only.
CHECK For Moisture At The Connector. Possible Sources Are:
* Damaged or lost connector seals.
* Missing or loose wire hole plugs.
* Wires not entering the back of the connector straight. If wires enter at an angle, there may not
be a good seal between the connector and the wire insulation.
* Other connectors with poor seals may allow moisture to travel inside the wire insulation.
CHECK The Fit Of Each Contact (Pin And Socket):
Insert a new pin or socket into each contact of the connector. It should fit snugly. The new pin or
socket should stay in place if the connector is held with the contacts facing down.

CMS Service Connector

https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb... 20/02/2015

966F Series II Wheel Loader 1SL00507-UP (MACHINE) POWERED BY 3306 Engin... Pgina 4 de 53

Connectors (966F Shown)


(1) Harness code connector. (2) Units connector. (3) Service connector. (4) CAT data link connector.

Service connector (3) provides access to the service and clear inputs. Connector contact 1 is the
service input and contact 2 is the clear input. Service connector (3) is usually located under the dash
within the operator compartment. The service connector is a Sure-Seal or DT type of connector. For
a more accurate service connector location and connector requirements, see the Electrical System
Schematic in the machine Service Manual.

Service Connector With Jumpers - Typical Example Connector end view shows Sure Seal and DT types of connector.
(3) Service connector. (5) Jumper - service contact grounded. (6) Jumper - clear contact grounded.

Various diagnostic functions require the grounding and/or opening of the service and clear contacts at
the service connector. During troubleshooting, it is necessary for the service person to make the
proper electrical connections between the contacts of the service connector. These electrical
connections are made with two jumpers. Also see the topic Service Tools.

Service Tools
The following service tools should be used to make troubleshooting the electrical system easier.

https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb... 20/02/2015

966F Series II Wheel Loader 1SL00507-UP (MACHINE) POWERED BY 3306 Engin... Pgina 5 de 53

6V-7070 or 9U-7330 or equivalent Digital Multimeter.8T-3224 Needle Tip Group.7X-1710 Cable


Probe Group.8T-8726 Adapter Cable6V-3000 Repair Kit - Sure Seal4C-3406 Connector Repair Kit Deutsch
Use the digital multimeter for making continuity (resistance) checks or voltage measurements. For
instruction on use of the 6V-7070, see Special Instruction SEHS7734. The 7X-1710 Cable Probe
Group is used to make measurements at connectors without disconnecting them. The probes are
pushed in the back of the connector alongside the wire. The 8T-8726 Adapter Cable is a 3 pin
breakout cable used to make measurements in sensor circuits.
NOTE: Use of continuity testers (such as 8T-0500), or voltage testers (such as 5P-7277) are not
recommended for use on present-day Caterpillar electrical circuits, except for harness tests.

4C-8195 Control Service Tool

https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb... 20/02/2015

966F Series II Wheel Loader 1SL00507-UP (MACHINE) POWERED BY 3306 Engin... Pgina 6 de 53

The 4C-8195 Control Service Tool is helpful for the service person to make the proper electrical
connections at the service connector during troubleshooting. Three connectors are wired in parallel so
that the service tool is usable on the different types of machine harnesses.
Actuating the mode switch scrolls through the display modes. Actuating the scroll switch scrolls the
display with the control in the service or numeric readout mode. Actuating the clear switch when in
service mode, clears the fault being continuously shown. Actuating the clear switch when in tattle tale
mode, clears all extreme values.

Diagnostic Summary

https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb... 20/02/2015

966F Series II Wheel Loader 1SL00507-UP (MACHINE) POWERED BY 3306 Engin... Pgina 7 de 53

The following topics summarize the diagnostics of CMS. See the Systems Operation section of this
Service Manual for a detailed explanation of the topics.

Changing Modes

Digital Readout Area


(1) Mode readout.

CMS has five modes of operation. The different modes are identified by the mode number which is
shown on mode readout (1). The five modes of operation and the corresponding mode numbers are:
Normal Mode - "-0-" is shown on mode readout (1).
Service Mode - "-1-" is shown on mode readout (1).
Status Mode - "-2-" is shown on mode readout (1).
Tattletale Mode - "-3-" is shown on mode readout (1).
Numeric Readout Mode - "-4-" is shown on mode readout (1).
CMS enters normal mode when power is applied. The mode of operation is changeable at any time.
Grounding the service and clear contacts of the service connector at the same time initiates the
scrolling of the mode numbers on mode readout (1). Removing ground from both connector contacts,
causes the CMS control to enter the mode which is currently shown.
Procedure
1. Turn key start switch ON. Wait for the Self Test to finish; approximately seven seconds.
2. At the same time, ground the service and clear contacts of the service connector. This causes the
mode numbers ("-0-" through "-4-") to scroll on mode readout (1).

https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb... 20/02/2015

966F Series II Wheel Loader 1SL00507-UP (MACHINE) POWERED BY 3306 Engin... Pgina 8 de 53

3. When the desired mode number is shown on mode readout (1), remove ground from (open) the
service and clear contacts. The desired mode is now entered and active.

Service Mode (Mode 1)

Service Mode Display


(1) Module identifier (MID). (2) Failure mode identifier (FMI). (3) Component identifier (CID). (4) Fault present
indicator. (5) Status change identifier. (6) CMS contact identifier.

Service mode diagnoses detected faults in the output circuits and sensor input circuits. The
information available from service mode is:
* MID (1) shows which electronic machine system detected and diagnosed the fault. Some
MID's are:
CMS ... 26
Electronic Transmission Control ... 27
Autoshift Transmission Control ... 81
All the MID's for the electronic controls that "talk" to CMS on a particular machine are listed
on the Electrical System Schematic.
* CID (3) shows which component is faulty. For a list of CID codes for CMS, see the CMS
Detected Faults chart in the Detected Faults section.
* FMI (2) shows what type of failure has occurred. For a list of FMI codes that CMS uses, see
the CMS Detected Faults chart in the Detected Faults section.
* Fault present indicator (4) shows the status of the fault shown. If fault present indicator (4)
shows "SERV CODE", then the fault is currently present. If fault present indicator (4) is OFF,
then the fault was present in the past but is not present now (intermittent).
* The action alarm SOUNDS when the fault shown changes status (present or not present).

https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb... 20/02/2015

966F Series II Wheel Loader 1SL00507-UP (MACHINE) POWERED BY 3306 Engin... Pgina 9 de 53

* CMS contact identifier (6) shows the CMS connector contact for the fault currently shown.
* Status change identifier (5) shows the CMS connector contact for any faults that change status
(present or not present).
There are three display operations while in service mode: scrolling faults, holding faults and clearing
faults. When service mode is first entered the fault shown is on-hold.
* To scroll through all faults, ground the service contact of the service connector.
* To hold a fault, open (remove ground from) the service contact of the service connector while
the desired fault is shown.
* To clear a fault, ground the clear contact of the service connector while the fault is on-hold. A
fault that is currently present (fault present indicator shows "SERV CODE") can not be cleared.
For a detailed explanation, see the topic Service Mode (Mode 1) in the Systems Operation section.

Status Mode (Mode 2)

https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb... 20/02/2015

966F Series II Wheel Loader 1SL00507-UP (MACHINE) POWERED BY 3306 Eng... Pgina 10 de 53

https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb... 20/02/2015

966F Series II Wheel Loader 1SL00507-UP (MACHINE) POWERED BY 3306 Eng... Pgina 11 de 53

Status Mode Display


(1) Status change identifier. (2) Open contact identifier. (3) Alert indicators with assigned numbers.

There are two versions of status mode, one version for earlier CMS controls and one version for later
CMS controls. Status mode on earlier CMS controls, uses both the alert indicators and the open
contact identifier to show the status of the switch inputs. Status mode on later CMS controls, uses
only the open contact identifier to show the status of the switch inputs; the alert indicators are not
used. Earlier CMS controls are Part Numbers: 9X9887 and 101-3371. All other CMS part numbers
are later CMS controls.
Status mode diagnostics assist with troubleshooting of faults in the switch input circuits. The
information available from status mode is:
* The action alarm SOUNDS when any switch input changes status (open or ground).
* Status change identifier (1) shows the CMS connector contact for any switch inputs that
change status (open or ground).
* Open contact identifier (2) shows the CMS connector contact for any switch inputs that are
open. On earlier CMS controls, the alert indicator which is ON CONTINUOUSLY corresponds
to the connector contacts that are now shown.
* On earlier CMS controls, alert indicators (3) show the status (open or grounded) of switch
inputs. If alert indicator (3) is OFF, then the corresponding switch type input is grounded. If
alert indicator (3) is FLASHING, then the corresponding switch type input is open. If alert
indicator (3) is ON CONTINUOUSLY, then the corresponding switch type input is open and
the CMS connector contact is now shown at open contact identifier (2).
On earlier CMS controls, selection is the only display operation of status mode. Which group of CMS
connector contacts are shown on the CMS display is determined by the status of the clear contact of
the service connector.
* To select CMS connector contacts 19, 30 - 40; open the clear contact of the service connector.

https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb... 20/02/2015

966F Series II Wheel Loader 1SL00507-UP (MACHINE) POWERED BY 3306 Eng... Pgina 12 de 53

* To select CMS connector contacts 5, 6, 20, 21, 22, 25 - 29; ground the clear contact of the
service connector.
For a detailed explanation of status mode, see the topic Status Mode (Mode 2) in the Systems
Operation section.

Tattletale Mode (Mode 3)


Tattletale mode diagnostics show the extreme value for each machine condition monitored. The
values are shown and read in the same manner as when in normal mode. Clearing is the only display
operation of tattletale mode. To clear all the extreme values; ground the clear contact of the service
connector. For a detailed explanation, see the topic Tattletale Mode (Mode 3) in the Systems
Operation section.

Numeric Readout Mode (Mode 4)


Numeric readout mode diagnostics show a numeric value of the information from each sensor input.
(Sensor input information is that which is shown on the gauges and the speed readout.) The numeric
value shown is constantly updated to reflect any changes that occur.
Scrolling and holding are the display operations of numeric readout mode.
* To hold the desired information, open the service contact of the service connector.
* To scroll all the information, ground the service contact of the service connector.
NOTE: For the earliest CMS controls, activation of scrolling and holding is the opposite of what is
described above. To scroll, open the service contact. To hold, ground the service contact.
For a detailed explanation, see the topic Numeric Readout Mode (Mode 4) in the Systems Operation
section.

Detected Faults

https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb... 20/02/2015

966F Series II Wheel Loader 1SL00507-UP (MACHINE) POWERED BY 3306 Eng... Pgina 13 de 53

When the CMS control detects a fault while in normal mode, the service code indicator shows "SERV
CODE"; which notifies the service person. Service mode shows the diagnostics for the detected fault.
For detailed information, see the topic Service Mode (Mode 1) in the Systems Operation section.
NOTE: When a sensor fault is present, the corresponding warning for the operator is also activated.
For example, if the signal wire for the engine coolant temperature sensor is shorted to +battery, then:
a. SERV CODE indicator is ON.
b. The corresponding service code is stored in memory.
c. The gauge for engine coolant temperature shows in the problem region.
d. The action lamp is FLASHING.

https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb... 20/02/2015

966F Series II Wheel Loader 1SL00507-UP (MACHINE) POWERED BY 3306 Eng... Pgina 14 de 53

Notice that the above items c and d are the same warning indications that are activated if the engine
were to actually overheat.
NOTE: This Service Manual applies only to CMS faults. When in service mode (on appropriately
equipped machines), faults from electronic control modules other than the CMS control are shown.
The CAT data link facilitates the transfer of diagnostic information from other electronic control
modules to the CMS control. This diagnostic information is shown when CMS is in service mode.
The module identifier (MID) tells which electronic control module is diagnosing the detected fault.
The MID code for CMS is "26". This Service Manual applies only to faults with a MID of "26" (CMS
faults). The MID code of other electronic control modules (transmission, engine) on a particular
machine are listed on the Electrical System Schematic.

Initial Troubleshooting Procedure

Digital Readout Area


(1) Module identifier (MID). (2) Failure mode identifier (FMI). (3) Component identifier (CID). (4) Fault present
indicator. (5) Status change identifier. (6) CMS contact identifier.

Use the following procedure when a fault is detected. When a fault is detected, the service code
indicator shows "SERV CODE" while in normal mode.
1. Enter service mode (mode 1).
2. A single fault is shown and is on-hold at this time. When no fault is available; MID (1) shows "--",
CID (3) shows "---" and FMI (2) shows "-F".
3. To see all detected faults, scroll the faults. To do so, ground the service contact of the service
connector.
4. Place the desired fault on-hold (stop the scrolling). To do so, remove ground from the service
contact of the service connector when the desired fault is shown.

https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb... 20/02/2015

966F Series II Wheel Loader 1SL00507-UP (MACHINE) POWERED BY 3306 Eng... Pgina 15 de 53

5. Make sure that MID (1) is "26". If not, see the topic Service Mode (Mode 1).
6. Observe fault present indicator (4):
* If fault present indicator (4) shows "SERV CODE", then the fault shown is currently present.
* If fault present indicator (4) is OFF, then the fault shown is not present at this time. The fault
has occurred and then went away, sometime in the past (intermittent).
7. To troubleshoot the fault, go to the procedure with the same CID and FMI.
8. After a fault is corrected or it is no longer needed, clear the fault. To do so, momentarily ground the
clear contact of the service connector while the fault is on-hold. After clearing, the display advances
to the next available fault.
9. Repeat Steps 2 through 8 for the remaining faults. Return to normal mode when finished.

Troubleshooting Procedures:
Go to the procedure which corresponds to the CID and FMI shown on the CMS display in the digital
readout area.

CID 096 Procedure (Fuel Level Sensor), CID 100 Procedure (Engine Oil Pressure
Sensor), CID 110 Procedure (Engine Coolant Temp Sensor), CID 177 Procedure
(Power Train Oil Temp Sensor), CID 427 Procedure (Front Brake Oil Temp
Sensor), CID 428 Procedure (Rear Brake Oil Temp Sensor), CID 600 Procedure
(Hydraulic Oil Temp Sensor), CID 601 Procedure (Brake Air Pressure Sensor)
Service Notes: Ensure that the desired fault (CID and FMI) is on-hold. Ensure that the fault present
indicator shows "SERV CODE". Make a note of the connector contact shown on the CMS contact
identifier. This is the signal contact of the CMS connector which corresponds to the currently shown
CID.
NOTE: The Sensor Voltage Test within the topic PWM Sensor Tests also covers the troubleshooting
of the sensor fault.
FMI 0F
This fault is recorded when the CMS control reads the sensor signal as too high. The result of this
fault condition is that the corresponding gauge FLASHES. The possible causes are:
* Sensor is defective.
* Sensor ground circuit in the machine harness is open.
* Signal circuit in the machine harness is shorted to +battery.
* Signal circuit in the machine harness is open (a disconnected sensor is included).
* CMS control is defective.

https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb... 20/02/2015

966F Series II Wheel Loader 1SL00507-UP (MACHINE) POWERED BY 3306 Eng... Pgina 16 de 53

1. CHECK CONTROL AND HARNESS - Turn the disconnect and key start switches to the ON
position. Disconnect the machine harness from the sensor. At the machine harness connector for the
sensor, measure the voltage (DCV) between the signal contact and the ground contact.
* Voltage is 5.0 0.5 DCV; CMS control and harness are correct. The sensor is defective.
Replace the sensor, also see the topic PWM Sensor Tests.
* Voltage is NOT 5.0 0.5 DCV; CMS control or harness are defective. Go to Step 2.
2. CHECK HARNESS GROUND CIRCUIT - The sensor remains disconnected. Turn the disconnect
and key start switches to the OFF position. Disconnect the machine harness from the CMS control. At
the machine harness connector for the sensor, measure the resistance between the ground contact and
frame ground.
* Resistance is greater than 2.0 Ohms; the ground circuit in the harness is defective. There is an
open circuit between the ground contact and frame ground. Repair or replace the machine
harness.
* Resistance is less than 2.0 Ohms; harness resistance is correct. Go to Step 3.
3. CHECK FOR SHORTED HARNESS - The sensor and CMS control remain disconnected from the
machine harness. The disconnect switch remains OFF. At the machine harness connector for the
sensor, measure the resistance between the signal contact and the +battery contact (+V).
* Resistance is less than 5000 Ohms; the machine harness is defective. There is a short between
the +battery circuit and the signal circuit in the machine harness. Repair or replace the machine
harness.
* Resistance is greater than 5000 Ohms; harness circuit resistance is correct. Go to Step 4.
4. CHECK FOR OPEN HARNESS - The sensor and CMS control remain disconnected from the
machine harness. The disconnect switch remains OFF. Check the continuity of the signal circuit from
the CMS machine harness connector to the sensor machine harness connector.
* Resistance is less than 5 Ohms; the signal circuit is correct. The CMS control is defective.
Replace the CMS control; see CMS Control Replacement.
* Resistance is greater than 5 Ohms; the signal circuit is defective. The signal circuit is open in
the machine harness. Repair or replace the machine harness.
FMI 1F
This fault is recorded when the CMS control reads the sensor signal as too low. The result of this fault
condition is that the corresponding gauge FLASHES. The possible causes are:
* Sensor is defective.
* Signal circuit in the machine harness is shorted to ground.
* CMS control is defective.
NOTE: Step 1 can create an FMI OF fault for the same CID No. When all harnesses are reconnected,
this fault is shown as not present. Clear the FMI OF fault after this procedure is completed.

https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb... 20/02/2015

966F Series II Wheel Loader 1SL00507-UP (MACHINE) POWERED BY 3306 Eng... Pgina 17 de 53

1. CHECK SENSOR - Ensure that the desired fault (CID) is on-hold and that the fault present
indicator shows "SERV CODE". Observe the status of the fault present indicator or listen for the
SOUNDING of the action alarm. Disconnect the machine harness from the sensor.
* "SERV CODE" is NO longer shown or the action alarm SOUNDED; indicates the fault is no
longer present. The sensor is defective. Replace the sensor, also see the topic PWM Sensor
Tests.
* "SERV CODE" remains shown or the action alarm did NOT SOUND; indicates the fault
remains present. The sensor is not causing the fault. Go to Step 2.
2. CHECK FOR SHORT TO GROUND - The sensor remains disconnected from the machine
harness. Turn the disconnect switch to the OFF position. Disconnect the machine harness from the
CMS control. At the machine harness connector for the CMS control, measure the resistance between
the signal contact and frame ground.
* Resistance is greater than 5000 Ohms; harness circuit resistance is correct. The control is
defective. Replace the CMS control; see CMS Control Replacement.
* Resistance is less than 5000 Ohms; the machine harness is defective. There is a short between
frame ground and the signal circuit in the machine harness. Repair or replace the machine
harness.

CID 168 Procedure (Electrical System Voltage)


Service Notes: Ensure that the fault present indicator shows "SERV CODE".
FMI 3F
This fault is recorded when the CMS control reads the electrical system voltage as above normal. The
result of this fault condition is that the system voltage gauge FLASHES if the machine is so equipped.
CHECK SYSTEM VOLTAGE - Run the engine at high idle. Measure the system voltage (+battery)
at the alternator circuit breaker or at the batteries.
* Voltage is greater or equal to 36.0 DCV; the charging system is defective. A possible cause is
a faulty alternator with excessive current output and therefore high voltage. Repair the charging
system. See the topic Electrical System Tests in the Testing And Adjusting section of this
Service Manual.
* Voltage is less than 36.0 DCV; the charging system voltage is less than the required amount
to cause this fault. The CMS control is defective. Replace the CMS control; see CMS Control
Replacement.

CID 248 Procedure (CAT Data Link)


Service Notes: Ensure that the fault present indicator shows "SERV CODE".
FMI 9F
This fault is recorded when the CMS control does not receive expected information. For example;
engine oil pressure or actual gear information is not received from other electronic control modules

https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb... 20/02/2015

966F Series II Wheel Loader 1SL00507-UP (MACHINE) POWERED BY 3306 Eng... Pgina 18 de 53

through the CAT data link. The result of this fault condition is that the gauges dependent upon the
CAT data link FLASH. The possible causes (listed in order of probability) are:
1. Poor electrical connection at a machine harness connector.
2. CAT data link circuit in the machine harness is shorted to ground.
3. CAT data link circuit in the machine harness is shorted to +battery.
4. CAT data link circuit in the machine harness is open.
5. An electronic control module which uses CAT data link is defective (CMS control, engine
control, transmission control, etc.)
NOTE: If the CMS control was recently replaced, see the topic Initialization.
1. Check other electronic control modules for a similar fault. If a similar fault is found, use the
procedures for that electronic control module to troubleshoot the fault. Otherwise, go to Step 2.
2. INSPECT HARNESS CONNECTORS - Turn the disconnect to the OFF position. Inspect the
machine harness connections related to the CAT data link. Make sure that connectors are clean and
tight. If necessary, repair or replace the machine harness. Otherwise, go to Step 3.
3. CHECK FOR SHORT TO GROUND - The disconnect switch remains OFF. Disconnect the
machine harness from all electronic control modules that use the CAT data link. At the machine
harness connector for the CMS control, measure the resistance between frame ground and the CAT
data link circuits (CMS connector contacts 23 and 24).
* Resistance is less than 5000 Ohms; the machine harness is defective. There is a short between
frame ground and the CAT data link circuit in the machine harness. Repair or replace the
machine harness.
* Resistance is greater than 5000 Ohms; harness circuit resistance is correct. Go to Step 4.
4. CHECK FOR SHORT TO +BATTERY - The disconnect switch remains OFF. All related control
modules remain disconnected from the machine harness. At the machine harness connector for the
CMS control, measure the resistance between +battery (contact 1) and the CAT data link circuits
(CMS connector contacts 23 and 24).
* Resistance is less than 5000 Ohms; the machine harness is defective. There is a short between
+battery and the CAT data link circuit in the machine harness. Repair or replace the machine
harness.
* Resistance is greater than 5000 Ohms; harness circuit resistance is correct. Go to Step 5.
5. CHECK FOR OPEN HARNESS - The disconnect switch remains OFF. All related control modules
remain disconnected from the machine harness. Check the continuity of the CAT data link circuit in
the machine harness. Measure from the CMS control connector (contacts 23 and 24) to the connector
for each of the related electronic control modules.
* Resistance is greater than 5 Ohms; the machine harness is defective. The CAT data link
circuit is open in the machine harness. Repair or replace the machine harness.
* Resistance is less than 5 Ohms; the CAT data link circuit in the machine harness is correct.
The CMS control is defective. Replace the CMS control; see CMS Control Replacement.

CID 270 Procedure (CMS Harness Code)

https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb... 20/02/2015

966F Series II Wheel Loader 1SL00507-UP (MACHINE) POWERED BY 3306 Eng... Pgina 19 de 53

Service Notes: The connector contacts, which correspond to CID 270, are not shown on the CMS
contact identifier. The fault is present in any of the five harness code contacts. Ensure that the fault
present indicator shows "SERV CODE".
NOTE: To troubleshoot an intermittent CID 270 fault, see the topic Harness Code Fault in the
Undetected Faults section.
FMI 2F
This fault is recorded when the harness code circuits change during normal operation. If this fault is
present when CMS is turned ON, the control does not function correctly. This is easily noticed
because the self test does not function and only the CAT logo is shown in the digital readout area.
1. Perform the self test, see Self Test.
* Passes the self test and fault CID 270 remains present; the control is defective. Replace the
CMS control; see CMS Control Replacement.
* Fails the self test; there is a defect. More troubleshooting is required; see the topic Harness
Code Fault in the Undetected Fault section.

CID 271 Procedure (Action Alarm)


Service Notes: Ensure that fault CID 271 and the desired FMI are on-hold. Ensure that the fault
present indicator shows "SERV CODE". Make a note of the connector contact shown on the CMS
contact identifier. This is the contact of the CMS connector which corresponds to fault CID 271.
FMI 3F
This fault is recorded when the CMS control reads the voltage of the action alarm circuit (410-WH) as
above normal (shorted to +battery). The result of this fault condition is that the action alarm SOUNDS
CONTINUOUSLY.
CHECK ALARM CIRCUIT - Turn the disconnect and the key start switches to the OFF position.
Disconnect the machine harness from the CMS control. Turn the disconnect switch to the ON
position. Listen for the SOUNDING of the action alarm. Turn the key start switch to the ON position.
* The alarm SOUNDS; harness circuit 410-WH is shorted to +battery. Repair or replace the
harness.
* The alarm does NOT SOUND; the control is defective. Replace the CMS control; see CMS
Control Replacement.
FMI 4F
This fault is recorded when the CMS control reads the voltage of the action alarm circuit (410-WH) as
below normal (shorted to ground). The result of this fault condition is that the action alarm does not
SOUND.
NOTE: This procedure can create a CID 271 FMI 5F fault. When all harnesses are reconnected, this
fault is shown as not present. Clear the CID 271 FMI 5F fault after this procedure is completed.

https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb... 20/02/2015

966F Series II Wheel Loader 1SL00507-UP (MACHINE) POWERED BY 3306 Eng... Pgina 20 de 53

1. CHECK ALARM - Ensure that CID 271 FMI 4F is on-hold and that the fault present indicator
shows "SERV CODE". Observe the status of the fault present indicator. Disconnect the machine
harness from the alarm.
* "SERV CODE" is NO longer shown; the alarm is defective. Replace the action alarm. (Note:
The correct resistance for a good alarm is 200 100 Ohms.)
* "SERV CODE" remains shown; indicates the fault remains present. The action alarm is not
causing the fault. Go to Step 2.
2. CHECK FOR SHORT TO GROUND - Turn the disconnect switch to the OFF position. The alarm
remains disconnected from the machine harness. Disconnect the machine harness from the CMS
control. At the machine harness connector for the CMS control, measure the resistance between
contact 3 (410-WH) and frame ground.
* Resistance is less than 5000 Ohms; harness is defective. Repair or replace the machine
harness.
* Resistance is greater than 5000 Ohms; harness resistance is correct. Go to Step 3.
3. CHECK CONTROL - Remove contact 3 from the machine harness connector for the CMS control.
Reconnect the harness connector to the CMS control. Turn the disconnect switch to the ON position.
Put the system in service mode with CID 271 FMI 4F on-hold. Observe the fault present indicator.
* "SERV CODE" is shown; indicates the control thinks the fault is present. The control is
defective. Replace the CMS control; see CMS Control Replacement.
* "SERV CODE" is NOT shown; indicates the fault is no longer present. The control is not
causing the fault. The fault is intermittent. The probable cause is poor electrical connection at
the harness connectors or a damaged harness. Check the harness for damage and clean the
harness connectors.
FMI 5F
This fault is recorded when the CMS control reads the current of the action alarm circuit (410-WH) as
below normal (open circuit). The result of this fault condition is that the action alarm does not
SOUND.
NOTE: This procedure can create a CID 271 FMI 4F fault. When all harnesses are reconnected, this
fault is shown as not present. Clear the CID 271 FMI 4F fault after this procedure is completed.
1. CHECK ALARM - Ensure that CID 271 FMI 5F is on-hold and that the fault present indicator
shows "SERV CODE". Observe the status of the fault present indicator. Disconnect the machine
harness from the alarm. At the machine harness connector for the alarm, place a jumper across the
two contacts.
* "SERV CODE" is NO longer shown; the alarm is open. Replace the action alarm. (Note: The
correct resistance for a good alarm is 200 100 Ohms.)
* "SERV CODE" remains shown; indicates the fault remains present. The action alarm is not
causing the fault. Go to Step 2.
2. CHECK HARNESS - Turn the disconnect switch to the OFF position. From Step 1; remove the
jumper and reconnect the alarm to the machine harness. Disconnect the machine harness from the

https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb... 20/02/2015

966F Series II Wheel Loader 1SL00507-UP (MACHINE) POWERED BY 3306 Eng... Pgina 21 de 53

CMS control. At the machine harness connector for the CMS control, measure the resistance between
contact 3 (410-WH) and frame ground.
* Resistance is greater than 300 Ohms; harness circuit is open. Go to Step 3.
* Resistance is less than 300 Ohms; harness circuit resistance is correct. Go to Step 4.
3. CHECK HARNESS - Disconnect the machine harness from the alarm. Check for an open in circuit
410-WH between CMS machine harness connector (contact 3) and action alarm machine harness
connector (contact 1). Also, check for an open in circuit 201-BK between action alarm machine
harness connector (contact 2) and frame ground. Repair or replace the harness.
4. CHECK CONTROL - Reconnect the harness connector to the CMS control. Reconnect the alarm
to the machine harness. Turn the disconnect switch to the ON position. Put the system in service
mode with CID 271 FMI 5F on-hold. Observe the fault present indicator.
* "SERV CODE" is shown; indicates the control thinks the fault is present. The control is
defective. Replace the CMS control; see CMS Control Replacement.
* "SERV CODE" is NOT shown; indicates the fault is no longer present. The control is not
causing the fault. The fault is intermittent. The probable cause is poor electrical connection at
the harness connectors or a damaged harness. Check the harness for damage and clean the
harness connectors.

CID 324 Procedure (Action Lamp)


Service Notes: Ensure that fault CID 324 and the desired FMI are on-hold. Ensure that the fault
present indicator shows "SERV CODE". Make a note of the connector contact shown on the CMS
contact identifier. This is the contact of the CMS connector which corresponds to fault CID 324.
FMI 3F
This fault is recorded when the CMS control reads the voltage of the action lamp circuit (411-PK) as
above normal (shorted to +battery). The result of this fault condition is that the action lamp is ON
CONTINUOUSLY.
CHECK LAMP CIRCUIT - Turn the disconnect and the key start switches to the OFF position.
Disconnect the machine harness from the CMS control. Turn the disconnect switch to the ON
position. Observe the action lamp. Turn the key start switch to the ON position.
* The lamp is ON; harness circuit 411-PK is shorted to +battery. Repair or replace the harness.
* The lamp is OFF; the control is defective. Replace the CMS control; see CMS Control
Replacement.
FMI 4F
This fault is recorded when the CMS control reads the voltage of the action lamp circuit (411-PK) as
below normal (shorted to ground). The result of this fault condition is that the action lamp does not
light.

https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb... 20/02/2015

966F Series II Wheel Loader 1SL00507-UP (MACHINE) POWERED BY 3306 Eng... Pgina 22 de 53

NOTE: This procedure can create a CID 324 FMI 5F fault. When all harnesses are reconnected, this
fault is shown as not present. Clear the CID 324 FMI 5F fault after this procedure is completed.
1. CHECK LAMP - Ensure that CID 324 FMI 4F is on-hold and that the fault present indicator shows
"SERV CODE". Observe the status of the fault present indicator or listen for the SOUNDING of the
action alarm. At the action lamp, disconnect wire 411-PK from the action lamp socket.
* "SERV CODE" is NO longer shown or the action alarm SOUNDED; the lamp is defective.
Replace the action lamp. (Note: For the purposes of this procedure, the correct resistance for a
lamp is greater than 2 Ohms.)
* "SERV CODE" remains shown or the action alarm did NOT SOUND; indicates the fault
remains present. The action lamp is not causing the fault. Go to Step 2.
2. CHECK FOR SHORT TO GROUND - Turn the disconnect switch to the OFF position. Wire 411PK remains disconnected from the action lamp. Disconnect the machine harness from the CMS
control. At the machine harness connector for the CMS control, measure the resistance between
contact 4 (411-PK) and frame ground.
* Resistance is less than 5000 Ohms; harness is defective. Repair or replace the machine
harness.
* Resistance is greater than 5000 Ohms; harness resistance is correct. Go to Step 3.
3. CHECK CONTROL - Remove contact 4 from the machine harness connector for the CMS control.
Reconnect the harness connector to the CMS control. Turn the disconnect switch to the ON position.
Put the system in service mode with CID 324 FMI 4F on-hold. Observe the fault present indicator.
* "SERV CODE" is shown; indicates the control thinks the fault is present. The control is
defective. Replace the CMS control; see CMS Control Replacement.
* "SERV CODE" is NOT shown; indicates the fault is no longer present. The control is not
causing the fault. The fault is intermittent. The probable cause is poor electrical connection at
the harness connectors or a damaged harness. Check the harness for damage and clean the
harness connectors.
FMI 5F
This fault is recorded when the CMS control reads the current of the action lamp circuit (411-PK) as
below normal (open circuit). The result of this fault condition is that the action lamp does not light.
NOTE: This procedure can create a CID 324 FMI 4F fault. When all harnesses are reconnected, this
fault is shown as not present. Clear the CID 324 FMI 4F fault after this procedure is completed.
1. CHECK LAMP - Ensure that CID 324 FMI 5F is on-hold and that the fault present indicator shows
"SERV CODE". Observe the status of the fault present indicator or listen for the SOUNDING of the
action alarm. At the action lamp, use a jumper to connect wire 411-PK to frame ground.
* "SERV CODE" is NO longer shown or the action alarm SOUNDED; the lamp is open.
Replace the action lamp. (Note: For the purposes of this procedure, the correct resistance for a
lamp is less than 200 Ohms.)
* "SERV CODE" remains shown or the action alarm did NOT SOUND; indicates the fault
remains present. The action lamp is not causing the fault. Go to Step 2.

https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb... 20/02/2015

966F Series II Wheel Loader 1SL00507-UP (MACHINE) POWERED BY 3306 Eng... Pgina 23 de 53

2. CHECK HARNESS - Turn the disconnect switch to the OFF position. From Step 1; remove the
jumper and make sure the action lamp is connected to the machine harness. Disconnect the machine
harness from the CMS control. At the machine harness connector for the CMS control, measure the
resistance between contact 4 (411-PK) and frame ground.
* Resistance is greater than 100 Ohms; harness circuit is open. Go to Step 3.
* Resistance is less than 100 Ohms; harness circuit resistance is correct. Replace the CMS
control.
3. CHECK HARNESS - At the action lamp, disconnect wire 411-PK from the action lamp socket.
Check for an open in circuit 411-PK between contact 4 of the CMS harness connector and the lamp
socket. Also, check for an open in circuit 201-BK between the lamp socket and frame ground. Repair
or replace the harness.

CID 627 Procedure (Parking Brake Pressure Switch)


Service Notes: The connector contacts, which correspond to CID 627, are not shown on the CMS
contact identifier. The actual fault is present in either of the two parking brake pressure circuits.
Ensure that the fault present indicator shows "SERV CODE".
FMI 2F
This fault is recorded when the CMS control reads the parking brake pressure circuits as wrong.
CMS detects the status of the two parking brake pressure circuits. The status is correct, when one
circuit is open and one is grounded. The status is wrong, when both circuits are open or grounded at
the same time. Use status mode for troubleshooting these two switch type inputs; see the Undetected
Faults section.

Undetected Faults

https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb... 20/02/2015

966F Series II Wheel Loader 1SL00507-UP (MACHINE) POWERED BY 3306 Eng... Pgina 24 de 53

https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb... 20/02/2015

966F Series II Wheel Loader 1SL00507-UP (MACHINE) POWERED BY 3306 Eng... Pgina 25 de 53

Status Mode Display


(1) Status change identifier. (2) Open contact identifier. (3) Alert indicators with assigned numbers.

All the topics within this section (Undetected Faults) deal with switch type inputs. CMS does not
detect faults with switch type inputs. However, the diagnostics of status mode (mode 2) assist with
troubleshooting these faults. Status mode shows the open or grounded status of each switch input and
SOUNDS the action alarm when any switch input changes status. These status mode functions are
used extensively in the following procedures. When performing the procedures refer to the Status
Mode Diagnostics chart and the Status Mode Display illustration. For a detailed description of status
mode, see the topic Diagnostic Summary in the Testing And Adjusting section, or the topic Status
Mode (Mode 2) in the Systems Operation section.

Indicator Faults
Indicator faults are any faults that occur with the indicators of the CMS display area. The indicators
reflect the open or grounded status of the corresponding switch type inputs. A fault is when the
operation of an indicator does not correspond to a known machine condition. Indicator faults consist
of alert indicators and lighting indicators. Alert indicators are the indicators within the alert indicator
area on the right side of the CMS display. Lighting indicators (right turn, left turn and high beam) are
located in the center area of the CMS display.
Before troubleshooting, ensure that a fault does exist. For a description of what normal conditions
cause the alert indicators to FLASH and the lighting indicators to illuminate, see the machine
Operation & Maintenance Manual. Perform the following procedures only if a fault is suspected.
NOTE: One alert indicator is often used to indicate an electrical system problem. The alert indicator
for the electrical system gets information from sensor inputs, not switch inputs. See the topic Detected
Faults in the Testing And Adjusting section.
The operator or service person discovers an indicator fault when the operation of an indicator does not
correspond to a known machine condition. For example; the alert indicator for brake oil temperature

https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb... 20/02/2015

966F Series II Wheel Loader 1SL00507-UP (MACHINE) POWERED BY 3306 Eng... Pgina 26 de 53

always FLASHES (even after overnight shutdown of the machine), or the high beam indicator is
never ON (even though the high beam headlamps are on). As observed during normal CMS operation,
the possible fault conditions for the indicators are:
* Alert indicator always FLASHING; see the Alert Indicator Always FLASHING procedure.
* Alert indicator never FLASHES; see the Alert Indicator Never FLASHES procedure.
* Lighting indicator always ON; see the Lighting Indicator Always ON procedure.
* Lighting indicator never ON; see the Lighting Indicator Never ON procedure.
NOTE: While in normal mode (mode 0), it is possible to troubleshoot indicator faults. The indicators
reflect the open or grounded condition of the uncommitted switch inputs and the lighting switch
inputs. When a switch input is open, the corresponding alert indicator FLASHES or the lighting
indicator is ON. When a switch input is grounded, the corresponding alert indicator or lighting
indicator is OFF. Therefore to check a circuit, the service person opens and grounds the
corresponding switch wire while watching for the correct result on the indicators.

Alert Indicator Always Flashing


This procedure is for an alert indicator that is FLASHING all the time. The always FLASHING
condition is most likely caused by an undesired open circuit or a defective CMS control (unlikely).
Procedure
1. Locate the switch which corresponds to the indicator which is always FLASHING. (If necessary,
use the Electrical System Schematic to assist in locating the switch.)
2. Place CMS in status mode (mode 2).
3. CHECK HARNESS - Disconnect the signal wire from the switch. Open and close the circuit
several times by touching the signal wire to the ground wire. (If a ground wire is not present, touch
the signal wire to frame ground.) Listen for the SOUNDING of the action alarm as the circuit is
opened and closed.
* The alarm SOUNDS; the circuit is operating correctly. The switch is defective. Check or
replace the switch.
* The alarm does NOT SOUND; the machine harness is open or the control is defective. Go to
Step 4.
4. CHECK FOR OPEN HARNESS - Turn the disconnect switch to the OFF position. At the machine
harness for the switch, place a jumper from the signal wire to the ground wire. (If a ground wire is not
present, jumper the signal wire to frame ground.)
On the Electrical System Schematic trace the signal wire from the switch to the CMS control.
Determine the signal contact (connector contact) of the machine harness at the CMS control.
Disconnect the machine harness from the CMS control. At the machine harness connector for the
CMS control, check for continuity between the signal contact and contact 2 (ground).
* Resistance is greater than 5 Ohms; the harness is defective. Repair or replace the harness.
* Resistance is less than 5 Ohms; the harness is not causing the fault. The control is defective.
Replace the CMS control; see CMS Control Replacement.

https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb... 20/02/2015

966F Series II Wheel Loader 1SL00507-UP (MACHINE) POWERED BY 3306 Eng... Pgina 27 de 53

Alert Indicator Never Flashes


This procedure is for an alert indicator that never FLASHES. The never FLASHING condition is
most likely caused by a short to ground or a defective CMS control (unlikely).
Procedure
1. CHECK ALERT INDICATOR - Perform the Self Test. Observe the alert indicators for
FLASHING during the Self Test. See Self Test.
* Alert indicator does NOT FLASH; the CMS control is defective. Replace the CMS control;
see CMS Control Replacement.
* Alert indicator FLASHES; the CMS control is not causing the fault. Go to Step 2.
2. Locate the switch which corresponds to the indicator which never FLASHES. (If necessary, use the
Electrical System Schematic to assist in locating the switch.)
3. Place CMS in status mode (mode 2).
4. CHECK SIGNAL WIRE - Disconnect the signal wire from the switch. Open and close the circuit
several times by touching the signal wire to the ground wire. (If a ground wire is not present, touch
the signal wire to frame ground.) Listen for the SOUNDING of the action alarm as the circuit is
opened and closed.
* The alarm SOUNDS; the circuit is operating correctly. The switch is defective. Check or
replace the switch.
* The alarm does NOT SOUND; the circuit is defective. The signal wire is shorted to ground.
Go to Step 5.
5. CHECK FOR OPEN HARNESS - Turn the disconnect switch to the OFF position. The signal wire
remains disconnected from the switch; do not allow it to touch anything.
On the Electrical System Schematic trace the signal wire from the switch to the CMS control.
Determine the signal contact (connector contact) of the machine harness at the CMS control.
Disconnect the machine harness from the CMS control. At the machine harness connector for the
CMS control, check for continuity between the signal contact and contact 2 (ground).
* Resistance is greater than 5 Ohms; the harness is not causing the fault. The control is
defective. Replace the CMS control; see CMS Control Replacement.
* Resistance is less than 5 Ohms; the harness is defective. The signal wire within the harness is
shorted to ground. Repair or replace the harness.

Lighting Indicator Always ON


This procedure is for a lighting indicator (right turn, left turn or high beam) that is ON all the time.
The always ON condition is most likely caused by an undesired open circuit (burned out bulbs) or a
defective CMS control (unlikely).
NOTE: The usual cause for this Always ON condition, is that both bulbs of the circuit are burned out.
Check both related lamps before performing the following procedure. For the turn signal indicators,

https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb... 20/02/2015

966F Series II Wheel Loader 1SL00507-UP (MACHINE) POWERED BY 3306 Eng... Pgina 28 de 53

check both corresponding right or left turn signal lamps. For the high beam indicator, check both high
beam head lamps.
Procedure
1. CHECK LIGHTING CIRCUIT - Check that both lamps (right turn, left turn or high beam) of the
related lighting circuit operate properly. Activate the related circuit (turn on the turn signal switch or
high beam head lamps). Observe the related lamps.
* Lamps illuminate; lighting circuit is not causing the fault. The signal wire within the harness
is open or the CMS control is defective. Go to Step 2.
* Lamps do NOT illuminate; lighting circuit is defective. Check lamps, fuses, switches, and
lighting ground path. Repair the circuit.
If the lighting circuit is fixed and the related lighting indicator remains always ON, Go to Step 2.
2. CHECK FOR OPEN SIGNAL WIRE - Turn the disconnect switch to the OFF position. Disconnect
the machine harness from a related lamp (right turn, left turn or high beam). At this connector place a
jumper from the lighting wire to the ground wire.
The signal wire connects the CMS control to the lighting circuit. The signal contact is the CMS
connector contact that corresponds to the signal wire. The signal contacts are:
High beam signal wire ... signal contact 6
Left turn signal wire ... signal contact 21
Right turn signal wire ... signal contact 22
Disconnect the machine harness from the CMS control. At the machine harness connector for the
CMS control, check for continuity between the signal contact and contact 2 (ground).
* Resistance is greater than 5 Ohms; the harness is defective. Repair or replace the harness.
* Resistance is less than 5 Ohms; the harness is not causing the fault. The control is defective.
Replace the CMS control; see CMS Control Replacement.

Lighting Indicator Never ON


This procedure is for a lighting indicator (right turn, left turn or high beam) that is never ON. The
never ON condition is most likely caused by a short to ground (therefore a blown fuse) or a defective
CMS control (unlikely).
Procedure
1. CHECK LIGHTING CIRCUIT - Check that both lamps (right turn, left turn or high beam) of the
related lighting circuit operate properly. Turn the disconnect and the key start switches to the ON
position. Activate the related circuit (turn on the turn signal switch or high beam head lamps).
Observe the related lamps.

https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb... 20/02/2015

966F Series II Wheel Loader 1SL00507-UP (MACHINE) POWERED BY 3306 Eng... Pgina 29 de 53

* Lamps illuminate and lighting indicator remains OFF; lighting circuit is not causing the fault.
The CMS control is defective. Replace the CMS control; see CMS Control Replacement.
* Lamps do NOT illuminate and lighting indicator remains OFF; lighting circuit is shorted to
ground. Either the harness or the CMS control is defective. Go to Step 2.
2. CHECK FOR SHORT TO GROUND - Turn the disconnect switch to the OFF position. Disconnect
the machine harness from the CMS control. Check the machine harnesses for a short to ground in the
related lighting circuit. (The short to ground causes the fuse or circuit breaker to open.)
Also check the related CMS signal wire. The signal wire connects the CMS control to the lighting
circuit. The signal contact is the CMS connector contact that corresponds to the signal wire. Measure
the resistance between the signal contact and frame ground. The signal contacts are:
High beam signal wire ... signal contact 6
Left turn signal wire ... signal contact 21
Right turn signal wire ... signal contact 22
* Resistance is less than 5000 Ohms; harness is defective. Repair or replace the defective
harness.
* Resistance is greater than 5000 Ohms; harness resistance is correct. The CMS control is
defective. Verify that the CMS control is defective by; seeing if the related lamps on the
machine illuminate correctly with the CMS control disconnected. If so, replace the CMS
control; see CMS Control Replacement.

Display Brightness Fault


There are three different methods used to control the brightness of the CMS display area: automatic
method, display dimmer method and display brightness adjust method. Go to the method that
corresponds to the specific machine.

Automatic Method
On machines with the automatic method, the CMS control automatically controls the brightness
function; there are six brightness levels. A photosensor is located above the alert indicators within the
CMS display area. If the display is too dim, check the display area for something blocking the amount
of light available to the photosensor. Possible causes are: decal inadvertently placed over photosensor,
dirt or mud blocking photosensor.

Display Dimmer Method


On machines with the display dimmer method, the display dimmer switch (SPST) controls the
brightness function. The switch controls the dim input. When the input is grounded the display
brightness cycles; first the brightness decreases in steps to the minimum level, and then increases in
steps to the maximum level. The cycle repeats until the input is opened and then the brightness
remains at that level.

https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb... 20/02/2015

966F Series II Wheel Loader 1SL00507-UP (MACHINE) POWERED BY 3306 Eng... Pgina 30 de 53

If the display brightness continuously changes without activating the switch or does not respond
correctly when the switch is activated, check the dim circuit. To troubleshoot the dim input, use status
mode. The CMS connector contact for the dim input is contact 5. Check for an undesired open or
grounded circuit in the harness wiring or the dimmer switch.
NOTE: On earlier CMS controls (when in status mode): To select the dim input (contact 5), ground
the clear input. Also, contact 5 corresponds to alert indicator No. 12.

Display Brightness Adjust Method


On machines with the display brightness adjust method, the display brightness switch (SPDT)
controls the brightness function. The switch controls the dim input and the brightness input. When the
dim input is grounded the brightness decreases in steps until the input is opened or till the minimum
level is reached. When the brightness input is grounded the brightness increases in steps until the
maximum brightness level is reached or until the input is opened.
If the brightness of the display does not function as described, check the dim circuit and the brightness
circuit. The dim input is at CMS connector contact 5. Determine the CMS connector contact that
correspond to the brightness input, use the Electrical System Schematic in the machine Service
Manual. To troubleshoot use status mode. Check for an undesired open or grounded circuit in the
harness wiring or the display brightness switch.

Gauge Method Fault


If the gauges change back and forth between single-segment and multi-segment methods or if the
wrong method is functioning, check the gauge method input. The multi-segment method functions
when the gauge method circuit is open. The single-segment method functions when the gauge method
circuit is grounded.
To troubleshoot the gauge method input, use status mode. The CMS connector contact for the gauge
method input is contact 19. Check for an undesired open or grounded circuit.
NOTE: On earlier CMS controls (when in status mode): To select the gauge method input (contact
19), open the clear input. Also, contact 19 corresponds to alert indicator No. 12.

Units Fault
If the unit indicators change back and forth between U.S. and metric units of measurement or if the
wrong units are shown, check the units input. U.S. units of measurement (mph) are shown when the
units input is open. Metric units of measurement (km/h) are shown when the units input is grounded.
To troubleshoot the units input, use status mode. The CMS connector contact for the units input is
contact 20. Check for an undesired open or grounded circuit.
NOTE: On earlier CMS controls (when in status mode): To select the units input (contact 20), ground
the clear input. Also, contact 20 corresponds to alert indicator No. 8.

Harness Code Fault

https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb... 20/02/2015

966F Series II Wheel Loader 1SL00507-UP (MACHINE) POWERED BY 3306 Eng... Pgina 31 de 53

https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb... 20/02/2015

966F Series II Wheel Loader 1SL00507-UP (MACHINE) POWERED BY 3306 Eng... Pgina 32 de 53

Status Mode Display


(1) Open contact identifier.

This procedure is only necessary if the CMS control has failed the Self Test. Before performing this
procedure, always perform the Self Test noting the machine code that is shown. Make sure the CMS
control has the correct part No. for the machine it is installed on. If the machine code is not shown
correctly this procedure determines which component is malfunctioning; defective CMS control,
wrong harness code or defective harness.
NOTE: Harness code and machine code are similar terms used to describe the particular machine that
the CMS control is installed on. Harness code is the status (open or ground) of the five harness code
inputs (connector contacts 25 through 29). Machine code is the number that CMS has assigned to a
particular harness code for a particular machine. The machine code is shown during the Self Test.
Each sales model has a specific harness code and therefore also a specific machine code. The specific
machine code is listed in the topic Self Test. The specific harness code is given in the Electrical
System Schematic module.
Status mode diagnostics are used to check the harness code that the CMS control is receiving. The
diagnostics assist in troubleshooting and reduce the continuity checks the service person performs to
"wring out" a harness. The following procedure determines the actual status (open or ground) of each
harness code input. The actual status must agree with the specified status (as listed in the Harness
Code Troubleshooting chart).

Procedure
1. Determine the machine code. The machine code is listed in the topic Self Test. After finding the
machine code, use the Harness Code Troubleshooting chart to find the corresponding specified
harness code.
If the machine code is NOT found (unknown), determine the harness code from the Electrical System
Schematic in the machine Service Manual. Then record the specified open or grounded status into the
row titled "Unknown" in the Harness Code Troubleshooting chart.
Go to Step 2.

https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb... 20/02/2015

966F Series II Wheel Loader 1SL00507-UP (MACHINE) POWERED BY 3306 Eng... Pgina 33 de 53

2. Place CMS in status mode (mode 2). While in status mode, the status of all switch inputs (including
the harness code inputs) is shown on open contact identifier (1). Go to Step 3.
NOTE: On earlier CMS controls, ground the clear contact at the service connector to select the
harness code inputs.
3. Observe open contact identifier (1) for numbers 29, 28, 27, 26 and 25; any number shown is open,
any number NOT shown is grounded. Record the actual open or grounded status into the row titled
"Actual Status" in the Harness Code Troubleshooting chart. Go to Step 4.
4. From the chart, compare the specified status (Step 1) to the actual status (recorded in Step 3).
* Status agrees; the harness code is not causing the fault. Perform a Self Test again to recheck
the CMS control. If the CMS control still fails the self test, replace the control. See CMS
Control Replacement.
* Status does NOT agree; there is a defect in the harness code circuits that do not agree. Go to
Step 5.
5. CHECK FAULTY HARNESS CODE CIRCUITS - The remaining Steps make use of the
information obtained in Step 4 and recorded on the Harness Code Troubleshooting chart. The chart
identifies the connector contacts and wire identification of the harness code circuits. Further testing is
only necessary on the faulty harness code circuits.
* For contacts that are actually grounded but are specified open, there is a short to ground in the
corresponding harness code circuit. Go to Step 6.
* For contacts that are actually open but are specified grounded, there is an OPEN in the
corresponding harness code circuit. Go to Step 7.
6. CHECK FOR SHORTS - (For harness code circuits with corresponding contacts that are actually
grounded but are specified open). Turn the disconnect to the OFF position. Disconnect the machine
harness from the CMS control. At the machine harness connector for the CMS control, measure the
resistance between the corresponding faulty connector contact (25 through 29) and contact 2 (ground).
* Resistance is greater than 5000 Ohms; the harness code circuit is not shorted to ground. No
defect was found in the harness code circuits. Reconnect the harness connectors. Perform a Self
Test again to recheck the CMS control. If the CMS control still fails the self test, replace the
control. See CMS Control Replacement.
* Resistance is less than 5000 Ohms; the harness code circuit is shorted to ground in the
machine harness. Check the harness code plug on so equipped machines. Repair the shorted
harness code circuits or replace the harness.
7. CHECK FOR OPENS - (For harness code circuits with corresponding contacts that are actually
open but are specified grounded). Turn the disconnect to the OFF position. Disconnect the machine
harness from the CMS control. At the machine harness connector for the CMS control, check for
continuity between the corresponding faulty connector contact (25 through 29) and contact 2
(ground).
* Resistance is less than 5 Ohms; the harness code circuit is not open. No defect was found in
the harness code circuits. Reconnect the harness connectors. Perform a Self Test again to

https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb... 20/02/2015

966F Series II Wheel Loader 1SL00507-UP (MACHINE) POWERED BY 3306 Eng... Pgina 34 de 53

recheck the CMS control. If the CMS control still fails the self test, replace the control. See
CMS Control Replacement.
* Resistance is greater than 5 Ohms; the harness code circuit is open. Check the harness code
plug on so equipped machines. Repair the open harness code circuits or replace the harness.

Electrical System Tests


When an electrical system problem is present, the alert indicator for the electrical system FLASHES.
These tests apply to warning category 1 or 3 problems. For a description of the warning indications
for an electrical system problem, see the topic Warning Operation in the Systems Operation section.
One of the following conditions cause the electrical system problem:
* The speed of the alternator is low; alternator "R" terminal frequency is less than 90 Hz. The
probable cause is a slipping belt or an internal alternator malfunction.
* System voltage (+battery) is too low. The probable cause is an excessive electrical load
(especially at low idle), alternator malfunction or defective batteries.
* System voltage (+battery) is too high. The probable cause is a defective alternator.
When engine speed is low, the operation of large electrical loads (such as air conditioning and/or
lighting) places a great demand on the charging system. If operating under these conditions, increase
the engine speed to high idle to generate more output from the alternator and then check the alert
indicator.
* If the alert indicator turns OFF within about one minute, the charging system is probably
overloaded while at low engine speed. To correct the problem, change the machine operation by
increasing the engine speed and/or decreasing the electrical load (use medium or low fan speed
instead of high).
* If the alert indicator remains FLASHING, there is a malfunction that requires service.
Perform the Electrical System Troubleshooting procedures.

Electrical System Troubleshooting


Procedure
1. VISUAL CHECK - Check the alternator belt pulley and the belt tension.
* Pulley nut torque and belt tension are proper; go to Step 2.
* Pulley and belt are NOT proper; fix or adjust.
2. CHECK BATTERY VOLTAGE - Measure the battery voltage at the battery posts.
* Voltage is between 24.8 and 29.5 DCV; battery voltage is correct. Go to Step 3.
* Voltage is NOT between 24.8 and 29.5 DCV; there is a defect in the electrical system. Check
the charging system, go to Charging System Test.
3. CHECK SYSTEM VOLTAGE HARNESS CIRCUIT - Turn the key start switch to the OFF
position. Disconnect the machine harness from the CMS control. Start the engine and run at high idle.

https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb... 20/02/2015

966F Series II Wheel Loader 1SL00507-UP (MACHINE) POWERED BY 3306 Eng... Pgina 35 de 53

At the machine harness connector for the CMS control, measure the voltage between contact 7
(system voltage circuit) and contact 2 (ground).
* Voltage is between 24.8 and 29.5 DCV; system voltage is correct. Go to Step 4.
* Voltage is NOT between 24.8 and 29.5 DCV; there is a defect in the harness. Repair or
replace the harness.
4. CHECK "R" TERMINAL HARNESS CIRCUIT - Start the engine and run at high idle. At the
harness connector, measure the voltage between contact 12 (alternator "R" terminal circuit) and
contact 2 (ground).
* Voltage is between 12.4 and 14.75 DCV; the "R" terminal voltage is correct. Replace the
CMS control; see CMS Control Replacement.
* Voltage is NOT between 12.4 and 14.75 DCV; there is a defect in the harness. Repair or
replace the harness.

Charging System Test

Procedure
1. Put the multimeter positive (+) lead on the Bat terminal of the alternator. Put the negative (-) lead
on the ground terminal or the frame of the alternator. Put the clamp-on ammeter around the positive
output wire of the alternator.
2. Turn off all electrical accessories. With the fuel off, crank the engine for 30 seconds. Wait two
minutes to let the starting motor cool. If it is believed that the batteries are fully charged, crank the
engine again for 30 seconds.

https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb... 20/02/2015

966F Series II Wheel Loader 1SL00507-UP (MACHINE) POWERED BY 3306 Eng... Pgina 36 de 53

NOTE: Cranking the engine for 30 seconds partially discharges the battery in order to do a charging
test. If the battery is already low in charge, skip this step. Jump-start engine or charge as required.
3. Start the engine and run at full throttle.
4. Immediately check output current. For correct operation, this initial charging current is equal to or
slightly greater than the full output current shown below:
5S9088 Alternator ... 50A
8N0999 Alternator ... 75A
5. For correct operation, within approximately 10 minutes at full throttle (possibly longer depending
upon battery size, condition and alternator rating), the alternator output voltage is 26.5 to 29.0 DCV.
See the Fault Conditions And Possible Causes chart.
6. The charging current during this period should taper off to less than approximately 10 amps with
accessories turned OFF, depending again upon battery and alternator capacities. See the Fault
Conditions And Possible Causes chart.
7. Turn on all electrical accessories. The alternator must maintain 26.5 to 29.0 DCV. The ammeter
shows total charging current.

Speed Sensor Test

Portion Of CMS Control - From Machine Schematic

NOTE: More than one speed sensor exists for the different applications of CMS. One sensor has a
nominal resistance of 150 Ohms and the other has a nominal resistance of 500 Ohms.
The following procedure is useful if the speed indication on the speed gauge or speed readout is
faulty. For example; the speed shown is 0 RPM when the engine is running or shows 0 MPH when the
machine is moving.
To use the procedure it is necessary to know the CMS connector contact that corresponds to the fault.
The engine RPM and ground MPH (km/h) inputs are frequency type sensor inputs. CMS connector
contacts 10 and 11 are the frequency sensor inputs. Use the Electrical System Schematic in the
machine Service Manual to determine the CMS connector contact that corresponds to engine RPM

https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb... 20/02/2015

966F Series II Wheel Loader 1SL00507-UP (MACHINE) POWERED BY 3306 Eng... Pgina 37 de 53

and ground MPH (km/h). For example according to the above illustration; engine speed (ENG RPM)
corresponds to connector contact 11, ground speed (XMSN RPM) corresponds to connector contact
10.
NOTE: The diagnostics of the CMS do not detect faults in the speed circuits (frequency sensor).
Procedure

Speed Sensor

1. CHECK SENSOR RESISTANCE - Turn the disconnect switch to the OFF position. Disconnect the
machine harness from the sensor. At the machine harness connector, for the sensor, measure the
resistance between the two contacts.
* Resistance is NOT between 100 and 600 Ohms; the speed sensor is defective. Replace the
sensor. Adjust the speed sensor properly when installing it. See Speed Sensor Adjustment.
* Resistance is between 100 and 600 Ohms; the speed sensor resistance is correct. Go to Step 2.
2. CHECK SENSOR VOLTAGE - Reconnect the sensor to the machine harness. Disconnect the
machine harness from the CMS control. Start the engine and run at low idle. At the machine harness
connector, for the CMS control, measure the voltage (ACV) between contact 2 (ground) and contact
10 or 11.
* Voltage is greater than 3.0 ACV; the speed sensor voltage is correct. Replace the CMS
control; see CMS Control Replacement.
* Voltage is less than 3.0 ACV; the speed sensor voltage is NOT correct. Go to Step 3.
3. CHECK SENSOR ADJUSTMENT - Check the speed sensor adjustment, see Speed Sensor
Adjustment. Perform Step 2 again.
* Voltage remains less than 3.0 ACV; there is a defect. Go to Step 4.
* Voltage is now greater than 3.0 ACV. Problem is NOT present; adjustment of the speed
sensor corrected the problem.
4. CHECK HARNESS - Connect the sensor to the machine harness. The CMS control remains
disconnected from the machine harness. At the machine harness connector, for the CMS control,
measure the resistance between contact 2 (ground) and contact 10 or 11.

https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb... 20/02/2015

966F Series II Wheel Loader 1SL00507-UP (MACHINE) POWERED BY 3306 Eng... Pgina 38 de 53

* Resistance is between 100 and 600 Ohms; the machine harness resistance is correct. Replace
the sensor. Adjust the speed sensor properly when installing it. See Speed Sensor Adjustment.
* Resistance is NOT between 100 and 600 Ohms; the machine harness is shorted or open.
Repair or replace the harness.

Speed Sensor Adjustment

Speed Sensor
(1) Air gap. (2) Locknut.

1. Remove the speed sensor. Align a gear tooth directly in the center of the threaded sensor opening.
2. By hand, screw the sensor into the hole until the end of the sensor just makes contact with the gear
tooth.
3. Turn the sensor back out 1/2 turn (180 in the counterclockwise direction). This sets air gap (1) to
0.89 mm (.035 in).
4. Tighten locknut (2) to 13 1 Nm (115 9 lb in).
NOTE: Do not allow the sensor to turn as locknut (2) is tightened.

PWM Sensor Tests


https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb... 20/02/2015

966F Series II Wheel Loader 1SL00507-UP (MACHINE) POWERED BY 3306 Eng... Pgina 39 de 53

NOTE: In addition to these tests, CMS diagnostics are helpful when troubleshooting sensors.
Numeric readout mode diagnostics show a numeric value of the information from each sensor input.
For a detailed explanation, see the topic Numeric Readout Mode (Mode 4) in the Systems Operation
section.
Troubleshoot sensor circuits in the following order.
1. Perform Sensor Voltage Test. The test checks sensor voltages at the sensor with all circuits
connected. DISCONNECT NOTHING. Troubleshoot "as is" before disconnecting any circuits.
Disconnecting first may alter a poor connection and make proof-of-cause difficult or impossible.
2. Perform Sensor Dynamic Test.
3. If sensor and harness check correctly, the CMS control is likely defective. Replace the CMS
control, see CMS Control Replacement.
To identify sensor wires and connector contacts, refer to the following Sensor Wire And contact
Identification section. Otherwise proceed to Sensor Voltage Test

Sensor Wire And Contact Identification

Typical PWM Sensor - Schematic Symbol

When testing a sensor, it is necessary to identify the connector contacts and the harness wires. The
Electrical System Schematic shows the connector contact No.'s which correspond to the wire
numbers. See the Electrical System Schematic in the machine Service Manual.
On all machines, the wire numbers and connector contacts are identified by these general rules:
* The +V wire number (power) is between 100 and 199. The +V contact corresponds to this
wire number.

https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb... 20/02/2015

966F Series II Wheel Loader 1SL00507-UP (MACHINE) POWERED BY 3306 Eng... Pgina 40 de 53

* The ground wire number is between 200 and 299. The ground contact corresponds to this
wire number.
* The signal wire number is between 400 and 499. The signal contact corresponds to this wire
number.
For example, in the above Typical PWM Sensor illustration:
The +V wire is wire number 113.
The +V contact is contact A.
The ground wire is wire number 201.
The ground contact is contact B.
The signal wire is wire number 443.
The signal contact is contact C.

Sensor Voltage Test (CMS Control Connected)

https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb... 20/02/2015

966F Series II Wheel Loader 1SL00507-UP (MACHINE) POWERED BY 3306 Eng... Pgina 41 de 53

Procedure
Locate the suspect sensor. Identify the sensor wires and connector contacts; see Sensor Wire And
Contact Identification. DO NOT DISCONNECT ANY HARNESS CONNECTORS AT THIS TIME.

https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb... 20/02/2015

966F Series II Wheel Loader 1SL00507-UP (MACHINE) POWERED BY 3306 Eng... Pgina 42 de 53

Turn the key start switch to the ON position. DO NOT START THE ENGINE. Use the 7X1710
Cable Probe (Spoons) to make voltage measurements by probing through the back of the harness
connectors.
1. CHECK SYSTEM VOLTAGE - Between the sensor and the sensor connector, identify the +V and
ground circuits. Use the 7X1710 Cable Probe (Spoons), measure the system voltage between the +V
and ground wires.
* Voltage is between 24.0 and 29.5 DCV; system voltage is present. Go to Step 2.
* Voltage is NOT between 24.0 and 29.5 DCV; there is an open circuit. Trace the +V and
ground circuits in the machine harness. Repair or replace the harness.
2. CHECK SIGNAL VOLTAGE - Between the sensor and the sensor connector, identify the signal
and ground circuits. Use the 7X1710 Cable Probe (Spoons), measure and record the signal voltage
between the signal and ground wires.
NOTE: If more precise signal voltage specifications are necessary, use the specifications listed in the
Sensor Voltage Specifications at the beginning of this test.
* Voltage is between approximately 1.0 and 7.0 DCV; signal voltage at the sensor is correct.
Go to Step 3.
* Voltage is NOT between approximately 1.0 and 7.0 DCV; signal voltage is not correct.
If voltage is greater than 7.0 DCV, Go to Step 4.
If voltage is less than 1.0 DCV, Go to Step 5.
3. CHECK MACHINE HARNESS SIGNAL CIRCUIT - At the machine harness for the CMS
control, identify the signal and ground circuits. DO NOT DISCONNECT THE HARNESS
CONNECTOR. Use the 7X1710 Cable Probe (Spoons), measure and record the signal voltage
between the signal and ground wires. Compare this measurement with the voltage measured in Step 2.
* Voltage is the same as in Step 2; the CMS is receiving a valid signal voltage. If the problem
still persists, further testing is required; see Sensor Dynamic Test.
* Voltage is NOT the same as in Step 2; the machine harness has an open in the signal or
ground circuits. Repair or replace the machine harness.
4. CHECK MACHINE HARNESS - Signal voltage is greater than 7.0 DCV. The probable cause is a
short to system voltage (+battery) in the machine harness or the sensor is defective. Disconnect the
machine harness from the sensor. At the machine harness connector for the sensor, measure the
voltage between the signal contact and the ground contact.
* Voltage is greater than 5.0 0.5 DCV; the voltage is not correct. The signal circuit of the
machine harness is shorted to +battery. Repair or replace the machine harness. If the machine
harness is not defective, replace the CMS control.
* Voltage is 5.0 0.5 DCV; the voltage is correct for a good harness. The sensor is defective.
Replace the sensor.
NOTE: Fuel level sensors consist of a buffer and a sender. Before replacing either, check the sender.
See Fuel Level Sender Check.

https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb... 20/02/2015

966F Series II Wheel Loader 1SL00507-UP (MACHINE) POWERED BY 3306 Eng... Pgina 43 de 53

5. CHECK MACHINE HARNESS - Signal voltage is less than approximately 1.0 DCV. The
probable cause is a short to ground in the machine harness or the sensor is defective. Disconnect the
machine harness from the sensor. At the machine harness connector for the sensor, measure the
voltage between the signal contact and the ground contact.
* Voltage is less than 5.0 0.5 DCV; the voltage is not correct. The signal circuit of the
machine harness is shorted to ground. Repair or replace the machine harness. If the machine
harness is not defective, replace the CMS control.
* Voltage is 5.0 0.5 DCV; the voltage is correct for a good harness and CMS control. The
sensor is defective. Replace the sensor.
NOTE: Fuel level sensors consist of a buffer and a sender. Before replacing either, check the sender.
See Fuel Level Sender Check.

Sensor Dynamic Test (CMS Control Disconnected)

https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb... 20/02/2015

966F Series II Wheel Loader 1SL00507-UP (MACHINE) POWERED BY 3306 Eng... Pgina 44 de 53

https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb... 20/02/2015

966F Series II Wheel Loader 1SL00507-UP (MACHINE) POWERED BY 3306 Eng... Pgina 45 de 53

Portion Of CMS Control - From Machine Schematic

This test is a quick check to determine if the sensor is functioning. It does not check the accuracy of
the sensor. Perform this test only after successfully completing the Sensor Voltage Test.
To use the following procedure it is necessary to know the CMS connector contact that corresponds to
the fault. The CMS connector contacts that correspond to the PWM sensors are: 13, 15, 16, 17 and 18.
Use the Electrical System Schematic in the machine Service Manual to determine the CMS connector
contact that corresponds to the machine condition under test (engine coolant temperature, brake air
pressure etc.). For example according to the above illustration; brake air pressure corresponds to
connector contact 14 and hydraulic oil temperature corresponds to connector contact 15.
NOTE: The sensors are provided power directly from system voltage, not from the CMS control.
Therefore the sensors function even if the CMS control is disconnected.
Two items are checked in this test:
* That a sensor signal is present at the CMS control.
* That the signal voltage increases/decreases with a corresponding increase/decrease in the
system being monitored.

Procedure
The required machine conditions are:
* For temperature sensors, the coolant is below operating temperature.
* For pressure sensors, the pressure is below operating pressure.
* For fuel level sensors (buffer and sender), the fuel level is low.
1. SETUP - Ensure that the key start switch is OFF and the sensor is connected to the machine
harness. Disconnect the machine harness from the CMS control. Turn the key start switch to the ON
position. DO NOT START THE ENGINE.
NOTE: For fuel level sensors, the buffer remains connected to the sender.
2. CHECK SIGNAL VOLTAGE - At the machine harness connector for the CMS, measure and
record the voltage (DCV) between the signal and ground contacts. For correct operation, the
approximate voltage is between 2.0 and 9.4 DCV.

https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb... 20/02/2015

966F Series II Wheel Loader 1SL00507-UP (MACHINE) POWERED BY 3306 Eng... Pgina 46 de 53

NOTE: If more precise signal voltage specifications are necessary, use the specifications listed in the
Sensor Voltage Specifications chart at the beginning of this test.
* Voltage is between approximately 2.0 and 9.4 DCV; signal voltage to CMS control is correct.
Go to Step 4.
* Voltage is NOT between approximately 2.0 and 9.4 DCV; signal voltage to CMS control is
not correct. The probable cause is a defective sensor. Replace the sensor.
NOTE: Fuel level sensors consist of a buffer and a sender. Before replacing either, check the sender.
See Fuel Level Sender Check.
3. CHANGE THE RELATED MACHINE CONDITION - Increase the temperature, pressure or fuel
level of the system being tested. For example: run the engine to increase the engine coolant
temperature, operate the implement controls to increase the hydraulic oil temperature, or add fuel to
increase the fuel level. Go to Step 4.
4. CHECK SIGNAL VOLTAGE - At the machine harness connector for the CMS control, measure
the voltage (DCV) between the signal and ground contacts. For correct operation, the voltage (DCV)
is greater (and increases smoothly without step increases) than the voltage recorded in Step 2.
NOTE: The larger the change in the system being monitored (in Step 3), the greater the difference
between Step 2 and Step 4 voltages.
* Voltage is greater and operates smoothly; the sensor is not defective.
* Voltage is NOT greater; the probable cause is a defective sensor. Replace the sensor.
NOTE: Fuel level sensors consist of a buffer and a sender. Before replacing either, check the sender.
See Fuel Level Sender Check.

Fuel Level Sender Check


Fuel level sensing consists of a buffer and a sender. Before replacing either, check the fuel level
sender. The fuel level sender is located on the fuel tank.

Procedure
NOTE: This procedure covers the different fuel level senders that are used with CMS.
Disconnect the sender harness from the buffer harness. Measure the resistance between the two
contacts of the sender connector. The correct approximate resistance is:
Empty tank ... 66 to 95 Ohms
Half tank ... 33 to 48 Ohms
Full Tank ... 0.5 to 1.0 Ohms
If desired, check the sender further by removing the sender. Actuate the sender by hand while
measuring the resistance. The resistance should change (similar to above) as the sender is actuated
through the empty to full range.

https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb... 20/02/2015

966F Series II Wheel Loader 1SL00507-UP (MACHINE) POWERED BY 3306 Eng... Pgina 47 de 53

Self Test

CMS Display Area - Typical Example


(1) Gauge area. (2) Speed gauge. (3) Left turn signal indicator. (4) High beam indicator. (5) Digital readout area. (6)
Retarder indicator. (7) Right turn signal indicator. (8) Alert indicator area. (9) Photosensor. (10) Gauges. (11) Gear
readout. (12) CAT logo. (13) Service code indicator. (14) Speed readout. (15) Unit indicators. (16) Alert indicators.

The self test verifies that the CMS control is operating properly. The CMS control performs an
automatic self test each time the key start switch is turned from the OFF to the ON position.
The internal circuits and the outputs (display, action lamp and action alarm) are automatically
checked. The operator must observe the outputs to determine whether or not the CMS control is
operating properly. The length of time for a self test is approximately seven seconds.
NOTE: Only the functions of the CMS display area that are used on a particular machine are tested;
see the corresponding Operation & Maintenance Manual.
During the self test:
* All alert indicators (16) FLASH.
* Speed gauge (2) and gauges (10) ramp from left to right (low range to high range) and back
again. Gauges that are not used, do not illuminate.
* Speed readout (14) shows the following in sequence:
1. A two digit machine code. The machine code must match the machine sales model.
See the Machine Code chart. The machine code is a two digit representation of the
harness code.
2. A two digit software version. This number identifies the software which is used within
the CMS control.
3. "8880". This tests all segments of speed readout (14).
* Gear readout (11) shows "18R" (only on machines equipped with an electronic transmission
control).
* The action lamp is ON CONTINUOUSLY.

https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb... 20/02/2015

966F Series II Wheel Loader 1SL00507-UP (MACHINE) POWERED BY 3306 Eng... Pgina 48 de 53

* The action alarm SOUNDS once.


* On machines so equipped, these indicators are ON CONTINUOUSLY: right turn, left turn,
high beam and retarder.
The CMS control then goes into normal mode of operation (or scrolls the modes if the service and
clear inputs are grounded).
If the CMS control operates as described; the control is operating properly. If the CMS control does
not operate as described; there is a harness code problem or the control is defective. Check the harness
code, see the topic Harness Code Fault in the Undetected Fault section.

NOTE: The CMS Machine Codes chart has been updated to include additional sales models.

https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb... 20/02/2015

966F Series II Wheel Loader 1SL00507-UP (MACHINE) POWERED BY 3306 Eng... Pgina 49 de 53

CMS Control Replacement


Prior to replacement of the CMS control, ensure that replacement is absolutely necessary. Rarely is
the CMS control the cause of a fault. Always check that power is available to the CMS control;
battery voltage is required between CMS connector contacts 1 and 2 of the machine harness.
Procedure
1. Turn the key start switch to the OFF position. Disconnect the machine harness from the CMS
control.
2. Remove the CMS control from the dash. (There are four internally threaded bosses on the rear used
for mounting.)
3. Make sure the replacement control has the correct part number.
4. Install the replacement CMS control.
NOTE: If the replacement CMS control was previously removed from service, see the topic
Initialization.
5. Connect the machine harness to the CMS control. On so equipped machines, make sure the harness
code plug is installed.
6. Turn the disconnect and key start switches to the ON position. Make sure the CMS control
successfully completes the self test; see Self Test.

Initialization
Initialization is an internal process within the CMS control. During initialization, the CMS control
listens to the CAT data link and the harness code inputs. From this information, the CMS control
learns about the machine it is installed on. Things such as: engine oil pressure is coming from an
electronic engine control or that actual gear information is coming from an electronic transmission
control.
Normally initialization occurs when the CMS control is replaced (the harness code changes).
However, when a previously used CMS control is used as a replacement, initialization is possibly
necessary. Unexplainable faults with the CAT data link can occur if the CMS control is not initialized
correctly. The service person must activate the initialization process when the following condition
exists or is suspected. The condition is:
The CMS control to be installed was taken out of service from an application that had the same
machine code as the CMS control to be removed.
If this condition exists or is suspected, then perform the Initialization Procedure.

Initialization Procedure

https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb... 20/02/2015

966F Series II Wheel Loader 1SL00507-UP (MACHINE) POWERED BY 3306 Eng... Pgina 50 de 53

This procedure causes the initialization process to occur on any CMS control. Initialization basically
requires that the CMS control be powered up with a harness code that is different than the harness
code when it was last powered down.
1. Turn the key start switch to the OFF position. Determine whether the harness code inputs are hard
wired in the machine harness or accessible at a harness code plug; use the Electrical System
Schematic in the machine Service Manual.
* There is a harness code plug. Remove the harness code plug. Go to Step 4.
* The harness code inputs are hard wired in the machine harness. Go to Step 2.
2. Disconnect the machine harness from the CMS control. At the machine harness connector, for the
CMS control, remove one of the following contacts which is grounded. Grounded connector contact
to be removed: No. 25, 26, 27, 28 or 29. The connector contact that is removed must be connected to
a ground wire in the machine harness.
3. With tape, secure the removed connector contact out of the way. Reconnect the machine harness to
the CMS control.
4. Turn the disconnect and key start switches to the ON position.
5. Various indicators in the CMS display area illuminate. Wait 10 seconds.
6. Turn the key start switch to the OFF position. Depending on the previous procedure performed
either reinstall the harness code plug (from Step 1) or reinstall the grounded connector contact (from
Step 2).
7. Make sure the CMS control successfully completes the self test; see, Self Test.

Glossary Of CMS Terms


+Battery
+Battery refers 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.
+V
+V is a constant voltage that is supplied to a component to provide electrical power for its
operation. +V is provided by an electronic control module or the battery.
Abnormal
Abnormal refers to a machine condition or signal that is not normal. The presence of an
abnormal condition or signal means a problem exists and warning operation is activated which
notifies the operator.
Alert Indicator
An alert indicator is an indicator on the right side of the CMS display area which flashes red
when a problem exists. The associated pictograph symbol identifies the abnormal machine
system.
CID (Component Identifier)
The CID is a diagnostic code that tells which component or system is faulty. For example;
transmission oil temperature, speed sensor, action lamp or engine boost pressure. The CID is a
three digit code that is located in the digital readout area when in service mode.

https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb... 20/02/2015

966F Series II Wheel Loader 1SL00507-UP (MACHINE) POWERED BY 3306 Eng... Pgina 51 de 53

Clear
Clear refers to removing diagnostic information from the memory of the CMS control. Before
clearing information, it is necessary that the information is on-hold.
Connector Contact
A connector contact is the component of a harness connector that actually makes the electrical
connection. Connector contacts are either pins or sockets.
Detected Fault
A detected fault is a fault that has been found by CMS. The fault is recorded and diagnostic
information is available when in service mode.
Diagnostic
Diagnostic refers to the showing, monitoring and/or recording of information other than normal.
Diagnostic information is available from service, status, tattletale or numeric readout mode.
Display
Display refers to the gauges, indicators or readouts within the CMS display area.
Fault
A fault is a failure of a component of the system. For example; open or shorted harness,
defective switch, sensor or control.
Floating
The status or the state of a control input that is not connected to a positive source or ground.
FMI (Failure Mode Identifier)
The FMI is a diagnostic code that tells what type of failure has occurred. For example; voltage
above normal, current below normal or abnormal frequency. The FMI is a one or two digit code
followed with the letter "F" that is located in the digital readout area when in service mode.
Hard Wired
Hard wired refers to electrical connections made within the harness that are permanent. These
soldered or crimped connections are not meant to be altered.
Harness Code
Harness code refers to the grounded or open condition of the five harness code inputs
(connector contacts 25 through 29). The harness code tells the CMS control the characteristics
of the machine it is installed on, such as: engine size, idle speed, tire size and attachments. The
CMS control operates on different machines, but it must know the characteristics of the
machine it is installed on.
Hold or On-Hold
Hold or On-hold refers to holding (or locking) a set of diagnostic information that is shown in
the digital display area when in service mode or numeric readout mode. It is necessary to hold
the set of diagnostic information before troubleshooting or clearing.
Indicator
An indicator is any of the items within the CMS display area which operate in an ON,
FLASHING or OFF manner to bring attention to a machine condition.
Indicator Fault
An indicator fault is when the operation of an indicator does not correspond to a known
machine condition.
Jumper
A jumper is a piece of wire used to make an electrical connection during troubleshooting.
Lamp
Lamp refers to a component of the machine lighting system.
Lighting Indicator
The lighting indicators are in the CMS display area and reflect the status of the right turn lamps,
left turn lamps and high beam lamps.

https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb... 20/02/2015

966F Series II Wheel Loader 1SL00507-UP (MACHINE) POWERED BY 3306 Eng... Pgina 52 de 53

MID (Module Identifier)


The MID is a diagnostic code that tells which electronic control module diagnosed the fault. For
example; CMS, engine control module or transmission control module. The MID is a two digit
code that is located in the digital readout area when in service mode.
Problem
Problem refers to the presence of an abnormal machine condition. For example; low engine oil
pressure or high hydraulic oil temperature. When a problem exists, warning operation is
activated and CMS notifies the operator.
PWM (Pulse Width Modulated)
A PWM signal is a signal in which the duty cycle (time on verses time off) varies according to
the machine conditions that are monitored. The frequency of a PWM signal is constant. The
CMS has sensors which provide a PWM signal to the CMS control.
Scroll
Scrolling is the process of showing (within the digital display area) all available sets of
diagnostic information, one set at a time. A set of diagnostic information is shown briefly and
then the display automatically advances to the next set. After all sets are shown the sets are
repeated.
Show
Show refers to information within the CMS display area that is viewed by the operator or
service person.
Signal Wire
The signal wire is the harness wire which connects the sensor or switch to the CMS control.
Switch Input
A switch input is any input of the CMS control which is expecting only a open (floating) or
grounded signal.
System Voltage
System voltage is the actual voltage that exists between the positive battery post and frame
ground. System voltage is also referred to as +battery voltage.
Uncommitted Switch Input
Uncommitted switch inputs are switch inputs whose function varies according to the
application. Information from the uncommitted switch inputs is typically used to operate the
alert indicators.
Undetected Fault
An undetected fault is a fault that exists and is not found by CMS but is found by the operator
or service person. The many diagnostic functions of CMS assist with the troubleshooting of
undetected faults.
Machine Code
The machine code is a two digit number that CMS has assigned to a particular harness code for
a particular machine. The machine code is shown on the speed readout during the Self Test.
Each sales model has a specific harness code and therefore also a specific machine code. The
correct machine code is given in the Operations And Maintenance manual.
VFD (Vacuum Fluorescent Displays)
VFD is the type of illumination used on all elements of the CMS display area except the alert
indicators.
Wring Out
Wring out refers to checking the continuity of a harness.

Typical CMS Schematic


https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb... 20/02/2015

966F Series II Wheel Loader 1SL00507-UP (MACHINE) POWERED BY 3306 Eng... Pgina 53 de 53

NOTE: This is a typical CMS system schematic, showing all possible inputs. On some machines,
certain sensors are not part of CMS. However, CMS receives the sensor information over the CAT
data link from an electronic control. For example; an electronic engine control sends engine speed
information to the CMS control over the CAT data link. In this situation, the engine speed sensor is
not part of CMS. For an accurate schematic of a particular machine, always see the Electrical System
Schematic module in the machine Service Manual.

Copyright 1993 - 2015 Caterpillar Inc.

Fri Feb 20 11:06:17 UTC-0430 2015

Todos los derechos reservados.


Red privada para licenciados del SIS.

https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb... 20/02/2015