RENR5740-05

November 2003

Systems Operation
Troubleshooting
Testing and Adjusting
120H, 12H, 135H, 140H, 143H, 14H,
160H, 163H and 16H Motor Graders
Caterpillar Monitoring System
1241-Up (Machine)
1251-Up (Machine)
1261-Up (Machine)
CCA1-Up (Machine)
CBC1-Up (Machine)
ASD1-Up (Machine)
ASE1-Up (Machine)
CAF1-Up (Machine)
CBK1-Up (Machine)
ARL1-Up (Machine)
APM1-Up (Machine)
APN1-Up (Machine)
CCP1-Up (Machine)
ATS1-Up (Machine)
AMX1-Up (Machine)
ALZ1-Up (Machine)
AMZ1-Up (Machine)
 i01658146

Important Safety Information

Most accidents that involve product operation, maintenance and repair are caused by failure to observe
basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous
situations before an accident occurs. A person must be alert to potential hazards. This person should also
have the necessary training, skills and tools to perform these functions properly.
Improper operation, lubrication, maintenance or repair of this product can be dangerous and
could result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have
read and understood the operation, lubrication, maintenance and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings
are not heeded, bodily injury or death could occur to you or to other persons.
The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as
“DANGER”, “WARNING” or “CAUTION”. The Safety Alert “WARNING” label is shown below.

The meaning of this safety alert symbol is as follows:

Attention! Become Alert! Your Safety is Involved.
The message that appears under the warning explains the hazard and can be either written or pictorially
presented.
Operations that may cause product damage are identified by “NOTICE” labels on the product and in
this publication.
Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard.
The warnings in this publication and on the product are, therefore, not all inclusive. If a tool,
procedure, work method or operating technique that is not specifically recommended by Caterpillar
is used, you must satisfy yourself that it is safe for you and for others. You should also ensure that
the product will not be damaged or be made unsafe by the operation, lubrication, maintenance or
repair procedures that you choose.
The information, specifications, and illustrations in this publication are on the basis of information that
was available at the time that the publication was written. The specifications, torques, pressures,
measurements, adjustments, illustrations, and other items can change at any time. These changes can
affect the service that is given to the product. Obtain the complete and most current information before you
start any job. Caterpillar dealers have the most current information available.

When replacement parts are required for this

product Caterpillar recommends using Caterpil-
lar replacement parts or parts with equivalent
specifications including, but not limited to, phys-
ical dimensions, type, strength and material.

Failure to heed this warning can lead to prema-

ture failures, product damage, personal injury or
death.
 3
Table of Contents

Table of Contents MID 030 - CID 0601 - FMI 08

MID 030 - CID 0615 - FMI 03
...............................
...............................
62
62
MID 030 - CID 0615 - FMI 04 ............................... 64
MID 030 - CID 0819 - FMI 02 ............................... 65
Systems Operation Section MID 030 - CID 0821 - FMI 03 ............................... 68
MID 030 - CID 0821 - FMI 04 ............................... 69
General Information ................................................ 4
Modes of Operation ................................................ 8
Diagnostic System Procedures
Normal Mode .......................................................... 9
Alert Indicator Is Always Flashing ......................... 71
Service Meter Mode .............................................. 10
Alert Indicator Never Flashes ............................... 72
Odometer Mode ..................................................... 11
Harness Code ....................................................... 73
Tachometer Mode .................................................. 11
Pulse Width Modulated Sensor ............................ 76
Scrolling Mode ....................................................... 11
Sensor Signal Voltage .......................................... 77
Harness Code Mode ............................................. 12
Sensor Dynamic Operation ................................... 79
Numeric Readout Mode ........................................ 12
Fuel Level Sender ................................................. 81
Additional Operator Modes ................................... 13
Switch Circuits ...................................................... 82
Service Mode ........................................................ 14
Switch Circuits ...................................................... 83
Tattletale Mode ..................................................... 16
Charging System .................................................. 85
Units Mode ............................................................ 18
Setup Mode .......................................................... 18
Calibration Mode ................................................... 18 Testing and Adjusting Section
Articulation Gauge Calibration Mode .................... 22
Warning Operation ................................................ 24 Testing and Adjusting
Alert Indicator Description ..................................... 25 System Self Test ................................................... 94
Component Description ........................................ 27 Wiring Harness (Open Circuit) - Test .................... 94
Main Display Module ............................................ 27 Wiring Harness (Short Circuit) - Test .................... 95
Display Components ............................................. 31 Wiring Harness (Short Circuit) - Test .................... 96
Quad Gauge Module ............................................ 31 Electrical Connector - Inspect ............................... 96
Speedometer/Tachometer Module ........................ 32 Module - Replace .................................................. 97
Switches ............................................................... 32 Main Display Module Initialization - Adjust ........... 97
Senders ................................................................ 33 Main Display Module - Flash Program .................. 98
Sensors ................................................................. 34 Glossary of Terms ................................................. 99
Action Lamp .......................................................... 36 Connector Contact Description of Main Display
Action Alarm ......................................................... 36 Module ............................................................. 101
Related Components ............................................ 37 System Schematic .............................................. 104

Troubleshooting Section Index Section

Introduction Index ................................................................... 109

General Information .............................................. 38
Service Tools ........................................................ 38
Electrical Component and Connector Locations ... 40
Diagnostic Capabilities ......................................... 42

Diagnostic Code Procedures

Diagnostic Code List ............................................. 44
Using Caterpillar Monitoring System to Determine
Diagnostic Codes ................................................ 45
Using Caterpillar Electronic Technician to Determine
Diagnostic Codes ................................................ 46
MID 030 - CID 0084 - FMI 08 ............................... 48
MID 030 - CID 0096 - FMI 03 ............................... 50
MID 030 - CID 0096 - FMI 04 ............................... 51
MID 030 - CID 0096 - FMI 08 ............................... 52
MID 030 - CID 0248 - FMI 02 ............................... 52
MID 030 - CID 0263 - FMI 03 ............................... 54
MID 030 - CID 0263 - FMI 04 ............................... 55
MID 030 - CID 0271 - FMI 03 ............................... 56
MID 030 - CID 0271 - FMI 05 ............................... 57
MID 030 - CID 0271 - FMI 06 ............................... 58
MID 030 - CID 0324 - FMI 03 ............................... 59
MID 030 - CID 0324 - FMI 05 ............................... 60
MID 030 - CID 0324 - FMI 06 ............................... 61
4
Systems Operation Section

Systems Operation Section

i01853880

General Information
SMCS Code: 7490

Introduction

g00944992
Illustration 1
Caterpillar Monitoring System for the 140H, 143H, 160H and 163H
The quad gauge module and the speedometer/tachometer module are optional components.
 5
Systems Operation Section

g00863307
Illustration 2
Caterpillar Monitoring System for the 14H and 16H
The quad gauge module and the speedometer/tachometer module are optional components.
6
Systems Operation Section

g00945076
Illustration 3
Caterpillar Monitoring System for the 12H, 120H and 135H
The quad gauge module and the speedometer/tachometer module are optional components.
 7
Systems Operation Section

The main display module is the brain of the system.

This module receives information from the switches,
sensors and other electronic controls on the machine
via the CAT data link. The main display module
processes all of the information. The module then
activates various outputs. The outputs could be in the
display area of the main display module, the quad
gauge module, the speedometer/tachometer module,
the action lamp, or the action alarm. The display
components show the condition of the machine
systems. The operator can also obtain system
diagnostic information.

The same monitoring system operates on a variety of

different machines. All the possible system functions
are not performed on every machine. After the main
display module has been installed, the module
recognizes the machine. The module will perform
only the intended functions for that machine. The
main display module is required for the monitoring
system to operate. The quad gauge module and
the speedometer/tachometer module may not be
used on some machines. The maximum number of
other modules that can be used with the main display
module at any one time is four. The modules that
can be used are two quad gauge modules and two
speedometer/tachometer modules.

Main Display Module

• The ten alert indicators (4) show abnormal
conditions in the machine.

• A six digit display area (9) is provided. The

Illustration 4
g00789331 display shows the following modes: machine
Typical Example operational hours (service meter), engine speed
(tachometer), machine distance (odometer),
Caterpillar Monitoring System Display Components
and diagnostic codes. The information for the
(1) Quad gauge module speedometer/tachometer module, and any gauge
(2) Speedometer/tachometer module
(3) Main display module of the quad gauge module can also be shown as a
(4) Alert indicators number on this readout. The display area contains
(5) Gauges seven unit indicators and a service indicator. The
(6) Tachometer operator selects the information in order to be
(7) Speed readout
(8) Transmission gear readout
shown on the display area.
(9) Display area
• Seven different unit indicators can be shown in
The Caterpillar Monitoring System is an electronic the display area. The unit indicators that can be
monitoring system that continuously watches shown are “°C”, “kPa”, “MILES”, “KM”, “RPM”,
machine systems. The system is a flexible modular “LITERS” and “HOURMETER” symbol. These
monitoring system that includes the following indicators show the units of measurement for the
devices: a main display module, various switches data on the six digit display area. The indicators
and sensors, an action lamp, and an action alarm. are turned ON and OFF in order to correspond with
The system may include a speedometer/tachometer the information on the six digit display area.
module. A different number of quad gauge modules
may be included in the system. • In order to indicate a current fault, a service code
indicator is used. The service code indicator is used
in service mode and diagnostic scrolling mode.

Speedometer/Tachometer Module
• One tachometer gauge (6) shows the information
on the engine speed (RPM).
8
Systems Operation Section
• One three digit display area (7) shows the
information on the ground speed. The speed is
displayed in “MPH” and “km/h”.
• Information on the transmission gear and the
direction are shown on a two digit gear readout (8).
Quad Gauge Module
• The four gauges (5) show the condition of
the machine. The quad gauge will display the
following information: engine coolant temperature,
articulation angle, system voltage, and fuel level.
According to the application, the type and the
quantity of indications that are used in the display
areas varies. All of the indications are not used on
the machine. The quantity of quad gauge modules
and speedometer/tachometer modules may vary
with each machine. An action lamp and an action
alarm indicate the severity (warning category) of a
problem. To determine the functions that are used
on a particular machine, see the corresponding
Operation and Maintenance Manual.
i01962268
Modes of Operation
SMCS Code: 7490
g00297408
Illustration 5
This is a typical example of the Display Area (Mode 2).
The Caterpillar Monitoring System has many different
possible modes of operation. The modes are operator
modes and service modes. Each mode provides
important information regarding the condition of
the machine. Each mode also provides information
regarding the setup of the monitoring system. All
modes are not available on all machines. The system
that is installed on the machine determines the
modes that are available. All the modes are given
names and the modes are referenced in this manual.
The mode is shown as a number on the display area
of the main display module. This number is assigned
by the software in the main display module.
The operator modes are accessible by using the
selector switch for the operator mode that is located
in the operator’s compartment. The following table
shows the available modes. See the Operation and
Maintenance Manual of the machine that is being
serviced for specific information on the operator
mode.
When power is applied, the Caterpillar Monitoring
System performs the self test. After the self test is
complete the Caterpillar Monitoring System enters
the Normal Mode. Normal Mode is service mode 0.
Normal Mode contains the operator modes. In order
to enter the other service modes, the service and
clear inputs must be grounded at the same time.
Access to the service and clear inputs is provided
with the service connector. The service connector is
located within the operator compartment. Information
on the location of the service connector is in the
Electrical System Schematic for the machine that is
being serviced.
When the service and clear inputs are grounded, the
service mode numbers scroll sequentially on the six
digit display area of the main display module.
Note: When you are scrolling through the modes,
mode 0 (Normal Mode) is not shown on the display
area as a number. When you reach mode 0, the
display area begins showing the information for mode
0 (Normal Mode).
When ground is removed from the service and clear
inputs, the monitoring system enters the mode which
corresponds to the number that is presently shown.
The following situation is an example. When you see
the mode number “- 1-” on the display, remove the
ground. This action causes the monitoring system to
enter the Harness Code Mode.
Note: The monitoring system must finish performing
the self test before you ground the service and clear
inputs in order to begin scrolling through the service
modes.
 9
Systems Operation Section

Table 1 i01856906

12H, 14H, 16H, 120H, 135H, 140H, 143H,

160H And 163H
Normal Mode
Operator Modes SMCS Code: 7490
Operator Mode Mode Number
Service Meter 0
Odometer 1
Digital Tachometer 2
Diagnostic Scrolling 3
Cumulative Fuel 4
Trip Machine Hours 5
Trip Odometer 6
Trip Fuel 7
Reset Trip Values 8

Table 2
12H, 14H, 16H, 120H, 135H, 140H, 143H,
160H And 163H
Service Modes
Service Mode Mode Number
Harness Code 1
Parameter Display 2
Diagnostic Service 3
Tattletale 4
Digital Tattletale 4
Units 5
Calibration (Articulation Gauge) 6
Calibration (Transmission Control) 7 g00789331
Illustration 6
Calibration (Transmission Control) 8 Caterpillar Monitoring System Display Components
Calibration (All Wheel Drive Control) 9 (1) (1) Quad gauge module
(143H, 163H) (2) Speedometer/tachometer module
(3) Main display module
Setup 9 (4) Alert indicators
(5) Gauges
Setup (143H, 163H) 10 (6) Tachometer
(7) Ground speed readout
(1) This mode is not operational at this time. This mode is reserved (8) Transmission gear readout
for future use. (9) Display area

Normal mode is used during normal machine

operation. When you are in normal mode, the
Caterpillar Monitoring System performs the following
operations.

• A monitoring system that is operating properly

will perform a self test whenever the key switch is
turned to the ON position. The outputs also operate
for a brief instant. See Testing and Adjusting,
“System Self Test ”.
10
Systems Operation Section
• The main display module continuously watches
machine systems. If the gauges are available, the
gauges in the quad gauge module show a value
in a normal range. Ground speed readout (7) is
shown as a numeric value and the transmission
gear readout (8) on the module shows numeric
values. The value for a condition may also be
shown in the display area.
• The main display can show a problem with the
machine. The main display module continuously
monitors machine systems. When an abnormal
condition (problem) exists, the corresponding alert
indicator (4) FLASHES. As the severity of the
problem increases, the action lamp FLASHES and
the action alarm SOUNDS. See System Operation,
“Warning Operation”.
Note: The main display module may notify the
operator when a diagnostic code exists in other
electronic systems. This is done in different ways.
The following example is of a diagnostic code that
occurs in the engine electronic system. The service
code indicator will show “SERV CODE” and the
alert indicator for “check engine” FLASHES. See the
Operation And Maintenance Manual for the machine
that is being serviced for more specific information
on the machine.
Operator Modes
Table 3
12H, 14H, 16H, 120H, 135H, 140H, 143H,
160H And 163H
Operator Modes
Operator Mode Mode Number
Service Meter 0 in order to determine the mode number for the
Odometer 1 corresponding machine.
Digital Tachometer 2
Diagnostic Scrolling 3
Cumulative Fuel 4 Service Meter Mode
Trip Machine Hours 5 SMCS Code: 7490
Trip Odometer 6
Trip Fuel 7
Reset Trip Values 8
The six digit display area (9) is used to show various
conditions of the machine system to the operator
(Operator Modes). Operator modes that are available
to the operator are dependent to the monitoring
system that is installed on the machine. The table
above lists the operator modes by the machine.
The default condition is shown on the six digit display
area when the main display module enters normal
mode. This condition is normally the service meter.
See System Operation, “Service Meter Mode” for
more information.
The six digit display area scrolls through the available
operator modes when the operator switch input
is grounded. Opening the switch input will stop
the scrolling on the currently shown mode. Mode
numbers are not displayed when operator modes are
scrolling.
See the topic with the corresponding name on the
following pages for a more detailed explanation of
each mode.
Optional Machine Conditions
The display area may be used to show other
information on the condition of the machine. For
example, the display area may be used as a gear
readout when the speedometer/tachometer module
is not used. The following situation occurs in order
to function as a gear readout. The six digit display
area changes from the default condition to the gear
readout when the parking brake is DISENGAGED.
The symbol for the service meter turns OFF and the
information on the transmission gear is shown on the
six digit display area.
The display area may also be used when ether is
being injected with a flashing “E”. A flashing “P” in
the display area may be used when the engine is
being prelubed. The following display modes are also
available: the load count, the engine oil pressure, and
the charge pressure. See the table for the Monitoring
System Mode on the Electrical System Schematic
i00971876
Illustration 7
g00298101
Display Area

The main display module keeps track of the total
number of engine hours. The total machine operating
hours are shown on the six digit display area when
you are in service meter mode. The symbol for the
service meter is ON in order to indicate when the
display is functioning as a service meter. The value is
continuously updated when the engine is operating.
The main display module monitors the following
electrical inputs in order to determine when the
machine engine is operating: the engine speed,
terminal for alternator “R”, and the engine oil
pressure. The main display module starts the service
meter for the machine when one of these inputs is
in the normal range.
i01461542
Odometer Mode
SMCS Code: 7490
g00298418
Illustration 8
Display Area
The total distance for the machine is displayed on the
six digit display area when the main display module
is in odometer mode. The indicator for the units
shows “MILES” or “KM”. This depends on the setting
for units of measure of the main display module.
The main display module receives information from
the transmission output speed sensor from the
transmission electronic control module. This is done
by using the CAT data link. The unit of measure
can be set by using the units mode. See Systems
Operation, “Units Mode” for more information.
i01518524
Tachometer Mode
SMCS Code: 7490
g00298698
Illustration 9
Display Area
11
Systems Operation Section
The engine RPM is shown on the six digit display
area when the main display module is in tachometer
mode. The indicator for the units shows “RPM”. The
main display module can calculate engine speed with
a frequency sensor. The main display module may
also receive information from a frequency sensor
from another electronic control module. This can be
done by way of the CAT data link.
i01456960
Scrolling Mode
SMCS Code: 7490
g00495188
Illustration 10
(1) First display. (2) Second display. (3) Module identifier (MID). (4)
Service code indicator “SERV CODE”. (5) Component identifier
(CID). (6) Failure mode identifier (FMI).
Scrolling mode allows service personnel or an
operator to see diagnostic codes that were stored by
the main display module. The diagnostic code in this
mode can not be cleared. The diagnostic code can
also not be placed on hold.
The diagnostic codes momentarily scroll on the
display area upon entering the scrolling mode. The
MID is shown first as each diagnostic code is shown
for about one second. The corresponding CID and
the corresponding FMI is shown second for about
two seconds. “End” appears when the last diagnostic
code has been shown. The diagnostic codes are
then shown. The display shows “- - -” when the main
display module has no diagnostic codes.
The “SERV CODE” functions as a diagnostic present
indicator in scrolling mode. The diagnostic that has
caused a diagnostic code to be shown currently is
present when “SERV CODE” is ON. “SERV CODE”
is OFF when the fault is not present, but the fault has
previously occurred.
12
Systems Operation Section

i01996543 Some machines do not utilize a harness code plug.

This can be verified with the electrical schematic
Harness Code Mode for the machine. If the machine does not utilize
a harness code plug, then the machine does not
SMCS Code: 7490 have a harness code. However, the machines that
do not have a harness code will also display a
machine code in harness code mode. The machine
code does not represent the harness code in this
case. The machine code represents the monitoring
system configuration code. The monitoring system
configuration code is configured in the software for
the ECM with Caterpillar ET. The monitoring system
configuration code is the numeric number in the sales
g00298918
Illustration 11 model of the machine. For example, the monitoring
Display Area system configuration code for a 160H is 160.

Harness code mode is always mode 1. The machine

i01804895
code is shown on the six digit display area when the
main display module is in harness code mode. The
machine code must correspond with the monitoring
Numeric Readout Mode
system that is installed on the machine sales model. SMCS Code: 7490
See the following table for Machine Codes. The
machine code is a two-digit representation of the
harness code. An incorrect harness code is one that
does not match the machine. Incorrect operation of
the monitoring system will be caused by an erroneous
harness code. Excessive diagnostic service codes
could be recorded as a result of this situation.

Table 4 g00299479
Illustration 12
Machine Codes
Display Area
Sales Model Machine Code
Numeric readout mode is always mode 2. Numeric
14H 14 readout mode assists service personnel with
140H 40 troubleshooting of sensor inputs. The inputs supply
information for the gauges in the quad gauge
143H 43 modules. Numeric readout mode more accurately
160H 60 shows the same information that is shown on the
gauges in normal mode. The system identifier and
163H 63 the numeric value for the system scrolls on the six
120H 20 digit display area. The system identifier identifies the
system that is currently shown on the six digit display
135H 35 area. See table 5 for “System Identification” and
12H 12 illustration 13 in order to match the system identifier
to the appropriate gauge.
16H 16
 13
Systems Operation Section

When you enter the numeric readout mode, the six

digit display area is showing information for system
GA-1. The display momentarily shows the system
identifier. The display then shows the value for the
corresponding system on the six digit display area.
Grounding the service input causes all the systems
to scroll on the display. This will show the system
identifiers. Removing ground from the service input
stops the scrolling, when the desired system is
shown. The six digit display area continues to show
the system identifier momentarily. The six digit
display area then shows the value of the system. The
system is now shown on hold. While the system is on
hold, the numeric value of the system is continuously
updated.

i01525238

Additional Operator Modes

SMCS Code: 7490
g00789385
Illustration 13
Quad gauge modules
Trip Hourmeter Mode

g00299481
Illustration 14 g00298101
Illustration 15
This is an illustration of the display area on the Main Display
Module that is showing an example of a system identifier. Display Area

Table 5 The main display module keeps track of the trip

hourmeter. The trip hourmeter will accumulate
System Identification
machine distance based upon the vehicle speed that
System Identifier Gauge (System) is received from the transmission ECM. The total
trip hourmeter is shown on the six digit display area
GA-1 1
when you are in trip hourmeter mode. The symbol for
GA-2 2 the trip hourmeter is ON in order to indicate when the
display is functioning as a trip hourmeter. The value is
GA-3 3 continuously updated when the engine is operating.
GA-4 4
The main display module monitors the following
Table 6
electrical inputs in order to determine when the
machine engine is operating: the engine speed,
Units terminal for alternator “R”, and the engine oil
Condition Units of Measurement pressure. The main display module starts the trip
hourmeter for the machine when one of these inputs
Temperature °C is in the normal range.
Angle °
Voltage 0.1 volts
Level % full

In addition to the table and the illustration, only the

gauge for the system that is shown on the six digit
display area is operational. All other gauges in the
quad gauge modules are shut off. The gauge needles
will move to the far left position.
14
Systems Operation Section
Trip Odometer Mode
g00298418
Illustration 16
Display Area
The total distance for the machine is displayed on the
six digit display area when the main display module
is in trip odometer mode. The indicator for the units
shows “MILES” or “KM”. This depends on the setting
for units of measure of the main display module. The
main display module receives information from the
frequency sensor from the transmission ECM. This is
done by using the CAT data link. The unit of measure
can be set by using the units mode. See Systems
Operation, “Units Mode” for more information.
Trip Fuel Consumption Mode
Illustration 17
g00678891
Display Area
The fuel level is shown on the six digit display area
when the main display module is in fuel level mode.
The display will show “% full”, and no unit indicators
are illuminated. The main display module calculates
fuel level from a resistive sender, which is directly
connected to the main display module.
i01520209
Service Mode
SMCS Code: 7490
g00427558
Illustration 18
Diagnostic Example
(1) First display. (2) Second display. (3) Module identifier (MID). (4)
Service code indicator (“SERV CODE”). (5) Component identifier
(CID). (6) Failure Mode identifier (FMI).
Service mode is mode 3. The main display module
detects faults that occur with sensor inputs, sender
inputs, and main display module outputs while
the main display module is in normal mode. The
signal is at the contact of the main display module.
A diagnostic code is detected when the signal is
outside a valid range. The main display module then
records the diagnostic code. The diagnostic code
remains stored for future reference when the fault
is not present.
The main display module detects faults and the main
display module diagnoses faults in the following
circuits:
• Display output modules
• Action alarm output
• Action lamp output
• Sensor input
• Harness code
Note: The main display module does not detect
switch input faults.

Service personnel can see the diagnostic codes and
service personnel can troubleshoot the diagnostic
codes when the main display module has detected
a fault. All detected faults are shown in the display
area as a diagnostic code. The diagnostic codes can
be placed on hold and the diagnostic codes can be
cleared while the main display module is in service
mode.
Note: Diagnostic codes from other machine systems
under electronic control are shown in the display
area of the main display module when the main
display module is in Service Mode. The CAT data
link allows the transfer of diagnostic information from
other electronic control modules to the main display
module. This diagnostic information is then shown
when the main display module is in service mode.
The diagnostic code for faults from other electronic
control modules has a MID that is unique to the
control. These diagnostic codes can scroll similarly to
the diagnostic codes from the Caterpillar Monitoring
System. See the following description of Module
Identifier (MID).
The diagnostics of the Caterpillar Monitoring System
are available to assist with the troubleshooting of
diagnostic codes when the main display module is
placed in service mode. A diagnostic code is used
to specify each fault. The diagnostic code is made
up of three identifiers (MID, CID and FMI). These
identifiers are shown in the display area. The display
area continuously changes between the following
identifiers when the diagnostic code is on hold:
Module Identifier (MID) – The MID is a three-digit
code that is shown on the display area. The MID
is shown for approximately one second before the
diagnostic code that is shown in the same area. The
electronic control module that has diagnosed the
diagnostic code is logged by the MID. The following
examples are of some MID.
Caterpillar Monitoring System ......................
Engine Control (ADEM) ................................
Power Train Electronic Control System ........
All Wheel Drive Electronic Control System ...
See the table for the Module Identifier (MID) on
the Electrical System Schematic for the machine
that is being serviced for the most complete list.
To troubleshoot diagnostic codes, use the service
manual for the control that detected the code.
15
Systems Operation Section
Component Identifier (CID) – The components that
are faulty are noted by the CID. These components
are examples: transmission oil temperature sensor,
speed sensor, action lamp, and boost pressure
sensor. The CID is a four digit code that is shown on
the six digit display area. The CID and the FMI are
shown together after the MID has been displayed.
See the table “Diagnostic Codes For Caterpillar
Monitoring System” in Testing And Adjusting,
“Troubleshooting Diagnostic Codes”. This will show a
list of CID codes for the main display module.
Failure Mode Identifier (FMI) – The FMI tells the
type of failure that has occurred. The following
situations are examples: voltage above normal,
current below normal, and abnormal frequency.
The FMI is a two digit code that is shown on the
six digit display area. The CID and the FMI are
shown after the MID is displayed. The CID and the
FMI are separated by a decimal point “.”. See the
table “Diagnostic Codes For Caterpillar Monitoring
System” in Testing And Adjusting, “Troubleshooting
Diagnostic Codes”. This table will show a list of failure
mode identifiers for the main display module.
When the main display module enters the service
mode, the MID, the CID, and the FMI are shown. At
this time, the diagnostic code that is shown is on hold.
The display area continuously changes between
the following identifiers when the diagnostic code is
on hold: MID, CID, and FMI. This is maintained as
long as the service and clear inputs remain open.
Troubleshooting is performed while the diagnostic
code is on hold.
Note: The display shows “- - -” when the main display
module has no diagnostic codes.
All diagnostic codes are shown one at a time in
the display area when the diagnostic codes are
scrolling. Grounding the service input causes the
display to scroll when the main display module is
030 in service mode. This will momentarily show the
036 MID. The display will show the CID and the FMI that
081 corresponds. Removing ground from the service
075 input stops the scrolling when the diagnostic code
that is desired is shown. The diagnostic code that
is shown is now on hold.
Note: The diagnostic codes from other electronic
control modules can be shown on the display. Use
the same procedure in order to place the diagnostic
codes on hold.
16
Systems Operation Section
Diagnostics are provided in order to assist service
personnel during troubleshooting of intermittent
faults. The service code indicator “SERV CODE” is
shown when the diagnostic code is present. This
can aid in troubleshooting of intermittent faults. The
service code indicator changes from “SERV CODE”
that is OFF to “SERV CODE” that is ON. This will
occur when the fault changes status. The action
alarm SOUNDS briefly during the change of status
when the diagnostic code is on hold for a fault.
These diagnostics signal the service personnel while
inspections are performed. These diagnostics assist
in troubleshooting intermittent faults by one service
person.
A diagnostic code is removed from the memory of
the main display module when the diagnostic code
has been cleared. When a fault is corrected, it is
necessary to remove the corresponding diagnostic
code from the memory of the main display module.
In order to remove the diagnostic code from the
memory, place the diagnostic code on hold and
ground the clear input. The memory of the main
display module saves a diagnostic code until the
code is cleared. The main display module does not
allow clearing of a diagnostic code that corresponds
to a fault which is present.
Note: The diagnostic codes from other electronic
control modules should be cleared by using the main
display module.
g00427558
Illustration 19
Diagnostic Example
(1) First display. (2) Second display. (3) Module identifier (MID). (4)
Service code indicator (“SERV CODE”). (5) Component identifier
(CID). (6) Failure Mode identifier (FMI).
Brief Explanation
Illustration 19 shows a main display module that is
currently receiving a signal. This signal is from the
transmission oil temperature sensor and the signal
is out of range.
Detailed Explanation
MID (3) – “030”. This code concerns the Caterpillar
Monitoring System. The Caterpillar Monitoring
System service manual should be used to
troubleshoot the diagnostic code. If the MID that was
shown was “081”, the diagnostic code would concern
the power train electronic control. The service module
for the power train electronic control should be used
to troubleshoot the diagnostic code.
CID (5) – “0110”. This code means that a fault has
occurred in the sensor circuit for the engine coolant
temperature of MID “030”. See the table for Detected
Faults in Testing And Adjusting, “Troubleshooting
Diagnostic Codes”. This will show a list of CID codes
for the Caterpillar Monitoring System.
FMI (6) – “08”. This identifier means that a signal
of abnormal frequency, pulse width or period is
being received concerning CID “0110”. See the
table for Detected Faults in Testing And Adjusting,
“Troubleshooting Diagnostic Codes”. This table will
show a list of FMI codes for the Caterpillar Monitoring
System.
Service code indicator (4) is ON in Illustration 19.
When the main display module is in service mode,
the service code indicator (4) functions as a fault
present indicator. Therefore, the CID “0110” fault is
present. The service code indicator changes from ON
to OFF when the CID “0110” fault changes status.
Also, the action alarm sounds when the CID “0110”
fault changes status. This action will take place while
the main display module is in service mode.
i01520269
Tattletale Mode
SMCS Code: 7490
g00301362
Illustration 20
Display Area
 17
Systems Operation Section

Gauges (5) show the highest reading or lowest

reading that has been attained by the corresponding
machine system. The gauges show the highest
reading for systems with increasing abnormal
values. The gauges also show the lowest reading
for systems with decreasing abnormal values. The
gauge alternates between the highest reading and
lowest reading. This will occur for the gauges that
are double ended.

Tachometer (6) and speed readout (7) show the

highest reading that has been obtained.

Alert indicators (4) turn on when an abnormal

condition has existed.

Information from the tattletale is retained until the

information is cleared. Grounding the clear input
erases the information. After clearing, all information
is reset to a nominal value and the recording of new
extreme values begins.

Note: The date, time or duration of the extreme value

that has occurred is not recorded.

Example

This example explains the information that is shown

in the illustration for the Tattletale Mode.

• Gauge (5) for the engine coolant temperature has

a pointer that indicates a value above the normal
temperature range. Therefore, a high abnormal
value has existed in this system.
g00789331
Illustration 21
Caterpillar Monitoring System Display Components
• Gauge (5) for the battery charge level has a pointer
that indicates a value below or a value above the
(1) Quad gauge module normal battery charge range. Therefore, a low
(2) Speedometer/tachometer module
(3) Main display module
abnormal value or a high abnormal value has
(4) Alert indicators existed in this system.
(5) Gauges
(6) Tachometer • Gauge (5) for the articulation angle has a pointer
(7) Speed readout that indicates a value for the articulation angle of
(8) Transmission gear readout
(9) Display area the machine. Therefore, no abnormal value has
existed in these systems.
Tattletale Mode is a tool for management and
maintenance. The history of the machine can be • Gauge (5) for the fuel level has a pointer that
recorded by this mode. The main display module indicates a level of 50%. Therefore, the highest
records the extreme value for each condition of the amount of fuel that has existed is 50%.
machine that is monitored. The values come from
sensor inputs, switch inputs and the CAT data link. • The pointer on tachometer (6) indicates a
The values in tattletale mode are updated whenever maximum value (2100 RPM). Therefore, an engine
a value occurs with more importance than the speed of 2100 rpm has existed.
previous value. These values are ignored for a short
period of time after each start-up. This allows the • Speed readout (7) shows “13 MPH”. Therefore, 13
machine systems to stabilize before the recording MPH is the highest ground speed that has been
of information. attained.

• Alert indicator (4) is ON. Therefore, an abnormal

condition has existed in this system.

• All other alert indicators (4) are OFF. Therefore, no

abnormal values have existed in these systems.
18
Systems Operation Section
Note: No information from the tattletale mode is
stored for the highest transmission gear or lowest
transmission gear that has been selected.
i01041208
Units Mode
SMCS Code: 7490
g00301504
Illustration 22
Caterpillar Monitoring System
(1) Speedometer/tachometer module. (2) Main display module. (3)
Odometer units. (4) Speed readout. (5) Speedometer units. (6)
Display area. (7) Six digit display area.
The units mode is mode 5. The units mode is used to
toggle the displays of the monitoring system between
US and Metric units of measure. When the main
display module enters units mode, six digit display
area (7) shows the current setting. The display reads
“US” when the mode is set to US units. The display
reads “SI” when the mode is set to Metric units.
When the units mode is set to US units, the main
display module shows “MILES” on display area (6)
when the main display module is in odometer mode.
The display for the speedometer/tachometer module
shows “MPH”. The display area (6) shows “KM”
when the main display module is set to Metric units.
The display for the speedometer/tachometer module
shows “km/h”.
In order to toggle the units, ground the clear input
while the service input is open. The units continuously
toggle when the clear input is grounded. Opening
both of the inputs will set the main display module to
the currently displayed setting.
i01963289
Setup Mode
SMCS Code: 7490
g01019884
Illustration 23
Display Area
Setup Mode is mode 9 on all of the motor graders
except the 143H and the 163H. Setup Mode is
mode 10 on the 143H and the 163H. This mode
is used in order to configure the installation status
of the speedometer/tachometer module. If the
speedometer/tachometer module is already installed,
the display will read “t1 YES” when you enter
the Setup Mode. If the speedometer/tachometer
module is not installed, the display will read “t1
NO”. In order to change the status of the module,
ground the clear input for two seconds. If multiple
speedometer/tachometer modules are present on
the machine, grounding the service input for two
seconds will display the status of the next module.
For example, the display may read “t2 YES”. The
display will read “END” once you have scrolled
through all of the modules. Grounding the service
input for two seconds will start scrolling through the
status of the modules again from the first module.
i01963535
Calibration Mode
SMCS Code: 7490
Calibration Mode 7 and Calibration Mode 8 are
associated with the power train ECM. Calibration
Mode 7 and Calibration Mode 8 are identical. Both
modes contain the same submodes and perform the
same calibrations. Calibration Mode is used on some
machines in order to perform special functions of
calibration. The operation of the Calibration Mode will
vary depending on the machine and the system that
is being calibrated. The Service Manual Module for
the controls that require the Calibration Mode should
be used in order to determine the operation.

Submodes
Calibration Mode 7 and Calibration Mode 8 include
submodes in order to extend the diagnostic
capabilities. After you have entered mode 7 or mode
8, use the service switch in order to scroll through
the submodes.
Submode 7.29 / 8.29 (Calibration Of The
Inching Pedal Position Sensor )
This procedure allows the calibration of the travel
limits of the inching pedal position sensor. The inching
pedal must be calibrated if any of the conditions that
are listed below have occurred:
• The power train ECM has been replaced.
• New software has been flashed into the power
train ECM and a diagnostic code of CID 0573 FMI
13 is active.
• The position sensor for the inching pedal has been
replaced.
• The linkage for the inching pedal has been
adjusted.
1. Connect the 4C-8195 Control Service Tool to the
service tool connector.
2. Use the 4C-8195 Control Service Tool in order
to enter the “Power Train Calibration” Mode (7)
via the “MODE” switch. Then use the “SCROLL”
switch to enter submode number 29.
3. Ensure that the inching pedal is not pressed. Use
the “INCREMENT (+)” position of the “CLEAR”
switch to start the calibration. The display on the
4C-8195 Control Service Tool will change to
“C01”.
4. Press and hold the inching pedal to the down limit.
Select “INCREMENT (+)” position of the “CLEAR”
switch. The display on the 4C-8195 Control
Service Tool will change to “C02”.
5. Release the inching pedal. Select the
“INCREMENT (+)” position of the “CLEAR”
switch. The display on the 4C-8195 Control
Service Tool will change to “---” if the calibration
was successful. If an error occurred during the
calibration, The display on the 4C-8195 Control
Service Tool will change to “Exx”. The “xx” is one
of the failure codes that are listed below:
E01 – The calibration value is too high.
E02 – The calibration value is too low.
E03 – The calibration value is too large.
19
Systems Operation Section
E04 – The calibration value is too small.
The error codes indicate that the inching pedal
position sensor may be adjusted improperly.
Perform the Testing and Adjusting, “Inching Pedal
- Adjust” procedure in this manual and then repeat
the calibration procedure.
6. Exit submode number 29 by scrolling to the next
submode number by using the “SCROLL” switch
or by exiting the “Power Train Calibration” mode
by using the “Mode” Switch.
Calibration Of The Engagement Pressure
For The Transmission Clutch
Incorrect transmission clutch pressure adversely
affects the life of the transmission. Submodes 31
through 33 are used in order to set the transmission
clutch pressure of the direction clutches (No. 1
through No. 3). In this process, the service technician
adjusts the electrical current that is sent to the
transmission solenoid valve in order to obtain the
specified pressure for the transmission clutch. The
calibration of the transmission clutch pressure must
be performed prior to the transmission clutch fill
calibration (submode 40).
The transmission system must be calibrated if any of
the following conditions have occurred:
• A transmission solenoid valve has been replaced
or cleaned.
• A different power train ECM has been installed.
• New flash software has been flashed into the ECM.
• A transmission clutch has been rebuilt.
• The transmission clutch does not shift correctly.
20
Systems Operation Section

Illustration 24
Transmission Clutch Solenoid Valves
(1) Transmission solenoid valve (No. 3)
(2) Transmission solenoid valve (No. 1)
(3) Transmission solenoid valve (No. 2)
g00795884
(4) Transmission solenoid valve (No. 8) (7) Transmission solenoid valve (No. 5)
(5) Transmission solenoid valve (No. 4) (8) Transmission solenoid valve (No. 7)
(6) Transmission solenoid valve (No. 6)

Table 7 For more information on the calibration procedure,

Error Codes for the Calibration of the
refer to the Testing and Adjusting, RENR4104,
Transmission Clutch “Engagement Pressure for the Transmission Clutch
- Calibrate”.
The Clutch Solenoid or the Speed Sensor
E01
has an Active Fault.
Submode 7.40 / 8.40 (Transmission
The Inching Pedal was not released when Clutch Fill Calibration)
E02
you entered the Submode.
Active Fault For the Position sensor Improper calibration of the transmission clutch fill will
E03
(Inching Pedal) cause transmission shifting problems. The automatic
calibration procedure for setting the transmission
The Transmission Lever is Not in
E04 clutch fill will achieve greater consistency. The
the PARK Position.
calibration of the transmission clutch engagement
Temperature of the Transmission Oil is pressure (submode 31 through submode 33)
E05 Below the Fault Threshold. should be performed prior to the calibration of the
(60 °C (140 °F)) transmission clutch fill (submode 40).
The Engine Speed is Below the Fault
E06 During the transmission clutch fill calibration
Threshold of 1800 rpm.
(submode 40), error codes (EXX) can occur. The
E09 Machine Speed Is Not Zero. error codes will appear in the display area of the
Caterpillar Monitoring System. The error codes will
During calibration of the transmission clutch pressure, appear if a problem occurs during the calibration or if
error codes (EXX) can occur. The error codes there is a problem with the results of the calibration.
will appear in the display area of the Caterpillar
Monitoring System. The error codes will appear if a
problem occurs during the calibration.
 21
Systems Operation Section

Table 8
Error Codes for the Calibration of the
Transmission Clutch Fill
The Clutch Solenoid or the Speed Sensor
E01
has an Active Failure.
E04 The Transmission is Not in the Park Position.
The Temperature of the Transmission Oil
E05 is Below the Fault Threshold.
(68 °C (154 °F))
The Engine Speed is Below the Fault
E06
Threshold of 1800 rpm.
E09 Machine Speed Is Not Zero.
Calibration of the Engagement Pressure
E11
Is Not Completed.
E21 Number 1 Clutch at a Limit
E22 Number 2 Clutch at a Limit
E23 Number 3 Clutch at a Limit

The calibration software may need to adjust one

of the parameters beyond the limit of the design
specification. In this case, error codes E21, E22,
or E23 will appear in the display area after the
calibration procedure is complete. The software will
select the best values, but the error code indicates
that an error exists in either the conditions for
calibration or the transmission system. If error codes
E21 through E23 are displayed, check the following
conditions for the source of the error:

• Make sure that the transmission oil and the

transmission components are fully warmed in order
to run the calibration.

• Make sure that the transmission solenoid valves

are correctly torqued. (Make sure that the valves
are cool when the valves are torqued.)

• Worn seals are causing leakage.

• The clutch is worn beyond the allowable range.
• The transmission solenoid valve is damaged.
• A new transmission solenoid valve was not
energized sufficiently.
22
Systems Operation Section

Illustration 25
Transmission Solenoid Valves
(1) Transmission solenoid valve (No. 3)
(2) Transmission solenoid valve (No. 1)
(3) Transmission solenoid valve (No. 2)
(4) Transmission solenoid valve (No. 8)
g00795884
(5) Transmission solenoid valve (No. 4)
(6) Transmission solenoid valve (No. 6)
(7) Transmission solenoid valve (No. 5)
(8) Transmission solenoid valve (No. 7)

Note: If a new transmission solenoid valve was i01529536

installed, you must shift the transmission into a speed
or a direction that uses the transmission solenoid
valve. The transmission must be shifted at least 12
times. Refer to Illustration 25 in order to identify the
transmission solenoid valve and the corresponding
clutch. Allow sufficient time for the corresponding
clutch to be fully pressurized.
During the transmission clutch fill calibration, error
codes (EXX) can occur. The error codes will appear in
the display area of the Caterpillar Monitoring System.
The error codes will appear if a problem occurs
during the calibration or if there is a problem with the
results of the calibration. If there are no problems or if
the problems are fixed, run the calibration (submode
40) again.
For more information on the calibration procedure,
refer to the Testing and Adjusting, RENR4104, “Fill
Time for the Transmission Clutch - Calibrate”.
Articulation Gauge Calibration
Mode
SMCS Code: 7490
The 4C-8195 Service Tool allows personnel to
access information that is related to service. The
service tool attaches to the connector that is
located behind a plate directly below the Caterpillar
Monitoring System. The connector has four pins.
In order to calibrate the articulation gauge needle,
enter mode 6 and perform the following procedure:
1. Attach the service tool to the service mode
connector on the Caterpillar Monitoring System.
 23
Systems Operation Section

Note: If the needle appears centered, the switches

must be pressed in order to record the articulation
sender resistance.

g00794045
Illustration 26
Display Area (Mode 6)

2. Press up both the service “SCROLL” and “CLEAR”

switches on the service tool. When both switches
are pressed, the Caterpillar Monitoring System
will scroll to different display modes in the display
area. Display mode 6 is used to calibrate the
articulation gauge needle. The two switches
should be held until the Caterpillar Monitoring
System display area shows “-6-”.

g00530894
Illustration 27
Up Stop Display

3. Pressing and releasing the “SCROLL” switch will

move the needle to the right one degree at a time.
When the value is changed, the needle will move
one degree, and a up arrow will flash once on the
display. The amount of adjustment is limited to
10 degrees from the default. If this limit has been
reached, a up stop will flash once on the display.

g00531227
Illustration 28
Down Stop Display

4. Pressing and releasing the “CLEAR” switch will

move the needle to the left one degree at a time.
When the value is changed, the needle will move
one degree, and a down arrow will flash once on
the display. The amount of adjustment is limited
to 10 degrees from the default. If this limit has
been reached, a down stop will flash once on the
display.

5. When the needle appears centered, exit the

calibration mode.
24
Systems Operation Section

i01862466

Warning Operation
SMCS Code: 7490

Table 9
WARNING OPERATION
Warning Indications (1)

“Alert “Action “Action

Warning Indicator Lamp Alarm
Category Flashes ”(3) Flashes”(4) Sounds ” “Operator Action Required” “Possible Result ”(2)
1 X No immediate action is required. No harmful effects or no
The system needs attention soon. damaging effects.
2 X X (4) Change machine operation or Severe damage to
perform maintenance to the system. components can occur.
2-S X X (4) X (5) Immediately change the machine Severe damage to machine
operation. components
3 X X (4) X (6) Immediately perform a safe engine Injury to the operator
shutdown. or severe damage to
components can occur.
(1) The active warning indications are marked with an X.
(2) This is the possible result if no action is taken by the operator.
(3) The alert indicator flashes at a 8 Hz rate.
(4) The action lamp flashes at a 1 Hz rate (1 second ON, 1 second OFF).
(5) Steady
(6) The action alarm sounds at a 1 Hz rate (1 second ON, 1 second Off).

g00427600
Illustration 30
Speedometer/Tachometer Module
(3) Tachometer
(4) Pictograph symbol
(5) Ground speed readout
(6) Transmission gear readout
g00789595
Illustration 29
Quad Gauge Module
(1) Gauge warning area
(2) Pictograph symbol
 25
Systems Operation Section

The Category 2-S is a conventional Category2 with

a continuous action alarm. A Category 2 that is
considered to be a severe condition will cause a
category 2-S to be logged. A Category 2 tells the
operator to change machine operation in order
to correct the warning condition. The operator is
instructed to IMMEDIATELY change operation of the
machine that relates to certain Category 2-S events.

Note: Most category 3 events cannot be

acknowledged by the operator.

Note: See the Operation And Maintenance Manual

for complete information on the Warning Operation.
g00302085
Illustration 31
Main Display Module i01854075

(7) Alert indicator

(8) Display area
Alert Indicator Description
SMCS Code: 7490
The Caterpillar Monitoring System notifies the
operator of an immediate problem with a machine
system or an impending problem with a machine
system. Warning operation begins when the main
display module receives a problem signal. The
problem signal reflects an abnormal condition of
the machine. Warning operation also begins when
the main display module detects a problem with
the control system. Switches, sensors, and other
electronic control modules on the machine provide
signals to the main display module. The problem
signals are the following conditions:

• An open switch. When a condition exceeds the trip

point of the switch, the switch opens.

• A sensor signal exceeds the limits. The main

display module determines the limits.

• Another condition is an abnormal condition that is

detected by another electronic control module. The
abnormal condition is then communicated over the
CAT data link to the main display module.

The main display module analyzes the problem

signals. In order to notify the operator of a warning,
the display components on the main display module
activate the appropriate warning indication. The
following warning indications will notify the operator: Illustration 32
g00789816

Alert Indicators For 143H And 163H

• The alert indicator FLASHES approximately nine
times per second. (1) Hydraulic Oil Temperature
(2) Parking Brake Status
(3) Charging System Status
• The action lamp FLASHES for one second and the (4) All Wheel Drive Status
action lamp is OFF for two seconds. (5) Check Engine Status
(6) Engine Coolant Temperature
(7) Steering System Status
• The action alarm SOUNDS for one second and the (8) Engine Oil Pressure
action alarm is OFF for two seconds. (9) Brake Air Pressure
(10) Transmission System Status
Note: In order to activate warning indications, more
than one input is required. The main display module
decides when the warning indications are activated.
26
Systems Operation Section

g00923072 g00923075
Illustration 33 Illustration 34
Alert Indicators For 140H, 160H, 12H, 120H And 135H Alert Indicators For 14H And 16H
(1) Hydraulic Oil Temperature (1) Hydraulic Oil Temperature
(2) Parking Brake Status (2) Parking Brake Status
(3) Charging System Status (3) Charging System Status
(4) Unused (4) Unused
(5) Check Engine Status (5) Check Engine Status
(6) Engine Coolant Temperature (6) Engine Coolant Temperature
(7) Steering System Status (7) Steering System Status
(8) Engine Oil Pressure (8) Engine Oil Pressure
(9) Brake Air Pressure (9) Brake Air Pressure
(10) Transmission System Status (10) Unused

Hydraulic Oil Temperature – This light will

indicate that the hydraulic oil temperature
is greater than 100 °C for the 14H, 140H
and the 160H. This light indicates that the hydraulic
oil temperature is greater than 88 °C for the 143H
and the 163H. The temperature is received from the
hydraulic oil temperature sensor.

Parking Brake Engaged – The light

indicates that the parking brake is engaged.
Parking brake status is received over the
data link. The information is used to modify the
warning level of this indicator. If the machine is in
neutral, only the indicator lights. However, if the
machine is in a forward gear or a reverse gear, the
action lamp and the action alarm also activates.

Charging System Status – The light
indicates that battery voltage is outside the
range of 24.8 to 29.5 DCV. While the engine
is running, the light also turns on when the alternator
frequency is below 90 Hz. In addition to the lighting
of the indicator, the action lamp and the action alarm
will also activate when the battery voltage rises
above 32 DCV.
Check The Engine – This application is
used with HEUI engines. The light indicates
that the engine system requires service.
The status is received from the engine ECM via the
CAT data link.
Steering System Status – The light
indicates that the primary steering pressure
is low. The pressure is received via the CAT
data link.
Low Engine Oil Pressure – This light
indicates that the engine oil pressure is low.
This signal is received by the Caterpillar
Monitoring System from the engine ECM via the CAT
data link. The indicator lights when the switch voltage
is high or the switch voltage is floating.
Transmission System Status – The light
indicates that the transmission conditions
are not working properly. The information
is received from the power train ECM via the CAT
data link.
i01862477
Component Description
SMCS Code: 7490
This arrangement of the Caterpillar Monitoring
System will work on the current Motor Graders.
Three modules constitute the Caterpillar Monitoring
System: main display module, quad gauge module,
and speedometer/tachometer module. All of the
following electrical components are not present on
every machine. The main display module recognizes
the machine and the components that are present.
For the location of the electrical components, see the
Electrical System Schematic in the Service Manual
for the machine.
27
Systems Operation Section
i01855060
Main Display Module
SMCS Code: 7490
g00297407
Illustration 35
Main Display Module
(1) Alert Indicators. (2) Display area.
The main display module continuously monitors all
machine systems. The main display module makes
decisions that are based upon the input from the
machine systems or other electronic control modules.
The main display module sends information to other
electronic controls on the machine. The input and
output of this information takes place over the CAT
data link. The outputs on the main display module
notify the operator and the service person of the
status of the machine systems. The following outputs
are on the Caterpillar Monitoring System: the quad
gauge, the speedometer/tachometer module, the
main display module, the action lamp, and the action
alarm. A connector with 40 contacts is located on
the rear of the module. This connector connects
the necessary harness wiring to the inputs and
outputs. For a complete description of the connector,
see Testing And Adjusting, “Connector Contact
Description of Main Display Module”.
Inputs/Outputs
CAT Data Link
The CAT data link (connector contacts 5 and 14) is
used to communicate with other electronic control
modules on the machine. The CAT data link is
bidirectional. This allows the modules to input the
information. Also, the modules can output the
information. This permits sharing of information
such as engine oil pressure, harness codes and
diagnostics.
28
Systems Operation Section
Display Data Link
The display data link (connector contacts 15, 25
and 35) provides the electrical signals in order to
operate the speedometer/tachometer module and
the quad guage module. These display modules
provide information about the machine systems to
the operator. Each module and each display indicator
is identified by an identifier or an address. Data is
continuously output from the main display module
to the other display modules. The module that is
addressed returns the data to the main display
module. This confirms the receipt of the data.
Inputs
The operation and the status of the machine is
transferred from the inputs to the main display
module. Three types of inputs exist: switch type
input, sensor type input, and sender type input.
Switches and harness wiring provide a ground
or an open signal to the switch inputs. Sensors
provide a changing signal to the sensor inputs of the
main display module. Senders provide a changing
resistance to the sender inputs of the main display
module.
Some inputs are multipurpose (switch, sensor or
sender). The following examples are of multipurpose
inputs: connector contacts 7, 17, 27 and 37 may be
either switch inputs or PWM sensor inputs, connector
contacts 9 and 18 may be either switch inputs or
0-240 ohm sender inputs, and connector contacts 8,
10, 28 and 38 may be switch inputs, PWM sensor
inputs or 70-800 ohm sender inputs. These inputs
are programmed at the time of installation in order to
define the components that are monitored. In order
to determine the inputs on the main display module
that are programmed, see the Electrical System
Schematic in the Service Manual.
Switch Inputs - Uncommitted
The uncommitted switch inputs (connector contacts
11, 19, 20, 21, 29, 32, 39, and 40) provide the
information that is used in order to operate the
ten alert indicators. The alert indicators are part
of the outputs on the main display module. These
switch inputs may be programmed at the time of
installation to work independently. The switch inputs
may be programmed with other switch inputs and/or
sensor inputs. The switch inputs will operate an
alarm indicator and the input will determine the
appropriate warning category (1,2 or 3). During
normal operation, these switch inputs are closed to
ground. The grounded inputs tell the main display
module that the conditions of the system are normal
and no alert indicators should be ON. These inputs
receive information from the following switches that
are located within the machine systems: pressure,
temperature, flow, level, and mechanical.
Other inputs for the main display module may be
programmed at the time of installation in order to
function as uncommitted switch inputs. For more
information, see the topics “Sensor Inputs - PWM”,
“Sender Inputs - 0-240 ohm” and “Sender Inputs -
70-800 ohm”.
Any one of the switch inputs may be programmed
to operate from an operator switch that is used to
operate the display area on the main display module.
For the location of this switch input, see the wiring
diagram for the machine. For information on the
operation of this switch, see System Operation,
“Normal Mode”.
Note: The alert indicators may also be programmed
to operate from sensor inputs. One of the ten alert
indicators is normally dedicated to the charging
system. The system uses the input for the battery
power and the input for the alternator terminal “R”.
Switch Inputs - Programming
The operation of the main display module is
determined by the programming switch inputs
(connector pins 3, 6, 12, 16, 22 and 31). The
main display module operates in a manner that
corresponds to the open state or the grounded state
of the programming switch inputs. These inputs
receive information from a permanent connection or
a harness code connector within the harness wiring.
The inputs for the programming switch consist of the
information from the harness code.
The inputs from the harness code switch tell the main
display module the machine model. Information of the
model is necessary because of the differences in the
machines. Information from the machine is necessary
for the main display module to make decisions.

Switch Inputs - Service
The inputs from the service switches (connector
contacts 23 and 33) control the setup, the mode
of operation, and certain diagnostic functions.
Grounding the service input (connector contact 23)
and the clear input (connector contact 33) at the same
time will initiate a change in the monitoring system
mode of operation. Removing ground from these two
inputs locks the main display module in the selected
mode. Other diagnostic functions are also performed
when the service inputs are grounded and/or opened
at the proper time. For more information, see System
Operation, “Modes Of Operation”.
Sensor Inputs - PWM
Each PWM sensor input (connector contacts 7, 17,
27 and 37) may be programmed in order to operate
as either a sensor input or a switch input.
A PWM signal is present when the sensor input is
programmed to operate as a PWM sensor input. A
PWM signal represents the condition of a machine
system. As the condition of the machine changes, the
duty cycle of the signal changes. The duty cycle is the
percentage of time that the signal is ON compared
to the time the signal is OFF. The frequency of
the signal is constant. The following examples are
conditions that are monitored: temperature, pressure,
and level. The main display module measures the
duty cycle of the output for the PWM sensor. The
information is then sent to the quad gauge in order
to be shown on one of the gauges.
Note: See “Switch Input - Uncommitted” for
input operation when the PWM sensor input is
programmed to operate as a switch input. Use the
Electrical System Schematic of the machine that is
being serviced in order to determine the inputs that
are programmed.
Note: The input from the PWM sensor may be
programmed to operate a gauge or an alarm
indicator. The sensor can also be programmed to
operate both a gauge and an alarm indicator.
Sensor Input - Frequency
At each frequency sensor input (connector contacts
26, 30 and 36), an AC signal is present. The
signal represents the speed of a machine system.
Frequency sensors for engine speed and machine
speed provide an AC signal to the main display
module. The main display module measures the
frequency (Hz) of the AC signals. The information is
then sent to the speedometer/tachometer module.
29
Systems Operation Section
At the input for the alternator terminal “R” (connector
contact 30), the terminal “R” of the alternator provides
an AC signal to the main display module. The
main display module determines the speed of the
alternator by measuring the frequency (Hz) of the AC
signal. The alternator R terminal helps determine the
condition of the electrical charging system. Harness
wiring directly connects the alternator terminal
“R” to the sensor input for the alternator “R”. The
information on the alternator terminal “R” is used with
other inputs (engine oil pressure, engine speed, etc)
in order to determine when the engine is running.
Sender Input - 0- 240 Ohm
Each 0-240 ohm sender input (connector contacts 9
and 18) may be programmed in order to operate as
either a sender input or a switch input.
A sender input measures a resistance value in order
to determine the condition of the system. A resistive
fuel level sender (or a component with a similar
output signal) provides this information. The output
resistance of the fuel level sender corresponds to the
depth of fuel within the tank. The main display module
measures the resistance value. The information is
then sent to the quad gauge in order to be shown on
one of the gauges.
Note: See “Switch Input - Uncommitted” for input
operation when the 0-240 ohm sender input is
programmed to operate as a switch input. Use the
Electrical System Schematic of the machine that is
being serviced in order to determine the inputs that
are programmed.
Note: The 0-240 ohm sender input may be
programmed to operate a gauge or an alarm
indicator. The sensor can also be programmed to
operate both a gauge and an alarm indicator.
Sender Input - 70-800 Ohm
Each 70-800 ohm sender input (connector contacts
8, 10, 28 and 38) may be programmed in order to
operate as a sender input, a PWM sensor input or
a switch input.
The 70-800 ohm sender input measures a resistance
value in order to read the condition of the system. The
temperature sender (or a component with a similar
output signal) provides this information. The output
resistance of the temperature sender corresponds to
the temperature of the fluid that is being measured.
Oil, coolant and hydraulic temperature are examples
of fluid temperatures that are measured. The main
display module measures the resistance value. The
information is then sent to the quad gauge in order
to be shown on one of the gauges.
30
Systems Operation Section
Note: The 70-800 ohm sender input may be
programmed to operate a gauge or an alarm
indicator. The sensor can also be programmed to
operate both a gauge and an alarm indicator.
Note: See “Sensor Inputs - PWM” for input operation
when the 70-800 ohm sender input is programmed to
operate as a PWM sensor input. Use the Electrical
System Schematic of the machine that is being
serviced in order to determine the inputs that are
programmed.
Note: See “Switch Input - Uncommitted” for input
operation when the 70-800 ohm sender input is
programmed to operate as a switch input. Use the
Electrical System Schematic of the machine that is
being serviced in order to determine the inputs that
are programmed.
Input - Voltage
The input for battery voltage (connector contact 1
and 2) provides the main display module with power.
The voltage input is also used by the main display
module to monitor the machine electrical system.
This information from the voltage helps determine the
condition of the electrical system.
When an alert indicator is used in order to indicate
the voltage of the machine system, the battery signal
is combined with the signal for the terminal “R”
within the main display module. When an electrical
system fault occurs, there are two possible warning
categories. The category is set by the type of fault.
Category 1 – The frequency for the terminal “R”
from the alternator is less than 90 Hz or the system
voltage is greater than 29.5 volts for at least 2
seconds. The system voltage is less than 24.8 volts
for a least 2 seconds.
Category 3 – The system voltage is less than 23.0
volts for at least 2 seconds or the system voltage is
greater than 32.0 volts for at least 2 seconds.
Outputs
g00297407
Illustration 36
Main Display Module
(1) Alert Indicators. (2) Display area.
The outputs of the Caterpillar Monitoring System
notify the operator of the status of the machine
systems. The main display module provides electrical
power for the other display modules and the sensors.
The following outputs are on the Caterpillar
Monitoring System: the display for the main display
module, the display data link, the alert indicators,
the action lamp, the action alarm, the sensor power
supply, and the power supply for the main display
module.
The outputs on the main display module are the alert
indicators (1) and the display area (2).
The alert indicators notify the operator of abnormal
conditions with the machine. The main display
module uses the status of the uncommitted switch
inputs, sender inputs and/or sensor inputs in
order to determine when an abnormal condition is
present. The main display module then FLASHES
the appropriate alert indicator. The symbol of the
FLASHING alert indicator identifies the responsible
machine system. When an alert indicator FLASHES,
an abnormal condition exists. For more information,
see System Operation, “Warning Operation”.
Note: The main display module may use a
combination of inputs in order to determine abnormal
conditions. For example, engine oil pressure and
engine rpm may be used to enable the alert indicator
for the machine electrical system. The alert indicator
for the machine electrical system will FLASH if an
abnormal condition exists on the input for the terminal
“R” or the input for +battery.
 31
Systems Operation Section

The display area has various symbols that show the Table 10
condition of the machine systems. The symbols also Contact Description Of Display Components
show information for service and setup. The type of Connector
information that is shown on the display depends
on the operating mode. For more information about No. Function Type
the display area, see System Operation, “Modes of 1 +9 DCV Input
Operation”.
2 Ground Ground
Action Lamp 3 Display Clock Input

When a serious abnormal condition exists, the 4 Display Data Input

main display module activates the output for the
action lamp (connector contact 13) and the action
lamp FLASHES. For more information, see System
Operation, “Warning Operation”.
Action Alarm
When a critical abnormal condition exists, the
main display module activates the output for the
action alarm (connector contact 4) and the action
alarm SOUNDS. For more information, see System
Operation, “Warning Operation”.
Power Supply Output - Sensor
5 Display Load Input
6 Harness Code Open(1)
(1) Used to give two display components of the same type a unique
component number. This is needed so the main display module
can send unique information to each identical component.
Since all monitoring system configurations included in this
manual have at most one module, this input should be open.
The display components receive information from
the main display module. The information that
is shown notifies the operator and the service
person of the status of the machine systems. The
components are the quad gauge module and the
speedometer/tachometer module.

The output for the sensor power supply (connector i01858071

contact 24) provides 8 DCV for the PWM sensors
that are connected to the inputs of the main display Quad Gauge Module
module.
SMCS Code: 7450
Power Supply Output - Display Modules
The output for the power supply to the display
module (connector contact 34) provides 9 DCV for
the display modules. The quad gauge module and
the speedometer/tachometer module cannot function
without this power output.

i01521112

Display Components
SMCS Code: 7450

The following table shows the contact description for

all the display components.

g00789595
Illustration 37
An Example Of A Quad Gauge Module
(1) Gauge warning area. (2) Pictograph symbol.
32
Systems Operation Section

The quad gauge module shows the following Note: The input is received from the fuel level sender.
information: engine coolant temperature, articulation The warning level for this gauge is a Level I.
angle, system voltage, and fuel level. The main
display module uses the information from sensor
i01020517
inputs or the CAT data link in order to calculate the
values that are shown on the gauges. Pictograph
symbol (2) identifies the parameter for the machine
Speedometer/Tachometer
system which is shown on each gauge. Abnormal Module
values are shown by the gauge warning area (1).
SMCS Code: 7450
Table 11
Engine Coolant Temperature Gauge
Minimum Displayed Value 40 °C (104 °F)
Midpoint Value 82 °C (179 °F)
Red Zone Value 107 °C (224 °F)

Maximum Displayed Value 140 °C (284 °F)

Note: The information is received from the engine

coolant temperature sensor. The warning level for
this gauge is a Level II.
g00357114
Illustration 38
Table 12
Speedometer/Tachometer module
Articulation Angle Sensor Gauge (1) Tachometer. (2) Pictograph symbol. (3) Speed readout. (4)
Gear readout.
Minimum Displayed Value −20 °C (−4 °F)
Midpoint Value 0 °C (32 °F) Speed readout (3) consists of three digits and the
readout may show the machine ground speed in
Maximum Displayed Value 20 °C (68 °F)
MPH (km/h). The main display module calculates
speed by using the information from a frequency
Note: The information is received from the articulation sensor input or the CAT data link. Illumination of the
angle sensor. appropriate digits shows the speed.
Table 13 Gear readout (4) consists of two digits that show the
System Voltage Gauge transmission gear which is engaged. The left digit
shows the actual gear, “1”, “2”, “3”, etc. The right digit
Minimum Displayed Value 22 V shows the direction that is selected, “F”, “N” or “R”.
Midpoint Value 26.2 V
Tachometer (1) shows the engine speed in RPM.
Red Zone Low 23.8 V The engine speed is determined by the information
Red Zone High 28.5 V that is sent to the main display module over the CAT
data link. The engine speed is also determined from
Maximum Displayed Value 31 V a frequency sensor input.

Note: The information is received via the CAT data

i01858111
link.

Table 14
Switches
Fuel Level Gauge SMCS Code: 1435; 7332
Minimum Displayed Value 5%
Switches provide information (input) to the main
Midpoint Value 50% display module. Switches are two state devices. The
two states of the switches are open and closed.
Red Zone Value 10%
Maximum Displayed Value 95% Closed – The switch connects the control input to
frame ground.
 33
Systems Operation Section

Open – The switch connects the control input to Pressure Switch (RH Brake System)
nothing. (The input is floating.)

During normal operation, all the switches are closed

to ground. When a condition exceeds the trip point
of the switch, the switch opens. This tells the main
display module of the abnormal condition. The main
display module then begins the warning operation
and the module notifies the operator of the abnormal
condition (problem).

Note: For specifications on the switches, see the

Electrical System Schematic for that particular
machine.

Rocker Switch (Operator Mode Illustration 40

g00793486

Selector) Pressure Switch

(1) Schematic symbol
Grounding the operator mode selector switch (2) Switch
causes the main display module to scroll through the
available operator modes for the machine. Opening During normal operation, pressure switch (2) is open
the selector switch places the Caterpillar Monitoring to ground. The switch closes when brake system air
System in the currently displayed operator mode. pressure is present. The switch opens when brake
A list of possible operator modes is shown at the system air pressure is too low.
beginning of the Modes of Operation section. See
the Operation And Maintenance Manual in order to
determine the “Operator Modes” that are available for i01802612
the machine that is being serviced.
Senders
Temperature Switch (Hydraulic Oil) SMCS Code: 1408-UN

Level Sender (Fuel)

g00304432
Illustration 39
Temperature Switch (Hydraulic Oil)
(1) Switch. (2) Schematic symbol.
During normal operation, temperature switch (1)
is closed to ground. The switch opens when the
temperature of the fluid system is greater than the
specified value. The open switch tells the main
display module that there is a high temperature. The
switch is closed when the switch is off the machine.
Pressure Switch
Pressure Switch (Parking Brake)
Pressure Switch (LH Brake System)
g00303717
Illustration 41
Level Sender (Fuel)
(1) Sender
(2) Schematic symbol
Fuel level sender (1) provides fuel level sensing. A
resistive signal which corresponds to the depth of
fuel within the fuel tank is sent from the sender to the
main display module. Typically, there are two possible
types of senders: 0 to 90 ohms and 33 to 240 ohms.
The main display module measures the resistance
value in order to determine the fuel that is remaining
in the tank. Typical gauge readings for the fuel level:
34
Systems Operation Section
• When the fuel tank is at 4% of capacity, the gauge
shows that the tank is empty.
• When the fuel tank is at 14% of capacity, the gauge
shows the needle at the red zone on the gauge.
• When the fuel tank is at 95% of capacity, the gauge
shows that the tank is full.
Temperature Sender
g00303718
Illustration 42
Temperature Sender
(1) Schematic symbol
(2) Sender
Temperature sender (2) provides a method for
sensing fluid temperature. The temperature sender
produces a resistive signal which corresponds to
the temperature of the fluid that is being monitored.
Typically, the resistance range of the sender is
from 70 ohms at 110°C (230°F) to 3000 ohms at
25°C (77°F). The main display module measures
the resistance value in order to determine the fluid
temperature.
Position Sender (Articulation
Angle)
g00793324
Illustration 43
Position Sender (Articulation Angle)
(1) Schematic symbol
(2) Sender
Position sender (2) provides articulation sensing. A
resistive signal which corresponds to the articulation
angle is sent from the sender to the main display
module. The main display module measures the
resistance value in order to determine the articulation
angle.
i01060965
Sensors
SMCS Code: 1408-NS
General Information
Sensors provide information (input) to the main
display module about changing conditions. The
sensor signal changes in a proportional manner in
order to reflect the changing condition. The main
display module shows the information from the
sensors on the gauges. The main display module
recognizes two types of sensor signals.
Frequency – The sensor produces an AC signal.
The frequency (Hz) varies as the condition changes.
Pulse Width Modulated (PWM) – The sensor
produces a digital signal. The duty cycle varies as
the condition changes. The frequency of this signal
is constant.
Frequency Sensors
Frequency sensors produce an AC signal. The
frequency (Hz) varies as the condition changes.
 35
Systems Operation Section

Speed Sensor Pulse Width Modulated (PWM)

Sensors

g00304924
Illustration 44
Speed Sensor
(1) Sensor. (2) Schematic symbol.

Speed sensor (1) is a frequency sensor. Speed

sensors are used in order to measure engine speed
(RPM) and machine speed (MPH (km/h)). The sensor
generates an AC signal from the passing gear teeth.
The signal is sent to the main display module. The
main display module measures the sensor frequency
(one pulse per gear tooth). The main display module
determines the engine speed or the machine speed.
The speed is then shown on the display.
g00304925
The engine speed sensor is located on the flywheel Illustration 45
housing. The speed sensor for the machine is located Pulse Width Modulated Signal
at the output end of the transmission housing.

g00304926
Illustration 46
Typical PWM Sensor Schematic

Pulse width modulated (PWM) sensors produce a

digital signal. The duty cycle varies as the condition
changes. The frequency remains constant.
36
Systems Operation Section
Temperature Sensor
g00304927
Illustration 47
Temperature Sensor
(1) Schematic symbol. (2) Sensor.
Temperature sensor (2) reacts to the temperature of
fluids. Examples of the fluids are hydraulic oil, power
train oil, and engine coolant. The sensor receives
operating power from the main display module (8
DCV) or from the battery (24 DCV). The sensor sends
the main display module a PWM signal. The signal
changes as the fluid temperature changes. The main
display module measures the duty cycle of the sensor
signal in order to determine the fluid temperature.
Pressure Sensor
g00304929
Illustration 48
Pressure Sensor
(1) Schematic symbol. (2) Sensor.
Pressure sensor (2) reacts to the pressure of fluids.
The sensor receives operating power from the main
display module (8 DCV) or from the battery (24 DCV).
The sensor sends the main display module a PWM
signal. The signal changes as the fluid pressure
changes. The main display module measures the
duty cycle of the sensor signal in order to determine
the fluid pressure.
i01679184
Action Lamp
SMCS Code: 1408-LMP; 7400-LMP
g00304970
Illustration 49
Action Lamp Symbol
The action lamp connects to an output of the main
display module. The action lamp is an LED that
is located within the operator’s viewing area. The
FLASHING of the action lamp tells the operator that a
condition exists. The condition will require changing
the operation of the machine. The action lamp is
located on the main display module. The action
lamp will FLASH whenever a warning category 2,
a warning category “2S”, or a warning category 3
problem exists.
i01940097
Action Alarm
SMCS Code: 7407
g00307223
Illustration 50
Action Alarm
(1) Schematic symbol. (2) Action alarm.
The action alarm connects to an output of the main
display module. When the action alarm is audible, the
machine needs immediate attention. A safe machine
shutdown is required. The main display module will
sound the action alarm whenever a warning category
3 problem exists. An alarm for a warning category
3 is a pulsating sound. The alarm for a warning
category 2S is a continuous tone.
 37
Systems Operation Section

The action alarm does not operate when the engine

is stopped. The main display module uses functions
in order to determine when the engine is running.
The following functions are examples: engine oil
pressure, alternator speed, and engine speed. If
necessary, the action alarm SOUNDS when the main
display module decides that the engine is running.

i00703569

Related Components
SMCS Code: 1408; 7450

Alternator
The R terminal of the alternator is connected to an
input of the main display module. The main display
module monitors the frequency at the R terminal of
the alternator. This tells the main display module if
the alternator is rotating.

Other Electronic Controls

Some machines have electronic control modules
that communicate with the main display module.
The CAT data link connects these electronic controls
together. This connection allows the sharing of
information. The following information is an example
of the information that is shared: engine oil pressure,
harness codes, and diagnostic information. For
example, an electronic engine control sends the
engine speed information to the main display module
over the CAT data link. In this situation, the engine
speed sensor is not a Caterpillar Monitoring System
component. If there is a problem with the engine
speed sensor, the electronic engine control service
manual would be used to troubleshoot the speed
sensor circuit.
38
Troubleshooting Section

Troubleshooting Section i01966052

Service Tools
Introduction SMCS Code: 0785

The following service tools should be used to aid in

i01400224 troubleshooting the electrical system.
General Information Table 15
Service Tools
SMCS Code: 7490
Part Number Part
Troubleshooting the Caterpillar Monitoring System
CAT Electronic Technician
requires additional information from the machine’s
Service Manual. The additional manuals that may 6V-7070 Digital Multimeter
be required are the Service Manual, the System 9U-7330
Schematic, the Parts Manual and the Operation and 8T-3224 Needle Tip Group
Maintenance Manual for the machine that is being
serviced. 7X-1710 Multimeter Probe Group
8T-8726 Adapter Cable Assembly
As a guide, a typical system schematic is included at
the end of this manual. For an accurate representation 6V-3000 Connector Repair Kit (Sure Seal)
of the machine that is being diagnosed, refer to
9U-7246 Connector Repair Kit (Deutsch DT)
Electrical System Schematic in the Service Manual
for the machine that is being serviced. 4C-3406 Connector Repair Kit (Deutsch)
4C-8195 Control Service Tool (Switch Box)
When the troubleshooting procedure instructs you to
“REPAIR THE HARNESS”, use the Electrical System
Schematic for the machine that is being serviced
to trace the circuit. Perform continuity checks at
the harness connectors in order to locate harness
failures. At the connectors of the components, always
check the ground circuit. Less than five ohms of
resistance is required between the ground contacts
of the connector and the frame ground. Excessive
ground resistance that is greater than five ohms can
cause incorrect diagnosing of problems.

During troubleshooting, inspect all connections before

any component is replaced. If these connections are
not clean and tight, permanent electrical problems or
intermittent electrical problems can result. Check that
the wires are pushed into the connectors completely.
Make sure that the connections are tight before other
tests are made.
Failure of an electrical component can cause the
failure of other components. Also, failure of an
electrical component can be caused by the failure
of other components. Always attempt to correct the
cause of an electrical system failure before you
replace a component.
g00280782
Illustration 51
Connections for the Electronic Technician (ET)
The components that are needed in order to use the CAT Electronic
Technician in order to determine diagnostic codes are listed:
(1) An IBM-COMPATIBLE personal computer with an installed
current version of Caterpillar Electronic Technician software
(2) 139-4166 Data Link Cable or 7X-1570 Data Link Cable
(3) 7X-1425 Cable and 4C-6805 Adapter
(4) Special Publication, JEBD3003, Special Publication,
JERD2124, Special Publication, JERD2129 ; Caterpillar
Electronic Technician software
(5) 7X-1700 Communication Adapter Tool with Special
Publication, NEXG4323, “Communications Adapter Software”

Illustration 52
g00774942
Connections for the Communication Adapter II and the Electronic
Technician (ET)
The components that are needed in order to use the
Communication Adapter II and the CAT Electronic Technician in
order to determine diagnostic codes are listed:
(6) Cable
(7) 171-4400 Communication Adapter II
(8) Service diagnostic cable.
(9) Current version of Caterpillar Electronic Technician software
and an IBM-COMPATIBLE personal computer
Reference: See Special Publication, NEHS0758,
“Communications Adapter II User’s Manual Contains
Software”.
Note: Caterpillar Electronic Technician (ET) is a
software program that can be used on an IBM
compatible personal computer.
In order to use the Caterpillar Electronic Technician
(ET), order the following materials: Special
Publication, JERD2124, “ET Single Use Program
License”, Special Publication, JEHP1026,
“Information and Requirements Sheet”, 7X-1425
Data Link Cable and the Data Subscription, and
Special Publication, JERD2142, “Data Subscription”.
The Special Publication, JEHP1026, “Information
and Requirements Sheet” lists the required hardware
and the features of the ET.
The Electronic Technician (ET) is not required in
order to determine the diagnostic codes and the
ET is not required in order to clear the diagnostic
codes. However, the process of determining the
diagnostic codes is easier and faster by using the ET.
The ET can also display information on the history
of a diagnostic code and the parameter status of
diagnostic codes. These features allow the ET to be
a useful tool for troubleshooting.
39
Troubleshooting Section
The Electronic Technician (ET) is used to
communicate to the electronic control module over
the data link by connecting to the machine diagnostic
connector. For more information and the locations
of the connectors, see Troubleshooting, “Electrical
Components and Connector Locations” and the
Electrical System Schematic in your machine’s
Service Manual.
For instructions on servicing Sure Seal connectors,
see Special Instruction, SMHS7531. For instructions
on servicing Deutsch DT connectors, see Special
Instruction, SEHS9615.
Use the digital multimeter for making continuity
checks or for measuring voltage. For instructions
about the use of the 6V-7070 Digital Multimeter,
see Special Instruction, SEHS7734. The 7X-1710
Multimeter Probe measures the voltage at the
connectors without disconnecting the connectors.
The probe cables are pushed into the back of the
connector along the wire. The 8T-8726 Adapter
Cable has a 3 pin breakout connector. The adapter
cable is used for measurements in the sensor circuits.
Note: Except for harness tests, using continuity
testers such as the 8T-0500 Continuity Tester or
voltage testers such as the 5P-7277 Voltage Tester
is not recommended for today’s Caterpillar electrical
circuits.
Service Switches
During troubleshooting, it is necessary for the service
person to use the diagnostic operations of Caterpillar
Monitoring System. Service personnel use the
service switches in order to access the different
display modes of diagnostic operation.
The switches are the momentary type of switch. The
service personnel activate the switches by pressing
and holding. Pressing the clear switch grounds the
clear input (contact 33) of the monitor. Pressing the
set switch grounds the service switch (contact 23)
of the monitor. The location of the service switches
will vary depending on the machine that is being
serviced. Not all machines are equipped with service
switches. For a more accurate location of the service
switches, see the Electrical System Schematic in the
Service Manual for the machine.
40
Troubleshooting Section

4C-8195 Control Service Tool Changing Modes

Table 16
Activation Of Display Operations (Quick Reference)
Display Service Clear Contact(1)
Operation Contact(1)
Changing Modes:
To Scroll Ground Ground
To Hold Open Open
Service Modes:
To Scroll Ground Open
To Hold Open(2) Open
g00743610
Illustration 53
To Clear(3) Open Ground
4C-8195 Control Service Tool
Tattletale Mode:
To Clear Open Ground
Numeric Readout Mode:
To Scroll Ground Open
To Hold Open Open
(1) of the service connector.
(2) Open when the desired information is shown during scrolling.
(3) A diagnostic code can be cleared only while it is on hold. The
diagnostic code for a fault that is currently present can not be
cleared

For a detailed explanation of the different modes, see

Systems Operation, “Modes of Operation”.
g00743652
Illustration 54
Schematic for the Control Service Tool
i01398954

The 4C-8195 Control Service Tool is used on Electrical Component and

machines that are not equipped with service
switches. 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 will scroll through
the display while the main display module is in
the service mode or the numeric readout mode.
Actuating the clear switch clears the diagnostic code
that is being continuously shown when the main
display module is in service mode. Actuating the
clear switch clears all extreme values when the main
display module is in tattletale mode.
Connector Locations
SMCS Code: 7553-546-WW
General Information
The Electrical System Schematic, Parts Manual and
Operation and Maintenance Manual for the machine
that is being serviced should be used to locate
electrical components and connectors.
The following information is a guide to reading
the tables on the back of the Electrical System
Schematic.
• The “Component Location” table uses white circles
to mark the locations in the profile of the machine
and in the area views. Alphabetical letters in the
“Machine Location” column indicate a general
area of the machine. Refer to the corresponding
footnote at the end of the table for a description
of the location.
 41
Troubleshooting Section

• The “Harness Connector Location” table uses

white circles to mark the locations in the general
view and in the area views. Alphabetical letters in
the “Machine Location” column indicate a general
area of the machine. Refer to the corresponding
footnote at the end of the table for a description
of the location.

Note: The “Harness Connector Location” table uses

black circles on certain electrical system schematics.

Connector Contact Numbers for

the Main Display Module
g00309224
Illustration 56
Service connector with jumpers (typical example)
(1) Jumper. Service contact grounded (2) Jumper. Clear contact
grounded (3) Service connector.

g00309227
Illustration 57
End view of service connectors

Various diagnostic functions require the grounding

and/or the 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
g00309228 the service connector. These electrical connections
Illustration 55
Connector of the main display module are made with two jumpers. See Troubleshooting,
“Accessing Diagnostic Information”.
Service Connector
The service connector provides access to the
service and clear inputs of the main display module.
Connector contact 1 is the service input and contact
2 is the clear input. Contacts 3 and 4 could be any
wire from the 200 family. The service connector
is usually located under the dashboard within the
operator compartment. The service connector is a
DT type of connector. For a more accurate location
of the service connector, see the Electrical System
Schematic in the Service Manual.
42
Troubleshooting Section

i01671837

Diagnostic Capabilities
SMCS Code: 7490

The Caterpillar Electronic

Technician (ET)

g00777826
Illustration 58

The Caterpillar Electronic Technician (ET) is a
software program that is used to access data. The
service technician can use the Caterpillar Electronic
Technician in order to perform maintenance work on
the machine. Some of the options that are available
with the Caterpillar Electronic Technician are listed
below:
• View Diagnostic codes. See Troubleshooting,
“Using the Caterpillar Electronic Technician to
Determine Diagnostic Codes”.
• View the status of parameters.
• Clear active diagnostic codes and clear logged
diagnostic codes
• Perform calibration of machine systems.
• Program the ECM (Flash). This is done with the
“WINflash” program. See Testing and Adjusting,
“Electronic Control Module (ECM) - Flash
Program”.
• Print reports.
The following list contains some of the diagnostic
functions and programming functions that are
performed by the service tools.
• The failures of the ECM system are displayed.
• The status of most of the inputs and the outputs
are displayed.
• The settings for the ECM are displayed.
• Display the status of the input and output
parameters in real time.
 43
Troubleshooting Section

• Display the clock hour of the internal diagnostic

clock.

• The number of occurrences and the clock hour

of the first occurrence and the last occurrence is
displayed for each logged diagnostic code.

• The definition for each logged diagnostic code and

each event is displayed.

• Load new FLASH software.

See Troubleshooting, “Diagnostic Code List” for the
list of diagnostic codes for the ECM.

See Troubleshooting, “Using the Caterpillar

Electronic Technician to Determine Diagnostic
Codes”. Diagnostic information is accessed with the
following drop down menus:

• Active diagnostic codes

• Logged diagnostic codes
Status Groups For The Electronic
Technician
The Status groups are lists of machine parameters.
The status of the parameters are shown in real time.

g00867289
Illustration 59
Typical ET Status Screen
44
Troubleshooting Section

Diagnostic Code (Table 17, contd)

Diagnostic Codes For Caterpillar Monitoring
Procedures System (MID 030)(1)
CID/FMI Description
i01663522
FMI 03 Signal voltage above normal or short to
Diagnostic Code List +battery
FMI 04 Voltage below normal or short to ground
SMCS Code: 7569 (1) This table pertains only to faults with a MID of 030.
Table 17
Note: Every machine may not have all of the
Diagnostic Codes For Caterpillar Monitoring diagnostic codes that are listed in the preceding
System (MID 030)(1)
table. Also, every machine may not have all the FMI
CID/FMI Description for a given CID.
CID 0084 Speed Sensor (Ground):
Note: The preceding table shows the diagnostic
FMI 08 Signal is abnormal codes for the Caterpillar Monitoring System. When
the Caterpillar Monitoring System is in the service
CID 0096 Level Sender (Fuel): mode, diagnostic codes from the other electronic
FMI 03 Signal voltage above normal or short to control modules are shown on the display area of
+battery the Caterpillar Monitoring System. The information
from the diagnostic code is transferred from other
FMI 04 Voltage below normal or short to ground
electronic control modules via the CAT data link to
FMI 08 Signal is abnormal the main display module. This diagnostic information
is shown when the main display module is in the
CID 0248 Data Link:
service mode. The module identifier (MID) indicates
FMI 02 Data erratic, intermittent, or incorrect the electronic control module that is sending
the diagnostic code. The MID for the Caterpillar
CID 0263 Sensor Power Supply: Monitoring System is “030”. This Service Manual
FMI 03 Signal voltage above normal or short to is used for diagnostic codes with a MID of “030”.
+battery The MID of other electronic control modules on a
particular machine are listed on the Electrical System
FMI 04 Voltage below normal or short to ground
Schematic. Troubleshooting information for those
CID 0271 Alarm (Action): diagnostic codes can be found in the service manual
for that system.
FMI 03 Signal voltage above normal or short to
+battery
Note: When a sensor fault is present, the
FMI 05 Current below normal or open circuit corresponding warning for that sensor is also
activated for the operator. For example, if the signal
FMI 06 Current above normal or short to ground
wire for the engine coolant temperature sensor is
CID 0324 Lamp (Action): shorted to the +battery circuit, then the following
actions take place:
FMI 03 Signal voltage above normal or short to
+battery
• The corresponding diagnostic code is stored in
FMI 05 Current below normal or open circuit memory.
FMI 06 Current above normal or short to ground
• The gauge for the engine coolant temperature is
CID 0615 Position Sender (Articulation) indicating in the warning region.
FMI 03 Signal voltage above normal or short to
+battery • The action lamp is FLASHING.
FMI 04 Voltage below normal or short to ground Notice that the second and third above items are the
CID 0819 Display Data Link:
same warning indications that are activated if the
engine overheats.
FMI 02 Data erratic, intermittent, or incorrect
CID 0821 Display Power Supply:
(continued)

i01672648
Using Caterpillar Monitoring
System to Determine
Diagnostic Codes
SMCS Code: 7490; 7569
Procedure
g00429460
Illustration 60
Display Area
(1) First display. (2) Second display. (3) Module identifier (MID). (4)
service code indicator (“SERV CODE”). (5) Component identifier
(CID). (6) Failure mode identifier (FMI).
The following procedures may cause new diagnostic
codes to be logged. Therefore, before any procedures
are performed make a list of all the active diagnostic
codes in order to determine the system problems.
Clear the diagnostic codes that were caused by the
procedure, when each procedure is complete.
Note: Before performing a procedure, always check
all the circuit breakers. Repair the cause of any circuit
breaker that is tripped.
Use the following procedure to troubleshoot
diagnostic code information.
1. Place the Caterpillar Monitoring System in service
mode (mode 3). In order to place the Caterpillar
Monitoring System in service mode, close the
service and clear switches. Open the switches
when service mode “3” is shown on the display.
45
Troubleshooting Section
Note: The diagnostic scrolling mode may be
entered in order to see the diagnostic codes, but the
diagnostic codes can be more easily diagnosed by
using the service mode. The service mode allows
the diagnostic codes to be placed on hold for further
investigation. The service mode allows the diagnostic
codes to be cleared when the problem has been
fixed.
2. The diagnostic code is shown and the diagnostic
code is on hold at this time. The display toggles
between showing MID (3) and CID (5) and FMI
(6). If you are in the service mode and a diagnostic
code is not present, “---” will be displayed.
3. In order to view all the diagnostic codes, scroll
through the diagnostic codes. In order to scroll
through the diagnostic codes, close the service
switch. The display momentarily shows MID (3),
CID (5) and FMI (6) for each diagnostic code. The
word “End” will be shown after the last diagnostic
code in the list.
4. Place the desired diagnostic code on hold. In
order to place the diagnostic code on hold, open
the service switch when the desired diagnostic
code is shown.
5. Use the information from the MID in order
to determine the ECM that is generating the
diagnostic code. If the MID is not 027, see
Electrical System Schematic, “Module Identifier
(MID) Table” of the machine that is being serviced.
Use the table to determine the ECM that has
detected the diagnostic code. Then see the
service manual module for that electronic control.
If the MID is 082, use this Service Manual Module
to troubleshoot the diagnostic code that generated
the diagnostic code.
6. Observe the “SERV CODE” indicator (4). In
the service mode, the “SERV CODE” indicator
functions as a “SERV CODE” indicator.
• If the “SERV CODE” indicator (4) shows
“SERV CODE”, then the failure that caused
the diagnostic code that is shown is currently
present.
• If the “SERV CODE” indicator (4) is OFF, then
the diagnostic code that caused the diagnostic
code that is shown is not present at this time.
7. See the corresponding test in order to troubleshoot
the diagnostic code. Use the Service Manual for
the ECM that is generating the diagnostic code.
8. After a diagnostic code is corrected, clear the
diagnostic code. In order to clear the diagnostic
code, close the clear switch while the diagnostic
code is on hold. After clearing, the display
advances to the next available diagnostic code.
46
Troubleshooting Section

9. Repeat Steps 2 through 8 for the remaining

diagnostic codes. Return to the normal mode
when you are finished. In order to return to
the normal mode, close the service and clear
switches. Open the switches when mode “0” is
shown on the display.

i01782268

Using Caterpillar Electronic

Technician to Determine
Diagnostic Codes
SMCS Code: 0785-UE; 7569

Connect the Caterpillar ET to the machine. Turn the

key switch to the RUN position. Start the Cat ET.
The Cat ET will initiate communications with the
Electronic Control Modules on the machine. After
communication has been established, the Cat ET
will list the Electronic Control Modules. Choose
the desired Electronic Control Module. After the
diagnostic codes have been determined with the Cat
ET, see the test procedure for the corresponding
diagnostic code.

Reference: Troubleshooting, “Service Tools”

Active Diagnostic Codes

 47
Troubleshooting Section

g00859671
Illustration 61
Typical Cat ET screen for active diagnostic codes

The following procedures may cause new diagnostic

codes to be logged. Therefore, before any procedures
are performed make a list of all the active diagnostic
codes in order to determine the system problems.
Clear the diagnostic codes that were caused by the
procedure, when each procedure is complete.

Note: Before performing a procedure, always check

all the circuit breakers. Repair the cause of any circuit
breaker that is tripped.

A screen is provided in Cat ET for active diagnostic

codes. The screen will display the diagnostic codes
that are active. Active diagnostic information shall
include a component identifier (CID), a failure mode
identifier (FMI) and a text description of the problem.

Logged Diagnostic Codes

48
Troubleshooting Section

g00859762
Illustration 62
Typical Cat ET screen for logged diagnostic codes

A screen is provided in Cat ET for logged diagnostic i01802609

codes. The screen will display diagnostic codes that
are logged. The Cat ET will log diagnostic codes that MID 030 - CID 0084 - FMI 08
are intermittent. The logged diagnostic data shall
include a component identifier (CID), a failure mode SMCS Code: 7493-038
identifier (FMI), and a text description of the problem.
Also, the logged diagnostic data shall include the Conditions Which Generate This Code:
number of occurrences of the problem and two time
stamps. The time stamp displays the first occurrence
of the problem and the time stamp displays the most
recent occurrence of the problem.

Diagnostics are logged in non-volatile memory. On

powerup, the ECM will clear any diagnostic codes
that have not been detected or active within the last
150 hours of machine operation.

g00866484
Illustration 63
Schematic for the ground speed sensor

This diagnostic code is associated with the ground
speed sensor. The FMI 08 means that the main
display module has determined that the signal
frequency or the signal pulse width is not within the
expected range.
The possible causes of this diagnostic code are listed
below:
• The sensor has failed.
• Intermittent connections or poor connections
• Mechanical devices are loose.
• The main display module has failed. This is
unlikely.
Note: The following test procedure may create other
diagnostic codes. Ignore these created diagnostic
codes and clear the diagnostic codes when the
original diagnostic code has been corrected. Ensure
that the diagnostic code of CID 0084 FMI 08 is
active before performing this procedure.
Note: Use the 146-4080 Digital Multimeter for the
measurements in this procedure.
Test Step 1. CHECK THE SENSOR.
A. Turn the key start switch and the disconnect
switch to the OFF position.
B. Disconnect the sensor from the machine harness.
C. At the harness connector for the sensor, measure
the resistance between signal contact 3 (wire
C913-BU) and ground contact 2 (wire 210-BK).
Expected Result:
The resistance that is measured is greater than 5000
ohms.
Results:
• YES – The resistance that is measured is greater
than 5000 ohms. The resistance is correct.
Proceed to test step 2.
• NO – The resistance that is measured is less than
5000 ohms. The sensor has failed.
Repair: Replace the sensor.
STOP.
Test Step 2. CHECK THE WIRING
HARNESS.
A. The key start switch and the disconnect switch
remain in the OFF position.
49
Troubleshooting Section
B. Disconnect the J1 machine harness connector
from the main display module.
C. The sensor remains disconnected.
D. At the machine harness connector for the sensor,
measure the resistance from the signal contact
3 (wire C913-BU) and ground contact 2 (wire
210-BK).
E. At the machine harness connector for the sensor,
measure the resistance from the signal contact
3 (wire C913-BU) and + battery contact 1 (wire
113-OR).
Expected Result:
The resistance that is measured is greater than 5000
ohms.
Results:
• YES – The resistance that is measured is greater
than 5000 ohms. The resistance of the harness is
correct. Proceed to test step 3.
• NO – The resistance measures less than 5000
ohms. The machine harness has failed.
Repair: There is a short between the signal contact
J1-26 and the circuit with the low resistance
measurement. Repair the harness or replace the
harness.
STOP.
Test Step 3. CHECK FOR AN OPEN IN
THE SIGNAL CIRCUIT.
A. The sensor and the main display module remain
disconnected from the machine harness.
B. The key start switch and the disconnect switch
remain in the OFF position.
C. Measure the resistance of the signal circuit from
contact J1-26 (wire C913-BU) to contact 3 (wire
C913-BU) of the sensor.
Expected Result:
The resistance measures less than 5 ohms.
Results:
• YES – The resistance measures less than 5 ohms.
The signal circuit is correct. The diagnostic code
may be caused by an intermittent failure in the
machine harness.
50
Troubleshooting Section
Repair: It is unlikely that the main display module
has failed. Exit this procedure and perform this
procedure again. If the cause of the diagnostic
code is not found, replace the main display module.
See Testing and Adjusting, “Module - Replace”.
STOP.
• NO – The resistance is greater than 5000 ohms.
Repair: The signal circuit has failed. There is an
open in the signal circuit of the machine harness.
Repair the machine harness or replace the
machine harness.
STOP.
i01678169
MID 030 - CID 0096 - FMI 03
SMCS Code: 1273-038-UN
Conditions Which Generate This Code:
Illustration 64 g00866238
Schematic for the fuel level sender
This diagnostic code is recorded when the main
display module reads the signal voltage of the fuel
level sender and the voltage is too high. The possible
causes of this diagnostic code are listed here:
• The sender has failed.
• The return circuit of the sender is open in the
machine harness.
• The signal circuit in the machine harness is shorted
to a source of positive voltage.
• The signal circuit in the machine harness is open
or the sender is disconnected.
• The main display module has failed. This is
unlikely.
System Response:
This failure causes the fuel gauge to always
indicate an empty fuel tank or the fuel gauge may
intermittently indicate an empty fuel tank.
Test Step 1. CHECK THE CONTROL AND
THE HARNESS.
A. Turn the disconnect switch and the key start
switch to the ON position.
B. Disconnect the machine harness connector from
the fuel level sender.
C. At the machine harness connector for the sender,
measure the voltage (DCV) between the signal
contact 1 (wire 447-PK) and the return contact 2
(wire 201-BK).
Expected Result:
The voltage is between 4.5 and 8.0 DCV.
Results:
• OK – The voltage is between 4.5 and 8.0 DCV. The
main display module and the harness are correct.
Repair: Replace the sender.
STOP.
• NOT OK – The voltage is not between 4.5 and 8.0
DCV. The main display module or the harness has
failed. Proceed to Test Step 2.
Test Step 2. CHECK THE RETURN
CIRCUIT OF THE HARNESS.
A. The sender remains disconnected.
B. Turn the disconnect switch and the key start
switch to the OFF position.
C. Disconnect the J1 machine harness connector
from the main display module.
D. Measure the resistance of the return circuit
between contact 2 (wire 201-BK) of the machine
harness for the sender and contact J1-2 of the
machine harness for the main control module.
Expected Result:
The resistance is less than 5.0 ohms.
Results:
• OK – The resistance is less than 5.0 ohms. The
harness resistance is correct. Proceed to Test Step
3.
• NOT OK – The resistance is greater than 5.0
ohms. The ground circuit in the harness has failed.
There is an open circuit between the ground
contact and frame ground.

Repair: Repair the machine harness or replace the
machine harness.
STOP.
Test Step 3. CHECK FOR A SHORTED
HARNESS
A. The sender and the main display module remain
disconnected from the machine harness.
B. The disconnect switch and the key start switch
remain in the OFF position.
C. At the machine harness connector for the sender,
measure the resistance between the signal
contact 1 (wire 447-PK) and the +battery circuit at
the contact J1-1 of the machine harness connector
for the main display module.
Expected Result:
The resistance is greater than 5000 ohms.
Results:
• OK – The resistance is greater than 5000 ohms.
The main display module has failed.
Repair: It is unlikely that an ECM has failed. Exit
this procedure. Perform this CID 0096 FMI 03
procedure again. If the failure is not found, replace
the main display module. Refer to the Testing and
Adjusting, “Module - Replace”.
STOP.
• NOT OK – The resistance is less than 5000 ohms.
The machine harness has failed. There is a short
between the +battery circuit and the signal circuit
in the machine harness.
Repair: Repair the machine harness or replace the
machine harness.
STOP.
51
Troubleshooting Section
i01678452
MID 030 - CID 0096 - FMI 04
SMCS Code: 1273-038-UN
Conditions Which Generate This Code:
g00866238
Illustration 65
Schematic for the fuel level sender
This diagnostic code is recorded when the main
display module reads the signal voltage of the fuel
level sender and the voltage is too low.
The possible causes of this failure are listed here:
• The sender has failed.
• The signal circuit in the machine harness is shorted
to ground.
• The main display module has failed. This is
unlikely.
This failure causes the fuel gauge to always
indicate an empty fuel tank or the fuel gauge may
intermittently indicate an empty fuel tank.
Test Step 1. CHECK THE SENDER.
A. Disconnect the machine harness from the sender.
Expected Result:
The diagnostic code changes from CID 0096 FMI
04 to CID 0096 FMI 03.
Results:
• OK – The diagnostic code changed from CID 0096
FMI 04 to CID 0096 FMI 03. This indicates that the
failure is no longer present. The sender has failed.
Repair: Replace the sender.
STOP.
• NOT OK – The diagnostic code remains. The
failure remains present. The sender is not causing
the failure. Proceed to test step 2.
Test Step 2. CHECK THE HARNESS.
A. The sender remains disconnected from the
machine harness.
52
Troubleshooting Section
B. Turn the disconnect switch and the key start
switch to the OFF position.
C. Disconnect the J1 machine harness connector
from the main display module.
D. At the machine harness connector for the sender,
measure the resistance between the signal
contact 1 (wire 447-PK) and frame ground.
Expected Result:
The resistance is greater than 5000 ohms.
Results:
• OK – The resistance is greater than 5000 ohms.
The harness circuit resistance is correct. The main
display module has failed.
Repair: It is unlikely that the ECM has failed. Exit
this procedure, and perform this procedure again.
If the failure is not found, replace the ECM. See
Testing and Adjusting, “ Module - Replace”.
STOP.
• NOT OK – The resistance is less than 5000 ohms.
The machine harness has failed. There is a short
between frame ground and the signal circuit in the
machine harness.
Repair: Repair the machine harness or replace the
machine harness.
STOP.
i01916153
MID 030 - CID 0096 - FMI 08
SMCS Code: 1273-038-UN
Conditions Which Generate This Code:
g00866238
Illustration 66
Schematic for the fuel level sender
Service Notes: Ensure that the desired code (CID
and FMI) is on hold. Ensure that the diagnostic code
indicator shows “SERV CODE”. The schematic that
is shown above represents a typical installation of
the component. Verify the connector contact and wire
numbers by using the Electrical System Schematic
for the machine that is being serviced.
Note: See Troubleshooting, “Sensor Signal Voltage”
in order to troubleshoot this component.
Perform the following diagnostic procedure: “Sensor
Signal Voltage ”
Results:
• OK – STOP.
• REPAIRED, OK – STOP.
i01858627
MID 030 - CID 0248 - FMI 02
SMCS Code: 7490-038
Conditions Which Generate This Code:
g00530708
Illustration 67
Schematic for the Caterpillar data link
This diagnostic code is recorded when the
main display module does not receive expected
information. The following example shows a possible
diagnostic code. The information from the actual gear
status is not being received from other electronic
control modules through the CAT data link. The
information from the CAT data link indicates the
abnormal values in the readout. The possible causes
of this diagnostic code are listed below. The causes
are listed in order of probability:
• Poor electrical connection at a machine harness
connector
• The circuit for the CAT data link in the machine
harness is shorted to ground.
• The circuit for the CAT data link in the machine
harness is shorted to the +battery.
• The circuit for the CAT data link in the machine
harness is open.

Note: An electronic control module which uses the
CAT data link may have lost power or an electronic
control may have failed. This is unlikely. If the main
display module was recently replaced, see Testing
and Adjusting, “Main Display Module Initialization -
Adjust”.
Service Notes: Ensure that the desired diagnostic
code (CID and FMI) is on hold. Ensure that the
service code indicator shows “SERV CODE”.
Test Step 1. CHECK FOR OTHER CODES.
A. Check other electronic control modules for a
similar diagnostic code. If a similar diagnostic code
is found, exit this test. Perform the corresponding
procedures for the other diagnostic codes that are
shown.
Expected Result:
There are other diagnostic codes that are showing.
Results:
• YES – Exit this procedure and perform the other
procedures for the diagnostic codes that are
shown. STOP.
• NO – There are not any other diagnostic codes
that are shown. Proceed to test step 2.
Test Step 2. INSPECT THE HARNESS
CONNECTORS.
A. Turn the disconnect switch to the OFF position.
B. Inspect the connections for the machine harness
that are related to the CAT data link.
C. Make sure that connectors are clean and tight.
Expected Result:
The machine harness is correct.
Results:
• OK – The machine harness is correct. Proceed
to test step 3.
• NOT OK – The machine harness is not correct.
Repair: Repair the machine harness or replace the
machine harness.
STOP.
Test Step 3. CHECK FOR A SHORT TO
GROUND.
A. The disconnect switch remains OFF.
53
Troubleshooting Section
B. Disconnect the machine harness from all the
electronic control modules that use the CAT data
link.
C. At the machine harness connector for the main
display module, measure the resistance between
frame ground and the CAT data link circuits
(contacts 5 and 14).
Expected Result:
The resistance that is measured is less than 5000
ohms.
Results:
• YES – The resistance is less than 5000 ohms.
The machine harness has failed. There is a short
between the frame ground and the CAT data link
circuit in the machine harness.
Repair: Repair the machine harness or replace the
machine harness.
STOP.
• NO – The resistance is greater than 5000 ohms.
The harness circuit resistance is correct. Proceed
to test step 4.
Test Step 4. CHECK FOR A SHORT TO
THE +BATTERY.
A. The disconnect switch remains OFF.
B. All related control modules remain disconnected
from the machine harness.
C. At the machine harness connector for the main
display module, measure the resistance between
the +battery (contact 1) and the CAT data link
circuits (contacts 5 and 14).
Expected Result:
The resistance is greater than 5000 ohms.
Results:
• OK – The resistance is greater than 5000 ohms.
The harness circuit resistance is correct. Proceed
to test step 5.
• NOT OK – The resistance is less than 5000 ohms.
The machine harness has failed. There is a short
between the +battery and the CAT data link circuit
in the machine harness.
Repair: Repair the machine harness or replace the
machine harness.
STOP.
54
Troubleshooting Section
Test Step 5. CHECK FOR AN OPEN
HARNESS.
A. The disconnect switch remains OFF.
B. All related control modules remain disconnected
from the machine harness.
C. Check the continuity of the CAT data link circuit
in the machine harness.
D. Measure the resistance from the connector of the
main display module (contact 5 and 14) to the
connector for each of the related electronic control
modules.
Expected Result:
The resistance is less than 5 ohms.
Results:
• YES – The resistance is less than 5 ohms. The
CAT data link circuit in the machine harness is
correct.
Repair: It is unlikely that the main display module
has failed. Exit this procedure and perform this
procedure again. Also, recheck if the diagnostic
code indicator is illuminated for this diagnostic
code. If the cause of the diagnostic code is not
found, replace the main display module. See
Testing and Adjusting, “Module - Replace”.
STOP.
• NO – The resistance is greater than 5 ohms. The
machine harness has failed. The CAT data link
circuit is open in the machine harness.
Repair: Repair the machine harness or replace the
machine harness.
STOP.
i01440228
MID 030 - CID 0263 - FMI 03
SMCS Code: 7490-038-NS
Conditions Which Generate This Code:
g00754378
Illustration 68
Schematic for the sensor power supply
This diagnostic code is recorded when the main
display module reads an above normal sensor supply
voltage (+24 DCV).
Note: The procedures that are used to troubleshoot
this diagnostic code may cause additional diagnostic
codes to be logged. Find the cause and repair the
cause of this diagnostic code before you troubleshoot
any new diagnostic codes.
Test Step 1. CHECK THE VOLTAGE AT
THE MAIN DISPLAY MODULE.
A. Use the 7X-1710 Multimeter Probe in order to
check the voltage at the connector for the main
display module. Measure the voltage from the
contact 1 to the contact 2 (ground). DO NOT
disconnect the harness from the module.
Expected Result:
The supply voltage that is measured is 24.0 ± 0.5
DCV.
Results:
• YES – The voltage is 24.0 ± 0.5 DCV. The sensor
supply voltage is correct. Verify that the diagnostic
code is still present. If the diagnostic code is still
present the main display module has failed.
Repair: It is unlikely that the main display module
has failed. Exit this procedure and perform this
procedure again. Also, recheck if the diagnostic
code indicator is illuminated for this diagnostic
code. If the cause of the diagnostic code is not
found, replace the module. See Testing and
Adjusting, “Module - Replace”.
STOP.

• NO – The voltage is NOT 24.0 ± 0.5 DCV. The
sensor supply voltage is NOT correct. Proceed to
test step 2.
Test Step 2. CHECK THE HARNESS FOR
A SHORT TO THE +BATTERY CIRCUIT.
A. Disconnect the machine harness from the main
display module.
B. At the machine harness connector for the main
display module, measure the voltage from the
connector contact 1 to 2 (ground).
Expected Result:
The voltage that is measured should be approximately
0 DCV.
Results:
• YES – The voltage is approximately 0 DCV. The
voltage is correct.
Repair: It is unlikely that the main display module
has failed. Exit this procedure and perform this
procedure again. Also, recheck if the diagnostic
code indicator is illuminated for this diagnostic
code. If the cause of the diagnostic code is not
found, replace the module. See Testing and
Adjusting, “Module - Replace”.
STOP.
• NO – The voltage is NOT approximately 0 DCV.
The harness or a sensor has failed. Proceed to
test step 3.
Test Step 3. DISCONNECT THE
SENSORS.
A. Disconnect one of the sensors that are connected
to the +24 DCV sensor supply of the main display
module from the machine harness.
B. After you disconnect the sensor, measure the
voltage from the connector contact 2 (ground) to
contact 1 of the machine harness connector for
the main display module.
Expected Result:
The voltage that is measured should be approximately
0 DCV.
Results:
• YES – The voltage is approximately 0 DCV.
The voltage is correct. The sensor that was just
disconnected has failed.
55
Troubleshooting Section
Repair: Replace the sensor.
STOP.
• NO – The voltage is NOT approximately 0 DCV.
The harness or a sensor has failed. Repeat
this test. The machine harness is shorted to
the +battery circuit if all the sensors have been
disconnected from the machine harness and the
voltage is NOT approximately 0 DCV.
Repair: Repair the harness or replace the harness.
STOP.
i01440283
MID 030 - CID 0263 - FMI 04
SMCS Code: 7490-038-NS
Conditions Which Generate This Code:
g00754378
Illustration 69
Schematic for the sensor power supply
This diagnostic code is recorded when the main
display module reads the signal voltage. The voltage
from the sensor is too low.
Test Step 1. CHECK THE VOLTAGE AT
THE MAIN DISPLAY.
A. Use the 7X-1710 Multimeter Probe in order to
check the voltage at the connector for the main
display module. Measure the voltage from contact
1 to contact 2 (ground). DO NOT disconnect the
harness from the module.
Expected Result:
The voltage measures 24.0 ± 0.5 DCV.
Results:
• YES – The voltage is 24.0 ± 0.5 DCV. The sensor
supply voltage is correct. Verify that the diagnostic
code exists.
56
Troubleshooting Section
Repair: It is unlikely that the main display module
has failed. Exit this procedure and perform this
procedure again. Also, recheck if the diagnostic
code indicator is illuminated for this diagnostic
code. If the cause of the diagnostic code is not
found, replace the main display module. See
Testing and Adjusting, “Module - Replace”.
STOP.
• NO – The voltage is NOT 24.0 ± 0.5 DCV. The
sensor supply voltage is NOT correct. Proceed to
test step 2.
Test Step 2. DISCONNECT THE
SENSORS.
A. Continue to monitor the sensor supply voltage.
B. Disconnect one of the sensors that are connected
to the +24 DCV sensor supply of the main display
module from the machine harness.
C. After you disconnect the sensor, check the voltage
reading on the multimeter.
Expected Result:
The voltage that is measured is 24.0 ± 0.5 DCV.
Results:
• YES – The voltage is 24.0 ± 0.5 DCV. The
sensor supply is correct. The sensor that was just
disconnected has failed.
Repair: Replace the sensor.
STOP.
• NO – The voltage is NOT 24.0 ± 0.5 DCV. Repeat
this test step for the remaining sensors. If the
voltage is NOT correct after the remaining sensors
are disconnected and tested. Continue to the next
test step. Proceed to test step 3.
Test Step 3. CHECK FOR A SHORT TO
GROUND.
A. Turn the disconnect switch and the key start
switch to the OFF position.
B. The sensors remain disconnected.
C. Disconnect the machine harness from the main
display module.
D. At the machine harness connector for the main
display module, measure the resistance between
the frame ground and the sensor supply circuit
(connector contact 1).
Expected Result:
The resistance that is measured is greater than 5000
ohms.
Results:
• YES – The resistance is greater than 5000 ohms.
The harness circuit resistance is correct. The main
display module has failed.
Repair: It is unlikely that the main display module
has failed. Exit this procedure and perform this
procedure again. Also, recheck if the diagnostic
code indicator is illuminated for this diagnostic
code. If the cause of the diagnostic code is not
found, replace the main display module. See
Testing and Adjusting, “Module - Replace”.
STOP.
• NO – The resistance is less than 5000 ohms. The
machine harness has failed. There is a short to
ground in the machine harness.
Repair: Repair the harness or replace the harness.
STOP.
i01394484
MID 030 - CID 0271 - FMI 03
SMCS Code: 7407-038
Conditions Which Generate This Code:
g00544121
Illustration 70
Schematic for the alarm (action)
This diagnostic code is recorded when the main
display module reads the voltage of the circuit for
the action alarm as above normal. The result of this
diagnostic code is the continuous sounding of the
action alarm. The schematic that is shown above
represents a typical installation of the component.
Verify the connector contact and wire numbers
by using the Electrical System Schematic for the
machine that is being serviced.

CHECK THE ALARM CIRCUIT.
A. Turn the disconnect switch and the key start
switch to the OFF position.
B. Disconnect the machine harness from the main
display module.
C. Turn the disconnect switch to the ON position.
D. Listen for the SOUNDING of the action alarm.
E. Turn the key start switch to the ON position.
Expected Result:
The alarm is sounding.
Results:
• YES – The alarm is SOUNDING. The harness
circuit 410-WH is shorted to the +battery.
Repair: Repair the harness or replace the harness.
STOP.
• NO – The alarm does NOT SOUND. The main
display module has failed.
Repair: It is unlikely that the main display module
has failed. Exit this procedure and perform this
procedure again. Also, recheck if the diagnostic
code indicator is illuminated for this diagnostic
code. If the cause of the diagnostic code is not
found, replace the main display module. See
Testing and Adjusting, “Module - Replace”.
STOP.
i01394545
MID 030 - CID 0271 - FMI 05
SMCS Code: 7407-038
Conditions Which Generate This Code:
g00544121
Illustration 71
Schematic for the alarm (action)
57
Troubleshooting Section
This diagnostic code is recorded when the main
display module reads the current of the action alarm.
The current for the action alarm is below normal.
The action alarm does not SOUND as a result of this
diagnostic code. The schematic that is shown above
represents a typical installation of the component.
Verify the connector contact and wire numbers
by using the Electrical System Schematic for the
machine that is being serviced.
Test Step 1. CHECK THE ALARM.
A. Disconnect the machine harness from the alarm.
B. At the machine harness connector for the alarm,
place a jumper across the two contacts.
Expected Result:
The CID 0271 FMI 05 is still present.
Results:
• YES – The CID 0271 FMI 05 remains present. The
action alarm is not causing the diagnostic code.
Verify that the action alarm is correct. The correct
resistance for a good alarm is 200 ± 100 ohms.
Proceed to test step 2.
• NO – The CID 0271 FMI 05 is NO longer present.
The alarm is open.
Repair: Replace the action alarm. Verify that the
action alarm is open. The correct resistance for a
good alarm is 200 ±100 ohms.
STOP.
Test Step 2. CHECK THE HARNESS.
A. Turn the disconnect switch and the key start
switch to the OFF position.
B. Remove the jumper from the connector of the
alarm and reconnect the alarm to the machine
harness.
C. Disconnect the machine harness from the main
display module.
D. At the machine harness connector for the module,
measure the resistance between contact 4
(410-WH) and frame ground.
Expected Result:
The resistance is greater than 300 ohms.
Results:
• OK – The resistance is greater than 300 ohms.
The harness circuit is open. Proceed to test step 3.
58
Troubleshooting Section
• NOT OK – The resistance is less than 300 ohms.
The harness circuit resistance is correct. Proceed
to test step 4.
Test Step 3. CHECK THE HARNESS.
A. Disconnect the machine harness from the alarm.
B. Check for an open in the circuit 410-WH. Check
between the harness connector for the main
display module (contact 4) and the harness
connector for the action alarm (contact 1).
C. Check for an open in the circuit 201-BK. Check
between the harness connector for the action
alarm (contact 2) and the frame ground.
Expected Result:
The machine harness is correct.
Results:
• OK – The machine harness is correct. STOP.
• NOT OK – The machine harness is not correct.
Repair: Repair the machine harness or replace the
machine harness.
STOP.
Test Step 4. CHECK THE MAIN DISPLAY
MODULE.
A. Reconnect the machine harness connector to the
main display module.
B. Reconnect the alarm to the machine harness.
C. Turn the disconnect switch and the key start
switch to the ON position.
Expected Result:
The CID 0271 FMI 05 is still present.
Results:
• YES – The CID 0271 FMI 05 remains present. The
main display module has failed.
Repair: It is unlikely that the main display module
has failed. Exit this procedure and perform this
procedure again. Also, recheck if the diagnostic
code indicator is illuminated for this diagnostic
code. If the cause of the diagnostic code is not
found, replace the main display module. See
Testing and Adjusting, “Module - Replace”.
STOP.
• NO – The diagnostic code is NO longer active.
The diagnostic code does not exist at this time.
The initial diagnostic code was probably caused by
a poor electrical connection or a short at one of
the harness connectors that was disconnected and
reconnected. Resume normal machine operation.
STOP.
i01394618
MID 030 - CID 0271 - FMI 06
SMCS Code: 7407-038
Conditions Which Generate This Code:
Illustration 72 g00544121
Schematic for the alarm (action)
This diagnostic code is recorded when the main
display module reads the voltage of the circuit for the
action alarm as above normal. The action alarm does
not SOUND as a result of this diagnostic code. The
schematic that is shown above represents a typical
installation of the component. Verify the connector
contact and wire numbers by using the Electrical
System Schematic for the machine that is being
serviced.
Test Step 1. CHECK THE ALARM.
A. Disconnect the machine harness from the alarm.
Expected Result:
The CID 0271 FMI 06 remains present.
Results:
• OK – The diagnostic code remains present. The
action alarm is not causing the diagnostic code.
Proceed to test step 2.
• NOT OK – The diagnostic code is NO longer
present. The correct resistance for a good alarm is
200 ± 100 ohms. The alarm has failed.
Repair: Replace the action alarm.
STOP.

Test Step 2. CHECK THE HARNESS.
A. Turn the disconnect switch to the OFF position.
B. The alarm remains disconnected from the
machine harness.
C. Disconnect the machine harness from the main
display module.
D. At the machine harness connector for the main
display module, measure the resistance between
contact 4 (410-WH) and frame ground.
Expected Result:
The resistance is greater than 5000 ohms.
Results:
• OK – The resistance is greater than 5000 ohms.
The harness resistance is correct. Proceed to test
step 3.
• NOT OK – The resistance is less than 5000 ohms.
The harness has failed.
Repair: Repair the machine harness or replace the
machine harness.
STOP.
Test Step 3. CHECK THE MODULE.
A. Remove contact 4 from the machine harness
connector for the main display module by using
the correct service tools.
B. Reconnect the machine harness connector to the
module.
C. Turn the disconnect switch and the key start
switch to the ON position.
D. Place the same diagnostic code on hold and
check the service code indicator.
Expected Result:
The CID 0271 FMI 06 is present.
Results:
• OK – The CID 0271 FMI 06 remains present. The
main display module has failed.
Repair: It is unlikely that the module has failed.
Exit this procedure and perform this diagnostic
code procedure again. If the problem has not been
found, then replace the main display module. See
Testing and Adjusting, “Module - Replace”.
STOP.
59
Troubleshooting Section
• NOT OK – The diagnostic code is NO longer
active. The diagnostic code does not exist at this
time. The initial diagnostic code was probably
caused by a poor electrical connection or a
short at one of the harness connectors that was
disconnected and reconnected. Resume normal
machine operation. STOP.
i01394739
MID 030 - CID 0324 - FMI 03
SMCS Code: 7431-038-LMP
Conditions Which Generate This Code:
g00544436
Illustration 73
Schematic for the lamp (action)
This diagnostic code is recorded when the main
display module reads the voltage of the circuit for the
action lamp as above normal. The action lamp is
ON CONTINUOUSLY as a result of this diagnostic
code. The schematic that is shown above represents
a typical installation of the component. Verify the
connector contact and wire numbers by using the
Electrical System Schematic for the machine that is
being serviced.
CHECK THE LAMP CIRCUIT.
A. Turn the disconnect switch and the key start
switch to the OFF position.
B. Disconnect the machine harness from the main
display module.
C. Turn the disconnect switch to the ON position.
D. Observe the action lamp.
E. Turn the key start switch to the ON position.
Expected Result:
The action lamp is ON.
Results:
• OK – The action lamp is ON. The harness circuit
411-PK is shorted to the +battery.
Repair: Repair the harness or replace the harness.
STOP.
60
Troubleshooting Section
• NOT OK – The action lamp is OFF. The module
has failed.
Repair: It is unlikely that the main display module
has failed. Exit this procedure and perform this
procedure again. Also, recheck if the diagnostic
code indicator is illuminated for this diagnostic
code. If the cause of the diagnostic code is not
found, replace the main display module. See
Testing and Adjusting, “Module - Replace”.
STOP.
i01394817
MID 030 - CID 0324 - FMI 05
SMCS Code: 7431-038-LMP
Conditions Which Generate This Code:
g00544436
Illustration 74
Schematic for the action lamp
This diagnostic code is recorded when the main
display module reads the current of the circuit for
the action lamp and the current is below normal.
The action lamp does not light as a result of this
diagnostic code. The schematic that is shown above
represents a typical installation of the component.
Verify the connector contact and wire numbers
by using the Electrical System Schematic for the
machine that is being serviced.
Test Step 1. CHECK THE LAMP.
A. At the action lamp, use a jumper to connect wire
411-PK to frame ground.
Expected Result:
The CID 0324 FMI 05 is no longer present.
Results:
• OK – The CID 0324 FMI 05 is no longer present.
The lamp or the lamp socket is open.
Repair: Replace the action lamp. NOTE: For the
purposes of this test, the correct resistance for
a lamp is less than 200 ohms.
STOP.
• NOT OK – The CID 0324 FMI 05 is present. The
action lamp is not causing the diagnostic code.
Proceed to test step 2.
Test Step 2. CHECK THE HARNESS.
A. Turn the disconnect switch and the key start
switch to the OFF position.
B. Remove the jumper from wire 411-PK to frame
ground. Make sure that the action lamp is
connected to the machine harness.
C. Disconnect the machine harness from the main
display module.
D. At the machine harness connector for the main
display module, measure the resistance between
contact 13 (411-PK) and frame ground.
Expected Result:
The resistance is greater than 100 ohms.
Results:
• OK – The resistance is greater than 100 ohms.
The harness circuit is open. Proceed to test step 3.
• NOT OK – The resistance is less than 100 ohms.
The harness circuit resistance is correct. Replace
the main display module.
Repair: It is unlikely that the main display module
has failed. Exit this procedure and perform this
procedure again. Also, recheck if the diagnostic
code indicator is illuminated for this diagnostic
code. If the cause of the diagnostic code is not
found, replace the main display module. See
Testing and Adjusting, “Module - Replace”.
STOP.
Test Step 3. CHECK THE HARNESS.
A. At the action lamp, disconnect wire 411-PK from
the lamp socket.
B. Check for an open in the circuit 411-PK. Check
between contact 13 of the harness connector for
the main display module and the lamp socket.
C. Check for an open in the circuit 201-BK. Check
between the lamp socket and the frame ground.
Expected Result:
The circuits are correct.

Results:
• OK – The circuits are correct. STOP.
• NOT OK – The circuits are NOT correct.
Repair: Repair the harness or replace the harness.
STOP.
i01394886
MID 030 - CID 0324 - FMI 06
SMCS Code: 7431-038-LMP
Conditions Which Generate This Code:
g00544436
Illustration 75
Schematic for the action lamp
This diagnostic code is recorded when the main
display module reads the voltage of the circuit for
the action lamp and the current is above normal.
The action lamp does not light as a result of this
diagnostic code. The schematic that is shown above
represents a typical installation of the component.
Verify the connector contact and wire numbers
by using the Electrical System Schematic for the
machine that is being serviced.
Test Step 1. CHECK THE LAMP.
A. At the action lamp, disconnect wire 411-PK from
the lamp socket.
Expected Result:
The CID 0324 FMI 06 is present.
Results:
• OK – The CID 0324 FMI 06 is present. The action
lamp is not causing the diagnostic code. Proceed
to test step 2.
• NOT OK – The CID 0324 FMI 06 is NO longer
present. The lamp or the lamp socket has failed.
The correct resistance for a lamp is greater than
10 ohms.
Repair: Replace the action lamp.
STOP.
61
Troubleshooting Section
Test Step 2. CHECK THE HARNESS.
A. Turn the disconnect switch to the OFF position.
B. Wire 411-PK remains disconnected from the
action lamp.
C. Disconnect the machine harness from the main
display module.
D. At the machine harness connector for the main
display module, measure the resistance between
contact 13 (411-PK) and frame ground.
Expected Result:
The resistance is greater than 5000 ohms.
Results:
• OK – The resistance is greater than 5000 ohms.
The harness resistance is correct. Proceed to test
step 3.
• NOT OK – The resistance is less than 5000 ohms.
The harness has failed.
Repair: Repair the machine harness or replace the
machine harness.
STOP.
Test Step 3. CHECK THE MAIN DISPLAY
MODULE.
A. Remove contact 13 from the machine harness
connector for the main display module.
B. Reconnect the harness connector to the main
display module.
C. Turn the disconnect switch and the key start
switches to the ON position.
D. Place the same diagnostic code on hold. Check
the service code indicator.
Expected Result:
The CID 0324 FMI 06 is present.
Results:
• OK – The CID 0324 FMI 06 remains present. The
main display module has failed.
62
Troubleshooting Section
Repair: It is unlikely that the main display module
has failed. Exit this procedure and perform this
procedure again. Also, recheck if the diagnostic
code indicator is illuminated for this diagnostic
code. If the cause of the diagnostic code is not
found, replace the main display module. See
Testing and Adjusting, “Module - Replace”.
STOP.
• NOT OK – The diagnostic code is NO longer
active. The diagnostic code does not exist at this
time. The initial diagnostic code was probably
caused by a poor electrical connection or a
short at one of the harness connectors that was
disconnected and reconnected. Resume normal
machine operation. STOP.
i01441628
MID 030 - CID 0601 - FMI 08
SMCS Code: 4250-038-NS
Conditions Which Generate This Code:
Illustration 76
g00528295
Schematic for the pressure sensor (brake air)
Service Notes: Ensure that the desired diagnostic
code is on hold. Ensure that the diagnostic code
indicator shows “SERV CODE”. The schematic that
is shown above represents a typical installation of the
component. Verify the connector contact and the wire
numbers by using the Electrical System Schematic
for the machine that is being serviced.
Note: See Diagnostic Function, “Sensor Signal
Voltage” in order to troubleshoot this component.
Perform the following diagnostic procedure: “Sensor
Signal Voltage”
Results:
• OK – STOP.
• REPAIRED, OK – STOP.
i01528712
MID 030 - CID 0615 - FMI 03
SMCS Code: 4806-038-UN
Conditions Which Generate This Code:
g00793582
Illustration 77
Schematic for the articulation position sender
This diagnostic code is recorded when the main
display module reads the signal voltage. The voltage
from the sender is too high. The articulation angle
gauge on the Caterpillar Monitoring System does
not work when this diagnostic code is active. The
following causes could signal this diagnostic code:
• The sender has failed.
• The ground circuit for the sender in the machine
harness is shorted to +battery.
• The signal circuit in the machine harness is shorted
to +battery.
• The signal circuit in the machine harness is open
or the sender is disconnected.
• The main display module has failed.
Service Notes: Ensure that the desired diagnostic
code (CID and FMI) is on hold. Ensure that the
diagnostic code indicator shows “SERV CODE”. The
schematic that is shown above represents a typical
installation of the component. Verify the connector
and wire numbers by using the Electrical System
Schematic for the machine that is being serviced.
Test Step 1. CHECK THE MAIN DISPLAY
MODULE AND THE HARNESS.
A. Turn the disconnect switch and the key start
switch to the ON position.
B. The diagnostic code indicator should show “SERV
CODE” for the diagnostic code.
C. Disconnect the machine harness from the sender
that is causing the diagnostic code.
D. Connect the signal wire A429-PK to the ground
wire 201-BK on the machine harness connector.

E. Observe the diagnostic code indicator.
Expected Result:
The diagnostic code indicator remains ON.
Results:
• YES – The diagnostic code indicator remains ON.
The harness wiring or the main display module has
failed. Proceed to test step 2.
• NO – The diagnostic code indicator turns OFF.
The sender has failed.
Repair: Replace the sender.
STOP.
Test Step 2. CHECK FOR AN OPEN
GROUND.
A. Remove the jumper wire between the signal wire
A429-PK and the ground wire 201-BK.
B. Turn the disconnect switch and the key start
switch to the OFF position.
C. Measure the resistance between frame ground
and the ground wire for the sender.
Expected Result:
The resistance is 5 ohms or less.
Results:
• YES – The resistance is 5 ohms or less. Proceed
to test step 3.
• NO – The resistance is greater than 5 ohms. The
ground wire for the harness is open.
Repair: Repair the ground wire or replace the
ground wire for the sender.
STOP.
Test Step 3. CHECK THE SIGNAL WIRE
FOR THE SENDER.
A. Turn the disconnect switch and the key start
switch to the ON position.
B. Measure the voltage between the frame ground
and the signal wire for the sender.
Expected Result:
The voltage measurement should be within one of
the following specifications.
63
Troubleshooting Section
Results:
• 6.0 ± 0.5 DCV – The voltage is 6.0 ± 0.5 DCV. The
voltage is correct. Verify that the diagnostic code
is still present.
Repair: It is unlikely that the main display module
has failed. Exit this procedure and perform this
procedure again. Also, recheck if the diagnostic
code indicator is illuminated for this diagnostic
code. If the cause of the diagnostic code is not
found, replace the main display module. See
Testing and Adjusting, “Module - Replace”.
STOP.
• LESS THAN 0.5 DCV – The voltage is less than
0.5 DCV. The harness wiring has failed. There is
an open circuit or a short to ground in the signal
wire for the sender.
Repair: Repair the harness or replace the harness.
Exit this procedure and perform this procedure
again. Also, recheck if the diagnostic code
indicator is illuminated for this diagnostic code. It
is unlikely that the main display module has failed.
If the cause of the diagnostic code is not found,
replace the main display module. See Testing and
Adjusting, “Module - Replace”.
STOP.
• NOT 6.0 BUT ABOVE 0.5 DCV – The voltage is
less than 0.5 DCV. The harness wiring has failed.
There is an open circuit or a short to ground in the
signal wire for the sender.
Repair: Repair the harness or replace the harness.
Exit this procedure and perform this procedure
again. Also, recheck if the diagnostic code
indicator is illuminated for this diagnostic code. It
is unlikely that the main display module has failed.
If the cause of the diagnostic code is not found,
replace the main display module. See Testing and
Adjusting, “Module - Replace”.
STOP.
64
Troubleshooting Section
i01528825
MID 030 - CID 0615 - FMI 04
SMCS Code: 4806-038-UN
Conditions Which Generate This Code:
g00793582
Illustration 78
Schematic for the articulation position sender
This diagnostic code is recorded when the main
display module reads a low sender signal. When
this diagnostic code occurs, the gauge indicates
an abnormally high value. The following symptoms
could cause the diagnostic code:
• The sender has failed.
• The signal circuit in the machine harness is shorted
to ground.
• The main display module has failed.
Note: The main display module is unable to
determine when a sender is open. Also, the main
display module is unable to determine when a sender
signal harness is open. This condition is recognized
when the gauge constantly indicates a value at the
far left side of the scale.
Service Notes: Ensure that the desired diagnostic
code is on hold. Ensure that the diagnostic code
indicator shows “SERV CODE”. The schematic that
is shown above represents a typical installation of
the component. Verify the connector contact and wire
numbers by using the Electrical System Schematic
for the machine that is being serviced.
Test Step 1. CHECK THE MAIN DISPLAY
MODULE AND THE HARNESS.
A. Turn the disconnect switch and the key start
switch to the ON position.
B. The diagnostic code indicator should show “SERV
CODE”.
C. Disconnect the machine harness from the sender
that is causing the diagnostic code.
D. Observe the diagnostic code indicator.
Expected Result:
The diagnostic code indicator is ON.
Results:
• YES – The diagnostic code indicator stays ON.
The harness wiring or the main display module has
failed. Proceed to test step 2.
• NO – The diagnostic code indicator turns OFF.
The sender has failed.
Repair: Replace the sender.
STOP.
Test Step 2. CHECK THE SIGNAL WIRE
FOR A SHORT TO GROUND.
A. The disconnect switch and the key start switch
remain in the ON position.
B. At the machine harness for the sender, measure
the voltage between the frame ground and the
sender signal wire.
Expected Result:
The voltage that is measured is within one of the
following specifications.
Results:
• 6.0 ± 0.5 DCV – The voltage is 6.0 ± 0.5 DCV. The
voltage is correct. Verify that the diagnostic code
remains.
Repair: It is unlikely that the main display module
has failed. Exit this procedure and perform this
procedure again. Also, recheck if the diagnostic
code indicator is illuminated for this diagnostic
code. If the cause of the diagnostic code is not
found, replace the main display module. See
Testing and Adjusting, “Module - Replace”.
STOP.
• LESS THAN 0.5 DCV – The voltage is less than
0.5 DCV. The harness wiring has failed. There is
an open circuit or a short to ground in the signal
wire for the sensor.
 65
Troubleshooting Section

Repair: Repair the harness or replace the harness.

Exit this procedure and perform this procedure
again. Also, recheck if the diagnostic code
indicator is illuminated for this diagnostic code. It
is unlikely that the main display module has failed.
If the cause of the diagnostic code is not found,
replace the main display module. See Testing and
Adjusting, “Module - Replace”.

STOP.

• NOT 6.0 BUT ABOVE 0.5 DCV – The voltage is

less than 0.5 DCV. The harness wiring has failed.
There is an open circuit or a short to ground in the
signal wire for the sensor.

Repair: Repair the harness or replace the harness.

Exit this procedure and perform this procedure
again. Also, recheck if the diagnostic code
indicator is illuminated for this diagnostic code. It
is unlikely that the main display module has failed.
If the cause of the diagnostic code is not found,
replace the main display module. See Testing and
Adjusting, “Module - Replace”.

STOP.

i01944181

MID 030 - CID 0819 - FMI 02

SMCS Code: 7450-038

Conditions Which Generate This Code:

g00737908
Illustration 79
Schematic for the display power supply
66
Troubleshooting Section
This diagnostic code is recorded when the
main display module does not receive expected
information. When the main display module sends
information to a display component, the display
component sends a signal back to the main display
module. The signal confirms correct information.
When the main display module does not receive
expected information, the diagnostic code is logged.
As a result of this diagnostic code, the main display
module may not respond to the information that is
received. Gauges and readouts could be incorrect
when the main display module is in normal mode.
Check the connections for the display data link.
Check for opens or shorts in the harness wiring for
the display data link.
Test Step 1. INSPECT THE HARNESS
CONNECTIONS.
A. Turn the disconnect switch to the OFF position.
B. Inspect the harness connections that are related
to the display data link. Make sure that the
connectors are clean and tight.
C. Check the mating of the harness connectors.
D. Check wires at the connector.
E. Check each wire for nicks or signs of abrasion in
the insulation.
F. Check for moisture at the connector.
G. Check for dirty contacts or corroded contacts.
H. Check each pin and each socket.
Expected Result:
The machine harness connectors are tight and free
of corrosion.
Results:
• OK – The machine harness connectors are tight
and free of corrosion. Proceed to test step 2.
• NOT OK – The machine harness connectors are
NOT tight and free of corrosion.
Repair: Repair the machine harness or replace the
machine harness.
STOP.
Test Step 2. CHECK FOR A SHORT TO
+BATTERY.
A. Turn the key start switch and the disconnect
switch to the OFF position.
B. Disconnect the harness from the main display
module.
C. Disconnect the machine harness connectors from
all of the display components.
D. At the harness connectors for the main display
module, measure the resistance between the
contacts that are listed below:
• Connector contact 1 (wire 113-OR) and the
Display Data Link circuit contact 4 (wire
C413-YL).
• Connector contact 1 (wire 113-OR) and the
Display Data Link circuit contact 5 (wire
C414-BU).
• Connector contact 1 (wire 113-OR) and
the Display Data Link circuit contact 3 (wire
E708-PK).
Expected Result:
The resistance is greater than 5000 ohms.
Results:
• OK – The resistance is greater than 5000 ohms.
Proceed to test step 3.
• NOT OK – The resistance is less than 5 ohms.
The machine harness has failed.
Repair: There is a short between the +battery and
the circuits of the display data link in the machine
harness. Replace the machine harness or repair
the machine harness.
STOP.
Test Step 3. CHECK FOR AN OPEN
HARNESS.
A. The disconnect switch and the key start switch
remain in the OFF position.
B. All the display modules remain disconnected from
the machine harness.
C. Measure the resistance of the circuits of the
display data link that are listed below:
• Measure the resistance between connector
contact 35 (wire C413-YL) to connector contact
4 (wire C413-YL) of the message center
module.
 67
Troubleshooting Section

• Measure the resistance between connector
contact 15 (wire C414-BU) to connector contact
5 (wire C414-BU) of the message center
module.
• Measure the resistance between connector
contact 25 (wire E708-PK) to connector contact
3 (wire E708-PK) of the message center
module.
Expected Result:
The resistance is less than 5 ohms.
Results:
• OK – The resistance is less than 5 ohms. The
circuit resistance is correct. Proceed to test step 4.
• – The resistance is greater than 5000 ohms.
Test Step 5. CHECK FOR + 12 DCV
A. Reconnect all modules to the machine harness.
B. Turn the disconnect switch and the key start
switch to the ON position.
C. Use the 7X-1710 Cable probes to check the
voltage at the contact 1 (wire E707-GN) to contact
2 (wire 201-BK) of the message center module.
Expected Result:
The voltage is 9.0 ± 0.5 DCV.
Results:
• OK – The voltage is 9.0 ± 0.5 DCV.
Repair: Replace the message center module.

Repair: There is an open in the machine harness. STOP.

Repair the machine harness or Replace the
machine harness. • NOT OK – The voltage is NOT 9.0 ± 0.5 DCV. The
voltage is not correct.
STOP.
Repair: The main display module has failed. It is
Test Step 4. CHECK FOR A SHORT TO unlikely that the main display module has failed.
GROUND Exit this procedure and perform this procedure
again. If the problem is not found, replace the
A. The disconnect switch and the key start switch main display module. See Testing and Adjusting,
remain in the OFF position. “Module - Replace”.

B. The main display module and all the display STOP.

components remain disconnected from the
machine harness.

C. At the machine harness connector for the main

display module, measure the resistance between
frame ground and the connector contacts 35
(wire C413-YL), 15 (wire C414-BU) and 25(wire
E708-PK) of the display data link.

Expected Result:

The resistance is greater than 5000 ohms.

Results:

• OK – The resistance is greater than 5000 ohms.

The resistance of the circuit is correct. Proceed
to test step 5.

• NOT OK – The resistance is less than 5000 ohms.

The resistance of the circuit is not correct.

Repair: There is a short between frame ground

and the circuits of the display data link in the
machine harness. Replace the machine harness or
repair the machine harness.

STOP.
68
Troubleshooting Section
i01395272
MID 030 - CID 0821 - FMI 03
SMCS Code: 7450-038
Conditions Which Generate This Code:
Illustration 80
Schematic for the display power supply
This diagnostic code is recorded when the main
display module reads the voltage of the display
power supply circuit and the voltage is above normal.
Normal display power supply voltage is 9.0 ± 0.5
DCV. The schematic that is shown above represents
a typical installation of the component. Verify the
connector contact and wire numbers by using the
Electrical System Schematic for the machine that is
being serviced.
Test Step 1. CHECK THE VOLTAGE AT
THE MAIN DISPLAY MODULE.
A. Use the 7X-1710 Multimeter Probe Group. Check
the voltage at the connector for the main display
module. Measure the voltage from the contact 34
to the contact 2 (ground).
B. DO NOT disconnect the harness from the module.
C. The correct voltage should measure 9.0 ± 0.5
DCV.
Expected Result:
The voltage that is measured is 9.0 ± 0.5 DCV.
g00737908
Results:
• OK – The voltage is 9.0 ± 0.5 DCV. The display
power supply voltage is correct. Check the main
display module for the same diagnostic code. If the
service code indicator is still ON, the main display
module has failed.
Repair: It is unlikely that the main display module
has failed. Exit this procedure and perform this
procedure again. Also, recheck if the diagnostic
code indicator is illuminated for this diagnostic
code. If the cause of the diagnostic code is not
found, replace the main display module. See
Testing and Adjusting, “Module - Replace”.
STOP.
• NOT OK – The voltage is NOT 9.0 ± 0.5 DCV.
The display power supply voltage is NOT correct.
Proceed to test step 2.
Test Step 2. CHECK THE HARNESS FOR
A SHORT TO +BATTERY.
A. Disconnect the machine harness from the main
display module.
 69
Troubleshooting Section

B. At the machine harness connector for the main

display module, measure the voltage from the
connector contact 34 to 2 (ground).

Expected Result:

The voltage that is measured is 0.0 ± 0.5 DCV.

Results:

• OK – The voltage is 0.0 ± 0.5 DCV. The voltage is

correct. The main display module has failed.

Repair: It is unlikely that the main display module

has failed. Exit this procedure and perform this
procedure again. Also, recheck if the diagnostic
code indicator is illuminated for this diagnostic
code. If the cause of the diagnostic code is not
found, replace the main display module. See
Testing and Adjusting, “Module - Replace”.

STOP.

• NOT OK – The voltage is NOT 0.0 ± 0.5 DCV. The

harness has failed.

Repair: Repair the harness or replace the harness.

STOP.

i01487073

MID 030 - CID 0821 - FMI 04

SMCS Code: 7450-038

Conditions Which Generate This Code:

g00737908
Illustration 81
Schematic for the display power supply
70
Troubleshooting Section
This diagnostic code is recorded when the main
display module reads the voltage of the display
power supply circuit and the voltage is below normal.
Normal display power supply voltage is 9.0 ± 0.5
DCV. The schematic that is shown above represents
a typical installation of the component. Verify the
connector contact and wire numbers by using the
Electrical System Schematic for the machine that is
being serviced.
Test Step 1. CHECK THE VOLTAGE AT
THE MAIN DISPLAY MODULE.
A. DO NOT disconnect the harness from the module.
B. Use the 7X-1710 Multimeter Probe Group. Check
the voltage at the connector for the main display
module. Measure the voltage from contact 34 to
contact 2 (ground).
Expected Result:
The voltage measures 9.0 ± 0.5 DCV.
Results:
• OK – The voltage is 9.0 ± 0.5 DCV. The display
power supply voltage is correct. Check the main
display module for the same diagnostic code. If the
service code indicator is still ON, the main display
module has failed.
Repair: It is unlikely that the main display module
has failed. Exit this procedure and perform this
procedure again. Also, recheck if the diagnostic
code indicator is illuminated for this diagnostic
code. If the cause of the diagnostic code is not
found, replace the main display module. See
Testing and Adjusting, “Module - Replace”.
STOP.
• NOT OK – The voltage is NOT 9.0 ± 0.5 DCV.
The display power supply voltage is NOT correct.
Proceed to test step 2.
Test Step 2. DISCONNECT THE
MODULES.
A. Use the 7X-1710 Multimeter Probe Group. Check
the voltage at the connector for the main display
module. Measure the voltage from contact 34 to
contact 2 (ground).
B. Disconnect a module from the machine harness
one at a time.
C. Continue to measure the voltage at the connector
for the main display module. Measure the voltage
from contact 34 to contact 2.
Expected Result:
The voltage that is measured is 9.0 ± 0.5 DCV.
Results:
• OK – The voltage is 9.0 ± 0.5 DCV. The power
supply to the module is correct. The module that
was just disconnected has failed.
Repair: Replace the module that was
disconnected.
STOP.
• NOT OK – The voltage is NOT 9.0 ± 0.5 DCV.
The display power supply voltage is not correct.
Repeat this test step again. All the modules have
been disconnected from the machine harness and
the voltage is NOT 9.0 ± 0.5 DCV. Proceed to test
step 3.
Test Step 3. CHECK FOR A SHORT TO
GROUND.
A. Turn the disconnect switch and the key start
switch to the OFF position.
B. Disconnect the machine harness from the main
display module.
C. At the machine harness connector for the main
display module, measure the resistance. Measure
the resistance between harness connector contact
34 and harness connector contact 2.
Expected Result:
The resistance that is measured is greater than 5000
ohms.
Results:
• OK – The resistance is greater than 5000 ohms.
STOP.
• NOT OK – The resistance is less than 5000 ohms.
The harness has failed.
Repair: Repair the harness or replace the harness.
STOP.

Diagnostic System
Procedures
i01432657
Alert Indicator Is Always
Flashing
SMCS Code: 7400-038-IND
System Operation Description:
This procedure is for the parameter that has the
alert indicator which is FLASHING constantly. This
condition is caused by an undesired open circuit or a
failed main display module.
The main display module is unable to identify system
errors in simple circuits. No service code is available
in order to assist the operator with troubleshooting. A
possible problem exists when the operation of an alert
indicator does not correspond to a known condition of
the machine. For example, the alert indicator always
FLASHES regardless of the actual pressure of the
engine oil. Before you start troubleshooting, ensure
that a diagnostic code exists. For a description of
normal conditions that cause these events, see
the Operation and Maintenance Manual for the
machine that is being serviced. Perform the following
procedures only if a fault is suspected.
Note: The indicator reflects the open or grounded
condition of the switch inputs. When a switch input is
open, the corresponding alert indicator FLASHES.
When a switch input is grounded, the corresponding
alert indicator is OFF. Therefore, in order to check a
circuit, the service person opens the switch. Then,
the service person grounds the switch. This is done
while the service person is watching for the correct
result on the alert indicator.
Test Step 1. LOCATE THE SWITCH.
A. Locate the switch which corresponds to the
parameter that always FLASHES the alert
indicator. (If necessary, use the Electrical System
Schematic in order to assist in locating the switch.)
Expected Result:
The appropriate switch is located.
Results:
• OK – The appropriate switch is located. Proceed
to test step 2.
Test Step 2. CHECK THE HARNESS.
A. Disconnect the signal wire from the switch.
71
Troubleshooting Section
B. Place a jumper wire from the signal wire to the
ground wire. (If a ground wire is not present,
connect the signal wire to frame ground.)
Expected Result:
The alert indicator continues FLASHING.
Results:
• YES – The alert indicator continues FLASHING.
The machine harness is open or the main display
module has failed. Proceed to test step 3.
• NO – The alert indicator stops FLASHING. The
circuit is operating correctly. The switch has failed.
Repair: Check or replace the switch.
STOP.
Test Step 3. CHECK THE HARNESS.
A. Turn the disconnect switch and the key start
switch to the OFF position.
B. On the Electrical System Schematic, trace the
signal wire from the switch to the main display
module.
C. Determine the signal contact (connector contact)
of the machine harness at the main display
module.
D. Disconnect the machine harness from the main
display module.
E. At the machine harness connector for the main
display, check for continuity between the signal
contact and contact 2 or frame ground if a ground
wire is not present at contact 2. (The jumper is in
place from the previous test.)
Expected Result:
The resistance is greater than 5.0 ohms.
Results:
• YES – The resistance is greater than 5 ohms.
Repair: Repair the harness or replace the harness.
STOP.
• NO – The resistance is less than 5 ohms. The
harness is not causing the problem. The main
display module has failed.
72
Troubleshooting Section
Repair: It is unlikely that the main display module
has failed. Exit this procedure and perform this
procedure again. Also, recheck if the diagnostic
code indicator is illuminated for this diagnostic
code. If the cause of the diagnostic code is not
found, replace the main display module. See
Testing and Adjusting, “Module - Replace”.
STOP.
i01432665
Alert Indicator Never Flashes
SMCS Code: 7450-038-IND
System Operation Description:
The main display module is unable to identify system
errors in simple circuits. No service code is available
in order to assist the operator with troubleshooting. A
possible failure exists when the operation of an alert
indicator does not correspond to a known condition
of the machine. For example, the alert indicator
never FLASHES regardless of the actual pressure
of the engine oil. Before you start troubleshooting,
ensure that a problem exists. For a description of
normal conditions that cause these events, see
the Operation and Maintenance Manual for the
machine that is being serviced. Perform the following
procedures only if a failure is suspected.
The indicator reflects the open or grounded condition
of the switch inputs. When a switch input is open,
the corresponding alert indicator FLASHES. When
a switch input is grounded, the corresponding alert
indicator is OFF. Therefore, in order to check a
circuit, the service person opens the switch. Then,
the service person grounds the switch. This is done
while the service person is watching for the correct
result on the alert indicator.
Test Step 1. LOCATE THE SWITCH
A. Locate the switch for the alert indicator that never
flashes. (If necessary, use the Electrical System
Schematic to assist in locating the switch.)
Expected Result:
The switch is located.
Results:
• OK – The switch is located. Proceed to test step 2.
Test Step 2. CHECK THE HARNESS.
A. Disconnect the signal wire from the switch.
Expected Result:
The alert indicator is FLASHING.
Results:
• YES – The alert indicator FLASHES. The circuit is
operating correctly. The switch has failed.
Repair: Repair the switch or replace the switch.
STOP.
• NO – The alert indicator does NOT FLASH. The
circuit has failed. The signal wire is probably
shorted to ground. Proceed to test step 3.
Test Step 3. CHECK THE HARNESS
A. Turn the disconnect switch and the key start
switch to the OFF position.
B. The signal wire remains disconnected from the
switch. Do not allow the signal wire to touch any
objects.
C. On the Electrical System Schematic, trace the
signal wire from the switch to the main display
module.
D. Determine the signal contact (connector contact)
of the machine harness at the main display
module.
E. Disconnect the machine harness from the main
display module.
F. At the machine harness connector for the display
module, check for continuity between the signal
contact and contact 2 or frame ground if a ground
wire is not present at contact 2.
Expected Result:
The resistance is greater than 5000 ohms.
Results:
• YES – The resistance is greater than 5000 ohms.
The harness is not causing the failure. The main
display module has failed.
Repair: It is unlikely that the main display module
has failed. Exit this procedure and perform this
procedure again. Also, recheck if the diagnostic
code indicator is illuminated for this diagnostic
code. If the cause of the diagnostic code is not
found, replace the main display module. See
Testing and Adjusting, “Module - Replace”.
STOP.
 73
Troubleshooting Section

• NO – The resistance is less than 5000 ohms.

The harness has failed. The signal wire within the
harness is shorted to ground.

Repair: Repair the harness or replace the harness.

STOP.

i01398181

Harness Code
SMCS Code: 1408-038
S/N: ASD1-Up
S/N: ARL1-Up
S/N: APM1-Up
S/N: APN1-Up

System Operation Description:

Table 18
Harness Code Troubleshooting(1)
Main Display Module 31 3 12 22 16 6
Connector Contact
Wire Identification 270-BK 271-BK 272-BK 273-BK 274-BK 275-BK
Harness Code Plug Contact(2) 1 2 3 4 5 6

Machine Code Specified Status

01 O(3) G(4) G G G G
02 G O G G G G
03 O O G G G G
04 G G O G G G
05 O G O G G G
06 G O O G G G
07 O O O G G G
08 G G G O G G
09 O G G O G G
10 G O G O G G
11 O O G O G G
12 G G O O G G
13 O G O O G G
14 G O O O G G
15 O O O O G G
16 G G G G O G
17 O G G G O G
18 G O G G O G
(continued)
74
Troubleshooting Section

(Table 18, contd)

Harness Code Troubleshooting(1)
Main Display Module 31 3 12 22 16 6
Connector Contact
19 O O G G O G
20 G G O G O G
21 O G O G O G
22 G O O G O G
23 O O O G O G
24 G G G O O G
25 O G G O O G
26 G O G O O G
27 O O G O O G
28 G G O O O G
29 O G O O O G
30 G O O O O G
31 O O O O O G
32 G G G G G O
33 O G G G G O
34 G O G G G O
35 O O G G G O
36 G G O G G O
37 O G O G G O
38 G O O G G O
39 O O O G G O
40 G G G O G O
41 O G G O G O
42 G O G O G O
43 O O G O G O
44 G G O O G O
45 O G O O G O
46 G O O O G O
47 O O O O G O
48 G G G G O O
49 O G G G O O
50 G O G G O O
51 O O G G O O
52 G G O G O O
53 O G O G O O
54 G O O G O O
(continued)
 75
Troubleshooting Section

(Table 18, contd)

Harness Code Troubleshooting(1)
Main Display Module 31 3 12 22 16 6
Connector Contact
55 O O O G O O
56 G G G O O O
57 O G G O O O
58 G O G O O O
59 O O G O O O
60 G G O O O O
61 O G O O O O
62 G O O O O O
(1) Main display module is in the Harness Code Mode (Mode 1).
(2) For machines so equipped. For machines without a harness code plug, permanent harness code connections are in the machine harness.
(3) O = open
(4) G = grounded

Before you perform this procedure, determine the
proper machine code. The main display module
must have the correct part number for the particular
machine. If the machine code is not shown correctly,
this procedure determines the component that is
malfunctioning. This failure could be caused by a
failure in the main display module, a wrong harness
code plug or a harness that has failed.
C. Check for continuity between the connector
contacts that are grounded contacts and contact
2 (ground). Check for continuity at the machine
harness connector for the main display module.
Expected Result:
The resistance measures 5.0 Ohms or less.

Note: The harness code and the machine code are
similar terms. The codes describe the particular
machine. The harness code is the status (open or
ground) of the six harness code inputs (connector
contacts 3, 6, 12, 16, 22 and 31). The main display
module assigns a number to a machine. This
number is the machine code. The machine code
is shown during harness code mode. Each sales
model has a specific harness code. Therefore, each
sales model also has a specific machine code. The
specific machine code is listed in Systems Operation,
“Harness Code Mode”. The specific harness code is
given in the Electrical System Schematic.
Note: The following procedure checks for incorrect
harness codes on the inputs for the main display
module. Compare the status of the harness code that
is found in the test “Determine the machine code” to
the status at the inputs for the main display module.
The table identifies the connector contacts and wire
identification of the harness code circuits. Contacts
that are specified as grounded contacts should be
checked for opens in the harness. Contacts that are
specified as open contacts should be checked for
shorts in the harness.
Test Step 1. CHECK FOR OPENS
A. Turn the disconnect switch to the OFF position.
B. Disconnect the machine harness from the main
display module.
Results:
• YES – The resistance is 5.0 Ohms or less. The
circuit for the harness code is not open. No defect
was found in the ground circuits for the harness
code. Proceed to test step 2.
• NO – The resistance is greater than 5.0 Ohms.
The circuit for the harness code is open. Check
the harness code plug on so equipped machines.
Record the open contact of the machine harness
connector.
Repair: Repair the open circuits for the harness
code that is found or replace the machine harness.
If conditions are not resolved, proceed to test step
2.
Test Step 2. CHECK FOR SHORTS
A. The disconnect switch remains in the OFF
position. The machine harness to the main display
module remains disconnected.
B. Measure the resistance between the connector
contacts that are specified as open contacts and
contact 2 (ground). Measure the resistance at the
machine harness connector for the main display
module.
76
Troubleshooting Section
Expected Result:
The resistance measures 5000 Ohms or more.
Results:
• YES – The resistance is 5000 Ohms or more.
The circuit for the harness code is not shorted to
ground. No defect was found in the circuit for the
harness code. STOP.
• NO – The resistance is less than 5000 Ohms.
The circuit for the harness code is shorted. Check
the harness code plug on so equipped machines.
Record the shorted contact of the machine harness
connector.
Repair: Repair the shorted circuits of the harness
code that are found or replace the machine
harness.
If conditions are not resolved, proceed to test step
3.
Test Step 3. CHECK IF THE PROBLEM
REMAINS
A. Reconnect the harness connectors.
B. Turn the disconnect switch and the key start
switch to the ON position.
C. Recheck the machine code.
Expected Result:
The main display module shows the correct machine
code.
Results:
• YES – The main display module shows the correct
machine code. STOP.
• NO – The main display module does not show the
correct machine code. Replace the module.
Repair: It is unlikely that the module has failed.
Exit this procedure and perform this diagnostic
code procedure again. If the problem has not been
found, then replace the main display module. See
Testing and Adjusting, “Module - Replace”.
STOP.
i01916278
Pulse Width Modulated Sensor
SMCS Code: 7490-038-NS
System Operation Description:
g00315944
Illustration 82
Schematic symbol for a typical pulse width modulated sensor
(PWM)
Note: In addition to these tests, the Caterpillar
Monitoring System diagnostics are helpful for
troubleshooting sensors. Numeric readout mode
shows a numeric value of the information from each
sensor input. For a detailed explanation, refer to
Systems Operation, “Numeric Readout Mode”.
When you are testing a sensor, it is necessary to
identify the connector contacts and the harness
wires. The Electrical System Schematic shows the
connector contact numbers and corresponding wire
numbers. See the Electrical System Schematic in the
Service Manual for the machine.
On all machines, the wire numbers and connector
contacts are identified by these general rules:
• The “+V” wire numbers are from 100 to 199. The
“+V” contact corresponds to this wire number.
• The ground wire number is between 200 and
299. The ground contact corresponds to this wire
number.
• The wire number for the signal circuits is from 400
to 499. The signal contact corresponds to this wire
number.
For an example, see Illustration 82:
• The “+V” wire is wire number 113.
• The “+V” contact is contact “A”.
• The ground wire is wire number 201.
 77
Troubleshooting Section

• The ground contact is contact “B”. Repair: If the sensor and the harness are correct,
it is likely that the main display module has failed.
• The signal wire is wire number 443. Replace the main display module. See Testing and
Adjusting, “Module - Replace”.
• The signal contact is contact “C”.
STOP.
Table 19
Tools Needed
i01916286
9U-7330 Multimeter 1
Sensor Signal Voltage
7X-1710 Multimeter Probe Group 1
SMCS Code: 7490-038-NS
Test Step 1. TROUBLESHOOT THE
SENSORS. System Operation Description:

Troubleshoot sensor circuits in the following order. Note: The main display module is connected.

Table 20
A. Perform the Troubleshooting, “Sensor Signal
Voltage” procedure. This procedure checks the Sensor Voltage Specifications
sensor voltages at the sensor while the circuits For The Sensor Voltage Test
remain connected. DISCONNECT NOTHING. 100-3055 Temperature Sensor And 131-0427
Troubleshoot “as is” before disconnecting any Temperature Sensor
circuits. Disconnecting circuits first may alter a
poor connection. Proving the original cause of a Temperature Signal Voltage(1) Duty Cycle
problem may be difficult or impossible. −20 to 0°C 1.1 to 1.4 DCV 11 to 15%
(−4 to 32°F)
Expected Result:
0 to 20°C 1.4 to 2.0 DCV 15 to 23%
(32 to 68°F)
The Troubleshooting, “Sensor Signal Voltage”
procedure has determined the cause of the problem. 20 to 40°C 2.0 to 3.1 DCV 23 to 37%
(68 to 104°F)
Results:
40 to 60°C 3.1 to 4.5 DCV 37 to 55%
• OK – This test step has determined the cause of (104 to 140°F)
the problem. STOP.
60 to 80°C 4.5 to 5.7 DCV 55 to 71%
• NOT OK – This test step has NOT determined the (140 to 176°F)
cause of the problem. Proceed to test step 2. 80 to 100°C 5.7 to 6.6 DCV 71 to 82%
(176 to 212°F)
Test Step 2. TROUBLESHOOT THE
SENSORS 100 to 120°C 6.6 to 7.2 DCV 82 to 89%
(212 to 248°F)
A. Perform the Troubleshooting, “Sensor Dynamic 120 to 140°C 7.2 to 7.4 DCV 89 to 93%
Operation” procedure. This is an additional test. (248 to 275°F)
This will test the sensor during actual operating (1) These voltages are guidelines for troubleshooting and are not
conditions. considered exact. The tolerance is ± 10%, depending on the
condition of the harness. Most important is that the output
Expected Result: voltage changes smoothly as the temperature changes.

The Troubleshooting, “Sensor Dynamic Operation”

procedure has determined the cause of the problem.

Results:

• OK – This test step has determined the cause of

the problem. STOP.

• NOT OK – This test step has NOT determined the

cause of the problem.
78
Troubleshooting Section

Table 21 Results:
Sensor Voltage Specifications
For Sensor Voltage Test • YES – The voltage is between 7.5 and 8.5 DCV.
The system voltage is present. Proceed to test
3E-5370 Temperature Sensor Group And step 2.
131-0784 Temperature Sensor
Temperature Signal Voltage(1) Duty Cycle • NO – The voltage is not between 7.5 and 8.5 DCV.
There is an open circuit. Trace the +V and ground
−40 to 20°C 0.8 to 1.5 DCV 4 to 11% circuits in the machine harness.
(−40 to −4°F)
−20 to 0°C 1.5 to 2.5 DCV 11 to 22% Repair: Repair the machine harness or replace the
(−4 to 32°F) machine harness.
0 to 20°C 2.5 to 3.7 DCV 22 to 34% STOP.
(32 to 68°F)
20 to 40°C 3.7 to 4.8 DCV 34 to 46% Test Step 2. CHECK THE SIGNAL
(68 to 104°F) VOLTAGE.
40 to 60°C 4.8 to 6.0 DCV 46 to 59%
(104 to 140°F) A. At the sensor connector, identify the signal and
ground circuits.
60 to 80°C 6.0 to 7.2 DCV 59 to 71%
(140 to 176°F) B. Push the 7X-1710 Cable Probes in the back of
80 to 100°C 7.2 to 8.1 DCV 71 to 81% the sensor connector along side of the signal and
(176 to 212°F) the ground circuit wires.
100 to 120°C 8.1 to 8.8 DCV 81 to 87% C. Measure the signal voltage and record the signal
(212 to 248°F) voltage.
120 to 140°C 8.8 to 9.2 DCV 87 to 92%
(248 to 275°F) Note: If a precise signal voltage is necessary, use the
(1) These voltages are guidelines for troubleshooting and are not
specifications that are listed in the provided tables.
considered exact. The tolerance is ± 10%, depending on the
condition of the harness. Most important is that the output Expected Result:
voltage changes smoothly as the temperature changes.
The measured signal voltage is approximately
Locate the suspect sensor. Identify the sensor wires between 1.0 and 7.0 DCV. The measured signal
and connector contacts. See Troubleshooting, “Pulse voltage is approximately between 1.0 and 9.0 DCV
Width Modulated (PWM) Sensor - Test”. DO NOT when using the 3E-5370 Temperature Sensor
DISCONNECT ANY HARNESS CONNECTORS Group.
AT THIS TIME. Turn the key start switch to the ON
position. DO NOT START THE ENGINE. Results:

Test Step 1. CHECK THE SENSOR • FROM 1.0 TO 7.0 (9.0) DCV – The voltage is
POWER. between approximately 1.0 and 7.0 DCV (9.0 DCV
for 3E-5370 Temperature Sensor Group). The
A. At the sensor connector, identify the +V and signal voltage at the sensor is correct.
ground circuits.
Repair: The harness and the main display module
B. Push the 7X-1710 Cable Probes in the back of are working properly. The voltage that is measured
the sensor connector along side of the +V and is correct. The sensor has failed. Replace the
ground circuit wires. sensor.

C. Measure the system voltage. Proceed to test step 3.

Expected Result: • GREATER THAN 7.0 (9.0) – The voltage is NOT

between approximately 1.0 and 7.0 DCV. (9.0 DCV
The voltage that is measured is between 7.5 and 8.5 for 3E-5370 Temperature Sensor Group). The
DCV. signal voltage is not correct. The signal circuit of
the machine harness is shorted to the +battery.
 79
Troubleshooting Section

Repair: Repair the machine harness or replace the Repair: Repair the machine harness or replace the
machine harness. Repeat this test step in order machine harness.
to verify that the problem has been corrected. If
the problem has not been corrected replace the STOP.
main display module. See Testing and Adjusting,
“Module - Replace”. Test Step 4.
STOP. Perform the following diagnostic procedure: “Sensor
Dynamic Operation”
• LESS THAN 1.0 DCV – The voltage is less than
1.0 DCV. The signal voltage is not correct. The Results:
signal circuit of the machine harness is shorted
to ground. • OK – STOP.
Repair: Repair the machine harness or replace the • REPAIRED, OK – STOP.
machine harness. Repeat this test step in order
to verify that the problem has been corrected. If
the problem has not been corrected replace the i01396902
main display module. See Testing and Adjusting,
“Module - Replace”. Sensor Dynamic Operation
STOP. SMCS Code: 7490-038-NS

Test Step 3. CHECK THE SIGNAL System Operation Description:

CIRCUIT FOR THE MACHINE HARNESS .
Note: The main display module is connected.
A. At the machine harness connector for the main
display module, identify the signal and ground
circuits.

Note: DO NOT DISCONNECT THE HARNESS

CONNECTOR.

B. Push the 7X-1710 Cable Probes in the back of

the machine harness connector along side of the
signal and ground circuit wires.

C. Measure the signal voltage.

D. Compare this measurement with the voltage that

was measured in the previous test “Check the
signal voltage”.

Expected Result:

The main display module is receiving a valid signal

voltage of 1.0 to 7.0 DCV.

Results:

• OK – The main display module is receiving a valid

signal voltage. If the problem has been corrected
exit this procedure. No further testing is required. If
the problem still persists, further testing is required.
Proceed to test step 4.

• NOT OK – The voltage is not the same as in

the previous test “Check the signal voltage”. The
machine harness has an open in the signal or
ground circuits.
80
Troubleshooting Section

Table 22 Table 23
Sensor Voltage Specifications (1) Sensor Voltage Specifications (1)

For Sensor Dynamic Test For Sensor Dynamic Test

100-3055 Temperature Sensor And 131-0427 3E-5370 Temperature Sensor Group And
Temperature Sensor 131-0784 Temperature Sensor
Temperature Signal Voltage(2) Duty Temperature Signal Duty
Cycle Voltage(2) Cycle
−40 to 20°C (−40 to −4°F) 1.0 to 1.1 DCV 10 to −40 to 20°C (−40 to −4°F) 0.8 to 1.5 DCV 4 to
11% 11%
−20 to 0°C (−4 to 32°F) 1.1 to 1.4 DCV 11 to −20 to 0°C (−4 to 32°F) 1.5 to 2.5 DCV 11 to
15% 22%
0 to 20°C (32 to 68°F) 1.4 to 2.0 DCV 15 to 0 to 20°C (32 to 68°F) 2.5 to 3.7 DCV 22 to
23% 34%
20 to 40°C (68 to 104°F) 2.0 to 3.1 DCV 23 to 20 to 40°C (68 to 104°F) 3.7 to 4.8 DCV 34 to
37% 46%
40 to 60°C (104 to 140°F) 3.1 to 4.5 DCV 37 to 40 to 60°C (104 to 140°F) 4.8 to 6.0 DCV 46 to
55% 59%
60 to 80°C (140 to 176°F) 4.5 to 5.7 DCV 55 to 60 to 80°C (140 to 176°F) 6.0 to 7.2 DCV 59 to
71% 71%
80 to 100°C (176 to 212°F) 5.7 to 6.6 DCV 71 to 80 to 100°C (176 to 212°F) 7.2 to 8.1 DCV 71 to
82% 81%
100 to 120°C 6.6 to 7.2 DCV 82 to 100 to 120°C 8.1 to 8.8 DCV 81 to
(212 to 248°F) 89% (212 to 248°F) 87%
120 to 140°C 7.2 to 7.4 DCV 89 to 120 to 140°C 8.8 to 9.2 DCV 87 to
(248 to 275°F) 93% (248 to 275°F) 92%
(1) If desired, use these specifications with the following procedure. (1) If desired, use these specifications with the following procedure.
(2) These voltages are guidelines for troubleshooting and are not (2) These voltages are guidelines for troubleshooting and are not
considered exact. The tolerance is ± 10%, depending on the considered exact. The tolerance is ± 10%, depending on the
condition of the harness. Most important is that the output condition of the harness. Most important is that the output
voltage changes smoothly as the temperature changes. voltage changes smoothly as the temperature changes.

To use the following procedure, it is necessary to

know the connector contact of the main display
module and the contact that corresponds to the
service code. See the Electrical System Schematic
in the Service Manual for the machine in order to
determine the proper connector contact of the main
display module. Use the 7X-1710 Cable Probe on
the connector contact of the sensor signal wire on
the main display module.

Note: The sensors are provided power from the

main display module . Therefore, the main display
module must be connected in order for the sensors
to function.

Two items are checked in this test:

• A sensor signal is present at the main display

module.

• For an increase and/or a decrease in the system

that is being monitored, the signal voltage will
increase and/or the signal voltage will decrease.

Test Step 1. CHECK THE INITIAL SIGNAL
VOLTAGE.
A. The engine coolant and the temperature sensors
should be below operating temperature.
B. Ensure that the engine coolant and temperature
sensors are below normal. Ensure that the key
switch is OFF and that the sensor is connected
to the machine harness.
C. Turn the key switch to the ON position. DO NOT
START THE ENGINE.
D. At the machine harness connector for the main
display module, measure the voltage and record
the voltage (DCV) between the signal contact
and frame ground. For correct operation, the
approximate voltage is between 1.0 and 7.0 DCV.
For the 3E-5370 and 131-0784 Temperature
Sensor Groups the approximate voltage is
between 1.0 and 9.0 DCV.
Note: When precise specifications for the signal
voltage are necessary, use the specifications that are
listed in the provided tables.
Expected Result:
The voltage that is measured is within the
specifications.
Results:
• YES – The approximate voltage is between 1.0
and 7.0 DCV. For the 3E-5370 and 131-0784
Temperature Sensor Groups the approximate
voltage is between 1.0 and 9.0 DCV. The signal
voltage to the main display module is correct.
Proceed to test step 2.
• NO – The approximate voltage is NOT between
1.0 and 7.0 DCV. For the 3E-5370 and 131-0784
Temperature Sensor Groups the approximate
voltage is NOT between 1.0 and 9.0 DCV. The
signal voltage to the main display module is not
correct. The probable cause is a failed sensor.
Repair: The sensor has failed. Replace the sensor.
STOP.
Test Step 2. CHECK THE SIGNAL
VOLTAGE WITH THE NEW CONDITIONS.
A. Increase the temperature, the pressure or the
fuel level of the system that is being tested.
The following procedures are examples: run the
engine in order to increase the engine coolant
temperature, operate the implement controls in
order to increase the hydraulic oil temperature,
and add fuel in order to increase the fuel level.
81
Troubleshooting Section
B. At the machine harness connector for the main
display module, measure the voltage (DCV)
between the signal contact and frame ground.
C. For the correct operation, the voltage (DCV) is
greater (and increases smoothly without step
increases) than the voltage that was recorded in
the previous test “Check the initial signal voltage”.
Note: The larger the change in the system that is
being monitored, the greater the difference between
the voltages of this test “Check the signal voltage
with new conditions” and the previous test “Check
the initial signal voltage”.
Expected Result:
The voltage increases during the test procedure.
Results:
• OK – The voltage increase during the test
procedure and the sensor operates smoothly. The
sensor has not failed. STOP.
• NOT OK – The voltage does not increase during
the test procedure. The probable cause is a failed
sensor.
Repair: The sensor has failed. Replace the sensor.
STOP.
i01397975
Fuel Level Sender
SMCS Code: 1273-038-UN
System Operation Description:
For the most accurate specifications for the sender,
see the table “Resistor, Solenoid And Sender
Specification”. This table is located in the Electrical
System Schematic for the machine that is being
serviced.
CHECK THE SENDER
A. Disconnect the sender from the machine harness.
B. Measure the resistance between the two contacts
of the sender.
The following data is the correct approximate
resistance:
106-3535 Level Sender Assembly and
134-3033 Fuel Level Sender
Empty tank ................................. 240 to 260 Ω
Half tank ....................................... 97 to 118 Ω
Full tank ......................................... 27 to 40 Ω
82
Troubleshooting Section
104-5546 Level Sender Assembly, 115-2086
Fuel Level Sender, 121-3174 Fuel Level Sender,
136-1617 Fuel Level Sender, 137-5156 Fuel
Level Sender, 150-2995 Fuel Sender, and
151-1399 Sender
Empty tank ..................................... 92 to 98 Ω
Full tank .......................................... 0 to 3.5 Ω
9X-4942 Fuel Level Sender
Empty tank ..................................... 80 to 85 Ω
Half tank ......................................... 40 to 43 Ω
Full tank ............................................. 0 to 2 Ω
C. Actuate the sender by hand while you are
measuring the resistance.
D. The resistance should change as the sender is
actuated through the empty range to the full range.
Expected Result:
The resistance that is measured is within the
specifications.
Results:
• OK – The resistance for the fuel level sender is
correct. STOP.
• NOT OK – The resistance for the fuel level sender
is NOT correct.
Repair: Replace the fuel level sender.
STOP.
i01968414
Switch Circuits
SMCS Code: 1435-038; 7332-038
System Operation Description:
When a filter has been replaced and the bypass
switch continues to indicate that a problem exists,
further troubleshooting is necessary to isolate the
fault. Refer to the Systems Operations, “Switches”
section for additional information on the individual
switches.
The possible causes of these failures are listed
below:
• The signal circuit in the machine harness is open.
• The switch has failed.
• The ECM has failed.
Test Step 1. CHECK FOR AN OPEN IN
THE HARNESS
A. Locate the switch that corresponds to the alert
indicator that is located on the main display
module. (If necessary, use the Electrical System
Schematic to assist in locating the switch.)
B. Disconnect the signal wire from the switch.
C. Place a jumper wire from the signal wire to the
ground wire.
Expected Result:
The alert indicator is no longer active on the main
display module.
Results:
• OK – The alert indicator is no longer active on the
main display module.
Repair: The switch has failed. Check or replace
the switch.
STOP.
• NOT OK – The alert indicator remains on the main
display module. The machine harness is open or
the ECM has failed. Proceed to test step 2.
Test Step 2. CHECK THE VOLTAGE OF
THE ECM.
A. Remove the jumper that was used in the previous
test step.
B. The signal wire remains disconnected.
C. Measure the pull-up voltage from the signal wire
to the ground wire with a digital multimeter.
Expected Result:
The voltage is 8 ± 0.5 volts.
Results:
• OK – The voltage is 8 ± 0.5 volts.
Repair: The voltage is correct. The ECM has
failed. It is unlikely that the ECM has failed. Exit
this procedure and perform this procedure again.
If the fault is not found, replace the ECM. See
Testing and Adjusting, “Module - Replace”.
STOP.
• NOT OK – The voltage is NOT 8 ± 0.5 volts.
Proceed to test step 3.
 83
Troubleshooting Section

Test Step 3. CHECK THE SIGNAL
CIRCUIT OF THE HARNESS.
A. Turn the key start switch and the disconnect
switch to the OFF position.
B. Use the Electrical System Schematic to trace the
signal wire from the switch back to the ECM.
Repair: The machine harness is not the cause
of the failure. The ECM has failed. It is unlikely
that the ECM has failed. Exit this procedure
and perform this procedure again. If the fault is
not found, replace the ECM. See Testing and
Adjusting, “Module - Replace”.
STOP.

C. Determine the signal contact (connector contact) • NOT OK – The resistance is greater than 5.0
of the machine harness at the ECM. ohms.

D. Disconnect the machine harness connectors J1 Repair: The machine harness has failed. Repair
and J2 from the ECM. the machine harness or replace the machine
harness.
E. At the machine harness connector for the ECM,
measure the resistance between the signal STOP.
contact and contact 2 of the switch.
i01428111
Expected Result:

The resistance is less than 5 ohms.

Switch Circuits
SMCS Code: 1435-038; 7332-038
Results:
S/N: 1241-Up
• OK – The resistance is less than 5 ohms. The
signal circuit of the harness is correct. Proceed to S/N: 1251-Up
test step 4.
S/N: 1261-Up
• NOT OK – The resistance is greater than 5.0 S/N: CCA1-Up
ohms.
S/N: CBC1-Up
Repair: The signal circuit of the harness is not
correct. Repair the machine harness or replace the S/N: ASD1-Up
machine harness. S/N: CAF1-Up
STOP. S/N: CBK1-Up

Test Step 4. CHECK THE GROUND S/N: ARL1-Up

CIRCUIT OF THE HARNESS.
S/N: APM1-Up
A. The key start switch and the disconnect switch S/N: APN1-Up
remain in the OFF position.
S/N: CCP1-Up
B. The machine harness connectors J1 and J2
remain disconnected. S/N: AMX1-Up
S/N: ALZ1-Up
C. Use the Electrical System Schematic to trace the
ground for the switch. S/N: AMZ1-Up
D. At the switch, measure the resistance between System Operation Description:
the ground wire and frame ground.
When a filter has been replaced and the bypass
Expected Result: switch continues to indicate that a problem exists,
further troubleshooting is necessary to isolate the
The resistance is less than 5 ohms. fault. Refer to the Systems Operations, “Switches”
section for additional information on the individual
Results: switches.

• OK – The resistance is less than 5 ohms. The possible causes of these failures are listed
below:

• The signal circuit in the machine harness is open.

84
Troubleshooting Section
• The switch has failed.
• The ECM has failed.
Test Step 1. CHECK FOR AN OPEN IN
THE HARNESS
A. Locate the switch that corresponds to the alert
indicator that is located on the main display
module. (If necessary, use the Electrical System
Schematic to assist in locating the switch.)
B. Disconnect the signal wire from the switch.
C. Place a jumper wire from the signal wire to the
ground wire.
Expected Result:
The alert indicator is no longer active on the main
display module.
Results:
• OK – The alert indicator is no longer active on the
main display module.
Repair: The switch has failed. Check or replace
the switch.
STOP.
• NOT OK – The alert indicator remains on the main
display module. The machine harness is open or
the ECM has failed. Proceed to test step 2.
Test Step 2. CHECK THE VOLTAGE OF
THE ECM.
A. Remove the jumper that was used in the previous
test step.
B. The signal wire remains disconnected.
C. Measure the pull-up voltage from the signal wire
to the ground wire with a digital multimeter.
Expected Result:
The voltage is 8 ± 0.5 volts.
Results:
• OK – The voltage is 8 ± 0.5 volts.
Repair: The voltage is correct. The ECM has
failed. It is unlikely that the ECM has failed. Exit
this procedure and perform this procedure again.
If the fault is not found, replace the ECM. See
Testing and Adjusting, “Module - Replace”.
STOP.
• NOT OK – The voltage is NOT 8 ± 0.5 volts.
Proceed to test step 3.
Test Step 3. CHECK THE SIGNAL
CIRCUIT OF THE HARNESS.
A. Turn the key start switch and the disconnect
switch to the OFF position.
B. Use the Electrical System Schematic to trace the
signal wire from the switch back to the ECM.
C. Determine the signal contact (connector contact)
of the machine harness at the ECM.
D. Disconnect the machine harness connectors J1
and J2 from the ECM.
E. At the machine harness connector for the ECM,
measure the resistance between the signal
contact and contact 2 of the switch.
Expected Result:
The resistance is less than 5 ohms.
Results:
• OK – The resistance is less than 5 ohms. The
signal circuit of the harness is correct. Proceed to
test step 4.
• NOT OK – The resistance is greater than 5.0
ohms.
Repair: The signal circuit of the harness is not
correct. Repair the machine harness or replace the
machine harness.
STOP.
Test Step 4. CHECK THE GROUND
CIRCUIT OF THE HARNESS.
A. The key start switch and the disconnect switch
remain in the OFF position.
B. The machine harness connectors J1 and J2
remain disconnected.
C. Use the Electrical System Schematic to trace the
ground for the switch.
 85
Troubleshooting Section

D. At the switch, measure the resistance between Table 24

the ground wire and frame ground. Alternator Specifications
Expected Result: Peak Minimum
Current Peak
The resistance is less than 5 ohms. Rating Current
(Amps) (Amps)
Results: 12 Volt Alternators
8C-5535 32 28
• OK – The resistance is less than 5 ohms.
7N-4784, OR-5201 40 36
Repair: The machine harness is not the cause
of the failure. The ECM has failed. It is unlikely 6T-1396, 7T-2096, 8C-5908, 51 46
that the ECM has failed. Exit this procedure OR-3654
and perform this procedure again. If the fault is 9W-2648, 9W-2949, 55 49
not found, replace the ECM. See Testing and 8T-9700, 105-2811(IG),
Adjusting, “Module - Replace”. OR-4327(IG), 105-2812(IG),
OR-9273(IG), 34-3268,
STOP. 68-4139, 3E-7295(D+),
7T-2876(D+), 100-8223
• NOT OK – The resistance is greater than 5.0 7G-7889 60 54
ohms.
8C-5510(I), OR5200 61 55
Repair: The machine harness has failed. Repair 8N-2268 75 68
the machine harness or replace the machine
harness. 3E-7892, OR-3616 85 77
105-2813(IG), OR-9274(IG), 90 81
STOP. 105-2814(IG), OR-4328(IG),
149-2064(REG),
OR-9410(REG),
i01969322 9X-0341(D+)
Charging System 8C-6163, OR-1699, 105 95
107-2519
SMCS Code: 1406-038 167-7816 110 99
System Operation Description: 9X-6796, 9X-9096, 115 104
121-4134, 121-4136,
Often when problems with the charging system OR-3527
are being investigated, the alternator is not the 3E-8827, 121-4135, 130 117
problem. If a low battery condition is present test the 117-1379(I)
batteries first. See Special Instruction, SEHS7633,
“Battery Test Procedure” for more information. If the 152-8746 135 122
engine cranks slowly, then test the starting system. 125-9597, OR-8332 145 131
See Service Magazine, SEPD0020, “Testing The
Starter On The Engine” for more information. If a 24 Volt Alternators
warning indicator for the charging system is ON, see 200-2232 67.5 26
Service Magazine, SEBD1751, “Difference Between
Alternator Indicator In Electronic Monitoring System 169-3345 50 30
(EMS) And Low Voltage Indicator In Operating 200-8281 67.5 26
Monitoring System (OMS)”.
2P-1204, 3Y-8200 19 17
Note: Severely discharged batteries can cause low 2Y-8310 21 19
system voltage. This can occur even while the engine
is running above idle, and the alternator is working 6T-1395, 7T-2095, OR-3653 33 30
properly. Proper low engine idle is also important. 6N-9294, OR-5217, OR-3482 35 32
5N-5692, OR-2698 45 41
5S-9088, 100-5047, 50 45
112-5041, 3E-7578,
OR-5206, OR-3667,
OR-3668
(continued)
86
Troubleshooting Section

(Table 24, contd) Results:

Alternator Specifications
• Method 1 – The alternator has a “1”, “REG”, or
Peak Minimum “D+” terminal. Proceed to test step 2.
Current Peak
Rating Current
(Amps) (Amps)
• Method 2 – The alternator is self-excited. Proceed
to test step 4.
109-2362, 9W-3043 55 50
, OR-3652(D+), 112-8032 • Method 3 – The alternator has an “IG” terminal.
Proceed to test step 3.
3E-7772(IG), OR-9437(IG), 60 54
105-3132(IG), 4N-3986,
OR-5203 Test Step 2. CHECK THE RESISTANCE IN
THE EXCITATION CIRCUIT.
155-7434, 132-2156(I), 70 63
107-7977(I), OR-8279(I) A. Turn the key start switch to the ON position.
169-4319, 167-7812 75 67.5
B. Verify voltage at the excitation terminal. Connect
107-7976, 114-2401, 75 68 the red lead from a multimeter to the excitation
OR-8997, 3E-7577, OR-3615 terminal. Connect the black lead to a ground
165-5140 100 90 source (alternator case ground).
9X-7803, OR-3749 100 90 C. Read the voltage that is shown on the multimeter.
Parts-Service Only Discontinued 12 Volt Alternators
Expected Result:
6T-1193 18 16
7N-6118, 6N-5460, 4N-4540 40 36 The voltage reads at least .2 volts.
6T-1195 42 38 Results:
7X-1340 45 41
• YES – The voltage reads .2 volts or more. The
9G-6079, 6T-1194 63 57 excitation circuit is correct. Proceed to test step 4.
Parts-Service Only Discontinued 24 Volt Alternators
• NO – The voltage is less than .2 volts. There is a
9G-6081, 6T-1196 40 36 problem in the wiring harness to the alternator or
D+ - Diode trio output. Alternator requires external there is a poor electrical connection. Correct the
excitation. problem and operate the machine. Watch for a
recurrence of the problem. STOP.
REG - Regulator Terminal. Alternator requires external
excitation. Test Step 3. CHECK THE RESISTANCE IN
I - Ignition Terminal. Alternator can be externally excited THE EXCITATION CIRCUIT (CONTINUED).
through this terminal.
Note: This step is only for alternators with external
IG - Ignition Terminal. System voltage must be supplied
to this terminal to turn on the alternator. Some of these
excitation when the terminal for excitation is labelled:
alternators use the IG terminal as a sense terminal. “IG”.

A. Turn the key start switch to the ON position.

Test Step 1. DETERMINE THE
ALTERNATOR EXCITATION METHOD.
A. Check the rear of your alternator in order to
determine the method of excitation. See table 24
in order to verify the proper alternator excitation.
Expected Result:
Test method 1. These alternators have a “1”, “REG”,
or “D+” terminal. Test method 2. These alternators
are self-excited. Test method 3. These alternators
have a “IG” terminal.
B. Verify voltage at the excitation terminal. Connect
the red lead from a multimeter to the excitation
terminal. Connect the black test lead to a ground
source (alternator case ground).
Note: For G3B, K3A, and L3A alternators, Insert a
7X-1710 Multimeter Probe Group into the rear of the
middle wire in the connector. See figure 83 below.
Insert the probes spoon lead between the seal and
the wire that surrounds the wire and the outer shell of
the connector. Do not insert the probe between the
wire insulation and the black seal. This terminal (IG)
is the terminal for excitation.

Illustration 83
g00496660
Special wire probe technique for G3B, Y3A, and L3A alternators.
C. Read the voltage that is shown on the multimeter.
Expected Result:
The voltage measurement is within .5 volts of the
battery voltage.
Results:
• YES – The voltage reads battery voltage. The
excitation circuit is correct. 4.
• NO – The voltage that is measured is more than
a .5 volt less than the battery voltage. There is a
problem in the wiring harness to the alternator or
there is a poor electrical connection. Correct the
problem and operate the machine. Watch for a
recurrence of the problem. STOP.
Test Step 4. CHECK THE SYSTEM
VOLTAGE.
A. Before you start the machine, connect a voltmeter
between the “B+” terminal and the case of the
alternator. Turn OFF all electrical loads.
B. Turn the key to the ON position but do not start
the engine. Read the voltage on the voltmeter.
Make a note of the voltage that was measured.
Expected Result:
This voltage should be approximately system voltage.
Results:
• YES – The voltage is approximately system
voltage. Proceed to test step 5.
87
Troubleshooting Section
• NO – The voltage is less than system voltage.
Proceed to test step 7.
Test Step 5. CHECK THE OPERATION OF
THE ALTERNATOR.
A. The voltmeter remains connected between the
“B+” terminal and the case of the alternator.
B. Start the machine. Set the throttle to at least 75
percent. Read the voltage on the voltmeter. Make
a note of the voltage that was measured.
Expected Result:
The voltage measurement is greater than the voltage
that was recorded in the previous test step “Check
The System Voltage”.
Results:
• VOLTAGE HIGHER – The voltage measurement
is greater than the voltage that was observed in the
previous test step “Check The System Voltage”.
The voltage is also less than the maximum voltage
that is listed in the specifications for the alternator.
The alternator is partially charging the battery.
Proceed to test step 6.
• VOLTGE TOO HIGH – The voltage measurement
is greater than the voltage that was observed in the
previous test step “Check The System Voltage”.
The voltage is also greater than the maximum
voltage that is listed in the specifications for the
alternator. The alternator is over charging. Proceed
to test step 19.
• VOLTAGE LOWER – The voltage is not higher
than the voltage that was observed in the previous
test step. Proceed to test step 7.
Test Step 6. TEST THE ALTERNATOR
OUTPUT.
Note: For the proper output current, refer to table 24.
A. Ensure that the batteries are NOT fully charged.
Note: A fully charged battery may have open circuit
voltage above 12.5 volts on 12 volt systems. 24 volt
systems may be as high as 25 volts.
B. If the batteries are fully charged, then crank the
engine for 30 seconds. This action reduces the
battery voltage. Operate the lights for 10 minutes
while the engine is off as an alternative.
C. Connect the 9U-5795 Current Probe or 8T-0900
Ammeter to a DMM (digital multimeter). The
multimeter must have a peak hold feature. Clamp
the probe around the alternator output wire “B+”.
Before you clamp the probe around the wire,
ensure that the probe is “zeroed”.
88
Troubleshooting Section
D. Set the digital multimeter to “peak hold” or “max
mode” on the “mV” scale.
E. Turn on all electrical accessories: lights, air
conditioning, and radio.
F. Start the machine, and immediately set the throttle
to at least 75%. The peak current will appear on
the voltmeter in “peak hold” or “max” mode.
Expected Result:
The current reading should be at least 90% of the
specified peak output.
Results:
• YES – The current is at least 90% of the specified
peak output. Proceed to test step 13.
• NO – The current is less than 90% of the specified
peak output. Proceed to test step 7.
Test Step 7. CHECK THE DRIVE SYSTEM
OF THE ALTERNATOR.
A. Check the condition of the alternator drive belt.
Clean the pulley and replace the drive belt if the
drive belt is oily. Dry the drive belt if the belt is wet.
Replace the drive belt, if the belt is worn.
B. Check the tension of the alternator drive belt.
Adjust the drive belt to the correct tension.
C. Check the nut on the alternator pulley. Tighten the
nut if the nut is loose.
Expected Result:
The drive system of the alternator is functioning
correctly. No corrections to the drive system were
necessary.
Results:
• YES – The drive system of the alternator
is functioning correctly. No corrections were
necessary. Proceed to test step 8.
• NO – The drive system of the alternator was not
functioning correctly. Corrections were necessary.
Repair: Ensure that the problems have been
corrected. Exit this procedure and retest the
alternator charging system.
STOP.
Test Step 8. TEST THE CHARGING
CIRCUIT.
A. Verify that the nut on the “B+” alternator terminal
is tight. Also, verify that the wire has a good
connection to the “B+” terminal.
B. Many Caterpillar machines are equipped with a
connector for the 6V-2150 Starting/Charging
Analyzer. Use of this tester replaces the remainder
of this test step. To operate the analyzer, refer to
Tool Operating Manual, SEHS7768, “Using the
6V-2150”.
C. Start the engine and set the throttle to at least 75
percent. Turn ON all electrical accessories for the
remainder of this test step. Allow the engine to run
for at least 3 minutes before continuing.
D. Measure the voltage between the “B+” alternator
terminal and the alternator case ground. Make a
note of the measured voltage. Perform the next
measurement immediately.
E. Measure the voltage across the battery. Put the
red lead on the battery positive terminal, and put
the black lead on the battery negative terminal.
Make a note of the voltage that was measured.
Expected Result:
The voltage at the battery should be less than the
voltage at the alternator. The difference in voltages
should not be more than 1 volt on 12 volt systems.
The difference should not be more than 2 volts on
24 volt systems.
Results:
• YES – The voltage at the battery is less than the
voltage at the alternator. Also, the difference in
voltages is less than 1 volt for 12 volt systems
and the difference is less than 2 volts for 24 volt
systems. The wiring that is related to the alternator
is correct at this time.
Repair: There is an internal problem with the
alternator. Repair or replace the alternator.
STOP.
• NO – The voltage at the battery is less than the
voltage at the alternator. However, the difference in
voltages is greater than 1 volt for 12 volt systems
and the difference is greater than 2 volts for 24 volt
systems. Proceed to test step 9.

Test Step 9. TEST THE POSITIVE SIDE
OF THE CHARGING CIRCUIT.
A. Measure the voltage between the frame ground
and the “B+” alternator terminal. Make a note of
the voltage that was measured. Perform the next
measurement immediately.
B. Measure the voltage between the frame ground
and the + battery post. Make a note of the voltage
that was measured.
Expected Result:
The voltage difference does not exceed 1 volt on 24
volt systems or 0.5 volts on 12 volt systems.
Results:
• YES – The voltage difference does not exceed
the tolerance. The positive circuit is good. Proceed
to test step 10.
• NO – The voltage difference exceeds the
tolerance.
Repair: There is high resistance in the positive
side of the charging circuit that is caused by one of
the following conditions:
• An electrical connection has loosened.
• An electrical connection has corroded.
• The main relay has failed.
• A circuit breaker has failed.
Repair the problem or replace any component
that has failed. Exit this procedure and retest the
alternator charging system.
STOP.
Test Step 10. TEST THE NEGATIVE SIDE
OF THE CHARGING CIRCUIT.
A. Check the voltage between the negative battery
post and the alternator case ground.
Expected Result:
The voltage does not exceed 1 volt on 24 volt
systems or 0.5 volts on 12 volt systems.
Results:
• YES – The voltage difference does not exceed the
tolerance. The negative circuit is good. Proceed
to test step 11.
• NO – The voltage difference exceeds the
tolerance.
89
Troubleshooting Section
Repair: There is high resistance in the negative
side of the charging circuit that is caused by one of
the following conditions:
• An electrical connection has loosened.
• The alternator ground has loosened.
• The engine ground has opened.
Repair the problem or replace any component
that has failed. Exit this procedure and retest the
alternator charging system.
STOP.
Test Step 11. TEST THE CIRCUIT OF THE
“R” TERMINAL.
A. Start the engine and set the throttle to at least
75%.
B. Connect a voltmeter between the “B+” terminal
and the alternator case ground.
C. Disconnect the wire from the “R” terminal. Select
“YES” if the “R” terminal is not used on the
machine.
Expected Result:
The voltage does not change.
Results:
• YES – The voltage does not change. Proceed to
test step 12.
• NO – The voltage rises and the alternator begins
charging.
Repair: The wire to the “R” terminal is shorted.
Repair the wiring or replace the wiring. Exit this
procedure and retest the alternator charging
system.
STOP.
Test Step 12. RESTORE THE RESIDUAL
MAGNETISM OF THE ROTOR.
A. Connect one end of a jumper wire to the “B+”
terminal (D+ terminal for K1, N1, and N3) of the
alternator.
B. Connect the other end of the jumper wire to the
“R” terminal of the alternator for two seconds.
Expected Result:
The voltage output rises on the “B+” terminal. The
residual magnetism of the rotor has been restored.
90
Troubleshooting Section
Results:
• YES – The voltage output rises. The residual
magnetism of the rotor has been restored. The
alternator is now charging.
Repair: Exit this procedure and retest the
alternator charging system.
STOP.
• NO – The voltage output does not rise.
Repair: There is an internal problem with the
alternator. Repair or replace the alternator.
STOP.
Test Step 13. TEST FOR UNDESIRABLE
CURRENT FLOW IN THE ALTERNATOR
CHARGING SYSTEM.
A. Turn off all of the accessories. Turn the keyswitch
to the OFF position.
B. Clamp a 9U-5795 Current Probe or 8T-0900
Ammeter around the main ground cable. Clamp
the tool with the positive side away from the
battery. Reset the probe (zero) before you clamp
the probe around the wire. Read the current on
the meter. Make a note of the current that was
measured.
Expected Result:
The current is below 2 amperes. The “YES” selection
is dependent on the presence of a main disconnect
switch on the machine that is being tested.
Results:
• YES - WITH DISCONNECT SWITCH – The
current is below 2 amperes. For machines with a
main disconnect switch, proceed to test step 14.
• YES - WITHOUT DISCONNECT SWITCH – The
current is below 2 amperes. For machines without
a main disconnect switch, proceed to test step 15.
• NO – The current is above 2 amperes. There is a
current draw in the system. Proceed to test step 16.
Test Step 14. MEASURE THE CURRENT
OF THE SYSTEM BY USING THE MAIN
DISCONNECT SWITCH.
A. Turn the disconnect switch to the ON position.
B. Connect an ammeter across the disconnect switch
terminals. Connect the red lead to the terminal
on the frame side. Connect the black lead to the
terminal on the battery side. If a multimeter is
being utilized for this test, use the 10A connections
in order to avoid damage.
C. Turn the disconnect switch to the OFF position and
read the current. Make a note of the measured
current.
Note: The standard acceptable current draw is 50
milliamperes. A current draw above 50 milliamperes
usually indicates a problem. However, some large
machines with multiple electronic control modules
have a higher acceptable limit. For more information,
contact a Caterpillar dealer or contact the business
unit that produces the machine.
Expected Result:
The current is below 0.050 amperes (50
milliamperes).
Results:
• YES – The current is below 0.050 amperes. The
charging system is functioning properly at this time.
The failure is possibly an intermittent draw in the
system. The batteries may have failed. Ensure
that NO accessories were ON during the test. Exit
this procedure and retest the alternator charging
system. STOP.
• NO – The current is above 0.050 amperes. There
is a draw in the system. Proceed to test step 16.
Test Step 15. MEASURE THE CURRENT
OF THE SYSTEM BY REMOVING THE
NEGATIVE BATTERY CABLE.
A. Disconnect the ground cable from the negative
battery post. There may be more than one battery
that is connected to ground. Disconnect all of the
batteries that are connected to ground. Do not
disconnect cables that are between batteries that
are connected in series.
B. Connect an ammeter between the disconnected
battery ground cable and one of the negative
battery terminals. Connect the red positive lead
of the ammeter to the cable. The negative lead
should be connected to the battery terminal. If a
multimeter is being utilized for this test, use the 10
ampere connections in order to avoid damage.

Note: The standard acceptable current draw is 50
milliamperes. A current draw above 50 milliamperes
usually indicates a problem. However, some large
machines with multiple electronic control modules
have a higher acceptable limit. For more information,
contact a Caterpillar dealer or contact the business
unit that produces the machine.
Expected Result:
The current is below .050 amperes (50 milliamperes).
Results:
• YES – The current is below 0.050 amperes. The
charging system is currently good. The problem is
a possible intermittent current draw in the system.
The batteries may have failed. Check that NO
accessories were ON during the test. STOP.
• NO – The current is above 0.050 amperes. There
is excessive current flow in the system. Proceed
to test step 16.
Test Step 16. TEST THE CURRENT OF
THE ALTERNATOR OUTPUT BELOW 2
AMPERES.
A. Turn the keyswitch to the OFF position.
B. Connect the 9U-5795 Current Probe or 8T-0900
Ammeter to a DMM (digital multimeter). Clamp
the probe around the “B+” wire of the alternator.
Before you clamp the probe around the wire,
ensure that the probe is “zeroed”.
C. Read the current on the meter. Make a note of the
current that was measured.
Expected Result:
The current is under 2 amperes.
Results:
• YES – The current is under 2 amperes. Proceed
to test step17.
• NO – The current is over 2 amperes.
Repair: There is an internal problem with the
alternator. Repair or Replace the alternator.
STOP.
91
Troubleshooting Section
Test Step 17. TEST THE OUTPUT
CURRENT OF THE ALTERNATOR
BELOW 0.015 AMPERES.
A. Disconnect the wire from the “B+” terminal of
the alternator. Set the multimeter on the 10 amp
scale. Connect the red lead of the multimeter to
the wire that was disconnected. Connect the black
lead of the multimeter to the “B+” terminal of the
alternator. Make a note of the current that was
measured.
Expected Result:
The current is less than 0.015 amperes.
Results:
• YES – The current is under 0.015 amperes. The
alternator is operating correctly. There may be a
current draw on the machine. Proceed to test step
18.
• NO – The current is over 0.015 amperes.
Repair: There is an internal problem with the
alternator. Repair or replace the alternator.
STOP.
Test Step 18. IDENTIFY THE SOURCE OF
EXCESSIVE CURRENT DRAW.
A. Make sure that every electrical component is
turned OFF. Make sure that the keyswitch is turned
OFF. Make sure that the dome lights are OFF.
B. Clamp a 9U-5795 Current Probe or 8T-0900
Ammeter around the main ground cable. Clamp
the tool with the positive side away from the
battery. Reset the probe (zero) before clamping
the probe around the wire. Use the current probe if
the draw is above approximately 2 amperes. Use
the Ammeter if the draw is below approximately
2 amperes.
C. Remove the fuses or open the circuit breakers
one at a time. Check the current after each fuse
has been removed or each circuit breaker has
been opened. After observing the current, reinstall
the fuse or close the circuit breaker. Start with the
main circuits first, and proceed to smaller circuits.
D. Check if any components on the circuit are ON.
E. If everything is OFF, then disconnect electrical
components on the circuit one at a time. Monitor
the current after each component is disconnected.
92
Troubleshooting Section
F. All of the components in the circuit should be
disconnected. If the problem still exists, then
check the wiring in the circuit. There may be
circuit leakage through corrosion or circuit leakage
through a short.
Note: The standard acceptable current draw is 50
milliamperes. A current draw above 50 milliamperes
usually indicates a problem. However, some large
machines with multiple electronic control modules
have a higher acceptable limit. For more information,
contact a Caterpillar dealer or contact the business
unit that produces the machine.
Expected Result:
The source of the excessive current draw was
determined.
Results:
• YES – The source of the excessive current draw
was determined.
Repair: Repair the problem or replace any
component that has failed. Exit this procedure and
retest the alternator charging system.
STOP.
• NO – The source of the excessive current draw
was not determined.
Repair: Exit this procedure and retest the
alternator charging system.
STOP.
Test Step 19. TEST FOR AN
OVERCHARGING CONDITION FROM THE
ALTERNATOR.
A. Verify that the nut on the “B+” alternator terminal
is tight. Also, verify that the wire has a good
connection to the “B+” terminal.
B. Many Caterpillar machines are equipped with a
connector for the 6V-2150 Starting/Charging
Analyzer. Use of this tester replaces the remainder
of this test step. To operate the analyzer, refer to
Tool Operating Manual, SEHS7768, “Using the
6V-2150”.
C. Start the engine and set the throttle to at least 75
percent. Turn ON all electrical accessories for the
remainder of this test step. Allow the engine to run
for at least 3 minutes before continuing.
D. Measure the voltage between the “B+” terminal of
the alternator and the case of the alternator. Make
a note of the voltage that was measured. Perform
the next measurement immediately.
E. Measure the voltage across the battery. Put the
red lead on the positive terminal of the battery,
and put the black lead on the negative terminal of
the battery. Make a note of the voltage that was
measured.
Expected Result:
The voltage at the battery should be less than the
voltage at the alternator. On systems that are 12 volt,
the difference in voltages should not be more than
1 volt. On systems that are 24 volt, the difference
should not be more than 2 volts.
Results:
• YES – The voltage at the battery is less than the
voltage at the alternator. Also, the difference in
voltages is less than 1 volt for 12 volt systems
and the difference is less than 2 volts for 24 volt
systems. The wiring that is related to the alternator
is correct at this time.
Repair: There is an internal problem with the
alternator. Repair or Replace the alternator.
STOP.
• NO – The voltage at the battery is less than the
voltage at the alternator. However, the difference in
voltages is greater than 1 volt for 12 volt systems
and the difference is greater than 2 volts for 24 volt
systems. Proceed to test step 20.
Test Step 20. TEST THE POSITIVE SIDE
OF THE CHARGING CIRCUIT.
A. Measure the voltage between the frame of the
machine and the “B+” terminal of the alternator.
Make a note of the voltage that was measured.
Perform the next measurement immediately.
B. Measure the voltage between the frame of the
machine and the positive terminal of the battery.
Make a note of the voltage that was measured.
Expected Result:
The voltage difference does not exceed 1 volt on 24
volt systems or 0.5 volts on 12 volt systems.
Results:
• VOLTAGE OK - ALT. WITHOUT IG/S TERM. – The
voltage difference does not exceed the tolerance.
The positive circuit is good.
 93
Troubleshooting Section

Repair: There is an internal problem with the

alternator. Repair or Replace the alternator.

STOP.

• VOLTAGE EXCESSIVE - ALL ALT. – The voltage

difference exceeds the tolerance.

Repair: There is high resistance in the positive

side of the charging circuit that is caused by one of
the following conditions:

• An electrical connection has loosened.

• An electrical connection has corroded.
• The main relay has failed.
• A circuit breaker has failed.
Correct the problem. Exit this procedure and retest
the alternator charging system.

STOP.

• VOLTAGE OK - ALT. WITH IG/S TERM. – The

voltage difference does not exceed the tolerance.
The positive circuit is good. Proceed to test step 21.

Test Step 21. ALTERNATOR

OVERCHARGING TEST.
A. Start the engine and set the throttle to at least 75
percent.

B. Measure the voltage between the sense terminal

(S) and/or the “IG” terminal to the case of the
alternator.

Expected Result:

The voltage at the “S” terminal and/or “IG” terminal is

above the specification.

Results:

• YES – The measured voltage exceeds the

specification. There is an internal malfunction in
the alternator. See the appropriate service manual
for the alternator in order to test the internal
components and connections. STOP.

• NO – The measured voltage is below the

measurement that was taken in the initial tests
(B+ to alternator case). The sense circuit in
the generator set has high resistance. Correct
the problem. Exit this procedure and retest the
alternator charging system. STOP.
94
Testing and Adjusting Section
Testing and Adjusting
Section
Testing and Adjusting
i01916579
System Self Test
SMCS Code: 7490-038
Illustration 84
g00296905
Caterpillar Monitoring System
(1) Quad gauge module. (2) Speedometer/tachometer module.
(3) Main display module. (4) Alert indicators. (5) Gauges. (6)
Tachometer gauge. (7) Speed readout. (8) Transmission gear
readout. (9) Display area.
The self test verifies that the main display module
and the display modules are operating properly. The
main display module performs an automatic self test
when the key start switch is turned from the OFF
position to the ON position.
The internal circuits and the outputs (displays,
action lamp and action alarm) are automatically
checked. The operator must observe the outputs in
order to determine if the modules and the outputs
are operating properly. The alert indicators and the
display area are tested for approximately one second:
• All alert indicators (4) FLASH.
• Display area (9) shows: unit indicators, “SERV
CODE” indicator, symbol for service meter, and
“888.X.8.8” on the six digit display area.
The display modules are tested for approximately
three seconds:
• The test for the LCD segments for rpm, gear and
direction (8) will turn on every segment of the
display. The readout looks like a “0” with an “X” and
a “+”. There should be twelve of these symbols
next to each other on the lamp/gear module.
• The alert indicators (3) and the mode indicators (7)
for the lamp/gear module will turn ON.
• Tachometer gauge (6) and gauges (5) jump to
half scale. The gauges go to zero. The gauges
then go to full scale. After reaching full scale, the
tachometer and the gauges return to the current
machine values.
• The actual transmission gear readout (8) turns on
every segment of the readout. The readout looks
like a “0” with an “X” and a “+”. There should be
two of these symbols next to each other.
• Ground speed readout (7) turns on every segment
of the readout. The readout looks like “188”. “MPH”
and “km/h” are both turned ON.
• The action lamp turns ON.
• The action alarm SOUNDS once.
The main display module then goes into the normal
mode of operation. The main display module can
also scroll through the modes if the inputs to the
operator switch, the service switch or the clear switch
are grounded.
The module is operating properly if the main display
module operates, as described. There is a problem
with the harness code or the module has failed
if the main display module does not operate, as
described. In order to check the harness code, see
Troubleshooting, “ Harness Code ”.
i01547858
Wiring Harness (Open Circuit)
- Test
SMCS Code: 1408-081
An open is a failure of an electrical circuit that
results in no flow of electrical current. An open
circuit is usually caused by failed electrical wires
or a poor connection of electrical connectors. If an
electrical wire or a connection is broken, the flow of
electrical current through the circuit is interrupted. A
normally closed circuit will have less than 5 ohms of
resistance. The following procedure explains the test
for an open circuit:
 95
Testing and Adjusting Section

Reference: For a complete electrical schematic, TEST FOR A SHORT CIRCUIT.

refer to Electrical System Schematic for the machine
that is being serviced. 1. Identify the connectors and the wire numbers of
the suspect circuits. Use the Electrical System
TEST FOR AN OPEN CIRCUIT. Schematic of the machine to identify the circuits.

1. Identify the connectors and the wire numbers of
the suspect circuits. Use the Electrical System
Schematic of the machine to identify the circuits.
2. Turn the key start switch and the disconnect
switch to the OFF position.
3. Disconnect the component and the ECM from the
wiring harness.
2. Turn the key start switch and the disconnect
switch to the OFF position.
3. Disconnect the component and the ECM from the
wiring harness.
4. At the machine harness connector for the ECM,
place one of the multimeter probes on the contact
of the suspect wire.

4. At one of the disconnected harness connections, 5. Use the other multimeter probe to check the
place a jumper wire from the contact of the resistance across all other contacts in the
suspect wire to frame ground. connector(s) of the ECM and frame ground.

5. At the other connector of the machine harness,
use the multimeter probes to measure the
resistance from the contact of the suspect wire to
frame ground.
Expected Result: The resistance is less than 5
ohms.
OK – The resistance is less than 5 ohms. The
harness circuit is correct.
Stop.
NOT OK – The resistance is greater than 5000
ohms. There is an open in the machine harness.
Repair: Repair the machine harness or replace
the machine harness.
Expected Result: The resistance is greater than
5000 ohms for all the measurements.
OK – The resistance is greater than 5000 ohms
for all the measurements. The harness circuits
are correct.
Stop.
NOT OK – The resistance is less than 5 ohms.
There is a short in the machine harness. The short
is between the suspected wire and the wire with
the lowest resistance measurement.
Repair: Repair the machine harness or replace
the machine harness.
Stop.

Stop.

i01547498

Wiring Harness (Short Circuit)

- Test
SMCS Code: 1408-081

A short circuit is a failure of an electrical circuit that

results in undesired electrical current. Usually, a
short circuit is a bypass of the circuit across a load.
For example, a short across the wires in a circuit for
a lamp produces too much current in the wires but
no current is felt at the lamp. The lamp is shorted
out. The resistance in a normal circuit is greater than
5000 ohms. The following procedure explains the
test for a short circuit:

Reference: For a complete electrical schematic,

refer to Electrical System Schematic for the machine
that is being serviced.
96
Testing and Adjusting Section

i01744672 NOT OK – The resistance is less than 5 ohms.

There is a short in the machine harness. The short
Wiring Harness (Short Circuit) is between the suspected wire and the wire with
- Test the lowest resistance measurement.

SMCS Code: 1408-081 Repair: Repair the machine harness or replace

the machine harness.
S/N: ASD1-Up
Stop.
S/N: ARL1-Up
S/N: APM1-Up i01205456

S/N: APN1-Up Electrical Connector - Inspect

S/N: ATS1-Up
SMCS Code: 7553-040-WW
A short circuit is a failure of an electrical circuit that
Intermittent electrical problems are often caused by
results in undesired electrical current. Usually, a
poor connections. Use the following checks as a
short circuit is a bypass of the circuit across a load.
reference for inspecting connectors.
For example, a short across the wires in a circuit for
a lamp produces too much current in the wires but
1. Check the connection of the connectors.
no current is felt at the lamp. The lamp is shorted
out. The resistance in a normal circuit can vary, but
the resistance between a particular circuit and other • Ensure that the locking rings are properly
locked.
unrelated circuits is always greater than 5000 ohms.
The following procedure explains the test for a short
circuit: • Ensure that locking clips are used on Sure Seal
connectors.
Reference: For a complete electrical schematic,
refer to Electrical System Schematic for the machine • Ensure that the center of the connector is tight.
that is being serviced.
• Ensure that the connector pins and sockets
align properly.
TEST FOR A SHORT CIRCUIT.
2. Check the wires at the connector.
1. Identify the connectors and the wire numbers of
the suspect circuits. Use the Electrical System
Schematic of the machine to identify the circuits. • Ensure that the wires enter the back of the
connector straight.
2. Turn the key start switch and the disconnect
switch to the OFF position. • Ensure that each wire is properly crimped into
the proper connector contact.
3. Disconnect the component and the ECM from the
wiring harness. • Ensure that each connector contact is properly
locked into the connector contact. When the
connector contact is locked properly, the contact
4. At the machine harness connector for the ECM,
(wire) cannot be pulled out of the connector
place one of the multimeter probes on the contact
body without excessive force.
of the suspect wire.
3. Check each wire for nicks or signs of abrasion
5. Use the other multimeter probe to check the
in the insulation.
resistance across all other contacts in the
connector(s) of the ECM and frame ground.
4. Check for moisture at the connector.
Expected Result: The resistance is greater than
5000 ohms for all the measurements. • Check for damaged connector seals or lost
connector seals.
OK – The resistance is greater than 5000 ohms
for all the measurements. The harness circuits • Check for missing or loose wire hole plugs.
are correct.
• Check for wires that do not enter the connector
properly.
Stop.

• If the wires enter the connector at an angle,
there may not be a good seal between the
connector and the wire insulation.
• Moisture can enter the connector through the
wire insulation.
5. Check for dirty contacts or corroded contacts.
• Clean contacts with a cotton swab or a soft
brush and denatured alcohol only.
6. Check each pin and each socket.
• Check each contact of the connector for a snug
fit by using a new pin and socket. The new
contact should stay connected if the connector
is held with the contacts that are facing down.
i01855646
Module - Replace
SMCS Code: 7490-510
Prior to replacement of a module, ensure that
replacement is absolutely necessary. A diagnostic
code is seldom caused by the module. Always ensure
that the machine code is correct for the machine.
Also ensure that the power is available to the main
display module. The system voltage is required
between the contacts 1 and 2 of the connector for the
main display module. To check the machine code,
see System Operation, “Harness Code Mode”.
Procedure
1. Replace the module.
a. Turn the key start switch to the OFF position.
b. Disconnect the machine harness from the
module.
c. Ensure that the module that is replacing the old
module has the correct part number.
d. Install the new module.
Note: If the main display module that is replacing the
old module was previously removed from service,
see Testing and Adjusting, “Main Display Module
Initialization - Adjust”.
e. Connect the machine harness to the module.
On so equipped machines, make sure that the
harness code plug is installed.
f. Turn the disconnect switch and the key start
switches to the ON position. Make sure that the
module successfully completes the self test:
see Testing and Adjusting, “System Self Test”.
97
Testing and Adjusting Section
Expected Result: The module has been
successfully replaced and the module has
completed the self test.
Results:
• YES - The module has been successfully
replaced and has completed the self test.
Proceed to 2.
• NO - The module has been successfully
replaced but has not performed the self test
properly. Ensure that the module is correct.
Ensure that the installation is correct and
ensure that no related diagnostic codes are
present. STOP.
2. Setup
a. Set up the optional display modules, see
Systems Operation, “Setup Mode”.
b. Set the desired units (English or Metric), see
System Operation, “Units Mode”.
Note: Once the module has been replaced
successfully, see Testing and Adjusting, “Main
Display Module-Flash Program”.
i01104167
Main Display Module
Initialization - Adjust
SMCS Code: 7490-025
The initialization is an internal process within the
main display module. During the initialization, the
main display module listens to the CAT data link and
the harness code inputs. From this information, the
module learns about the machine. For example, the
module learns that the information for the engine oil
pressure is coming from an engine ECM.
Normally, the initialization occurs when the main
display module is replaced. Also, the initialization
occurs when there is a change in the harness code.
However, when a previously used main display
module is used as a replacement, initialization could
be necessary. Faults that can not be explained with
the CAT data link can occur if the main display
module is not initialized correctly. The service
person must activate the initialization when the
main display module has been previously used.
Initialization is used if the module was taken out
of an application that had the same machine code
as the main display module that is to be removed.
98
Testing and Adjusting Section
Procedure For Initialization
This procedure causes the initialization to occur on
any main display module. Initialization requires that
the main display module be powered up with a valid
harness code that is different than the harness code
when it was last powered down. For a list of valid
harness codes, see the table for Machine Codes in
System Operation, “Harness Code Mode”.
1. Code input configuration.
a. Turn the key start switch to the OFF position.
b. 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 Service
Manual for the machine.
Expected Result: There is a harness code
plug.
Results:
• YES - There is a harness code plug. Remove
the harness code plug. Proceed to 3.
• NO - The harness code inputs are hard wired
in the machine harness. Proceed to 2.
2. Hard wired procedure.
a. Disconnect the machine harness from the main
display module.
b. At the machine harness connector for the main
display module, remove the wire for one of
the following contacts (3, 6, 12, 16, 22 or 31).
Choose one that is connected to ground.
c. With tape, secure the removed connector
contact out of the way.
d. Reconnect the machine harness to the main
display.
Results:
• CONTINUE - Proceed to 3.
3. Reconnection and verification.
a. Turn the disconnect switch and the key start
switches to the ON position.
b. Various indicators in the Caterpillar Monitoring
System display area will illuminate. Wait 10
seconds.
c. Turn the key switch to the OFF position.
d. Depending on the previous procedure that
was performed, either reinstall the harness
code plug (from “Code input configuration”) or
reinstall the ground connector contact (from
“Hard wired procedure”).
e. Make sure the main display module
successfully completes the self test, see
Testing and Adjusting, “System Self Test”.
f. Check the machine code. See System
Operation, “Harness Code Mode”.
Expected Result: The display module has
successfully completed the self test.
Results:
• OK - The display module successfully
completed the self test. STOP.
• NOT OK - The display module did not
complete the self test. Exit this procedure.
Determine the cause of the failure and repeat
“Initialization”. STOP.
i01519504
Main Display Module - Flash
Program
SMCS Code: 7490-591
Perform the following procedure in order to flash
program the ECM. The ECM is flashed in order
to upgrade the software. Flash programming of
the ECM must also be done if the ECM has been
replaced. The Caterpillar Electronic Technician (ET)
contains the program WinFlash. WinFlash is used in
order to load software into the ECM. The following
procedure is used in order to FLASH software into
the ECM for the Caterpillar Monitoring System.
1. Procedure
a. Connect the 7X-1425 Data Link Cable
between the 7x-1700 Communication Adapter
and the Electronic Technician.
b. Connect the 139-4166 Data Link Cable
between the 7x-1700 Communication Adapter
and the diagnostic connector of the machine.
c. Turn the key to the ON position.
d. Use WinFlash in order to load the software.
Note: Flash programming is not allowed if the engine
is running, or the machine is moving.

i01425096
Glossary of Terms
SMCS Code: 7490
Abnormal – This means a condition that is not
normal. The presence of an abnormal condition or an
abnormal signal indicates the existence of a problem.
A warning is activated in order to alert the operator.
Alert Indicator – An alert indicator is a red indicator
lamp that is located on the top portion of the main
display module. The alert indicator notifies the
operator of an abnormal condition.
+Battery – This pertains to any of the harness
wiring which is part of the circuit that connects to the
positive battery post. +Battery voltage is also referred
to as system voltage.
Caterpillar Electronic Technician (ET) – This is
a Windows based program, that is used to service
Caterpillar products. The software operates on a
service tool (personal computer).
Component Identifier (CID) – The CID is a
diagnostic code that informs the operator of
component or the system that has failed. The CID is
a four digit code, that is located in the digital display
area when the main display module is in service
mode.
Clear – This is the removal of diagnostic information
that is stored in the memory of the ECM. Before a
failure is cleared, the failure must be on hold and the
failure must not be present.
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 Diagnostic Code – A detected diagnostic
code is a problem that has been found by the
main display module. A service code that has
been recorded for the problem and the diagnostic
information is available when the main display
module is in service mode.
Diagnostic – This is a process that takes place
within an electronic control. The control senses the
abnormal machine information. The control displays
the abnormal machine information. The control
stores the abnormal machine information. This stored
information can aid the service technician.
Display – Display refers to the gauges, indicators,
or readouts within the Caterpillar Monitoring System
display area.
99
Testing and Adjusting Section
Failure Mode Identifier (FMI) – An FMI is a
diagnostic code that identifies the type of failure that
has occurred. The FMI consists of two digit code
which is preceded by a decimal point “.”. This code
is shown on the display area when the main display
module is in service mode.
Diagnostic Code – A diagnostic code is a failure of
a component in an electronic system. An associated
CID FMI identifies the type of problem.
Diagnostic Event – This is a type of maintenance
event. This event is displayed when an electronic
control detects an abnormal condition in the electrical
system. Sometimes abnormal conditions in the
mechanical system can be detected through the
electrical system.
Gauge – This is a display device that is typically
circular in shape with an indicator needle. The gauge
can be a mechanical device or the gauge can be a
solid state device.
Ground (B-) – This is the reference point for the
electrical system. On CAT products, ground is the
machine frame or the engine. This is the connection
point for the negative side of the battery.
Floating – This describes the end of a circuit that
is open. The circuit is not connected to any other
component.
Hard Wired – Hard wired refers to an electrical
connection that is made within the harness. The
connections are permanent. These soldered
connections or crimped connections are not meant to
be altered.
Harness – This is an assembly or a bundle of two
or more wires that electrically connects system
components. Typically, the harness is held together
by a loom.
Harness Code – This refers to the grounded
condition or the open circuit condition of the inputs
for the harness code . The harness code provides
the characteristics of the machine such as engine
oil pressure, maximum engine speed, etc. The
monitoring system uses this hard wired code in order
to determine the module identifier (MID) that is used
for data link communications.
Hertz (Hz) – This is a measure of frequency. The
units are cycles per second.
Hysteresis – This is a measure of the “lag time that
occurs between the turn ON and turn OFF values of
a switch or a sensor”. As an example, the warning
lamp may turn on at 40 psi with decreasing pressure
and the warning lamp may turn off at 45 psi with
increasing pressure. The hysteresis is 5 psi.
100
Testing and Adjusting Section
Indicator – An indicator is any of the items within
the Caterpillar Monitoring System display area which
operate in an ON, FLASHING or OFF manner in
order to bring attention to a machine condition.
Jumper – A jumper is a piece of wire that is used to
make an electrical connection during troubleshooting.
Key Start Switch – This is an automotive type key
start that provides engine cranking/starting .
Lamp – This is a component of the machine
electrical system that emits light by converting
electrical energy into light.
Light Emitting Diode (LED) – This is a solid state
device. The device emits light that is visible to the
human eye when an electrical current is passed
through the device. The LED is used as a lamp
in electronic controls because the device is very
reliable.
Liquid Crystal Display (LCD) – This is a type
of solid state display that uses a liquid crystalline
material. The material is sealed between two glass
sheets. An electrical signal causes segments of the
crystal material to be visible to the eye.
Machine Service Connector – This is a harness
connector for the machine or for engine electrical
systems. The harness connector will allow the
connection of a service tool for diagnostics.
Module Identifier (MID) – An MID is a diagnostic
code that identifies the electronic control module
which diagnosed the diagnostic code. The two-digit
code is displayed in the display area when the
machine is in the service mode.
Open Circuit – This is a condition that exists when
an electrical circuit is broken.
Pressure Sensor – This is a device that generates
a signal that is proportional to the pressure that is
sensed.
Problem – This refers to the presence of an
abnormal machine condition. When a problem exists,
warning operation is activated and the main display
module notifies the operator.
Pounds per square inch (psi) – This is an English
unit of pressure measurement. The measurement
represents the force that is applied to one square
inch. The value is measured in pounds. 6.89 kPa
(1 psi)
Pull up Voltage – This is the voltage that is
measured on the input of an electronic control. The
measurement is taken when an input device (sensor
or switch) has been disconnected.
Pulse Width Modulation (PWM) – The PWM
is a signal that consists of variable pulse widths
at fixed intervals. The duty cycle can be varied.
The frequency of a PWM signal is constant. The
Caterpillar Monitoring System has sensors which
provide a PWM signal to the main display module.
Scroll – When you scroll through information in
the display area, all available sets of diagnostic
information are shown by one set at a time. A set of
diagnostic information is shown briefly. Then, the
display automatically advances to the next set. After
all sets have been shown, the sets are repeated.
Sender – This is a device that changes resistance
according to a physical condition. The sender then
sends a signal to a gauge. A single connection
provides the signal and the power.
Sensor – This is a device that monitors the physical
condition of a machine system. The sensors can
monitor the conditions that are listed here: pressure,
temperature, flow, and mechanical movement. The
sensors convert the condition into an electrical signal
that can be understood by an electronic control.
Service Code – This is a type of maintenance code
that describes a condition that has been identified
by an electronic control system. The code indicates
when service is required. This code is stored in the
control for the service technician. This term was
previously referred to as a fault code. This code is
now referred to as a service type of maintenance
event.
Service Tool – This is a tool that is used in order to
service Caterpillar machines. This term most often
refers to the service equipment that is listed here:
Electronic Control Analyzer Programmer (ECAP),
Caterpillar Electronic Technician (ET), a digital
multimeter, and laptop computer This may also refer
to any other dedicated service equipment.
Short Circuit – A connection between two points in
a circuit that is normally unwanted.
Show – This pertains to information that is within
the Caterpillar Monitoring System display area that is
viewed by the operator or a service person.
Signal – This is the changing voltage that is used
to carry information. A signal is typically sent from a
sensor to an electronic control. For example, a signal
is sent from the transmission output speed sensor
(TOS) to the transmission control.
Signal Wire – This is the harness wire that carries
the signal voltage to the electronic control. The signal
is sent by any of the components that are listed here:
a sensor, a switch, and any other similar components.
 101
Testing and Adjusting Section

Speedometer/Tachometer Module – This is a

display module that contains the components that
are listed here: a speedometer for machine ground
speed, a tachometer for engine speed, and a display
for actual gear.

Switch Input – This is an input to an ECM. This

input may be ground. The input may be open. The
input may be positive voltage (+battery).

System Voltage – System voltage is the actual

voltage that exists between the positive battery post
and the frame ground. The system voltage is referred
to as the + battery.

Temperature Sensor – This is a device that

generates a signal that is proportional to the change
in temperature.

Uncommitted Switch Input – Uncommitted switch

inputs are switch inputs that function according to the
application. Information from the uncommitted switch
inputs is typically used to operate the alert indicators.

Undetected Problem – This is a problem that is not

detected by the main display module, but the problem
is found by the operator or by a service technician.
The many diagnostic functions of the main display
module assist with the troubleshooting of undetected
problems.

+V – This pertains to a constant voltage that is

supplied to a component. +V is provided by an
electronic control module or the battery.

i01857510

Connector Contact Description

of Main Display Module
SMCS Code: 7490-546-CY

Table 25
Contact Description Of Main Module Connector
12H, 120H, 135H, 140H, 143H, 160H And 163H
No. Function Type Description
1 + Battery Input - Voltage (Power) 28 VDC
2 Ground Ground 0 VDC
3 Harness Code 1 Switch Input - Programming Programming Switch(1)
4 Action Alarm Output Alarm Driver
5 CAT Data Link + Input/Output - Data Link Driver/Receiver (+)
6 Harness Code 5 Switch Input - Programming Programming Switch(1)
7 PWM/Switch 1 Sensor Or Switch Input Unassigned
8 PWM/Switch/Sender 5 Sensor, Switch Or Sender Input Unassigned
9 Switch /Sender 10 Switch Or Sender Input Fuel Level
(continued)
102
Testing and Adjusting Section

(Table 25, contd)

Contact Description Of Main Module Connector
12H, 120H, 135H, 140H, 143H, 160H And 163H
No. Function Type Description
10 PWM/Switch/Sender 6 Sensor, Switch Or Input Unassigned
11 Switch 7 Switch Input Unassigned
12 Harness Code 2 Switch Input - Programming Programming Switch(1)
13 Action Lamp Output Lamp Driver
14 CAT Data Link - Input/Output - Data Link Driver/Receiver (-)
15 Display Module Load Output Driver for Gauge Module
16 Harness Code 4 Switch Input - Programming Programming Switch(1)
17 PWM/Switch 2 Sensor Or Switch Input Unassigned
18 Switch/Sender 9 Switch Or Sender Input Articulation Angle Sender
19 Switch 1 Switch Input Brake System Pressure Switch
20 Switch 4 Switch Input Operator Mode Switch
21 Switch 8 Switch Input Unassigned
22 Harness Code 3 Switch Input - Programming Programming Switch(1)
23 Service Switch Input Scroll Switch
24 Sensor Power Supply Output Unassigned
25 Display Module Clock Output Driver for Gauge Sequencing
26 Frequency 1 Sensor Input - Frequency Unassigned
27 PWM/Switch 4 Sensor or Switch Input Unassigned
28 PWM/Switch/Sender 7 Sensor, Switch Or Sender Input Unassigned
29 Switch 2 Switch Input Park Brake
30 Alternator R terminal Sensor Input - Frequency Alternator Frequency
31 Harness Code 0 Switch Input - Programming Programming Switch(1)
32 Switch 6 Switch Input Hydraulic Temperature
33 Clear Switch Input Clear Switch
34 Display Module Power Supply Output 9 VDC
35 Display Module Data Input/Output Data for Gauge Module
36 Frequency 2 Sensor Input - Frequency Unassigned
37 PWM/Switch 3 Sensor Or Switch Input Unassigned
38 PWM/Switch/Sender 8 Sensor, Switch Or Sender Input Unassigned
39 Switch 3 Switch Input Unassigned
40 Switch 5 Switch Input Primary Steering Pressure
(1) This pin is only used on early model machines for the 140H, 143H, 160H, And 163H. Newer machines use flash software to program the
harness code.
 103
Testing and Adjusting Section

Table 26
Contact Description Of Main Module Connector
14H, And 16H
No. Function Type Description
1 + Battery Input - Voltage (Power) 28 VDC
2 Ground Ground 0 VDC
3 Harness Code 1 Switch Input - Programming Unassigned
4 Action Alarm Output Alarm Driver
5 CAT Data Link + Input/Output - Data Link Driver/Receiver (+)
6 Harness Code 5 Switch Input - Programming Unassigned
7 PWM/Switch 1 Sensor Or Switch Input Unassigned
8 PWM/Switch/Sender 5 Sensor, Switch Or Sender Input Unassigned
9 Switch /Sender 10 Switch Or Sender Input Fuel Level
10 PWM/Switch/Sender 6 Sensor, Switch Or Input Unassigned
11 Switch 7 Switch Input Neutral Start Switch
12 Harness Code 2 Switch Input - Programming Unassigned
13 Action Lamp Output Lamp Driver
14 CAT Data Link - Input/Output - Data Link Driver/Receiver (-)
15 Display Module Load Output Driver for Gauge Module
16 Harness Code 4 Switch Input - Programming Unassigned
17 PWM/Switch 2 Sensor Or Switch Input Reverse/Backup Alarm Switch
18 Switch/Sender 9 Switch Or Sender Input Articulation Angle Sender
19 Switch 1 Switch Input Brake System Pressure Switch
20 Switch 4 Switch Input Operator Mode Switch
21 Switch 8 Switch Input Unassigned
22 Harness Code 3 Switch Input - Programming Unassigned
23 Service Switch Input Scroll Switch
24 Sensor Power Supply Output Unassigned
25 Display Module Clock Output Driver for Gauge Sequencing
26 Frequency 1 Sensor Input - Frequency Ground Speed Sensor
27 PWM/Switch 4 Sensor or Switch Input Unassigned
28 PWM/Switch/Sender 7 Sensor, Switch Or Sender Input Unassigned
29 Switch 2 Switch Input Park Brake
30 Alternator R terminal Sensor Input - Frequency Alternator Frequency
31 Harness Code 0 Switch Input - Programming Unassigned
32 Switch 6 Switch Input Hydraulic Temperature
33 Clear Switch Input Clear Switch
34 Display Module Power Supply Output 9 VDC
35 Display Module Data Input/Output Data for Gauge Module
36 Frequency 2 Sensor Input - Frequency Unassigned
37 PWM/Switch 3 Sensor Or Switch Input Unassigned
(continued)
104
Testing and Adjusting Section

(Table 26, contd)

Contact Description Of Main Module Connector
14H, And 16H
No. Function Type Description
38 PWM/Switch/Sender 8 Sensor, Switch Or Sender Input Unassigned
39 Switch 3 Switch Input Unassigned
40 Switch 5 Switch Input Primary Steering Pressure

i01857839

System Schematic
SMCS Code: 7566

These schematics are typical Caterpillar Monitoring

System schematics, that show possible inputs and
outputs. On some machines, certain sensors are
not part of the system. However, the main display
module receives the sensor information over the
CAT data link from other electronic controls. For an
accurate schematic of a particular machine, always
see the Electrical System Schematic in the machine
Service Manual.
 105
Testing and Adjusting Section

140H, 143H, 160H And 163H

g00947079
Illustration 85
106
Testing and Adjusting Section

14H

g00865621
Illustration 86
 107
Testing and Adjusting Section

16H

g00947028
Illustration 87
108
Testing and Adjusting Section

12H, 120H, 135H, 140H, 143, 160H,

And 163H

g00947030
Illustration 88

Index
A I
Action Alarm .......................................................... 36
Action Lamp........................................................... 36
Additional Operator Modes.................................... 13
Trip Fuel Consumption Mode............................. 14
Trip Hourmeter Mode ......................................... 13
Trip Odometer Mode .......................................... 14
Alert Indicator Description ..................................... 25
Alert Indicator Is Always Flashing.......................... 71
Alert Indicator Never Flashes ................................ 72
Articulation Gauge Calibration Mode..................... 22
C Procedure For Initialization ................................ 98
Calibration Mode ................................................... 18
Submodes.......................................................... 19
Charging System ................................................... 85
Component Description ......................................... 27
Connector Contact Description of Main Display
Module ............................................................... 101
D MID 030 - CID 0271 - FMI 06 ................................ 58
Diagnostic Capabilities .......................................... 42
The Caterpillar Electronic Technician (ET)......... 42
Diagnostic Code List.............................................. 44
Diagnostic Code Procedures................................. 44
Diagnostic System Procedures ............................. 71
Display Components ............................................. 31
E Modes of Operation ................................................. 8
Electrical Component and Connector Locations ... 40
Connector Contact Numbers for the Main Display
Module ............................................................. 41
General Information ........................................... 40
Service Connector ............................................. 41
Electrical Connector - Inspect................................ 96
F
Fuel Level Sender ................................................. 81
G
General Information........................................... 4, 38
Introduction .......................................................... 4
Glossary of Terms.................................................. 99
H
Harness Code........................................................ 73
Harness Code Mode.............................................. 12
109
Index Section
Important Safety Information ................................... 2
Introduction............................................................ 38
M
Main Display Module ............................................. 27
Inputs ................................................................. 28
Inputs/Outputs.................................................... 27
Outputs .............................................................. 30
Main Display Module - Flash Program .................. 98
Main Display Module Initialization - Adjust ............ 97
MID 030 - CID 0084 - FMI 08 ................................ 48
MID 030 - CID 0096 - FMI 03 ................................ 50
MID 030 - CID 0096 - FMI 04 ................................ 51
MID 030 - CID 0096 - FMI 08 ................................ 52
MID 030 - CID 0248 - FMI 02 ................................ 52
MID 030 - CID 0263 - FMI 03 ................................ 54
MID 030 - CID 0263 - FMI 04 ................................ 55
MID 030 - CID 0271 - FMI 03 ................................ 56
MID 030 - CID 0271 - FMI 05 ................................ 57
MID 030 - CID 0324 - FMI 03 ................................ 59
MID 030 - CID 0324 - FMI 05 ................................ 60
MID 030 - CID 0324 - FMI 06 ................................ 61
MID 030 - CID 0601 - FMI 08 ................................ 62
MID 030 - CID 0615 - FMI 03 ................................ 62
MID 030 - CID 0615 - FMI 04 ................................ 64
MID 030 - CID 0819 - FMI 02 ................................ 65
MID 030 - CID 0821 - FMI 03 ................................ 68
MID 030 - CID 0821 - FMI 04 ................................ 69
Module - Replace .................................................. 97
Procedure .......................................................... 97
N
Normal Mode ........................................................... 9
Numeric Readout Mode......................................... 12
O
Odometer Mode...................................................... 11
P
Pulse Width Modulated Sensor ............................. 76
Q
Quad Gauge Module ............................................. 31
110
Index Section

R W

Related Components............................................. 37 Warning Operation ................................................ 24

Alternator ........................................................... 37 Wiring Harness (Open Circuit) - Test..................... 94
Other Electronic Controls................................... 37 Wiring Harness (Short Circuit) - Test ............... 95–96

Scrolling Mode........................................................ 11
Senders ................................................................. 33
Level Sender (Fuel) ........................................... 33
Position Sender (Articulation Angle) .................. 34
Temperature Sender .......................................... 34
Sensor Dynamic Operation ................................... 79
Sensor Signal Voltage ........................................... 77
Sensors ................................................................. 34
Frequency Sensors............................................ 34
General Information ........................................... 34
Pulse Width Modulated (PWM) Sensors............ 35
Service Meter Mode .............................................. 10
Service Mode......................................................... 14
Service Tools ......................................................... 38
4C-8195 Control Service Tool........................... 40
Changing Modes................................................ 40
Service Switches................................................ 39
Setup Mode ........................................................... 18
Speedometer/Tachometer Module ........................ 32
Switch Circuits ................................................. 82–83
Switches ................................................................ 32
Pressure Switch ................................................. 33
Rocker Switch (Operator Mode Selector) .......... 33
Temperature Switch (Hydraulic Oil) ................... 33
System Schematic............................................... 104
12H, 120H, 135H, 140H, 143, 160H, And
163H............................................................... 108
140H, 143H, 160H And 163H ......................... 105
14H .................................................................. 106
16H .................................................................. 107
System Self Test.................................................... 94
Systems Operation Section ..................................... 4

Table of Contents..................................................... 3
Tachometer Mode................................................... 11
Tattletale Mode ...................................................... 16
Testing and Adjusting ............................................ 94
Testing and Adjusting Section ............................... 94
Troubleshooting Section ........................................ 38

Units Mode ............................................................ 18

Using Caterpillar Electronic Technician to Determine
Diagnostic Codes................................................. 46
Using Caterpillar Monitoring System to Determine
Diagnostic Codes................................................. 45
Procedure .......................................................... 45
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Index Section
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