Caterpillar Electronic-Systems: A Basic,Coutse Unit'12 Troubleshooting Part TwoContents Foreword Troubleshooting A System By Grouping Components Conelusion Mlustrations Run-Neutral Switch Input Branch Diagram Individual Component Testing Group Testing Demonstrations Troubleshooting The Electronic Switching System © 1983 Caterpillar Inc. Produced By Caterpillar Service Training ene 6-18Unit 12 - Troubleshooting Caterpillar Electronic Systems, Part 2 Foreword This unit of the course is designed to The special equipment you will need to help you troubleshoot Caterpillar electronic complete this unit of the course is as control systems that have several harness follows. assemblies in a single system branch easier and faster. 1. A Caterpillar SEKV2 100 Electronic Switching Demonstration System. 2. Any Caterpillar digital multimeter. Complete this unit as follows: READ THIS UNIT. COMPLETE THE DEMONSTRATIONS OF THIS UNIT.Troubleshooting a System by Grouping Components In troubleshooting an electronic control system that has several harness assemblies ina single branch, and in which each component of the branch has the same Possibility of failure, you can group these components to make the testing of the system easier and faster. An example of a system that has several harness assemblies and other components in a single branch is the Electronic Switching System. For example, think of the Tun-neutral switch input branch of this system. It can be diagrammed as shown in Figure 1 It there would be a problem in a branch like this, and if from our analysis of the problem we determine that the possible cause is in any one or more components of the branch, we can test the branch in ‘one of two ways — 1) we can test each component separately, and — 2) we can break the branch into two smaller groups for testing. It we test each component of this branch separately we will have made a total of five disconnections and tested six components to see exactly which components are good and which are bad. In other words we will have disconnected each component from all ‘other components, and tested each one. See Figure 2 eozs7s | sezasa | 661352 | 266720 | 561266 RUN/WEUTRAL] HARNESS | HARNESS | HARNESS | HARNESS SuITCH Lt ROUND CONNECTION Run-Neutral Switch Input Branch Diagram Figure 1 802676 eszaes 661353 256720 651266 651388 swiTon Les fet be of [3 PT uneness [4] wnaness [> P| unaness Lt TEST we 0K x ox * * AD RESULTS, Individual Component Testing Figure 2lf we group our components for test we will find our work is different. For example, if we first break the branch at its center point and then test each group as a unit, our work and results will be as shown in Figure 3. The result is that we have found the same bad component with a total of two or three disconnections and having made four to six tests. In other words, it is Possible to have found the same bad component with approximately half as much work. GROUP 1 srovr 2 802676 | sezaes | 661953 ||, | 266720 | soizss | co1398 SNITCH | HARNESS | HARNESS HARNESS | HARNESS | HARNESS Test ee ox BaD RESULTS | THEN THIS. on THIS GROUP 3 GROUP 3 266720 | 661266 661388 266720 661266 | 661388 HaRwess | HARNESS [2 “P) HARNESS: namuess [2 -P) wnawess | HARNESS Tes] ox Bo RESULTS Group Testing Figure 3 % ro AND THEN THIS y 561266 661388 wngness [2 waeness Tesi ox RD RESULTS:Space for notes —Look for failures of the same kind as you found in Unit 11 in the demonstrations that follow, and group the components when possible to make your work easier. Make ready the SEKV2100 Electronic Switching Demonstration System as shown below. POSITION 115/230V SWITCH CORRECTLY WITH RESPECT 10 OUTLET POWER OO NOTICE Never connect a battery or any other outside power source directly to any component on the face of this training aid. If this is done it can damage the system. ELECTRONIC SWITCHING DEMONSTRATION SYSTEM SEKV2100 ~~ 115/230 ACV OUTLET NOTE: Before you begin the demonstrations that follow, be sure that none of the switches across the top of the system are in the down position.Demonstration 1 {@) Read the information that follows: — A customer has reported that his 637D Scraper sync light is always ON. Machine operates OK (b) Push down switch button 1 at the top of the electronic Switching Demonstration System and operate the system to see the problem. (e) Use the information in Unit 9 about how the syne light was designed to operate normally, and your information about the problem, to give a possible cause of the problem. Write your possible cause on the form on the opposite page. (a) Group your components if necessary, and test the groups/components. Write your results on the form on the opposite page. (e) Continue to group and test components as needed until you can give @ probable cause of the problem. Write your results and probable cause on the form on the opposite page.Information: System - — Problem a Analysis: Possible Cause Tests: 4. Component Resutt 2. Component — Result 3. Component Result 4. Component Result — 5. Component Result — 6. Component Result _ 7. Component Result 8. Component Result 9. Component Result 10. Component Result Diagnosis: Probable CauseCheck the work you have just done with the flow diagram below, and the record on the opposite page. If you find that your work does not make an acceptable comparison with the work indicated by these records, get assistance from your training instructor. 203127 | sszaee | 661352 | 266720 | ssrzss | corsee | 16144 LIGHT | eves | HARNESS | HARNESS | HARNESS | HARNESS } CONTROL (REF) EF) Test ano RESULTS nour 1 enour 2 snai27 | sezas4 | 561383 266720 | so12se | se1sea | r6144 LIGHT | HARNESS | HARNESS HARWESS | HARNESS | HARNESS | CONTROL «ner (Re) TEST a0 1 RESULTS ! \ anai27 | se24e4 661383 LIGHT | HARNESS HARNESS (Re) Test —e nD * RESULTS Work Flow Diagram For Demonstration 1Completed Work Record For Demonstration 1 — Information: system 6370 ELECTRONIC SWITCHING SYSTEM Problem SYNC LIGHT ALWAYS ON Anal Possible Cause SHORT TO Z4 VOLT POWER OR CONTROL. Tests: 4. Component SYNC LIGHT BRANCH Result SHORTED —~ ZS OKMS a 2. Component WIRING GRoUP to Result SHORTED - ZS OUMS a 3. Component _WIRING GRouP 2 oe Result INSULATION OK 4 Component 642484 HARNESS Result SHORTED — Z5 OHMS 5. Component 6GI353 HARNESS Result INSULATION OK oe 6. Component Result a —_— 7. Component Oo Result 8. Component a Result 9. Component Result 1. Component Result Diagnosis: Probable Cause FAILED 6GZ484. HARNESS (Requires write-in)Demonstration 2 (a) Read the information that follows: — A customer has reported that his 637D Scraper shifts wrong. (b) Release switch button 1 and push down switch button 2 at the top of the Electronic Switching Demonstration System and operate the system to see the problem. (©) Use the information in Unit 9 and your information about the problem to give a possible cause of the problem. Write your possible cause on the form on the opposite page 10 (d) Group your components if necessary, and test the groups/components. Write your results on the form on the opposite page. {e) Continue to group and test components as needed until you can give a probable cause of the problem. Write your results and probable cause on the form on the opposite page.Information: System Problem Analysi Possible Cause Tests: 4. Component Result 2. Component Result 3. Component Result 4. Component Result 5. Component Result 6. Component Result 7. Component Result & Component Result 9. Component Result 10. Component Result Diagnosis: Probable Cause 4Check the work you have just done with the work record on the opposite page. If you find that your work does not make an acceptable comparison with the work indicated, get assistance from your training instructor. 12Completed Work Record For Demonstration 2 — Information: system __637D ELECTRONIC SWITCHING SYSTEM Problen __ SHIFTS 6K To ZND GEAR, FRONT LeD 1 OFF Analysis: Possible Cause _FRONT GEAR INPUT OR CONTROL Tests: 4. Component AGIBIZ SWITCH INPUT To CoNTROL Result ___ AV AcRoSS PIN 6 = ZERO - 2 Component AGI8IZ SWITCH Rest AN Across PIN 6 = 617 WITH MULTIMETER 3. Component WIRE ©/R_ - Result ___ CONTINUITY OK os 4, Component Result ___ 5. Component Result a 6 Component — - - Result a - 7. Component —— Result 8 Component Result 9. Component Result 10. Component Result Diagnosis: Probable Cause FAILED 7TGIA4 CONTROL 13Demonstration 3 (a) Read the information that follows: —_A customer has reported that his 637D Scraper does not work. The operator can not shift the rear to neutral with the run-neutral switch. (b) Release switch button 2 and push down switch button 3 at the top of the Electronic Switching Demonstration System and operate the system to see the problem. (€) Use the information in Unit 9 and your information about the problem to give a possible cause of the problem. Write your possible cause on the form on the opposite page. 14 (a) Group your components if necessary, and test the groups/components. Write your results on the form on the opposite page. (e) Continue to group and test components as needed until you can give a probable cause of the problem. Write your results and probable cause on the form on the opposite pageInformati System Problem - Analysis: Possible Cause Tests: 4. Component — a Result 2. Component Result 3. Component Result 4. Component Result 5. Component Result 6. Component, Result 7, Component Result 8 Component Result 9. Component Result 10. Component Result Diagnosi Probable Cause 15Check the work you have just done with the flow diagram below, and the record on the opposite page. If you find that your work does not make an acceptable comparison with the work indicated by these records, get assistance from your training instructor. an2sie | se2aes | 661283 | 266720 | soizss | soiaee | ro144 SUIT | mNE eess | Russ | mene] Ess |cONTROL Lt est RESULTS ono nour 1 orour 2 202676 | ssovea | 61359 2es720 | 661266 | seisee | rsi44 SWITCH | HARNESS | HARNESS ass | mene |e | con OL > Test pe RESULTS sap ts onour 3 1 en2s7s | sszue4 £61383 saves |maes | HARNESS Test RESULTS ep ie i | 202676 sozaey sutton nae 1st —e an * RESULTS Work Flow Diagram For Demonstration 3 16Completed Work Record For Demonstration 3 — Information: system __637D ELECTRONIC SWITCHING SYSTEM. EN IN NEUTRAL Problem _ Analysis: Possible Cause _ NEUTRAL/RUN INPUT OR CONTROL Tests: 4. Component _ NEUTRAL / RUN INPUT BRANCH Resut ____ LACKS CONTINUITY — 750 OHMS 2 Component WIRING GRouP 4 _ Result — LACKS CoNTINUITY — 750 OHMS 3. Component WIRING GROUP 2 Result __ Continuity OK 4. Component WIRING GRouP Bo i Result __LACKS CONTINUITY — 750 OHMS 5. Component 1353 HARNESS Result __ CONTINUITY OK 6. Component SO 2Z6T6 SWITCH Resut ss LACKS CONTINUITY — 750 OHNS 7. Component 6GZ484 HARKNESS Resut CONTINUITY OK 8. Component ae Result : 9. Component Result = 10. Component Result Oo a Diagnosis: Probable Cause FAILED BD2676 SWITCHDemonstration 4 (a) Read the information that follows: —_A customer has reported that his 67D Scraper Electronic sync light is always ON. Machine operates OK. (b) Release switch button 3 and push down switch button 4 at the top of the Electronic Switching Demonstration System and operate the system to see the problem. (c) Use the information in Unit 9 and your information about the problem to give a possible cause of the problem. Write your Possible cause on the form on the opposite page. 18 {d) Group your components it necessary, and test the group/components. Write your results on the form on the opposite page. (e) Continue to group and test components as needed until you can give a probable cause of the problem. Write your results and probable cause on the form on the opposite page () When you have made your diagnosis of the probable cause of the problem for this demonstration, get a copy of the Work Flow Diagram and Work Record for Demonstration 4 of this unit from your training instructor. Compare your work with the work indicated by these records. If you find that your work does not make an acceptable comparison, get assistance from your training instructor.Information: System Problem — = Analysis: Possible Cause Tests: 1. Component = Result 2 Component Result 3. Component a Result 4. Component Result 5. Component Result 6. Component Result 7, Component Result 8. Component Result 9. Component Result 10. Component Result Diagnosis: Probable Cause 19On the opposite page is the customer complaint for the Electronic. Switching Demonstration System Problem 5 (switch button 5). Use this problem for additional learning experience. Be sure to have only one problem switch button pushed down at any one time. 20Customer Report For Problem No. 5 Sync light is ON. Machine operates OK. Information: System Problem Analysis: Possible Cause Tests: 1. Component — Result = 2, Component Resutt 3. Component — Result 4. Component — Result 5. Component —_____ Result 6. Component Result 7, Component Resutt 8. Component Result 9. Component Result 10. Component Result Probable Cause atConclusion Where an electronic control system has several harness assemblies in a single branch and each has the same possibility for failure, testing the harness assemblies in groups will make the testing easier and faster CATERPILLAR” This booklet is one of fourteen. All fourteen booklets are available only as a set under FORM NO. SEBV0525. 22 PRINTED IN U.S.A.