CAT 16H Service Manual

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 Caterpillar replacement parts or parts with equivalent
specifications including, but not limited to, physical dimensions, type, strength and material.
Failure to heed this warning can lead to premature failures, product damage, personal injury or
death.
3
Table of Contents
Table of Contents
Systems Operation Section
MID 030 - CID 0601 - FMI 08

MID 030 - CID 0615 - FMI 03
MID 030 - CID 0615 - FMI 04
MID 030 - CID 0819 - FMI 02
MID 030 - CID 0821 - FMI 03
MID 030 - CID 0821 - FMI 04
...............................
...............................
...............................
...............................
...............................
...............................
62
62
64
65
68
69
Diagnostic System Procedures

Alert Indicator Is Always Flashing .........................
Alert Indicator Never Flashes ...............................
Harness Code .......................................................
Pulse Width Modulated Sensor ............................
Sensor Signal Voltage ..........................................
Sensor Dynamic Operation ...................................
Fuel Level Sender .................................................
Switch Circuits ......................................................
Switch Circuits ......................................................
Charging System ..................................................
71
72
73
76
77
79
81
82
83
85
General Information ................................................ 4

Modes of Operation ................................................ 8
Normal Mode .......................................................... 9
Service Meter Mode .............................................. 10
Odometer Mode ..................................................... 11
Tachometer Mode .................................................. 11
Scrolling Mode ....................................................... 11
Harness Code Mode ............................................. 12
Numeric Readout Mode ........................................ 12
Additional Operator Modes ................................... 13
Service Mode ........................................................ 14
Tattletale Mode ..................................................... 16
Units Mode ............................................................ 18
Setup Mode .......................................................... 18
Calibration Mode ................................................... 18
Articulation Gauge Calibration Mode .................... 22
Warning Operation ................................................ 24
Alert Indicator Description ..................................... 25
Component Description ........................................ 27
Main Display Module ............................................ 27
Display Components ............................................. 31
Quad Gauge Module ............................................ 31
Speedometer/Tachometer Module ........................ 32
Switches ............................................................... 32
Senders ................................................................ 33
Sensors ................................................................. 34
Action Lamp .......................................................... 36
Action Alarm ......................................................... 36
Related Components ............................................ 37
Testing and Adjusting Section
Troubleshooting Section
Index Section
Introduction
General Information ..............................................
Service Tools ........................................................
Electrical Component and Connector Locations ...
Diagnostic Capabilities .........................................

System Self Test ................................................... 94
Wiring Harness (Open Circuit) - Test .................... 94
Wiring Harness (Short Circuit) - Test .................... 95
Wiring Harness (Short Circuit) - Test .................... 96
Electrical Connector - Inspect ............................... 96
Module - Replace .................................................. 97
Main Display Module Initialization - Adjust ........... 97
Main Display Module - Flash Program .................. 98
Glossary of Terms ................................................. 99
Connector Contact Description of Main Display
Module ............................................................. 101
System Schematic .............................................. 104
Index ................................................................... 109

38
38
40
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

i01853880
General Information
SMCS Code: 7490
Introduction
Illustration 1
Caterpillar Monitoring System for the 140H, 143H, 160H and 163H
The quad gauge module and the speedometer/tachometer module are optional components.
g00944992
5
Illustration 2
Caterpillar Monitoring System for the 14H and 16H
g00863307
6
Illustration 3
Caterpillar Monitoring System for the 12H, 120H and 135H
g00945076
7
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.
Illustration 4
g00789331
Typical Example
Caterpillar Monitoring System Display Components
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
Quad gauge module

Speedometer/tachometer module
Main display module
Alert indicators
Gauges
Tachometer
Speed readout
Transmission gear readout
Display area
The Caterpillar Monitoring System is an electronic

monitoring system that continuously watches
machine systems. The system is a flexible modular
monitoring system that includes the following
devices: a main display module, various switches
and sensors, an action lamp, and an action alarm.
The system may include a speedometer/tachometer
module. A different number of quad gauge modules
may be included in the system.
A six digit display area (9) is provided. The
display shows the following modes: machine

operational hours (service meter), engine speed
(tachometer), machine distance (odometer),
and diagnostic codes. The information for the
speedometer/tachometer module, and any gauge
of the quad gauge module can also be shown as a
number on this readout. The display area contains
seven unit indicators and a service indicator. The
operator selects the information in order to be
shown on the display area.
Seven different unit indicators can be shown in
the display area. The unit indicators that can be

shown are C, kPa, MILES, KM, RPM,
LITERS and HOURMETER symbol. These
indicators show the units of measurement for the
data on the six digit display area. The indicators
are turned ON and OFF in order to correspond with
the information on the six digit display area.
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
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
Illustration 5
g00297408
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 operators 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
Table 1
i01856906
12H, 14H, 16H, 120H, 135H, 140H, 143H,

160H And 163H
Normal Mode
SMCS Code: 7490
Operator Modes
Mode Number
Operator Mode
Service Meter
Odometer
Digital Tachometer
Diagnostic Scrolling
Cumulative Fuel
Trip Machine Hours
Trip Odometer
Trip Fuel
Reset Trip Values
Table 2
12H, 14H, 16H, 120H, 135H, 140H, 143H,

160H And 163H
Service Modes
Service Mode
Mode Number
Harness Code
Parameter Display
Diagnostic Service
Tattletale
Digital Tattletale
Units
Calibration (Articulation Gauge)
Calibration (Transmission Control)
Calibration (Transmission Control)
Calibration (All Wheel Drive Control)

(143H, 163H)
(1)
Setup
Setup (143H, 163H)
10
(1)
This mode is not operational at this time. This mode is reserved

for future use.
Illustration 6
g00789331

(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
Quad gauge module

Main display module
Alert indicators
Gauges
Tachometer
Ground speed readout
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
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
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
in order to determine the mode number for the
corresponding machine.
Service Meter
Odometer
Digital Tachometer
Diagnostic Scrolling
Cumulative Fuel
Service Meter Mode
Trip Machine Hours
SMCS Code: 7490
Trip Odometer
Trip Fuel
Reset Trip Values
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.
i00971876
Illustration 7
Display Area
g00298101
11
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.
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
i01461542
Odometer Mode
SMCS Code: 7490
Illustration 8
g00298418
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.
Illustration 10
g00495188
(1) First display. (2) Second display. (3) Module identifier (MID). (4)
Service code indicator SERV CODE. (5) Component identifier
(CID). (6) Failure mode identifier (FMI).
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.
i01518524
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.
Tachometer Mode
SMCS Code: 7490
Illustration 9
Display Area
g00298698
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
i01996543
Harness Code Mode

SMCS Code: 7490
g00298918
Illustration 11
Display Area
Harness code mode is always mode 1. The machine

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
system that is installed on the machine sales model.
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
i01804895
Numeric Readout Mode

SMCS Code: 7490
Illustration 12
Machine Codes
Sales Model
Some machines do not utilize a harness code plug.

This can be verified with the electrical schematic
for the machine. If the machine does not utilize
a harness code plug, then the machine does not
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
model of the machine. For example, the monitoring
system configuration code for a 160H is 160.
g00299479
Display Area
Machine Code
14H
14
140H
40
143H
43
160H
60
163H
63
120H
20
135H
35
12H
12
16H
16
Numeric readout mode is always mode 2. Numeric

readout mode assists service personnel with
troubleshooting of sensor inputs. The inputs supply
information for the gauges in the quad gauge
modules. Numeric readout mode more accurately
shows the same information that is shown on the
gauges in normal mode. The system identifier and
the numeric value for the system scrolls on the six
digit display area. The system identifier identifies the
system that is currently shown on the six digit display
area. See table 5 for System Identification and
illustration 13 in order to match the system identifier
to the appropriate gauge.
13
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

g00789385
Illustration 13
Trip Hourmeter Mode
Quad gauge modules
g00299481
Illustration 14
This is an illustration of the display area on the Main Display

Module that is showing an example of a system identifier.
Table 5
System Identification
System Identifier
Gauge (System)
GA-1
GA-2
GA-3
GA-4
Table 6
Units
Condition
Temperature
Angle
Voltage
Level
SMCS Code: 7490
Units of Measurement
C
0.1 volts
% 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.
Illustration 15
g00298101
Display Area
The main display module keeps track of the trip

hourmeter. The trip hourmeter will accumulate
machine distance based upon the vehicle speed that
is received from the transmission ECM. The total
trip hourmeter is shown on the six digit display area
when you are in trip hourmeter mode. The symbol for
the trip hourmeter is ON in order to indicate when the
display is functioning as a trip hourmeter. 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 trip
hourmeter for the machine when one of these inputs
is in the normal range.
14
Trip Odometer Mode
i01520209
Service Mode
SMCS Code: 7490
Illustration 16
g00298418
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 18
g00427558
Diagnostic Example
Service code indicator (SERV CODE). (5) Component identifier
(CID). (6) Failure Mode identifier (FMI).
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.
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.
15
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 ...
030
036
081
075
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.
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
in service mode. This will momentarily show the
MID. The display will show the CID and the FMI that
corresponds. Removing ground from the service
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
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.
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
Illustration 19
g00427558
Diagnostic Example
Service code indicator (SERV CODE). (5) Component identifier
(CID). (6) Failure Mode identifier (FMI).
Brief Explanation
Illustration 20
Display Area
g00301362
17
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.
Illustration 21
g00789331

(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
Quad gauge module

Main display module
Alert indicators
Gauges
Tachometer
Speed readout
Display area
Tattletale Mode is a tool for management and

maintenance. The history of the machine can be
recorded by this mode. The main display module
records the extreme value for each condition of the
machine that is monitored. The values come from
sensor inputs, switch inputs and the CAT data link.
The values in tattletale mode are updated whenever
a value occurs with more importance than the
previous value. These values are ignored for a short
period of time after each start-up. This allows the
machine systems to stabilize before the recording
of information.
Gauge (5) for the battery charge level has a pointer

that indicates a value below or a value above the
normal battery charge range. Therefore, a low
abnormal value or a high abnormal value has
existed in this system.
Gauge (5) for the articulation angle has a pointer

that indicates a value for the articulation angle of
the machine. Therefore, no abnormal value has
existed in these systems.
Gauge (5) for the fuel level has a pointer that
indicates a level of 50%. Therefore, the highest

amount of fuel that has existed is 50%.
The pointer on tachometer (6) indicates a
maximum value (2100 RPM). Therefore, an engine

speed of 2100 rpm has existed.
Speed readout (7) shows 13 MPH. Therefore, 13

MPH is the highest ground speed that has been
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
Note: No information from the tattletale mode is

stored for the highest transmission gear or lowest
transmission gear that has been selected.
i01963289
Setup Mode
SMCS Code: 7490
i01041208
Units Mode
SMCS Code: 7490
Illustration 23
g01019884
Display Area
Illustration 22
g00301504

(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.
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.
19
Submodes
E04 The calibration value is too small.
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.
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.
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.
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).
1. Connect the 4C-8195 Control Service Tool to the

service tool connector.
The transmission system must be calibrated if any of

the following conditions have occurred:
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.
A transmission solenoid valve has been replaced
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.
New flash software has been flashed into the ECM.
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.
or cleaned.
A different power train ECM has been installed.
A transmission clutch has been rebuilt.

The transmission clutch does not shift correctly.
20
g00795884
Illustration 24
Transmission Clutch Solenoid Valves
(1) Transmission solenoid valve (No. 3)

Table 7
Error Codes for the Calibration of the

Transmission Clutch
E01
The Clutch Solenoid or the Speed Sensor

has an Active Fault.
E02
The Inching Pedal was not released when

you entered the Submode.
E03
Active Fault For the Position sensor

(Inching Pedal)
E04
The Transmission Lever is Not in

the PARK Position.
E05
Temperature of the Transmission Oil is

Below the Fault Threshold.
(60 C (140 F))
E06
The Engine Speed is Below the Fault

Threshold of 1800 rpm.
E09
Machine Speed Is Not Zero.
During calibration of the transmission clutch pressure,

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.

For more information on the calibration procedure,

refer to the Testing and Adjusting, RENR4104,
Engagement Pressure for the Transmission Clutch
- Calibrate.
Submode 7.40 / 8.40 (Transmission

Clutch Fill Calibration)
Improper calibration of the transmission clutch fill will
cause transmission shifting problems. The automatic
calibration procedure for setting the transmission
clutch fill will achieve greater consistency. The
calibration of the transmission clutch engagement
pressure (submode 31 through submode 33)
should be performed prior to the calibration of the
transmission clutch fill (submode 40).
During the transmission clutch fill calibration
(submode 40), 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.
21
Table 8
Error Codes for the Calibration of the

Transmission Clutch Fill
E01
The Clutch Solenoid or the Speed Sensor

has an Active Failure.
E04
The Transmission is Not in the Park Position.
E05
The Temperature of the Transmission Oil

is Below the Fault Threshold.
(68 C (154 F))
E06
The Engine Speed is Below the Fault

Threshold of 1800 rpm.
E09
Machine Speed Is Not Zero.
E11
Calibration of the Engagement Pressure

Is Not Completed.
E21
Number 1 Clutch at a Limit
E22
E23
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
g00795884
Illustration 25
Transmission Solenoid Valves

Note: If a new transmission solenoid valve was

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.
i01529536
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
Note: If the needle appears centered, the switches

must be pressed in order to record the articulation
sender resistance.
Illustration 26
g00794045
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-.
Illustration 27
g00530894
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.
Illustration 28
g00531227
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
i01862466
Warning Operation
SMCS Code: 7490
Table 9
WARNING OPERATION
Warning Indications
Warning
Category
Alert
Indicator
Flashes (3)
(4)
2-S
(4)
(4)
(1)
(2)
(3)
(4)
(5)
(6)
Action
Lamp
Flashes(4)
(1)
Action
Alarm
Sounds
Operator Action Required
Possible Result (2)
No immediate action is required.

The system needs attention soon.
No harmful effects or no
damaging effects.
Change machine operation or

perform maintenance to the system.
Severe damage to
components can occur.
(5)
Immediately change the machine

operation.
Severe damage to machine

components
(6)
Immediately perform a safe engine

shutdown.
Injury to the operator

or severe damage to
components can occur.
The active warning indications are marked with an X.

This is the possible result if no action is taken by the operator.
The alert indicator flashes at a 8 Hz rate.
The action lamp flashes at a 1 Hz rate (1 second ON, 1 second OFF).
Steady
The action alarm sounds at a 1 Hz rate (1 second ON, 1 second Off).
Illustration 30
Speedometer/Tachometer Module
(3)
(4)
(5)
(6)
Illustration 29
Quad Gauge Module
(1) Gauge warning area
(2) Pictograph symbol
g00789595
Tachometer
Pictograph symbol
Ground speed readout
g00427600
25
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.
Illustration 31
g00302085
i01854075
Main Display Module

(7) Alert indicator
(8) Display area
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:
Alert Indicator Description

SMCS Code: 7490
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:
The alert indicator FLASHES approximately nine

times per second.
The action lamp FLASHES for one second and the

action lamp is OFF for two seconds.
The action alarm SOUNDS for one second and the

action alarm is OFF for two seconds.
Note: In order to activate warning indications, more

than one input is required. The main display module
decides when the warning indications are activated.
Illustration 32
Alert Indicators For 143H And 163H
(1) Hydraulic Oil Temperature
(2) Parking Brake Status
(3) Charging System Status
(4) All Wheel Drive Status
(5) Check Engine Status
(6) Engine Coolant Temperature
(7) Steering System Status
(8) Engine Oil Pressure
(9) Brake Air Pressure
(10) Transmission System Status
g00789816
26
Illustration 33
g00923072
Illustration 34
Alert Indicators For 140H, 160H, 12H, 120H And 135H
Alert Indicators For 14H And 16H

(4) Unused
(10) Transmission System Status

(4) Unused
(10) Unused
g00923075
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.
27
i01855060
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.
Main Display Module

SMCS Code: 7490
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.
data link.
Steering System Status The light

indicates that the primary steering pressure
is low. The pressure is received via the CAT
Illustration 35
g00297407
Main Display Module
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.
(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
Display Data Link
Switch Inputs - Uncommitted
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.
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.
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.
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.
29
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.
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
are programmed.
Note: The 0-240 ohm sender input may be
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
Note: The 70-800 ohm sender input may be

Outputs
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
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.
Illustration 36
g00297407
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
The display area has various symbols that show the

condition of the machine systems. The symbols also
show information for service and setup. The type of
information that is shown on the display depends
on the operating mode. For more information about
the display area, see System Operation, Modes of
Operation.
Table 10
Contact Description Of Display Components

Connector
No.
Function
Type
+9 DCV
Input
Ground
Ground
Action Lamp
Display Clock
Input
When a serious abnormal condition exists, the

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.
Display Data
Input
Display Load
Input
Harness Code
Open(1)
Action Alarm
When a critical abnormal condition exists, the
main display module activates the output for the
action alarm (connector contact 4) and the action
alarm SOUNDS. For more information, see System
Operation, Warning Operation.
Power Supply Output - Sensor

The output for the sensor power supply (connector
contact 24) provides 8 DCV for the PWM sensors
that are connected to the inputs of the main display
module.
(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.
i01858071
Quad Gauge 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.
Illustration 37
An Example Of A Quad Gauge Module
(1) Gauge warning area. (2) Pictograph symbol.
g00789595
32
The quad gauge module shows the following

information: engine coolant temperature, articulation
angle, system voltage, and fuel level. The main
display module uses the information from sensor
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
system which is shown on each gauge. Abnormal
values are shown by the gauge warning area (1).
Note: The input is received from the fuel level sender.

The warning level for this gauge is a Level I.
i01020517
Speedometer/Tachometer
Module
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.
Illustration 38
Table 12
g00357114
Speedometer/Tachometer module
Articulation Angle Sensor Gauge

20 C (4 F)
Midpoint Value
0 C (32 F)
20 C (68 F)
Note: The information is received from the articulation

angle sensor.
Table 13
System Voltage Gauge

22 V
Midpoint Value
26.2 V
Red Zone Low
23.8 V
Red Zone High
28.5 V
31 V
Note: The information is received via the CAT data

link.
Table 14
(1) Tachometer. (2) Pictograph symbol. (3) Speed readout. (4)

Gear readout.
Speed readout (3) consists of three digits and the

readout may show the machine ground speed in
MPH (km/h). The main display module calculates
speed by using the information from a frequency
sensor input or the CAT data link. Illumination of the
appropriate digits shows the speed.
Gear readout (4) consists of two digits that show the
transmission gear which is engaged. The left digit
shows the actual gear, 1, 2, 3, etc. The right digit
shows the direction that is selected, F, N or R.
Tachometer (1) shows the engine speed in RPM.
The engine speed is determined by the information
that is sent to the main display module over the CAT
data link. The engine speed is also determined from
a frequency sensor input.
i01858111
Switches
SMCS Code: 1435; 7332
Fuel Level Gauge

5%
Midpoint Value
50%
Red Zone Value
10%
95%
Switches provide information (input) to the main

display module. Switches are two state devices. The
two states of the switches are open and closed.
Closed The switch connects the control input to
frame ground.
33
Open The switch connects the control input to

nothing. (The input is floating.)
Pressure Switch (RH Brake System)
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

Selector)
Grounding the operator mode selector switch
causes the main display module to scroll through the
available operator modes for the machine. Opening
the selector switch places the Caterpillar Monitoring
System in the currently displayed operator mode.
A list of possible operator modes is shown at the
beginning of the Modes of Operation section. See
the Operation And Maintenance Manual in order to
determine the Operator Modes that are available for
the machine that is being serviced.
Temperature Switch (Hydraulic Oil)
Illustration 40
g00793486
Pressure Switch
(1) Schematic symbol
(2) Switch
During normal operation, pressure switch (2) is open

to ground. The switch closes when brake system air
pressure is present. The switch opens when brake
system air pressure is too low.
i01802612
Senders
SMCS Code: 1408-UN
Level Sender (Fuel)
Illustration 39
g00304432
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)
Illustration 41
g00303717
Level Sender (Fuel)

(1) Sender
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
When the fuel tank is at 4% of capacity, the gauge

shows that the tank is empty.
Position Sender (Articulation

Angle)

shows the needle at the red zone on the gauge.

shows that the tank is full.
Temperature Sender
Illustration 43
g00793324
Position Sender (Articulation Angle)

(2) Sender
Illustration 42
g00303718
Temperature Sender
(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 110C (230F) to 3000 ohms at
25C (77F). The main display module measures
the resistance value in order to determine the fluid
temperature.
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
Pulse Width Modulated (PWM)

Sensors
Speed Sensor
Illustration 44
g00304924
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.
The engine speed sensor is located on the flywheel
housing. The speed sensor for the machine is located
at the output end of the transmission housing.
Illustration 45
g00304925
Pulse Width Modulated Signal
Illustration 46
g00304926
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
Temperature Sensor
i01679184
Action Lamp
SMCS Code: 1408-LMP; 7400-LMP
Illustration 49
g00304970
Action Lamp Symbol

Illustration 47
g00304927
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
Illustration 48
The action lamp connects to an output of the main

display module. The action lamp is an LED that
is located within the operators 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
g00304929
Pressure Sensor
Illustration 50
(1) Schematic symbol. (2) Sensor.
Action Alarm
g00307223
(1) Schematic symbol. (2) Action alarm.
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.
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
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
Introduction
i01966052
Service Tools
SMCS Code: 0785
i01400224
General Information
The following service tools should be used to aid in

troubleshooting the electrical system.
Table 15
Service Tools
SMCS Code: 7490

Part Number
Troubleshooting the Caterpillar Monitoring System

requires additional information from the machines
Service Manual. The additional manuals that may
be required are the Service Manual, the System
Schematic, the Parts Manual and the Operation and
Maintenance Manual for the machine that is being
serviced.
As a guide, a typical system schematic is included at
the end of this manual. For an accurate representation
of the machine that is being diagnosed, refer to
Electrical System Schematic in the Service Manual
for the machine that is being serviced.
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.
Part
CAT Electronic Technician
6V-7070
9U-7330
Digital Multimeter
8T-3224
Needle Tip Group
7X-1710
Multimeter Probe Group
8T-8726
Adapter Cable Assembly
6V-3000
Connector Repair Kit (Sure Seal)
9U-7246
Connector Repair Kit (Deutsch DT)
4C-3406
Connector Repair Kit (Deutsch)
4C-8195
Control Service Tool (Switch Box)
Illustration 51
g00280782
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
39
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 machines
Service Manual.
For instructions on servicing Sure Seal connectors,
see Special Instruction, SMHS7531. For instructions
on servicing Deutsch DT connectors, see Special
Instruction, SEHS9615.
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)
(7)
(8)
(9)
Cable
171-4400 Communication Adapter II
Service diagnostic cable.
Current version of Caterpillar Electronic Technician software
and an IBM-COMPATIBLE personal computer
Reference: See Special Publication, NEHS0758,

Communications Adapter II Users 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.
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 todays 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
4C-8195 Control Service Tool
Changing Modes
Table 16
Activation Of Display Operations (Quick Reference)

Display
Operation
Service
Contact(1)
Clear Contact(1)
To Scroll
Ground
Ground
To Hold
Open
Open
To Scroll
Ground
Open
To Hold
Open(2)
Open
Open
Ground
Open
Ground
Changing Modes:
Service Modes:
Illustration 53
g00743610
To
4C-8195 Control Service Tool
Clear(3)
Tattletale Mode:
To Clear
Numeric Readout Mode:
(1)
(2)
(3)
Illustration 54
g00743652
To Scroll
Ground
Open
To Hold
Open
Open
of the service connector.

Open when the desired information is shown during scrolling.
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.
Schematic for the Control Service Tool
The 4C-8195 Control Service Tool is used on

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.
i01398954
Electrical Component and

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
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
Illustration 56
g00309224
Service connector with jumpers (typical example)

(1) Jumper. Service contact grounded (2) Jumper. Clear contact
grounded (3) Service connector.
Illustration 57
g00309227
End view of service connectors
Illustration 55
g00309228
Connector of the main display module
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.
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
the service connector. These electrical connections
are made with two jumpers. See Troubleshooting,
Accessing Diagnostic Information.
42
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
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.
Illustration 59
Typical ET Status Screen
g00867289
44
Diagnostic Code
Procedures
(Table 17, contd)
Diagnostic Codes For Caterpillar Monitoring

System (MID 030)(1)
CID/FMI
i01663522
Diagnostic Code List

SMCS Code: 7569
(1)
Table 17
Diagnostic Codes For Caterpillar Monitoring

System (MID 030)(1)
Description
CID/FMI
CID 0084 Speed Sensor (Ground):

FMI 08
Signal is abnormal
CID 0096 Level Sender (Fuel):

FMI 03
Signal voltage above normal or short to

+battery
FMI 04
Voltage below normal or short to ground
FMI 08
Signal is abnormal
CID 0248 Data Link:

FMI 02
Data erratic, intermittent, or incorrect
CID 0263 Sensor Power Supply:

FMI 03

+battery
FMI 04
CID 0271 Alarm (Action):

FMI 03

+battery
FMI 05
Current below normal or open circuit
FMI 06
Current above normal or short to ground
CID 0324 Lamp (Action):

FMI 03

+battery
FMI 05
Current below normal or open circuit
FMI 06
Current above normal or short to ground
Description
FMI 03

+battery
FMI 04
This table pertains only to faults with a MID of 030.
Note: Every machine may not have all of the

diagnostic codes that are listed in the preceding
table. Also, every machine may not have all the FMI
for a given CID.
Note: The preceding table shows the diagnostic
codes for the Caterpillar Monitoring System. When
the Caterpillar Monitoring System is in the service
mode, diagnostic codes from the other electronic
control modules are shown on the display area of
the Caterpillar Monitoring System. The information
from the diagnostic code is transferred from other
electronic control modules via the CAT data link to
the main display module. This diagnostic information
is shown when the main display module is in the
service mode. The module identifier (MID) indicates
the electronic control module that is sending
the diagnostic code. The MID for the Caterpillar
Monitoring System is 030. This Service Manual
is used for diagnostic codes with a MID of 030.
The MID of other electronic control modules on a
particular machine are listed on the Electrical System
Schematic. Troubleshooting information for those
diagnostic codes can be found in the service manual
for that system.
Note: When a sensor fault is present, the
corresponding warning for that sensor is also
activated for the operator. For example, if the signal
wire for the engine coolant temperature sensor is
shorted to the +battery circuit, then the following
actions take place:
The corresponding diagnostic code is stored in

memory.
The gauge for the engine coolant temperature is

indicating in the warning region.
CID 0615 Position Sender (Articulation)

FMI 03

+battery
The action lamp is FLASHING.
FMI 04
Notice that the second and third above items are the
same warning indications that are activated if the
engine overheats.
CID 0819 Display Data Link:

FMI 02
Data erratic, intermittent, or incorrect
CID 0821 Display Power Supply:

(continued)
45
i01672648
Using Caterpillar Monitoring

System to Determine
Diagnostic Codes
SMCS Code: 7490; 7569
Procedure
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.
Illustration 60
g00429460
Display Area
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.
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
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
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
g00859671
48
g00859762
Illustration 62
Typical Cat ET screen for logged diagnostic codes
A screen is provided in Cat ET for logged diagnostic

codes. The screen will display diagnostic codes that
are logged. The Cat ET will log diagnostic codes that
are intermittent. The logged diagnostic data shall
include a component identifier (CID), a failure mode
identifier (FMI), and a text description of the problem.
Also, the logged diagnostic data shall include the
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.
i01802609
MID 030 - CID 0084 - FMI 08

SMCS Code: 7493-038
Conditions Which Generate This Code:
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.
Illustration 63
Schematic for the ground speed sensor
g00866484
49
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.
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).
Mechanical devices are loose.
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).
The main display module has failed. This is
Expected Result:
Intermittent connections or poor connections
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

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:
5000 ohms. The sensor has failed.
The resistance measures less than 5 ohms.
Repair: Replace the sensor.
Results:
STOP.
YES The resistance measures less than 5 ohms.
Test Step 2. CHECK THE WIRING

HARNESS.
A. The key start switch and the disconnect switch
The signal circuit is correct. The diagnostic code

may be caused by an intermittent failure in the
machine harness.
50
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.
Test Step 1. CHECK THE CONTROL AND

THE HARNESS.
STOP.
B. Disconnect the machine harness connector from

the fuel level sender.
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.
A. Turn the disconnect switch and the key start

switch to the ON position.
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:
STOP.
The voltage is between 4.5 and 8.0 DCV.

i01678169
MID 030 - CID 0096 - FMI 03
Results:
OK The voltage is between 4.5 and 8.0 DCV. The
SMCS Code: 1273-038-UN
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.
Illustration 64
g00866238
Test Step 2. CHECK THE RETURN

CIRCUIT OF THE HARNESS.
Schematic for the fuel level sender
A. The sender remains disconnected.
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:
B. Turn the disconnect switch and the key start

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.

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.
C. Disconnect the J1 machine harness connector

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.
51
Repair: Repair the machine harness or replace the

machine harness.
STOP.
Test Step 3. CHECK FOR A SHORTED

HARNESS
i01678452
MID 030 - CID 0096 - FMI 04

A. The sender and the main display module remain

disconnected from the machine harness.
B. The disconnect switch and the key start switch
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.
Illustration 65
g00866238
Expected Result:

display module reads the signal voltage of the fuel
level sender and the voltage is too low.
The resistance is greater than 5000 ohms.
The possible causes of this failure are listed here:
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.
to ground.

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.
The machine harness has failed. There is a short

between the +battery circuit and the signal circuit
in the machine harness.
A. Disconnect the machine harness from the sender.

machine harness.
The diagnostic code changes from CID 0096 FMI

04 to CID 0096 FMI 03.
STOP.
Results:
Expected Result:
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.
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

C. Disconnect the J1 machine harness connector
D. At the machine harness connector for the sender,
contact 1 (wire 447-PK) and frame ground.
Expected Result:
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
Note: See Troubleshooting, Sensor Signal Voltage
in order to troubleshoot this component.
Perform the following diagnostic procedure: Sensor

Signal Voltage
Results:
Results:
OK STOP.
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.
REPAIRED, OK STOP.
i01858627
MID 030 - CID 0248 - FMI 02

SMCS Code: 7490-038
STOP.

between frame ground and the signal circuit in the
machine harness.

machine harness.
STOP.
Illustration 67
g00530708
Schematic for the Caterpillar data link

i01916153
MID 030 - CID 0096 - FMI 08

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
Illustration 66
g00866238
The circuit for the CAT data link in the machine

harness is shorted to ground.

harness is shorted to the +battery.

harness is open.
53
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.

machine harness.
STOP.
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.

between the frame ground and the CAT data link
circuit in the machine harness.
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.
the +battery (contact 1) and the CAT data link
circuits (contacts 5 and 14).
Expected Result:
Results:

to test step 5.

between the +battery and the CAT data link circuit

GROUND.

machine harness.
STOP.
54
Test Step 5. CHECK FOR AN OPEN

HARNESS.
B. All related control modules remain disconnected
from the machine harness.
i01440228
MID 030 - CID 0263 - FMI 03

SMCS Code: 7490-038-NS
C. Check the continuity of the CAT data link circuit

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.
Illustration 68
g00754378
Expected Result:
Schematic for the sensor power supply
The resistance is less than 5 ohms.

display module reads an above normal sensor supply
voltage (+24 DCV).
Results:
YES The resistance is less than 5 ohms. The

CAT data link circuit in the machine harness is
correct.

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
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.

machine harness.
STOP.
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.
found, replace the module. See Testing and
STOP.
55
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).

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.
Expected Result:
The voltage that is measured should be approximately
0 DCV.
i01440283
MID 030 - CID 0263 - FMI 04
Results:
YES The voltage is approximately 0 DCV. The
voltage is correct.

found, replace the module. See Testing and
STOP.
Illustration 69
g00754378
Schematic for the sensor power supply
NO The voltage is NOT approximately 0 DCV.

display module reads the signal voltage. The voltage
from the sensor is too low.
Test Step 3. DISCONNECT THE

SENSORS.

THE MAIN DISPLAY.
A. Disconnect one of the sensors that are connected

to the +24 DCV sensor supply of the main display
module from the machine harness.
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.
The harness or a sensor has failed. Proceed to

test step 3.
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.
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

STOP.
NO The voltage is NOT 24.0 0.5 DCV. The
sensor supply voltage is NOT correct. Proceed to

test step 2.

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:
Expected Result:
ohms.
Results:
YES The resistance is greater than 5000 ohms.
The harness circuit resistance is correct. The main

STOP.
NO The resistance is less than 5000 ohms. The

machine harness has failed. There is a short to
ground in the machine harness.

STOP.
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.
i01394484
MID 030 - CID 0271 - FMI 03

SMCS Code: 7407-038
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.

GROUND.
B. The sensors remain disconnected.
C. Disconnect the machine harness from the main
display module.
D. At the machine harness connector for the main
the frame ground and the sensor supply circuit
(connector contact 1).
Illustration 70
g00544121
Schematic for the alarm (action)

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.
57
CHECK THE ALARM CIRCUIT.
C. Turn the disconnect switch to the ON position.

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
D. Listen for the SOUNDING of the action alarm.
Test Step 1. CHECK THE ALARM.
E. Turn the key start switch to the ON position.
A. Disconnect the machine harness from the alarm.
Expected Result:
B. At the machine harness connector for the alarm,

place a jumper across the two contacts.

B. Disconnect the machine harness from the main
display module.
The alarm is sounding.
Expected Result:
Results:
YES The alarm is SOUNDING. The harness
The CID 0271 FMI 05 is still present.
circuit 410-WH is shorted to the +battery.
Results:
YES The CID 0271 FMI 05 remains present. The
STOP.
NO The alarm does NOT SOUND. The main


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.
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.
STOP.
i01394545
MID 030 - CID 0271 - FMI 05

SMCS Code: 7407-038

B. Remove the jumper from the connector of the
alarm and reconnect the alarm to the machine
harness.
display module.
D. At the machine harness connector for the module,
measure the resistance between contact 4
(410-WH) and frame ground.
Expected Result:
Illustration 71
g00544121

Results:
The harness circuit is open. Proceed to test step 3.
58

to test step 4.

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.
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
Expected Result:
The machine harness is correct.
Results:
OK The machine harness is correct. STOP.

NOT OK The machine harness is not correct.
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.
Illustration 72
g00544121

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.

C. Turn the disconnect switch and the key start

Expected Result:
Expected Result:
The CID 0271 FMI 06 remains present.
The CID 0271 FMI 05 is still present.
Results:
Results:
OK The diagnostic code remains present. The
YES The CID 0271 FMI 05 remains present. The

main display module has failed.

STOP.
action alarm is not causing the diagnostic code.

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.
59

B. The alarm remains disconnected from the
machine harness.
display module.
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

contact 4 (410-WH) and frame ground.
MID 030 - CID 0324 - FMI 03
Expected Result:
SMCS Code: 7431-038-LMP

Results:
The harness resistance is correct. Proceed to test

step 3.
Illustration 73
g00544436
The harness has failed.
Schematic for the lamp (action)

machine harness.

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
being serviced.
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.
CHECK THE LAMP CIRCUIT.

display module.
D. Place the same diagnostic code on hold and

check the service code indicator.
C. Turn the disconnect switch to the ON position.
Expected Result:
D. Observe the action lamp.
The CID 0271 FMI 06 is present.
E. Turn the key start switch to the ON position.
Results:
Expected Result:
OK The CID 0271 FMI 06 remains present. The
The action lamp is ON.
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
STOP.
Results:
OK The action lamp is ON. The harness circuit

411-PK is shorted to the +battery.

STOP.
60
NOT OK The action lamp is OFF. The module

has failed.

STOP.
i01394817
MID 030 - CID 0324 - FMI 05

NOT OK The CID 0324 FMI 05 is present. The

action lamp is not causing the diagnostic code.

B. Remove the jumper from wire 411-PK to frame
ground. Make sure that the action lamp is
connected to the machine harness.
display module.
contact 13 (411-PK) and frame ground.
Expected Result:
Results:
The harness circuit is open. Proceed to test step 3.
Illustration 74
g00544436
Schematic for the action lamp

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
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.

The harness circuit resistance is correct. Replace

STOP.

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.
61
Results:
OK The circuits are correct. STOP.
NOT OK The circuits are NOT correct.
B. Wire 411-PK remains disconnected from the

action lamp.

STOP.
i01394886
MID 030 - CID 0324 - FMI 06

display module.
contact 13 (411-PK) and frame ground.
Expected Result:

Results:
The harness resistance is correct. Proceed to test

step 3.

Illustration 75
g00544436
Schematic for the action lamp

machine harness.

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

MODULE.
Test Step 1. CHECK THE LAMP.
B. Reconnect the harness connector to the main

display module.
A. At the action lamp, disconnect wire 411-PK from

the lamp socket.

switches to the ON position.
Expected Result:
D. Place the same diagnostic code on hold. Check

the service code indicator.

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.
STOP.
A. Remove contact 13 from the machine harness

connector for the main display module.
Expected Result:
Results:
OK The CID 0324 FMI 06 remains present. The

62

i01528712
MID 030 - CID 0615 - FMI 03

STOP.
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

Illustration 77
g00793582
Schematic for the articulation position sender

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 ground circuit for the sender in the machine
harness is shorted to +battery.

to +battery.
Illustration 76
g00528295
Schematic for the pressure sensor (brake air)

code is on hold. Ensure that the diagnostic code
is shown above represents a typical installation of the
component. Verify the connector contact and the wire
Note: See Diagnostic Function, Sensor Signal
Voltage in order to troubleshoot this component.
Signal Voltage
Results:
OK STOP.
REPAIRED, OK STOP.
The signal circuit in the machine harness is open

or the sender is disconnected.

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.

MODULE AND THE HARNESS.
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.
63
E. Observe the diagnostic code indicator.
Results:
Expected Result:
6.0 0.5 DCV The voltage is 6.0 0.5 DCV. The
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.


STOP.

GROUND.
A. Remove the jumper wire between the signal wire
A429-PK and the ground wire 201-BK.
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
voltage is correct. Verify that the diagnostic code

is still present.

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.

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
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 ground wire or replace the

ground wire for the sender.

STOP.
STOP.
to test step 3.
NO The resistance is greater than 5 ohms. The

ground wire for the harness is open.
Test Step 3. CHECK THE SIGNAL WIRE

FOR THE SENDER.
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.
64
i01528825
Expected Result:
MID 030 - CID 0615 - FMI 04
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.


Illustration 78
g00793582
Schematic for the articulation position sender

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:

to ground.

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.
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.

code is on hold. Ensure that the diagnostic code
is shown above represents a typical installation of
the component. Verify the connector contact and wire


MODULE AND THE HARNESS.
STOP.

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.

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

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.
STOP.
i01944181
MID 030 - CID 0819 - FMI 02

SMCS Code: 7450-038
Illustration 79
Schematic for the display power supply
g00737908
66
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.
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:
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:
Results:


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.

HARNESS.
OK The machine harness connectors are tight

B. All the display modules remain disconnected from

and free of corrosion. Proceed to test step 2.
NOT OK The machine harness connectors are

NOT tight and free of corrosion.
machine harness.
STOP.

+BATTERY.
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
contact 15 (wire C414-BU) to connector contact

5 (wire C414-BU) of the message center
module.
contact 25 (wire E708-PK) to connector contact

3 (wire E708-PK) of the message center
module.
Expected Result:
Results:
OK The resistance is less than 5 ohms. The
circuit resistance is correct. Proceed to test step 4.

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

GROUND
B. The main display module and all the display
components remain disconnected from the
machine harness.
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:
Results:

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

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.
Test Step 5. CHECK FOR + 12 DCV

A. Reconnect all modules to the machine harness.
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.
STOP.
NOT OK The voltage is NOT 9.0 0.5 DCV. The

voltage is not correct.
Repair: The main display module has failed. It is

unlikely that the main display module has failed.
again. If the problem is not found, replace the
main display module. See Testing and Adjusting,
Module - Replace.
STOP.
68
i01395272
MID 030 - CID 0821 - FMI 03

SMCS Code: 7450-038
g00737908
Illustration 80

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
being serviced.

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:
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.
STOP.
NOT OK The voltage is NOT 9.0 0.5 DCV.
The display power supply voltage is NOT correct.

Test Step 2. CHECK THE HARNESS FOR

A SHORT TO +BATTERY.
A. Disconnect the machine harness from the main
display module.
69

display module, measure the voltage from the
connector contact 34 to 2 (ground).
Expected Result:
Results:
OK The voltage is 0.0 0.5 DCV. The voltage is

correct. The main display module has failed.

STOP.
NOT OK The voltage is NOT 0.0 0.5 DCV. The

harness has failed.

STOP.
i01487073
MID 030 - CID 0821 - FMI 04

SMCS Code: 7450-038
Illustration 81
g00737908
70

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
being serviced.
Expected Result:
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.
A. DO NOT disconnect the harness from the module.
STOP.
B. Use the 7X-1710 Multimeter Probe Group. Check

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.
STOP.
The display power supply voltage is NOT correct.


MODULES.
A. Use the 7X-1710 Multimeter Probe Group. Check
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.
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.

GROUND.
display module.
display module, measure the resistance. Measure
the resistance between harness connector contact
34 and harness connector contact 2.
Expected Result:
ohms.
Results:

STOP.


STOP.
71
Diagnostic System
Procedures
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.)
i01432657
Expected Result:
Alert Indicator Is Always

Flashing
The alert indicator continues FLASHING.
SMCS Code: 7400-038-IND
YES The alert indicator continues FLASHING.
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.
Results:
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.

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.)
Test Step 1. LOCATE THE SWITCH.
Expected Result:
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.)
The resistance is greater than 5.0 ohms.
Expected Result:
The appropriate switch is located.
Results:
OK The appropriate switch is located. Proceed

to test step 2.

A. Disconnect the signal wire from the switch.
Results:

STOP.
NO The resistance is less than 5 ohms. The

harness is not causing the problem. The main
72

STOP.
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.

i01432665
Alert Indicator Never Flashes

SMCS Code: 7450-038-IND
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.
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

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.
Test Step 1. LOCATE THE SWITCH
Expected Result:
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.

A. Disconnect the signal wire from the switch.
Results:
The harness is not causing the failure. The main

STOP.
73
NO The resistance is less than 5000 ohms.
The harness has failed. The signal wire within the

harness is shorted to ground.
STOP.
i01398181
Harness Code
SMCS Code: 1408-038
S/N: ASD1-Up
S/N: ARL1-Up
S/N: APM1-Up
S/N: APN1-Up
Table 18
Harness Code Troubleshooting(1)

Main Display Module
Connector Contact
31
12
22
16
Wire Identification
270-BK
271-BK
272-BK
273-BK
274-BK
275-BK
Harness Code Plug Contact(2)
Machine Code
Specified Status
01
O(3)
G(4)
02
03
04
05
06
07
08
09
10
11
12
13
14
15
16
17
18
G
(continued)
74
(Table 18, contd)

Main Display Module
Connector Contact
31
12
22
16
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
O
(continued)
75
(Table 18, contd)
(1)
(2)
(3)
(4)
Main Display Module

Connector Contact
31
12
22
16
55
56
57
58
59
60
61
62
Main display module is in the Harness Code Mode (Mode 1).

For machines so equipped. For machines without a harness code plug, permanent harness code connections are in the machine harness.
O = open
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.
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.
Results:
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

display module.
Expected Result:
The resistance measures 5.0 Ohms or less.
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
Expected Result:
i01916278
The resistance measures 5000 Ohms or more.
Pulse Width Modulated Sensor
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.
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
STOP.
Illustration 82
g00315944
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
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.
Replace the main display module. See Testing and
The signal wire is wire number 443.

The signal contact is contact C.
STOP.
Table 19
Tools Needed
i01916286
9U-7330
Multimeter
7X-1710
Multimeter Probe Group
Sensor Signal Voltage

Test Step 1. TROUBLESHOOT THE

SENSORS.
Troubleshoot sensor circuits in the following order.
Note: The main display module is connected.
A. Perform the Troubleshooting, Sensor Signal

Voltage procedure. This procedure checks the
sensor voltages at the sensor while the circuits
remain connected. DISCONNECT NOTHING.
Troubleshoot as is before disconnecting any
circuits. Disconnecting circuits first may alter a
poor connection. Proving the original cause of a
problem may be difficult or impossible.
Table 20
Sensor Voltage Specifications

For The Sensor Voltage Test
100-3055 Temperature Sensor And 131-0427
Temperature Sensor
Temperature
Signal Voltage(1)
20 to 0C
(4 to 32F)
1.1 to 1.4 DCV
11 to 15%
0 to 20C
(32 to 68F)
1.4 to 2.0 DCV
15 to 23%
20 to 40C
(68 to 104F)
2.0 to 3.1 DCV
23 to 37%
OK This test step has determined the cause of
40 to 60C
(104 to 140F)
3.1 to 4.5 DCV
37 to 55%
60 to 80C
(140 to 176F)
4.5 to 5.7 DCV
55 to 71%
NOT OK This test step has NOT determined the
80 to 100C
(176 to 212F)
5.7 to 6.6 DCV
71 to 82%
100 to 120C
(212 to 248F)
6.6 to 7.2 DCV
82 to 89%
120 to 140C
(248 to 275F)
7.2 to 7.4 DCV
89 to 93%
Expected Result:
The Troubleshooting, Sensor Signal Voltage
procedure has determined the cause of the problem.
Duty Cycle
Results:
the problem. STOP.
cause of the problem. Proceed to test step 2.
Test Step 2. TROUBLESHOOT THE

SENSORS
A. Perform the Troubleshooting, Sensor Dynamic
Operation procedure. This is an additional test.
This will test the sensor during actual operating
conditions.
Expected Result:
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.
(1)
These voltages are guidelines for troubleshooting and are not

considered exact. The tolerance is 10%, depending on the
condition of the harness. Most important is that the output
voltage changes smoothly as the temperature changes.
78
Results:
Table 21

For Sensor Voltage Test
3E-5370 Temperature Sensor Group And
131-0784 Temperature Sensor
Temperature
Signal Voltage(1)
Duty Cycle
YES The voltage is between 7.5 and 8.5 DCV.

The system voltage is present. Proceed to test
step 2.
NO The voltage is not between 7.5 and 8.5 DCV.
40 to 20C
(40 to 4F)
0.8 to 1.5 DCV
4 to 11%
There is an open circuit. Trace the +V and ground

circuits in the machine harness.
20 to 0C
(4 to 32F)
1.5 to 2.5 DCV
11 to 22%

machine harness.
0 to 20C
(32 to 68F)
2.5 to 3.7 DCV
22 to 34%
STOP.
20 to 40C
(68 to 104F)
3.7 to 4.8 DCV
34 to 46%
40 to 60C
(104 to 140F)
4.8 to 6.0 DCV
46 to 59%
60 to 80C
(140 to 176F)
6.0 to 7.2 DCV
59 to 71%
80 to 100C
(176 to 212F)
7.2 to 8.1 DCV
71 to 81%
100 to 120C
(212 to 248F)
8.1 to 8.8 DCV
81 to 87%
120 to 140C
(248 to 275F)
8.8 to 9.2 DCV
87 to 92%
(1)

Locate the suspect sensor. Identify the sensor wires

and connector contacts. See Troubleshooting, Pulse
Width Modulated (PWM) Sensor - Test. DO NOT
DISCONNECT ANY HARNESS CONNECTORS
AT THIS TIME. Turn the key start switch to the ON
position. DO NOT START THE ENGINE.
Test Step 1. CHECK THE SENSOR

POWER.
A. At the sensor connector, identify the +V and
ground circuits.
Test Step 2. CHECK THE SIGNAL

VOLTAGE.
A. At the sensor connector, identify the signal and
ground circuits.
B. Push the 7X-1710 Cable Probes in the back of
the sensor connector along side of the signal and
the ground circuit wires.
C. Measure the signal voltage and record the signal
voltage.
Note: If a precise signal voltage is necessary, use the
specifications that are listed in the provided tables.
Expected Result:
The measured signal voltage is approximately
between 1.0 and 7.0 DCV. The measured signal
voltage is approximately between 1.0 and 9.0 DCV
when using the 3E-5370 Temperature Sensor
Group.
Results:
FROM 1.0 TO 7.0 (9.0) DCV The voltage is
between approximately 1.0 and 7.0 DCV (9.0 DCV

for 3E-5370 Temperature Sensor Group). The
signal voltage at the sensor is correct.

the sensor connector along side of the +V and
ground circuit wires.
Repair: The harness and the main display module

are working properly. The voltage that is measured
is correct. The sensor has failed. Replace the
sensor.
C. Measure the system voltage.
Expected Result:
The voltage that is measured is between 7.5 and 8.5
DCV.
GREATER THAN 7.0 (9.0) The voltage is NOT
between approximately 1.0 and 7.0 DCV. (9.0 DCV

for 3E-5370 Temperature Sensor Group). The
signal voltage is not correct. The signal circuit of
the machine harness is shorted to the +battery.
79

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
Module - Replace.
STOP.

machine harness.
STOP.
Test Step 4.
Dynamic Operation
1.0 DCV. The signal voltage is not correct. The

signal circuit of the machine harness is shorted
to ground.
Results:

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
Module - Replace.
REPAIRED, OK STOP.
STOP.

CIRCUIT FOR THE MACHINE HARNESS .
A. At the machine harness connector for the main
display module, identify the signal and ground
circuits.
Note: DO NOT DISCONNECT THE HARNESS
CONNECTOR.
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.
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.
OK STOP.
i01396902
Sensor Dynamic Operation

Note: The main display module is connected.
80
Table 22
Table 23

For Sensor Dynamic Test

For Sensor Dynamic Test
(1)
100-3055 Temperature Sensor And 131-0427

Temperature Sensor
Temperature
Signal Voltage(2)
(1)
3E-5370 Temperature Sensor Group And

131-0784 Temperature Sensor
Duty
Cycle
Temperature
Signal
Voltage(2)
Duty
Cycle
40 to 20C (40 to 4F)
1.0 to 1.1 DCV
10 to
11%
40 to 20C (40 to 4F)
0.8 to 1.5 DCV
4 to
11%
20 to 0C (4 to 32F)
1.1 to 1.4 DCV
11 to
15%
20 to 0C (4 to 32F)
1.5 to 2.5 DCV
11 to
22%
0 to 20C (32 to 68F)
1.4 to 2.0 DCV
15 to
23%
0 to 20C (32 to 68F)
2.5 to 3.7 DCV
22 to
34%
20 to 40C (68 to 104F)
2.0 to 3.1 DCV
23 to
37%
20 to 40C (68 to 104F)
3.7 to 4.8 DCV
34 to
46%
40 to 60C (104 to 140F)
3.1 to 4.5 DCV
37 to
55%
40 to 60C (104 to 140F)
4.8 to 6.0 DCV
46 to
59%
60 to 80C (140 to 176F)
4.5 to 5.7 DCV
55 to
71%
60 to 80C (140 to 176F)
6.0 to 7.2 DCV
59 to
71%
80 to 100C (176 to 212F)
5.7 to 6.6 DCV
71 to
82%
80 to 100C (176 to 212F)
7.2 to 8.1 DCV
71 to
81%
100 to 120C
(212 to 248F)
6.6 to 7.2 DCV
82 to
89%
100 to 120C
(212 to 248F)
8.1 to 8.8 DCV
81 to
87%
120 to 140C
(248 to 275F)
7.2 to 7.4 DCV
89 to
93%
120 to 140C
(248 to 275F)
8.8 to 9.2 DCV
87 to
92%
(1)
(2)
If desired, use these specifications with the following procedure.

(1)
(2)
If desired, use these specifications with the following procedure.

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
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.
81
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.

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.

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.
OK The voltage increase during the test
Note: When precise specifications for the signal

voltage are necessary, use the specifications that are
listed in the provided tables.
NOT OK The voltage does not increase during
Expected Result:
The voltage that is measured is within the
specifications.
Expected Result:
The voltage increases during the test procedure.
Results:
procedure and the sensor operates smoothly. The
sensor has not failed. STOP.
the test procedure. The probable cause is a failed
sensor.
Repair: The sensor has failed. Replace the sensor.
STOP.
Results:
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.
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.

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.
i01397975
Fuel Level Sender

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
Half tank ....................................... 97 to 118
Full tank ......................................... 27 to 40
82
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
Full tank .......................................... 0 to 3.5

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
B. Disconnect the signal wire from the switch.
9X-4942 Fuel Level Sender

Empty tank ..................................... 80 to 85
Half tank ......................................... 40 to 43
Full tank ............................................. 0 to 2
C. Actuate the sender by hand while you are
measuring the resistance.
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.
D. The resistance should change as the sender is

actuated through the empty range to the full range.
Results:
Expected Result:
OK The alert indicator is no longer active on the

The resistance that is measured is within the

specifications.
Results:
STOP.
OK The resistance for the fuel level sender is

correct. STOP.
NOT OK The resistance for the fuel level sender

is NOT correct.
display module. The machine harness is open or

the ECM has failed. Proceed to test step 2.
A. Remove the jumper that was used in the previous

test step.
STOP.
i01968414
Switch Circuits
SMCS Code: 1435-038; 7332-038
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 ECM has failed.
NOT OK The alert indicator remains on the main

Test Step 2. CHECK THE VOLTAGE OF
THE ECM.
Repair: Replace the fuel level sender.
The switch has failed.
Repair: The switch has failed. Check or replace

the switch.
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
STOP.
NOT OK The voltage is NOT 8 0.5 volts.

83

B. Use the Electrical System Schematic to trace the
signal wire from the switch back to the ECM.
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,
contact and contact 2 of the switch.
Expected Result:
Results:
signal circuit of the harness is correct. Proceed to

test step 4.

ohms.
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
STOP.

ohms.
Repair: The machine harness has failed. Repair

the machine harness or replace the machine
harness.
STOP.
i01428111
Switch Circuits
SMCS Code: 1435-038; 7332-038
S/N: 1241-Up
S/N: 1251-Up
S/N: 1261-Up
S/N: CCA1-Up
S/N: CBC1-Up
Repair: The signal circuit of the harness is not

correct. Repair the machine harness or replace the
machine harness.
S/N: ASD1-Up
STOP.
S/N: CBK1-Up
S/N: CAF1-Up
Test Step 4. CHECK THE GROUND

S/N: ARL1-Up

S/N: APN1-Up
B. The machine harness connectors J1 and J2

remain disconnected.
C. Use the Electrical System Schematic to trace the
ground for the switch.
D. At the switch, measure the resistance between
the ground wire and frame ground.
Expected Result:
Results:
OK The resistance is less than 5 ohms.
S/N: APM1-Up
S/N: CCP1-Up
S/N: AMX1-Up
S/N: ALZ1-Up
S/N: AMZ1-Up
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.
84
The switch has failed.

The ECM has failed.
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
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
STOP.
NOT OK The voltage is NOT 8 0.5 volts.

B. Disconnect the signal wire from the switch.

C. Place a jumper wire from the signal wire to the

ground wire.

Expected Result:
B. Use the Electrical System Schematic to trace the

signal wire from the switch back to the ECM.
The alert indicator is no longer active on the main

display module.
Results:
OK The alert indicator is no longer active on the


of the machine harness at the ECM.
D. Disconnect the machine harness connectors J1
and J2 from the ECM.
Repair: The switch has failed. Check or replace

the switch.
E. At the machine harness connector for the ECM,

contact and contact 2 of the switch.
STOP.
Expected Result:
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.

Results:
signal circuit of the harness is correct. Proceed to

test step 4.

ohms.
C. Measure the pull-up voltage from the signal wire

to the ground wire with a digital multimeter.
Repair: The signal circuit of the harness is not

correct. Repair the machine harness or replace the
machine harness.
Expected Result:
STOP.
The voltage is 8 0.5 volts.

Results:
OK The voltage is 8 0.5 volts.
Test Step 4. CHECK THE GROUND

B. The machine harness connectors J1 and J2
remain disconnected.
C. Use the Electrical System Schematic to trace the
ground for the switch.
85
D. At the switch, measure the resistance between

the ground wire and frame ground.
Table 24
Alternator Specifications
Expected Result:
Peak
Current
Rating
(Amps)
Minimum
Peak
Current
(Amps)
Results:
12 Volt Alternators
OK The resistance is less than 5 ohms.
8C-5535
32
28
7N-4784, OR-5201
40
36
6T-1396, 7T-2096, 8C-5908,

OR-3654
51
46
9W-2648, 9W-2949,
8T-9700, 105-2811(IG),
OR-4327(IG), 105-2812(IG),
OR-9273(IG), 34-3268,
68-4139, 3E-7295(D+),
7T-2876(D+), 100-8223
55
49
7G-7889
60
54
8C-5510(I), OR5200
61
55
8N-2268
75
68
3E-7892, OR-3616
85
77
105-2813(IG), OR-9274(IG),
105-2814(IG), OR-4328(IG),
149-2064(REG),
OR-9410(REG),
9X-0341(D+)
90
81
8C-6163, OR-1699,
107-2519
105
95
167-7816
110
99
9X-6796, 9X-9096,
121-4134, 121-4136,
OR-3527
115
104
3E-8827, 121-4135,
117-1379(I)
130
117
152-8746
135
122
125-9597, OR-8332
145
131
200-2232
67.5
26
169-3345
50
30
200-8281
67.5
26
2P-1204, 3Y-8200
19
17
2Y-8310
21
19
6T-1395, 7T-2095, OR-3653
33
30
6N-9294, OR-5217, OR-3482
35
32
5N-5692, OR-2698
45
41
5S-9088, 100-5047,
112-5041, 3E-7578,
OR-5206, OR-3667,
OR-3668
50
45
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
STOP.

ohms.
Repair: The machine harness has failed. Repair

the machine harness or replace the machine
harness.
STOP.
i01969322
Charging System
SMCS Code: 1406-038
Often when problems with the charging system
are being investigated, the alternator is not the
problem. If a low battery condition is present test the
batteries first. See Special Instruction, SEHS7633,
Battery Test Procedure for more information. If the
engine cranks slowly, then test the starting system.
See Service Magazine, SEPD0020, Testing The
Starter On The Engine for more information. If a
warning indicator for the charging system is ON, see
Service Magazine, SEBD1751, Difference Between
Alternator Indicator In Electronic Monitoring System
(EMS) And Low Voltage Indicator In Operating
Monitoring System (OMS).
Note: Severely discharged batteries can cause low
system voltage. This can occur even while the engine
is running above idle, and the alternator is working
properly. Proper low engine idle is also important.
24 Volt Alternators
(continued)
86
Results:
(Table 24, contd)
Alternator Specifications
Peak
Current
Rating
(Amps)
Minimum
Peak
Current
(Amps)
Method 1 The alternator has a 1, REG, or

D+ terminal. Proceed to test step 2.
Method 2 The alternator is self-excited. Proceed

to test step 4.
109-2362, 9W-3043
, OR-3652(D+), 112-8032
55
50
3E-7772(IG), OR-9437(IG),
105-3132(IG), 4N-3986,
OR-5203
60
54
155-7434, 132-2156(I),
107-7977(I), OR-8279(I)
70
63
169-4319, 167-7812
75
67.5
107-7976, 114-2401,
OR-8997, 3E-7577, OR-3615
75
68
165-5140
100
90
B. Verify voltage at the excitation terminal. Connect

the red lead from a multimeter to the excitation
terminal. Connect the black lead to a ground
source (alternator case ground).
9X-7803, OR-3749
100
90
C. Read the voltage that is shown on the multimeter.
Method 3 The alternator has an IG terminal.

Test Step 2. CHECK THE RESISTANCE IN

THE EXCITATION CIRCUIT.
A. Turn the key start switch to the ON position.
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
9G-6079, 6T-1194
63
57
Parts-Service Only Discontinued 24 Volt Alternators

9G-6081, 6T-1196
40
36
D+ - Diode trio output. Alternator requires external

excitation.
REG - Regulator Terminal. Alternator requires external
excitation.
I - Ignition Terminal. Alternator can be externally excited
through this terminal.
IG - Ignition Terminal. System voltage must be supplied
to this terminal to turn on the alternator. Some of these
alternators use the IG terminal as a sense terminal.
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.
YES The voltage reads .2 volts or more. The
excitation circuit is correct. Proceed to test step 4.
NO The voltage is less than .2 volts. 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 3. CHECK THE RESISTANCE IN

THE EXCITATION CIRCUIT (CONTINUED).
Note: This step is only for alternators with external
excitation when the terminal for excitation is labelled:
IG.
A. Turn the key start switch to the ON position.
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.
87
NO The voltage is less than system voltage.

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:
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.
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.
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
D. Set the digital multimeter to peak hold or max

mode on the mV scale.
Test Step 8. TEST THE CHARGING

CIRCUIT.
E. Turn on all electrical accessories: lights, air

conditioning, and radio.
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.
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.
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.
Expected Result:
C. Check the nut on the alternator pulley. Tighten the

nut if the nut is loose.
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.
Expected Result:
Results:
The drive system of the alternator is functioning

correctly. No corrections to the drive system were
necessary.
YES The voltage at the battery is less than the
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.
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.
89
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
STOP.
Test Step 10. TEST THE NEGATIVE SIDE

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.
Repair: There is high resistance in the negative


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
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
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
STOP.
NO The voltage output does not rise.

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.
91

Test Step 17. TEST THE OUTPUT

CURRENT OF THE ALTERNATOR
BELOW 0.015 AMPERES.
The current is below .050 amperes (50 milliamperes).
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.
Results:
Expected Result:
YES The current is below 0.050 amperes. The
The current is less than 0.015 amperes.
Expected Result:
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.
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.

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.

alternator. Repair or Replace the alternator.
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.
STOP.
D. Check if any components on the circuit are ON.
NO The current is over 2 amperes.
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
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.
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 source of the excessive current draw was

determined.
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:
Results:
YES The source of the excessive current draw
YES The voltage at the battery is less than the
Expected Result:
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

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.
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.
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

A. Measure the voltage between the frame of the
machine and the B+ terminal of the alternator.
Perform the next measurement immediately.
B. Measure the voltage between the frame of the
machine and the positive terminal of the battery.
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

STOP.
VOLTAGE EXCESSIVE - ALL ALT. The voltage

difference exceeds the tolerance.
Repair: There is high resistance in the positive


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

Section
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.
i01916579
System Self Test
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.
SMCS Code: 7490-038
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.
Illustration 84
g00296905

(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 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
Reference: For a complete electrical schematic,

refer to Electrical System Schematic for the machine
that is being serviced.
TEST FOR AN OPEN CIRCUIT.
1. Identify the connectors and the wire numbers of
the suspect circuits. Use the Electrical System
Schematic of the machine to identify the circuits.
2. Turn the key start switch and the disconnect
TEST FOR A SHORT CIRCUIT.

3. Disconnect the component and the ECM from the
wiring harness.

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,

place a jumper wire from the contact of the
suspect wire to frame ground.
5. Use the other multimeter probe to check the

resistance across all other contacts in the
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.
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
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:
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.
There is a short in the machine harness. The short
is between the suspected wire and the wire with
the lowest resistance measurement.
Stop.
96
i01744672
Wiring Harness (Short Circuit)

- Test
SMCS Code: 1408-081
S/N: ASD1-Up
S/N: ARL1-Up

There is a short in the machine harness. The short
is between the suspected wire and the wire with
the lowest resistance measurement.
Stop.
S/N: APM1-Up
S/N: APN1-Up
S/N: ATS1-Up
A short circuit is a failure of an electrical circuit that
results in undesired electrical current. Usually, a
short circuit is a bypass of the circuit across a load.
For example, a short across the wires in a circuit for
a lamp produces too much current in the wires but
no current is felt at the lamp. The lamp is shorted
out. The resistance in a normal circuit can vary, but
the resistance between a particular circuit and other
unrelated circuits is always greater than 5000 ohms.
The following procedure explains the test for a short
circuit:
TEST FOR A SHORT CIRCUIT.
i01205456
Electrical Connector - Inspect

SMCS Code: 7553-040-WW
Intermittent electrical problems are often caused by
poor connections. Use the following checks as a
reference for inspecting connectors.
1. Check the connection of the connectors.
Ensure that the locking rings are properly

locked.
Ensure that locking clips are used on Sure Seal

connectors.
Ensure that the center of the connector is tight.

Ensure that the connector pins and sockets
align properly.
2. Check the wires at the connector.
Ensure that the wires enter the back of the

connector straight.

Ensure that each wire is properly crimped into

wiring harness.
Ensure that each connector contact is properly
4. At the machine harness connector for the ECM,

place one of the multimeter probes on the contact
of the suspect wire.
5. Use the other multimeter probe to check the
resistance across all other contacts in the
connector(s) of the ECM and frame ground.
the proper connector contact.
locked into the connector contact. When the

connector contact is locked properly, the contact
(wire) cannot be pulled out of the connector
body without excessive force.
3. Check each wire for nicks or signs of abrasion

in the insulation.
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
OK The resistance is greater than 5000 ohms

for all the measurements. The harness circuits
are correct.
Check for missing or loose wire hole plugs.
Stop.
connector seals.
Check for wires that do not enter the connector

properly.
97
If the wires enter the connector at an angle,
Expected Result: The module has been

successfully replaced and the module has
completed the self test.
Moisture can enter the connector through the
Results:
there may not be a good seal between the

connector and the wire insulation.
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.
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
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.
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.
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.
OK - The display module successfully
Expected Result: There is a harness code

plug.
NOT OK - The display module did not
Results:
YES - There is a harness code plug. Remove
Results:
completed the self test. STOP.
complete the self test. Exit this procedure.

Determine the cause of the failure and repeat
Initialization. STOP.
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.
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.
99
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.
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.
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.
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.
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.
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.
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.
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.
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.
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
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
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
+ Battery
Input - Voltage (Power)
28 VDC
Ground
Ground
0 VDC
Harness Code 1
Switch Input - Programming
Programming Switch(1)
Action Alarm
Output
Alarm Driver
CAT Data Link +
Input/Output - Data Link
Driver/Receiver (+)
Harness Code 5
PWM/Switch 1
Sensor Or Switch Input
Unassigned
PWM/Switch/Sender 5
Sensor, Switch Or Sender Input
Unassigned
Switch /Sender 10
Switch Or Sender Input
Fuel Level
(continued)
102
(Table 25, contd)

12H, 120H, 135H, 140H, 143H, 160H And 163H
No.
(1)
Function
Type
Description
10
PWM/Switch/Sender 6
Sensor, Switch Or Input
Unassigned
11
Switch 7
Switch Input
Unassigned
12
Harness Code 2
13
Action Lamp
Output
Lamp Driver
14
CAT Data Link -
Driver/Receiver (-)
15
Display Module Load
Output
Driver for Gauge Module
16
Harness Code 4
17
PWM/Switch 2
Unassigned
18
Switch/Sender 9
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
23
Service
Switch Input
Scroll Switch
24
Sensor Power Supply
Output
Unassigned
25
Display Module Clock
Output
Driver for Gauge Sequencing
26
Frequency 1
Unassigned
27
PWM/Switch 4
Sensor or Switch Input
Unassigned
28
PWM/Switch/Sender 7
Unassigned
29
Switch 2
Switch Input
Park Brake
30
Alternator R terminal
Alternator Frequency
31
Harness Code 0
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
Unassigned
37
PWM/Switch 3
Unassigned
38
PWM/Switch/Sender 8
Unassigned
39
Switch 3
Switch Input
Unassigned
40
Switch 5
Switch Input
Primary Steering Pressure
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
Table 26

14H, And 16H
No.
Function
Type
Description
+ Battery
Input - Voltage (Power)
28 VDC
Ground
Ground
0 VDC
Harness Code 1
Unassigned
Action Alarm
Output
Alarm Driver
CAT Data Link +
Driver/Receiver (+)
Harness Code 5
Unassigned
PWM/Switch 1
Unassigned
PWM/Switch/Sender 5
Unassigned
Switch /Sender 10
Fuel Level
10
PWM/Switch/Sender 6
Sensor, Switch Or Input
Unassigned
11
Switch 7
Switch Input
Neutral Start Switch
12
Harness Code 2
Unassigned
13
Action Lamp
Output
Lamp Driver
14
CAT Data Link -
Driver/Receiver (-)
15
Display Module Load
Output
Driver for Gauge Module
16
Harness Code 4
Unassigned
17
PWM/Switch 2
Reverse/Backup Alarm Switch
18
Switch/Sender 9
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
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
Ground Speed Sensor
27
PWM/Switch 4
Sensor or Switch Input
Unassigned
28
PWM/Switch/Sender 7
Unassigned
29
Switch 2
Switch Input
Park Brake
30
Alternator R terminal
Alternator Frequency
31
Harness Code 0
Unassigned
32
Switch 6
Switch Input
Hydraulic Temperature
33
Clear
Switch Input
Clear Switch
34
Display Module Power Supply
Output
9 VDC
35
Display Module Data
Input/Output
Data for Gauge Module
36
Frequency 2
Unassigned
37
PWM/Switch 3
Unassigned
(continued)
104
(Table 26, contd)

14H, And 16H
No.
Function
Type
Description
38
PWM/Switch/Sender 8
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
140H, 143H, 160H And 163H
Illustration 85
g00947079
106
14H
Illustration 86
g00865621
107
16H
Illustration 87
g00947028
108
12H, 120H, 135H, 140H, 143, 160H,

And 163H
Illustration 88
g00947030
109
Index Section
Index
A
Action Alarm ..........................................................
Action Lamp...........................................................
Additional Operator Modes....................................
Trip Fuel Consumption Mode.............................
Trip Hourmeter Mode .........................................
Trip Odometer Mode ..........................................
Alert Indicator Description .....................................
Alert Indicator Is Always Flashing..........................
Alert Indicator Never Flashes ................................
Articulation Gauge Calibration Mode.....................
I
36
36
13
14
13
14
25
71
72
22
C
Calibration Mode ................................................... 18
Submodes.......................................................... 19
Charging System ................................................... 85
Component Description ......................................... 27
Connector Contact Description of Main Display
Module ............................................................... 101
D
Diagnostic Capabilities ..........................................
The Caterpillar Electronic Technician (ET).........
Diagnostic Code List..............................................
Diagnostic Code Procedures.................................
Diagnostic System Procedures .............................
Display Components .............................................
42
42
44
44
71
31
E
Electrical Component and Connector Locations ... 40
Connector Contact Numbers for the Main Display
Module ............................................................. 41
General Information ........................................... 40
Service Connector ............................................. 41
Electrical Connector - Inspect................................ 96
F
Fuel Level Sender ................................................. 81
G
General Information........................................... 4, 38
Introduction .......................................................... 4
Glossary of Terms.................................................. 99
H
Harness Code........................................................ 73
Harness Code Mode.............................................. 12
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
Procedure For Initialization ................................ 98
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
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
Modes of Operation ................................................. 8
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
Related Components............................................. 37
Alternator ........................................................... 37
Other Electronic Controls................................... 37
Warning Operation ................................................ 24

Wiring Harness (Open Circuit) - Test..................... 94
Wiring Harness (Short Circuit) - Test ............... 9596
S
Scrolling Mode........................................................ 11
Senders ................................................................. 33
Level Sender (Fuel) ........................................... 33
Position Sender (Articulation Angle) .................. 34
Temperature Sender .......................................... 34
Sensor Dynamic Operation ................................... 79
Sensor Signal Voltage ........................................... 77
Sensors ................................................................. 34
Frequency Sensors............................................ 34
General Information ........................................... 34
Pulse Width Modulated (PWM) Sensors............ 35
Service Meter Mode .............................................. 10
Service Mode......................................................... 14
Service Tools ......................................................... 38
4C-8195 Control Service Tool........................... 40
Changing Modes................................................ 40
Service Switches................................................ 39
Setup Mode ........................................................... 18
Speedometer/Tachometer Module ........................ 32
Switch Circuits ................................................. 8283
Switches ................................................................ 32
Pressure Switch ................................................. 33
Rocker Switch (Operator Mode Selector) .......... 33
Temperature Switch (Hydraulic Oil) ................... 33
System Schematic............................................... 104
12H, 120H, 135H, 140H, 143, 160H, And
163H............................................................... 108
140H, 143H, 160H And 163H ......................... 105
14H .................................................................. 106
16H .................................................................. 107
System Self Test.................................................... 94
Systems Operation Section ..................................... 4
T
Table of Contents..................................................... 3
Tachometer Mode................................................... 11
Tattletale Mode ...................................................... 16
Testing and Adjusting ............................................ 94
Testing and Adjusting Section ............................... 94
Troubleshooting Section ........................................ 38
U
Units Mode ............................................................ 18
Using Caterpillar Electronic Technician to Determine
Diagnostic Codes................................................. 46
Using Caterpillar Monitoring System to Determine
Diagnostic Codes................................................. 45
Procedure .......................................................... 45
111
Index Section
2003 Caterpillar
All Rights Reserved
Printed in U.S.A.

CAT 16H Service Manual

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RENR5740-05

Important Safety Information

The meaning of this safety alert symbol is as follows:

When replacement parts are required for this

MID 030 - CID 0601 - FMI 08

Diagnostic System Procedures

General Information ................................................ 4

Testing and Adjusting Section

Testing and Adjusting

Index ................................................................... 109

Diagnostic Code Procedures

Systems Operation Section

The main display module is the brain of the system.

Main Display Module

Quad gauge module

The Caterpillar Monitoring System is an electronic

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

display shows the following modes: machine

Seven different unit indicators can be shown in

the display area. The unit indicators that can be

In order to indicate a current fault, a service code

indicator is used. The service code indicator is used

One three digit display area (7) shows the

information on the ground speed. The speed is

Information on the transmission gear and the

direction are shown on a two digit gear readout (8).

Quad Gauge Module

the machine. The quad gauge will display the

According to the application, the type and the

This is a typical example of the Display Area (Mode 2).

The Caterpillar Monitoring System has many different

The operator modes are accessible by using the

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

Trip Machine Hours

Reset Trip Values

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

Calibration (Articulation Gauge)

Calibration (Transmission Control)

Calibration (Transmission Control)

Calibration (All Wheel Drive Control)

Setup (143H, 163H)

This mode is not operational at this time. This mode is reserved

Caterpillar Monitoring System Display Components

Quad gauge module

Normal mode is used during normal machine

A monitoring system that is operating properly

will perform a self test whenever the key switch is

The main display module continuously watches

machine systems. If the gauges are available, the

The main display can show a problem with the

machine. The main display module continuously

Note: The main display module may notify the

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

The default condition is shown on the six digit display

Service Meter Mode

Trip Machine Hours

SMCS Code: 7490

Reset Trip Values

The six digit display area (9) is used to show various

The main display module keeps track of the total

The engine RPM is shown on the six digit display

The total distance for the machine is displayed on the

Scrolling mode allows service personnel or an