30/3/2017 906CompactWheelLoader6ZS00001UP(MACHINE)POWEREDBY3034Engine(SEBP281974)Sistemasycomponentes

Pantallaanterior
Bienvenido:r120fitafta
Producto:COMPACTWHEELLOADER
Modelo:906COMPACTWHEELLOADER6ZS
Configuracin:906CompactWheelLoader6ZS00001UP(MACHINE)
POWEREDBY3034Engine

PruebasyAjustes
COMPACTWHEELLOADERTRANSMISSIONELECTRONICCONTROLSYSTEM
NmerodemedioSENR125800 Fechadepublicacin01/06/1998 Fechadeactualizacin05/08/2002

TestingAndAdjusting

Introduction
Reference:Forsystemsoperationandtestingandadjustinginformationofthepowertrain,makereferenceto
thePowerTrainSystemsOperation,TestingAndAdjustingmodule

Reference:Forelectricalcircuitschematics,makereferencetotheElectricalSystemSchematicmodule.

GeneralTroubleshootingInformation
Thediagnosticindicatorforthehydrostatictransmissioncontrolsystemistheflashingneutrallamplocatedon
therightsideofthefrontconsole.Troubleshootingthehydrostatictransmissioncontrolsystemrequires
additionalinformationfromthemachineServiceManual.TheElectricalSystemSchematic,thePartsManual
andtheOperation&MaintenanceManualarerequiredsupportmaterial.

Asaguide,asimplifiedsystemschematicisattheendofthismanual.Foracompletemachineelectrical
schematic,seetheElectricalSystemSchematicinthemachineServiceManual.

WhenthetroubleshootingprocedureinstructstoREPAIRTHEHARNESS,usetheElectricalSystemSchematic
inthemachineServiceManualtotracethecircuit.Performcontinuitychecksatconnectorstolocateharness
failures.Atcomponentconnectors,alwayscheckthegroundcircuit.Lessthanfiveohmsofresistanceis
requiredbetweentheconnectorgroundcontactsandframeground.Excessivegroundresistance,greaterthan
fiveohms,cancauseincorrectdiagnosingofproblems.

Duringtroubleshooting,inspectallcomponentandharnessconnectionsbeforeanycomponentisreplaced.If
theseconnectionsarenotcleanandtighttheycancauseelectricalproblems,eitherpermanentorintermittent
(comeandgo).Checkthatthewiresarepushedintotheconnectorscompletely.Makesuretheconnectionsare
tightbeforeothertestsaremade.

Ifwireinsulationispuncturedduringtroubleshooting,repairafterprobing.Sealthepunctureswith8T0065
Adhesive.Covertheadhesivewithtwolayersof1P0810Tape.

Failureofanelectricalcomponentcancause,orbecausedbythefailureofoneormoreothercomponents.
Alwaysattempttofindandcorrectthecauseofelectricalsystemfailurebeforemakingreplacementofa
component.

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Whenremovingthemachineharnessfromthecontrol,usethesinglescrewinthecenteroftheharness
connector.

ServiceTools
Thefollowingservicetoolsshouldbeusedtoaidintroubleshootingtheelectricalsystem.

6V7070or9U7330DigitalMultimeterorequivalent.8T3224NeedleTipGroup7X1710CableProbe
Group8T8726AdapterCable6V3000RepairKitSureSeal4C3406ConnectorRepairKitDeutsch

Usethedigitalmultimeterformakingcontinuity(resistance)checksorvoltagemeasurements.Forinstructionon
useofthe6V7070,seeSpecialInstructionSEHS7734.The7X1710CableProbeGroupisusedtomake
measurementsatconnectorswithoutdisconnectingthem.Theprobesarepushedinthebackoftheconnector
alongsidethewire.The8T8726AdapterCableisa3pinbreakoutcableusedtomakemeasurementsinsensor
circuits.

NOTE:Useofcontinuitytesters(suchas8T0500),orvoltagetesters(suchas5P7277)arenotrecommended
foruseonpresentdayCaterpillarelectricalcircuits,exceptforharnesstests.

ElectricalComponentAndConnectorLocations

ComponentLocation
(1)Control.

Thehydrostatictransmissioncontrolislocatedinsidetherightsideconsole.

TheElectricalSystemSchematic,PartsManualandtheOperation&MaintenanceManualforthemachine
beingserviced,shouldallbeusedtolocateotherelectricalcomponentsandconnectors.

ThefollowingisaguidetoreadingtheHarnessConnectorandComponentLocationcharts,themachineprofile
andtheareaviewsallfoundonthebacksideoftheElectricalSystemSchematicmodule.

*ComponentLocationChart:

Thecomponentlocationchartuseswhitecirclesaslocationlabelsinthemachineprofileandareaviews.
Alphabeticallettersinthemachinelocationcolumnindicateageneralareaofthemachine.Seethe
correspondingfootnoteattheendofthechartforadescriptionofthelocation.

*HarnessConnectorLocationChart:

Theharnessconnectorlocationchartuseswhitecirclesaslocationlabelsinthegeneralandareaviews.
Alphabeticallettersinthemachinelocationcolumnindicateageneralareaofthemachine.Seethe

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correspondingfootnoteattheendofthechartforadescriptionofthelocation.Connectorsthatare
attacheddirectlytocomponentsarenotlocatedseparatelyfromthecomponent.

ConnectorContactNumbers

HydrostaticTransmissionControlConnector
(1)Screw.

Toremovethemachineharnessfromthecontrol,usescrew(1)inthecenteroftheharnessconnector.

TroubleshootingInitialProcedure
Starttroubleshootingthehydrostatictransmissioncontrolsystembyobservingthemachineoperationandthe
diagnosticindicator(flashingneutrallamp).

Thistroubleshootingprocedureisdifferentduetothediagnosticcapabilityofthecontrolsystem.

IfANYfaultoccurswiththecontrolmoduleorsystemcomponentstheNeutralLamp(rightsideofsteering
console)willflash.

NOTE:Thetransmissioncontrolisunlikelytofail.Accesstothetransmissioncontrolandconnectorisdifficult.
Thistroubleshootingguideiswrittentominimizeaccessingthetransmissioncontrolandconnectorasmuchas
possible.

NOTE:AvoidremovingtheTOPoftherightsideconsole.ItiseasytoremovebutDIFFICULTtoinstall.Ifyou
removethetoptakethetimetolabelthenine(9)connectorsthatmustberemovedfromtheswitchestogain
accesstothetransmissioncontrol.

TroubleshootingProcedures
Thefollowingproceduresmaycausenewfaultstobecreated.

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NOTE:Duringtroubleshooting,inspectallcomponentandharnessconnectionsbeforeanycomponentis
replaced.Iftheseconnectionsarenotcleanandtighttheycancauseelectricalproblems,eitherpermanentor
intermittent(comeandgo).Checkthatthewiresarepushedintotheconnectorscompletely.Makesurethe
connectionsaretightbeforeothertestsaremade.

Symptom(ElectricalSystemVoltage)
Thecontrolmoduleisnotabletodiagnoseproblemswiththeelectricalsystemvoltage.Systemundervoltages
willresultinintermittentoperationasthevoltagedropsbelowthesolenoidpullinorholdinvoltage.

1.CHECKBATTERYVOLTAGEStarttheengineandrunathighidleforseveralminutes.Measurethe
batteryvoltageatthebatteryposts.

*Voltageisatorabove12DCVbatteryvoltageiscorrect.GotoStep2.
*Voltageisbelow12DCVthechargingsystemisnotcorrect.Checkthechargingsystem.

2.CHECKSYSTEMVOLTAGEATCONTROLNOTE:Accesstothetransmissioncontrolisdifficult.(The
frontoftherightsideconsolemustberemovedandtheharnessconnectormustberemoved).

NOTE:Theeasiestwaytomeasurethesystemvoltageisbyremovingtheconnectorfromthetransmission
controlandmeasuringbetweencontacts1and3oftheharnessconnectorwiththekeystartswitchintheON
position.

*Voltageisbelow12DCVharnessisnotcorrect.Repairorreplacetheharness.
*Voltageisatorabove12DCVsystemvoltageiscorrect.Disconnectthecontrolharnessconnectorand
inspectcontacts1and3.Connectharnessconnectortothecontrol.Ifsystemisstillnotworkingreplace
control.SeeControlReplacementsectioninthisbook.

Symptom(EngineWillNotCrank)NeutralLampON.

Enginewillnotcrankwhenthekeystartswitchisinthestartposition.

1.CHECKFNRSWITCHMakesuretheFNRswitchisintheNeutralpositionandthatNeutralLampinON.

*Engineshouldcrank.
*Ifenginedoesnotcrank.GotoStep2.

2.CHECKSTARTRELAYThekeystartswitchappliesbatteryvoltagetothetransmissioncontrol(connector
contact62)wheninthestartposition.ThekeystartswitchINPUTisreadbythecontrolandthestartrelay
OUTPUTisenergized(connectorcontact64).

*Thevoltageisatorabove10DCVonwire306WHonthestartrelaywiththekeystartswitchinthe
STARTposition.ThetransmissioncontrolisOKandthekeystartswitchisOK.GotoStep3.
*Thevoltageisbelow10DCVonwire306WHonthestartrelaywiththekeystartswitchintheSTART
position.GotoStep4.

3.CHECKSTARTRELAYOPERATIONMakesuretheinputwire(109RD)isatorabove10DCVwiththe
keystartswitchintheONposition.Measurethevoltageonthe304WHwire.Itshouldbeatorabove10DCV
withthekeystartswitchintheSTARTposition.Ifnotreplacetherelay.

4.CHECKGROUNDANDHARNESSCONNECTIONSInspectthegroundstudslocatednearthewasher
bottlesonthefrontANDtherearofthecab.Alsocheckthegroundstrap(locatedinfrontofthebattery)from
thecabtotheframerail.Inspectthewiresandmakesurethegroundsarereliable.Checkharnessconnections.
Repairorreplaceharness.

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*Ifvoltageisatorabove10DCVengineshouldcrank.ThestartrelayisNOTthesourceofproblem.
*Ifvoltageisbelow10DCVon306GN.GotoStep5.

5.CHECKKEYSTARTSWITCHCheckkeystartswitchforproperoperation.Repairorreplacetheswitch.
NOTE:Accesstothekeystartswitchisdifficult.(Thefrontoftherightsideconsolemustberemovedand
measurementstakenfromthekeystartswitchareverydifficult).

Symptom(EngineWillNotCrank)NeutralLampFLASHING.
Enginewillnotcrankwhenthekeystartswitchisinthestartposition.

1.CHECKFNRSWITCHMakesuretheFNRswitchisintheNeutralpositionandthatNeutralLampinON.

*Engineshouldcrank.
*Ifneutrallampisflashing.GotoStep2.

2.FNRSWITCHTESTTransmissioncontrolmusthaveavalidneutralsignal(connectorcontact58)to
groundtoenergizestartrelay.RemovefrontofrightconsoleseeConsoleRemovalsectioninthisbook.Thefour
pinconnectortotheFNRswitchislocatedinthefrontoftheconsole(seephoto).

FNRSwitch

(1)ConnectorLocation

(2)TransmissionControlConnector(ShownwithConsolecoverRemoved)

DisconnecttheFNRswitchconnector.Usethefollowingcharttocheckthestatusofeachinputforallthree
switchpositions.

*IfFNRswitchoperationiscorrectgotoStep3.
*IfFNRswitchoperationisNOTcorrect.ReplaceFNRswitch.

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3.TurnthekeystartswitchtotheONposition.DoNOTstarttheengine.Measurevoltagesonharnesssideof
theconnectorbetweencontacts1,2,3,andcontact4.

DisconnecttheFNRswitchconnector.Usethefollowingcharttocheckthestatusofeachoutput.

*Operationiscorrect.Theharnessandthetransmissioncontrolarecorrect.
*OperationisNOTcorrect.Repairorreplacetheharness.Ifthisdoesnotsolvetheproblemreplacethe
control.SeeControlReplacementsectioninthisbook.

Symptom(WillNOTGoIntoGear)NeutralLampFlashing.
ThetransmissioncontrolwillNOTengagethedirectionsolenoidsiftheparkingbrakeisENGAGED.Whenthe
parkingbrakeinput(connectorcontact42)isopentheparkingbrakeisENGAGED.Whentheparkingbrake
input(connectorcontact42)isgroundedtheparkingbrakeisDISENGAGED.

1.CHECKPARKINGBRAKEChecktoseeiftheparkingbrakeisDISENGAGEDandtheparkingbrake
lampisON.

*Checkswitchadjustment.Removeparkingbrakecovertogainaccesstoparkingbrakeswitch.With
parkingbrakeDISENGAGED.Measurevoltagebetweenthenormallyopen(NO)pin(765BR)andthe
commonpin(201BK).Voltageshouldbe0V.
*Ifoperationiscorrect(parkingbrakelampgoesOFF)thetransmissioncontrolandharnessarecorrect.
Theparkingbrakeswitchisnotthesourceoftheproblem.
*IfoperationisNOTcorrect.GotoStep2.

2.Reapplyparkingbrake.Measurevoltagebetweenthenormallyopen(NO)pin(765BR)andthecommonpin
(201BK).Voltageshouldmeasure9.5V0.5.

*Ifoperationiscorrectthetransmissioncontrol,parkingbrakeswitch,andharnessarecorrect.The
parkingbrakeswitchisnotthesourceoftheproblem.
*IfoperationisNOTcorrect.GotoStep3.

3.Checkparkingbrakeswitchoperation.

*Ifoperationiscorrectthetransmissioncontrol,parkingbrakeswitch,andharnessarecorrect.The
parkingbrakeswitchisnotthesourceoftheproblem.GotoStep4.
*IfoperationisNOTcorrect.Repairorreplaceswitch.Repairorreplaceharness.Repairorreplace
ground.

4.CHECKFNRSWITCHSeeFNRswitchtestchartslocatedearlierinthistext.

*Ifoperationiscorrect.GotoStep5.
*IfoperationisNOTcorrect.ReplaceFNRswitch.

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5.CHECKDIRECTIONSOLENOIDSDisconnectthedirectionsolenoidconnector.Thereisonefourpin
connectorforbothsolenoids.Thesolenoidsarelocatedonthehystatpumpbody.Measurethevoltage(onthe
harness)betweenpins1and2(Forward).Thevoltageshouldbe4.5V0.5.Measurethevoltage(ontheharness)
betweenpins3and4(Reverse).Thevoltageshouldbe4.5V0.5.

*Ifthevoltageiscorrect.GotoStep6.
*IfthevoltageisNOTcorrect.Repairorreplacetheharness.SeeStep7.

6.CHECKDIRECTIONSOLENOIDRESISTANCEMeasurebetweenpins1and2(Forward).Theresistance
shouldbe52ohms.Measurebetweenpins3and4(Reverse).Theresistanceshouldbe52ohms.

*Ifresistanceiscorrect.GotoStep7.
*IfresistanceisNOTcorrect.Replacetheappropriatedirectionsolenoid.

7.NOTE:IftheFNRindicatorlampsthatlightupthedirectionarrowsandneutrallamp(locatedontheright
sideofthedash)areshortedtoground.Thecontrolmaythinkthedirectionsolenoidsareshorted.Theselamps
areinparallelwiththesolenoids.Thechanceofthisoccurringisveryrare.Thisshortwouldhavetosinkin
excessof4.5A.ThishasNOToccurredintestingorinthefield.

Symptom(SystemWorkingProperlyButIndicatorLampsNOTWorkingProperly)Lamp
GroupFunction(FNRandFlashingNeutral)
1.DisconnectharnessfromLampGroupFunctionmodule.

PlaceFNRswitchinForward.Measurevoltagebetweenpin6(E801OR)andchassisground.Voltageshouldbe
greaterthan10DCV.

PlaceFNRswitchinNeutral.Measurevoltagebetweenpin5(330YL)andchassisground.Voltageshouldbe
greaterthan10DCV.

PlaceFNRswitchinReverse.Measurevoltagebetweenpin8(E802YL)andchassisground.Voltageshouldbe
greaterthan10DCV.

*Ifoperationiscorrect.GotoStep2.
*IfoperationisNOTcorrect.Repairorreplaceharness.

2.CHECKLAMPGROUPFUNCTIONMODULEGROUNDRepairorreplacegroundtomoduleconnector.

*Ifoperationiscorrect.Indicatorlampsarestillnotworkingproperly.ReplaceLampGroupFunction
module.
*IfoperationisNOTcorrect.Repairorreplaceground.

Procedure(ReverseMotorSolenoid)

TheReverse2outputhasnodiagnosticsontheoutputsexceptovercurrentdetectiontoprotecttheelectronic
controlmodule.

OpencircuitsandshortstogroundontheReverse2output(connectorcontact13)willcausethebackupalarm
andreversemotorsolenoidtoNOTbeenergizedwhentheFNRswitchisinthereverseposition.

Shortstobatteryontheoutputline(connectorcontact13)willresultinthebackupalarmandreversemotor
solenoidbeingcontinuallyenergized.

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1.CHECKSOLENOIDTurnthekeystartswitchtotheOFFposition.Disconnectthereversemotorsolenoid
fromthemachineharness.(ThisconnectorisfourcontactsandalsohaswiringfortheSpeedSelectorswitch
solenoid).TurnthekeystartswitchtotheONposition.(WithengineNOTrunning).PlacetheFNRswitchin
thereverse(R)position.Attheharnessconnectorforthesolenoid,measurethevoltagefromcontact1(751BU)
tocontact2(202BK).Voltageshouldbe10V0.5

*Ifoperationiscorrect.GotoStep2.
*IfoperationisNOTcorrect.Repairorreplaceharness.

2.CHECKSOLENOIDRESISTANCEMeasurebetweenpins1and2(ReverseMotor).Theresistanceshould
be52ohms.Measurebetweenpins3and4(SpeedSelector).Theresistanceshouldbe52ohms.

*Ifresistanceiscorrect.SeeControlReplacementsectioninthisbook.
*IfresistanceisNOTcorrect.Replacetheappropriatesolenoid.

Procedure(BackupAlarmRelay)
Thereisnodiagnosticsforthebackupalarmrelay.Thebackupalarmrelayisinparallelwiththereverse
directionsolenoid.WhenevertheFNRswitchisplacedinreverseitENGAGESthereversedirectionsolenoid
(connectorcontact13)andthebackupalarmrelay.

1.CHECKBACKUPALARMRELAYTheFNRswitchgroundsthereverseinput(connectorcontact47)of
thetransmissioncontrolwhenplacedinthereverseposition.

*Thevoltageisatorabove10DCVonwire751GNonthebackupalarmrelaywiththekeystartswitch
intheONpositionandFNRswitchisinthereverseposition.
*Ifoperationiscorrect.GotoStep2.
*IfoperationisNOTcorrect.GotoStep3.

2.CHECKGROUNDANDHARNESSCONNECTIONSInspectthewiresandmakesurethegroundsare
reliable.Checkharnessconnections.Repairorreplaceharness.IfstillNOTcorrect.GotoStep3.

3.CHECKBACKUPALARMRELAYOPERATIONMakesuretheinputwire(120YL)isatorabove10
DCVwiththekeystartswitchintheONposition.Measurethevoltageonthe321BRwire.Itshouldbeator
above10DCVwiththekeystartswitchintheONpositionandtheFNRswitchinthereverseposition.

*Ifoperationiscorrectthebackupalarmrelayisnotthesourceoftheproblem.GotoStep4.
*IfoperationisNOTcorrect.Replacetherelay.

4.CHECKBACKUPALARMTestthebackupalarmrelayforproperoperation.Iffaultyreplacebackup
alarm.

ControlReplacement
Priortoreplacementofthecontrol,ensurethatreplacementisabsolutelynecessary.Rarelyisthecontrolthe
causeofafault.Alwayscheckthatbatteryvoltageisavailabletothecontrolbatteryvoltageisrequiredbetween
controlconnectorcontacts1and3ofthemachineharness.

Procedure

1.TurnthekeyswitchtotheOFFposition.Disconnectthemachineharnessfromthecontrol.

2.Removethecontrol.

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3.Makesurethereplacementcontrolhasthecorrectpartnumber.

4.Connectthemachineharnesstothecontrol.

5.Installthereplacementcontrol.

6.TurnthedisconnectandkeyswitchestotheONposition.

ConsoleAccessRightSide
Priortoextensivetroubleshootingofthetransmissioncontrolitmaybenecessarytoremovethefrontofthe
rightsideconsole.

Procedure

1.Removefusepanelcover.

2.RemovethetwoPhillipsheadscrewsthatwerecoveredbythefusepanelcover.

PhillipsHeadScrews

3.Removethearmrestfromtheconsole.

(1)AllenScrew

4.RemovethelargePhillipsheadscrewthatwascoveredbythearmrest.

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Phillipsheadscrew

5.Removethefrontconsolecover.

GlossaryOfTerms
+Battery
+Batteryreferstoanyoftheharnesswiringwhichispartofthecircuitthatconnectstothepositivebattery
post.
+V
+Visaconstantvoltagethatissuppliedtoacomponenttoprovideelectricalpowerforitsoperation.+V
isprovidedbyanelectroniccontrolmoduleorthebattery.
Abnormal
Abnormalreferstoamachineconditionorsignalthatisnotnormal.Thepresenceofanabnormal
conditionorsignalmeansaproblemexistsandwarningoperationisactivatedwhichnotifiestheoperator.
ConnectorContact
Aconnectorcontactisthecomponentofaharnessconnectorthatactuallymakestheelectricalconnection.
Connectorcontactsareeitherpinsorsockets.
Diagnostic
Diagnosticreferstotheshowing,monitoringand/orrecordingofinformationotherthannormal.
Fault
Afaultisafailureofacomponentofthesystem.Forexampleopenorshortedharness,faultyswitch,
sensororcontrol.
HardWired
Hardwiredreferstoelectricalconnectionsmadewithintheharnessthatarepermanent.Thesesolderedor
crimpedconnectionsarenotmeanttobealtered.
Jumper
Ajumperisapieceofwireusedtomakeanelectricalconnectionduringtroubleshooting.
SignalWire
Thesignalwireistheharnesswirewhichconnectsthesensororswitchtothecontroloracontroloutput
toanotherelectronicdevice.
SwitchInput
Aswitchinputisanyinputofthecontrolwhichisexpectingonlyanopen(floating)orgroundedsignal.
SystemVoltage
Systemvoltageistheactualvoltagethatexistsbetweenthepositivebatterypostandframeground.
Systemvoltageisalsoreferredtoas+batteryvoltage.
N/C
NormallyClosed.
N/O
NormallyOpen.

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ElectronicTransmissionControlSystemSchematic

Copyright19932017CaterpillarInc.
Todoslosderechosreservados.
WedMar29201723:59:58GMT0300(HoraveranoSudamricaPacfico)
r120fitafta
RedprivadaparalicenciadosdelSIS.

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