CAT 16H service manual

8/18/2019 CAT 16H service manual

1/112

RENR5740-05

November 2003

Systems OperationTroubleshooting

Testing and Adjusting120H, 12H, 135H, 140H, 143H, 14H,160H, 163H and 16H Motor GradersCaterpillar 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)


2/112

i01658146

Important Safety InformationMost accidents that involve product operation, maintenance and repair are caused by failure to observebasic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardoussituations before an accident occurs. A person must be alert to potential hazards. This person should alsohave the necessary training, skills and tools to perform these functions properly.

Improper operation, lubrication, maintenance or repair of this product can be dangerous andcould result in injury or death.

Do not operate or perform any lubrication, maintenance or repair on this product, until you haveread 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 warningsare 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 pictoriallypresented.

Operations that may cause product damage are identified by “NOTICE” labels on the product and inthis 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 thatthe 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 thatwas 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 canaffect the service that is given to the product. Obtain the complete and most current information before youstart any job. Caterpillar dealers have the most current information available.

When replacement parts are required for thisproduct Caterpillar recommends using Caterpil-lar replacement parts or parts with equivalentspecifications including, but not limited to, phys-ical dimensions, type, strength and material.

Failure to heed this warning can lead to prema-ture failures, product damage, personal injury or death.


3/112

3Table of Contents

Table of Contents

Systems Operation Section

General Information ................................................ 4Modes of Operation ................................................ 8Normal Mode .......................................................... 9Service Meter Mode .............................................. 10Odometer Mode ..................................................... 11Tachometer Mode .................................................. 11Scrolling Mode ....................................................... 11Harness Code Mode ............................................. 12Numeric Readout Mode ........................................ 12

Additional Operator Modes ................................... 13Service Mode ........................................................ 14Tattletale Mode ..................................................... 16Units Mode ............................................................ 18Setup Mode .......................................................... 18Calibration Mode ................................................... 18

Articulation Gauge Calibration Mode .................... 22Warning Operation ................................................ 24 Alert Indicator Description ..................................... 25Component Description ........................................ 27Main Display Module ............................................ 27Display Components ............................................. 31Quad Gauge Module ............................................ 31Speedometer/Tachometer Module ........................ 32Switches ............................................................... 32Senders ................................................................ 33Sensors ................................................................. 34

Action Lamp .......................................................... 36 Action Alarm ......................................................... 36Related Components ............................................ 37

Troubleshooting Section

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

Diagnostic Code ProceduresDiagnostic Code List ............................................. 44Using Caterpillar Monitoring System to Determine

Diagnostic Codes ................................................ 45Using Caterpillar Electronic Technician to Determine

Diagnostic Codes ................................................ 46MID 030 - CID 0084 - FMI 08 ............................... 48MID 030 - CID 0096 - FMI 03 ............................... 50MID 030 - CID 0096 - FMI 04 ............................... 51MID 030 - CID 0096 - FMI 08 ............................... 52MID 030 - CID 0248 - FMI 02 ............................... 52MID 030 - CID 0263 - FMI 03 ............................... 54MID 030 - CID 0263 - FMI 04 ............................... 55MID 030 - CID 0271 - FMI 03 ............................... 56MID 030 - CID 0271 - FMI 05 ............................... 57MID 030 - CID 0271 - FMI 06 ............................... 58MID 030 - CID 0324 - FMI 03 ............................... 59MID 030 - CID 0324 - FMI 05 ............................... 60MID 030 - CID 0324 - FMI 06 ............................... 61

MID 030 - CID 0601 - FMI 08 ............................... 62MID 030 - CID 0615 - FMI 03 ............................... 62MID 030 - CID 0615 - FMI 04 ............................... 64MID 030 - CID 0819 - FMI 02 ............................... 65MID 030 - CID 0821 - FMI 03 ............................... 68MID 030 - CID 0821 - FMI 04 ............................... 69

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

Testing and Adjusting Section

Testing and AdjustingSystem Self Test ................................................... 94Wiring Harness (Open Circuit) - Test .................... 94Wiring Harness (Short Circuit) - Test .................... 95Wiring Harness (Short Circuit) - Test .................... 96Electrical Connector - Inspect ............................... 96Module - Replace .................................................. 97Main Display Module Initialization - Adjust ........... 97Main Display Module - Flash Program .................. 98Glossary of Terms ................................................. 99Connector Contact Description of Main Display

Module ............................................................. 101System Schematic .............................................. 104

Index Section

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


4/112

4Systems Operation Section

Systems Operation Section

i01853880

General Information

SMCS Code: 7490

Introduction

g00944992Illustration 1

Caterpillar Monitoring System for the 140H, 143H, 160H and 163H

The quad gauge module and the speedometer/tachometer module are optional components.


5/112



Caterpillar Monitoring System for the 14H and 16H



6/112



Caterpillar Monitoring System for the 12H, 120H and 135H



7/112


g00789331

Illustration 4Typical Example

Caterpillar Monitoring System Display Components

(1) Quad gauge module(2) Speedometer/tachometer module(3) Main display module(4) Alert indicators(5) Gauges(6) Tachometer (7) Speed r eadout(8) Transmission gear readout(9) Display area

The Caterpillar Monitoring System is an electronicmonitoring system that continuously watches

machine systems. The system is a flexible modular monitoring system that includes the followingdevices: a main display module, various switchesand sensors, an action lamp, and an action alarm.The system may include a speedometer/tachometer module. A different number of quad gauge modulesmay be included in the system.

The main display module is the brain of the system.This module receives information from the switches,sensors and other electronic controls on the machinevia the CAT data link. The main display moduleprocesses all of the information. The module thenactivates various outputs. The outputs could be in thedisplay area of the main display module, the quad

gauge module, the speedometer/tachometer module,the action lamp, or the action alarm. The displaycomponents show the condition of the machinesystems. The operator can also obtain systemdiagnostic information.

The same monitoring system operates on a variety of different machines. All the possible system functionsare not performed on every machine. After the maindisplay module has been installed, the modulerecognizes the machine. The module will performonly the intended functions for that machine. Themain display module is required for the monitoringsystem to operate. The quad gauge module and

the speedometer/tachometer module may not beused on some machines. The maximum number of other modules that can be used with the main displaymodule at any one time is four. The modules thatcan be used are two quad gauge modules and twospeedometer/tachometer modules.

Main Display Module

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

• A six digit display area (9) is provided. Thedisplay shows the following modes: machineoperational hours (service meter), engine speed(tachometer), machine distance (odometer),and diagnostic codes. The information for thespeedometer/tachometer module, and any gaugeof the quad gauge module can also be shown as anumber on this readout. The display area containsseven unit indicators and a service indicator. Theoperator selects the information in order to beshown on the display area.

• Seven different unit indicators can be shown inthe display area. The unit indicators that can beshown are “°C”, “kPa”, “MILES”, “KM”, “RPM”,

“LITERS” and “HOURMETER” symbol. Theseindicators show the units of measurement for thedata on the six digit display area. The indicatorsare turned ON and OFF in order to correspond withthe information on the six digit display area.

• In order to indicate a current fault, a service codeindicator is used. The service code indicator is usedin service mode and diagnostic scrolling mode.

Speedometer/Tachometer Module

• One tachometer gauge (6) shows the informationon the engine speed (RPM).


8/112


• One three digit display area (7) shows theinformation on the ground speed. The speed isdisplayed in “MPH” and “km/h”.

• Information on the transmission gear and thedirection 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 thefollowing information: engine coolant temperature,articulation angle, system voltage, and fuel level.

According to the application, the type and thequantity of indications that are used in the displayareas varies. All of the indications are not used onthe machine. The quantity of quad gauge modulesand speedometer/tachometer modules may varywith each machine. An action lamp and an actionalarm indicate the severity (warning category) of aproblem. To determine the functions that are usedon a particular machine, see the correspondingOperation and Maintenance Manual.

i01962268

Modes of Operation

SMCS Code: 7490


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

The Caterpillar Monitoring System has many differentpossible modes of operation. The modes are operator modes and service modes. Each mode providesimportant information regarding the condition of the machine. Each mode also provides informationregarding the setup of the monitoring system. Allmodes are not available on all machines. The system

that is installed on the machine determines themodes that are available. All the modes are givennames and the modes are referenced in this manual.The mode is shown as a number on the display areaof the main display module. This number is assignedby the software in the main display module.

The operator modes are accessible by using theselector switch for the operator mode that is locatedin the operator’s compartment. The following tableshows the available modes. See the Operation andMaintenance Manual of the machine that is beingserviced for specific information on the operator mode.

When power is applied, the Caterpillar MonitoringSystem performs the self test. After the self test iscomplete the Caterpillar Monitoring System entersthe Normal Mode. Normal Mode is service mode 0.Normal Mode contains the operator modes. In order to enter the other service modes, the service andclear inputs must be grounded at the same time.

Access to the service and clear inputs is providedwith the service connector. The service connector islocated within the operator compartment. Informationon the location of the service connector is in theElectrical System Schematic for the machine that isbeing serviced.

When the service and clear inputs are grounded, theservice mode numbers scroll sequentially on the sixdigit display area of the main display module.

Note: When you are scrolling through the modes,mode 0 (Normal Mode) is not shown on the displayarea as a number. When you reach mode 0, thedisplay area begins showing the information for mode0 (Normal Mode).

When ground is removed from the service and clear inputs, the monitoring system enters the mode whichcorresponds to the number that is presently shown.

The following situation is an example. When you seethe mode number “- 1-” on the display, remove theground. This action causes the monitoring system toenter the Harness Code Mode.

Note: The monitoring system must finish performingthe self test before you ground the service and clear inputs in order to begin scrolling through the servicemodes.


9/112


Table 1

12H, 14H, 16H, 120H, 135H, 140H, 143H,160H And 163H

Operator Modes

Operator Mode Mode Number

Service Meter 0

Odometer 1

Digital Tachometer 2

Diagnostic Scrolling 3

Cumulative Fuel 4

Trip Machine Hours 5

Trip Odometer 6

Trip Fuel 7

Reset Trip Values 8

Table 2

12H, 14H, 16H, 120H, 135H, 140H, 143H,160H And 163H

Service Modes

Service Mode Mode Number

Harness Code 1

Parameter Display 2

Diagnostic Service 3

Tattletale 4

Digital Tattletale 4

Units 5

Calibration (Articulation Gauge) 6

Calibration (Transmission Control) 7

Calibration (Transmission Control) 8

Calibration (All Wheel Drive Control)(143H, 163H)

9 (1)

Setup 9

Setup (143H, 163H) 10

(1) This mode is not operational at this time. This mode is reservedfor future use.

i01856906

Normal Mode

SMCS Code: 7490


Caterpillar Monitoring System Display Components

(1) Quad gauge module(2) Speedometer/tachometer module(3) Main display module(4) Alert indicators(5) Gauges(6) Tachometer (7) Ground speed readout(8) Transmission gear readout(9) Display area

Normal mode is used during normal machineoperation. When you are in normal mode, theCaterpillar Monitoring System performs the followingoperations.

• A monitoring system that is operating properlywill perform a self test whenever the key switch isturned to the ON position. The outputs also operatefor a brief instant. See Testing and Adjusting,“System Self Test ”.


10/112


• The main display module continuously watchesmachine systems. If the gauges are available, thegauges in the quad gauge module show a valuein a normal range. Ground speed readout (7) isshown as a numeric value and the transmissiongear readout (8) on the module shows numericvalues. The value for a condition may also be

shown in the display area.

• The main display can show a problem with themachine. The main display module continuouslymonitors machine systems. When an abnormalcondition (problem) exists, the corresponding alertindicator (4) FLASHES. As the severity of theproblem increases, the action lamp FLASHES andthe action alarm SOUNDS. See System Operation,“Warning Operation”.

Note: The main display module may notify theoperator when a diagnostic code exists in other electronic systems. This is done in different ways.

The following example is of a diagnostic code thatoccurs in the engine electronic system. The servicecode indicator will show “SERV CODE” and thealert indicator for “check engine” FLASHES. See theOperation And Maintenance Manual for the machinethat is being serviced for more specific informationon the machine.

Operator Modes

Table 3

12H, 14H, 16H, 120H, 135H, 140H, 143H,160H And 163H

Operator Modes

Operator Mode Mode Number

Service Meter 0

Odometer 1

Digital Tachometer 2

Diagnostic Scrolling 3

Cumulative Fuel 4

Trip Machine Hours 5

Trip Odometer 6

Trip Fuel 7Reset Trip Values 8

The six digit display area (9) is used to show variousconditions of the machine system to the operator (Operator Modes). Operator modes that are availableto the operator are dependent to the monitoringsystem that is installed on the machine. The tableabove lists the operator modes by the machine.

The default condition is shown on the six digit displayarea when the main display module enters normalmode. 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 inputis grounded. Opening the switch input will stopthe scrolling on the currently shown mode. Modenumbers are not displayed when operator modes arescrolling.

See the topic with the corresponding name on thefollowing 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 moduleis not used. The following situation occurs in order to function as a gear readout. The six digit displayarea changes from the default condition to the gear readout when the parking brake is DISENGAGED.The symbol for the service meter turns OFF and theinformation on the transmission gear is shown on thesix digit display area.

The display area may also be used when ether isbeing injected with a flashing “E”. A flashing “P” inthe display area may be used when the engine isbeing prelubed. The following display modes are also

available: the load count, the engine oil pressure, andthe charge pressure. See the table for the MonitoringSystem Mode on the Electrical System Schematicin order to determine the mode number for thecorresponding machine.

i00971876

Service Meter Mode

SMCS Code: 7490


Display Area


11/112


The main display module keeps track of the totalnumber of engine hours. The total machine operatinghours are shown on the six digit display area whenyou are in service meter mode. The symbol for theservice meter is ON in order to indicate when thedisplay is functioning as a service meter. The value iscontinuously updated when the engine is operating.

The main display module monitors the followingelectrical inputs in order to determine when themachine engine is operating: the engine speed,terminal for alternator “R”, and the engine oilpressure. The main display module starts the servicemeter for the machine when one of these inputs isin the normal range.

i01461542

Odometer Mode

SMCS Code: 7490


Display Area

The total distance for the machine is displayed on thesix digit display area when the main display module

is in odometer mode. The indicator for the unitsshows “MILES” or “KM”. This depends on the settingfor units of measure of the main display module.The main display module receives information fromthe transmission output speed sensor from thetransmission electronic control module. This is doneby using the CAT data link. The unit of measurecan be set by using the units mode. See SystemsOperation, “Units Mode” for more information.

i01518524

Tachometer Mode

SMCS Code: 7490


Display Area

The engine RPM is shown on the six digit displayarea when the main display module is in tachometer mode. The indicator for the units shows “RPM”. Themain display module can calculate engine speed witha frequency sensor. The main display module mayalso 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


(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 anoperator to see diagnostic codes that were stored bythe main display module. The diagnostic code in thismode can not be cleared. The diagnostic code canalso not be placed on hold.

The diagnostic codes momentarily scroll on thedisplay area upon entering the scrolling mode. The

MID is shown first as each diagnostic code is shownfor about one second. The corresponding CID andthe corresponding FMI is shown second for abouttwo seconds. “End” appears when the last diagnosticcode has been shown. The diagnostic codes arethen shown. The display shows “- - -” when the maindisplay module has no diagnostic codes.

The “SERV CODE” functions as a diagnostic presentindicator in scrolling mode. The diagnostic that hascaused a diagnostic code to be shown currently ispresent when “SERV CODE” is ON. “SERV CODE”is OFF when the fault is not present, but the fault haspreviously occurred.


12/112


i01996543

Harness Code Mode

SMCS Code: 7490


Display Area

Harness code mode is always mode 1. The machinecode is shown on the six digit display area when themain display module is in harness code mode. Themachine code must correspond with the monitoringsystem that is installed on the machine sales model.

See the following table for Machine Codes. Themachine code is a two-digit representation of theharness code. An incorrect harness code is one thatdoes not match the machine. Incorrect operation of the monitoring system will be caused by an erroneousharness code. Excessive diagnostic service codescould be recorded as a result of this situation.

Table 4

Machine Codes

Sales Model Machine Code

14H 14

140H 40

143H 43

160H 60

163H 63

120H 20

135H 35

12H 12

16H 16

Some machines do not utilize a harness code plug.This can be verified with the electrical schematicfor the machine. If the machine does not utilizea harness code plug, then the machine does nothave a harness code. However, the machines thatdo not have a harness code will also display amachine code in harness code mode. The machine

code does not represent the harness code in thiscase. The machine code represents the monitoringsystem configuration code. The monitoring systemconfiguration code is configured in the software for the ECM with Caterpillar ET. The monitoring systemconfiguration code is the numeric number in the salesmodel of the machine. For example, the monitoringsystem configuration code for a 160H is 160.

i01804895

Numeric Readout Mode

SMCS Code: 7490


Display Area

Numeric readout mode is always mode 2. Numericreadout mode assists service personnel with

troubleshooting of sensor inputs. The inputs supplyinformation for the gauges in the quad gaugemodules. Numeric readout mode more accuratelyshows the same information that is shown on thegauges in normal mode. The system identifier andthe numeric value for the system scrolls on the sixdigit display area. The system identifier identifies thesystem that is currently shown on the six digit displayarea. See table 5 for “System Identification” andillustration 13 in order to match the system identifier to the appropriate gauge.


13/112



Quad gauge modules


This is an illustration of the display area on the Main DisplayModule that is showing an example of a system identifier.

Table 5

System Identification

System Identifier Gauge (System)

GA-1 1

GA-2 2

GA-3 3

GA-4 4

Table 6

UnitsCondition Units of Measurement

Temperature °C

Angle °

Voltage 0.1 volts

Level % full

In addition to the table and the illustration, only thegauge for the system that is shown on the six digitdisplay area is operational. All other gauges in thequad gauge modules are shut off. The gauge needles

will move to the far left position.

When you enter the numeric readout mode, the sixdigit display area is showing information for systemGA-1. The display momentarily shows the systemidentifier. The display then shows the value for thecorresponding system on the six digit display area.Grounding the service input causes all the systemsto scroll on the display. This will show the system

identifiers. Removing ground from the service inputstops the scrolling, when the desired system isshown. The six digit display area continues to showthe system identifier momentarily. The six digitdisplay area then shows the value of the system. Thesystem is now shown on hold. While the system is onhold, the numeric value of the system is continuouslyupdated.

i01525238

Additional Operator Modes

SMCS Code: 7490

Trip Hourmeter Mode


Display Ar ea

The main display module keeps track of the triphourmeter . The trip hourmeter will accumulatemachine distance based upon the vehicle speed thatis received from the transmission ECM. The totaltrip hour meter is shown on the six digit display areawhen you are in trip hourmeter mode. The symbol for the trip hourmeter is ON in order to indicate when thedisplay is functioning as a trip hourmeter. The value iscontinuously updated when the engine is operating.

The main display module monitors the followingelectrical inputs in order to determine when themachine engine is operating: the engine speed,

terminal for alternator “R”, and the engine oilpressure. The main display module starts the triphourmeter for the machine when one of these inputsis in the normal range.


14/112


Trip Odometer Mode


Display Area

The total distance for the machine is displayed on thesix digit display area when the main display moduleis in trip odometer mode. The indicator for the unitsshows “MILES” or “KM”. This depends on the settingfor units of measure of the main display module. Themain display module receives information from thefrequency sensor from the transmission ECM. This isdone by using the CAT data link. The unit of measure

can be set by using the units mode. See SystemsOperation, “Units Mode” for more information.

Trip Fuel Consumption Mode


Display Area

The fuel level is shown on the six digit display areawhen the main display module is in fuel level mode.The display will show “% full”, and no unit indicatorsare illuminated. The main display module calculatesfuel level from a resistive sender, which is directlyconnected to the main display module.

i01520209

Service Mode

SMCS Code: 7490


Diagnostic Example

(1) First display. (2) Second display. (3) Module identifier (MID). (4)Service code indicator (“SERV CODE”). (5) Component identifier (CID). (6) Failure Mode identifier (FMI).

Service mode is mode 3. The main display moduledetects faults that occur with sensor inputs, sender inputs, and main display module outputs while

the main display module is in normal mode. Thesignal is at the contact of the main display module.

A diagnostic code is detected when the signal isoutside a valid range. The main display module thenrecords the diagnostic code. The diagnostic coderemains stored for future reference when the faultis not present.

The main display module detects faults and the maindisplay module diagnoses faults in the followingcircuits:

• Display output modules

• Action alarm output

• Action lamp output

• Sensor input

• Harness code

Note: The main display module does not detectswitch input faults.


15/112


Service personnel can see the diagnostic codes andservice personnel can troubleshoot the diagnosticcodes when the main display module has detecteda fault. All detected faults are shown in the displayarea as a diagnostic code. The diagnostic codes canbe placed on hold and the diagnostic codes can becleared while the main display module is in service

mode.

Note: Diagnostic codes from other machine systemsunder electronic control are shown in the displayarea of the main display module when the maindisplay module is in Service Mode. The CAT datalink allows the transfer of diagnostic information fromother electronic control modules to the main displaymodule. This diagnostic information is then shownwhen the main display module is in service mode.The diagnostic code for faults from other electroniccontrol modules has a MID that is unique to thecontrol. These diagnostic codes can scroll similarly tothe diagnostic codes from the Caterpillar Monitoring

System. See the following description of ModuleIdentifier (MID).

The diagnostics of the Caterpillar Monitoring Systemare available to assist with the troubleshooting of diagnostic codes when the main display module isplaced in service mode. A diagnostic code is usedto specify each fault. The diagnostic code is madeup of three identifiers (MID, CID and FMI). Theseidentifiers are shown in the display area. The displayarea continuously changes between the followingidentifiers 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 MIDis shown for approximately one second before thediagnostic code that is shown in the same area. Theelectronic control module that has diagnosed thediagnostic code is logged by the MID. The followingexamples are of some MID.

Caterpillar Monitoring System ...................... 030Engine Control (ADEM) ................................ 036Power Train Electronic Control System ........ 081

All Wheel Drive Electronic Control System ... 075

See the table for the Module Identifier (MID) onthe Electrical System Schematic for the machine

that is being serviced for the most complete list.To troubleshoot diagnostic codes, use the servicemanual for the control that detected the code.

Component Identifier (CID) – The components thatare faulty are noted by the CID. These componentsare examples: transmission oil temperature sensor,speed sensor, action lamp, and boost pressuresensor. The CID is a four digit code that is shown onthe six digit display area. The CID and the FMI areshown 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 alist of CID codes for the main display module.

Failure Mode Identifier (FMI) – The FMI tells thetype of failure that has occurred. The followingsituations are examples: voltage above normal,current below normal, and abnormal frequency.The FMI is a two digit code that is shown on thesix digit display area. The CID and the FMI areshown after the MID is displayed. The CID and theFMI are separated by a decimal point “.”. See thetable “Diagnostic Codes For Caterpillar Monitoring

System” in Testing And Adjusting, “TroubleshootingDiagnostic Codes”. This table will show a list of failuremode identifiers for the main display module.

When the main display module enters the servicemode, the MID, the CID, and the FMI are shown. Atthis time, the diagnostic code that is shown is on hold.The display area continuously changes betweenthe following identifiers when the diagnostic code ison hold: MID, CID, and FMI. This is maintained aslong as the service and clear inputs remain open.Troubleshooting is performed while the diagnosticcode is on hold.

Note: The display shows “- - -” when the main displaymodule has no diagnostic codes.

All diagnostic codes are shown one at a time inthe display area when the diagnostic codes arescrolling. Grounding the service input causes thedisplay to scroll when the main display module isin service mode. This will momentarily show theMID. The display will show the CID and the FMI thatcorresponds. Removing ground from the serviceinput stops the scrolling when the diagnostic codethat is desired is shown. The diagnostic code thatis shown is now on hold.

Note: The diagnostic codes from other electroniccontrol modules can be shown on the display. Usethe same procedure in order to place the diagnosticcodes on hold.


16/112


Diagnostics are provided in order to assist servicepersonnel during troubleshooting of intermittentfaults. The service code indicator “SERV CODE” isshown when the diagnostic code is present. Thiscan aid in troubleshooting of intermittent faults. Theservice code indicator changes from “SERV CODE”that is OFF to “SERV CODE” that is ON. This will

occur when the fault changes status. The actionalarm SOUNDS briefly during the change of statuswhen the diagnostic code is on hold for a fault.These diagnostics signal the service personnel whileinspections are performed. These diagnostics assistin troubleshooting intermittent faults by one serviceperson.

A diagnostic code is removed from the memory of the main display module when the diagnostic codehas been cleared. When a fault is corrected, it isnecessary to remove the corresponding diagnosticcode from the memory of the main display module.In order to remove the diagnostic code from the

memory, place the diagnostic code on hold andground the clear input. The memory of the maindisplay module saves a diagnostic code until thecode is cleared. The main display module does notallow clearing of a diagnostic code that correspondsto a fault which is present.

Note: The diagnostic codes from other electroniccontrol modules should be cleared by using the maindisplay module.


Diagnostic Example

(1) First display. (2) Second display. (3) Module identifier (MID). (4)Service code indicator (“SERV CODE”). (5) Component identifier (CID). (6) Failure Mode identifier (FMI).

Brief Explanation

Illustration 19 shows a main display module that iscurrently receiving a signal. This signal is from thetransmission oil temperature sensor and the signalis out of range.

Detailed Explanation

MID (3) – “030”. This code concerns the Caterpillar Monitoring System. The Caterpillar MonitoringSystem service manual should be used totroubleshoot the diagnostic code. If the MID that wasshown was “081”, the diagnostic code would concernthe power train electronic control. The service modulefor the power train electronic control should be usedto troubleshoot the diagnostic code.

CID (5) – “0110”. This code means that a fault hasoccurred in the sensor circuit for the engine coolanttemperature of MID “030”. See the table for DetectedFaults in Testing And Adjusting, “TroubleshootingDiagnostic Codes”. This will show a list of CID codes

for the Caterpillar Monitoring System.

FMI (6) – “08”. This identifier means that a signalof abnormal frequency, pulse width or period isbeing received concerning CID “0110”. See thetable for Detected Faults in Testing And Adjusting,“Troubleshooting Diagnostic Codes”. This table willshow a list of FMI codes for the Caterpillar MonitoringSystem.

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 faultpresent indicator. Therefore, the CID “0110” fault is

present. The service code indicator changes from ONto 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 whilethe main display module is in service mode.

i01520269

Tattletale Mode

SMCS Code: 7490


Display Area


17/112


g00789331

Illustration 21Caterpillar Monitoring System Display Components

(1) Quad gauge module(2) Speedometer/tachometer module(3) Main display module(4) Alert indicators(5) Gauges(6) Tachometer (7) Speed readout(8) Transmission gear readout(9) Display area

Tattletale Mode is a tool for management andmaintenance. The history of the machine can berecorded by this mode. The main display module

records the extreme value for each condition of themachine that is monitored. The values come fromsensor inputs, switch inputs and the CAT data link.The values in tattletale mode are updated whenever a value occurs with more importance than theprevious value. These values are ignored for a shortperiod of time after each start-up. This allows themachine systems to stabilize before the recordingof information.

Gauges (5) show the highest reading or lowestreading that has been attained by the correspondingmachine system. The gauges show the highestreading for systems with increasing abnormalvalues. The gauges also show the lowest readingfor systems with decreasing abnormal values. Thegauge alternates between the highest reading and

lowest reading. This will occur for the gauges thatare double ended.

Tachometer (6) and speed readout (7) show thehighest reading that has been obtained.

Alert indicators (4) turn on when an abnormalcondition has existed.

Information from the tattletale is retained until theinformation is cleared. Grounding the clear inputerases the information. After clearing, all informationis reset to a nominal value and the recording of newextreme values begins.

Note: The date, time or duration of the extreme valuethat has occurred is not recorded.

Example

This example explains the information that is shownin the illustration for the Tattletale Mode.

• Gauge (5) for the engine coolant temperature hasa pointer that indicates a value above the normaltemperature range. Therefore, a high abnormalvalue has existed in this system.

• Gauge (5) for the battery charge level has a pointer that indicates a value below or a value above thenormal battery charge range. Therefore, a lowabnormal value or a high abnormal value hasexisted 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 hasexisted in these systems.

• Gauge (5) for the fuel level has a pointer thatindicates a level of 50%. Therefore, the highestamount of fuel that has existed is 50%.

• The pointer on tachometer (6) indicates amaximum value (2100 RPM). Therefore, an enginespeed of 2100 rpm has existed.

• Speed readout (7) shows “13 MPH”. Therefore, 13MPH is the highest ground speed that has beenattained.

• Alert indicator (4) is ON. Therefore, an abnormalcondition has existed in this system.

• All other alert indicators (4) are OFF. Therefore, noabnormal values have existed in these systems.


18/112


Note: No information from the tattletale mode isstored for the highest transmission gear or lowesttransmission gear that has been selected.

i01041208

Units Mode

SMCS Code: 7490


Caterpillar Monitoring System

(1) Speedometer/tachometer module. (2) Main display module. (3)Odometer units. (4) Speed readout. (5) Speedometer units. (6)Display area. (7) Six digit display area.

The units mode is mode 5. The units mode is used totoggle the displays of the monitoring system betweenUS and Metric units of measure. When the maindisplay module enters units mode, six digit displayarea (7) shows the current setting. The display reads“US” when the mode is set to US units. The displayreads “SI” when the mode is set to Metric units.

When the units mode is set to US units, the maindisplay module shows “MILES” on display area (6)when the main display module is in odometer mode.The display for the speedometer/tachometer moduleshows “MPH”. The display area (6) shows “KM”when the main display module is set to Metric units.The display for the speedometer/tachometer moduleshows “km/h”.

In order to toggle the units, ground the clear inputwhile the service input is open. The units continuouslytoggle when the clear input is grounded. Openingboth of the inputs will set the main display module tothe currently displayed setting.

i01963289

Setup Mode

SMCS Code: 7490


Display Area

Setup Mode is mode 9 on all of the motor gradersexcept the 143H and the 163H. Setup Mode ismode 10 on the 143H and the 163H. This modeis used in order to configure the installation statusof the speedometer/tachometer module. If thespeedometer/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 “t1NO”. In order to change the status of the module,ground the clear input for two seconds. If multiplespeedometer/tachometer modules are present on

the machine, grounding the service input for twoseconds will display the status of the next module.For example, the display may read “t2 YES”. Thedisplay will read “END” once you have scrolledthrough all of the modules. Grounding the serviceinput for two seconds will start scrolling through thestatus of the modules again from the first module.

i01963535

Calibration Mode

SMCS Code: 7490

Calibration Mode 7 and Calibration Mode 8 areassociated with the power train ECM. CalibrationMode 7 and Calibration Mode 8 are identical. Bothmodes contain the same submodes and perform thesame calibrations. Calibration Mode is used on somemachines in order to perform special functions of calibration. The operation of the Calibration Mode willvary depending on the machine and the system thatis being calibrated. The Service Manual Module for the controls that require the Calibration Mode shouldbe used in order to determine the operation.


19/112


Submodes

Calibration Mode 7 and Calibration Mode 8 includesubmodes in order to extend the diagnosticcapabilities. After you have entered mode 7 or mode8, use the service switch in order to scroll throughthe submodes.

Submode 7.29 / 8.29 (Calibration Of TheInching Pedal Position Sensor )

This procedure allows the calibration of the travellimits of the inching pedal position sensor. The inchingpedal must be calibrated if any of the conditions thatare 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 beenreplaced.

• The linkage for the inching pedal has beenadjusted.

1. Connect the 4C-8195 Control Service Tool to theservice tool connector.

2. Use the 4C-8195 Control Service Tool in order to enter the “Power Train Calibration” Mode (7)via the “MODE” switch. Then use the “SCROLL”

switch to enter submode number 29.

3. Ensure that the inching pedal is not pressed. Usethe “INCREMENT (+)” position of the “CLEAR”switch to start the calibration. The display on the4C-8195 Control Service Tool will change to“C01”.

4. Press and hold the inching pedal to the down limit.Select “INCREMENT (+)” position of the “CLEAR”switch. The display on the 4C-8195 ControlService Tool will change to “C02”.

5. Release the inching pedal. Select the

“INCREMENT (+)” position of the “CLEAR”switch. The display on the 4C-8195 ControlService Tool will change to “---” if the calibrationwas successful. If an error occurred during thecalibration, The display on the 4C-8195 ControlService Tool will change to “Exx”. The “xx” is oneof 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.

E04 – The calibration value is too small.

The error codes indicate that the inching pedalposition sensor may be adjusted improperly.Perform the Testing and Adjusting, “Inching Pedal- Adjust” procedure in this manual and then repeatthe calibration procedure.

6. Exit submode number 29 by scrolling to the nextsubmode number by using the “SCROLL” switchor by exiting the “Power Train Calibration” modeby using the “Mode” Switch.

Calibration Of The Engagement PressureFor The Transmission Clutch

Incorrect transmission clutch pressure adverselyaffects the life of the transmission. Submodes 31through 33 are used in order to set the transmissionclutch pressure of the direction clutches (No. 1

through No. 3). In this process, the service technicianadjusts the electrical current that is sent to thetransmission solenoid valve in order to obtain thespecified pressure for the transmission clutch. Thecalibration of the transmission clutch pressure mustbe performed prior to the transmission clutch fillcalibration (submode 40).

The transmission system must be calibrated if any of the following conditions have occurred:

• A transmission solenoid valve has been replacedor cleaned.

• A different power train ECM has been installed.

• New flash software has been flashed into the ECM.

• A transmission clutch has been rebuilt.

• The transmission clutch does not shift correctly.


20/112



Transmission Clutch Solenoid Valves

(1) Transmission solenoid valve (No. 3)(2) Transmission solenoid valve (No. 1)(3) Transmission solenoid valve (No. 2)

(4) Transmission solenoid valve (No. 8)(5) Transmission solenoid valve (No. 4)(6) Transmission solenoid valve (No. 6)

(7) Transmission solenoid valve (No. 5)(8) Transmission solenoid valve (No. 7)

Table 7

Error Codes for the Calibration of theTransmission 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.

E05Temperature 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 codeswill appear in the display area of the Caterpillar Monitoring System. The error codes will appear if aproblem 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 (TransmissionClutch Fill Calibration)

Improper calibration of the transmission clutch fill willcause transmission shifting problems. The automaticcalibration procedure for setting the transmissionclutch fill will achieve greater consistency. Thecalibration of the transmission clutch engagementpressure (submode 31 through submode 33)should be performed prior to the calibration of thetransmission clutch fill (submode 40).

During the transmission clutch fill calibration(submode 40), error codes (EXX) can occur. Theerror codes will appear in the display area of theCaterpillar Monitoring System. The error codes willappear if a problem occurs during the calibration or if there is a problem with the results of the calibration.


21/112


Table 8

Error Codes for the Calibration of theTransmission Clutch Fill

E01 The Clutch Solenoid or the Speed Sensor

has an Active Failure.

E04 The Transmission is Not in the Park Position.

E05The 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



The calibration software may need to adjust oneof the parameters beyond the limit of the designspecification. In this case, error codes E21, E22,or E23 will appear in the display area after thecalibration procedure is complete. The software willselect the best values, but the error code indicatesthat an error exists in either the conditions for calibration or the transmission system. If error codesE21 through E23 are displayed, check the followingconditions for the source of the error:

• Make sure that the transmission oil and thetransmission components are fully warmed in order to run the calibration.

• Make sure that the transmission solenoid valvesare correctly torqued. (Make sure that the valvesare 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 notenergized sufficiently.


22/112



Transmission Solenoid Valves

(1) Transmission solenoid valve (No. 3)(2) Transmission solenoid valve (No. 1)(3) Transmission solenoid valve (No. 2)(4) Transmission solenoid valve (No. 8)

(5) Transmission solenoid valve (No. 4)(6) Transmission solenoid valve (No. 6)(7) Transmission solenoid valve (No. 5)(8) Transmission solenoid valve (No. 7)

Note: If a new transmission solenoid valve wasinstalled, you must shift the transmission into a speedor a direction that uses the transmission solenoidvalve. The transmission must be shifted at least 12times. Refer to Illustration 25 in order to identify thetransmission solenoid valve and the correspondingclutch. Allow sufficient time for the correspondingclutch to be fully pressurized.

During the transmission clutch fill calibration, error codes (EXX) can occur. The error codes will appear inthe display area of the Caterpillar Monitoring System.The error codes will appear if a problem occursduring 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 (submode40) again.

For more information on the calibration procedure,refer to the Testing and Adjusting, RENR4104, “FillTime for the Transmission Clutch - Calibrate”.

i01529536

Articulation Gauge CalibrationMode

SMCS Code: 7490

The 4C-8195 Service Tool allows personnel toaccess information that is related to service. Theservice tool attaches to the connector that islocated 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 modeconnector on the Caterpillar Monitoring System.


23/112



Display Area (Mode 6)

2. Press up both the service “SCROLL” and “CLEAR”switches on the service tool. When both switchesare pressed, the Caterpillar Monitoring Systemwill scroll to different display modes in the displayarea. Display mode 6 is used to calibrate thearticulation gauge needle. The two switchesshould be held until the Caterpillar MonitoringSystem display area shows “-6-”.


Up Stop Display

3. Pressing and releasing the “SCROLL” switch willmove the needle to the right one degree at a time.When the value is changed, the needle will moveone degree, and a up arrow will flash once on the

display. The amount of adjustment is limited to10 degrees from the default. If this limit has beenreached, a up stop will flash once on the display.


Down Stop Display

4. Pressing and releasing the “CLEAR” switch willmove the needle to the left one degree at a time.When the value is changed, the needle will moveone degree, and a down arrow will flash once onthe display. The amount of adjustment is limitedto 10 degrees from the default. If this limit hasbeen reached, a down stop will flash once on thedisplay.

5. When the needle appears centered, exit thecalibration mode.

Note: If the needle appears centered, the switchesmust be pressed in order to record the articulationsender resistance.


24/112


i01862466

Warning Operation

SMCS Code: 7490

Table 9

WARNING OPERATION

Warning Indications (1)

WarningCategory

“AlertIndicator

Flashes ”(3)

“ActionLamp

Flashes”(4)

“ActionAlarm

Sounds ” “Operator Action Required” “Possible Result ”(2)

1 X No immediate action is required.The system needs attention soon.

No harmful effects or nodamaging effects.

2 X X (4) Change machine operation or perform maintenance to the system.

Severe damage tocomponents can occur.

2-S X X (4) X (5) Immediately change the machineoperation.

Severe damage to machinecomponents

3 X X (4)

X (6)

Immediately perform a safe engineshutdown. Injury to the operator or severe damage tocomponents can occur.

(1) The active warning indications are marked with an X.(2) This is the possible result if no action is taken by the operator.(3) The alert indicator flashes at a 8 Hz rate.(4) The action lamp flashes at a 1 Hz rate (1 second ON, 1 second OFF).(5) Steady(6) The action alarm sounds at a 1 Hz rate (1 second ON, 1 second Off).


Quad Gauge Module

(1) Gauge warning area(2) Pictograph symbol


Speedometer/Tachometer Module

(3) Tachometer (4) Pictograph symbol

(5) Ground speed readout(6) Transmission gear readout


25/112



Main Display Module

(7) Alert indicator (8) Display area

The Caterpillar Monitoring System notifies the

operator of an immediate problem with a machinesystem or an impending problem with a machinesystem. Warning operation begins when the maindisplay module receives a problem signal. Theproblem signal reflects an abnormal condition of the machine. Warning operation also begins whenthe main display module detects a problem withthe control system. Switches, sensors, and other electronic control modules on the machine providesignals to the main display module. The problemsignals are the following conditions:

• An open switch. When a condition exceeds the trippoint of the switch, the switch opens.

• A sensor signal exceeds the limits. The maindisplay module determines the limits.

• Another condition is an abnormal condition that isdetected by another electronic control module. Theabnormal condition is then communicated over theCAT data link to the main display module.

The main display module analyzes the problemsignals. In order to notify the operator of a warning,the display components on the main display moduleactivate the appropriate warning indication. Thefollowing warning indications will notify the operator:

• The alert indicator FLASHES approximately ninetimes per second.

• The action lamp FLASHES for one second and theaction lamp is OFF for two seconds.

• The action alarm SOUNDS for one second and theaction alarm is OFF for two seconds.

Note: In order to activate warning indications, morethan one input is required. The main display moduledecides when the warning indications are activated.

The Category 2-S is a conventional Category2 witha continuous action alarm. A Category 2 that isconsidered to be a severe condition will cause acategory 2-S to be logged. A Category 2 tells theoperator to change machine operation in order to correct the warning condition. The operator isinstructed to IMMEDIATELY change operation of the

machine that relates to certain Category 2-S events.

Note: Most category 3 events cannot beacknowledged by the operator.

Note: See the Operation And Maintenance Manualfor complete information on the Warning Operation.

i01854075

Alert Indicator Description

SMCS Code: 7490


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


26/112



Alert Indicators For 140H, 160H, 12H, 120H And 135H

(1) Hydraulic Oil Temperature(2) Parking Brake Status(3) Charging System Status(4) Unused(5) Check Engine Status(6) Engine Coolant Temperature(7) Steering System Status(8) Engine Oil Pressure(9) Brake Air Pressure(10) Transmission System Status


Alert Indicators For 14H And 16H

(1) Hydraulic Oil Temperature(2) Parking Brake Status(3) Charging System Status(4) Unused(5) Check Engine Status(6) Engine Coolant Temperature(7) Steering System Status(8) Engine Oil Pressure(9) Brake Air Pressure(10) Unused

Hydraulic Oil Temperature – This light willindicate that the hydraulic oil temperatureis greater than 100 °C for the 14H, 140H

and the 160H. This light indicates that the hydraulicoil temperature is greater than 88 °C for the 143Hand the 163H. The temperature is received from thehydraulic 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 thewarning level of this indicator. If the machine is inneutral, only the indicator lights. However, if themachine is in a forward gear or a reverse gear, theaction lamp and the action alarm also activates.


27/112


Charging System Status – The lightindicates that battery voltage is outside therange 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 lightingof the indicator, the action lamp and the action alarm

will also activate when the battery voltage risesabove 32 DCV.

Check The Engine – This application isused with HEUI engines. The light indicatesthat the engine system requires service.

The status is received from the engine ECM via theCAT data link.

Steering System Status – The lightindicates that the primary steering pressureis low. The pressure is received via the CAT

data link.

Low Engine Oil Pressure – This lightindicates that the engine oil pressure is low.This signal is received by the Caterpillar

Monitoring System from the engine ECM via the CATdata link. The indicator lights when the switch voltageis high or the switch voltage is floating.

Transmission System Status – The lightindicates that the transmission conditionsare not working properly. The information

is received from the power train ECM via the CATdata link.

i01862477

Component Description

SMCS Code: 7490

This arrangement of the Caterpillar MonitoringSystem will work on the current Motor Graders.Three modules constitute the Caterpillar MonitoringSystem: main display module, quad gauge module,and speedometer/tachometer module. All of thefollowing electrical components are not present onevery machine. The main display module recognizesthe machine and the components that are present.For the location of the electrical components, see theElectrical System Schematic in the Service Manualfor the machine.

i01855060

Main Display Module

SMCS Code: 7490


Main Display Module(1) Alert Indicators. (2) Display area.

The main display module continuously monitors allmachine systems. The main display module makesdecisions that are based upon the input from themachine systems or other electronic control modules.The main display module sends information to other electronic controls on the machine. The input andoutput of this information takes place over the CATdata link. The outputs on the main display modulenotify the operator and the service person of thestatus of the machine systems. The following outputsare on the Caterpillar Monitoring System: the quad

gauge, the speedometer/tachometer module, themain display module, the action lamp, and the actionalarm. A connector with 40 contacts is located onthe rear of the module. This connector connectsthe necessary harness wiring to the inputs andoutputs. For a complete description of the connector,see Testing And Adjusting, “Connector ContactDescription of Main Display Module”.

Inputs/Outputs

CAT Data Link

The CAT data link (connector contacts 5 and 14) isused to communicate with other electronic controlmodules on the machine. The CAT data link isbidirectional. This allows the modules to input theinformation. Also, the modules can output theinformation. This permits sharing of informationsuch as engine oil pressure, harness codes anddiagnostics.


28/112


Display Data Link

The display data link (connector contacts 15, 25and 35) provides the electrical signals in order tooperate the speedometer/tachometer module andthe quad guage module. These display modulesprovide information about the machine systems to

the operator. Each module and each display indicator is identified by an identifier or an address. Data iscontinuously output from the main display moduleto the other display modules. The module that isaddressed returns the data to the main displaymodule. This confirms the receipt of the data.

Inputs

The operation and the status of the machine istransferred from the inputs to the main displaymodule. Three types of inputs exist: switch typeinput, sensor type input, and sender type input.

Switches and harness wiring provide a groundor an open signal to the switch inputs. Sensorsprovide a changing signal to the sensor inputs of themain display module. Senders provide a changingresistance to the sender inputs of the main displaymodule.

Some inputs are multipurpose (switch, sensor or sender). The following examples are of multipurposeinputs: connector contacts 7, 17, 27 and 37 may beeither 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 inputsare programmed at the time of installation in order todefine the components that are monitored. In order to determine the inputs on the main display modulethat are programmed, see the Electrical SystemSchematic in the Service Manual.

Switch Inputs - Uncommitted

The uncommitted switch inputs (connector contacts11, 19, 20, 21, 29, 32, 39, and 40) provide theinformation that is used in order to operate theten alert indicators. The alert indicators are partof the outputs on the main display module. These

switch inputs may be programmed at the time of installation to work independently. The switch inputsmay be programmed with other switch inputs and/or sensor inputs. The switch inputs will operate analarm indicator and the input will determine theappropriate warning category (1,2 or 3). Duringnormal operation, these switch inputs are closed toground. The grounded inputs tell the main displaymodule that the conditions of the system are normaland no alert indicators should be ON. These inputsreceive information from the following switches thatare located within the machine systems: pressure,temperature, flow, level, and mechanical.

Other inputs for the main display module may beprogrammed at the time of installation in order tofunction as uncommitted switch inputs. For moreinformation, 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 programmedto operate from an operator switch that is used tooperate the display area on the main display module.For the location of this switch input, see the wiringdiagram for the machine. For information on theoperation of this switch, see System Operation,“Normal Mode”.

Note: The alert indicators may also be programmedto operate from sensor inputs. One of the ten alertindicators is normally dedicated to the chargingsystem. The system uses the input for the batterypower and the input for the alternator terminal “R”.

Switch Inputs - Programming

The operation of the main display module isdetermined by the programming switch inputs(connector pins 3, 6, 12, 16, 22 and 31). Themain display module operates in a manner that

corresponds to the open state or the grounded stateof the programming switch inputs. These inputsreceive information from a permanent connection or a harness code connector within the harness wiring.The inputs for the programming switch consist of theinformation from the harness code.

The inputs from the harness code switch tell the maindisplay module the machine model. Information of themodel is necessary because of the differences in themachines. Information from the machine is necessaryfor the main display module to make decisions.


29/112


30/112


Note: The 70-800 ohm sender input may beprogrammed to operate a gauge or an alarmindicator. The sensor can also be programmed tooperate both a gauge and an alarm indicator.

Note: See “Sensor Inputs - PWM” for input operationwhen the 70-800 ohm sender input is programmed to

operate as a PWM sensor input. Use the ElectricalSystem Schematic of the machine that is beingserviced in order to determine the inputs that areprogrammed.

Note: See “Switch Input - Uncommitted” for inputoperation when the 70-800 ohm sender input isprogrammed to operate as a switch input. Use theElectrical System Schematic of the machine that isbeing serviced in order to determine the inputs thatare programmed.

Input - Voltage

The input for battery voltage (connector contact 1and 2) provides the main display module with power.The voltage input is also used by the main displaymodule to monitor the machine electrical system.This information from the voltage helps determine thecondition of the electrical system.

When an alert indicator is used in order to indicatethe voltage of the machine system, the battery signalis combined with the signal for the terminal “R”within the main display module. When an electricalsystem fault occurs, there are two possible warningcategories. 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 systemvoltage is greater than 29.5 volts for at least 2seconds. The system voltage is less than 24.8 voltsfor a least 2 seconds.

Category 3 – The system voltage is less than 23.0volts for at least 2 seconds or the system voltage isgreater than 32.0 volts for at least 2 seconds.

Outputs


Main Display Module

(1) Alert Indicators. (2) Display area.

The outputs of the Caterpillar Monitoring Systemnotify the operator of the status of the machinesystems. The main display module provides electricalpower for the other display modules and the sensors.

The following outputs are on the Caterpillar Monitoring System: the display for the main displaymodule, the display data link, the alert indicators,the action lamp, the action alarm, the sensor power supply, and the power supply for the main displaymodule.

The outputs on the main display module are the alertindicators (1) and the display area (2).

The alert indicators notify the operator of abnormalconditions with the machine. The main displaymodule uses the status of the uncommitted switchinputs, sender inputs and/or sensor inputs inorder to determine when an abnormal condition ispresent. The main display module then FLASHESthe appropriate alert indicator. The symbol of theFLASHING alert indicator identifies the responsiblemachine 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 abnormalconditions. For example, engine oil pressure andengine 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 anabnormal condition exists on the input for the terminal“R” or the input for +battery.


31/112


The display area has various symbols that show thecondition of the machine systems. The symbols alsoshow information for service and setup. The type of information that is shown on the display dependson the operating mode. For more information aboutthe display area, see System Operation, “Modes of Operation”.

Action Lamp

When a serious abnormal condition exists, themain display module activates the output for theaction lamp (connector contact 13) and the actionlamp FLASHES. For more information, see SystemOperation, “Warning Operation”.

Action Alarm

When a critical abnormal condition exists, themain display module activates the output for the

action alarm (connector contact 4) and the actionalarm SOUNDS. For more information, see SystemOperation, “Warning Operation”.

Power Supply Output - Sensor

The output for the sensor power supply (connector contact 24) provides 8 DCV for the PWM sensorsthat are connected to the inputs of the main displaymodule.

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 andthe speedometer/tachometer module cannot functionwithout this power output.

i01521112

Display Components

SMCS Code: 7450

The following table shows the contact description for all the display components.

Table 10

Contact Description Of Display ComponentsConnector

No. Function Type

1 +9 DCV Input

2 Ground Ground

3 Display Clock Input

4 Display Data Input

5 Display Load Input

6 Harness Code Open(1)

(1) Used to give two display components of the same type a uniquecomponent number. This is needed so the main display modulecan send unique information to each identical component.Since all monitoring system configurations included in thismanual have at most one module, this input should be open.

The display components receive information from

the main display module. The information thatis shown notifies the operator and the serviceperson of the status of the machine systems. Thecomponents are the quad gauge module and thespeedometer/tachometer module.

i01858071

Quad Gauge Module

SMCS Code: 7450


An Example Of A Quad Gauge Module

(1) Gauge warning area. (2) Pictograph symbol.


32/112


The quad gauge module shows the followinginformation: engine coolant temperature, articulationangle, system voltage, and fuel level. The maindisplay module uses the information from sensor inputs or the CAT data link in order to calculate thevalues that are shown on the gauges. Pictographsymbol (2) identifies the parameter for the machine

system which is shown on each gauge. Abnormalvalues are shown by the gauge warning area (1).

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 enginecoolant temperature sensor. The warning level for this gauge is a Level II.

Table 12

Articulation Angle Sensor Gauge

Minimum Displayed Value −20 °C (−4 °F)

Midpoint Value 0 °C (32 °F)

Maximum Displayed Value 20 °C (68 °F)

Note: The information is received from the articulation

angle sensor.

Table 13

System Voltage Gauge

Minimum Displayed Value 22 V

Midpoint Value 26.2 V

Red Zone Low 23.8 V

Red Zone High 28.5 V

Maximum Displayed Value 31 V

Note: The information is received via the CAT data

link.

Table 14

Fuel Level Gauge

Minimum Displayed Value 5%

Midpoint Value 50%

Red Zone Value 10%

Maximum Displayed Value 95%

Note: The input is received from the fuel level sender.The warning level for this gauge is a Level I.

i01020517

Speedometer/Tachometer

ModuleSMCS Code: 7450


Speedometer/Tachometer module

(1) Tachometer. (2) Pictograph symbol. (3) Speed readout. (4)Gear readout.

Speed readout (3) consists of three digits and thereadout may show the machine ground speed inMPH (km/h). The main display module calculatesspeed by using the information from a frequencysensor input or the CAT data link. Illumination of the

appropriate digits shows the speed.

Gear readout (4) consists of two digits that show thetransmission gear which is engaged. The left digitshows the actual gear, “1”, “2”, “3”, etc. The right digitshows the direction that is selected, “F”, “N” or “R”.

Tachometer (1) shows the engine speed in RPM.The engine speed is determined by the informationthat is sent to the main display module over the CATdata link. The engine speed is also determined froma frequency sensor input.

i01858111

Switches

SMCS Code: 1435; 7332

Switches provide information (input) to the maindisplay module. Switches are two state devices. Thetwo states of the switches are open and closed.

Closed – The switch connects the control input toframe ground.


33/112


Open – The switch connects the control input tonothing. (The input is floating.)

During normal operation, all the switches are closedto ground. When a condition exceeds the trip pointof the switch, the switch opens. This tells the maindisplay module of the abnormal condition. The main

display module then begins the warning operationand the module notifies the operator of the abnormalcondition (problem).

Note: For specifications on the switches, see theElectrical System Schematic for that particular machine.

Rocker Switch (Operator ModeSelector)

Grounding the operator mode selector switchcauses the main display module to scroll through the

available operator modes for the machine. Openingthe selector switch places the Caterpillar MonitoringSystem in the currently displayed operator mode.

A list of possible operator modes is shown at thebeginning of the Modes of Operation section. Seethe Operation And Maintenance Manual in order todetermine the “Operator Modes” that are available for the machine that is being serviced.

Temperature Switch (Hydraulic Oil)


Temperature Switch (Hydraulic Oil)

(1) Switch. (2) Schematic symbol.

During normal operation, temperature switch (1)is closed to ground. The switch opens when thetemperature of the fluid system is greater than thespecified value. The open switch tells the maindisplay module that there is a high temperature. Theswitch is closed when the switch is off the machine.

Pressure Switch

Pressure Switch (Parking Brake)

Pressure Switch (LH Brake System)

Pressure Switch (RH Brake System)


Pressure Switch

(1) Schematic symbol(2) Switch

During normal operation, pressure switch (2) is opento ground. The switch closes when brake system air pressure is present. The switch opens when brakesystem air pressure is too low.

i01802612

Senders

SMCS Code: 1408-UN

Level Sender (Fuel)


Level Sender (Fuel)

(1) Sender (2) Schematic symbol

Fuel level sender (1) provides fuel level sensing. Aresistive signal which corresponds to the depth of fuel within the fuel tank is sent from the sender to themain display module. Typically, there are two possibletypes of senders: 0 to 90 ohms and 33 to 240 ohms.The main display module measures the resistancevalue in order to determine the fuel that is remainingin the tank. Typical gauge readings for the fuel level:


34/112


• When the fuel tank is at 4% of capacity, the gaugeshows that the tank is empty.

• When the fuel tank is at 14% of capacity, the gaugeshows the needle at the red zone on the gauge.

• When the fuel tank is at 95% of capacity, the gauge

shows that the tank is full.

Temperature Sender


Temperature Sender

(1) Schematic symbol(2) Sender

Temperature sender (2) provides a method for sensing fluid temperature. The temperature sender produces a resistive signal which corresponds tothe temperature of the fluid that is being monitored.

Typically, the resistance range of the sender isfrom 70 ohms at 110°C (230°F) to 3000 ohms at25°C (77°F). The main display module measuresthe resistance value in order to determine the fluidtemperature.

Position Sender (ArticulationAngle)


Position Sender (Articulation Angle)

(1) Schematic symbol

(2) Sender

Position sender (2) provides articulation sensing. Aresistive signal which corresponds to the articulationangle is sent from the sender to the main displaymodule. The main display module measures theresistance value in order to determine the articulationangle.

i01060965

Sensors

SMCS Code: 1408-NS

General Information

Sensors provide information (input) to the maindisplay module about changing conditions. Thesensor signal changes in a proportional manner inorder to reflect the changing condition. The maindisplay module shows the information from thesensors on the gauges. The main display modulerecognizes 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 asthe condition changes. The frequency of this signalis constant.

Frequency Sensors

Frequency sensors produce an AC signal. Thefrequency (Hz) varies as the condition changes.


35/112


Speed Sensor


Speed Sensor

(1) Sensor. (2) Schematic symbol.

Speed sensor (1) is a frequency sensor. Speedsensors 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. Themain display module measures the sensor frequency(one pulse per gear tooth). The main display moduledetermines the engine speed or the machine speed.The speed is then shown on the display.

The engine speed sensor is located on the flywheelhousing. The speed sensor for the machine is locatedat the output end of the transmission housing.

Pulse Width Modulated (PWM)Sensors


Pulse Width Modulated Signal


Typical PWM Sensor Schematic

Pulse width modulated (PWM) sensors produce adigital signal. The duty cycle varies as the conditionchanges. The frequency remains constant.


36/112


Temperature Sensor


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 receivesoperating power from the main display module (8DCV) or from the battery (24 DCV). The sensor sendsthe main display module a PWM signal. The signalchanges as the fluid temperature changes. The maindisplay module measures the duty cycle of the sensor signal in order to determine the fluid temperature.

Pressure Sensor


Pressure Sensor

(1) Schematic symbol. (2) Sensor.

Pressure sensor (2) reacts to the pressure of fluids.The sensor receives operating power from the maindisplay module (8 DCV) or from the battery (24 DCV).The sensor sends the main display module a PWMsignal. The signal changes as the fluid pressurechanges. The main display module measures theduty cycle of the sensor signal in order to determinethe fluid pressure.

i01679184

Action Lamp

SMCS Code: 1408-LMP; 7400-LMP


Action Lamp Symbol

The action lamp connects to an output of the maindisplay module. The action lamp is an LED thatis located within the operator’s viewing area. TheFLASHING of the action lamp tells the operator that acondition exists. The condition will require changing

the operation of the machine. The action lamp islocated on the main display module. The actionlamp will FLASH whenever a warning category 2,a warning category “2S”, or a warning category 3problem exi

Documents

CAT 16H service manual