Usage:
1. Once all connections have been checked, energize the system.
A) The RED indicator light should come on. This indicates that the control is 'OFF'.*
... If the LO indicator light is 'ON', it indicates an open connection on the BLUE output wire going to the center solenoid.
... If the MED indicator light is 'ON', it indicates an open connection on the YELLOW output wire going to the front and/or rear solenoids
*If the RED light starts to flash: This indicates that there is an open connection on the output.
If an open connection occurs, insure that there is a good connection at the solenoid, and at the output of the control module. If there is still a problem remove the harness connections on the 002299 terminal leadout. Measure the resistance of the solenoid at the 002299 terminal leadout on the Jake Brake housing (+ probe on the 002299 terminal, - probe to ground). The ohmmeter should read between 7 and 14 ohms. If it does not, replace the solenoid. If the problem still occurs, replace the suspected output wire, and insure a good connection at both ends of the wire.
2. If the RED indicator light does not come on, measure the voltage on the ORANGE wire (make sure it is not grounded). Place the (+) probe of the VOM on pin 'D' of the 6 way Weather Pack connector, and (-) probe on a good ground. The VOM should read +5 volts:
a) If it does not: replace the control module.
b) If it does: replace the dash module harness.
c) If the problem still exists: replace the dash module.
3. To turn the control 'ON', press the ON/OFF switch. The RED indicator light should now turn off, and the GREEN (LO) indicator light will come 'ON'. The control is now in the LO mode. To enter the medium mode, press the 'MED' switch, and the LO indicator light will now turn off and the GREEN (MED) indicator light should now come 'ON'. Repeat these steps for the 'HI' mode.*
This indicates that there is a SHORT on one of the output lines.
... If the LO indicator light is flashing, there is a short on the BLUE output wire going to the center solenoid.
... If the MED indicator light is flashing, there is a short on the YELLOW output wire going to the front and/or rear solenoids.
*If when the retarder comes on, the GREEN (LO or MED) indicator lights start to flash:
If a short connection occurs insure that there is a good connection at the solenoid, and at the output of the control module. If there is still a problem, remove the harness connections on the 002299 terminal leadout. Measure the resistance of the solenoid at the 002299 terminal leadout on the Jake Brake housing (+ probe on the 002299 terminal, - probe to ground). The ohmmeter should read between 7 and 14 ohms. If it does not, replace the solenoid. If the problem still occurs replace the suspected output wire, and insure a good connection at both ends of the wire.
4. If the retarder fails to operate correctly, continue with the procedure to enter the diagnostic mode.
A) To check the operation of the retarder, enter the diagnostic mode. Depress the 'HI' switch for at least 5 seconds. After 5 seconds, all 4 indicator lights will start to flash. The control module is now in the diagnostic mode. There are two main stages of this mode:
The first is stage 1 (input conditions). If the input conditions are correct, the indicator light configuration should be like Figure 2A. The GREEN (MED) indicator light shows the status of AUX HI (orange wire), if connected. AUX HI is used with an anti-skid system which disables the retarder if it is grounded.
To enter stage 2 of the diagnostic mode, press the (MED) switch. The dash module indicator light configuration should be like Figure 2B. Stage 2 is important to the proper operation of the control module. To check the operation of the PWM signal, ensure that the truck is in neutral and increase the engine speed to the engine rated rpm. Then release the throttle, and observe the dash-module light indicators:
*If the input signal is not present, ensure that the BROWN wire has a good connection, and is not shorted. If the fault signal is still present refer to the Caterpillar Electronic Troubleshooting, 3176 Diesel Truck Engine, Form No. SENR3913.
**If the interface signal from the engine computer is incorrect, or if there is a problem with the interface signal, 'RED' ON/OFF led will come ON.
5. To exit the diagnostic mode, press the ON/OFF switch. This will put the control back into the LO mode.