Hazardous Area Shift Selector Application and Installation Guide for Petroleum Transmissions{3065, 7490} Caterpillar

Transmission:

TH55FT-E70 (S/N: PCJ1-UP)

Petroleum Power Train Package:

CX31-P600-C13I (S/N: PDJ1-UP; PDN1-UP)

CX31-P600-C18I (S/N: PDC1-UP)

CX31-P600-C9I (S/N: PDZ1-UP)

CX35-P800-C18I (S/N: PCF1-UP; PCZ1-UP)

TH31-C9I (S/N: PAZ1-UP)

TH31-C9P (S/N: PFZ1-UP)

TH31-C9T (S/N: PAY1-UP)

TH35-C11I (S/N: PBZ1-UP)

TH35-C13I (S/N: PBY1-UP)

TH35-C13T (S/N: PBW1-UP)

TH35-C15I (S/N: PBN1-UP)

TH35-C15T (S/N: PBL1-UP)

TH48-E70-C27I (S/N: PKZ1-UP)

TH48-E70-C32I (S/N: PKY1-UP)

TH48-E70-C32P (S/N: PKG1-UP)

Petroleum Transmission:

CX31-P600 (S/N: PFW1-UP)

CX35-P800 (S/N: TRJ1-UP)

TH31-E61 (S/N: LWC1-UP; LAD1-UP; SKY1-UP)

TH35-E81 (S/N: MSB1-UP; TZM1-UP; PZT1-UP)

TH48-E70 (S/N: JGC1-UP; KSH1-UP)

TH48-E80 (S/N: FRT1-UP)

Introduction

This special installation supports the hazardous area shift selector for Petroleum Transmissions used in the work-over applications in the oil well industry. This publication is a resource for electrical and electronic wiring, programming, and other installation information.

This publication discusses the application, implementation, and installation of the display. This publication contains feature description, drawings, and specifications of display electronics.

This publication is for the use of OEM customers and the OEM engineers, technicians, and service personnel.

Certifications

The 373-2771 Display Module Gp (HAZARDOUS AREA SHIFT SELECTOR) is US/Canada certified for use in Zone 2 environments and NEC certified for use in Class 1, Division 2 / Zone 2 hazardous locations. The Display Module Gp is certified for Gas Group IIA and NEC Gas Groups D.The Display Module Gp Is Certified for Temperature Class T3 / T3C with an ambient capability of −10° C (14° F) < Ta < +70° C (158° F).

A ground strap connection is required from the frame of the display to the panel or to the machine ground. A 7x-6315 Ground Strap may be used to fulfill this requirement.

Description of the Shifting System

Illustration 1	g02160496
(1) Engine ECM (2) Transmission ECM (3) J1939 (4) Cat Data Link (5) J1939 shift selector (6) Hazardous area shift selector (7) Messenger

Engine ECM (1) communicates to the following components via J1939 (3) : transmission ECM (2), J1939 shift selector (5), hazardous area shift selector (6) and messenger (7). Transmission ECM (2) communicates with hazardous area shift selector (6) and messenger (7) via Cat Data Link (CDL) (4) .

Single Hazardous Area Shift Selector Requirements

Only one hazardous area shift selector may be installed on a J1939 network at any given time. In an application that requires multiple shift selectors, the other shift selectors must be second-generation push-button shift selectors such as part number 298-3860 Transmission Control Gp or a custom OEM J1939 shifter (PLC or others.)

Note: The first generation push-button shifter ( 255-6262 320-2891 Transmission Control Gp ) is not compatible with the hazardous location shifter. Transmission model-specific Application and Installation Guides should be referenced to facilitate design of a custom OEM J1939 shifter.

Shift Selector Power-Up

The hazardous area shift selector takes extra time to reach an operable state at keyswitch due to hardware requirements. Because of this situation, the transmission may not allow the starter relay to be enabled until the ECM is properly communicating with the shift selector. The operator may see a delay between the physical turning of the keyswitch to the start arrangement and the starter cranking.

System Schematic

The following simplified electrical schematics are electrically correct. The schematics do not show all related electrical systems on the machine. For a complete Electrical System Schematic of a particular machine, always refer to the Electrical System Schematic in the Service Manual for your machine.

Illustration 2	g02176378

Shift Selector Display

Shift Selector

The shift selector is used to control the operation of the transmission.

Operation

Buttons are provided on the shift selector to allow operator control of the gear range for the transmission. These buttons are labeled on the left side of the display and are available to be selected in every operating state of the shift selector. These buttons operate the same as a normal push-button shift selector. A single press and release of a button will send a request via J1939 (3) to transmission ECM (2) for the selected gear range.

Buttons

The display is able to provide five buttons on both sides of the screen. The five buttons on the left side of the display are used to control the transmission gear range. The five buttons are labeled as the following: Reverse or Mode, Neutral, Drive, Up and Down.

Inactive Shift Selector

Illustration 3	g02162694

The shift selector can provide visual confirmation of whether the shift selector is considered active or not. In a dual shift selector application, only one shift selector can be used at any given time. Transmission ECM (2) will only respond to selections on the active shift selector. Transmission ECM (2) will ignore selections on the inactive shift selector. When hazardous area shift selector (6) is not the active shift selector, the background button labels will change to a darker state. Refer to Illustration 3.

Menu Navigation Buttons

Arrows

The arrow buttons, on the right side, allow the user to navigate through the menu and submenus. Each button has a combination of functions and may be used differently depending on the menu currently displayed. When navigating the menu structure or setting values such as units or language, the arrows are used in an up and down manner. When setting contrast or brightness, the arrows are used in a left and right manner.

Return and Menu

The "Return" button allows the user to navigate back a screen or up a level. In a submenu, the "Return" button would return the operator to the main menu. While in the main menu, the "Return" button would return the user to the home screen. Pressing the "Return" button on the home screen will bring up the main menu.

Home

The "Home" button allows the user to return to the home screen immediately after the button is pressed. If the operator is in a submenu, pressing the "Home" button will exit all menu levels and navigate directly to the home screen. If the operator enters the menu again, the main menu will appear. The menu will not be placed in the same submenu that was displayed before the home button was pressed.

OK

The "Ok" button selects the current value and configures the shift selector to the desired operation.

Main Menu

Illustration 4	g02162960

The main menu displays all of the information contained on the shift selector as well as provide access to configurable settings. Refer to Illustration 4. The main menu is entered by pressing the "Return" button while on the home screen.

Key Engine Data

Key engine data provides basic information about the current state of the engine.

Key Transmission Data

Key transmission data provides basic information about the current state of the transmission.

Mode Request or Reverse Request

The purpose of the main menu selection "Reverse / Mode" request is to provide access to all features normally available on a push-button shift selector. Depending on the properties selected in the button settings menu, a selection will be provided for the enabling or disabling of the unselected option.

If operation requires the "Reverse" button to be on the main screen, the "Mode Request" option will be available in the main menu. If operation requires the "Mode Request" button to be on the main screen, the "Reverse" option will be available in the main menu. This option allows the occasional selection of mode or reverse, if needed, without having to reconfigure the button settings.

Service Menu

The service menu contains several submenus which contain information about the engine and transmission. Each submenu is defined by the type of information contained. This menu is provided for a service technician who may need information beyond the scope of the key engine or transmission data screens.

Diagnostics

The diagnostic screen displays information about diagnostics or events currently active or logged on J1939 or CAT Data Link (CDL). This screen lists all of the events with basic information about each. Every item is identified by the following information: the source of the message, the code and the current state. If an event is active, an "X" will be placed in the active column. Pressing the "OK" button will display details about the selected diagnostics if details are available for that particular code.

Settings

The shift selector has configurable settings which may be adjusted based on user preference.

Setting Menu

The settings submenu allows the operator to select physical properties which are most useful for the conditions in which the operator is working.

Operation

Each setting may be adjusted between predetermined values or limits. Values outside the range are not allowed.

Contrast/Brightness

Illustration 5	g02163168

The value may be adjusted between 0 and 100%. 0% refers to minimal display output, and 100% is full intensity. To keep the screen visible and readable, the range of values does not allow the user to lighten or darken the screen beyond certain points .

Units

Units may be adjusted between Metric and English.

Language

Language options may be available. English is programmed by default.

Button Settings

Button settings will determine which type of command should be the top button on the shift selector. The top button selected can be Reverse or Transmission Mode 1.

Button Settings

This function allows the operator to select which request would be most valuable to have on the main screen, assigned to the top button.

Operation

The shift selector will display the correct label and transmit the information that corresponds to the selection over J1939 to the transmission. The selection will stay in memory until the setting is reprogrammed or the shift selector is flashed.

Mode Selection

Illustration 6	g02178352
(8) Button

If "Mode" is selected as the desired setting, an icon will appear on the top button confirming the selection. Pressing button (8) will toggle between "Mode" enable or disable.

The operation of "Mode" is determined by the transmission configuration. For example, "Mode" may be used to enable Fuel Economy mode. If the transmission has received the "Mode" request and has enabled the feature, button (8) will be illuminated green. Refer to Illustration 6. Button (8) is the "Mode" indicator. The "Mode" indicator provides feedback to the operator that the feature was enabled. The "Mode" indicator status may be found on the home screen or the top bar when the operator is in a menu.

Reverse Selection

Illustration 7	g02339505
(8) Button

If "Reverse" is selected as the desired setting, an "R" icon will appear on the top button confirming the selection. Pressing button (8) will cause the shift selector to send out a reverse request message to the transmission.

Home Screen

Purpose

The home screen is the default screen during shift selector operation. The home screen displays key information and maximizes display size of important parameters. Larger display size allows an operator, who may not be close to the display, to know the state of the transmission.

Operation

At power up, the shift selector will default to the home screen unless operator input causes the shift selector to enter a menu screen. Pressing the home button will cause the shift selector to go directly to the home screen. The home button will not allow an operator to skip past any diagnostic alarms that may appear.

Requested and Current Gear Display

Requested range and current gear values are displayed at the top of the screen in larger characters. These values indicate the operating state of the transmission. These two values are the same characters that are displayed on any current push button or lever shift selector. These values may decrease in size to make room for menu selections or diagnostic alarms.

Status Values

Several transmission and engine status values are indicated on the home screen. Key information about the operating state is reflected in these values to the operator. The operator may need to use this information during normal operation.

Diagnostics

A single status value indicates the status of diagnostics that are currently received by the shift selector. This status value will be indicated as "None" if no diagnostics have been received. This status value will be indicated as "Active" if diagnostics or events are currently happening. This status value will be indicated as "Logged" if a diagnostic or event has been logged. A single active event or diagnostics will cause this value to be displayed over the logged or none states.

Oil Level Check

Note: The value given by the shift selector may not match the dipstick measurement. The oil level check routine is an estimate based on current conditions. The user or technician is responsible for checking the transmission oil manually. Consult the transmission service manual for specific instructions on checking oil level.

The oil level check routine is a method of gathering information about the status of the transmissions oil level using the shift selector. If an oil level sensor is installed on the transmission, information about the sensor will be displayed on the shift selector.

Before performing an oil level check, several conditions must be met before a reading is considered valid. The transmission or vehicle must meet the following conditions:

• Machine or transmission in neutral

• The requested gear is neutral

• No vehicle speed or transmission output speed

• Level ground

• Valid temperature ranges for an oil check

If these conditions are not met, the oil level check will not continue. The requirement that is not met will display in the "Oil Level Measurement" status value as follows:

• Engine Speed Low

• Engine Speed High

• Transmission Temperature High

• Transmission Temperature Low

• Vehicle Not Level

• Output Speed High

• Transmission In Gear

If conditions are considered valid, then a timer will start displaying. The transmission requires time to analyze the readings and receive an accurate value. The amount of time remaining will be displayed at the bottom of the screen under "Timer Status". The timer is not an active countdown and will only display the number of minutes left until the check is complete. If there is less than 1 minute left, the status will display "< 1 Minute". When the countdown is finished, the shift selector will display how many quarts of oil the transmission is high or low.

Warning Operation

Purpose

The purpose of diagnostic pop-ups and alarms are to alert the operator of active diagnostics or events.

Operation

Illustration 8	g02162902

The shift selector is always receiving diagnostic information from several sources on the datalinks. When diagnostics or events are active, the shift selector will alert the operator by displaying the diagnostic information. Refer to Illustration 8. The operator must acknowledge the alert by pressing the "OK" button for each diagnostic. The operator is still able to select gear ranges without pressing the "OK" button when a diagnostic or event is active. As long as the diagnostic or event is active, the shift selector will periodically bring up the alarm, prompting the operator to press "OK". Once the diagnostic is no longer active, or is considered logged, the alarm will no longer appear. However, viewing logged diagnostic codes and events is available on the diagnostics screen available through the main menu. The diagnostic alarm will display the diagnostics and the source of the diagnostics. If the shift selector recognizes the diagnostic, the shift selector will display component and failure information to the operator. If the shift selector does not recognize the diagnostic, the shift selector will notify the operator of an unknown component failure.

Note: Transmission diagnostics are communicated through Cat Data Link (CDL), reproducing the same codes as would be displayed with the transmission in Cat Electronic Technician. The engine diagnostics are reported through the J 1939 data link.

Mechanical Installation Guide

This section discusses the general standards of the mechanical installation of the ECM.

Environmental Specifications

Note: This section covers the use of the hazardous area shift selector for the Workover Rig application and does not apply to other ECMs or applications

Table 1

Operating temperature range	-10° C to +70° C
Vibration	9.8 G 24 to 2000 Hz

ECM Mounting

In the following the mounting of the Advisor Display is shown. The ECM should be installed suitably close to vertical to prevent from collecting a pool of water on the screen. The necessary parts for mounting are shown in Table 2.

Table 2

Required Parts
Part Number	Description	QTY
9X-8256	Washer	4
8T-4171	Bolt (M6)	4
259-5812	Control Mounting Gp	2

The torque specification for 8T-4171 Bolt is 12 ± 3 N·m (8.9 ± 2.2 lb ft).

Electrical Considerations

The following are a quick summary of some electrical considerations:

• When the keyswitch run terminal is turned off (open circuit). this action will place the ECM in a "sleep" mode

• When the keyswitch run terminal is turned on (connected to +battery), the ECM will "wake up" and the application will run.

70 Terminal ECM Connector Part Numbers

The ECM uses one integral rectangular 70 Terminal AMP connector to interface to. The J1 connector is AMP part number 776241-4. The Caterpillar part number is 147-1444 Connector Plug As .

ECM 70 Terminal Connector Allen Screw Torque

ECM Connector Screw torque should be 6 ± 1 N·m (4.4 ± 0.7 lb ft).

ECM Connector Wire Gauge Size

Connections may be #16 or #18 AWG SAE J1128 type SXL or #16 or #18 AWG SAE J1128 type GXL wire. Or equivalent wire.

Dimensions for Mounting

Illustration 9	g02160288
Panel Cutout (A) 125 ± 0.5 mm (4.92 ± 0.02 inch) (B) 206 ± 0.5 mm (8.11 ± 0.02 inch)

Illustration 10	g02160394
Side View of Display (C) 52 mm (2.05 inch) (D) 44 mm (1.73 inch) (E) 62 mm (2.44 inch) (F) 124 mm (4.88 inch)

Illustration 11	g02160396
Display Cover (G) 140 mm (5.51 inch) (H) 221 mm (8.70 inch)

Illustration 12	g02160402
Mounting Assembly (J) Bolt (K) Bracket (L) Cap

Electrical and Electronic Installation Guide

This section discusses the general standards of electrical and electronic installation of the ECM.

Hazardous Location Wiring Requirements

The power and signal connections of this shifter should be treated as incendive circuits and wired as per the wiring requirements of the area in which the shifter will be installed. Depending on the area classification, the following may be required: that the connectors meet IP54, have suitable impact resistance or protection from impact, be flame retardant, be separated physically from non-incendive circuits and run in conduit or extra-hard usage cable. Refer to the relevant hazardous area field wiring standards for more information. Caterpillar recommends the use of a 2A fuse on the power supply.

Grounding Requirements and Considerations

The shift selector ECM requires unswitched power and ground connections. An Ignition Key Switch input is used to wake up the ECM.

Other grounding considerations:

• When installing in hazardous locations, the relevant wiring standards may include requirements with respect to the provision of grounding cables within harnesses.

• Have frame grounds as close to battery as possible.

• Have ground strap across articulation joints.

• Engine connection to vehicle battery ground.

ECM Negative Battery Connections

Caterpillar requires the OEM to install the ECM "- Battery" wires into the harness connector.

Sensor Common Connections

Only those components interfacing directly to the ECM should be connected to the ECM Sensor Commons.

Suppression Of Voltage Transients and Electrical Noise

Caterpillar recommends that transient suppression is installed at the source of the transient in addition to the suppression in the ECM. Caterpillar controls are designed to comply with SAE J1455. The use of inductive devices such as relays and solenoids can result in the generation of voltage transients on the battery lines. Unsuppressed voltage transients can exceed SAE J1455 specifications and degrade control system performance.

Some specific devices that should use transient suppression are fan clutch solenoids, A/C clutch solenoids, and all relays. This list is not an all-inclusive list. The OEM should specify relays and solenoids with built-in voltage transient suppression on the vehicle where possible.

Illustration 13	g02160531
Examples of Voltage Transient Suppression

See Illustration 13 for an example of several possible suppression techniques. The suppression will minimize the generation of voltage transients from relays and solenoids without built-in voltage transient suppression. This method includes but is not limited to, installing a properly sized diode or resistor in parallel with solenoid and relay coils.

Inductive devices should be located to maximize the distance from control system components. OEM installed wiring harnesses should be routed to maximize the distance from the control system wiring harness to avoid inductive coupling of noise transients.

Voltage Requirements and Considerations

The control system has been designed to operate on a 12 V or 24 V electrical systems. Minimum and maximum voltage requirements for the control system are as follows:

Table 3

Nominal (V)	Range (V)
12 to 24	9 to 32

Welding on a Vehicle

Note: Before you weld on a vehicle that is equipped with an electronic transmission control, the following precautions must be observed:

1. Place the ignition switch in the OFF arrangement.

2. Disconnect the negative battery cable from the battery. If the vehicle is equipped with a battery disconnect switch, open the switch.

Show/hide table

NOTICE
DO NOT use electrical components in order to ground the welder. Do not use the ECU or sensors or any other electronic component in order to ground the welder. Clamp the ground cable for the welder to the component that will be welded. Place that clamp as close as possible to the weld. This method will reduce the possibility of damage to the bearings of the drive train, hydraulic components, ground straps, and other components of the vehicle.

3. Clamp the ground cable of the welder to the component that will be welded. Place the clamp as close as possible to the weld.

4. Protect any wiring harnesses from welding debris and spatter. Use proper welding procedures in order to weld the materials.

   ReferenceRefer to Special Instruction, REHS1841, "General Welding Procedures" for additional information.

Connectors and Wiring

Harness and Connector Wiring Guidelines

A good general rule of thumb for wiring harnesses is, If a harness moves, do not let the harness touch anything. If the harness touches, do not allow the harness to move. Below are some guidelines for machine wiring harness design and routing:

1. Wires or harnesses that lead to a component connector must be clipped within 150 mm (5.9 inch) of the connector.

2. Connectors must be mounted or clipped. Clipping connectors means tie wrapping the connectors down or preferably using the dovetail mounting method for the DT connectors. If a tie wrap is used, the tie wrap must not be placed over the connector detention release mechanism.

3. Tie-wraps should only be used on harnesses that DO NOT MOVE.

4. Harnesses that move such as flex joints, should be secured with insulated "P" clips.

5. Flex joints must not be in column loading. This method can force movements through clips and can also fatigue wires.

6. Connectors must not be placed in flex joints.

7. Breakouts must not be placed in flex joints.

8. Flex joints should incorporate a bend to facilitate bending/flexing.

9. Battery cables should not be secured with tie wraps. Use only "P" clips or Stauff clamps.

10. Distance between clip points should not allow the harness to sag, sway, or touch anything due to machine movement or vibration.

11. Smaller harnesses should be clipped more often due to the flexibility of the harness.

12. Do not route harnesses in area that is expected to or could be used as a step or standing location.

13. Do not locate harnesses, wires, and cables under filters or drains.

14. Do not locate harnesses, wires, and cables in areas where the harnesses can be used as handhold.

15. Do not clip harnesses, wires, and cables to hose or tubes.

16. Pay close attention to the routing of the "B+" and "B-" battery cables.

17. Add covers or boots on high-power terminals and connectors.

Illustration 14	g02160538

Connectors

Illustration 15	g02160540

Pull Test

The pull test is used to verify that the wire is properly crimped in the terminal and the terminal is properly inserted in the connector.

Perform the pull test on each wire. Each terminal (socket or pin) and each connector should easily withstand 45 N (10 lb) of pull and each wire should remain in the connector body.

Installation of Terminals and Seal Plugs

Illustration 16	g02160544

Caterpillar requires sealing plugs for all unused connector cavities. Correct installation of the cavity plugs is critical to maintain connector sealing integrity. The illustration below indicates correct insertion of the plug. The plug cap is designed to rest against the seal, not inserted into the hole in the seal.

The following requirements ensure the correct installation of terminals in the connectors:

• Do not solder the sockets and pins to the wires.

• Never crimp more than one wire into a socket or a pin. The 186-3735 Connector Pin and the 186-3736 Connector Socket are designed to accept only one 16 or 18 AWG wire. The 9W-0844 Connector Socket and the 9W-0852 Connector Pin are designed to accept only one 14 AWG wire. Do NOT insert multiple wires of a smaller gauge.

• All sockets and pins should be crimped on the wires. Use the 1U-5804 Crimp Tool for 12 to 26 AWG wire.

• All unused cavities for sockets and pins must be filled with 8T-8737 Seal Plugs in order to ensure that the connector is sealed. The seal plugs must be installed from the wire insertion side of the plug or receptacle. The seal plugs must seal correctly. The head of the seal plug should rest against the seal. Do not insert the head of the seal plug into the seal. Refer to Illustration 16 for correct installation of plugs.

Deutsche DT Connectors

A DT connector has a wedge that locks the pins and the sockets in place. The wedge can be removed and replaced without cutting the wires. The 147-6456 Wedge Removal Tool (DT Connector) aids in the removal of the wedges. When the receptacle is inserted into the plug, a click should be heard as the two halves lock together. The connector should not pull apart. The acceptable range for the diameter of the insulation on the wire that is used with the DT connectors is 2.24 to 3.81 mm (0.088 to 0.150 inch).

Inspect the plug and the receptacle in order to ensure that the following conditions are met:

• The connector seals are seated.

• The pins and sockets are not damaged.

• The pins and the sockets are securely installed on the wires. Perform the 44.5 N (10 lb) pull test.

• The correct number of pins and sockets exist on both halves of the connector.

• The pins align correctly with the sockets.

• The locking tabs are not damaged. Replace the connector if the tab is damaged.

• The wedges are not damaged.

Deutsche HD Connectors

Ensure that the wires in the plug align with the corresponding wires in the receptacle. Make sure to align the index markings on the plug and the receptacle. Rotate the plug until the plug slips into the receptacle. Rotate the coupling by approximately 90 degrees until a click is heard. Ensure that the plug and the receptacle cannot be pulled apart. The acceptable range for the diameter of the insulation of the wire that is used with the connectors is 2.54 to 3.94 mm (0.100 to 0.155 inch).

Heat Shrink Tubing for Wiring

The Caterpillar supplied engine wiring harness must not be spliced into or modified in any way that may affect the engine operation. Caterpillar recommends sealing all ring terminals and splices on the customer side of the J61/P61 customer connector. Seal the terminals with Raychem ES2000 adhesive lined heat shrink tubing, or an equivalent substitute. Refer to Table 4.

Table 4

Heat Shrink Tubing (Adhesive Lined)
Part Number	ID Before Shrink	ID After Shrink
8T-6342	3.20 mm (0.126 inch)	1.58 mm (0.062 inch)
3E-9553	4.70 mm (0.185 inch)	1.78 mm (0.070 inch)
125-7874	5.72 mm (0.225 inch)	1.27 mm (0.050 inch)
9X-2109	6.40 mm (0.252 inch)	3.20 mm (0.126 inch)
125-7585	7.44 mm (0.293 inch)	1.65 mm (0.065 inch)
119-3662	10.85 mm (0.427 inch)	2.41 mm (0.095 inch)
125-7876	17.78 mm (0.700 inch)	4.45 mm (0.175 inch)
8C-3423	68.00 mm (2.677 inch)	22.00 mm (0.866 inch)

Battery Circuit Requirements

Grounding

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NOTICE
Improper grounding can cause uncontrolled or unreliable circuit paths and electrical noise. This situation can result in damage to components. Proper grounding of the unit and the electrical systems is necessary for proper performance and reliability. Improper grounding results in unreliable electrical circuit paths. Improper grounding may also cause electrical noise, which may degrade the performance of the control system. Diagnosing and repairing these problems is often difficult.

CAN Wiring

Connecting Modules to the CAN Data Link

Table 5

Required Parts Installation of Single Module
Part Number	Description	QTY
5P-6001	Heat Shrink Tube 6.0 cm (2.36 inch)	1
125-7876	Heat Shrink Tube 15.0 cm (5.91 inch)	1
133-0969	Socket Connector	2
133-0970	Receptacle As (Tee)	1
134-2540	Resistor As (Termination Resistor)	1
153-2707	Electrical Cable (1) (Shielded Twisted Pair)	1
165-0200	Cable As	1
165-0201	Cable As	1
174-0503	Connecting Plug Kit (2)	1
186-3736	Connector Socket	4

( 1 )	Fabricate to length.
( 2 )	Use the blue wedge.

Table 6

Required Parts Installation of Each Additional Module
Part Number	Description	QTY
5P-6001	Heat Shrink Tube 6.0 cm (2.36 inch)	1
125-7876	Heat Shrink Tube 15.0 cm (5.91 inch)	1
133-0969	Socket Connector	2
133-0970	Receptacle As (Tee)	1
153-2707	Electrical Cable (1) (Shielded Twisted Pair)	1
165-0200	Cable As	1
174-0503	Connecting Plug Kit (2)	2
186-3736	Connector Socket	4

( 1 )	Fabricate to length.
( 2 )	Use the blue wedge.

Illustration 17	g02163160

Illustration 17 shows the connection of modules to the CAN data link. The following requirements must be met for installation of modules on the CAN data link:

• 153-2707 Electrical Cable (shielded twisted pair) must be used for all CAN data link runs.

• The total length of the data link run must not exceed 40 m (131 ft).

• All splices into the data link require a 133-0970 Receptacle As (tee).

• A 134-2540 Resistor As (termination resistor) must be installed at the end of the data link in order to ensure proper operation.

Note: A termination resistor for the CAN data link is included in the Caterpillar supplied wiring harness to the J61 customer connector. Only one additional termination resistor must be installed at the end of the data link run.

Illustration 18	g02163164

Illustration 19	g02163166

1. Run the CAN data link from the customer connector to a module.

   Note: The end of the data link must be within approximately 15 cm (6 inch) of the module. The total length of the data link run must not exceed 40 m (131 ft).

   1. Run 153-2707 Electrical Cable (shielded twisted pair cable) from the customer connector to the location of the first module. Cut the cable to length.

   2. Remove 25 mm (1.0 inch) of insulation from both ends of the cable.

   3. Remove 7 mm (0.28 inch) of insulation from each end of the green wire and the yellow wire.

   4. Crimp a 186-3736 Connector Socket on each end of the green wire and the yellow wire with a 1U-5804 Crimp Tool .

   5. Crimp a 133-0969 Socket Connector on each end of the shield with a 1U-5804 Crimp Tool .

   6. Cut two 30 mm (1.2 inch) pieces of 5P-6001 Tube (heat shrink tube). Slide a piece of the heat shrink tube over the shield at each end of the cable. Arrange the heat shrink tube so that 1 cm (0.4 inch) of the socket is covered and the remaining tubing is covering the shield. Apply heat until a complete seal is formed around the shield and the socket. Be careful to avoid skin contact with any hot glue that may seep from the heat shrink tube.

   7. Cut two 50 mm (2 inch) pieces of 125-7876 Heat Shrink Tube . Slide a piece of the heat shrink tube over each end of the cable.

   8. Insert the wires from one end of the data link into the customer connector. See Table 7.
      Show/hide table

      Table 7

      Terminal Locations in the Customer Connector
      Wire Color	Location
      Shield	16
      Yellow	17
      Green	18

   9. Arrange the 125-7876 Heat Shrink Tube so that 20 mm (0.8 inch) of the exposed wires are covered and the rest of the heat shrink tube is over the cable. Apply heat until a complete seal is formed. Be careful to avoid skin contact with any hot glue that may seep from the heat shrink tube.

   10. Insert the sockets at the opposite end of the CAN data link into a 174-0503 Connecting Plug Kit . See Table 8. Insert the blue wedge into the connector in order to secure the terminals in place.
       Show/hide table

       Table 8

       Terminal Locations in the Plug
       Wire Color	Location in the Plug
       Yellow	A
       Green	B
       Shield	C

   11. Arrange the 125-7876 Heat Shrink Tube so that 10 mm (0.4 inch) of the plug is covered and the rest of the heat shrink tube is over the cable. Apply heat until a complete seal is formed around both the plug and the cable. Be careful to avoid skin contact with any hot glue that may seep from the heat shrink tube.

   12. Plug the end of the data link into the single end of a 133-0970 Receptacle As .

Show/hide table



Illustration 20	g02163215

2. Run the data link from the tee to another tee for an additional module.

   Note: For installations of a single module, proceed to Step 3.

   Note: The end of the data link must be within approximately 150 mm (6 inch) of the module. The total length of the data link must not exceed 40 m (130 ft).

   1. Run 153-2707 Electrical Cable (shielded twisted pair cable) from the tee to the location of the next module. Cut the cable to length.

   2. Remove 25 mm (1.0 inch) of insulation from both ends of the cable.

   3. Remove 7 mm (0.28 inch) of insulation from each end of the green wire and the yellow wire.

   4. Crimp a 186-3736 Connector Socket on each end of the green wire and the yellow wire with a 1U-5804 Crimp Tool .

   5. Crimp a 133-0969 Connector Socket (Extended) on each end of the shield with a 1U-5804 Crimp Tool .

   6. Cut two 30 mm (1.2 inch) pieces of 5P-6001 Tube (heat shrink tube). Slide a piece of the heat shrink tube over the shield at each end of the cable. Arrange the heat shrink tube so that 10 mm (0.4 inch) of the socket is covered and the remaining tubing is covering the shield. Apply heat until a complete seal is formed around the shield and the socket. Be careful to avoid skin contact with any hot glue that may seep from the heat shrink tube.

   7. Cut two 50 mm (2 inch) pieces of 125-7876 Heat Shrink Tube . Slide a piece of the heat shrink tube over each end of the cable.

   8. Install a 174-0503 Connecting Plug Kit on each end of the cable. See Table 9. Insert the blue wedge into the connector in order to secure the terminals in place.
      Show/hide table

      Table 9

      Terminal Locations in the Plug
      Wire Color	Location in Plug
      Yellow	A
      Green	B
      Shield	C

   9. Arrange the 125-7876 Heat Shrink Tube so that 10 mm (0.4 inch) of the plug is covered and the rest of the heat shrink tube is over the cable. Apply heat until a complete seal is formed around both the plug and the cable. Be careful to avoid skin contact with any hot glue that may seep from the heat shrink tube. Perform this process on both ends of the cable.

   10. Plug one end of the new cable into one of the openings in the existing tee. Plug the other end of the new cable into the single end of a 133-0970 Receptacle As for the additional module.

   11. If you are installing additional modules, repeat Step 2 for each module.

Show/hide table



Illustration 21	g02163219

3. Connect a receiving module to the tee.

   1. Plug a 165-0200 Cable As into the 133-0970 Receptacle As .

   2. Cut a 50 mm (2 inch) piece of 125-7876 Heat Shrink Tube . Slide the heat shrink tube over the display connector of the cable assembly.

      Note: Do not connect the shield to the receiving module.

   3. Connect the green wire (J1939 Data-) and the yellow wire (J1939 Data+) on the module end of the cable assembly to the appropriate terminals. These terminals are in the module plug.

   4. Trim the shield back to the existing heat shrink tubing on the cable assembly. Position the 125-7876 Heat Shrink Tube so that the shield is insulated and a proper seal can be obtained. Apply heat until a complete seal is formed. Be careful to avoid skin contact with any hot glue that may seep from the heat shrink tubing.

   5. Repeat Step 3 for each module.

Show/hide table



Illustration 22	g02163225

4. Connect a termination resistor to the tee at the end of the data link.

   1. Plug one end of a 165-0201 Cable As into the open tee at the end of the data link.

   2. Connect a 134-2540 Resistor As (termination resistor) to the other end of the cable assembly.

Troubleshooting Section

General Information

The diagnostics for an ECM can be accessed through the Caterpillar Electronic Technician (Cat ET). Troubleshooting a system requires additional information from the vehicle Service Manual. The additional manuals that may be required are the Machine Monitor System, the Electrical System Schematic, the Parts Manual, and the Operation and Maintenance Manual for the vehicle that is being serviced.

As a reference, a simplified system schematic is included at the end of this manual. For an accurate representation of the vehicle that is being diagnosed, refer to Electrical System Schematic in the Service Manual for the vehicle that is being serviced.

When the troubleshooting procedure instructs you to "REPAIR THE HARNESS OR REPLACE THE HARNESS", use the Electrical System Schematic for the vehicle that is being serviced to trace the circuit. Perform continuity checks at the harness connectors in order to locate harness failures. At the connectors of the components, always check the ground circuit. There must be less than 5 ohms of resistance between any system ground and the frame ground. Excessive ground resistance that is greater than 5 ohms can cause incorrect diagnosing of problems.

During troubleshooting, inspect all connections before any component is replaced. If these connections are not clean and tight, permanent electrical problems or intermittent electrical problems can result. Check that the wires are pushed into the connectors completely. Make sure that the connections are tight before other tests are made.

If wire insulation is punctured during troubleshooting, repair the damage. Seal the damaged wires with 8T-0065 RTV Silicone Sealant . Cover the sealant with two layers of 1P-0810 Tape .

Failure of an electrical component can cause the failure of other components. Also, failure of an electrical component can be caused by the failure of other components. Always attempt to correct the cause of an electrical system failure before you replace a component.

When you are removing the machine harness from any ECM, use the single screw in the center of the harness connector.

Service Tools

The following service tools should be used to aid in troubleshooting the electrical system.

Table 10

Service Tools
Part Number	Part
	Caterpillar Electronic Technician (ET)
6V-7070 9U-7330	Digital Multimeter
8T-3224	Needle Tip Group
7X-1710	Multimeter Probe Group
8T-8726	Adapter Cable Assembly
9U-7246	Connector Repair Kit DT
4C-3406	Connector Repair Kit
4C-8195	Control Service Tool (Switch Box)
157-4829	Cable Adapter

Illustration 23	g02178350
Connections for the Communication Adapter II and Caterpillar Electronic Technician (ET) The components needed to use the Communication Adapter II and Caterpillar Electronic Technician (ET) to determine diagnostic trouble codes are listed: (9) Cable (10) 171-4400 Communication Adapter II (11) Service diagnostic cable. (12) Current version of Cat ET software and an IBM-COMPATIBLE personal computer

ReferenceSee Special Publication, NEHS0758, "Communications Adapter II User Manual Contains Software".

Note: Caterpillar Electronic Technician (ET) is a software program that can be used on an IBM compatible personal computer.

In order to use Cat ET, order the following materials: Special Publication, JERD2124, "ET Single Use Program License", Special Publication, JEHP1026, "Information and Requirements Sheet", 7X-1425 Data Link Cable and the Data Subscription and Special Publication, JERD2142, "Data Subscription". The Special Publication, JEHP1026, "Information and Requirements Sheet" lists the required hardware and the features of Cat ET.

Cat ET is not required to determine or clear the diagnostic trouble codes. However, the process of determining the diagnostic trouble codes is easier and faster by using Cat ET. Cat ET can also display information on the history of a diagnostic trouble code and the parameter status of diagnostic trouble codes. These features allow Cat ET to be a useful tool for troubleshooting.

Cat ET is used to communicate to the electronic control module over the data link by connecting to the machine diagnostic connector. For more information and the locations of the connectors, see Troubleshooting, "Electrical Components and Connector Locations" and the Electrical System Schematic in your vehicle Service Manual.

For instructions on servicing Sure Seal connectors, see Special Instruction, SMHS7531. For instructions on servicing Deutsch connectors, see Special Instruction, SEHS9615.

Use the digital multimeter for measuring resistance or for measuring voltage. For instructions about the use of the 6V-7070 Digital Multimeter , see Special Instruction, SEHS7734. The 7X-1710 Multimeter Probe measures the voltage at the connectors without disconnecting the connectors. The probe cables are pushed into the back of the connector along the wire. The 8T-8726 Adapter Cable has a breakout with three pins. The adapter cable is used for measurements in the sensor circuits.

Note: Except for harness tests, using continuity testers such as the 8T-0500 Continuity Tester or voltage testers such as the 5P-7277 Voltage Tester is not recommended for today's Caterpillar electrical circuits.

Data Link Communications

J1939

Shift Selector Communication

All shift selector required messaging is communicated over "J1939". The shift selector receives the following information from "J1939": requested and current gear, which shift selector is currently active and the mode indicators. Shift requests based on the buttons pressed are communicated over "J1939" to the transmission via a single parameter group number (PGN).

Status Values

Most of the status values indicated on the shift selector are received from various nodes via "J1939". All engine parameters and all transmission parameters, which do not deal with dropbox operation, are received from various nodes via "J1939". Supported PGN and SPN combinations are listed in the appendix. If a parameter is not being supported or transmitted correctly, the parameter will be displayed as a series of asterisks or displayed as UNKNOWN.

Engine and other ECM Diagnostics

Diagnostics from the engine and other common controllers are received over "J1939" on DM1 and DM2 messages. These diagnostics will be displayed on the Diagnostics submenu. These diagnostics will also initiate pop-ups or alarms. The shift selector will only display diagnostics from select Electronic Control Modules (ECMs) that were predetermined to be important to the system. Any other unexpected ECMs diagnostic messaging will not be displayed on the shift selector.

See ""Appendix" " for a list of sources.

CAT Data Link

Status Values

A handful of parameters which are not generally available over "J1939" are supported via Cat Data Link (CDL). These parameters deal with the dropbox status and serial numbers. If a parameter is not being supported or transmitted, the parameter will be displayed as a series of asterisks or displayed as UNKNOWN.

Transmission Diagnostics

Diagnostics and events from the transmission "MID 27" are received over Cat Data Link and match the ones displayed in the service tool. These diagnostics will be displayed on the Diagnostics submenu as well as initiate any pop-ups or alarms.

These diagnostics and events cannot be configured to show up in any certain manner nor permanently displayed. Only transmission diagnostics and events will be received via Cat Data Link.

See ""Transmission Diagnostics/Events Via Cat Data Link" " for a list of possible diagnostics that could be raised on the transmission and displayed on the shift selector. This list is not a complete list of all diagnostics that may be shown. Any diagnostics raised that are not in this list will be displayed on the shift selector. However, these diagnostics will have text describing the diagnostic as an unknown error.

Service Tool and Flashing Software

Requirements

The following components in Table 11 are required to use ET to service the transmission.

Table 11

Required Electronic Service Tools for the Use of ET
Part Number	Description
N/A	Required (IBM compatible PC with 1.8 GHz Pentium 1V processor. 512 MB of RAM. 1 GB of available hard drive space. 3.5 inch 1.44 MB floppy disk drive. Windows 2000 or XP. RS232 port with 16550AF UART VGA monitor or display. Internet Explorer 6.0 or higher)
N/A	Recommended (IBM compatible PC with 2.4 GHz Pentium IV processor. 1GB of RAM. 1 GB of available hard drive space. Microsoft Windows 2000 or XP. Internet Explorer 6.0 or higher)
JERD2124	Electronic Technician Program (ET)
JERD2129	Data Subscription for All Engines and Machines
275-5120 (1)	Communication Adapter Gp

( 1 )

A 171-4401 Communication Adapter As may also be used.

Flashing the Shift Selector

Illustration 24	g02160518

In order to flash the shift selector, connect to the ECM using J1939 or CDL in Winflash. As Caterpillar ECMs are located on the data links, the ECMs will be displayed as Detected ECMs. By clicking the shift selector ECM and having the name highlighted, the component has been selected as the target of flash (1). description (2) should identify the component as a shift selector for the petroleum transmission.

Illustration 25	g02160521

The technician may select a new file (3) to be flashed on the ECM by entering a location of the flash file. Or the technician may browse for the flash file on the computer. Once a flash file is selected, a description of the file shall appear in the space below (4). Check that the description in the space correctly correlates to the targeted ECM. More information about the file should be displayed at the bottom of the screen to confirm the type of software and purpose (5). A press of the "Begin Flash" button will begin flash sequence (6). However, make sure that the correct flash file has been selected and the target is the shift selector.

Illustration 26	g02160524

A flash progression bar will appear with the status of the flashing process and the estimated completion percentage. This process could take some time. The time depends on the data link that is being used for flashing, bus traffic, and the size of the flash file. If there is an error in the process, a box will be displayed in place of the flash progression bar. This box will describe the situation and the error.

Illustration 27	g02160525

Once flashing has successfully completed, the progression bar will change into a selection box which asks where the technician would like to proceed. If the user selects Cat ET or Winflash, the newly flashed software part number should be visible when the ECM reconnects to the software.

Diagnostic Capabilities

Caterpillar Electronic Technician (Cat ET)

Caterpillar Electronic Technician (Cat ET) is a software program that is used to access data. The service technician will use Cat ET to perform the maintenance on the vehicle. Some of the options that are available with Cat ET are listed below:

• Diagnosis of problems

• Viewing diagnostic trouble codes

• Viewing active event codes and logged event codes

• View the status of parameters

• Clear active diagnostic trouble codes and clear logged diagnostic trouble codes

• Perform calibration of machine systems

• Program the ECM (Flash). Programming is done with the "WINflash" program. See Testing and Adjusting, "Electronic Control Unit - Flash Program"

• Print reports

See Troubleshooting, "Determining Diagnostic Trouble Codes". Diagnostic information is accessed with the following drop-down menus:

• Active diagnostic trouble codes

• Logged diagnostic trouble codes

Electronic Control Module (ECM) Summery

Illustration 28	g02163580

Advisor can connect to the service tool over Cat Data Link to display basic information about the unit. The shift selector cannot configure any values or see any status screens. The shift selector only reports the Electronic Control Module (ECM) summary information. Refer to Illustration 28.

Symptom Procedures

Symptom Troubleshooting

Use the following guidelines as you troubleshoot a symptom:

Know the Machine

Understand the operation of the machine. Know if the symptom is a characteristic of normal operation or if the symptom is a failure.

Read the systems operation information in order to understand the systems of the machine. Understand the interaction of the machine systems.

Understand the Symptom

Speak with the operator about the symptom. Acquire the following Information:

• The performance of the machine prior to the failure

• First occurrence of the symptom

• The operating conditions at the time of the failure

• The sequence of events prior to the failure (order of the occurrences)

• The troubleshooting steps that have been taken

• The history of repairs of the machine

• The preventive maintenance of the machine

• Related service information about current problems that affect the serial number of the machine

• Inspect the Machine. Look for problems. Notice any unusual odors in the air. Listen for unusual noises.

Perform the "Visual Inspection" steps. Refer to Troubleshooting, "Machine Preparation for Troubleshooting".

Verify the Symptom

When possible, attempt to duplicate the symptom. Operate the machine and repeat the conditions that caused the failure. Check the gauges inside the cab. Notice any unusual odors in the air. Listen for unusual noises.

Determine if the ECM has detected any faults. A diagnostic code is used to specify each detected fault.

Determine Possible Causes

Use the information from the operator and your inspection. Attempt to identify a common cause if there is more than one symptom.

If you troubleshoot diagnostic codes and the problem is not resolved, continue troubleshooting using the "Symptom Troubleshooting" section of this manual. Identify the component that is the most probable cause of the symptom.

Test and Repair the System

Use the tests and procedures in this manual to verify the cause of the symptom. Once the cause has been identified, repair the failure. Then, test the system again in order to verify that the symptom is resolved.

Provide Feedback to Caterpillar

Share your troubleshooting information. After the correct repair has been performed, use the form in "SIS" or "CBT" feedback, to write a brief description about the symptom, testing, and repair of the machine. Include your phone number or your e-mail address so that you can be contacted. This feedback information helps Caterpillar improve service information.

Emerging Symptom Information

This space is for new symptom information for this product.

Note: Use the Service Information System on the Web in order to find the most up-to-date information.

Share your troubleshooting knowledge of symptoms. Use the form in "SIS" or "CBT" feedback to write a brief description about the symptom, testing, and repair of the machine. Your feedback information will help Caterpillar improve the symptom information for this product.

Shift Selector Identification Problem

Identification/Locator Pins

The shift selector source address on the data link is identified by the shift selector locator pins. Pin "14" or "15" must be grounded in order for the shift selector to function. This strategy is shared by current transmission push button and lever shift selectors.

If pin "14" is grounded and pin "15" is open, the hazardous area shift selector will assume the primary shift selector address. The shift selector will be referred to as the primary shift selector, or shift selector 1.

If pin "15" is grounded and pin "14" is open, the hazardous area shift selector will assume the secondary shift selector address. The shift selector will be referred to as the secondary shift selector, or shift selector 2.

Identification Not Specified

Illustration 29	g02163589

The shift selector will check the location pins to find out what source address should be claimed during power up. If both pins are either open or closed, the shift selector will not be able to connect to "J1939" or Cat Data Link (CDL). If no connection is made, the shift selector will not communicate with the transmission. If there is no communication, the shift selector will alert the operator that a wiring issue has been detected. Refer to Illustration 29. The operator must correct the wiring issue and cycle power to the shift selector for operation.

Identification Change

Illustration 30	g02163590

A wiring change to the shift selector will cause the shift selector to display a warning that the ID has been changed. Refer to Illustration 30. This warning will only appear if the wiring is still valid. The power will need to be cycled to ensure that the shift selector claims the correct address.

Identification Conflict

If two shift selectors have both been wired as either primary or secondary, both will attempt to claim the same source address. Since each source address must be unique, one of the shift selectors will be removed from the data link. The shift selector will display text to alert the user of this occurrence. Push-button shift selectors and lever "J1939" shift selectors will display text of "AA" if multiple primary addresses were claimed. Push-button shift selectors and lever "J1939" shift selectors will display text of "BB" if multiple secondary addresses are claimed.

Incompatible Primary and Secondary Shifters

The first-generation push-button shifters are incompatible with most other shifters. If these shifters are connected to the J1939 network, the keypad shifter will not display the gear selection properly, and the hazardous location will continue to display the desired and actual gear when it should not. The following tables identify specific shifter combinations which have been tested together and are known to work.

Table 12

Shifter Components
Part Number	Description
255-6262	Transmission Control Gp (Gen one push button shifter)
320-2981	Transmission Control Gp (Gen one push button with improved sealing)
298-3860	Transmission Control Gp (Gen two push button)
320-2982	Transmission Control Gp (Lever shifter)
373-2771	Display Module Gp (Hazardous area shift selector)

Table 13

Shifter Combinations
Primary	Secondary	Result
255-6262	373-2771	Does Not Work
373-2771	255-6262	Does Not Work
320-2981	373-2771	Does Not Work
373-2771	320-2981	Does Not Work
298-3860	373-2771	Works
373-2771	298-3860	Works
320-2982	373-2771	Works
320-2982	298-3860	Works
320-2982	255-6262	Does Not Work
320-2982	320-2981	Does Not Work

Diagnostic Code Procedures

Diagnostic Code List

Internal Events and Diagnostics

Diagnostics and events raised by the shift selector would be displayed in the same manner as other diagnostics and events. Diagnostic alerts will be identified as MID 117.

Table 14

Module Identifier 117 Diagnostic Codes (1)
CID 0168 Electrical System
FMI 03	Voltage above normal
FMI 04	Voltage below normal
CID 0247 Remote Communication Module
FMI 09	"J1939" Datalink Lost
CID 0248 Remote Communication Module
FMI 09	Cat Datalink Lost

( 1 )

For troubleshooting, see the procedure with the same CID FMI.

Using Caterpillar Electronic Technician (ET) to Determine Diagnostic Codes

Connect Caterpillar Electronic Technician to the machine. Turn the key switch to the RUN position. Start Cat ET. Cat ET will initiate communications with the Electronic Control Modules (ECMs) on the machine. After communication has been established, Cat ET will list the ECMs. After the diagnostic codes have been determined with Cat ET, see the test procedure for the corresponding diagnostic code.

ReferenceTroubleshooting, "Service Tools"

Active Diagnostic Codes

Illustration 31	g01810913
Typical Cat ET screen for active diagnostic codes

The following procedures may cause new diagnostics or events to be logged. Therefore, before performing any procedures, make a list of all the active diagnostics and events to determine the system problems. Clear the diagnostics and events that were caused by the procedure, when each procedure is complete.

Note: Before performing a procedure, always check all the circuit breakers. Repair the cause of any circuit breaker that is tripped.

A screen is provided in Cat ET for active diagnostic codes. The screen will display the diagnostic codes that are active. Active diagnostic information shall include a component identifier (CID), a failure mode identifier (FMI) and a text description of the problem.

Logged Diagnostic Codes

Illustration 32	g01810915
Typical Cat ET screen for logged diagnostic codes

A screen is provided in Cat ET for logged diagnostic codes. Cat ET will log diagnostic codes that are intermittent. The logged diagnostic data shall include a component identifier (CID), a failure mode identifier (FMI), and a text description of the problem. Also, the logged diagnostic data shall include the number of occurrences of the problem and two time stamps. The time stamp displays the first occurrence of the problem and the time stamp displays the most recent occurrence of the problem.

Diagnostics are logged in non-volatile memory. On powerup, the ECM will clear any diagnostics or events that have not been detected or active within the last 150 hours of machine operation.

MID 117 - CID 0168 - FMI 03

Conditions Which Generate This Code:

This diagnostic code is recorded when the ECM reads the system voltage as being greater than 32 DCV.

The possible causes of this diagnostic code are listed:

• A charging system component has failed.

• The wiring of the machine harness has failed.

• The ECM has failed. ECM failure is unlikely.

System Response:

When this diagnostic code occurs, the action lamp and the action alarm are ON. The lamp for system voltage is also ON.

Test Step 1. Check the charging system

1. Turn the disconnect switch and the key start switch to the ON position.

2. Place CID 0168 FMI 03 on hold.

3. View the status of the diagnostic code.

Expected Results:

The diagnostic code is NO longer active.

Results:

• YES - The diagnostic code is NO longer active.

Proceed to test Step 2.

• NO - The diagnostic code remains active.

Proceed to test Step 3.

Test Step 2. Check the charging system again

1. Start the engine.

2. Place CID 0168 FMI 03 on hold.

3. View the status of the diagnostic code.

Expected Results:

The diagnostic code is NO longer active.

Results:

• YES - The diagnostic code is NO longer active. Watch for a recurrence.

STOP.

• NO - The diagnostic code is active. The charging system is charging at an excessive voltage.

REPAIR: Check the charging system. See Special Instruction, REHS0354, "Charging System Troubleshooting" for more information.

STOP.

Test Step 3. Check the battery voltage

1. The engine should not be running.

2. At the battery, measure the voltage of the battery.

Expected Results:

The voltage should measure less than 32 DCV.

Results:

• YES - The voltage measures less than 32 DCV. The ECM must be recording this diagnostic code incorrectly. The ECM may have failed.

REPAIR: ECM failure is unlikely. Exit this procedure and perform this procedure again. If the cause of the diagnostic code is NOT found, replace the ECM. See Troubleshooting, "Electronic Control Module (ECM) - Replace".

STOP.

• NO - The voltage measurement is greater than 32 DCV. The charging system is charging at an excessive voltage.

REPAIR: Check the charging system.

STOP.

MID 117 - CID 0168 - FMI 04

Conditions Which Generate This Code:

This diagnostic code is recorded when the system voltage is below 22 VDC. When this code is active, the brake is applied and the transmission shifts into neutral.

The possible causes of this diagnostic code are listed below:

• The fuse for the power train is open.

• The wiring in the machine harness has failed.

• A charging system component has failed.

• The ECM has failed. ECM failure is unlikely.

Test Step 1. Check the battery voltage with the engine running

1. Start the engine and run at high idle for several minutes.

2. Measure the battery voltage at the battery posts.

Expected Results:

Battery voltage should be greater than 22 VDC.

Results:

• OK - Battery voltage is greater than 22 VDC. Battery voltage is correct.

Proceed to test Step 2.

• NOT OK - Battery voltage is less than 22 VDC.

REPAIR: The charging system is not correct. Check the charging system. See System Operation, SENR2947, "Starting and Charging System".

STOP.

Test Step 2. Check the system voltage at the ECM

1. The engine must still be running at high idle.

2. Do not disconnect the machine harness from the ECM. At connector "J1" of the ECM, prepare to make a voltage measurement by using a digital multimeter.

3. The + battery power connects to the ECM at four contacts on the J1 connector. Refer to the complete electrical schematic. At the J1 machine harness connector for the ECM, insert the multimeter probes into the contacts for wire 140-RD and for wire (202-BK). Measure the voltage.

Expected Results:

Voltage should be greater than 22 VDC.

Results:

• OK - Voltage is greater than 22 VDC.

• NOT OK - Voltage is less than 22 VDC.

REPAIR: The machine harness is not correct. Refer to the Electrical System Schematic. Ensure that the fuse is not open. Check all machine harness connectors that are involved in the circuit for tight connections or corrosion. Repair the machine harness or replace the machine harness.

STOP.

Test Step 3. Check the status of the diagnostic code

1. Inspect the harness connectors. Clean the contacts of the harness connectors and check the wires for damage to the insulation. Damage is caused by excessive heat, battery acid, or chafing.

2. Perform a 45 N (10 lb) pull test on each of the wires that are associated with the circuit.

3. Reconnect all of the harness connectors in order to make sure that the connectors are fully seated. Also, make sure that the clips for each connector are fastened.

4. Turn the disconnect switch and the key start switch to the ON position.

5. Operate the machine.

6. Determine if the CID 0168 FMI 04 is active.

Expected Results:

The CID 0168 FMI 04 diagnostic code is not active.

Results:

• OK - The CID 0168 FMI 04 code is not active. The problem does not exist at this time.

REPAIR: The initial diagnostic code was probably caused by a poor electrical connection that was disconnected and reconnected. Resume normal machine operation.

STOP.

• NOT OK - The CID 0168 FMI 04 code is active.

REPAIR: An ECM failure is unlikely. Exit this procedure and perform this procedure again. If the cause of the diagnostic code is not found, the ECM may have failed. Prior to replacing an ECM, always contact your technical communicator for possible consultation with Caterpillar. This consultation may greatly reduce repair time. Refer to Troubleshooting, "Electronic Control Module - Replace".

STOP.

MID 117 - CID 0247 - FMI 09

Conditions Which Generate This Code:

Illustration 33	g02165039
Schematic of the J1939 Data Link

The diagnostic trouble code is associated with the Transmission ECM. The FMI 09 means that the ECM is not receiving any of the expected information from the "J1939" data link.

The possible causes of this diagnostic trouble code are listed if only two modules cannot communicate:

• Loose harness connections

• Open wires

• Problems with the terminating resistors

• Wires that are shorted to ground

• Wires that are shorted to the battery

• The high data link wire is shorted to the low data link wire.

• High resistance across the Data Link

• Interference across the wires for the Data Link

• Incompatible Software

• Incorrect setup for parameters

• Failure of a smart device

• The ECM has failed. ECM failure is unlikely.

The possible causes of this diagnostic trouble code are listed if all of the control modules cannot communicate:

• Problems with the terminating resistors

• Wires that are shorted to ground

• Wires that are shorted to the battery

• The high data link wire is shorted to the low data link wire.

• Interference across the wires for the Data Link

Note: The high wires and low wires of the data link have a positive voltage. One does not have a negative voltage. The shield should not be used as a ground wire when the voltage is measured. Always use a clean, unpainted connection to the frame ground. The Caterpillar Electronic Technician (Cat ET) does not show that all of the controllers connected to the data link. The controller may not have been recognized by Cat ET. Cycling the key and restarting the Cat ET may correct the problem.

Test Step 1. Inspect the harness connections

1. Turn the disconnect switch to the OFF position.

2. Inspect all of the harness connections. Make sure that the connectors are clean and tight.

3. Check the connectors for proper mating. Ensure that all the seals are present and in place.

4. Check the harness for signs of damage or abrasion.

5. Check the wires at the connector. Ensure that the wires are secured tightly into the connector. Perform a 45 N (10 lb) pull test on each of the wires that are associated with the circuit. Take care not to pull the wire out of the connector.

6. Check the exposed wires at the connectors for nicks or signs of abrasion.

7. Check for moisture inside the connector.

8. Check the connectors for dirty contacts or corroded contacts.

9. Check each pin and each socket of the machine harness connectors. Ensure that the contacts are properly installed. The contacts should mate correctly when the two pieces of the connector are placed together.

Note: See Testing and Adjusting, "Electrical Connector - Inspect" for more information.

Expected Results:

The machine harness connectors are tight and free of corrosion.

Results:

• OK - The machine harness connectors are tight and free of corrosion. Proceed to test Step 2.

• NOT OK - The machine harness connectors are in need of repair.

REPAIR: Repair the machine harness or replace the machine harness.

Proceed to Test Step 8.

Test Step 2. Check the voltage of the data link

1. Turn the keyswitch and the disconnect switch to the ON position.

2. At the ECM, use an electrical spoon to measure the voltage. One at a time, measure the voltage of connector contact J2-67, J2-68, and J2-69 to frame ground.

   Note: Do not use the shield as a ground.

   Show/hide table

   Table 15

   J2-67	J2-68	J2-69
   0.5 V to 4.5 V	0.5 V to 4.5 V	0 V

Expected Results:

The shield does not have a voltage. A voltage on the shield means that there is a short to the battery. The voltage of the wires for the Data Link is correct.

Results:

• OK - The voltage of the wires for the Data Link is correct. Proceed to Test Step 3

• NOT OK - The voltage is greater than 4.5 V.

REPAIR: Repair the machine harness or replace the harness.

Proceed to Test Step 8.

• NOT OK - The voltage is less than 0.5 V.

Proceed to Test Step 3.

Test Step 3. Check for a short to ground

1. Turn the keyswitch and the disconnect switch to the OFF position.

2. Disconnect the J1 harness connector for the ECM. Disconnect the harness connector for the shift pad.

3. Measure the resistance of wire (K900-YL) to an unpainted frame ground. Measure the resistance of wire (K990-GN) to an unpainted frame ground.

Expected Results:

The resistance measurement is greater than 5000 ohms.

Results:

• OK - The resistance measurement is correct.

Proceed to Test Step 5.

• NOT OK - The resistance measurement is not correct. The wire with the low resistance measurement is shorted to ground.

REPAIR: Repair the machine harness or replace the machine harness.

Proceed to Test Step 8.

Test Step 4. Check for a short in the wires for the data link

1. The keyswitch and the disconnect switch remain in the OFF position.

2. Disconnect the terminating resistors if the resistors are a part of the circuit.

3. Measure the continuity between the data link wires.

Expected Results:

The resistance measurement is greater than 5000 ohms.

Results:

• OK - The resistance measurement is correct. Proceed to Test Step 5.

• NOT OK - The resistance measurement is not correct. The wires for the data link are connected.

REPAIR: Repair the machine harness or replace the machine harness.

Proceed to Test Step 8.

Test Step 5. Check for an open in the wires for the data link

1. The keyswitch and the disconnect switch remain in the OFF position.

2. Disconnect wire (K900-YL) and wire (K990-GN) from the ECM.

3. Measure the continuity of each wire individually. Use a jumper wire in order to connect to the other end of the wire in question.

Expected Results:

There is continuity from one end of the wire to the other end.

Results:

• OK - There is continuity from one end of the wire to the other end. The wire is correct.

Proceed to Test Step 6.

• NOT OK - There is not continuity from one end of the wire to the other end. The wire is not correct.

REPAIR: Repair the machine harness or replace the machine harness.

Proceed to Test Step 8.

Test Step 6. Check the terminating resistors

Note: Two 120 Ohm resistors should be located on the CAN Data Link. A resistance of 60 ohms should be found at any point on the data link. Terminating resistors are not always used on data links. The resistance measurement should be greater than 5000 ohms if resistors are not intentionally a part of the circuit.

1. The keyswitch and the disconnect switch remain in the OFF position.

2. Use an electrical spoon in order to connect to the back of the connector for one of the terminating resistors.

3. Measure the resistance between the wires.

Expected Results:

The resistance measurement is between 55 and 65 ohms.

Results:

• OK - The resistance measurement is correct.

Proceed to Test Step 7.

• NOT OK - The resistance measurement is approximately 120 ohms. One of the resistors is not functioning properly.

REPAIR: Ensure that the resistor is fully connected to the data link. Replace the resistor if the resistor has failed.

Proceed to Test Step 8.

• NOT OK - The resistance measurement is approximately 40 ohms.

REPAIR: There are more than two resistors on the circuit for the data link. Remove the extra resistor.

Proceed to Test Step 8.

Test Step 7. Check if the shield is shorted to ground

Note: Two 120 Ohm resistors should be located on the CAN Data Link. A resistance of 60 ohms should be found at any point on the data link. Terminating resistors are not always used on data links. The resistance measurement should be greater than 5000 ohms if resistors are not intentionally a part of the circuit.

1. The keyswitch and the disconnect switch remain in the OFF position.

2. Remove the shield (A249-BK) from the connector harness at the ECM for every ECM.

3. Use a multimeter in order to measure the resistance of wire (A249-BK) to an unpainted machine ground.

Expected Results:

The resistance measurement is greater than 5000 ohms.

Results:

• OK - The resistance measurement is greater than 5000 ohms. The circuit is correct.

• NOT OK - The resistance is less than 5000 ohms. The circuit is incorrect. The shield is shorted to ground.

REPAIR:Repair the machine harness or replace the machine harness.

Proceed to Test Step 8.

Test Step 8. Check if the diagnostic trouble code remains

1. Inspect the harness connectors. Clean the contacts of the harness connectors and check the wires for damage to the insulation. Damage can be caused by excessive heat, battery acid, or chafing.

2. Perform a 45 N (10 lb) pull test on each of the wires that are associated with the circuit.

3. Reconnect all harness connectors. Make sure that the harness connectors are fully seated and the clips for each connector are fastened completely.

4. Turn the disconnect switch and the key start switch to the ON position.

5. Operate the vehicle.

6. Check the status of the SPN 639 FMI 9.

Expected Results:

The diagnostic trouble code is active.

Results:

• YES - The diagnostic trouble code is active. The diagnostic trouble code has not been corrected.

REPAIR: Repair the machine harness or replace the machine harness.

• NO - The diagnostic trouble code is not active. The diagnostic trouble code does not exist at this time. The initial diagnostic trouble code was probably caused by a poor electrical connection at one of the harness connectors that was disconnected and reconnected. Resume normal vehicle operation.

STOP.

MID 117 - CID 0248 - FMI 09

Conditions Which Generate This Code:

Illustration 34	g02165094
Schematic of the Cat Data Link

This diagnostic trouble code is recorded when the Cat Data Link is not communicating correctly. For example, actual gear information is not received from other electronic control modules through the Cat Data Link. This diagnostic trouble code causes the readouts, that are dependent upon the Cat Data Link information, to indicate abnormal values.

• Poor electrical connection at a machine harness connector

• The circuit for the Cat Data Link in the machine harness is shorted to ground.

• The circuit for the Cat Data Link in the machine harness is shorted to the +battery.

• The circuit for the Cat Data Link in the machine harness is open.

Test Step 1. Check for other diagnostic trouble codes

1. Check for other diagnostic trouble codes that are related to the Cat Data Link.

Note: See Testing and Adjusting, "Electrical Connector - Inspect" for more information.

Expected Results:

There are other diagnostic trouble codes that are showing.

Results:

• YES - Exit this procedure and perform the other procedures for the diagnostic trouble codes that are shown.

STOP.

• NO - There are not any other diagnostic trouble codes that are shown.

Proceed to Test Step 2.

Test Step 2. Inspect the harness connectors

1. Turn the disconnect switch to the OFF position.

2. Inspect the connections for the machine harness that are related to the Cat Data Link.

3. Make sure that connectors are clean and tight.

Expected Results:

The machine harness is correct.

Results:

• OK - The machine harness is correct.

Proceed to Test Step 3.

• NOT OK - The machine harness is not correct.

REPAIR: Repair the machine harness or replace the machine harness.

STOP.

Test Step 3. Check for a short to ground

1. The disconnect switch remains in the OFF position.

2. Disconnect the machine harness from all of the electronic control units that use the Cat Data Link.

3. At the machine harness connector for the ECM, measure the resistance between frame ground and wire 893-GN and wire 892-BR of the Cat Data Link.

Expected Results:

The resistance is greater than 5000 ohms.

Results:

• YES - The resistance is greater than 5000 ohms. The harness circuit resistance is correct.

Proceed to Test Step 4.

• NO - The resistance is less than 5000 ohms. The machine harness has failed. There is a short between the frame ground and the Cat Data Link circuit in the machine harness.

REPAIR: Repair the machine harness or replace the machine harness.

STOP.

Test Step 4. Check for a short to the +battery

1. The disconnect switch remains OFF.

2. All related control modules remain disconnected from the machine harness.

3. At the machine harness connector for the ECM, measure the resistance between the +battery circuit J1-31 and the circuits of the Cat Data Link, contacts J1-10 (wire 893-GN) and J1-20 (wire 892-BR).

Expected Results:

The resistance is greater than 5000 ohms.

Results:

• OK - The resistance is greater than 5000 ohms. The harness circuit resistance is correct.

Proceed to Test Step 5.

• NOT OK - The resistance is less than 5000 ohms. The machine harness has failed. There is a short between the +battery and the Cat Data Link circuit in the machine harness.

REPAIR: Repair the machine harness or replace the machine harness.

STOP.

Test Step 5. Check for an open harness

1. The disconnect switch remains in the OFF position.

2. All related control modules remain disconnected from the machine harness.

3. Check the continuity of the Cat Data Link circuit in the machine harness.

4. Measure the resistance from the connector contacts J1-10 (wire 893-GN) and J1-20 (wire 892-BR) of the ECM to the connector for each of the related electronic control modules.

Expected Results:

The resistance is less than 5 ohms.

Results:

• YES - The resistance is less than 5 ohms. The Cat Data Link circuit in the machine harness is correct.

REPAIR: The Transmission ECM has probably not failed. Exit this procedure and perform this procedure again. Prior to replacing an ECM, contact your dealership for possible consultation with Caterpillar. This consultation may greatly reduce repair time. If the ECM requires replacement, refer to Testing and Adjusting, "Electronic Control Module Unit - Replace" for more information.

STOP.

• NO - There is not continuity from one end of the wire to the other end. The wire is not correct.

REPAIR: Repair the machine harness or replace the machine harness.

STOP.

MID 117 - CID 0820 - FMI 07

Conditions Which Generate This Code:

This diagnostic code is recorded if the shift selector determines that information on the "keypad data link" is erratic or the information makes no sense.

System response:

This condition causes the keypad to operate erratically or the keypad may not function at all.

Test Step 1. Inspect the buttons on the keypad

1. Turn the disconnect switch to the OFF position.

2. Inspect the buttons for the keypad in order to ensure that the buttons operate smoothly.

3. Toggle each button on the keypad.

Expected Results:

The buttons appear to move smoothly.

Results:

• OK - The buttons appear to move smoothly.

Proceed to Test Step 2.

• Not OK - One or more of the buttons appear to be improperly activated. The face plate of the advisor is causing one or more of the buttons to be improperly activated.

REPAIR: Either remove the face plate and reinstall the face plate or manipulate the buttons in order to ensure smooth operation.

STOP.

Test Step 2. Check if the diagnostic code remains

1. Turn the disconnect switch and the key start switch to the ON position.

2. Clear all inactive diagnostic codes.

3. Operate the machine.

4. Check the status of CID 0820 FMI 07.

Expected Results:

The diagnostic code is NO longer active.

Results:

• YES - The diagnostic code is NO longer active. The diagnostic code does NOT exist at this time. The initial diagnostic code was probably caused by a poor electrical connection of the buttons for the Advisor. Resume normal machine operation.

STOP.

• NO - The diagnostic code remains active. The shift selector failing is unlikely.

REPAIR: Exit this procedure and perform this procedure again.

STOP.

Diagnostic System Procedures

Power Supply Circuit

System Operation Description:

Power to the ECM can fail due to an open circuit in the wire, or a blown fuse. A fuse is blown out as a result of an overloaded circuit. For example, the +battery connection is shorted to ground.

Test Step 1. Check the ECM for power and ground

1. At the ECM, measure the voltage from contact 1 to contact 2.

Expected Results:

The voltage is system voltage.

Results:

• OK - The voltage is system voltage. The power supply circuit to the ECM is correct.

STOP.

• NOT OK - The voltage is not system voltage.

Proceed to Test Step 2.

Test Step 2. Check the fuse

1. Whenever the electronic components of the machine fail to function, check the appropriate fuse for the ECM.

Expected Results:

The fuse is correct.

Results:

• YES - The fuse is correct.

Proceed to Test Step 3.

• NO - The fuse is not correct.

REPAIR: Replace the blown fuse or reset the circuit breaker. Observe the machine for a recurrence of the problem. If the problem persists, the reason for the blown fuse must be isolated and corrected.

STOP.

Test Step 3. Check the power wire to the ECM

1. Turn the key start switch and the disconnect switch to the OFF position.

2. At the fuse, connect the lead from the multimeter to wire 113-RD.

3. At the ECM, connect the other lead from the multimeter to connector contact 1 and measure the resistance.

Expected Results:

The resistance is less than 5 ohms.

Results:

• OK - The resistance is less than 5 ohms. The wiring circuit is correct.

Proceed to Test Step 4.

• NOT OK - The resistance measurement is greater than 5000 ohms. The wiring has an open circuit.

REPAIR: Repair the wiring harness or replace the wiring harness.

STOP.

Test Step 4. Check the ECM ground connections

1. The keyswitch and the disconnect switch remain in the OFF position.

2. At the ECM, measure the resistance from connector contact 2 to frame ground.

Expected Results:

The resistance is less than 5 ohms.

Results:

• OK - The resistance is less than 5 ohms. The ground circuit is correct. The ECM may have failed. Failure of the ECM is unlikely. Perform this entire procedure again. If the problem remains, the ECM may need replaced. Contact your dealerships for possible consultation with Caterpillar. This consultation may greatly reduce repair time.

STOP.

• NOT OK - The resistance is greater than 5000 ohms. The ground circuit has failed.

REPAIR: The ground circuit has failed. Repair the wiring harness or replace the wiring harness.

STOP.

Testing and Adjusting

Electrical Connector - Inspect

ReferenceSpecial Instruction, SEHS9615, "Servicing DT Connectors".

ReferenceSpecial Instruction, REHS0970, "Cross-Reference for Electrical Connectors"

ReferenceSpecial Instruction, SEHS9065, "Use Of CE Connector Tools".

ReferenceService Magazine, SEPD0342 27 January, "Field Repair Of Single Wire Breaks In Harnesses (Sealed Splice)".

ReferenceService Magazine, SEPD0473 24 May, "New DT Connector Plugs With Improved Seal Retention".

ReferenceService Magazine, SEPD0545 09 October, "Dielectric Grease Should Not Be Used In Electrical Connectors".

The diagnostic code procedures in this troubleshooting guide instruct the user to check the condition of the electrical connectors that are involved in a suspect circuit.

One of the first actions to take when troubleshooting a circuit should be to inspect the harness connectors that are used for the circuit connections.

Poor connections can often be the cause of an active problem or an intermittent problem in an electrical circuit. Inspection of the connector housings, the pins, and the sockets on the mating connectors may lead to a quick resolution of a specific problem.

The following table lists the tools and the repair kits that will be useful for removal and repair of connector contacts and wires.

Table 16

Service Tools
Part Number	Part
8T-5319	CE/VE Connector Tool Group - Circuit Removal Tools - For Removal of terminals from the connector body
1U-5804	Crimp Tool - For crimping pins and sockets on a wire end
140-9944	Terminal Repair Kit - Assorted pins and sockets for connector repair
4C-3406	Deutsche Connector Repair Kit - For repair of Deutsche connectors
6V-4148	Electrical Connector Repair Kit - For repair of Amp connectors
270-5051	Ampseal Connector Kit - For repair of Ampseal connectors
6V-3000	Sure Seal Repair Kit - For repair of Sure Seal connectors
175-3700	DT Connector Service Kit - For repair of Deutsche DT connectors
9X-1314 9X-1315	Red, Black Pin Probe - For use with a multimeter to insert in a connector socket
309-6081 309-6082	Red, Black Socket Probe - For use with a multimeter to insert on a connector pin

Points to Consider When Inspecting a Wiring Harness Connector for Possible Problems:

1. Verify that a diagnostic code is active or an intermittent problem is occurring before disconnecting the harness connectors.

   1. When a connector is disconnected and reconnected, the chance for increased wear, damage to the connector, or contamination of the connector increases.

2. When possible, turn off the key start switch before disconnecting the harness connectors.

   1. Disconnecting connectors with the power off avoids the possibility of introducing voltage spikes into the system.

   2. When troubleshooting a circuit, a procedure may require the control voltage to be turned ON with a harness connector disconnected. Always inspect the connector before turning ON the control power. Ensure that the connector is clean, dry, and in good condition.

   3. The recommended practice is to turn OFF the key start switch before reconnecting of the connector.

Show/hide table



Illustration 35	g02138347
Examples of proper and improper wire routing in a harness

3. Before disconnecting the connector, check for improper wire routing into the connector. Wires that are improperly routed into a connector can deform the seal bore allowing moisture or other forms of contamination to enter the connector.

4. For intermittent conditions, disconnecting and reconnecting a connector may temporarily solve a problem. However, the indication is that there could be a problem in the connector. A problem in the connector or the harness close to the connector that has been temporarily resolved will most likely reoccur. If this situation occurs, check for the following conditions:

   1. Loose terminals, bent terminals, or improperly crimped terminals.

   2. Perform the 45 N (10 lb) pull test on each wire. Pull on the wires that are entering the connector in order to determine if all terminals are properly locked in the connector body. The pull test can also determine if a wire is broken at the terminal crimp.

   3. Examine the insulation on the wires that are entering the connector. Look for damage to the insulation in the form of abrasions, nicks, or cuts.

   4. For terminal replacement or wire repair, use the 1U-5804 Crimp Tool (12-GA TO 18-GA) to replace the terminal. Replace any damaged connectors as required.

   5. Ensure that the connectors lock properly to the mating connector when connected. After locking the connectors, ensure that the mating connectors cannot be pulled apart.

   6. Check the harness clamping that is close to the connector. The clamps or strap should hold the harness securely in place at the proper orientation. The clamp or strap should not be too tight.

   7. At the ECM harness connectors, ensure that the connector retaining bolt is properly tightened when connected to the ECM connector. Do not exceed 6.0 N·m (53.0 lb in) of torque on the retaining bolt when the connector is being installed on the ECM.

5. Check for moisture or contamination in the connector and check the condition of the connector seals.
   Show/hide table
   
   

   Illustration 36	g02138377
   Previous style DT connector with the seal (left) and newer style black DT connector with the improved seal (right)

   Show/hide table
   
   

   Illustration 37	g02138384
   Typical three-pin connector with an O-ring type seal (arrow)

   1. Check the connector terminals for moisture or corrosion.

   2. If moisture or corrosion are found in a connector, inspect the connector seal for damage that can include: missing seals, improperly installed seals, nicks, or tears in the sealing surface. The seal is replaceable. Replace the seal if the seal is damaged.

   3. Light abrasion on the connector seal is normal. If moisture is present in the connector, the cause of the problem must be determined and corrected. Check all of the connector seals and replace any seal that is damaged or missing. Replace the connector if necessary.

   4. Moisture can also travel from one connector through the inside of a wire to another connector. If moisture is found in a connector, thoroughly check all connectors and wires in the harness.

   5. Use only denatured alcohol with a soft brush or a cotton swab to clean the terminals and remove corrosion.

6. A Cat ET wiggle test can be used for finding intermittent problems in a wiring harness or in a harness connector. Use Cat ET wiggle test, if available, on the suspect machine harness or engine harness.

   1. When a Cat ET wiggle test is not available for your machine, moving the harness and connectors while troubleshooting a particular circuit can help to find a problem. Movement of the harness or a connector while observing a multimeter measurement may provide an indication of the location of a problem.

Wiring Harness (Open Circuit) - Test

An open is a failure of an electrical circuit that results in no flow of electrical current. An open circuit is usually caused by failed electrical wires or a poor connection of electrical connectors. If an electrical wire or a connection is broken, the flow of electrical current through the circuit is interrupted. A normally closed circuit will have less than 5 ohms of resistance. The following procedure explains the test for an open circuit:

ReferenceFor a complete electrical schematic, refer to Electrical System Schematic for the machine that is being serviced.

Test For An Open Circuit

1. Identify the connectors and the wire numbers of the suspect circuits. Use the Electrical System Schematic of the machine to identify the circuits.

2. Turn the key start switch and the disconnect switch to the OFF position.

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

4. At one of the disconnected harness connections, place a jumper wire from the contact of the suspect wire to frame ground.

5. At the other connector of the machine harness, use the multimeter probes to measure the resistance from the contact of the suspect wire to frame ground.

   Expected Result: The resistance is less than 5 ohms.

   OK - The resistance is less than 5 ohms. The harness circuit is correct.

   Stop.

   NOT OK - The resistance is greater than 5000 ohms. There is an open in the machine harness.

   Repair: Repair the machine harness or replace the machine harness.

   Stop.

Wiring Harness (Short Circuit) - Test

A short circuit is a failure of an electrical circuit that results in undesired electrical current. Usually, a short circuit is a bypass of the circuit across a load. For example, a short across the wires in a circuit for a lamp produces too much current in the wires but no current is felt at the lamp. The lamp is shorted out. The resistance in a normal circuit can vary, but the resistance between a particular circuit and other unrelated circuits is always greater than 5000 ohms. The following procedure explains the test for a short circuit:

ReferenceFor a complete electrical schematic, refer to Electrical System Schematic for the machine that is being serviced.

Test For A Short Circuit

1. Identify the connectors and the wire numbers of the suspect circuits. Use the Electrical System Schematic of the machine to identify the circuits.

2. Turn the key start switch and the disconnect switch to the OFF position.

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

4. At the machine harness connector for the ECM, place one of the multimeter probes on the contact of the suspect wire.

5. Use the other multimeter probe to check the resistance across all other contacts in the connector or connectors of the ECM and frame ground.

   Expected Result: The resistance is greater than 5000 ohms for all the measurements.

   OK - The resistance is greater than 5000 ohms for all the measurements. The harness circuits are correct.

   Stop.

   NOT OK - The resistance is less than 5 ohms. There is a short in the machine harness. The short is between the suspected wire and the wire with the lowest resistance measurement.

   Repair: Repair the machine harness or replace the machine harness.

   Stop.

Buttons Sticking

Illustration 38	g03732376
Rear view of shifter (1) Screw

The hazardous area shift selector is a sealed unit. Changes in atmospheric pressure may cause the buttons to stay depressed and commands not being accepted. This condition is caused by the pressure inside the shifter being lower than atmospheric pressure.

To resolve this issue, pressures need to balance inside and outside the shifter. Use the following steps:

1. Remove screw (1) .

2. Once the pressures have equalized, replace screw (1) .

   1. Apply sealant to the threads of screw (1) prior to assembly.

   2. Tighten screw (1) to 2 ± 0.1 N·m (17.7 ± 0.9 lb in)

Appendix

J1939 Source Addresses

Table 17

Module Description	Source Address
Transmission	0x03
Engine	0x00
Primary Shift Selector	0x05
Secondary Shift Selector	0x06
Messenger	0x28

Supported J1939 Status Parameters

Table 18

PGN	SPN	Source	Description
61445	162	Transmission	Requested Gear Range
	523	Transmission	Current Gear
61442	573	Transmission	Torque Converter Lockup Status
	161	Transmission	Input Shaft Speed
	191	Transmission	Output Shaft Speed
61444	190	Engine	Engine Speed
64917	3823	Transmission	Torque Converter Oil Temperature
65272	177	Transmission	Transmission Oil Temperature
65262	110	Engine	Engine Coolant Temperature
	175	Engine	Engine Oil Temperature
65263	94	Engine	Engine Fuel Delivery Pressure
	100	Engine	Engine Oil Pressure
	111	Engine	Engine Coolant Level
	98	Engine	Engine Oil Level
	109	Engine	Engine Coolant Pressure
65270	107	Engine	Engine Air Filter #1 Differential Pressure
65248	244	Engine	Trip Distance
	245	Engine	Total Vehicle Distance
65253	247	Engine	Engine Total Hours Operation
65257	182	Engine	Engine Trip Fuel
	250	Engine	Engine Total Fuel Used
65266	183	Engine	Engine Fuel Rate
65271	168	Transmission	Battery Potential
65098	2945	Transmission	Active Shift Selector Console
65272	3026	Transmission	Oil Level Measurement
	3027	Transmission	Oil Level High/Low
	3028	Transmission	Oil Level Check Timer

Cat Data Link Source Addresses

Table 19

Module Description	Source Address
Transmission	0x1B (27)
Petroleum Advisor Shift Selector	0x75 (117)
Messenger	0x35 (53)

Transmission Diagnostics/Events Via Cat Data Link

Table 20

CID/FMI	WCI	Description
41 - 3	1	8 V Supply Voltage Above Normal
41 – 4	1	8 V Supply Voltage Below Normal
124 – 3	1	Transmission Oil Level Sensor Voltage Above Normal
124 – 4	1	Transmission Oil Level Sensor Voltage Below Normal
126 – 3	2	Transmission Filter Differential Pressure Voltage Above Normal
126 – 16	2	Transmission Filter Differential Pressure Valid But Above Normal Range
141 – 2	1	Economy Mode Switch Erratic, Intermittent, or Incorrect
144 – 3	1	Backup Alary Relay Voltage Above Normal
144 – 5	1	Back up Alary Relay Current Below Normal
144 – 6	1	Back up Alary Relay Current Above Normal
168 – 1	2	Electrical System Voltage Valid But Below Normal
168 – 3	2	Electrical System Voltage Above Normal
168 – 4	2	Electrical System Voltage Below Normal
177 – 3	1	Transmission Oil Temperature Sensor Voltage Above Normal
177 – 4	1	Transmission Oil Temperature Sensor Voltage Below Normal
177 – 16	1	Transmission Oil Temperature Sensor Valid But Above Normal
190 – 2	1	Engine Speed Sensor Erratic, Intermittent, or Incorrect
190 – 8	1	Engine Speed Sensor Abnormal Signal
191 – 2	1	Transmission Output Speed Sensor Erratic, Intermittent, or Incorrect
191 – 8	1	Transmission Output Speed Sensor Abnormal Signal
191 – 15	2	Transmission Output Speed Sensor Valid But Above Normal
247 – 9	1	SAE J1939 Data Link Abnormal Update Rate
247 – 14	1	SAE J1939 Data Link Special Instruction
248 – 9	1	Cat Data Link Abnormal Update Rate
248 – 14	1	Cat Data Link Special Instruction
262 – 3	2	5 V Supply Voltage Above Normal
262 – 4	2	5 V Supply Voltage Below Normal
444 – 3	1	Starter Motor Relay Voltage Above Normal
444 – 5	1	Starter Motor Relay Current Below Normal
444 – 6	1	Starter Motor Relay Current Above Normal
585 – 2	1	Transmission Output Speed Sensor #1 Erratic, Intermittent, or Incorrect
585 – 8	1	Transmission Output Speed Sensor #1 Abnormal Signal
590 – 9	2	Engine Control Module Abnormal Update Rate
624 – 2	1	Transmission Neutral Switch Erratic, Intermittent, or Incorrect
624 – 3	1	Transmission Neutral Switch Voltage Above Normal
624 – 4	1	Transmission Neutral Switch Voltage Below Normal
668 – 9	1	Transmission Shift Lever Abnormal Update Rate
672 – 2	1	Torque Converter Output Speed Sensor Erratic, Intermittent, or Incorrect
672 – 8	1	Torque Converter Output Speed Sensor Abnormal Signal
673 – 2	1	Transmission Output Speed Sensor #2 Erratic, Intermittent, or Incorrect
673 – 8	1	Transmission Output Speed Sensor #2 Abnormal Signal
702 – 3		Transmission Gear Lever Selector Sensor Voltage Above Normal
702 – 4	1	Transmission Gear Lever Selector Sensor Voltage Below Normal
702 – 8	1	Transmission Gear Lever Selector Sensor Abnormal Signal
709 – 3	2	Transmission Lockup Clutch Solenoid Voltage Above Normal
709 – 5	2	Transmission Lockup Clutch Solenoid Current Below Normal
709 – 6	2	Transmission Lockup Clutch Solenoid Current Above Normal
709 – 11	2	Transmission Lockup Clutch Solenoid Failure Not Identifiable
718 – 13	1	Transmission System Out of Calibration
788 – 9	2	Engine Retarder Selector Switch Abnormal Update Rate
788 – 19	2	Engine Retarder Selector Switch Data Error
826 – 3	1	Torque Converter Oil Temperature Sensor Voltage Above Normal
826 – 4	1	Torque Converter Oil Temperature Sensor Voltage Below Normal
826 – 16	1	Torque Converter Oil Temperature Sensor Valid But Above Normal
1227 – 8	2	Retarder Lever Abnormal Signal
1227 – 13	2	Retarder Lever Out of Calibration
1248 – 3	2	Retarder Solenoid Voltage Above Normal
1248 – 5	2	Retarder Solenoid Current Below Normal
1248 – 6	2	Retarder Solenoid Current Above Normal
1248 – 11	2	Retarder Solenoid Failure Not Identifiable
1292 – 4	1	Gear Hold Switch Voltage Below Normal
1326 – 2	1	ECM Location Code Incorrect
1401 – 3	2	Transmission Solenoid #1 Voltage Above Normal
1401 – 5	2	Transmission Solenoid #1 Current Below Normal
1401 – 6	2	Transmission Solenoid #1 Current Above Normal
1401 – 11	2	Transmission Solenoid #1 Failure Not Identifiable
1402 – 3	2	Transmission Solenoid #2 Voltage Above Normal
1402 – 5	2	Transmission Solenoid #2 Current Below Normal
1402 – 6	2	Transmission Solenoid #2 Current Above Normal
1402 – 11	2	Transmission Solenoid #2 Failure Not Identifiable
1403 – 3	2	Transmission Solenoid #3 Voltage Above Normal
1403 – 5	2	Transmission Solenoid #3 Current Below Normal
1403 – 6	2	Transmission Solenoid #3 Current Above Normal
1403 – 11	2	Transmission Solenoid #3 Failure Not Identifiable
1404 – 3	2	Transmission Solenoid #4 Voltage Above Normal
1404 – 5	2	Transmission Solenoid #4 Current Below Normal
1404 – 6	2	Transmission Solenoid #4 Current Above Normal
1404 – 11	2	Transmission Solenoid #4 Failure Not Identifiable
1405 – 3	2	Transmission Solenoid #5 Voltage Above Normal
1405 – 5	2	Transmission Solenoid #5 Current Below Normal
1405 – 6	2	Transmission Solenoid #5 Current Above Normal
1405 – 11	2	Transmission Solenoid #5 Failure Not Identifiable
1406 – 3	2	Transmission Solenoid #6 Voltage Above Normal
1406 – 5		Transmission Solenoid #6 Current Below Normal
1406 – 6	2	Transmission Solenoid #6 Current Above Normal
1406 – 11	2	Transmission Solenoid #6 Failure Not Identifiable
1823 – 3	2	Shift Rail #1 Position Sensor Voltage Above Normal
1823 – 4	2	Shift Rail #1 Position Sensor Voltage Below Normal
1824 – 3	2	Shift Rail #2 Position Sensor Voltage Above Normal
1824 – 4	2	Shift Rail #2 Position Sensor Voltage Below Normal
1825 – 3	2	Shift Rail #3 Position Sensor Voltage Above Normal
1825 – 4	2	Shift Rail #3 Position Sensor Voltage Below Normal
1834 – 2	1	Ignition Switch Erratic, Intermittent, or Incorrect
1834 – 3	1	Ignition Switch Voltage Above Normal
2859 – 3	1	Dropbox Disconnect #1 Engage Solenoid Voltage Above Normal
2859 – 5	1	Dropbox Disconnect #1 Engage Solenoid Current Below Normal
2859 – 6	1	Dropbox Disconnect #1 Engage Solenoid Current Above Normal
2860 – 3	1	Dropbox Disconnect #2 Engage Solenoid Voltage Above Normal
2860 – 5	1	Dropbox Disconnect #2 Engage Solenoid Current Below Normal
2860 – 6	1	Dropbox Disconnect #2 Engage Solenoid Current Above Normal
2861 – 3	1	Dropbox Disconnect #3 Engage Solenoid Voltage Above Normal
2861 – 5	1	Dropbox Disconnect #3 Engage Solenoid Current Below Normal
2861 – 6	1	Dropbox Disconnect #3 Engage Solenoid Current Above Normal
2862 – 3	1	Dropbox Disconnect #1 Disengage Solenoid Voltage Above Normal
2862 – 5	1	Dropbox Disconnect #1 Disengage Solenoid Current Below Normal
2862 – 6	1	Dropbox Disconnect #1 Disengage Solenoid Current Above Normal
2863 – 3	1	Dropbox Disconnect #2 Disengage Solenoid Voltage Above Normal
2863 – 5	1	Dropbox Disconnect #2 Disengage Solenoid Current Below Normal
2863 – 6	1	Dropbox Disconnect #2 Disengage Solenoid Current Above Normal
2864 – 3	1	Dropbox Disconnect #3 Disengage Solenoid Voltage Above Normal
2864 – 5	1	Dropbox Disconnect #3 Disengage Solenoid Current Below Normal
2864 – 6	1	Dropbox Disconnect #3 Disengage Solenoid Current Below Normal
2990 – 9	2	Transmission Shifter Abnormal Update Rate
2991 – 9	2	Transmission Shifter #2 Abnormal Update Rate
2998 – 2	1	Dropbox Disconnect #1 Speed Sensor Erratic, Intermittent, or Incorrect
2998 – 8	1	Dropbox Disconnect #1 Speed Sensor Abnormal Signal
2999 – 2	1	Dropbox Disconnect #2 Speed Sensor Erratic, Intermittent, or Incorrect
2999 – 8	1	Dropbox Disconnect #2 Speed Sensor Abnormal Signal
3000 – 2	1	Dropbox Disconnect #3 Speed Sensor Erratic, Intermittent, or Incorrect
3000 – 8	1	Dropbox Disconnect #3 Speed Sensor Abnormal Signal
3013 – 2	1	Lockup Clutch Disable Switch Erratic, Intermittent, or Incorrect
3013 – 3	1	Lockup Clutch Disable Switch Erratic, Intermittent, or Incorrect
3013 – 4	1	Lockup Clutch Disable Switch Voltage Below Normal
3240 – 3	2	Transmission Dropbox Filter Bypass Switch Voltage Above Normal
3240 – 16	2	Transmission Dropbox Filter Bypass Switch Valid But Above Normal
3381 – 3	1	Transmission Shift Selector Switch Voltage Above Normal
3381 – 4	1	Transmission Shift Selector Switch Voltage Below Normal
3395 – 3	1	PTO #1 Attachment Pump Control Switch Voltage Above Normal
3395 – 4	1	PTO #1 Attachment Pump Control Switch Voltage Below Normal
3396 – 3	1	PTO #2 Attachment Pump Control Switch Voltage Above Normal
3396 - 4	1	PTO #2 Attachment Pump Control Switch Voltage Below Normal

Abbreviations and Acronyms

Table 21

Term	Description
A&I	Application and Installation
CID	A component identifier is a diagnostic code that informs the service personnel of specific component or system failure.
CDL	Cat Data Link
ECM	The Electronic Control Module provides improved emission, performance, advanced troubleshooting, and diagnostic capabilities. The ECM houses a microprocessor, reads inputs from several sources like from pressure sensors, determines the correct course of action. Then the ECM implements the actions through outputs like controlling the clutch pressure or turning on the backup alarm.
ET	Caterpillar Electronic Technician is an electronic service tool used with electronic controls to display fault codes, set up features, display parameter values, and perform diagnostics. ET requires a personal computer with ET software installed and either a Caterpillar Communication Adapter or MPSI Pro-Link. The MPSI Pro-Link should have a Caterpillar Cartridge to translate from the Vehicle ATA Data Link to the computer RS-232 port.
MID	Module Identifier is the source address of the corresponding ECM on the data link.
OEM	Original Equipment Manufacturer
PGN	Parameter Group Number
TBU	Transmission Business Unit
TSG	Technical Standards & Guidelines
SPN	Suspect Parameter Number

Disclaimer

Legal

Although Caterpillar exercises all reasonable effort to assure Caterpillar products perform properly in the OEMs equipment, the responsibility for the installation is the OEMs. Caterpillar assumes no responsibility for deficiencies in the installation.

The responsibility is the installer to consider and avoid possibly hazardous conditions that could develop from the systems involved in the specific installation. The suggestions provided in this guide regarding avoidance of hazardous conditions apply to all applications. And are necessarily of a general nature since only the installer is familiar with the details of the installation. The suggestions provided in this guide should be considered general examples only. And are in no way intended to cover every possible hazard in every installation.

Part Numbers

The listed part numbers are subject to change. Consult Caterpillar about the current part number of the specific part.

Confidentiality

The information contained within this document is classified as Caterpillar Confidential Information. Any reproduction, dissemination, or use of this information is forbidden without the prior express written consent of an authorized Caterpillar representative. All rights are reserved.