Service Training SEGV3005

Course Module July 1997

TECHNICAL PRESENTATION

TRUE RMS MULTIMETER

FLUKE 87
AUTO DC

0 0 00
0 1 2 3 4 5 6 7 8 9 0
V

4
CATERPILLAR
MIN MAX RANGE HOLD

REL Hz
Peak Min Max

MACHINE
---
mV

---
V

~V
mA
A ELECTRONICS
A

OFF
COURSE
A mA A COM V-

400mA MAX
FUSED

10A MAX 1000V MAX

FUSED

MODULE FIVE: DIAGNOSTIC TOOLING

AND TROUBLESHOOTING PROCEDURES
SEGV3005 -2- Module Five
7/97

TABLE OF CONTENTS

COURSE DESCRIPTION............................................................................................................3

MODULE DESCRIPTION/OBJECTIVES..................................................................................4

DIAGNOSTIC TROUBLESHOOTING ......................................................................................7

Exercise No. 1: Understanding And Using The Digital Multimeter ......................................8

Exercise No. 1A: Understanding And Using Metric Prefixes ................................................8

Exercise No. 1B: Resistance And Diode Measurements ........................................................9

Exercise No. 1C: Identifying And Measuring Electronic Signals ........................................12

Exercise No. 2: General Machine Electrical Systems .........................................................31

Exercise No. 2A: Testing The Alternator On A Machine.....................................................32

Exercise No. 2B: Testing the Starter On A Machine ............................................................33

Exercise No. 2C: Perform Maintenance-Free Battery Test On Machine..............................34

Exercise No. 3: Computerized Monitoring System Problem................................................35

Exercise No. 4: Caterpillar Monitoring System Problem .....................................................37

Exercise No. 5: Vital Information Management System Problem........................................39

Exercise No. 6: Basic Machine System Troubleshooting.....................................................42

BASIC 12V AND 24V MACHINE ELECTRICAL SYSTEMS STUDENT HANDOUT .......53
SEGV3005 -3- Module Five
7/97

COURSE DESCRIPTION

This module is a review of the basic electrical and electronic principles needed by a technician to
understand and maintain the complex machine systems installed in Caterpillar products. The modules
do not teach specific machine systems unless otherwise stated in the lesson description.

Each module contains a quiz/skill test to measure the student's electrical/electronic skills and
knowledge. It is recommended that the pretest be completed prior to scheduling training. The pretest is
designed to evaluate each module of the course and may be used as a "skills/knowledge inventory" for
the evaluation of each student.

Suggest the following procedure:

Pretest
Administer the pretest.
Do not answer questions regarding pretest content.
Collect pretest, do not review or discuss test with students.
Grade the pretest, but do not pass out scores.
Use the pretest to evaluate each students knowledge prior to receiving instruction.

Posttest
Each module lesson quiz/skill test will serve as a posttest for the individual modules.
Have students exchange tests and review and discuss each question.
Have students mark the incorrect responses.
Collect all copies of the quizzes/skill tests and file for future reference.

The course is designed as several modules. The current modules are:

Module 1: Basic Electrical and Electronic Principles (SEGV3001)

Module 2: Electronic Components (SEGV3002)
Module 3: Wire Maintenance (SEGV3003)
Module 4: Electrical Schematics (SEGV3004)
Module 5: Machine Electrical and Electronic Systems, Diagnostic Tooling and Troubleshooting
Procedures (SEGV3005)
Additional Support Information:
List of Acronyms and Glossary of Electrical/Electronic Terms (SEKV3001)
Machine Electronic Course Pretest (SEBV3001)
Machine Electronic Course Pretest Answers (SEEV3001)

Each module contains the following:

A module description
A module objective
A module plan
A list of reference materials or job aids needed to present the module
A student handout section (if applicable)
A student quiz and a master copy of the quiz for the instructor (with answers)
SEGV3005 -4- Module Five
7/97

Module Five MODULE FIVE: MACHINE ELECTRICAL AND ELECTRONIC

SYSTEMS, DIAGNOSTIC TOOLING AND
Time: 24 Hours TROUBLESHOOTING PROCEDURES

Presentation Methods Module Five Description

The electrical and electronic system, diagnostic tooling, and troubleshooting

Classroom Exercises
module provides the student with the procedures necessary to efficiently and
effectively diagnose electrical/electronic problems on Caterpillar machines.
Machine Exercises Utilizing extensive hands-on exercises, the students troubleshooting process
and logic techniques may be observed by the instructor and corrected as
necessary.

Note: Module five is the critical lesson of this course. It is the module
which measures all of the previous classroom lectures and lab exercises.
It is also a measure of how well you (the instructor) presented the
information. REMEMBER......There are no hard and proven processes
for diagnosing problems, but there are more efficient and effective ways to
solve problems. The job of the instructor is not to criticize a process that
does not achieve the desired results, but to help steer the student along a
logical troubleshooting path that will result in successfully determining
the root cause of the problem.

Module Five Objectives

After completion of this Module the student will have demonstrated the
skills necessary to diagnose and troubleshoot machine electrical and
electronic systems. A lab exercise will be developed for each specific
troubleshooting task and be included in this module.

Video Tapes

INSTRUCTOR "How to Test a CAT Battery" .................................................SEVN1590

REFERENCE "Testing the Alternator on the Engine" ..................................SEVN1591
MATERIALS "Testing the Starter on the Engine" ........................................SEVN1592
"6V2150 Starting/Charging Analyzer" ..................................SEVN9165
"Basic Wire Maintenance" .....................................................SEVN3197
"Using the 9U7330 Digital Multimeter" ................................SEVN3198
"VIMS--A powerful Tool For Mining"..................................AEVN3201
"The Intelligence of Powerful Connections".........................AEVN2974
SEGV3005 -5- Module Five
7/97

Service Manual Modules

Service Manual--Starting and Charging Systems . . . . . . . . . . . .SENR2947

Service Manual--Electronic Monitoring System (EMS) . . . . . ..SENR2945
Service Manual--Computerized Monitoring System (CMS)
with VFD Circular Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SENR5247
Service Manual--Caterpillar Monitoring System . . . . . . . . . . . .SENR6717
Service Manual--Vital Information Management System
(VIMS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SENR6059

Schematics

Order the appropriate Electrical Schematic for the specific machine being
used for training.

Technical Instruction Modules

Computerized Monitoring System . . . . . . . . . . . . . . . . . . . . . . .SEGV2578

Caterpillar Monitoring System--769D - 777D
Off-Highway Trucks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SEGV2622
Caterpillar Monitoring System--Track Type Tractors . . . . . . . .SEGV2619
Vital Information Management System--Introduction . . . . . . ..SEGV2597
Vital Information Management System--785B/789B/793B
Off-Highway Trucks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SEGV2610
Vital Information Management System--Large Hydraulic
Excavators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SEGV2605
Electronic Programmable Transmission Control . . . . . . . . . . . .SEGV2584
3500 Electronic Engine Control--Introduction . . . . . . . . . . . . . .SEGV2588
3500 Electronic Engine Control-Off-Highway Trucks . . . . . . .SEGV2589
936F - 970F Wheel Loader Autoshift Transmission . . . . . . . . .SEGV2590

Special Tooling/Job Aids

6V7070 Digital Multimeter

9U7330 Digital Multimeter
Fluke User's Manual, Fluke P/N 834218
Fluke Simulator Board, Fluke P/N 932707
8T9170 Electrical Components Group (if available)
7X1700 Communications Adapter/Cables
7X1710 Multimeter Cable Probes
4C8195 Control Service Tool
6V2150 Starting/Charging Analyzer
8T0900 AC/DC Clamp-On Ammeter, or
9U5795 AC/DC Current Probe
SEGV3005 -6- Module Five
7/97

PC (Service Tool) with the following software installed:

(1) Electronic Technician JERD2124/JERD2129
(2) Caterpillar Common Services JERD2093
(3) Vital Information Management System JERD2137/JERD2138
(4) Vital Information Management System 127-9797 Cable
(5) Electronic Technician Adapter Cable 7X1425
(4) Information System Builder

Miscellaneous Items

Special Instruction--Battery Procedures ...........................................SEHS7633

Special Instruction--Battery Charging Rate/Time Tables .................SEHS9014
Special Instruction--Use of 6V2150 Starting/Charging
Analyzer Group.................................................................................SEHS7633
Special Instruction--Signal Generator/Counter .............................SEHS8579
Special Instruction--Communication Adapter Group .......................SEHS9264
Special Instruction--Use of 6V7070 Digital Multimeter ..................SEHS7734

Student Handouts for each exercise (if applicable).

Note: It may be necessary to provide other service related materials

depending on the type of lab exercise. (Example): If the machine lab
exercise is related to a transmission problem, it would be helpful if the
service manual for the transmission is available to the technician during
troubleshooting.

Duplicate the Exercises: Select Desired Exercise(s)

following pages for
student exercises
Pages 20 - 30 Exercise No. 1: Use of diagnostic tools

Pages 32 - 34 Exercise No. 2: General Machine Electrical Systems

Page 36 Exercise No. 3: Computerized Monitoring System Problem

Page 38 Exercise No. 4: Caterpillar Monitoring System Problem

Page 41 Exercise No. 5: Vital Information Management System Problem

Pages 48 - 52 Exercise No. 6: Basic Machine System Troubleshooting

SEGV3005 -7- Module Five
7/97

Diagnostic Troubleshooting

Troubleshooting requires technicians to use their knowledge, skill, and

experience to solve the complex problems associated with today's
technology.

Troubleshooting involves more than just following a set of procedures in

a service manual. Caterpillar Service Training and Dealer Trainers must
develop effective programs for teaching diagnostic troubleshooting. The
technician must be provided with the knowledge, skills and practice
needed to work on machines equipped with Caterpillar's latest technology.

The following exercises are included in this lesson to measure the

students skills and knowledge in solving machine electrical and electronic
problems. They are:

Use of diagnostic tools and test equipment

Solving a general machine electrical problem

Solving CMS, Caterpillar Monitoring System, and VIMS problems

Schematic interpretation and logic process

Note: Each instructor should develop an alternate set of exercises to fit

their specific dealer needs.
SEGV3005 -8- Module Five
7/97 Exercise No. 1
Instructor Copy
Exercise No. 1 EXERCISE NO. 1

Understanding and Using the Digital Multimeter

Several diagnostic service tools are available to assist the technician in the
troubleshooting process. This course uses the various electronic monitoring
systems as a base for troubleshooting. The primary diagnostic tool discussed
in this lesson is the digital multimeter. Caterpillar currently lists two digital
multimeters in the diagnostic tool list. They are the 6V7070 Caterpillar
Digital Multimeter and the Fluke 9U7330 Digital Multimeter. Although both
multimeters may be used by a service technician, the 9U7330 multimeter
performs the more complex measurements on the newer electronic systems.

This exercise will use both multimeters to give the students hands-on
experience.

Multimeter not required Exercise 1A: Understanding and Using Metric Prefixes
for Exercise 1A
Directions: Express each of the following in the units indicated.

1. 2 A to milliamperes = 2,000 mA
2. 1327 mA to amperes = 1.327 A
3. 8.2 k to ohms = 8,200
4. 680 k to ohms = 680,000
5. 2.2 M to ohms = 2,200,000
6. 0.24 A to milliamperes = 240 mA
7. 0.013 kV to volts = 13 V
8. 10,000 V to kilovolts = 10 k
9. 5,600,000 to megohms = 5.6 M
10. 0.53 A to milliamps = 530 mA

Write the value for the following prefix:

11. mega (M) = 1,000,000

12. kilo (k) = 1,000
13. milli (m) = .001
14. micro () = .000,001
15. pico (p) = .000,000,001
16. nano (n) = .000,000,000,001
SEGV3005 -9- Module Five
7/97 Exercise No. 1
Instructor Copy
Exercise 1B: Resistance and Diode Measurements

All components may be Purchase a small electrical component board and five resistors (each resistor
purchased at Radio being a multiple of 15). Install the resistors in the locations shown below.
Shack or any other Ask each student to measure the resistor values and express the measurement
electrical parts dealer. in the units indicated. Recommend using both digital multimeters for this
Assemble as many exercise. Demonstrates non-autoranging and autoranging multimeters.
boards as needed for
class size.

Recommend this 1. 15 000 15 k

exercise be completed
15
twice by the student. 2. 15
Make measurements 15 000 000
using the 6V7070 3. 15 M
Multimeter and then 150
4.
using the 9U7330 150
Multimeter. This 1500
technique 5. 1.5 k
demonstrates the
difference between a
non-autoranging
Diode Measurements
multimeter and a
autoranging multimeter.
Purchase three small silicon diodes and install them on the same fabricated
board in positions #6, #7 and #8. Note the silver bands on the diode barrel.
Note: Turn the fabricated board over and solder a small wire on the ends of
the diode installed in position #8. This will simulate a shorted diode. Have
each student measure the voltage drop across each diode and record their
measurements.

6. .530 DCV - OL

7. OL - .530 DCV
8. OL - OL

9. The color band (silver) on the component identifies the _________.

a. anode
b. cathode
c. emitter
d. collector
SEGV3005 - 10 - Module Five
7/97 Exercise No. 1
Instructor Copy

Using the digital multimeter, test the component labeled #6. Connect the
leads as shown below. Does the display show a value between .500 and .900?
If yes, continue. If no, check the meter leads and function selector switch.

- +

(- Bk) .567 (+ Red)

Multimeter
Display

10. A digital display reading between .500 and .900 indicates ___________.
a. a resistance between .500 and .900 ohms.
b. a current flow between .500 and .900 amps.
c. a resistance between 500 and 900 milliohms.
d. a voltage drop between 500 and 900 millivolts.

11. With the multimeter leads connected as shown, a reading between .500
and .900 reflects a normal condition.
a. true
b. false

12. When the leads are reversed (changing polarity), the multimeter displays
a reading of OL.
a. OL indicates that the component is open.
b. OL indicates that the component is shorted.
c. OL indicates that the component is not conducting current.
d. OL indicates that the component is defective and should be
replaced.

CATHODE
(+)
ANODE (-)

Use the diode symbol for answering questions #13, #14, and #15.
SEGV3005 - 11 - Module Five
7/97 Exercise No. 1
Instructor Copy
The voltage drop Perform the following tests on the components labeled #6, #7, and #8 on the
across a silicon diode fabricated board and answer the questions.
depends on the type of
diode purchased. After 13. Component #6:
constructing the
fabricated component Red lead on the anode (+), black lead on the cathode (-), display reads: .531 DCV
boards measure the Black lead on the anode (+), red lead on the cathode (-), display reads: OL
voltage drop and Is the component serviceable or defective? (circle answer)
change the values for Explain your diagnosis: Diode conducts when forward biased and does not
this exercise. conduct when reversed biased.

The typical voltage drop

ranges from 500 to 900 14. Component #7:
millivolts.
Red lead on the anode (+), black lead on the cathode (-), display reads: .623 DCV
Black lead on the anode (+), red lead on the cathode (-), display reads: OL
Is the component serviceable or defective? (circle answer)
Explain your diagnosis: Diode conducts when forward biased and does not
conduct when reversed biased.

15. Component #8:

Red lead on the anode (+), black lead on the cathode (-), display reads: .000
Black lead on the anode (+), red lead on the cathode (-), display reads: .000
Is the component serviceable or defective? (circle answer)
Explain your diagnosis: The diode is shorted.
SEGV3005 - 12 - Module Five
7/97 Exercise No. 1
Instructor Copy
Exercise 1C: Identifying and Measuring Electronic Signals

Show Video "Using the 9U7330 Digital Multimeter" before starting exercise.
Directions: Identify and measure electronic signals using the 9U7330 Fluke multimeter, a Fluke
Simulator Board (Fluke P/N 932707), and a 9 volt battery. Use the 6V7070 multimeter to compare
readings when directed. A small screwdriver is needed to set adjustments.
Each Instructor needs to perform the measurements and document the results on this sheet prior to
class.

Measuring AC Voltage

Directions: Using the 9U7330 Fluke multimeter, set the multimeter to read AC volts. Place the RED
multimeter test lead in the V/ /Diode jack, and the BLACK test lead in the COM jack for all voltage
and resistance measurements. Hookup the battery, set the simulator adjustments and connect the leads
as shown below. Note: Observe the battery polarity and install the battery only when directed.

AMPL CW
+
9 VOLT PWM Centered
_
FREQ CW

GND TP1 TP2 TP3 TP4 TP5 TP6

Neg Pos

Record the AC voltage level displayed on the meter

Rotate any, or all of the adjustments, and observe the AC voltage level changing.
Observe the display autoranging between the 4V and 400 mV range when the adjustment knobs
are rotated.
Return the adjustments to the positions shown, and turn multimeter OFF.

Using the 6V7070 Digital Multimeter, set multimeter function selector to the highest AC volts
scale.

Record the AC voltage displayed on the 1000 volt AC scale.

Record the AC voltage displayed on the 200 volt AC scale.
Record the AC voltage displayed on the 20 volt AC scale.
Record the AC voltage displayed on the 2 volt AC scale.
Record the AC voltage displayed on the 200 m AC scale.
Which scale produced the most accurate reading?
Record the reading in volts.
SEGV3005 - 13 - Module Five
7/97 Exercise No. 1
Instructor Copy
Rotate any, or all of the adjustments, and observe AC voltage level changing. Did you need to
select a different scale to accurately read the AC voltage? If yes, explain why?

Measuring DC Voltage

Directions: Using the 9U7330 Fluke multimeter, set multimeter to read DC volts. Note, the Fluke 87
always powers up in the autorange mode and the word AUTO is displayed in the upper left corner of the
display.
To place the meter in the manual mode, press the RANGE button on the meter and observe the scale on
the lower right side of the display change each time the RANGE button is pressed.
Turn meter OFF and then back to the DC volts position.
Set the simulator adjustments and connect the leads as shown above.

AMPL CW
+
9 VOLT PWM CCW
_
FREQ CW

GND TP1 TP2 TP3 TP4 TP5 TP6

Neg Pos

Auto Mode
Record the DC voltage reading displayed on the meter.
Rotate the PWM adjustment knob slowly clockwise and observe the scale autoranging from the
4 volt to the 40 volt scale.
Record the DC voltage with the PWM knob fully clockwise.
Record the DC voltage with the PWM fully counterclockwise.
Rotate PWM adjustment fully counterclockwise and turn meter OFF.

Manual Mode
Set meter to DC volts, observe AUTO displayed in upper left corner of display.
With leads connected as shown above, press the RANGE button once. Observe the word AUTO
disappear from the display indicating that the meter is in the manual mode. Note the scale
remained at 4 volts.
Rotate the PWM adjustment knob slowly clockwise and observe the voltage level increase until
OL is displayed.
SEGV3005 - 14 - Module Five
7/97 Exercise No. 1
Instructor Copy
Press the RANGE button again and observe the scale change to the 40 volt scale.
Record the DC voltage with the PWM fully clockwise.
Record the DC voltage with the PWM fully counterclockwise.
Explain why the accuracy of the reading depends on the scale being used.

Note: The autorange feature of the 9U7330 can be used for both AC and DC readings. The autorange
feature is not available on the 6V7070 Digital multimeter. All ranges must be manually selected.

Using the MIN MAX Feature of the Fluke 87 Multimeter to Capture DC Signals

MIN MAX

The MIN MAX feature is useful for measuring voltage sweeps, or momentary voltage fluctuations in a
circuit. Use the same setup as you used for measuring DC voltage.

AMPL CW
+
9 VOLT PWM CCW
_
FREQ CW

GND TP1 TP2 TP3 TP4 TP5 TP6

Neg Pos

Turn the meter to the DC volt scale. Note the meter powers up in the autorange scale. Press and
release the RANGE button twice to place the meter display in the 40 volt DC manual scale
(AUTO is not displayed on meter).

Press and release the MIN MAX button once. The displays beeps once and RECORD appears
on the display telling you that the meter is in the MIN MAX mode.

Rotate the PWM adjustment on the simulator board a few times. This varies the DC voltage
signal. Record the MIN MAX readings: and .
SEGV3005 - 15 - Module Five
7/97 Exercise No. 1
Instructor Copy
Press and release the MIN MAX button once. Your meter reads the maximum voltage recorded.
Record the maximum voltage.

Press and release the MIN MAX button once again. Your meter reads the minimum voltage
recorded. Record the minimum voltage.

Press and release the MIN MAX button once again. Your meter reads the average voltage
recorded over the entire test. Record the average voltage.

To exit the MIN MAX mode, press and hold the MIN MAX button until you hear beep, and the
display returns to the manual mode.

Using the Touch Hold Feature of the Fluke 87 Multimeter to Capture DC Signals

HOLD

Use the Touch Hold for taking DC voltage measurements in hard to get places. To activate the Touch
Hold feature press the HOLD button until a beep is heard and an H appears on the meter display
indicating the display is in the Touch Hold mode.

Set your meter to DC volts, on the 40 volt scale.

Press and release the HOLD button. Beep is sounded and "H" appears.
Touch the meter leads to the battery terminal as shown below. Hold the leads on the battery
terminals until a beep is heard (change alert tone), remove the leads from the battery terminals.
Record the DC voltage signal reading.
The reading will remain displayed until the Touch Hold button is pressed again, or the meter is
turned off.

Pos AMPL CW
+
9 VOLT PWM CCW
_
Neg FREQ CW

GND TP1 TP2 TP3 TP4 TP5 TP6

Press Hold button again to disable, and turn meter OFF.

SEGV3005 - 16 - Module Five
7/97 Exercise No. 1
Instructor Copy
Measuring DC Millivolts

Using the 9U7330 Fluke multimeter, set multimeter to read DC volts.

Hookup the battery, set the simulator adjustments and connect the multimeter leads as shown
below.

AMPL CW
+
9 VOLT PWM CCW
_
FREQ CW

GND TP1 TP2 TP3 TP4 TP5 TP6

Neg Pos

Set multimeter to read DC volts, on the 4 volt scale.

Record the voltage on the display.

Switch the meter to read millivolts (mV).

Record the voltage on the display.

Turn meter OFF.

How many places did the decimal point move when you switched to the

millivolts scale?
SEGV3005 - 17 - Module Five
7/97 Exercise No. 1
Instructor Copy
Measuring DC Milliamps

Note: For the next exercise only, remove the test leads from the meter's test jacks. Rotate the 9V
battery as shown (the battery positive post is the only connection to the board). With the test leads
disconnected from the meter jacks, connect the negative lead (black) to the negative post of the 9V
battery. Connect the positive lead (red) to the negative terminal on the simulator board.

Neg
9 VOLT
AMPL CW
+
PWM Centered
_
Pos FREQ CW

GND TP1 TP2 TP3 TP4 TP5 TP6

Connect the negative (black) test lead to the COM jack on the meter.

Connect the positive (red) test lead to the mA jack on the meter.

Set the meter to read DC milliamps (mA)/A.

Record the DC milli-amp reading.

Disconnect the positive (red) lead from the negative terminal on the demonstrator board.

Switch the meter to read DC volts. What happened?

Note: That's the meter warning that the other end of the positive (red) lead is still plugged into
the amperage jack of the meter. Measuring a voltage with the positive lead connected to the
amperage jack would cause a direct short inside the meter, possibly blowing the fuses and
causing damage to the multimeter.

Never attempt to measure anything except current with the

leads plugged into the amps or milliamps jacks.
SEGV3005 - 18 - Module Five
7/97 Exercise No. 1
Instructor Copy
Measuring Frequency

Using the 9U7330 Fluke multimeter, set multimeter to read DC volts.

Hookup the battery, set the simulator adjustments, and connect the multimeter leads as shown
below.

Place the RED multimeter test lead in the V/ /Diode jack, and the BLACK test lead in the
COM jack for all voltage and resistance measurements.

AMPL CW
+
9 VOLT PWM CCW
_
FREQ Centered

GND TP1 TP2 TP3 TP4 TP5 TP6

Neg Pos

Hz

Press and release the Hz Button until Hz appears on the right side of the display.

Record the reading. The reading is the signal frequency. Rotate the frequency
adjustment knob and observe the frequency value change on the display.
SEGV3005 - 19 - Module Five
7/97 Exercise No. 1
Instructor Copy
Measuring Duty Cycle

Using the 9U7330 Fluke multimeter, set multimeter to read DC volts.

Hookup the battery, set the simulator adjustments and connect the multimeter leads as shown
below.

AMPL CW
+
9 VOLT PWM CW
_
FREQ CW

GND TP1 TP2 TP3 TP4 TP5 TP6

Neg Pos

Press and release the Hz button until % appears on the right side of the display.

Hz

Record the reading. ______________ The reading is the duty cycle displayed in percent, and
measured on the positive pulse. Note a (+) sign displayed in the lower left corner of the display.

Rotate the frequency adjustment knob and observe the frequency value change on the display.

To display the duty cycle measured on negative pulse, press and release the Peak MIN MAX
button and observe the (-) sign displayed on the lower left side of the meter display.

PEAK MIN MAX

Record the reading. ______________ The reading is the duty cycle displayed in percent, and
measured on the negative pulse. Note a (-) sign displayed in the lower left corner of the display.

Note: If a duty cycle reads 72% measured on the positive pulse, the duty cycle measured on the
negative pulse would read 28%.
SEGV3005 - 20 - Module Five
7/97 Exercise No. 1
Student Copy

EXERCISE NO. 1

Understanding and Using the Digital Multimeter

Several diagnostic service tools are available to assist the technician in the troubleshooting process.
This course uses the various electronic monitoring systems as a base for troubleshooting. The primary
diagnostic tool discussed in this lesson is the digital multimeter. Caterpillar currently lists two digital
multimeters in the diagnostic tool list. They are the 6V7070 Caterpillar Digital Multimeter and the
Fluke 9U7330 Digital Multimeter. Although both multimeters may be used by a service technician, the
9U7330 multimeter performs the more complex measurements on the newer electronic systems.

This exercise will use both multimeters to give the students hands-on experience.

Exercise 1A: Understanding and using metric prefixes

Directions: Express each of the following in the units indicated.

1. 2 A to milliamperes = ______________
2. 1327 mA to amperes = ______________
3. 8.2 k to ohms = ______________
4. 680 k to ohm = ______________
5. 2.2 M to ohms = ______________
6. 0.24 A to milliamperes = ______________
7. 0.013 kV to volts = ______________
8. 10,000 V to kilovolts = ______________
9. 5,600,000 to megohms = ______________
10. 0.53 A to milliamps = ______________

Write the value for the following prefix:

11. mega (M) = _______________

12. kilo (k) = _______________
13. milli (m) = _______________
14. micro () = _______________
15. pico (p) = _______________
16. nano (n) = _______________
SEGV3005 - 21 - Module Five
7/97 Exercise No. 1
Student Copy

Exercise 1B: Resistance and Diode Measurements

Directions: Using a fabricated electronic component board and a digital multimeter (use both the
6V7070 and 9U7330 multimeters to make measurements):

Measure the resistance of components labeled #1 through #5 on the component board. Write the value
in the space provided.

1. _________________k
2. _________________
3. _________________M
4. _________________
5. _________________k

Using the multimeter(s), measure the components installed on the fabricated board in positions #6, #7,
#8. Record the measurements.

6. _________________
7. _________________
8. _________________

9. The color band (silver) on the component identifies the ______________.

a. anode
b. cathode
c. emitter
d. collector

Using the digital multimeter, test the component labeled #6. Connect the leads as shown below. Does
the display show a value between .500 and .900? If yes, continue. If no, check the meter leads and
function selector switch.

- +

(- Bk) .567 (+ Red)

Multimeter
Display

10. A digital display reading between .500 and .900 indicates:

a. a resistance between .500 and .900 ohms.
b. a current flow between .500 and .900 amps.
c. a resistance between 500 and 900 milliohms.
d. a voltage drop between 500 and 900 millivolts.
SEGV3005 - 22 - Module Five
7/97 Exercise No. 1
Student Copy

11. With the multimeter leads connected as shown, a reading between .500 and .900 reflect a normal
condition.

a. true
b. false

12. When the leads are reversed (changing polarity), the multimeter displays a reading of OL.

a. OL indicates that the component is open.

b. OL indicates that the component is shorted.
c. OL indicates that the component is not conducting current.
d. OL indicates that the component is defective and should be replaced.

Use the diode symbol below for answering questions #13, #14, and #15.

CATHODE
(+)
ANODE (-)

Perform the following tests on the components labeled #6, #7, and #8 on the fabricated board and
answer the following questions.

13. Component #6:

Red lead on the anode (+), black lead on the cathode (-), display reads: _______
Black lead on the anode (+), red lead on the cathode (-), display reads: _______
Is the component serviceable or defective? (circle answer)
Explain your diagnosis: ___________________________________________________________
______________________________________________________.

14. Component #7:

Red lead on the anode (+), black lead on the cathode (-), display reads: _______
Black lead on the anode (+), red lead on the cathode (-), display reads: _______
Is the component serviceable or defective? (circle answer)
Explain your diagnosis: ___________________________________________________________
______________________________________________________.

15. Component #8:

Red lead on the anode (+), black lead on the cathode (-), display reads: ______
Black lead on the anode (+), red lead on the cathode (-), display reads: ______
Is the component serviceable or defective? (circle answer)
Explain your diagnosis: ___________________________________________________________
_______________________________________________________.
SEGV3005 - 23 - Module Five
7/97 Exercise No. 1
Student Copy

Exercise 1C: Identifying and Measuring Electronic Signals

Directions: Identify and measure electronic signals using the 9U7330 Fluke multimeter, a Fluke
Simulator Board (Fluke P/N 932707), and a 9 volt battery. Use the 6V7070 multimeter to compare
readings when directed. A small screwdriver is needed to set adjustments.

Measuring AC Voltage

Directions: Using the 9U7330 Fluke multimeter, set the multimeter to read AC volts. Place the RED
multimeter test lead in the V/ /Diode jack, and the BLACK test lead in the COM jack for all voltage
and resistance measurements. Hookup the battery, set the simulator adjustments and connect the leads
as shown below. Note: Observe the battery polarity and install the battery only when directed.

AMPL CW
+
9 VOLT PWM Centered
_
FREQ CW

GND TP1 TP2 TP3 TP4 TP5 TP6

Neg Pos

Record the AC voltage level displayed on the meter.

Rotate any, or all of the adjustments, and observe the AC voltage level changing.
Observe the display autoranging between the 4V and 400 mV range when the adjustment knobs
are rotated.
Return the adjustments to the positions shown, and turn multimeter OFF.

Using the 6V7070 Digital multimeter, set multimeter function selector to the highest AC volts
scale.

Record the AC voltage displayed on the 1000 volt AC scale.

Record the AC voltage displayed on the 200 volt AC scale.
Record the AC voltage displayed on the 20 volt AC scale.
Record the AC voltage displayed on the 2 volt AC scale .
Record the AC voltage displayed on the 200 m AC scale.
Which scale produced the most accurate reading.
Record the reading in volts.____________________
SEGV3005 - 24 - Module Five
7/97 Exercise No. 1
Student Copy
Rotate any, or all of the adjustments, and observe AC voltage level changing. Did you need to
select a different scale to accurately read the AC voltage? If yes, explain why?

Measuring DC Voltage

Directions: Using the 9U7330 Fluke multimeter, set multimeter to read DC volts. Note, the Fluke 87
always powers up in the autorange mode and the word AUTO is displayed in the upper left corner of the
display.
To place the meter in the manual mode, press the RANGE button on the meter and observe the scale on
the lower right side of the display change each time the RANGE button is pressed.
Turn meter OFF and then back to the DC volts position.
Set the simulator adjustments and connect the leads as shown above.

AMPL CW
+
9 VOLT PWM CCW
_
FREQ CW

GND TP1 TP2 TP3 TP4 TP5 TP6

Neg Pos

Auto Mode
Record the DC voltage reading displayed on the meter.
Rotate the PWM adjustment knob slowly clockwise and observe the scale autoranging from the
4 volt to the 40 volt scale.
Record the DC voltage with the PWM knob fully clockwise.
Record the DC voltage with the PWM fully counterclockwise.
Rotate PWM adjustment fully counterclockwise and turn meter OFF.

Manual Mode
Set meter to DC volts, observe AUTO displayed in upper left corner of display.
With leads connected as shown above, press the RANGE button once. Observe the word AUTO
disappear from the display indicating that the meter is in the manual mode. Note the scale
remained at 4 volts.
Rotate the PWM adjustment knob slowly clockwise and observe the voltage level increase until
OL is displayed.
SEGV3005 - 25 - Module Five
7/97 Exercise No. 1
Student Copy
Press the RANGE button again and observe the scale change to the 40 volt scale.
Record the DC voltage with the PWM fully clockwise.
Record the DC voltage with the PWM fully counterclockwise.
Explain why the accuracy of the reading depends on the scale being used.

Note: The autorange feature of the 9U7330 can be used for both AC and DC readings. The autorange
feature is not available on the 6V7070 Digital multimeter. All ranges must be manually selected.

Using the MIN MAX Feature of the Fluke 87 Multimeter to Capture DC Signals

MIN MAX

The MIN MAX feature is useful for measuring voltage sweeps, or momentary voltage fluctuations in a
circuit. Use the same setup as you used for measuring DC voltage.

AMPL CW
+
9 VOLT PWM CCW
_
FREQ CW

GND TP1 TP2 TP3 TP4 TP5 TP6

Neg Pos

Turn the meter to the DC volt scale. Note the meter powers up in the autorange scale. Press and
release the RANGE button twice to place the meter display in the 40 volt DC manual scale
(AUTO is not displayed on meter).

Press and release the MIN MAX button once. The displays beeps once and RECORD appears
on the display telling you that the meter is in the MIN MAX mode.

Rotate the PWM adjustment on the simulator board a few times. This varies the DC voltage
signal. Record the MIN MAX readings and .
SEGV3005 - 26 - Module Five
7/97 Exercise No. 1
Student Copy
Press and release the MIN MAX button once. Your meter reads the Maximum voltage recorded.
Record the Maximum voltage.

Press and release the MIN MAX button once again. Your meter reads the Minimum voltage
recorded. Record the Minimum voltage.

Press and release the MIN MAX button once again. Your meter reads the Average voltage
recorded over the entire test. Record the Average voltage.

To exit the MIN MAX mode, press and hold the Min Max button until you hear beep, and the
display returns to the manual mode.

Using the Touch Hold Feature of the Fluke 87 Multimeter to Capture DC Signals

HOLD

Use the Touch Hold for taking DC voltage measurements in hard to get places. To activate the Touch
Hold feature press the HOLD button until a beep is heard and an H appears on the meter display
indicating the display is in the Touch Hold mode.

Set your meter to DC volts, on the 40 volt scale.

Press and release the HOLD button. Beep is sounded and "H" appears.
Touch the meter leads to the battery terminal as shown below. Hold the leads on the battery
terminals until a beep is heard (change alert tone) and then remove the leads from the battery
terminals.
Record the DC voltage signal reading.
The reading will remain displayed until the Touch Hold button is pressed again, or the meter is
turned off.

Pos AMPL CW
+
9 VOLT PWM CCW
_
Neg FREQ CW

GND TP1 TP2 TP3 TP4 TP5 TP6

Press HOLD button again to disable, and turn meter OFF.

SEGV3005 - 27 - Module Five
7/97 Exercise No. 1
Student Copy
Measuring DC Millivolts

Using the 9U7330 Fluke multimeter, set multimeter to read DC volts.

Hookup the battery, set the simulator adjustments and connect the multimeter leads as shown
below.

AMPL CW
+
9 VOLT PWM CCW
_
FREQ CW

GND TP1 TP2 TP3 TP4 TP5 TP6

Neg Pos

Set multimeter to read DC volts, on the 4 volt scale.

Record the voltage on the display.

Switch the meter to read millivolts (mV).

Record the voltage on the display.

Turn meter OFF.

How many places did the decimal point move when you switched to the
millivolts scale?
SEGV3005 - 28 - Module Five
7/97 Exercise No. 1
Student Copy
Measuring DC Milliamps

Note: For the next exercise only, remove the test leads from the meter's test jacks. Rotate the 9V
battery as shown (the battery positive post is the only connection to the board). With the test leads
disconnected from the meter jacks, connect the negative lead (black) to the negative post of the 9V
battery. Connect the positive lead (red) to the negative terminal on the simulator board.

Neg
9 VOLT
AMPL CW
+
PWM Centered
_
Pos FREQ CW

GND TP1 TP2 TP3 TP4 TP5 TP6

Connect the negative (black) test lead to the COM jack on the meter.

Connect the positive (red) test lead to the mA jack on the meter.

Set the meter to read DC milliamps (mA)/A.

Record the DC milli-amp reading.

Disconnect the positive (red) lead from the negative terminal on the demonstrator board.

Switch the meter to read DC volts. What happened?

Note: That's the meter warning that the other end of the positive (red) lead is still plugged into
the amperage jack of the meter. Measuring a voltage with the positive lead connected to the
amperage jack would cause a direct short inside the meter, possibly blowing the fuses and
causing damage to the multimeter.

Never attempt to measure anything except current with the

leads plugged into the amps or milliamps jacks.
SEGV3005 - 29 - Module Five
7/97 Exercise No. 1
Student Copy
Measuring Frequency

Using the 9U7330 Fluke multimeter, set multimeter to read DC volts.

Hookup the battery, set the simulator adjustments, and connect the multimeter leads as shown
below.

Place the RED multimeter test lead in the V/ /Diode jack, and the BLACK test lead in the
COM jack for all voltage and resistance measurements.

AMPL CW
+
9 VOLT PWM CCW
_
FREQ Centered

GND TP1 TP2 TP3 TP4 TP5 TP6

Neg Pos

Hz

Press and release the Hz Button until Hz appears on the right side of the display.

Record the reading. The reading is the signal frequency. Rotate the frequency
adjustment knob and observe the frequency value change on the display.
SEGV3005 - 30 - Module Five
7/97 Exercise No. 1
Student Copy
Measuring Duty Cycle

Using the 9U7330 Fluke multimeter, set multimeter to read DC volts.

Hookup the battery, set the simulator adjustments and connect the multimeter leads as shown
below.

AMPL CW
+
9 VOLT PWM CW
_
FREQ CW

GND TP1 TP2 TP3 TP4 TP5 TP6

Neg Pos

Press and release the Hz button until % appears on the right side of the display.

Hz

Record the reading. ______________ The reading is the duty cycle displayed in percent, and
measured on the positive pulse. Note a (+) sign displayed in the lower left corner of the display.

Rotate the frequency adjustment knob and observe the frequency value change on the display.

To display the duty cycle measured on negative pulse, press and release the Peak MIN MAX
button and observe the (-) sign displayed on the lower left side of the meter display.

PEAK MIN MAX

Record the reading. ______________ The reading is the duty cycle displayed in percent, and
measured on the negative pulse. Note a (-) sign displayed in the lower left corner of the display.

Note: If a duty cycle reads 72% measured on the positive pulse, the duty cycle measured on the
negative pulse would read 28%.
SEGV3005 - 31 - Module Five
7/97 Exercise No. 2
Instructor Copy

Exercise No. 2 EXERCISE NO. 2

General Machine Electrical Systems

This exercise measures the students knowledge of the basic machine

electrical system and the use of basic diagnostic tools, such as, multimeter
and clamp-on ammeter.

Using the student reference materials for this lesson and the above diagnostic
tools perform the following tests.

Show the following Exercise 2: Testing the Alternator, Starter and Battery on a Machine
video's before starting
exercise. Reference Materials and Job Aids for this exercise are:
SEVN1591
SEVN1592 Handout "Basic 12V and 24V Machine Electrical Systems" located at the end
SEVN1590 of Lesson Five and Special Instruction--Battery Procedure SEHS7633

Provide student with 6V7070 or 9U7330 Digital Multimeter,

8T0900 AC/DC Clamp-On Ammeter or 9U5795 AC/DC
Current Probe.

Locate a 12V or 24V machine and the appropriate electrical

schematic.

Using the reference handout and diagnostic test equipment,

perform the following:

Individual Exercises:

2A. Testing the Alternator on the Engine (page 5)

2B. Testing the Starter on the Engine (page 6)

2C. Perform Maintenance-Free Battery test (page 3)

Note: Duplicate a copy of the student handout for this exercise. Instruct
student to take notes during testing. Observe the actual testing and after
exercise is completed conduct a roundtable discussion clearing up any
points of concern.
SEGV3005 - 32 - Module Five
7/97 Exercise No. 2
Student Copy

Exercise 2A: Testing the Alternator on a Machine

Using the handout reference material "Basic 12V and 24V Machine Electrical
Systems," perform the test as outlined in the reference material.

List the tools provided by the instructor.

___________________
___________________
___________________
___________________
___________________

List the machine model being used for test. __________________

Identify the machine electrical system (12v or 24V). ___________
What is the current rating of the alternator being tested? _________

Write a brief description of the testing process explaining the results of the
test. __________________________________________________________
______________________________________________________________
______________________________________________________________
______________________________________________________________
______________________________________________________________
______________________________________________________________
______________________________________________________________

Did you experience any problems during the test? (Describe)

______________________________________________________________
______________________________________________________________
______________________________________________________________
______________________________________________________________
______________________________________________________________

Discuss test with instructor.

SEGV3005 - 33 - Module Five
7/97 Exercise No. 2
Student Copy

Exercise 2B: Testing the Starter on a Machine

Using the handout reference material "Basic 12V and 24V Machine Electrical
Systems" (pages 6 - 9) perform the test as outlined in the reference material.

List the tools provided by the instructor.

___________________
___________________
___________________
___________________
___________________

List the machine model being used for test. __________________

Identify the machine electrical system (12v or 24V). ___________

Perform Test A: Describe test results. _______________________________

______________________________________________________________
______________________________________________________________
______________________________________________________________

Perform Test B: Describe test results. _______________________________

______________________________________________________________
______________________________________________________________
______________________________________________________________

Perform Test C: Describe test results. _______________________________

______________________________________________________________
______________________________________________________________
______________________________________________________________

Write a brief description of the testing process explaining the results of the
test. __________________________________________________________
______________________________________________________________
______________________________________________________________
______________________________________________________________
______________________________________________________________
______________________________________________________________
______________________________________________________________

Discuss test with instructor.

SEGV3005 - 34 - Module Five
7/97 Exercise No. 2
Student Copy

Exercise 2C: Perform Maintenance-Free Battery Test on a Machine

Using the handout reference material "Basic 12V and 24V Machine Electrical
Systems" (page 3) and Special Instruction SEHS7633, perform a test of a
maintenance-free battery.

List the tools provided by the instructor.

___________________
___________________
___________________
___________________
___________________

List the machine model being used for test. __________________

Identify the machine electrical system (12v or 24V). ___________

What is the "open circuit" voltage for the battery being tested? ___________

List the steps necessary to "remove the surface charge" of a 12V battery
installed in the machine.

Step #1:______________________________________________________

Step #2:______________________________________________________

Step #3:______________________________________________________

Step #4:______________________________________________________

Does the battery need to be charged? _______________________

Does the battery need to be "load" tested? ________________

What is the "cold cranking" (CCA) for the battery being tested? _________
(Consult PEDP0030 or PEKP9100 for CCA)

What is the minimum acceptable voltage, under load test for a serviceable
12V battery? ______________________
SEGV3005 - 35 - Module Five
7/97 Exercise No. 3
Instructor Copy
Exercise No. 3 EXERCISE NO. 3

Computerized Monitoring System Problem

This exercise measures the students knowledge of the Computerized

Monitoring System. The machine required for this exercise must have the
CMS--VFD system.

Reference Materials and Job Aids for this exercise are:

Machine equipped with CMS-VFD Monitoring System

Service Manual--Computerized Monitoring System (CMS) with VFD
Circular Gauges...............................................................................SENR5247
Appropriate Electrical Schematic for machine being tested
6V7070 or 9U7330 Digital Multimeter and 7X1710 Cable Probes

Machine Preparation:

Locate the magnetic speed sensor used to measure ground speed. Disconnect
the electrical connector from the sensor. Turn the speed sensor
counterclockwise three full turns (may need to turn more depending on depth
of gear). Reconnect the electrical connector to sensor. Start machine and
move machine while observing the speedometer. Speedometer should be
inoperative. If not, turn the sensor until the desired result is achieved.

Operator Complaint:

Operator reported that the speedometer was reading "0" MPH while the
machine was moving.

Desired Results:

Student must perform "speed sensor" test outlined in SENR5247, pages 65 -

66 to determine faulty condition. After performing the above tests, the
student determines that the condition is caused by a mis-adjusted speed
sensor.
SEGV3005 - 36 - Module Five
7/97 Exercise No. 3
Student Copy

EXERCISE NO. 3

Computerized Monitoring System Problem

Operator Complaint: Operator reported that the speedometer was reading

"0" MPH while the machine was moving.

Perform operational check.

Did the machine operate satisfactorily? _______

If not, was SERV CODE displayed on the dash? ___________

If SERV CODE was not displayed, explain why. ______________________

______________________________________________________________
____________________________________

Based on above answers, list the steps required to troubleshoot the problem.
______________________________________________________________
______________________________________________________________
______________________________________________________________
______________________________________________________________
______________________________________________________________
______________________________________________________________
______________________________________________________________
______________________________________________________________
______________________________________________________________

Write a brief explanation describing your troubleshooting process, what you

found to be the "root cause" of the problem and the steps required to fix
it.
______________________________________________________________
______________________________________________________________
______________________________________________________________
______________________________________________________________
______________________________________________________________
______________________________________________________________
______________________________________________________________
______________________________________________________________
______________________________________________________________
______________________________________________________________
______________________________________________________________
______________________________________________________________
______________________________________________________________
______________________________________________________________
______________________________________________________________
______________________________________________________________
______________________________________________________________
SEGV3005 - 37 - Module Five
7/97 Exercise No. 4
Instructor Copy
Exercise No. 4 EXERCISE NO. 4

Caterpillar Monitoring System Problem

This exercise measures the students knowledge of the Caterpillar Monitoring

System.

Reference Materials and Job Aids for this exercise are:

Machine equipped with Caterpillar Monitoring System

Service Manual--Caterpillar Monitoring System............................SENR6717
Appropriate Electrical Schematic for machine being tested
6V7070 or 9U7330 Digital Multimeter and 7X1710 Cable Probes

Machine Preparation:

Locate either the hydraulic oil temperature sender or the torque converter oil
temperature sender on the machine. At a convenient place, at the sender or in
a connector, open the signal wire. A sender has only one wire. The sender
body threads complete the ground circuit. An "open" signal wire will cause
the corresponding gauge on the monitoring system to read to the "far left."
The Caterpillar Monitoring Systems main display module is unable to
determine if the sender is faulty or the wire is open and will not provide the
technician with diagnostic information.

Note: The sender operates on a negative temperature coefficient where as

the resistance of the sender decreases as the temperature increases. Using
this theory, the module can not determine if the temperature is cold or the
wire is open (high resistance).

Operator Complaint:

Operator reported that the hydraulic temperature (or TC oil temp) gauge was
reading on the far left side of the gauge, even though the machine had been
operated for an extended period of time. No warning conditions were
present.

Desired Result:

Student must perform "troubleshooting procedures" test outlined in

SENR6717, pages 40 - 48 to determine faulty condition. After performing
the above tests, the student determines that the condition is caused by an open
signal wire between the sender and the main display module.
SEGV3005 - 38 - Module Five
7/97 Exercise No. 4
Student Copy

EXERCISE NO. 4

Caterpillar Monitoring System Problem

Operator Complaint: Operator reported that the hydraulic temperature oil

gauge was reading on the far left side of the gauge, even though the machine
had been operated for an extended period of time. No warning conditions
were present.

Perform operational check.

Did the gauge remain on the far left side (cold)? ________________

If not, was SERV CODE displayed on the main display module? _________

If SERV CODE was not displayed, explain why. ______________________

______________________________________________________________
______________________________________________________________
______________________________________________________________
_______________________________________

Based on above answers, list the steps required to troubleshoot the problem.
______________________________________________________________
______________________________________________________________
______________________________________________________________
______________________________________________________________
______________________________________________________________
______________________________________________________________
______________________________________________________________

Write a brief explanation describing your troubleshooting process, what you

found to be the "root cause" of the problem and the steps required to fix
it.
______________________________________________________________
______________________________________________________________
______________________________________________________________
______________________________________________________________
______________________________________________________________
______________________________________________________________
______________________________________________________________
______________________________________________________________
______________________________________________________________
______________________________________________________________
______________________________________________________________
______________________________________________________________
______________________________________________________________
______________________________________________________________
______________________________________________________________
SEGV3005 - 39 - Module Five
7/97 Exercise No. 5
Instructor Copy
Exercise No. 5 EXERCISE NO. 5

Vital Information Management System Problem

This exercise measures the students knowledge of the Vital Information

Management System.

Reference Materials and Job Aids for this exercise are:

Machine equipped with the Vital Information Management System

Service Manual--Vital Information Management System................SENR6059
Appropriate Electrical Schematic for machine being tested
6V7070 or 9U7330 Digital Multimeter and 7X1710 Cable Probes

Machine Preparation:

On a machine equipped with the Vital Information Management System set

the following condition(s):

1. Key switch OFF.

2. Slide contact pin No. 29 out of the 37 pin connector on the main
VIMS module. Use the correct Deutsch removal tool (black).

3. Turn the key switch ON; observe the VIMS display modules as
the self test is being performed.

4 Observe that the message center display reads "KEYPAD DATA

ERROR--CALL SHOP" after the self test has completed.

5. Turn the key switch OFF (preparation completed).

Operator Complaint:

Operator reported that after the key switch was turned ON and the VIMS
finished self testing, the message center read "KEYPAD DATA ERROR--
CALL SHOP"

Desired Result:

Student must perform diagnostic troubleshooting procedures as outlined in

Service Manual--Vital Information Management
System (VIMS).................................................................................SENR6059
SEGV3005 - 40 - Module Five
7/97 Exercise No. 5
Instructor Copy

Note: On a machine, the F1 key on the keypad can be pressed to display

stored diagnostic information. For this malfunction, pressing the F1 key
does nothing. The serviceman observed the small "red indicator" blinked
when the keys were pressed (indicating that the keystrokes are being
entered into the display), but diagnostic MID, CID, and FMI information
was not displayed.

The technician must recognize that a malfunction exists, but no diagnostic

information is available to assist in troubleshooting. The technician must use
the appropriate electrical schematic and normal troubleshooting procedures in
determining the "root" cause of the problem.

Actual Solution:

The technician recognized that a malfunction existed, but no diagnostic

information was available to assist him in troubleshooting. Using the
electrical schematic, he located the keypad module and concluded that the
keypad module is connected to a four pin Deutsch DT connector.

Also, from his earlier observation, he recalled that the "red indicator" blinked
when he tried to enter information using the keypad. This indication verified
that the module was receiving an input voltage (+V) and the keypad module
ground connection was complete. The only remaining circuit (wire C415-
WH) that is part of the instrumentation data link is connected between contact
pin No. 29 (on the main VIMS connector) and contact pin No. 3 (on the
keypad module connector).

The technician removed the main VIMS connector and the keypad connector.
Using his multimeter and cable probes (9X1710), he measured continuity
between contact pin No. 29 on the main VIMS module connector and contact
pin No. 3 on the keypad connector. The multimeter (on the ohms scale)
displayed "OL" indicating an open circuit between the main connector and
the keypad. Further investigation revealed an open contact pin in the main
VIMS connector. He replaced the contact pin and the system checked
normal.

NOTE: The serviceman may have chosen to take voltage measurements

instead of resistance. For the above problem, if the serviceman measured
the voltage between contacts No. 2 (ground) and No. 3 (data), a reading of
approximately 7.42 volts would be misleading and provide inconclusive
information, possibly causing the serviceman to change the keypad module
instead of pursuing a wire maintenance problem.
SEGV3005 - 41 - Module Five
7/97 Exercise No. 5
Student Copy

EXERCISE NO. 5

Vital Information Management System Problem

Operator Complaint: Operator reported that after the key switch was turned
ON and the VIMS finished self testing, the message center read "KEYPAD
DATA ERROR--CALL SHOP"

Perform operational check.

Did the VIMS fail to self test? _____________________

Did the message display read "KEYPAD DATA ERROR--CALL SHOP?"

__________

List the diagnostic information available on the message center:

MID ____________
CID ____________
FMI ____________

Based on the above answers, list the steps required to troubleshoot the
problem. ______________________________________________________
______________________________________________________________
______________________________________________________________
______________________________________________________________

Write a brief explanation describing your troubleshooting process and what

you found to be the "root cause" of the problem and the steps required to fix
it.
______________________________________________________________
______________________________________________________________
______________________________________________________________
______________________________________________________________
______________________________________________________________
______________________________________________________________
______________________________________________________________
______________________________________________________________
______________________________________________________________
______________________________________________________________
______________________________________________________________
______________________________________________________________
______________________________________________________________
______________________________________________________________
_______________________________________
SEGV3005 - 42 - Module Five
7/97 Exercise No. 6
Instructor Copy
EXERCISE NO. 6

Basic Machine System Troubleshooting

This exercise measures the students ability to apply basic troubleshooting logic in solving machine
electrical problems. The problems are presented in a schematic format. The student needs to study the
schematic and answer the questions as directed. This exercise not only covers basic electrical theory,
but requires the student to logically perform multimeter measurements.

Reference Materials and Job Aids for this exercise are: None

Directions: This lesson consists of five individual sections. It is necessary for the student to study the
schematic prior to answering the questions. The sections are:

6A Circuit Identification: Ask students to identify the type of circuit and then provide
an operator complaint. The student needs to study the circuit and
then determine the root cause of the complaint.

6B Voltage Measurements: Ask students to make voltage drop calculations between

several test points on the schematic.

6C Schematic Recognition: Ask students to measure voltages between two different sets of test
points. The student must recognize that the engine
compartment switch is OPEN to correctly measure the voltages.

6D Current Measurements: Ask students to measure the current flow between selected test
points. Requires the student to recognize that the components are
connected in a parallel circuit before calculating the
measurements.

6E Voltage and Current Ask students to measure the voltage drops and current flow
Measurements between selected test points. Requires students to recognize
that the components are connected in a series-parallel circuit
before calculating the measurements.

Handout student copies of the lesson prior to starting exercise.

SEGV3005 - 43 - Module Five
7/97 Exercise No. 6
Instructor Copy

620-RD-14

200-BK-14
1A

POS NEG POS NEG

12V 12V

TP6

Exercise 6A: Circuit Identification

Each internal lamp resistance equals 60 ohms.

1. The circuit above is:

a. series
b. parallel
c. series-parallel
d. series and parallel

2. The operator reported that the engine compartment lights were not working. He checked the fuse
and found the fuse to be open. The fuse was replaced with the same type fuse and when the engine
compartment light switch was turned ON, the new fuse immediately failed.

What caused the new fuse to fail? Explain Using ohm's law to calculate the circuit, the total
current flowing throughout the circuit is 1.2 amps. The fuse had a capacity of 1 amp, and blows
each time the switch is turned ON.

3. The total circuit voltage is 24 volts, the total current flow is 1.2 amps, and the
total circuit resistance is 20 ohms.
SEGV3005 - 44 - Module Five
7/97 Exercise No. 6
Instructor Copy

TP4

TP2 TP3
620-RD-14

200-BK-14
TP1
TP5
5A

POS NEG POS NEG

12V 12V

TP6

Exercise 6B: Voltage Measurements

System Operating Normal

Record the following voltage drops:

1. Voltage drop between TP1 and TP2 = 0 volts

2. Voltage drop between TP1 and TP6 = 24 volts

3. Voltage drop between TP3 and TP6 = 24 volts

4. Voltage drop between TP2 and TP3 = 0 volts

5. Voltage drop between TP5 and TP6 = 24 volts

6. Voltage drop between TP4 and TP5 = 0 volts

SEGV3005 - 45 - Module Five
7/97 Exercise No. 6
Instructor Copy

TP4

TP2 TP3
620-RD-14

200-BK-14
TP1
TP5
5A

POS NEG POS NEG

12V 12V

TP6

Exercise 6C: Schematic Recognition

Engine Compartment Switch OFF

Record the following voltage drops:

1. Voltage drop between TP1 and TP2 = 24 volts

2. Voltage drop between TP1 and TP6 = 24 volts

3. Voltage drop between TP3 and TP6 = 0 volts

4. Voltage drop between TP2 and TP3 = 0 volts

5. Voltage drop between TP5 and TP6 = 0 volts

6. Voltage drop between TP4 and TP5 = 0 volts

SEGV3005 - 46 - Module Five
7/97 Exercise No. 6
Instructor Copy

TP4
60
A

TP2 TP3
A 60
5

200-BK-14
Engine Compartment
Indicator Lamp
TP7
TP1
TP5
Engine Compartment
10 A Lamp Switch
60

POS NEG POS NEG

12V 12V

TP6

Exercise 6D: Current Measurements

Engine Compartment Switch ON

Record the following current measurements:

1. Ammeter reading between TP2 and TP3 = 1.2 Amps

2. Ammeter reading between TP3 and TP4. = .4 Amps

3. If an ammeter was connected between TP1 and TP2 it would read? 6 Amps

4. How much current is flowing through the engine compartment indicator lamp? 4.8 Amps

5. An ammeter is always connected in:

a. series with the load
b. parallel with the load
c. series-parallel with the load
d. does not matter
SEGV3005 - 47 - Module Five
7/97 Exercise No. 6
Instructor Copy

TP4
60
A

TP2 TP3
A 60

200-BK-14
Engine Compartment
Indicator Lamp
TP1
TP5
Engine Compartment
3A Lamp Switch
60

POS NEG POS NEG

12V 12V

TP6

Exercise 6E: Voltage and Current Measurements

Engine Compartment Switch ON

1. The circuit above is:

a. series
b. parallel
c. series-parallel
d. series and parallel

2. Ammeter reading between TP2 and TP3 = 960 milliamps

3. Ammeter reading between TP3 and TP4 = 320 milliamps

4. Voltage drop between TP1 and TP2 = 4.8 volts

5. Voltage drop between TP5 and TP6 = 19.2 volts

6. What is the total current flowing through the circuit? = 960 milliamps
SEGV3005 - 48 - Module Five
7/97 Exercise No. 6
Student Copy

620-RD-14

200-BK-14
1A

POS NEG POS NEG

12V 12V

TP6

Exercise 6A: Circuit Identification

Each internal lamp resistance equals 60 ohms.

1. The circuit above is:

a. series
b. parallel
c. series-parallel
d. series and parallel

2. The operator reported that the engine compartment lights were not working. He checked the fuse
and found the fuse to be open. The fuse was replaced with the same type fuse and when the engine
compartment light switch was turned ON, the new fuse immediately failed.

What caused the new fuse to fail? Explain ______________________________________________

___________________________________________________________________________________
___________________________________________________________________________________
_________________________________________

3. The total circuit voltage is ______ volts, the total current flow is ______ amps, and the
total circuit resistance is ______ ohms.
SEGV3005 - 49 - Module Five
7/97 Exercise No. 6
Student Copy

TP4

TP2 TP3
620-RD-14

200-BK-14
TP1
TP5
5A

POS NEG POS NEG

12V 12V

TP6

Exercise 6B: Voltage Measurements

System Operating Normal

Record the following voltage drops:

1. Voltage drop between TP1 and TP2 = _________

2. Voltage drop between TP1 and TP6 = _________

3. Voltage drop between TP3 and TP6 = _________

4. Voltage drop between TP2 and TP3 = _________

5. Voltage drop between TP5 and TP6 = _________

6. Voltage drop between TP4 and TP5 = _________

SEGV3005 - 50 - Module Five
7/97 Exercise No. 6
Student Copy

TP4

TP2 TP3
620-RD-14

200-BK-14
TP1
TP5
5A

POS NEG POS NEG

12V 12V

TP6

Exercise 6C: Schematic Recognition

Engine Compartment Switch OFF

Record the following voltage drops:

1. Voltage drop between TP1 and TP2 = ______

2. Voltage drop between TP1 and TP6 = ______

3. Voltage drop between TP3 and TP6 = ______

4. Voltage drop between TP2 and TP3 = ______

5. Voltage drop between TP5 and TP6 = ______

6. Voltage drop between TP4 and TP5 = ______

SEGV3005 - 51 - Module Five
7/97 Exercise No. 6
Student Copy

TP4
60
A

TP2 TP3
A 60
5

200-BK-14
Engine Compartment
Indicator Lamp
TP7
TP1
TP5
Engine Compartment
10 A Lamp Switch
60

POS NEG POS NEG

12V 12V

TP6

Exercise 6D: Current Measurements

Engine Compartment Switch ON

Record the following current measurements:

1. Ammeter reading between TP2 and TP3 = _______

2. Ammeter reading between TP3 and TP4 = _______

3. If an ammeter was connected between TP1 and TP2 it would read? _______

4. How much current is flowing through the engine compartment indicator lamp? _______

5. An ammeter is always connected in:

a. series with the load
b. parallel with the load
c. series-parallel with the load
d. does not matter
SEGV3005 - 52 - Module Five
7/97 Exercise No. 6
Student Copy

TP4
60
A

TP2 TP3
A 60

200-BK-14
Engine Compartment
Indicator Lamp
TP1
TP5
Engine Compartment
3A Lamp Switch
60

POS NEG POS NEG

12V 12V

TP6

Exercise 6E: Voltage and Current Measurements

Engine Compartment Switch ON

1. The circuit above is:

a. series
b. parallel
c. series-parallel
d. series and parallel

2. Ammeter reading between TP2 and TP3 = ______ milliamps

3. Ammeter reading between TP3 and TP4 = ______ milliamps

4. Voltage drop between TP1 and TP2 = _______ volts

5. Voltage drop between TP5 and TP6 = _______ volts

6. What is the total current flowing through the circuit? = _______ milliamps
SEGV3005 - 53 - Module Five
7/97 Student Handout

BASIC 12V AND 24V MACHINE ELECTRICAL

SYSTEMS

The information contained in this handout has been collected from

various service magazine articles over an extended period of time. The
information is a valuable resource for personnel who perform electrical
tests on various Caterpillar machines.

Duplicate the handout and give a copy to each student prior to presenting
the material in module five.
SEGV3005 - 54 - Module Five
7/97 Student Handout

STUDENT HANDOUT

START
TP1 RELAY TP2 START
SWITCH

C OFF

S ON
B ST

W X TP3
TP4
TP6

TP7 TP8
STARTER TP10 POS NEG POS NEG
MOTOR

BATTERIES
TP5 DISCONNECT
SWITCH
TP9

12-V AND 24-V

MACHINE
ELECTRICAL SYSTEMS
SEGV3005 - 55 - Module Five
7/97 Student Handout

Table of Contents

TITLE

Maintenance-Free Batteries Require Different Troubleshooting Procedures................................... 56

Preventive Maintenance For Batteries.............................................................................................. 57
Alternator/Generator Output Test On The Engine............................................................................ 58
Testing The Starter On The Engine................................................................................................... 59
Jump Starting Procedures.................................................................................................................. 63
How To Determine If Relays Are Functioning Correctly................................................................. 65
Be Sure Battery Cable To Starter Connection Has Correct Torque.................................................. 67
Electrical System Damage From High Voltage................................................................................ 68
Understanding Four Wire Windshield Wiper Motors (12 & 24V)................................................... 69
Procedure For Replacing Batteries Or Battery Cables...................................................................... 70
Procedure For Replacing Batteries Battery Cables Or Disconnect Switches................................... 70
Procedure For Replacing Batteries, Battery Cables Or Disconnect Switches.................................. 70
Understanding Causes Of Blown Fuses And Tripped Circuit Breakers........................................... 71
Understanding Circuit Breakers........................................................................................................ 72
Understanding "Shorts," "Opens" and "Intermittents"...................................................................... 73
How To Troubleshoot A Short-To-Ground In Power Wiring............................................................ 74
Limitations On Engine Cranking Time............................................................................................. 74
Operating Characteristics of Alternators Used in Backhoes............................................................. 75
SEGV3005 - 56 - Module Five
7/97 Student Handout

June 20, 1988 When maintenance-free batteries are deeply discharged,

they may not recharge if you just jump-start the engine. Cat
Maintenance-Free Batteries Require Different alternators produce 13.8 volts on 12 volt products and 27.5
Troubleshooting Procedures volts on 24 volt products. But 16 volts (32 volts on 24 volt
systems) may be required for charging to begin. Recharge
1401 with a battery charger capable of supplying 16 volts so that
Many new Cat products are now using maintenance free the batteries will accept a charge. Once they accept
batteries. These batteries require different test procedures charging current, indicated by an increase in the charger
from conventional batteries. Since there are no vent plugs ammeter reading, the voltage must then be reduced. lt is
on maintenance-free batteries, there is no way to check the important not to let the charging voltage exceed 16.0 volts,
specific gravity of the electrolyte. A hydrometer cannot be especially as the battery becomes fully charged.
used. Instead, the voltage of the battery must be checked to The Cat maintenance-free battery used in original
determine the state of charge. equipment (3T5760) is designed and built to rigid Cat
Measure the open circuit voltage of the battery. Use a specifications. lt can be deeply discharged, such as by
digital volt meter such as 6V7070 Multimeter Group. Set leaving the lights on over a weekend, and still be a good
the meter on the 20 volt DC scale and touch the probes to serviceable battery when fully recharged. For complete
the battery terminals. If the battery voltage is 12.40 or testing and charging information, refer to Special
above, the battery is ready for use, if below 12.40 volts, it Instruction, Form SEHS7633, "Battery Procedure."
must be recharged for satisfactory performance.
If a maintenance-free battery is being considered for
warranty, the same voltage check must be done before
performing a load test. Maintenance-free batteries below
12.40 volts will fail a load test, but still may be good,
serviceable batteries when recharged.
SEGV3005 - 57 - Module Five
7/97 Student Handout

March 27, 1989 Another important factor in prolonging battery life is proper
storage. Batteries are perishable items and can lose
Preventive Maintenance For Batteries efficiency when not in use. Batteries discharge faster in
1401 high temperatures so they should be stored in the coolest
place possible. Small, constant electrical current loads like
The battery is often overlooked in many preventive brushless alternators, electronics, clocks, etc., can run a
maintenance programs. This is unfortunate because, with a battery down when not in use. if a machine will not be used
little care, battery life can be substantially extended. for 30 days or more, open the disconnect switch or remove
Caterpillar suggests some relatively simple steps to ensure the ground (negative) cable from the battery.
greater reliability and longer battery life.
The next step is to check the batteries' state of charge. This
The most important is to make sure electrolyte levels are is called checking the open-circuit voltage. Use a digital
checked at appropriate intervals. Standard, or conventional, volt meter such as 6V7070 Multimeter. An analog meter
batteries should be checked every 100 hours. Electrolyte (moving needle type) is not accurate enough for battery use.
levels should be checked in low maintenance batteries at Set the voltmeter on the 20volt DC state and touch the
each 250-hour interval. No acid level check is required or probes to the battery terminals with the engine off. A
can be performed on the maintenance-free design. reading of 12.40 or more (for a 12 volt battery) means the
battery is charged sufficiently. Any reading less than 12.40
If the electrolyte level is low, add only distilled water to means the battery needs charging.
keep possible contaminants out of the battery. While
checking the electrolyte, make a few other visual If the battery has been recently charged, the surface charge
inspections: must be removed before making this test. To remove the
surface charge, crank the engine for about 5 seconds with
1. Is there any indication of damage or corrosion on the the fuel shut off, or turn on the headlights for about one
battery terminals, the battery box or wiring? If so, clean or minute. The open circuit voltage can then be accurately
replace the necessary components. Cleaning can best be checked.
done with a solution of baking soda and water (1 1/2 cups
baking soda per gallon of water). Visual inspection could If the battery is below 12.40 open circuit voltage, then it
also alert you to the possibility of a cracked battery which should be charged. The slow charge method for charging a
could only be identified by corrosion in the battery tray. battery will provide the best results. The battery should be
charged at the manufacturer's recommended rate or 3% of
2. Are the hold-downs tightened correctly? Vibration will the Cold Cranking Amps (CCA) rating. For example,
destroy a battery faster than anything else. Caterpillar's 8D battery is rated at 1250 CCA, thus the
3. Is there debris under the battery? This must be removed charge rate should be approximately 37 amps.
when hold-downs are tightened as this can cause holes to be The charging voltage should never exceed 16 volts. Too
worn in the case and result in loss of electrolyte. much voltage will cause serious damage to the battery.
4. Are all vent caps correctly in place? Loss of vent caps Charge time could be as little as a few hours for a battery
can pose a potential hazard and permit contamination of the near 12.40 open-circuit voltage to approximately 8 hours for
battery. a fully discharged battery.

5. Are the alternator belts tight? If not, the battery will not For more complete information on charging a battery, see
charge correctly and poor performance will result. either Special Instruction, SEHS9014, "Battery Charging
Rate/Time Tables", or SEHS7633 "Battery Test Procedure".
6. What is the alternator output voltage? Use a voltmeter to
check it. This will identify both low charging voltages due To assure the battery will function correctly, it should be
to loose fan belt and also high charging voltages which can load-tested. To do this, see Special Instruction SEHS7633
damage a battery. Alternator charging voltage should be "Battery Test Procedure".
13.5 to 14.5 volts for a 12 volt system and 27.0 to 29.0 for a Preventive maintenance and appropriate checking and
24 volt system. charging can increase battery life. There are two most
While the maintenance-free batteries do not require significant problems with batteries brought in for service:
electrolyte checks, do steps 1, 2, 3, 5 and 6 every 1,000 they have been discharged or they have been subjected to
hours for maximum battery life. abuse (for example: lack of water, loose hold-downs, etc.).
Regular preventive maintenance can reduce the possibility
of throwing away a good battery. You can obtain more
information on batteries and assistance in battery testing
from any Caterpillar dealer.
 SEGV3005 - 58 - Module Five
7/97 Student Handout

May 4, 1987 3. Start the engine and run at approximately 1/2 throttle.
Alternator/Generator Output Test On The 4. Immediately check output current. This initial charging
Engine current should be equal to or greater than the full output
current shown in the Service Manual. The most common
1401, 1404, 1405, 1406 alternators are:
All Caterpillar Engines 24V Systems
REFERENCE ARTICLE: 'Testing The Starter On The 6N9294 - 35A
Engine', in this issue. 5S9088 - 50A
8N999 - 75A
Servicemen often need a procedure to follow to determine if 6T1395 - 35A
an alternator or generator is working, or if it needs to be 7T2095 - 35A
replaced. This general procedure is valid for any type of
system. voltage, or charge rating. 12V Systems
7N4784 - 40A
Tools Needed: 6T1396 - 55A
. . . 6V7070 Digital Multimeter (or 6V/800 or 6V3030 or 7T2096 - 55A
equivalent 5. Within approximately 10 minutes at 1/2 throttle (possibly
. . . 8T900 AC/DC Clamp-on Ammeter or equivalent longer. depending upon battery size, condition and
alternator rating), the alternator output voltage should be
1. Put the multimeter positive (+) lead on the B+ terminal of 27.5 plus or minus 1 Volt- indicating the alternator is
the alternator. Put the negative (-) lead on the negative (-) performing within spec. See Fault Condition Chart.
terminal of the alternator. Put the clamp-on ammeter around
the positive output wire of the alternator. 12V System - 13.8 .5V
30V System - 34.4 1.3V
2. Turn off all electrical accessories. With the fuel off, crank 32V System - 36.7 1.3V
the engine for 30 seconds. Wait two minutes to let the
starter cool. If the system appears to be up to specifications, 6. The charging current during this period should taper off
crank the engine again for 30 seconds. to less than approximately 10 Amps, depending again upon
battery and alternator capacities. See chart.
NOTE
Cranking the engine for 30 seconds partially discharges the
batteries in order to do a charging test. if batteries are
already low in charge, skip this step. Jump-start engine or
charge batteries as required.

Fault Conditions and Possible Causes

Voltage After About Voltage After About Voltage After About
10 Min. is Below Spec. 10 Min. is In Spec. 10 Min. is Above Spec.

Current at Startup Replace alternator (defective Turn on all accessories. If voltage drops
Below Specification regulator, open stator phase, and/or below spec., replace alternator (open
rectifier) rectifier and/or stator phase

Current at Startup Replace alternator (defective Alternator and batteries in spec. Turn on Replace alternator
Reached spec. and regulator all accessories to verify. Voltage must (shorted regulator)
then tapered off stay in spec

Current at Startup Check batteries per Form SEHS7633. Check batteries per Form SEHS7633. Do Replace alternator
Exceeds spec. and Do alternator test again if necessary alternator test again if necessary (shorted regulator)
stays high
Check batteries for
possible damage

English SEHS 7633 is also available in French (SFHS7633) , Spanish (SSHS7633), and German (SGHS7633)
SEGV3005 - 59 - Module Five
7/97 Student Handout

May 28, 1990 REFERENCE: Special Instruction, SEHS7768, "Use of

6V2150 Starting/Charging Analyzer Group."
Testing The Starter On The Engine
This is a general procedure to help aid the serviceman
1453, 1450, 1401 determine if a starter needs replacement. It is NOT intended
This article replaces the article with the same title on Page to cover all possible problems and conditions, but to serve
12 of the May 4, 1987 Service Magazine. only as a guide. The most common 24V circuit is discussed
and 12V circuits are indicated as applicable. On engines
REFERENCE ARTICLE: Service Magazine; May 4, with a diagnostic connector, the 6V2150 Starting/Charging
1987; Page 10; "Alternator/Generator Output Test On The Analyzer Group helps you to do the following procedure in
Engine." seconds.
Service Magazine; December 10, 1984; "Starters That General Information
Remain Engaged After Engine Is Running."
Starting systems usually have four major components:
Service Magazine; April 24, 1989; "Page 1; "Causes And
Effects Of Low Battery Voltage On Electric Starters." . . .Start switch
. . .Start relay
. . .Starter solenoid
. . .Starter motor

START
TP1 RELAY TP2 START
SWITCH

C OFF

S ON
B ST

W X TP3
TP4
TP6

TP7 TP8
STARTER TP10 POS NEG POS NEG
MOTOR

BATTERIES
TP5 DISCONNECT
SWITCH
TP9
SEGV3005 - 60 - Module Five
7/97 Student Handout

The only exception to this typical cranking circuit is that Chart B shows maximum allowable voltage drops in the
some small engines do not require the start relay. In this high current battery circuit to the starter. These values are
case, the start switch is connected directly to the starter maximums for engines with more than about 2000 SMH.
solenoid. Newer engines have less voltage drops .
Start switches are relatively low current devices. They are
rated to switch approximately 5 to 20 amps. Because the
Chart B-Maximum Allowable System
coil of a start relay between TP2 (Test Point 2) and TP1 in
Voltage Drops During Cranking
Illustration 1 draws about 1 amp, the start switch can easily
turn on the start relay and have long life. Absolute Maximum
Voltage Reading
The switch contacts of a typical start relay are rated to Circuit 24V 12V
switch between 100 and 300 amps. Because a starter Batt. Pos. Post to Starter 0.5V 0.3V
solenoid requires only 5 to 50 amps, the start relay can Pos. Post (TP10 to TP6)
easily switch this load. Batt. Neg. Post to Starter 1.4V 0.7V
The starter solenoid has two functions: it engages the pinion Neg. Post (TP7 to TP5)
with the flywheel, and it is a high current switch rated about Drop Across Only 1.0V .5V
1000 amps that actually turns on the starting motor. Disconnect Switch
(TP8 to TP9)
The starter solenoid has two coils: the pull-in coil (W) Start Relay Contacts 0.8V 0.4V
draws about 40 amps and hold-in coil (X) requires about 5 (TP3 to TP6)
amps. The instant the start relay closes, both coils (W and
Solenoid Contacts 0.8V 0.4V
X) receive power. Battery voltage is applied to the high end
(TP6 to TP4)
of both coils, at Test Point (3) which is the "start" terminal
(S). The low end of hold-in coil (X) is permanently
connected to the ground post of the starter motor.
Grounding for the low end, Test Point (4), of pull-in coil
(W) is momentary, and takes place through the DC Voltage drops greater than those listed are usually caused by
resistance of the starter motor. When magnetic force builds loose and/or corroded connections or bad switch contacts.
in both coils, the starter pinion is moved to engage the ring The entire diagnostic procedure can be reduced to:
gear. Only then will the solenoid contacts close to power the
starter motor. This temporarily removes the ground from . . .confirming that batteries are within specifications
pull-in coil (W), and puts battery voltage on both ends of it . . .switches and cables/wiring from the batteries to the
while the motor cranks. During this period, the pull-in coil starter are not causing too much voltage loss.
is out of the circuit and draws no current. Cranking The flow chart in Illustration 2 shows the entire procedure .
continues until power to the motor solenoid is turned off by
the start switch. NOTE: If the engine is equipped with the diagnostic
connector, the 6V2150 Analyzer Group can quickly be used
The result of these switches and relays is to permit a 5 amp in place of this entire procedure.
dash-mounted switch to turn on a 500 to 1000 amp motor
for cranking an engine.
Battery voltage (power) available during cranking depends
on the temperature of the batteries. See Chart A. This chart
is only a GUIDE as to what to expect from a NORMAL
system.

Chart A-Typical System Voltage During

Cranking Versus Ambient Temperature

-23C To-7C -7C To 10C 10C To 27C

Temp. (-10F To 20F) (20F to 50F) (50F To 80F)
24 Volt 12V to 16V 14V to 18V 16V to 20V
System
12 Volt 6V to 8V 7V to 9V 8V to 10V
System
SEGV3005 - 61 - Module Five
7/97 Student Handout

TEST (A) TEST (B) TEST (C)

STARTER SLUGGISH TEST OF WIRING TEST OF ENGINE

SLOW OR NOT TO STARTER
CRANKING

READ MOTOR CHECK ENGINE

VOLTAGE TP4 TO LOCKED UP?
TEST BATTERY OIL VISCOSITY?
TP5 WHILE
CRANKING ENGINE PARASITIC LOADS?

READ VOLTAGE AT NO YES ENGINE YES

BATTERY POST VOLTAGE
MORE OR = TO LOCKED UP OR REPAIR
WHILE CRANKING HARD TO PARTS
ENGINE CHART (A) ?
TURN?
OPTIONAL
NO
YES
READ VOLTAGE DOES
STARTER REPLACE
TEST FOR YES DROPS IN
NO VOLTAGE CRANK? STARTER
SHORTED CRANKING CIRCUIT
MORE OR = TO CHART (B)
STARTER
WITH 8T900 CHART (A) ?
OPTIONAL
AMMETER NO
YES
YES HAS BUTT TRY TO
VOLTAGES ENGAGEMENT CRANK
TEST BATTERY PER OK? CHART (B) OCCURRED? AGAIN
SPEC INSTRUCTION
SEHS7633
NO NO

REPLACE
REPAIR OR STARTER
REPLACE
PART

Testing The Starter NOTE: Chart C lists the maximum current draw for
different families of engines.
Testing Equipment Required:
6V7070 Digital Multimeter (or 6V7800 or 6V3030 or Chart C
equivalent)
Family Of Maximum Rated
8T0900 Clamp-on Ammeter (optional) Engines System Voltage Starter Cranking Amps

NOTE: This procedure covers a problem where the starter 3200/3300 12 1200-1400
cranks either sluggishly (unusually slow) or not at all.
3200/3300 24 750
Test A. Check battery voltage at the battery posts while 3400 12 1200-1400
cranking, or attempting to crank.
3400 24 750
NOTE: Use the posts representing 12 or 24 Volts. Do not
check voltage on the cable post clamps. 3500 24 750

1. Is voltage equal to or greater than what is shown in Chart 3500 32 700

A?
. . . Yes - Go to Test B. Test B. Measure starter motor voltage from TP4 to TP5
while cranking, or attempting to crank.
. . . No - Voltage at batteries is too low. Test batteries per
Special Instruction SEHS7633. 1. Is voltage equal to or greater than that shown in Chart A?

NOTE: Low batteries can be caused by the battery . . . Yes - Batteries and starter cables down to motor are
condition or a shorted starter. electrically within specifications. Go to Test C.

. . . Optional: Check for shorted starter with 8T0900 Clamp- . . . No - Voltage drop (loss) between batteries and starter is
on Ammeter. (If voltage at battery post is within too great. Go to next step.
approximately two volts of the lowest value in the . . . Optional: Check for shorted starter with 8T0900 Clamp-
applicable temperature range of Chart A, and if larger on Ammeter. (If voltage at battery post is within about two
starter cables get hot, this suggests a shorted starter without Volts of the lowest value in Chart A, large starter cables
using an 8T0900 Ammeter). will get hot and confirm a shorted starter without using an
8T0900 Ammeter). Go to next step.
SEGV3005 - 62 - Module Five
7/97 Student Handout

2. Measure voltage drops in cranking circuit per Chart B. NOTE: Butt engagement and open starter solenoid contacts
Are all voltages within specifications? give the same electrical readings. That is, the solenoid is
activated, but the solenoid contacts can not close to turn on
. . . Yes - Check engine. Go to Test C. the starting motor because the pinion has struck the edge of
. . . No - Repair and/or replace faulty electrical component . the ring gear. If a butt engagement has occurred, the engine
will crank on the second attempt 90% of the time.
Test C. "Bar over" the engine to be sure it is not locked
up. Check engine oil viscosity (weight), parasitic loads, 3. Has butt engagement occurred?
etc. . . . Yes - Attempt to crank again.
1. Is engine locked up and/or hard to turn? . . . No - Replace starter.
. . . Yes - Repair engine as required.
. . . No - Go to next step.
2. Does starter crank? (Probably acts sluggish.)
. . . Yes - Replace starter.
. . . No - Listen for butt engagement (a clicking sound
caused by the pinion hitting, but not engaging the ring
gear). If this occurs, turn off the key switch. Then turn the
switch back to crank, and most likely the pinion will engage
the ring gear and crank the engine.
SEGV3005 - 63 - Module Five
7/97 Student Handout

May 28, 1990

Jump Starting Procedures NOTICE
When starting from another machine, make sure the
1450, 1453 machines do not touch. This could prevent damage to
engine bearings and electrical circuits.
All Caterpillar Machines And Engines Equipped With
Electric Starters Turn on (close) the disconnect switch on the stalled
machine prior to the jump connection to prevent damage to
REFERENCE ARTICLE: Service Magazine; May 4, electrical components.
1987; Page 12; "Testing The Starter On The Engine."
Severely discharged maintenance free batteries might not
Service Magazine; May 4, 1987; Page 10;
fully recharge by the alternator alone after jump starting.
"Alternator/Generator Output Test On Engine." Service
They should be charged to the proper voltage by a battery
Magazine; May 1,1989; Page 1; "Cause And Effects Of
charger.
Low Batter Voltage On Electric Starters." Service
Magazine; March 27, 1989; Page 6; "Preventive Many batteries thought to be unusable, are only discharged.
Maintenance For Batteries." Recharge and load test to confirm true battery condition.
Use only equal voltage for jump starting. Use of a higher
REFERENCE: Special Instruction, SEHS7633, "Battery
voltage can damage the electrical system.
Test Procedure."
Refer to Special Instruction, SEHS7633, Battery Test
The procedures that follow apply to systems of any voltage Procedure, for complete testing and charging information.
and either positive or negative ground.
Engine Starting with Jump (Formerly Called
Engine Starting with Jumper Cables
"Auxiliary") Start Receptacles
WARNING Some Caterpillar products may be equipped with jump start
receptacles as standard equipment. All other products can
be equipped with a parts service receptacle. A permanent
Batteries give off flammable fumes that can explode. This receptacle is then always available for jump starting.
can result in personal injury.
Two mating cable assemblies are also available to jump the
Prevent sparks near the batteries. They could cause vapors stalled machine from another machine also equipped with
to explode. Do not allow jumper cable ends to contact each this receptacle or an auxiliary power pack. Your Caterpillar
other or the machine. dealer can provide the correct cables in lengths for your
Add water if necessary to cover the plates in batteries on the application.
stalled machine. 1. Make initial determination as to failure of the stalled
Always thaw a frozen battery before jump starting. Frozen machine to crank. Refer to Special Instruction SEHS7768
batteries may explode causing personal injury. on use of 6V2150 Starting/Charging Analyzer Group. This
procedure applies even if the machine does not have a
Do not smoke when checking battery electrolyte levels.
diagnostic connector.
Electrolyte is an acid and can cause personal injury if it
2. Place the transmission control in NEUTRAL on the
contacts skin or eyes.
stalled machine. Engage the parking/secondary brake.
Always wear eye protection when starting a machine with Lower any attachment to the ground. Move all controls to
jumper cables. HOLD.
Incorrect jump procedures can cause an explosion resulting 3. Turn the start switch to OFF on the stalled machine. Turn
in personal injury. off all accessories.
Always connect battery positive (+) to battery positive (+) 4. Turn on (close) the disconnect switch (if equipped) on the
and battery negative (-) to battery negative stalled machine.
Jump only with a battery source and with the same voltage 5. Assure the batteries in the stalled machine are not frozen
as the stalled machine. and that electrolyte is above the plates in all cells.
Turn off all lights and accessories on the stalled machine. 6. Move the jump start source machine near enough to the
Otherwise, they will operate when the jump source is stalled machine for cables to reach, but DO NOT ALLOW
connected. MACHINES TO TOUCH.
7. Stop the engine on the jump source machine, or if using
an auxiliary power source, turn off the charging system.
SEGV3005 - 64 - Module Five
7/97 Student Handout

8. On the stalled machine, connect the appropriate jump NOTE: Batteries in series may be located in separate
start cable to the jump start receptacle. compartments. Use the terminal that is connected to the
9. Connect the other end of this cable to the jump start starter solenoid. This battery, or battery set, is normally on
receptacle of the jump source. the same side of the machine as the starter.
10. Start the engine on the jump source machine. Or, NOTE: On machines with two sets (two in each fender) of
energize the charging system on the auxiliary power source. two batteries (four total), connect to either set as per above
procedure.
11. Wait a minimum of two minutes for the batteries in the
stalled machine to partially charge. 9. Connect the other end of this positive jumper cable (red)
to the positive (+) terminal of the jump battery. Use the
12. Attempt to start the stalled engine. Refer to the procedure in Step 8 to determine the correct terminal.
beginning of "Engine Starting" in the Operation And
Maintenance Manual. 10. Connect one end of the negative (-) jumper cable to the
negative (-) terminal of the jump source as followS:
13. Immediately after starting the stalled engine, disconnect 12 Volt Systems: use the negative (-) terminal of the
the jump start cable from the JUMP SOURCE. jump battery.
14. Disconnect the other end of this cable from the stalled 24 Volt Systems: use the jump battery negative (-)
machine. terminal (connected to the disconnect switch) in the
15. Conclude failure analysis on starting/charging system of same battery set as used in Step 9.
the stalled machine as required, now that the engine is 11. Make final connection of the negative (-) cable t( the
running and charging system is operating. Use of Jumper stalled machine (not battery negative post) after answering
Cables the following:
When jump start receptacles (formerly called Question:
"auxiliary") are not available, use the following Does the stalled machine have a battery-cable size [00
procedure. gauge wire is 11.6 mm (.46") in diameter] ground
1. Make initial determination as to failure of machine to connection from the starter negative post to frame (typical
crank. Refer to Special Instruction SEHS7768 on use of 24 Volt system)?
6V2150 Starting/Charging Analyzer Group. This procedure NOTE: Machines with a small ground connection [6 gauge
applies even if the machine does not have a diagnostic wire diameter] from the starter negative post to the engine
connector. block do not fulfill this requirement.
2. Place the transmission control in NEUTRAL on the Yes - connect to frame (not battery negative post) away
stalled machine. Engage the parking/secondary brake. from battery, fuel or hydraulic lines, or moving parts.
Lower any attachment to the ground. Move all controls to No - connect to starter negative post (typical 24 Volt
HOLD. system) or engine block if starter negative post does not
exist (typical 12 Volt systems) away from battery, fuel
3. On stalled machine, turn the start switch to OFF. Turn off
or hydraulic lines.
all accessories.
12. Start the engine on the jump source machine. Or,
4. On stalled machine, turn on (close) the disconnect switch
energize the charging system on the auxiliary power source.
(if equipped).
13. Wait a minimum of two minutes for the batteries in the
5. Move jump source machine near enough to the stalled
stalled machine to partially charge.
machine for cables to reach, but DO NOT ALLOW
MACHINES TO TOUCH. 14. Attempt to start the stalled engine. Refer to section on
"Engine Starting" in the Operation And Maintenance
6. Stop the engine on the jump source machine. Or, if using
Manual.
an auxiliary power source, turn off the charging system.
15. Immediately after starting the stalled engine, disconnect
7. Make sure that water covers the plates in the batteries and
the jumper cables in reverse order.
that the batteries are not frozen in the stalled machine. Make
sure battery caps are all in place and tight on both machines. 16. Conclude failure analysis on starting/charging system of
stalled machine as required now that engine is running and
8. Connect the positive (+) jumper cable (red) to the
charging system is in operation.
positive (+) cable terminal of the discharged battery, or
battery set on the stalled machine. Do not allow positive
cable clamps to touch any metal other than the battery
terminals.
SEGV3005 - 65 - Module Five
7/97 Student Handout

August 29, 1988

How To Determine If Relays Are Functioning SINGLE POLE SINGLE THROW (SPST)
RELAY
Correctly COIL TERMINALS

1400, 1422
RELAY
COIL CONTACT
TERMINALS
This article provides a general test procedure with the relay
installed on the product. The procedure is for both 24 and
12 volt systems. The only test equipment needed is the
6V7070 Digital Multimeter, or equivalent such as the
6V7800 or 6V3030 Multimeter.
RELAY
CONTACTS
How A Relay Functions
Basically, a relay is a remote-controlled electrical switch
that is turned on and off by a small amount of electrical SINGLE POLE DOUBLE THROW (SPDT)
RELAY
current to let a large amount of current pass through its COIL TERMINALS
contacts to power a load (such as horns and starters). Low N.C. RELAY
current flows through the relay coil and forms an COIL

electromagnet, which opens or closes the relay contacts CONTACT RELAY

TERMINALS CONTACTS
(switch). See Illustration 1. Note the locations of the coil
terminals and the contact terminals. Unless otherwise
shown, contact designations of "normally open" (N.O.) and {
"normally closed" (N.C.) relate to the switch contact state
without power applied to the relay coil. N.O.

When the relay contacts are closed, a large amount of

current can now flow through the two contact terminals to Illustration 1. Schematics of two types of relays.
power the desired load. 1. Provide power to the relay, and if possible, turn on all
Testing The Relay equipment that is powered by the relay contacts. The engine
can either be off or running.
This test determines if there is an open in the relay coil
AND if the voltage drop across the contact terminal is 2. Connect the multimeter across the terminals as shown in
within specification. For 24V systems, this voltage drop Illustration 2 to check for system voltage at the relay coil
should typically be less than 0.5V, with a maximum terminals. For 24V systems, this voltage should be more
allowable drop of one volt. For 12V systems, the drop than 22V. For 12V systems, it should be more than 11V. If
should be less than 0.25V and the maximum allowable is voltage is less than specified or zero, proceed with the
0.5V. remainder of Step 2, otherwise go to Step 3.
. . . Connect the multimeter between the battery side of the
NOTE relay coil and machine ground. The multimeter should
read system voltage.
The test should determine faulty relays. However, there are
. . . If not, there is a faulty connection between the source of
many other variables that can cause electrical problems.
battery positive and the positive connection of the coil.
Correct this fault before proceeding with the test.
. . . If system voltage is present between the positive side of
the coil and ground, but not to the ground side of the
coil, then there is a faulty connection between the
ground side of the coil and frame ground. Correct fault
before proceeding.
SEGV3005 - 66 - Module Five
7/97 Student Handout

RELAY
COIL

MULTIMETER
WIRE (A) ELECTRICAL LOADS

RELAY
V SYSTEM VOLTAGE CONTACTS

GROUND
SYSTEM BATTERY SIDE
VOLTAGE V
SIDE
MULTIMETER (200 DC VOLT SCALE)
RELAY
COIL

RELAY
CONTACTS
Illustration 4. Checking the relay contacts for correct
IF ONLY ONE COIL TERMINAL, USE
REALY BRACKET FOR GROUND
CONNECTION.
operation.
5. If the relay contacts are closed during these conditions,
the meter should read less than one volt l maximum. (For
12V systems, 0.5V is the maximum.) ! For relay contacts
Illustration 2. Checking to see if system voltage is that are open under these conditions, the meter should read
available across the relay coil terminals. system voltage.
3. Connect the multimeter as shown in Illustration 3 to 6. Disconnect positive Wire (A), shown in Illustration 4,
check for system voltage at the relay contact battery from the coil terminal. This should cause the contacts to
terminal. if no voltage is present, correct this condition change positions (closed contacts to open, and open
before proceeding. contacts to close). As you touch and remove Wire (A) to the
coil terminal, you should hear a "clicking" noise caused by
the contacts opening and closing. This indicates a good
RELAY ELECTRICAL LOADS
relay coil, meaning it is not "open."
COIL

INPUT TERMINAL 7. With Wire (A) disconnected, measure voltage drop

across the contact terminals. Leave the meter connected as
shown in Illustration 4. The meter should show system
SYSTEM V
VOLTAGE RELAY
CONTACTS voltage for relay contacts which were formerly closed, but
MULTIMETER
are now open. For relay contacts which were formerly open,
but are now closed, the meter should show the voltage drop
to be less than one volt maximum for 24V systems (0.5V
for 12V systems). Reconnect Wire (A) and repeat this test
Illustration 3. Checking to see if system voltage is several times to verify the results.
available at the relay contact battery terminal.
8. When Wire (A) is disconnected the voltage across the
4. After you are sure that system voltage is present across contact terminals MUST alternate between system voltage
the relay coil terminals and at the contact battery terminal, and the allowable voltage (one volt max. for 24V, 0.5V
you are ready to check the relay contacts (switch). Connect max. for 12V) across the contact terminals. If this does not
the multimeter across the contact terminals as shown in occur, replace the relay.
Illustration 4. Use the 200 DCV . . . If the voltage across the relay contacts remains constant
during this step, either the relay is defective or the
circuit to the load is open or turned off.
. . . If the circuit to the load is not open, replace the relay as
stated.
. . . If the circuit to the load is open, correct the problem and
repeat the entire contact operation test beginning with
Step 5.
SEGV3005 - 67 - Module Five
7/97 Student Handout

March 14. 1988 Excessive tightening can cause the soft threads on the
copper studs to be stripped. Copper is used for these studs
Be Sure Battery Cable To Starter Connection because they are designed to carry high electrical currents.
Has Correct Torque A connection that is too tight can crack the stud insulators
on the starter solenoid. This can reduce the sealing
1453
capabilities of the insulator and allow moisture inside the
REFERENCEs: Service Manuals: SENR3550, Bosch JF solenoid. Moisture can corrode the solenoid switch contacts
Series Starting Motors; SENR3559, Bosch JE Series which can lower the voltage across the starter and cause
Starting Motors; SENR3536, Bosch KE Series Starting heat inside the solenoid. Moisture, over a period of time,
Motors; SENR3581, Delco Remy 37-MT/42MT Series can weaken insulating materials and cause them to break
Starting Motors; and SENR3860, Delco Remy 50-MT down. As the insulating materials break down, more heat
Series Starting Motors. may be generated inside the solenoid which can cause more
damage to the solenoid.
It is important that the battery cables are correctly tightened
on the starting motor for the starting system to operate as On Delco 35, 40, and 50 MT starters, moisture can leak past
expected. the solenoid-to-shift lever boot into the solenoid. Moisture
can cause rust inside solenoid bore. A 3R8801 Clamp can
A loose connection at the starter motor can prevent the be installed over the boot to help keep moisture out of the
starter from operating or result in lower voltage across the solenoid.
starter motor which would reduce starter torque. A loose nut
on a starter motor stud can cause a voltage drop across the The correct tightening torque for the nuts that fasten the
connection which can result in excessive heating or burning battery cables to the 12 volt starter motor on D3 Tractors,
at the connection damaging the stud insulators. 910 and 931 Loaders is 10 3 N-m (9 2 lb ft). The correct
tightening torque for the nuts that fasten the battery cables
to the 12 volt starter motor on 416, 426, and 428 Backhoe
Loaders is 28 4 N-m (21 3 lb ft). The correct tightening
torque for the nuts that fasten the battery cables to heavy-
duty 24 volt starter motors is 30 3 N-m (22 2 lb ft).
SEGV3005 - 68 - Module Five
7/97 Student Handout

July 2, 1990 Alternators serve two main functions in ANY electrical

Electrical System Damage From High Voltage system:
1. To recharge batteries after an engine startup.
1400, 1401, 1405, 1410, 1453
2. To supply ALL electrical system requirements after the
All Products With Direct Electric Starting engine is running.

REFERENCE ARTICLE: Service Magazine; May 28, If all connections are tight, full alternator output will, first,
1990; Page 4; "Jump Starting Procedures." Service cause battery damage. Batteries become the "load" for a
Magazine; May 4, 1987; Page 10; "Alternator/Generator runaway alternator. They absorb alternator current that is
Output Test on the Engine." above what is required for normal machine operation. This
high current causes battery damage from excessive:
Electrical components may suffer damage from high electrolyte temperatures, plate warping, and water loss. As
electrical system voltage. Damage identified by parts the electrolyte level (water) drops, the chance of battery
returned to the factory includes arc/burn spots in small explosion increases and system voltage will also increase
switches and connectors. Electronic controls show damage out of control. The result is damage to other electrical
to printed circuit boards. Electronic components show system components like relays, lighting and electronic
damage from arcing and burning. These damages are controls.
possible only from extremely high voltages.
Full alternator output with loose or poor connections in the
The cause of component damage is generally one of two charging circuit (even with batteries in good condition) can
possibilities: cause immediate high voltage damage to electrical system
1. Incorrect jump starting procedure, where a stalled engine components. Loose or poor connections, such as at the
is jumped by a source with voltage higher than the system battery terminals, can cause short periods of an "open
voltage of the stalled engine. See the first Reference Article. circuit," which has the same result as batteries with low
electrolyte. Opening the disconnect during an overcharging
condition also has the same effect as a loose connection.
WARNING The following are clues to high charging system voltage
due to voltage regulator failure:
Jump sources higher than system voltage of the stalled 1. More than one lighting component blackened or dead.
engine are sometimes thought to give better cranking One or more electronic controls dead.
speeds and subsequent startability. Higher-than-rated
jump sources cause damage to starters, batteries, and 2. Electrolyte level low in ALL cells of ALL batteries.
other electrical components. Batteries can also explode
3. If engine is operational, charging voltage measures over
causing personal injury. NEVER jump with a source
29.0 volts (or over 15.0 volts for 12V systems).
higher than the system of the stalled engine. Use a 12V
source on a 12V system and 24V on 24V system, etc. The following are clues to incorrect jump starting:
1. More than one lighting component blackened or dead.
2. When the alternator voltage regulator is shorted, causing
One or more electronic controls functioning incorrectly.
full (rated) charging current, AND an open circuit or loose
connection exists in the charging circuit. 2. One or more batteries exploded. Electrolyte level in
undamaged cells appears normal.
The regulator adjusts alternator output by varying field
current to maintain correct system voltage. Regulators have, 3. If engine is operational, charging voltage appears normal.
mainly, two failure modes: open or shorted. When open, If alternator was damaged by reverse hookup of jump
there is no field current and no alternator output. If shorted, source, the most likely failure would be low or no alternator
field current is maximum causing maximum rated, output.
uncontrolled, output current, provided the engine is running
at or above about 75% of rated engine speed.
Batteries serve two main functions in ANY electrical
system:
1. Provide energy for cranking the engine.
2. Act as an accumulator to provide a "smoothing" effect for
electrical system voltage variations.
SEGV3005 - 69 - Module Five
7/97 Student Handout

October 30, 1989

Understanding Four Wire Windshield Wiper

Motors (12 & 24V)
MOTOR
FROM BATTERY
7305, 1408 1 GN T

2 1 3 GY
4 BR
All Machines So Equipped 3
2 OR
5 4
6
REFERENCE ARTICLE: Service Magazine; May 26, WIPER MOTOR

1986; Page 5; "Wiper Motor Grounding." WIPER SWITCH

All Bosch wiper motors, like 6T6216, 3T0189 and 6T6529,

with four wires and a Sure-Seal) connector use one wire for
high speed, one wire for low speed and two wires for Illustration 1. Low speed
"parking". The motor is grounded electrically through a
motor-to-cab mounting. A good ground is required for
correct operation.
NOTE
All voltage measurements are made with respect to motor FROM BATTERY
MOTOR

case (housing). 1 GN T

2 1 3 GY
3 4 BR
The following troubleshooting includes most wiper 2 OR
5 4
problems. 6
WIPER MOTOR

Problem 1. Motor is dead or intermittent in either speed. WIPER SWITCH

Solution: Check ground connection as per reference

article.
Illustration 2. High speed
Problem 2. Motor is dead or intermittent in only one
speed.
Solution: Check wiring from switch speed connection to
motor side of four-pin motor Sure-Seal connector. if voltage
(system) is present at motor but will not run, replace the FROM BATTERY
MOTOR

motor. 1 GN T

2 1 3 GY
3 4 BR
Problem 3. Motor runs in both speeds but will not park. 2 OR
5 4
6
WIPER MOTOR
Solution: While parking, all parking wiring and park
switch should be at system voltage and connected to the low WIPER SWITCH

speed wiring. If not, find the break with a continuity meter

(6V7070 Multimeter Group, or equivalent).
NOTE
The illustrations are for a Challenger 65 Tractor, but the
method of wiring is typical for all machines so equipped.

MOTOR
FROM BATTERY
1 GN T

2 1 3 GY
3 4 BR
2 OR
5 4
6
WIPER MOTOR

WIPER SWITCH

Illustration 3. Wiper parking

SEGV3005 - 70 - Module Five
7/97 Student Handout

May 1, 1989 May 1, 1989

Procedure For Replacing Batteries Or Battery Procedure For Replacing Batteries, Battery
Cables Cables Or Disconnect Switches
1401, 1402, 1411 1401, 1402, 1411
All 12 Volt Products Equipped With Batteries All 24 Volt Products Equipped With Batteries and
When replacing the batteries or battery cables, use the Disconnect Switches
following procedure to reduce the possibility of When replacing the batteries, battery cables, or disconnect
sparks at the battery or cable connections. switch, use the following procedure to reduce the possibility
1. Turn off the start switch and all electrical loads such as of sparks at the battery or cable connections.
wipers, heater motors, etc. 1. Turn off the start switch and all electrical loads such as
2. At the battery, disconnect the negative cable routed from wipers, heater motors, etc.
the frame. When two or more batteries are involved,
2. Turn off (open) the disconnect switch and remove the
disconnect all negative battery terminal cables on all
key.
batteries that connect to the frame.
3. Complete necessary repairs to the system. 3. If the machine is equipped with an electrical
supplemental steering attachment (example: Off Highway
4. Do Step 2 in reverse order.
Trucks, Motor Graders), remove the fuse that powers the
supplemental steering control (3T3964).
May 1, 1989 4. Turn on an accessory light (except cab dome light). if the
Procedure For Replacing Batteries Battery accessory is dead, go to Step 6.1f accessory turns on,
Cables Or Disconnect Switches disconnect switch is shorted. Continue with Step 5.

1401, 1402, 1411 5. At the disconnect switch, disconnect the cable routed
from the frame of the product. (There are two cables at the
All 12 Volt Product Equipped With Batteries and disconnect switch. One cable connects to the frame, the
Disconnect Switches other to the negative battery terminal.) Be sure this loose
cable end cannot contact either stud on the disconnect
When replacing the batteries, battery cables, or disconnect switch. Diagnose and replace the disconnect switch as
switch, use the following procedure to reduce the possibility required.
of sparks at the battery or cable connections.
1. Turn off the start switch and all electrical loads such as 6. At the battery, disconnect the negative cable routed from
wipers, heater motors, etc. the disconnect switch. When two or more batteries are
2. Turn off (open) the disconnect switch and remove the involved, disconnect all negative battery terminal cables on
key. all batteries that connect to one side of the disconnect
switch.
3. Turn on an accessory light (except cab dome light). If the
accessory is dead, go to Step 5. If accessory turns on, 7. Complete necessary repairs to the system.
disconnect switch is shorted. Continue with Step 4.
8. Do Steps 2 through 6 in reverse.
4. At the disconnect switch, disconnect the cable routed
from the frame of the product. (There are two cables at the
disconnect switch. One cable connects to the frame, the
other to the negative battery terminal.) 8e sure this loose
cable end cannot contact either stud on the disconnect
switch. Diagnose and replace the disconnect switch as
required.
5. At the battery, disconnect the negative cable routed from
the disconnect switch. When two or more batteries are
involved, disconnect all negative battery terminal cables on
all batteries that connect to one side of the disconnect
switch.
6. Complete necessary repairs to the system.
7. Do Steps 2 through 5 in reverse.
SEGV3005 - 71 - Module Five
7/97 Student Handout

March 27, 1989 Will not fit fuse holder

Understanding Causes Of Blown Fuses And 1. Incorrect type or size of fuse for holder.
Tripped Circuit Breakers 2. Supplier tolerances are incorrect.

1400, 1420 BREAKER FAILURE MODES

REFERENCE ARTICLES: Understanding "Shorts," Open

"Opens" and "Intermittents; and How To Troubleshoot A An open circuit breaker is an automatic or manual
Short-To-Ground In Power Wiring in this issue. breaker that will not reset (reads "OL" on 6V7070
Fuses and circuit breakers are often reported as the CAUSE Multimeter). This usually occurs from gross circuit
of failure. This is very seldom correct. Open fuses and overload far beyond the breaker current rating. This is
circuit breakers are most often the RESULT of an electrical usually caused by a short circuit-to-ground from:
system overload. These components are electrical "flow . . .Incorrect troubleshooting as with a screwdriver.
control valves" connected in series with a given circuit to . . .A component short as in a forward warning horn.
protect wiring from high current damage. . . .A harness short where a wire (conductor) is pinched
to make a connection to ground.
Fuses are made of an electrical conductor with a low
melting temperature that melts "OPEN" during an overload Failure of a circuit breaker to reset is often caused by a
condition. Circuit breakers on earthmoving products use a melted disk or a disk that was so hot during overload that it
bimetallic disk that closes the circuit between the two is warped and cannot be reset to a closed position.
breaker terminals (generator sets use a different type). Shorted
During overload, the disk heats up and snaps ("oil cans") to
A shorted circuit breaker, one that will not open under an
open the circuit. On a manual reset breaker, the push button
overload, is rare and might be found in a circuit with wiring
snaps the disk into a position that again closes the circuit
and/or harness damage. This may possibly be caused by an
between the breaker terminals. The disk in an automatic-
overload condition that welded the disk in place.
reset breaker will snap closed when it cools down.
NOTE
Fuses and circuit breakers are almost never the
CAUSE of failure. When troubleshooting the actual
cause, report (on a SIMS or warranty claim) the part
number of the harness or component that caused the
fuse to blow or breaker to trip.
FUSE FAILURE MODES
Open
An open fuse is the result of system overload. Fuses with
the element visible can give a clue as to the cause. Testing
on a questionable fuse only requires a 6V7070 Multimeter
(or equivalent) on the 200 ohm scale A good fuse will read
less than approximately 0.2 ohms. An open fuse will read
"OL" for open circuit.
1. The glass or plastic housing is smoked or blackened.
This is caused by gross circuit overload far beyond the fuse
rating. This is usually caused by a short circuit-to-ground
from:
. . .Incorrect troubleshooting as with a screwdriver.
. . .A component short as in a forward warning horn.
. . .A harness short where a wire (conductor) is pinched
to make a connection to ground.
2. The glass or plastic housing is clear showing the fuse
element simply melted open. This is caused by a gentle
overload somewhat greater than the fuse rating.
SEGV3005 - 72 - Module Five
7/97 Student Handout

March 3, 1993 Because these circuit breakers trip based on the bimetal disk
temperatures, the current at which a circuit breaker actually
Understanding Circuit Breakers opens is related to the surrounding temperatures. This is
1400, 1420 why high ambient temperatures sometimes cause premature
trips.
Reference Article: Service Magazine; March 27, 1989;
Page 5; "Understanding Causes Of Blown Fuses And The following chart shows typical trip characteristics at
Tripped Circuit 8breakers". 25C (77.0F).

Circuit breakers used on Caterpillar earthmoving equipment Percent of Rating Time to Trip @ 25C (77.0F)
are often misunderstood. The following describes how they 100 Continuous
work and how to troubleshoot them.
130 10 seconds(min) to 1 hour (max)
Circuit breakers are either automatic reset or manual reset
and are the "thermal" type. This means they trip (OPEN) 200 5 seconds to 55 seconds
based on elevated temperature of the internal contact 300 1.5 seconds to 12 seconds
assembly. This contact assembly consists of two sets of
contacts mounted diametrically opposite each other on a The above information reduces ratings to 80% of the rating
circular disk. This disk is made of two metals that have at 57C (134.6F). This means a 10 amp breaker will only
different rates of expansion as their temperature changes hold 8 amps continuous at 57C (134.6F).
(often called a bi-metal disk).
The normal operating position of this disk assembly is dish-
shaped such that both sets of contacts are closed. The circuit
current passes from one set of contacts through the bi-metal
disk and out the second set of contacts. Electrical currents
that are greater than the breaker rating, will cause the bi-
metal disk to heat up and snap ("oil-can") into a dish-shape
inverted from normal operation. This action opens both sets
of contacts and breaks the flow of current. Circuit breakers
rated less than about 10 amps use a small heating element to
help warm the disk.
The thermal type of circuit breaker functions best with
moderate overloads. Dead short circuits occur very fast and
cause a high current overload. This often occurs so quickly
that the bi-metal disk does not have enough time to heat and
snap open before the high current melts the disk and
destroys the circuit breaker. The "screw driver test", is a
deliberate short circuit sometimes used to "test" the circuit
breaker, This test should never be used as it can destroy the
circuit breaker. The best test for a circuit breaker is to
measure the voltage drop across the circuit breaker. Put one
voltmeter lead on each terminal. The voltage drop at rated
current should never exceed 0.8 volts. Voltages that are
higher than this can cause overheating of the bi-metal disk
and premature tripping. Excessive voltage drops can also be
caused by loose connections on the circuit breaker.
Damaged internal contacts, come from previous trips or a
defective breaker.
SEGV3005 - 73 - Module Five
7/97 Student Handout

March 27, 1989 INTERMITTENT

Understanding "Shorts," "Opens" and An "intermittent" is an unwanted and erratic event that
"Intermittents" occurs in a normal or correctly-operating circuit. lt most
often causes a closed circuit (one that is "on") to open up or
1400 turn "off." It can also take place in a powered circuit (+12 or
+24V, etc.) where it might be connected to ground and
REFERENCE ARTICLES: Understanding Causes Of blows a fuse or trips a circuit breaker
Blown Fuses And Tripped Circuit Breakers and How To
Troubleshoot A Short-To-Ground In Power Wiring in this Examples of an "intermittent open": Vehicle tail lights
issue. that sometimes blink "off," EMS oil pressure LED that
sometimes blinks "on" during normal operation when
SIMS and claims comments are very helpful in diagnosing pressure has been confirmed to be within specifications,
failure modes of electrical components. "Shorted, open and when one or both gear indicator LED's blink "off" on
intermittent" can often be used to quickly and easily transmission controls, or a loose screw on a head light
identify the condition of a component that is not performing housing causes the light to blink.
correctly. These terms are often misunderstood. Correct
understanding of these terms aids correct reporting of Examples of an "intermittent short": A turn signal
component problems and speeds the problem switch in the "off" position that continues to flash the lights,
cause/resolution process. or start-aid push button that will not release (open) and
causes ether solenoid to burn out (often "shorts" and blows
OPEN the fuse/breaker), or wire-to-wire harness connection (short)
An "open" is an electrical circuit that will not conduct where application of brake lights also turns "on" tail lights.
current, a broken path for electron flow It is sometimes Examples of an "intermittent short-to-ground": Where a
described as "infinite" or many ohms. third LED turns "on" in a given gear on the transmission
Examples: Blown fuse or tripped circuit breaker, head lamp control, when a fan or wiper motor burns out (shorts) and
switch in "off" position. engine that will not crank because blows a fuse or trips a circuit breaker, when a powered wire
of corroded battery connection, dead wiper motor because is pinched to ground and blows a fuse/breaker, when a
of poor ground to cab, EMS oil pressure switch with dead screw driver is used to ground a circuit to see if it is "hot".
engine. or dead hour meter because engine oil pressure These conditions in power wiring often cause permanent
switch did not close during operation. damage to other components like switches, fuses, and
circuit breakers.
SHORT
A "short" is a direct electrical connection between two
points, usually very low resistance or opposition to current
flow. lt most often describes an unwanted or incorrect
connection and may draw higher than expected current.
Examples: Dead forward warning horn causing blown
fuses/breakers, head lamp switch that will not turn lights
off, engine oil pressure switch that will not turn off hour
meter, pinched harness causing blown fuses (or tripped
circuit breakers), or a start switch that keeps the starter
engaged.
SEGV3005 - 74 - Module Five
7/97 Student Handout

March 27, 1989 March 27, 1989

How To Troubleshoot A Short-To-Ground In Limitations On Engine Cranking Time

Power Wiring 1453,1401
1400 All Products With Electric Starting Motors (12, 24, 32,
REFERENCE ARTICLES: Understanding Causes Of 64 Volt Systems)
Blown Fuses And Tripped Circuit Breakers and REFERENCE ARTICLE: Service Magazine; April 25,
Understanding "Shorts," "Opens" and "Intermittents in this 1988; Page 7; "New Procedure To Prime Fuel System
issue. Using Engine Starter" on Backhoe Loaders.
Shorts-to-ground, either continuous or intermittent, may be Starter and battery life can be reduced, and sometimes
difficult to locate especially when they blow fuses or trips immediate damage results from overcranking an engine
breakers. The following procedure may be helpful to locate (prolonged engagement of the starter motor). The following
a short-to-ground that blows fuses or trips breakers. is a list of limitations agreed to by all of Caterpillar's starter
1. Disconnect one wire from the applicable circuit breaker suppliers. High parasitic cranking loads and/or incorrect
or remove the fuse. engine oil viscosities may still cause starter damage even
when following these guidelines. Even though machine
2. Temporarily connect a 9W1280 24-V Lamp (or any 35 to batteries will become dis charged during this procedure and
90 watt lamp) across (parallel to) the fuse holder or circuit require boost-starting, the same guidelines apply.
breaker.
1. Crank the engine for no more 30 seconds.
NOTE
Be sure temporary connections are reliable and will not 2. Wait for 2 minutes.
cause shorts (unwanted connections). 3. Repeat Steps 1 and 2 six times, for a total of seven
If the short is present, this lamp will be "on." 30-second cranking cycles.

To find the actual location of the short, disconnect, move, 4. Wait for 30 MINUTES.
push/pull, and/or disturb the wiring and components in the 5. Do Step 1 again.
effected circuit until the light blinks "on or off" according to
physical motion. 6. Do Step 2 again.
NOTE FROM THE INSTRUCTOR: Use a 12-V lamp 7. Repeat Steps 5 and 6 three times, for a total of seven
with 12-V systems. If a lamp is not available use a 30-second cranking cycles
multimeter and check for continuity by connecting one
probe to the frame and the other probe to the suspect wire. 8. Wait for 30 MINUTES.
If there is a short to ground the multimeter will show 9. Do Steps 5 through 8 as needed.
whatever resistance is in the wire. If there is no short to
ground the multimeter will show "O.L" indicating the path NOTE
is open. These guidelines supersede those included in the reference
article.
SEGV3005 - 75 - Module Five
7/97 Student Handout

Based on May 4, 1987 Service Magazine Article

Operating Characteristics of Alternators Used B+ TERMINAL

in Backhoes REGULATOR
ASSEMBLY

1405 D+ TERMINAL

416-438 and the 446

This article provides information about the operating
characteristics and troubleshooting of the alternator used in
backhoe loaders. The key start switch shown is for the "B"
series backhoes. The original key start switch did not have
W TERMINAL
an accessory position. (R TERMINAL 446) B- TERMINAL

On the series II and earlier backhoe loaders there are four

main external electrical terminals on the alternator: the B+
(positive) output terminal, the B- (negative) output terminal, Illustration 1. Location of electrical terminals for Series
The D+ terminal and the W terminal. See illustration 1. II and earlier backhoe loaders.
The electrical output for battery charging and for the
electrical accessories is the B+ (positive) terminal. The B-
(negative) terminal is connected to ground. The D+
terminal is connected to the key start switch through a SUPPORT
limiting resistor and diode. The W terminal is an output for BRACKET
a tachometer. (The "R" terminal is used on the 446 for the
output to the tachometer.) B+ TERMINAL
REGULATOR
ASSEMBLY
The B series machines have similar terminals except that
the alternator is now grounded through the mounting
bracket. D+ TERMINAL

The alternator is not self-energizing as is the more familiar

brushless alternator. The alternator requires battery voltage
in order to start up. Illustration 3 shows the alternator
connections in a typical charging circuit.. W TERMINAL
(R TERMINAL 446B)

Illustration 2. Location of electrical terminals for B

Series Backhoes.
NOTE: I have not been able to figure out a way to check
this alternator using this article. Also the circuit has been
changed. The diode and resistor may now be in the
alternator on the latest machines.
SEGV3005 - 76 - Module Five
7/97 Student Handout

MAIN
10 A
RELAY
10 A
10 A ENGINE
SHUTDOWN
SOLENOID

D+
B+ W KEY START
ALT A SWITCH
TACH RESISTOR

ALTERNATOR R

C OFF
DIODE ACC
S ON
B ST

POS NEG

Illustration 3. Typical charging circuit for 416-438 and 416B-438B backhoe loaders. The 446/446B
backhoe charing system is slightly different due to the operation of its engine shutdown solenoid.

When the key start switch is in either the ON or Start Troubleshooting alternator problems and locating the source
position, current is sent through the limiting resistor and the of the failure can be tricky. For example, consider the case
diode wire assembly, to the D+ terminal. From the D+ when the engine will not crank because the battery is low.
terminal, the current flows through th field coil of the And after jump starting, the alternator does not have output
alternator to start up. After the alternator has started up, it voltage. Do not jump to the conclusion that the alternator
begins to supply charging current to me battery and the rest has failed. Remember that this is not a self-energizing
of the vehicle's electrical circuits. The limiting resistor alternator. If the battery is too low, it will not be able to
protects the field coil in the alternator from excessive provide enough current to start the alternator charging
current. In addition, the limiting resistor and diode allow sequence. So when troubleshooting a charging system
the fuel shutoff solenoid to de-energize (normally energized problem, first check and charge the battery as required.
to run), and the power relay(s) to shut off when the key Then check alternator output. Also, always check the
switch is put to the OFF position. Without the diode, the circuit from the key start switch (R terminal) to the
alternator would keep those components powered up, and alternator D+ terminal for an open circuit. An open circuit
the engine would not shut down. will falsely indicate an alternator problem.
On the B backhoes the alternator is grounded to the support
bracket. A loose bracket or excessive paint may also lead to
the alternator not performing as desired.