24 UENR7061 Diagnostic Trouble Codes Diagnostic Trouble Codes i06225231 Determining Diagnostic Trouble Codes SMCS Code: 0785-UE; 7490; 7569 Illustration 10 g03861135 Connections for the Communication Adapter 3 and Cat ® Electronic Technician (Cat ET) Service Tool The components that are needed to use the Communication Adapter III and Cat ET to determine diagnostic codes are listed: (1) Cable (2) 317-7484 Communication Adapter Gp (3) 457-6114 CA3 Ethernet FLASH Cable (4) Current version of Cat ET pr
UENR7061 25 Diagnostic Trouble Codes • Special Publication, JERD2142, “Data Subscription” Table 7 Descriptions of the Failure Mode Identifiers (FMI) The following features make Cat ET a valuable tool for troubleshooting: FMI No.
26 UENR7061 Diagnostic Trouble Codes • The signal is below normal. (The voltage, pressure, or temperature is low.) • Timing is retarded For example, a certain PWM sensor is not expected to generate a PWM signal below 5 percent duty cycle even with zero air pressure. If the sensor generates a 4 percent duty cycle signal with the engine shutdown, the sensor is still working but below the expected signal limits. FMI 02 – “Data Erratic, Intermittent Or Incorrect.
UENR7061 27 Diagnostic Trouble Codes • Electronic control has an internal short to ground on the connector contact of signal input FMI 07 – “Mechanical System Not Responding Properly.” A mechanical system does not respond in the expected manner when electrical commands are received from the electronic control. For example, a sluggish solenoid valve causes a slow shift.
28 Diagnostic Trouble Codes If the MID is not for the MSS, see the Module Identifier chart on the Electrical System Schematic for the machine that is being serviced. Once you have determined the electronic control modules that detected the event, refer to the Service Manual for that control for troubleshooting information. The Service Manual modules for each control are part of the machine Service Manual.
UENR7061 29 Diagnostic Trouble Codes Diagnostic Codes Table 8 Machine Security System (MID 124) Description DTC Procedure 168-00 Electrical System Voltage : High Electrical Power Supply - Test 168-01 Electrical System Voltage : Low Electrical Power Supply - Test 248-12 Cat Data Link malfunction Cat Data Link - Test 1391-03 Theft Deterrent Output Driver #1 : Voltage Above Normal ECM Output Driver - Test 1391-04 Theft Deterrent Output Driver #1 : Voltage Below Normal ECM Output Driver - Test
30 UENR7061 Symptom Procedures Symptom Procedures • Inspect the Machine. Look for problems. Notice any unusual odors in the air. Listen for unusual noises. Verify the Symptom i06222412 Symptom Troubleshooting SMCS Code: 7000-035 Use the following guidelines as you troubleshoot a symptom: Know the Machine Understand the operation of the machine. Know if the symptom is a characteristic of normal operation or if the symptom is a failure.
UENR7061 31 Symptom Procedures To share your knowledge of symptoms: use the form in SIS Web or CBT feedback to write a brief description about the symptom, testing, and repair of the machine. Your feedback information will help Caterpillar ® improve the service information for this product. i06222432 Engine Does Not Crank and Status Indicator Is Green SMCS Code: 7631-035 The green LED of the status indicator informs the operator that the machine security system (MSS3s) ECM has recognized a valid key.
32 UENR7061 Symptom Procedures (Table 9, contd) 2. CHECK THE SYSTEM VOLTAGE AT THE MSS3s ECM. A. Measure the voltage between pin 24 and pin 26 of the MSS3s ECM. Yes - The voltage is approximately system voltage. The voltage is approximately system Proceed to Test Step 3. voltage. No - The voltage is not approximately system voltage. Repair: Check the battery and the associated wiring in the machine harness. STOP. 3. CHECK THE VOLTAGE FROM THE KEY SWITCH TO THE DRIVER (INPUT No. 1) OF THE ECM. A.
UENR7061 33 Symptom Procedures (Table 9, contd) 7. CHECK FOR A FAILED COMPONENT ON OUTPUT DRIVER (No. 1). A. Turn the keyswitch and the disconnect switch to the OFF position. If the machine is not equipped with a disconnect switch, remove the negative wire from the battery. Yes - The voltage is present and the voltage level is correct. Voltage should be The solenoid or the relay has failed. present. The voltage should be with- Repair: Replace the solenoid or relay. in 10% of the machine battery STOP.
34 UENR7061 Symptom Procedures (Table 9, contd) Yes - The voltage is present and the voltage level is correct. Voltage should be The solenoid or the relay has failed. present. The voltage should be with- Repair: Replace the solenoid or the relay. in 10% of the machine battery STOP. voltage. No - The voltage was not correct. 9. CHECK FOR A FAILED COMPONENT ON OUTPUT DRIVER (No. 2). A. Turn the keyswitch and the disconnect switch to the OFF position.
UENR7061 35 Symptom Procedures Table 10 Troubleshooting Test Steps Values Results Yes - The MSS reads the ID1 code and the ID2 code as 0. The The MSS reads the key may have failed or the problem may exist in the exciter coil. A. Connect the Cat Electronic Technician (Cat ET) to the ID1 code and the ID2 code as 0. Proceed to Test Step 2. Service Connector. 1. CHECK THE KEY. C. Turn the key switch to the ON position. No - The MSS reads the ID1 code and the ID2 code correctly.
36 UENR7061 Symptom Procedures (Table 10, contd) 4. CHECK THE WIRING OF THE MACHINE HARNESS The resistance is FOR A SHORT TO GROUND. Note: The output drivers of the MSS3s ECM are pro- greater than 5000 ohms. tected from excessive electrical current. Excessive electrical current is usually the result of a wire or a component that is shorted to ground. If the MSS3s ECM detects an excessive amount of electrical current, the MSS3s ECM will disable the output driver. A.
UENR7061 37 Circuit Tests Circuit Tests i06225351 Cat Data Link - Test SMCS Code: 1408-038 Theft Deterrent Module ECM The following is a list of codes that are associated with the Cat ® Data Link of the machine. Table 11 Theft Deterrent Module ECM (MID 436) DTC 248-12 Code Description Cat Data Link malfunction Each Cat Data Link circuit is an input and output of select electronic control modules. The data link is designed to carry communications between the electronic control modules.
38 UENR7061 Circuit Tests Table 12 FMI 12 Troubleshooting Troubleshooting Test Steps Values 1. CLEAR THE DIAGNOSTIC CODES A. Use the ET to clear the logged diagnostic codes. CID 0248 FMI 12 is present. Results OK - CID 0248 FMI 12 is present. The problem was not caused by the use of an invalid electronic key. Proceed to Test Step 2. B. Use a valid electronic key to start the machine. NOT OK - CID 0248 FMI 12 is NOT present.
UENR7061 39 Circuit Tests (Table 12, contd) FMI 12 Troubleshooting Troubleshooting Test Steps Values 3. CHECK FOR A SHORTED HARNESS A. Turn the battery disconnect switch to the OFF position. The resistance is greater than 5000 Ohms. Results OK - The resistance is greater than 5000 Ohms (no continuity). Harness circuit resistance is correct. Proceed to Test Step 4. B. Disconnect the connector for the machine wiring harness from the MSS3s ECM.
40 UENR7061 Circuit Tests Table 13 Theft Deterrent Module ECM (MID 436) DTC Code Description 1391-03 Theft Deterrent Output Driver #1 : Voltage Above Normal 1391-04 Theft Deterrent Output Driver #1 : Voltage Below Normal 1392-03 Theft Deterrent Output Driver #2 : Voltage Above Normal 1392-04 Theft Deterrent Output Driver #2 : Voltage Below Normal 5217-03 300mA Sourcing Driver Output #3 : Short to battery 5217-04 300mA Sourcing Driver Output #3 : Short to ground 5218-03 300mA Sourcing Driv
UENR7061 41 Circuit Tests Table 14 FMI 03 Troubleshooting Troubleshooting Test Steps Values 1. FLASH THE ECM Results OK - FMI 03 is present. FMI 03 is present. Go to Test Step 2. A. Load the latest software file for the MSS into the ECM. Refer to Testing and Adjusting, “Electronic Control Module (ECM) - Flash Program”. NOT OK - The diagnostic code was caused by a problem in the software. B. Clear the diagnostic code log. STOP. C. Start the machine and operate the machine. D.
42 UENR7061 Circuit Tests Table 15 FMI 04 Troubleshooting Troubleshooting Test Steps Values 1. CHECK THE WIRING HARNESS The resistance is greater than 5000 Ohms. A. Disconnect the wiring harness connector from the MSS3s ECM. Results OK - The resistance is greater than 5000 Ohms (no continuity). Harness circuit resistance is correct. Go to Test Step 3. B. Measure the resistance between the pin in the wiring harness and a ground on the machine. NOT OK - Resistance is less than 5000 Ohms (continuity).
UENR7061 43 Circuit Tests i06244599 Electrical Connector - Inspect SMCS Code: 1408-040-CY; 7553-040-WW Reference: Special Instruction, SEHS9615, “Servicing DT Connectors”. Reference: Special Instruction, REHS0148, “Listing Of Deutsch Connector Components” Reference: Special Instruction, SEHS9065, “Use Of CE Connector Tools”. Reference: Service Magazine, SEPD0342,27 January 97, “Field Repair Of Single Wire Breaks In Harnesses (Sealed Splice)”.
44 UENR7061 Circuit Tests 2. Disconnect the suspect connector and inspect the connector seal. Ensure that the seals are in good condition. If necessary, replace the connector. 3. Thoroughly inspect the connectors for evidence of moisture entry. Some minor seal abrasion on connector seals is normal. Minor seal abrasion will not allow the entry of moisture. If moisture or corrosion is evident in the connector, the source of the moisture entry must be found and repaired.
UENR7061 45 Circuit Tests Check the Wires for Damage to the Insulation Not OK – The terminals of the connector are damaged. 1. Carefully inspect each wire for signs of abrasion, of nicks, and of cuts. Inspect the wires for the following conditions: Repair • Exposed insulation Repair the terminals and/or replace the terminals, as required. Verify that the repair eliminates the problem.
46 UENR7061 Circuit Tests Expected Result The sockets provide good retention for the new pin. Results OK – The terminals are OK. Proceed to “Check the Locking Mechanism of the Connectors”. 2. Choose the appropriate group of parameters to monitor. 3. Press the “Start” button. Wiggle the wiring harness to reproduce intermittent problems If an intermittent problem exists, the status will be highlighted and an audible beep will be heard. Not OK – Terminals are damaged.
UENR7061 47 Circuit Tests Table 16 Theft Deterrent Module ECM (MID 127) DTC Code Description 168-00 Electrical System Voltage : High 168-01 Electrical System Voltage : Low The electrical power supply connections are the connections between the alternator and battery that power the control modules. The diagnostic code should be ACTIVE only if the engine is running. Possible causes for an FMI 00 diagnostic code are: • The alternator is producing too much voltage.
48 UENR7061 Circuit Tests Table 17 FMI 00 Troubleshooting Troubleshooting Test Steps 1. CHECK THE BATTERY VOLTAGE A. Start the engine and run the engine at high idle for several minutes. Make sure that no battery charger is connected to the engine. B. Measure the battery voltage at the battery posts. Values Results OK - The battery voltage is correct. The battery voltage should be less Proceed to Test Step 2. than 32.5 VDC for a 24V system, and NOT OK - The battery voltage is too high.
UENR7061 49 Circuit Tests Table 18 FMI 01 Troubleshooting Troubleshooting Test Steps Values OK - The battery voltage is good. 1. CHECK THE BATTERY VOLTAGE A. Start the engine and run the engine at high idle for several minutes. Make sure that no battery charger is connected to the engine. B. Measure the battery voltage at the battery posts. The battery voltage should be greater than 9 VDC for a 12V system. The battery voltage should be greater than 21.3 VDC for a 24V system. Proceed to Test Step 2.
50 UENR7061 Circuit Tests Test For An Open Circuit Table 19 Troubleshooting Test Steps Values 1. Identify Open Circuit Results OK - The harness circuit is correct. A. Identify the connectors and the wire numbers of the suspect circuits. Use the Electrical System Schematic of the machine to identify the circuits. The resistance is less than 5 Ω. STOP NOT OK - The resistance is greater than 5K Ω. There is an open in the machine harness. B. Turn the key start switch and the disconnect switch OFF.
UENR7061 51 Circuit Tests Test For A Short Circuit Table 20 Troubleshooting Test Steps Values Results OK - The harness circuits are correct. The resistance is A. Identify the connectors and the wire numbers of the greater than 5K Ω STOP suspect circuits. Use the Electrical System Schematic of for all the readings. the machine to identify the circuits. NOT OK - The resistance is less than 5 Ω. There is a short in the machine harness.
52 UENR7061 Service Service Note: After selecting the correct sales model, Cat ET will exit out of the configuration menu. i06229138 ECM Software - Install 8. With the key start switch returned to the ON position, Cat ET will initiate communications with all ECM modules on the machine. SMCS Code: 7620-012-MCH Perform the following procedure to flash program the ECM. The ECM is flashed to upgrade the software. Flash programming of the ECM must also be done if the ECM has been replaced.
UENR7061 53 Service 5. From the menu bar of the Cat ET service tool, select the following: “Service” , “Copy Configuration” , and then Fleet/Key Configuration from the submenu. If there is no recently loaded data available, the “No data is available...” message box displays. Click on the “Yes” button to load the data from the ECM. The “ECM Selector” dialog box is displayed. If necessary, highlight the Machine Security System ECM and Click on “OK” . As the data is loading from the ECM, the “Please wait.
54 Service 6. Click on the “Save to File” push button. The “Print New Document to File” dialog box is displayed. If you do not have a file open, a dialog box will ask you to choose one of the following options: open a file, create a file and cancel. Choose the “New” button to continue. Enter a document name and description in the appropriate text boxes. Click on “OK” . The “Fleet/Key Configuration saved successfully” message box should display. Click on “OK” .
UENR7061 55 Service Illustration 14 8. Click on the “Uninstall” button that is located at the lower left-hand corner of the “Machine Security System Uninstall” screen. This action will cause the Cat ET to display the message that is shown in Illustration 15 .
56 UENR7061 Service Illustration 15 g03863143 9. Click on the “Yes” button if you want to proceed with the “uninstall” of the Machine Security System. Note: Pressing the “No” button aborts the “uninstall” of the Machine Security System. 10. Turn the keyswitch and disconnect switch to the “OFF” position. If the machine does not have a disconnect switch, remove the ground cable from the battery. 11. Remove and retain the tagged master keys from the new ECM.
57 UENR7061 Service Illustration 16 g03866637 Append 17. Click on the “Append” button. Note: Replacing the key list adds the current master access level key to key list. The additional master access level key supplied will not be added. Appending the list adds both master access level keys that came with the MSS3s ECM to the key list that copied to the MSS3s ECM. Illustration 17 g03863151 18. Click on the “Yes” button if you are prompted.
58 UENR7061 Service Illustration 18 g03866642 ECM Selector dialog box Note: MSS has a maximum of 255 keys that can be stored at one time. The replacement ECM has two master access level keys pre-programmed into the ECM. Fleet/Key Configuration determines the number of keys slots not programmed on the MSS. You cannot program more keys than the maximum number allowed. If more than 253 keys from the saved file, a message box displays informing you of the number of key slots available. 19.
UENR7061 59 Service ECM Pull Up Voltage To aid in diagnostics of certain electrical circuits, an internal “pull up voltage” is connected to the ECM switch and sensor signal input contacts. An above normal voltage is internally connected to the ECM signal input circuit through a resistor. Illustration 19 g03863156 20. On the main menu bar, select “Service” and then “ECM Date/Time” . Verify that correct date, time, and time zone are displayed for your location.
60 Service Sensors provide an electrical signal to the ECM that constantly changes. The sensor input to the ECM can be one of several different types of electrical signals such as: pulse width modulated (PWM) signals, voltage signals and frequency input signals. Refer to the correct pilot machine schematic to verify each input to the ECM. Outputs The ECM sends electrical signals through the outputs. The outputs can create an action or the outputs can provide information to the ECM.
UENR7061 61 Testing and Adjusting Testing And Adjusting Section 1. Connect a laptop computer with the Caterpillar ® ET to the machine via the communication adapter. Testing and Adjusting 3. Turn the electronic key to the “ON” position. 2. Place an electronic key with master level access in the key start switch. 4. Start the Electronic Technician and establish communications with the MSS3s ECM.
62 Testing and Adjusting UENR7061 Illustration 20 g01097217 6. Select the “Product ID” selection that is displayed on the “Configuration” screen. 7. Click on the “Change” button that is located on the “Configuration” screen. This button will display a dialog box. Illustration 21 g01097232 8. Enter the “Product ID” of the machine. The “Product ID” must have 8 digits. The “Product ID” must be formatted as 3 alphanumeric characters and 5 numbers for a total of 8 digits.
UENR7061 63 Testing and Adjusting Note: Use the “Product ID” of MSS99999 for NonCaterpillar machines. Note: First Quarter 2001, the Caterpillar Product Identification Number (PIN) changed from 8 characters to 17 characters. The “Product ID” that is required by the Machine Security System is the last 8 digits. Refer to Item (4) in illustration 22 .
64 Testing and Adjusting Illustration 25 UENR7061 g03866141 Security Management Connect a laptop computer with the Caterpillar ET to the machine that will be programmed. After the laptop computer is connected to the machine, start the ET. Select the “Security Management” option from “Service” menu. The “Security Management” screen will be displayed. Refer to Illustration 25 .
UENR7061 65 Testing and Adjusting Adding Key Information Illustration 26 g06105900 Add key information The “Add” push button allows you to add a key to the list of Authorized Keys. Note: When a function requires a factory password, the “Enter Factory Passwords” box is displayed. 4. Connect a laptop computer with the Caterpillar Electronic Technician to the ECM on the machine. Select the “Machine Security System” from the menu in the ET. To add a key, perform the following steps: 5.
66 Testing and Adjusting 9. Select the access level of the key from the “Access Level” menu. 10. Select an “Expiration” button: “Disable” or “Enable” “Disable” does not have an “Expiration Date” . If “Enable” is selected, enter the “Expiration Date” and “Expiration Time” for that key. Note: Setting a Key with “Master Level Access” to the “Enable” status with an expiration date will cause the Key with “Master Level Access” to expire.
UENR7061 67 Testing and Adjusting Changing the Key Information Illustration 27 Change key information The “Change” push button allows you to change the “Description” , “Access Level” or “Expiration” of a key. ID1 and ID2 cannot be changed. Note: The “Change” push button is disabled until a key is selected from the authorized list. Note: When a function requires a factory level security password, the “Enter Factory Passwords” dialog box is displayed.
68 Testing and Adjusting UENR7061 Deleting Key Information Illustration 28 g03866151 Delete Key Note: You cannot delete the last Master key. An error message will display if deletion of the last master access level key is attempted. Printing Key Information Note: Deleting Keys requires a key with master access level or a factory password. To delete a key: 1. Highlight the key you want to delete. Press the “Delete” push button. The “Are you sure?” box is displayed. 2.
UENR7061 • ECM connection • List of parameter values • Information that is unique to the function that you are printing To print a report to a file: 1. Press the “Print” icon in the menu bar. The “Print Document” box is displayed. 2. Press the “Print to File” button. Press “OK” in order to print the report. Press “Cancel” in order to exit the “Print Document” box without saving the file. Note: If you do not have a file open, the “Printing” box asks you to open a file, create a new file, or cancel.
