815 Soil Compactor and 816 Landfill Compactor Systems Electrical Power Supply

Electrical Power Supply - Test

815 Soil Compactor and 816 Landfill Compactor Systems [M0113643]

815 Soil Compactor and 816 Landfill Compactor Systems ECM Location Code - Test

815 Soil Compactor and 816 Landfill Compactor Systems Parameter - Test

ELECTRICAL AND STARTING SYSTEM

BATTERY GP

815 Soil Compactor and 816 Landfill Compactor Systems Electrical Power Supply - Test

1.1. Transmission ECM

2.1. Implement ECM

3.1. Diagnostic Trouble Code Procedure

4.1. FMI 3

5.1. FMI 4

Transmission ECM

The following is a list of Diagnostic Trouble Codes (DTCs) that are associated with the electrical power supply for the ECM.

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Table 1
Transmission ECM (MID 081)
J1939	CDL	Code Description	System Response
	0168-3	Electrical System Voltage : Voltage Above Normal	The ECM activates this diagnostic code when the system voltage is above 32.0 VDC.
	0168-4	Electrical System Voltage : Voltage Below Normal	The ECM activates this diagnostic code when the system voltage is below 18.0 VDC.

The electrical power supply connections are the connections between the alternator and battery that power the control modules.

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Illustration 1	g06602097
Transmission ECM Power Supply connections

The preceding diagram is a simplified schematic of the system voltage Transmission ECM connections. The schematics are electrically correct. However, not all the possible harness connectors are shown. Refer to the latest revision of Electrical Schematic, M0115149 or Electrical Schematic, M0115151 for the complete schematic.

Implement ECM

The following is a list of Diagnostic Trouble Codes (DTCs) that are associated with the electrical power supply for the ECM.

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Table 2
Implement ECM (MID 082)
J1939	CDL	Code Description	System Response
	0168-3	Electrical System Voltage : Voltage Above Normal	The ECM activates this diagnostic code when the system voltage is above 32.0 VDC.
	0168-4	Electrical System Voltage : Voltage Below Normal	The ECM activates this diagnostic code when the system voltage is below 18.0 VDC.

The electrical power supply connections are the connections between the alternator and battery that power the control modules.

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Illustration 2	g06602103
Implement ECM Power Supply connections

The preceding diagram is a simplified schematic of the system voltage Implement ECM connections. The schematics are electrically correct. However, not all the possible harness connectors are shown. Refer to the latest revision of Electrical Schematic, M0115149 or Electrical Schematic, M0115151 for the complete schematic.

Diagnostic Trouble Code Procedure

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Table 3
Required Tools
Tool	Part Number	Description	Qty
T1	146-4080⁽¹⁾	Digital Multimeter Group	1
	8T-3224	Needle Tip Group	1
	7X-1710	Multimeter Probe Group	1
	8T-8726	Cable Assembly (Three Pin) (3-Pin Breakout)	1
T2	JERD2129	Cat^® Electronic Technician (Cat ET)	1
		Windows-based PC	1
	538-5051	Communication Adapter Gp	1
T3	6V-4148	Connector Repair Kit (Sure Seal)	1
T4	190-8900	Connector Field Repair Kit (Deutsch)	1
T5	175-3700	Connector Repair Kit Deutsch DT	1

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⁽¹⁾	This multimeter can use an RS232C cable to connect to a Laptop computer or Dataview tool gp for troubleshooting.

Prior to beginning this procedure, inspect the harness connectors that are involved in this circuit. Poor connections can often be the cause of a problem in an electrical circuit. Verify that all connections in the circuit are clean, secure, and in good condition. Ensure that the Charging System is functioning properly. Check the wiring harness for pinch points or abrasions. Look for and repair areas that indicate wires are exposed. If a problem with a connection is found, correct the problem and verify that the diagnostic code is active before performing a troubleshooting procedure.

Identify the active FMI code associated with the components.
Determine which code is present and use the list below to determine which procedure to follow.

FMI 3 diagnostic code, proceed to "FMI 3".
FMI 4 diagnostic code, proceed to "FMI 4".

FMI 3

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Table 4
Check System Voltage At The ECM
Troubleshooting Test Steps	Values	Results
1. Turn the disconnect switch and the key start switch to the OFF position. 2. At the J1 harness connector for the ECM, insert a 7X-1710 Multimeter Probe along the power supply. Use the other multimeter probe to make contact to frame ground. 3. Turn the disconnect switch to the ON position. Start the engine and run at half throttle. 4. Measure the voltage between the power supply contact and frame ground. 5. Measure the voltage between the power supply contact and the (-) battery contact at the ECM harness connector.	Both voltages are approximately the same and are within range of the system voltage. 28 ± 1 V for 24 V system.	Result: Each voltage is approximately the same and is within range of the system voltage. Proceed to "Check If The Diagnostic Code Remains" Table 9. Result: The voltages are approximately the same, however the voltages are unstable. There is a large variation in the voltages. Proceed to "Check The Alternator Current Output" Table 7. Result: The positive battery contact to frame ground measurement is stable and within range of the system voltage. However, the measurement between the ECM positive battery contact and the ECM negative battery contact is not always in the correct range. Proceed to "Check The Ground Circuits" Table 5.

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Table 5
Check The Ground Circuits
Troubleshooting Test Steps	Values	Results
1. Turn the key start switch and the disconnect switch to the OFF position. 2. Disconnect the J1 harness connector from the ECM. 3. At the J1 harness connector for the ECM, measure the resistance between each of the negative battery contacts and frame ground. The contacts for the negative battery connections are illustrated in the diagram at the beginning of this procedure.	Each resistance is less than 5.0 Ω.	Result: Each resistance is less than 5.0 Ω. Proceed to "Check The Supply Circuits" Table 6. Result: A resistance is greater than 5K Ω. There is an open circuit or a poor connection in the ground circuit. Note: A resistance that is greater than 5 Ω but less than 5K Ω would indicate a loose connection or a corroded connection in the circuit. A resistance measurement that is greater than 5K Ω would indicate an open in the circuit. Repair: The open or poor connection is in the ground circuit. Check all the connectors and splice points that are in the ground circuit. Ensure that all connections are clean, secure, and in good condition. Repair or replace the machine harness. Proceed to "Check If The Diagnostic Code Remains".Table 9.

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Table 6
Check The Supply Circuits
Troubleshooting Test Steps	Values	Results
1. The key start switch and disconnect switch remain OFF. The ECM harness connector remains disconnected. 2. At the J1 harness connector for the ECM measure the resistance between the alternator "B" terminal and each of the positive battery contacts of the J1 harness. The contacts for the five positive battery connections are illustrated in the diagram at the beginning of this procedure.	Each resistance is less than 5.0 Ω.	Result: Each resistance is less than 5.0 Ω. Proceed to "Check If The Diagnostic Code Remains".Table 9. Result: A resistance is greater than 5K Ω. There is an open circuit or a poor connection in the supply circuit. Note: A resistance that is greater than 5 Ω but less than 5K Ω would indicate a loose connection or a corroded connection in the circuit. A resistance measurement that is greater than 5K Ω would indicate an open in the circuit. Repair: The open or poor connection is in the ground circuit. Check all the connectors and splice points that are in the ground circuit. Ensure that all connections are clean, secure, and in good condition. Repair or replace the machine harness. Proceed to "Check If The Diagnostic Code Remains".Table 9.

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Table 7
Check The Alternator Current Output
Troubleshooting Test Steps	Values	Results
1. Reconnect the ECM harness connectors. 2. Partially discharge the batteries by cranking the engine for 30 seconds or turning on the lights for about 10 minutes without starting the engine. 3. Turn the disconnect switch and the key start switch to the OFF position. 4. Connect multimeter probes between the alternator "B" terminal and the alternator case. 5. Connect a clamp-on 225-8266 Ammeter Tool Gp or an equivalent ammeter around the output wire. 6. Turn the disconnect switch to the ON position. 7. Start the engine and run the engine at approximately half throttle. 8. Immediately check the alternator output current.	The alternator output current at half throttle( (75 amps)is approximately half the alternator full current output rating, and is stable.	Result: The alternator output current at half throttle is approximately half the alternator full current output rating, and is stable. Proceed to "Check The Alternator Voltage Output" 8. Result: The output current of the alternator at half throttle is not stable. There is a large variation in the currents. Repair: Refer to Service Manual, SENR4130 for brushless alternators for further testing and repair procedures. Proceed to "Check If The Diagnostic Code Remains".Table 9.

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Table 8
Check The Alternator Voltage Output
Troubleshooting Test Steps	Values	Results
1. The multimeter and the ammeter are still connected. 2. Run the engine for approximately 10 minutes at half throttle. 3. Check the alternator voltage at terminal "B".	The voltage is within range of system voltage. There is little or no variation in the voltage. 28 ± 1 V for 24 V system.	Result: The voltage is within range of system voltage and is stable. Proceed to "Check If The Diagnostic Code Remains".Table 9. Result: The voltage is not stable. There is a large voltage variation. Repair: Refer to Service Manual, SENR4130 for brushless alternators for further testing and repair procedures. Proceed to "Check If The Diagnostic Code Remains".Table 9.

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Table 9
Check If The Diagnostic Code Remains
Troubleshooting Test Steps	Values	Results
1. Reconnect all harness connectors. Return machine to normal operating condition. 2. Turn the key start switch and the disconnect switch to the ON position. 3. Clear all diagnostic codes. 4. Operate the machine. 5. Stop the machine and engage the safety lock. 6. Check if the diagnostic code is active.	The diagnostic code is no longer present.	Result: The diagnostic code does not exist currently. The initial diagnostic code may have been caused by poor electrical connection or short at one of the harness connections. Resume machine operation. STOP. Result: The diagnostic trouble code has not been corrected. If the diagnostic code has not been corrected after performing the procedure a second time, the ECM may require replacement. Prior to replacing the ECM, always contact the Technical Communicator at your dealership for possible consultation with AVSpare. This consultation may effect repair time. Follow the steps in Troubleshooting, "ECM - Replace" if the ECM needs to be replaced. STOP.

FMI 4

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Table 10
Check The Battery Voltage
Troubleshooting Test Steps	Values	Results
1. Start the engine and run the engine at high idle for several minutes. 2. Measure the voltage of the battery at the battery posts.	The voltage is within range of system voltage.	Result: The voltage is within range of system voltage. Proceed to "Check The System Voltage At The ECM" Table 11. Result: The voltage is not within the range of system voltage. Repair: Refer to Special Instruction, REHS0354. Proceed to "Check If The Diagnostic Code Remains" Table 12.

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Table 11
Check The System Voltage At The ECM
Troubleshooting Test Steps	Values	Results
1. The engine remains running at high idle. 2. Do not disconnect the machine harness from the ECM. 3. Use the 7x-1710 Multimeter Probe to measure the voltage between the supply contacts and ground contacts.	The voltage is within range of system voltage.	Result: The voltage is within range of system voltage. Proceed to "Check If The Diagnostic Code Remains" Table 12. Result: The voltage is not correct. The machine harness has failed. Repair: Repair or replace the machine harness. Proceed to "Check If The Diagnostic Code Remains" Table 12.

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Table 12
Check If The Diagnostic Code Remains
Troubleshooting Test Steps	Values	Results
1. Reconnect all harness connectors. Return machine to normal operating condition. 2. Turn the key start switch and the disconnect switch to the ON position. 3. Clear all diagnostic codes. 4. Operate the machine. 5. Stop the machine and engage the safety lock. 6. Check if the diagnostic code is active.	The diagnostic code is no longer present.	Result: The diagnostic code does not exist currently. The initial diagnostic code may have been caused by poor electrical connection or short at one of the harness connections. Resume machine operation. STOP. Result: The diagnostic trouble code has not been corrected. If the diagnostic code has not been corrected after performing the procedure a second time, the ECM may require replacement. Prior to replacing the ECM, always contact the Technical Communicator at your dealership for possible consultation with AVSpare. This consultation may effect repair time. Follow the steps in Troubleshooting, "ECM - Replace" if the ECM needs to be replaced. STOP.