CHECKING AND INTERPRETATION OF THE TROUBLESHOOTING CODES

STARTING THE ENGINE USING BOOSTER BATTERIES

WARNING: Explosive gas is produced while batteries are in use or being charged. Keep open flames and/or sparks away from the battery charging area. Charge the batteries in a well ventilated place. Park the machine on a dry firm, surface. Do not park on metal surfaces. Take care to make correct connections. Never connect a positive terminal (+) to a negative terminal (-).

IMPORTANT: The machine electrical system is 24 V with negative (-) ground. Use only booster batteries with same voltage.

Connecting booster batteries

Proceed in the following order: • Connect one terminal of the red cable (1) to the positive (+) pole of machine batteries and the other terminal of same cable to the positive (+) pole of booster batteries (loaded). • Connect one terminal of the black cable (2) to the negative (-) pole of booster batteries and the other terminal of same cable to ground (machine frame). • Start the engine.

IMPORTANT: The connection of booster batteries should not be accomplished by non-authorized personnel.

C

batteries (loaded)

B

batteries (unloaded)

D A

Cable connection order:

A B C D

Cable disconnection order:

D C B A

Disconnecting booster batteries

Proceed in the following order: • Disconnect the black cable (2) terminal from ground (machine frame), then disconnect the other terminal of same cable from the negative (-) pole of booster batteries (loaded). • Disconnect the red cable (1) terminal from the positive (+) pole of booster batteries, then disconnect the other terminal of same cable from the positive (+) pole of machine batteries (unloaded).

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TRANSMISSION AUXILIARY SYSTEM COME-HOME

The COME-HOME is an emergency function, used in event of failure of the transmission control module. If the immediate replacement of the module is not possible, this function allows the driving of the machine to the nearest repair shop. The switch (8) on the instrument panel is a threeposition switch: forward, neutral and reverse. To enable the system, turn off the machine, apply the parking brake and put the switch in the neutral position. Open the cover on the right hand side of the operator’s cab. This allows the access to two gray connectors and one black connector.

COME-HOME ACTIVATED

Close the side-cover, be sure the parking brake is applied, then start the engine. NOTE: After releasing the parking brake, select the desired driving direction (forward - reverse) through the COME-HOME switch on the instrument panel. Moving the COME-HOME switch to the “forward” position the system will select the second forward gear. Moving the COME-HOME switch to the “reverse” position, the system will select the first backup gear.

SIDE COVER !

WARNING:The inching pedal does not function when the COME-HOME mode is activated.

1

2 3

4 After repairs, reconnect the connectors to their former positions. Connect the connector 1 with connector 2 and connector 3 with connector 4.

COME-HOME NOT ACTIVATED

Disconnect the gray 1 and 2, 3 and 4 connectors. Then connect the 2 and 3 connectors.

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CARE TO BE TAKEN PRIOR TO PERFORMING ANY WELDING PROCEDURE ON THE MACHINE

Disconnect the positive (+) and negative (-) cables from batteries prior to performing any welding service on the machine. Connect the welding equipment ground cable to a 0,6 m (2 feet) maximum distance from the area being welded. Do not connect the welding equipment ground cable to the module cooling plate or to the engine control module (ECM) itself. Welding work is not recommended on installed engine or components.

Engine Control Module (ECM) Connectors Transmission Control Module (TCM) Connectors

X24 X23

B

A

C

ENGINE CONTROL MODULE (ECM) DETAILS, SHOWING LOCATION OF CONNECTORS A, B, AND C TO BE DISCONNECTED TRANSMISSION CONTROL MODULE (TCM) X24 BLACK CONNECTOR AND X23 GRAY CONNECTOR

When welding service is necessary to be performed on the machine, make sure to disconnect the X24 connector and the X23 connector from the right hand-side of the operator’s cab.

CAUTION:

If welding service is performed without disconnecting the X24 and X23 connectors shown in illustration, damages can be caused to the transmission control module (TCM).

POSITION OF THE ENGINE CONTROL MODULE (ECM), ON LEFT HAND-SIDE OF THE MACHINE, IN ENGINE COMPARTMENT.

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J4

J6

Prior to perform any welding service on the machine, disconnect J6 connector on left handside of the machine, next to the transmission.

When welding service is necessary to be performed on the machine, make sure to disconnect the transmission control lever J4 connector, located on the right hand-side console, above the fuse block.

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FUSE BOX

The fuse box is located inside the right console. To access the fuses for replacement or service of fuse box, open the front cover of the console.

Fuse and Relay List

Fuse Box 1

F1 7.5 amp To flasher relay and turn signal lights F2 15 amp To power outlet and Dual Power system F3 7.5 amp To rotating beacon and cab dome light F4 7.5 amp To head lights (low beam) F5 15 amp To horn F6 3 amp To E.D.M. (Electronic Data Panel) and buzzer F7 10 amp To Funk transmission system F8 10 amp To Funk transmission system F9 10 amp To Funk transmission system F10 7.5 amp To cab fans F11 10 amp To front wiper and washer pump F12 15 amp To hydraulic solenoid valves saddle lock pin and float control (opt) F13 7.5 amp To rear flood lights F14 7.5 amp To high beam F15 10 amp To starting aid (opt) F16 10 amp To rear wiper and washer pump

Fuse Box 2

F17 20 amp To air conditioner system (opt) F18 3 amp To reverse fan solenoid valve (opt) F19 3 amp To reverse signal on the gear selector F20 3 amp To air conditioner system mode door (opt) F21 10 amp To front wheel drive system F22 3 amp To differential lock (opt) F23 3 amp To back-up alarm (opt) F24 5 amp To electrical engine shut off F25 3 amp To brake light F26 15 amp To front lower wipers/washer/and air suspension seat (opt) F27 7.5 amp To cab lights F28 7.5 amp To working lights before moldboard (opt) F29 7.5 amp To working lights after moldboard (opt) F30 10 amp To radio and cigarette lighter F31 7.5 amp To alternator regulator and hability relay F32 7.5 amp To front equipment lights (opt)

Relays

K1 Hability Relay K2 “Dual Power (QSB, Tier 2 and Tier 3) Relay (See Note 1)” K3 Auxiliary starting relay K4 Low beam relay K5 High beam relay K6 Rear flood lights and rear work lights relay K7 Horn relay K8 Back-up alarm relay K9 Starting Aid (opt) (See Note 2) K10 Differential lock relay K11 “Dual power relay (Opt Tier 0, 1 and 2) (See Note 2)” K12 Magnetic clutch/compressor relay air conditioner system (opt) K13 On-off fan drive relay (opt) K14 Work light before moldboard relay (opt)

Note1:To QSB and Tier2 engine/To Tier3 engine 140 hp class

Note2:Only to mechanical engine

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LOGIC CHECKING FOR TIER3 CUMMINS ENGINE OPERATION Engine Protection System Standby Light For Starting

The engine protection system monitors the sensor readings of the engine control system and records failure codes when an abnormal operation condition occurs. The engine power can be reduced depending to the type of the occurred failure. The system informs the operator through the warning (A) and the stop (B) indicator lights.

Engine Stop

Turn on the main switch and turn the start switch to the IGN (Ignition) position. At that moment, the system checks the indicator and warning lights. If any of the lights does not light, replace the bulb. If no failure is detected, all lights will go off. The standby light for starting (C) (GRID HEATER light) will remain on, during the intake air preheating period. During this period the engine must not be started. When the heating is completed, the standby light for starting (C) (GRID HEATER light) will go off and the engine can be started. The intake air heating time occurs according to the environment temperature. Therefore, in case of very cold climates the standby light for starting (C) will remain on for a longer time, which does not mean that a failure is present. IMPORTANT: Never turn off the main switch when the starting switch is on the IGN (Ignition) position. This procedure will accumulate failure codes in the ECM memory, which will not be informed by the indicator lights.

Troubleshooting Codes

The engine protection system can indicate and record operation failures that are identified by failure codes. These codes facilitate the Troubleshooting. These codes can be read through the indicator lights interpretation, or by performing the software Insite of Cummins with a lap top. See Section Troubleshooting Codes Checking and Interpretation. NOTE: The failure codes do not indicate all anomalies of the engine.

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Indicator Lights

The indicator lights are located on the front instrument panel behind the steering wheel, and are: A.Warning indicator light (Yellow) B.Stop indicator light (Red) C.GRID HEATER standby light for starting

A.Warning indicator light

Needs the operator’s attention when this light is on. Indicates a slight failure.

B.Stop indicator light

Machine must be immediately stopped when this light is on. Indicates a serious failure. The specific high temperature of the engine coolant and the low pressure of the oil are not indicated by the indicator lights flashing code. In this condition the red bulb is on as long as the engine is running and the ECM will advance the reduction of the engine power. If this occurs, stop the machine for repairs to be performed by a CUMMINS Dealer.

C. Standby light for starting (C) (GRID

HEATER light)

The operator must wait until this light goes off in order to star the engine. The GRID HEATER is automatically activated and deactivated by the ECM. NOTE: In case of very cold climates the GRID HEATER can be activated during normal operation of the machine, allowing the indicator light to go on, which doesn’t means that a failure exists.

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