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Lesson 5: Row Crop Challenger

Lesson 5: Row Crop Challenger

Fig. 2.5.1

Introduction
This lesson discusses the electronic systems installed on Challenger
35, 45 and 55 Agricultural Tractors including the electronic control
modules, the network that allows the modules to communicate and
normal, warning and diagnostic operation.
Three electronic control modules are installed on the machine:
Electronic Monitoring Center (EMC) Module: The EMC is
located in the front dash. The EMC provides the operator with
machine operating conditions and other machine information on
the displays in the dash.
Right Hand Control (RHC) Module: The RHC is mounted in
the right side console. It controls many of the machine functions
initiated by the operator.
Chassis Control Module (CCM): The CCM is mounted on the
cab floor behind the operator's seat. The CCM controls
transmission shifting, the three-point hitch function and the draft
control function.
Unit 2 2-5-2 Machine Specific
Lesson 5

All the modules communicate information from sensors, switches and


operator controls to each other and to displays or actuators as
directed. The operator instructs the electronic modules what to do,
the modules interpret the commands and direct the machine
subsystems to complete the functions as required.
On the cover of the CCM and RHC is a red lamp. The state of each
red lamp indicates the status of the module.
FLASH: The module is operating normally.
CONSTANT ON: The module is malfunctioning.
OFF: The module is not receiving power (key start switch OFF)
or the CAN (Controller Area Network) Data Link is
malfunctioning.
The EMC green status lamp on the lower center section of the EMC
indicates the system and/or EMC status.
FLASH: A malfunction is detected in a system monitored by the
EMC and is shown on the warning lamps or bar graphs.
CONSTANT ON: The module is functioning normally.
NOTE: Two different part numbers exist for the CCM. One
part number is for machines with the three-point hitch function,
and one number is for machines without the three-point hitch
function.
The RHC and CCM do not contain any serviceable or
mechanical components. The only serviceable components on the
EMC are the lamps. The modules should never be opened or
disassembled.
Unit 2 2-5-3 Machine Specific
Lesson 5

ELECTRONIC
INPUTS: MONITORING OUTPUTS:
SWITCHES CENTER RELAYS
SENSORS (EMC) INDICATOR LAMPS
ALARM
INPUTS:
SWITCHES
SENSORS DIAGNOSTIC AND
MAINTENANCE (DAM)
CONNECTOR
CHASSIS
CONTROL
MODULE
(CCM)

OUTPUTS:
RELAYS
SOLENOIDS ELECTRONIC
RIGHT HAND
TECHNICIAN
INPUTS: CONTROL (RHC) OUTPUTS:
SWITCHES MODULE INDICATOR LAMPS
POTENTIOMETERS

Fig. 2.5.2

All the modules communicate information using a communications


network technology referred to as the CAN (Controller Area
Network) Data Link.
This technology allows modules to perform many functions through
the use of shared input and output resources, thus minimizing sensors
and wiring components. In addition, modules check for faults and
display or store this information as required for reference in
servicing. Two shielded signal wires of the CAN Data Link connect
all the modules.
The machine electronic system has 12 service modes which allow the
technician to troubleshoot most problems without disconnecting
modules or connectors. An additional feature of the electronic system
is the Diagnostic and Maintenance (DAM) connector. This connector
permits external diagnostic equipment to communicate with the
modules. The external diagnostic equipment is used for more
detailed testing, programming or calibration. The DAM connector is
located next to the main fuse panel.
Unit 2 2-5-4 Machine Specific
Lesson 5

MAIN RIGHT HAND


DISTRIBUTION PANEL CONTROL (RHC)
MODULE
MAIN FUSE PANEL
CHASSIS
ELECTRONIC CONTROL MODULE
MONITORING CENTER (CCM)
(EMC)

DIAGNOSTIC AND
MAINTENANCE (DAM)
CONNECTOR

Fig. 2.5.3

Six harnesses connect the various machine circuits. The harnesses


are: Cab Main (CM), Cab Roof (CR), Front Main (FM), Front Light
(FL), Right Hand Console (RH) and the Rear Main (RM). All
connectors are identified by the letter "C" and three digits such as
"C007." Each wiring harness has both color and letter identifiers on
each wire.
The Cab Main (CM) harness utilizes a Main Fuse Panel (MFP)
between the Main Distribution Panel (MDP) and the two batteries.
The MFP is located at the base of the right console near the cab floor.
The MFP houses eight large fuses to protect the MDP. The MDP is
located behind a cover on the right pillar inside the cab. The MDP
has 30 fuse locations and 17 relay locations.
NOTE: If an electrical failure in the transmission shifting system
occurs, a special tool can be used to temporarily operate the
transmission. The tool is called a "Limp Home Switch and Wire
Assembly." For more information, see the topic "Transmission
System Electrical Component Operation" in the Service Manual
module "Challenger 35/45/66 Agricultural Tractors Transmission
Systems Operation, Testing and Adjusting" (Form SENR8304).
Unit 2 2-5-5 Machine Specific
Lesson 5

ELECTRONIC MONITORING CENTER (EMC)

INTERCOOLER TRANS TEMP PRG


ALTERNATOR TRANS PRESS
COOL LEVEL FILTERS
COLD START PTO ON UP-SHIFT
AIR FILTER

DOWN-SHIFT

TRAILER BRAKE

1
TRACK TENSION
TRAILER 1 GEAR
2
TRAILER 2

FUEL LEVEL ENG OIL PRESS COOLANT TEMP TRANS TEMP

3 n/min RPM AREA/HR SPEED


4 4

1
2
SERVICE 1000
3 PTO AREA PTO RPM

MPH AREA ON %SLIP 1000


HOUR OFF ALARM PTO
1
km/h IMP WIDTH CAL % SLIP ENG HR

2 DIST FT METERS VOLTS

SET UP START
1 PANEL DIM SYSTEM STATUS P
SELECT STOP
E/M

Fig. 2.5.4

ELECTRONIC MONITORING CENTER

When the key start switch is turned ON, the Electronic Monitoring
Center (EMC) performs a self test. During the self test, all the
displays, bar graphs, alert indicators and the alarm horn are activated
for a brief time.
The EMC is divided into the following areas:
Fuel level and engine oil pressure are shown in the left bar graphs.
The upper section consists of 17 alert indicators, which provide
operating information or give warning of abnormal conditions.
The central display area shows transmission gear information on the
upper display. Engine speed is shown in the center display. The
lower display shows operating hours, ground speed or PTO speed, as
selected.
Coolant temperature and transmission temperature are shown in the
right bar graphs.
The Machine Performance Monitor (MPM) is on the right side of the
EMC. The MPM provides information on the three-point hitch and
other selected system information. Fault code information is also
shown.
The keypad has 11 touch-sensitive keys that are used to select
different EMC functions to be shown on the central display and
MPM. The keys are also used for calibration purposes.
Unit 2 2-5-6 Machine Specific
Lesson 5

The keys on the lower left side of the EMC are used to control the
work lights and to adjust the brightness of the back lighting (panel
dim) within the EMC.
The lower center section consists of three alert indicators (parking
brake, bright lights, and system status), which provide operating
information or give warning of abnormal conditions.

GEAR

CENTRAL
DISPLAY
AREA n/min RPM

SERVICE 1000
PTO
MPH
km/h

Fig. 2.5.5

Central Display Area

The central display area is divided into three multi-function displays.


The lower display is selectable and is activated by the keypad. The
functions shown in the central display area are:
The gear shift position is continuously shown on the upper display.
The engine speed (rpm) is continuously shown on the center display.
STOP is shown on center display during a critical warning
(shutdown).
The accumulated engine hours (actual time), the machine ground
speed (mph or km/h) or the PTO speed (rpm), selected at the keypad,
are shown on the lower display.
Two service alert indicators may be programmed to remind the
operator of the next scheduled service. The service alert indicators
are selected and programmed at the keypad and are also shown on the
lower display.
Unit 2 2-5-7 Machine Specific
Lesson 5

MACHINE
PERFORMANCE MONITOR

AREA/HR SPEED

AREA PTO RPM

AREA ON % SLIP 1000


HOUR OFF ALARM PTO
IMP WIDTH CAL
% SLIP ENG HR
DIST FT METERS VOLTS

SET UP START

SELECT STOP
E/M

Fig. 2.5.6

Machine Performance Monitor


Machine performance information is shown on the Machine
Performance Monitor (MPM). Some functions are shown on the
Machine Performance Monitor automatically, and some functions
must be selected.
The functions shown automatically are:
Three-Point Hitch Enabled: Used only on machines equipped
with a three-point hitch.
Numeric Value for Three-Point Hitch Position: Shown on the
two-digit readout; used only on machines equipped with a three-
point hitch.
Three-Point hitch Disabled: Used only on machines equipped
with a three-point hitch.
A numeric value (fault code) that represents a specific machine
electrical fault is shown on the four-digit readout.
The functions that are selected by the keypad and shown on the four-
digit readout are:
Area per hour forecaster (acres or hectares)
Area accumulated (acres or hectares)
Track slip percent (optional feature, must have radar)
Battery Voltage (Volts)
PTO speed (rpm)
Distance measurement (feet or meters)
Unit 2 2-5-8 Machine Specific
Lesson 5

Fig. 2.5.7

Normal Operation

During normal operation, the EMC (Electronic Monitoring Center)


shows the operator and service technician three machine conditions:
Normal Operation, Warning Operation and Diagnostic Operation.
The electronic control modules continually monitor machine systems.
A value is displayed for certain machine conditions being monitored.
The bar graphs of the EMC show a normal range value (in the central
region) for certain conditions.
The EMC also displays an abnormal machine condition. When an
abnormal condition (problem) exists for more than eight seconds, the
corresponding alert indicator or bar graph illuminates to notify the
operator.
The occurrence of an abnormal condition is stored in memory as a
specific fault code. Service personnel can view these fault codes to
assist with troubleshooting.
The EMC displays if a fault exists in the electrical system. The
electronic control modules continually check for faults in the
electrical circuits on the machine. When a fault is detected, the
"Read Your Manual" symbol (on the EMC) is turned ON, and the
event is stored in memory. Also, the corresponding fault code is
shown on the four-digit readout of the machine performance panel
(on the EMC).
The EMC enters the Normal Mode when it is powered up (key start
switch turned ON). Leaving the Normal Mode is accomplished by
initiating a service operation with the keypad.
Unit 2 2-5-9 Machine Specific
Lesson 5

ALERT INDICATORS
FILTER
ALTERNATOR TRANSMISSION TRANSMISSION RESTRICTED PTO
AIR FILTER COLD START COOLANT CHARGE AFTERCOOLER PRESSURE TEMPERATURE ON = ENGAGED
(BYPASS
RESTRICTION ACTIVATED LEVEL LOW IMPROPER OVERHEATED LOW HIGH OCCURRING) FLASHING = OVERSPEED
PROGRAMMED
UPSHIFT
ACTIVATED
TRAILER BRAKE PROGRAMMED
ENGAGED DOWNSHIFT
ALTERNATOR
INTERCOOLER TRANS TEMP TRANS PRESS
PRG ACTIVATED
COOL LEVEL FILTERS
TRAILER AIR FILTER
COLD START PTO ON UP-SHIFT
NO. 1 TURN TRACK
DOWN-SHIFT
SIGNAL TENSION
TRAILER BRAKE LOW
TRAILER
NO. 2 TURN 1 TRACK TENSION
SIGNAL TRAILER 1

LEFT RIGHT
TURN
2 TURN
SIGNAL TRAILER 2 SIGNAL

FUEL LEVEL ENG OIL PRESS COOLANT TEMP TRANS TEMP

SYSTEM STATUS P

HIGH BEAM SYSTEM STATUS PARKING


ACTIVATED ON = NORMAL BRAKE
FLASHING = ABNORMAL APPLIED

Fig. 2.5.8

Warning Operation

The twenty alert indicators and four bar graphs notify the operator of
the status of machine conditions or that an abnormal condition exists.
Also, an audible alarm notifies the operator.
The EMC analyzes the problem and activates the appropriate warning
indication to notify the operator. The indications are: status, non-
critical and critical.
Status Indication: Informs the operator of normal machine status.
For example, the turn signals, trailing equipment turn signals, cold
start indicator, upshift and downshift indicators, high beam lamp and
the parking brake lamp are alert indicators that show normal machine
status.
The operator can identify this type of warning by the presence of the
following indicators:
a. An alert indicator for status is illuminated.
b. The system status indicator is illuminated.

Non-Critical Warning Indication: An abnormal condition exists


that is non-critical. Investigate the cause at the earliest convenience.
The illuminated alert indicator identifies the problem system.
The operator can identify this type of warning by the presence of all
the following indicators:
a. An alert indicator is illuminated or a bar graph is flashing.
b. The system status indicator is flashing.
Unit 2 2-5-10 Machine Specific
Lesson 5

Critical Warning Indication (Shutdown): An abnormal condition


exists that is critical. The EMC will automatically shut down the
engine within 30 seconds. Stop the machine and immediately find
the cause of the problem to prevent damage to the machine. The
illuminated alert indicator identifies the problem system.
The operator can identify this type of warning by the presence of all
the following indicators:
a. An alert indicator is illuminated or a bar graph is flashing.
b. The system status indicator is flashing.
c. The audible alarm continuously sounds. The alarm will
continue until the problem is corrected or the engine is
stopped.
d. A STOP message appears in the central display area.
e. The fault code for the problem is logged.

Thirty seconds after the start of a critical warning, the engine is


automatically shutdown. The conditions that can cause a critical
warning to occur are: engine oil pressure too low, coolant
temperature too high, transmission oil pressure too low, transmission
oil temperature too high or oil is bypassing the steering filter. If oil is
bypassing the steering filter, a 90-second delay occurs before the
STOP message appears.
The automatic shutdown feature protects the engine and drive train of
an unattended machine that is performing PTO work. The shutdown
override switch on the front dash disables the automatic shutdown
feature and allows continued operation.
Unit 2 2-5-11 Machine Specific
Lesson 5

ELECTRONIC MONITORING CENTER


EVENT CODE DISPLAY

n/min RPM
AREA/HR SPEED

AREA PTO RPM

% SLIP ENG HR

SET UP START

SELECT STOP E/M

Fig. 2.5.9

Diagnostic Operation

The electronic control modules continually check for faults in the


electrical circuits on the machine. When a fault is detected, the
"Read Your Manual" symbol will flash and the event is stored in
memory. Also, the corresponding fault code will flash on the four-
digit display of the Machine Performance Monitor (MPM). During
normal operation, the operator can choose whether or not to have the
fault codes flash on the display.
A fault code is a three-digit number preceded by the letter "F." Each
fault code identifies the machine circuit or sensor in which the fault is
detected and the type of fault that has occurred. For example, fault
code F314 indicates that a high current has been detected in the PTO
solenoid circuit.
The EMC has several Service Modes to assist with troubleshooting.
The Service Modes that are directly involved with troubleshooting or
diagnostics are:
Mode 2: View/Clear Stored Fault Codes
Mode 3: All Module Input Diagnostics
Mode 4: EMC Output Diagnostics
Mode 5: RHC Output Diagnostics
Mode 6: CCM Draft Control Output Diagnostics
Mode 7: CCM Transmission Control Output Diagnostics
Unit 2 2-5-12 Machine Specific
Lesson 5

The View/Clear Stored Fault Mode (Mode 2) is the primary aid for
troubleshooting fault codes. Mode 2 provides information which
includes the number of times a fault code has occurred and the hour
at which the fault last occurred. Also, the fault codes can be cleared
while in Mode 2.

SERVICE MODES
Mode Mode No.
Operator Calibrations 1 1
View/Clear Stored Fault Codes 2
All Module Input Diagnostics 3
EMC Output Diagnostics 4
RHC Output Diagnostics 5
CCM Draft Control Output Diagnostics 6
CCM Transmission Control Output Diagnostics 7
EMC Lamp Test 8
Hardware/Software Revision Level 9
Transmission Calibration Review And Programming 1 10
Three-Point Hitch Status And Calibration 1 11
Machine Features Configuration 12
1 This mode can be accessed while the machine is operating.

Fig. 2.5.10

SERVICE OPERATIONS
Twelve service modes are available to aid in troubleshooting,
calibration and adjusting machine performance. The service modes
allow the technician to do most troubleshooting without
disconnecting modules or connectors. Some of the modes can be
accessed only with the engine off, while other modes allow the
operator to drive the machine and monitor its performance during
operation.
Each service mode is assigned a mode number. The service modes of
the EMC are listed in the Service Modes chart. This mode number is
entered into the EMC using the keypad, and the corresponding
service operation begins.
Unit 2 2-5-13 Machine Specific
Lesson 5

1
NORMAL
OPERATION

3 HOLD 2 TOUCH
SET UP SET UP

SELECT SELECT
MODES OF OPERATION
3
SECONDS
PTO DISPLAY
BATTERY VOLTAGE
DISTANCE MEASUREMENT

4 MODE 5 TOUCH MODE MODE MODE MODE MODE MODE MODE MODE MODE MODE MODE
_ _ _ 1** ___2 ___3 ___4 ___5 ___6 ___7 ___8 ___9 _ _ 10** _ _ 11** _ _ 12

6 HOLD 6 HOLD 6 HOLD 6 HOLD 6 HOLD 6 HOLD 3 HOLD 6 HOLD 6 HOLD 6 HOLD 6 HOLD 6 HOLD
TO
SET UP SELECT SET UP SET UP SET UP SET UP SET UP SET UP SET UP SET UP SET UP SET UP SET UP

SELECT SELECT SELECT SELECT SELECT SELECT SELECT SELECT SELECT SELECT SELECT SELECT

3 3 3 3 3 3 3 3 3 3 3 15
SECONDS SECONDS SECONDS SECONDS SECONDS SECONDS SECONDS SECONDS SECONDS SECONDS SECONDS SECONDS

7 IMP WIDTH 7 7 7 7 7 7 7 7 7 7 7
SERV I VIEW/ HARD & TRANS
CHECK CHECK CHECK CHECK CHECK EMC 3-PT TRACTOR
SERV II CLEAR SOFT CALIB &
ALL EMC RHC EDC ETC DISPLAY HITCH CONFIG
GROUND SPEED STORED WARE PROGRAM
INPUT OUTPUT OUTPUT OUTPUT OUTPUT TEST CALIB
AREA PRESET EVENT VERSION REVIEW
IDENTS IDENTS IDENTS IDENTS IDENTS REVIEW ***
EVENTS ON/OFF CODES ***
SLIP ALARM *

8 TOUCH 9 TOUCH

* Only tractors equipped with radar


E/M E/M ** MODE can be accessed with engine running
RETURN TO RETURN TO *** Hold SET UP/SELECT key for 3 seconds to save new values
MODE 1 NORMAL
OPERATION

Fig. 2.5.11

Procedure to enter a service mode:


1. The key start switch must be in the ON position.
2. Press and hold the "Setup/Select" key for three seconds (or until
the alarm briefly sounds).
3. The display will show "_ _ _ 1." This display indicates that Mode
1 is now accessible. By pressing the "Digit Set" key, the menu
will advance to the different modes.
4. Press the "Digit Set" key until the desired mode number is shown
on the display.
5. To enter the desired mode, press and hold the "Setup/Select" key
for three seconds.
The information in the mode can now be viewed or utilized for
diagnostics and/or calibration purposes.
Procedure to exit a service mode:
1. While in any Service Mode, pressing the "Exit/Mode" key will
return the display to the mode selection menu "_ _ _ 1."
2. Pressing the "Exit/Mode" key again will return the EMC to
normal operation.
NOTE: Turning the key start switch from ON to OFF and back
to ON again will also cause the EMC to begin normal operation.
Unit 2 2-5-14 Machine Specific
Lesson 5

MODE 1
REVIEW / SET OPERATION PARAMETERS

AREA/HR SPEED

AREA PTO RPM

% SLIP ENG HR

SET UP START

SELECT STOP
E/M

Fig. 2.5.12

Mode 1: Operator Calibrations

This mode allows the operator to change certain data for the EMC to
correctly calculate and display work done (area per hour, area
accumulated, etc.).
The functions that can be changed while in Mode 1 are:
Set Implement Width
Set Slip Alarm
Set Service Alert One
Set Service Alert Two
Ground Speed Calibration
Set Area Preset
Fault Codes ON/OFF
After entering Mode 1, each function can be changed individually.
When in Mode 1, repeatedly pressing the "Setup/Select" key will
cause the display to advance through the various functions in the
same order as the preceding list. The flashing of an indicator or a
digit also helps identify which function is currently selected.
Unit 2 2-5-15 Machine Specific
Lesson 5

SET IMPLEMENT WIDTH

AREA/HR SPEED

AREA PTO RPM

IMP WIDTH CAL


% SLIP ENG HR
FT

SET UP START

SELECT STOP
E/M

Fig. 2.5.13

For the EMC to calculate the work done, the working width of the
implement in use must be entered into the memory. To set the
implement width:
1. Enter the Operator Calibration Mode (Mode 1):
a. Turn the key start switch from OFF to ON.
b. Press and hold the "Setup/Select" key for three seconds.
c. Press the "Digit Set" key until the display shows "_ _ _ 1."
d. Press and hold the "Setup/Select" key for three seconds to
enter Mode 1. Release the key within two seconds after
entering Mode 1. If the key is held for more than three
seconds after entering Mode 1, the Ground Speed
Calibration Value may be inadvertently reset to an incorrect
value.

2. Select the Set Implement Width function. When this function is


selected, the indicator "IMP WIDTH CAL" appears on the
Machine Performance Monitor (MPM). Repeatedly press the
"Setup/Select" key until the indicator shows "IMP WIDTH CAL."
3. The value for implement width is a four-digit number shown on
the display. Depending on the units of measurement selected, the
value will appear as "000.0 FT" or "00.00 METERS." The left
digit of the display will flash. Use the "E/M" key to change units.
Unit 2 2-5-16 Machine Specific
Lesson 5

4. Enter the desired value. The value of each digit is changed


individually. The flashing digit identifies the digit to be changed.
Pressing the "Digit Set" key increases the numerical value of the
flashing digit. Pressing the "Digit Select" key also causes the
next digit to flash, and it can then be set with the "Digit Set" key.
For example: To set an implement working width of 12.5 feet, a
display of "012.5" is required.
a. Press the "Digit Select" key to cause the second digit from
the left to flash.
b. Press the "Digit Set" key to change the flashing digit from 0
to 1.
c. Use the "Digit Select" key and the "Digit Set" key to change
the remaining digits until "012.5" is showing.

5. With the desired value for implement width showing, press the
"Setup/Select" key. The implement width is entered into memory
and the display advances to the next function. For machines
equipped with radar, the next function is Set Slip Alarm. For
machines not equipped with radar, the next function is Set Service
Alert One. To return the EMC to normal operation, press the
"Exit/Mode" key twice.
NOTE: The area measured will be accurate only if no implement
overlap occurs when the machine turns around at the end of a
run to make another pass. Alternatively, the implement width
entered into the computer memory may be reduced by the
estimated amount of overlap. If the implement width is set to a
value of "000.0," the Area Per Hour and the Area Accumulated
functions of the Machine Performance Monitor will not operate.
Unit 2 2-5-17 Machine Specific
Lesson 5

SET SLIP ALARM

AREA/HR SPEED

AREA PTO RPM

% SLIP
ALARM
CAL
% SLIP ENG HR

SET UP START

SELECT STOP
E/M

Fig. 2.5.14

Slippage between the track system and the ground can occur. The Set
Slip Alarm function can be programmed to notify the operator when a
selected percentage of slippage occurs. The percentage is based on
the true ground speed (radar) as compared to the track speed. The Set
Slip Alarm function is only provided for machines with radar. If the
slip alarm is not required, set the percentage to "00."
Procedure to Set Slip Alarm:
1. Enter the Operator Calibration Mode (Mode 1):
a. Turn the key start switch from OFF to ON.
b. Press and hold the "Setup/Select" key for three seconds.
c. Press the "Digit Set" key until the display shows " _ _ _ 1."
d. Press and hold the "Setup/Select" key for three seconds to
enter Mode 1.

2. Select the function for Set Slip Alarm. When this function is
selected, the indicator "% SLIP ALARM CAL" appears on the
MPM. Repeatedly press the "Setup/Select" key until the indicator
shows "% SLIP ALARM CAL."
3. The value (percentage) for the slip alarm is a two-digit number
shown on the display. The left digit will be flashing.
Unit 2 2-5-18 Machine Specific
Lesson 5

4. Enter the desired value. The value of each digit is changed


individually. The flashing digit identifies the digit to be changed.
Pressing the "Digit Set" key increases the numerical value of the
flashing digit. Pressing the "Digit Select" key causes the next
digit to flash, and it can be set with the "Digit Set" key.
5. With the desired value (percentage) for the slip alarm showing,
press the "Setup/Select" key. The slip alarm percentage is entered
into memory and the display advances to the Set Service Alert
One function. To return the EMC to normal operation, press the
"Exit/Mode" key twice.
NOTE: If the value (percentage) for the slip alarm is set too low,
the slip alarm may sound during turns. If the slip alarm is not
required, set the value to"00." Use new software if available.
Unit 2 2-5-19 Machine Specific
Lesson 5

SET SERVICE ALERT ONE

SERVICE

Fig. 2.5.15

Two service alert indicators are provided: One and Two. Each
service alert indicator can be programmed to notify the operator when
a selected interval of time has elapsed. This interval of time (as
measured by the hourmeter) can correspond to a periodic
maintenance schedule. For example: The operator wants to be
notified every 50 hours that minor service is due and every 250 hours
that major service is due. Service Alert One is set at 50 hours, and
Service Alert Two is set at 250 hours.
During normal machine operation, the hourmeter will reach the
selected service interval. The indicator "SERVICE" will flash next to
the hourmeter symbol. The indicator "SERVICE" will continue
flashing for 10 hours of operation or until the display is reset.
To determine which service interval has elapsed (One or Two), the
operator must enter the Operator Calibration Mode (Mode 1) and
advance the display until the indicator "SERVICE" is flashing. At
this time, the previously selected time (50 or 250) will show on the
display. Service Alert One or Service Alert Two is identified by the
number of segments illuminated on the left digit of the display.
Service Alert One is identified by one segment illuminated on the left
digit. Service Alert Two is identified by two segments illuminated on
the left digit.
The operator can program one, two or no service alert indicators.
Entering a value of "000" disables a service alert indicator.
Unit 2 2-5-20 Machine Specific
Lesson 5

When a new time interval is selected, the countdown begins when the
new interval is saved. Saving occurs when the "Setup/Select" key is
pressed.
Procedure to Set Service Alert One:
1. Enter the Operator Calibration Mode (Mode 1):
a. Turn the key start switch from OFF to ON.
b. Press and hold the "Setup/Select" key for three seconds.
c. Press the "Digit Set" key until the display shows "_ _ _ 1."
d. Press and hold the "Setup/Select" key for three seconds to
enter Mode 1.

2. Select the Set Service Alert One function. When this function is
selected, the indicator "SERVICE" appears in the lower central
display. Also, the Service Alert Indicator One (single segment)
must be illuminated on the far left side of the display. Repeatedly
press the "Setup/Select" key until the indicators are showing.
3. The value for Service Alert One is a three-digit number shown on
the lower central display. The left digit will be flashing.
4. Enter the desired value. The value of each digit is changed
individually. The flashing digit identifies the digit to be changed.
Pressing the "Digit Set" key increases the numerical value of the
flashing digit. Pressing the "Digit/Select" key causes the next
digit to flash, and it can be set with the "Digit Set" key.
5. With the desired value for Service Alert One showing, press the
"Setup/Select" key. The value is entered into memory, and the
countdown of the new time interval is initiated. Also, the display
will advance to the Set Service Alert Two function. To return the
EMC to normal operation, press the "Exit/Mode" key twice.
NOTE: To cancel the Service Alert and reset the time interval to
the existing value, press and hold the "Start/Stop/Reset" key for
three seconds. If Service Alert One is not required, set the value
to "000."
Unit 2 2-5-21 Machine Specific
Lesson 5

SET SERVICE ALERT TWO

SERVICE

Fig. 2.5.16

Procedure to Set Service Alert Two:


1. Enter the Operator Calibration Mode (Mode 1):
a. Turn the key start switch from OFF to ON.
b. Press and hold the "Setup/Select" key for three seconds.
c. Press the "Digit Set" key until the display shows "_ _ _ 1."
d. Press and hold the "Setup/Select" key for three seconds to
enter Mode 1.

2. Select the Set Service Alert Two function. When this function is
selected, the indicator "SERVICE" appears in the lower central
display. Also, the Service Alert Indicator Two (two segments)
must be illuminated on the far left side of the display. Repeatedly
press the "Setup/Select" key until the indicators are showing.
3. The value for Service Alert Two is a three-digit number shown on
the lower central display. The left digit will be flashing.
4. Enter the desired value. The value of each digit is changed
individually. The flashing digit identifies the digit to be changed.
Pressing the "Digit Set" key increases the numerical value of the
flashing digit. Pressing the "Digit Select" key causes the next
digit to flash, and it can be set with the "Digit Set" key.
Unit 2 2-5-22 Machine Specific
Lesson 5

5. With the desired value for Service Alert Two showing, press the
"Setup/Select" key. The value is entered into memory, and the
countdown of the new time interval is initiated. Also, the display
will advance to the Ground Speed Calibration function. To return
the EMC to normal operation, press the "Exit/Mode" key twice.
NOTE: To cancel the Service Alert and reset the time interval to
the existing value, press and hold the "Start/Stop/Reset" key for
three seconds. If Service Alert Two is not required, set the value
to "000."

MACHINE PERFORMANCE MONITOR


GROUND SPEED CALIBRATION

LOWER CENTRAL
DISPLAY AREA AREA/HR SPEED

AREA PTO RPM

CAL
FT % SLIP ENG HR

SET UP START

SELECT STOP
E/M

Fig. 2.5.17

For the EMC to accurately calculate the ground speed, the static
radius of the rear drive wheels must be entered into the memory. The
range of values for the static radius is from 610 mm (24 in.) to 1397
mm (55 in.). The specified value is 744 mm (METERS shown on
display) or 29.3 in. (FT shown on display).
If the machine is equipped with a ground speed sensor (radar), setting
this value is not necessary. The number will automatically reset when
the machine moves above 10 miles per hour.
Procedure to Calibrate Ground Speed:
1. Enter the Operator Calibration Mode (Mode 1):
a. Turn the key start switch from OFF to ON.
b. Press and hold the "Setup/Select" key for three seconds.
c. Press the "Digit Set" key until the display shows "_ _ _ 1."
d. Press and hold the "Setup/Select" key for three seconds to
enter Mode 1.
Unit 2 2-5-23 Machine Specific
Lesson 5

2. Select the Ground Speed Calibration function. When this


function is selected, the indicators "CAL" and "FT" (or
"METERS") appear on the MPM. Repeatedly press the
"Setup/Select" key until the indicators are showing.
3. The value for ground speed is a three-digit number shown on the
lower central display. The left digit will be flashing.
4. Enter the specified value: 29.3 in. (FT) or 744 mm (METERS).
The value of each digit is changed individually. The flashing
digit identifies the digit to be changed. Pressing the "Digit Set"
key increases the numerical value of the flashing digit. Pressing
the "Digit Select" key causes the next digit to flash, and it can be
set with the "Digit Set" key.
5. With the specified value for ground speed showing, press the
"Setup/Select" key. The value is entered into memory and the
display advances to the Set Area Preset function. To return the
EMC to normal operation, press the "Exit/Mode" key twice.
If a value other than the specified value of 29.3 in. (FT) or 744 mm
(METERS) is necessary, the minimum allowable value is 24.0 in.
(FT) or 610 mm (METERS). The maximum allowable value is
55.0 in. (FT) or 1397 mm (METERS). If the value of the first (left)
digit is incorrectly selected as a number other than 0, press and hold
the "Start/Stop/Reset" key for three seconds to change the value to 0.
NOTE: When the values in metric units are entered, the values
are converted to English units, rounded up to the nearest quarter
inch and stored in English. When a metric value is requested to
be shown on the display, the value is reconverted from English
back to metric units and then shown. Therefore, the values may
change slightly due to the rounding and converting. The change
is not considered significant.
Unit 2 2-5-24 Machine Specific
Lesson 5

SET AREA PRESET

AREA/HR SPEED

AREA PTO RPM

AREA

CAL
% SLIP ENG HR
FT

SET UP START

SELECT STOP
E/M

Fig. 2.5.18

During normal machine operation, the area value is reset to zero by


pressing and holding the "Start/Stop" key until the alarm sounds
(approximately three seconds). However, the Area Preset Calibration
Mode allows an area value, other than zero, to be entered into
memory. This feature allows the operator to enter the area measured
from a previous operation.
The Area Accumulator function stops totalling when the three-point
hitch is raised. The "OFF" indicator appears on the MPM. Totalling
is resumed when the three-point hitch is lowered. The "ON"
indicator appears on the MPM.
Procedure to Set Area Preset:
1. Enter the Operator Calibration Mode (Mode 1):
a. Turn the key start switch from OFF to ON.
b. Press and hold the "Setup/Select" key for three seconds.
c. Press the "Digit Set" key until the display shows "_ _ _ 1."
d. Press and hold the "Setup/Select" key for three seconds to
enter Mode 1.

2. Select the Set Area Preset function. When this function is


selected, the indicators "AREA," "CAL" and "FT" appear on the
MPM. Repeatedly press the "Setup/Select" key until the
indicators are showing.
3. The value for Area is a four-digit number shown on the display of
the MPM. The left digit will be flashing.
Unit 2 2-5-25 Machine Specific
Lesson 5

4. Enter the desired value. The value of each digit is changed


individually. The flashing digit identifies the digit to be changed.
Pressing the "Digit Set" key increases the numerical value of the
flashing digit. Pressing the "Digit Select" key causes the next
digit to flash and it can be set with the "Digit Set" key.
5. With the desired value for Area Preset showing, press the
"Setup/Select" key. The value is entered into memory and the
display advances to the Fault Codes ON/OFF function. To return
the EMC to normal operation, press the "Exit/Mode" key twice.
When the area switch on the Machine Performance Panel is selected,
the value saved for Area Preset will be shown.
NOTE: A remote implement status switch can be added to the
machine. The connection point is the purple wire (CM40) located
behind the operator’s seat below the floor mat. The addition of a
contact switch to the trailing implement will start (implement
lowered) and stop (implement raised) the totalling of the area
accumulator function.
Unit 2 2-5-26 Machine Specific
Lesson 5

FAULT CODES ON/OFF

AREA/HR SPEED

AREA PTO RPM

% SLIP ENG HR

SET UP START

SELECT STOP
E/M

Fig. 2.5.19

Fault codes can be viewed (ON) or not shown (OFF) during normal
machine operation. When ON is selected, the fault codes display on
the MPM overrides the normal operation of the MPM. When faults
are detected, the fault codes will flash sequentially on the display.
When OFF is selected, normal operation of the MPM display
continues. Fault codes are always stored in memory and available for
viewing when the EMC is in Mode 2.
NOTE: The fault codes display can be temporarily stopped to
return to a normal display by holding the "Start/Stop/Reset" key
for three seconds. When the key start switch is turned to OFF
and then the machine is restarted, the fault code will reappear.
Use the "Start/Stop/Reset" key to again temporarily cancel the
fault codes display. The "Read Your Manual" indicator will
continue to flash.
Unit 2 2-5-27 Machine Specific
Lesson 5

SELECT AUTOMATIC
FAULT CODE VIEWING

AREA/HR SPEED

AREA PTO RPM

ON
OFF

% SLIP ENG HR

SET UP START

SELECT STOP
E/M

Fig. 2.5.20

Procedure to Select Automatic Fault Code Viewing:


1. Enter the Operator Calibration Mode (Mode 1):
a. Turn the key start switch from OFF to ON.
b. Press and hold the "Setup/Select" key for three seconds.
c. Press the "Digit Set" key until the display shows "_ _ _ 1."
d. Press and hold the "Setup/Select" key for three seconds to
enter Mode 1.

2. Select the Fault Codes ON/OFF function. When this function is


selected, the "Read Your Manual" indicator and either the
indicator "ON" or "OFF" appears on the MPM. Repeatedly press
the "Setup/Select" key until the indicators are showing.
3. Select ON or OFF. Press the "Start/Stop/Reset" key until the
desired ON or OFF indicator is showing.
When ON is showing, fault codes will appear as they occur.
When OFF is showing, fault codes will not be shown.
4. With the desired ON or OFF indicator showing, press the
"Setup/Select" key. The ON/OFF selection is entered into
memory, and the display advances to the Setting Implement
Width function.
To return the EMC to Service Mode selection, press the "Exit/Mode"
key once. To return the EMC to normal operation, press the
"Exit/Mode" key twice.
Unit 2 2-5-28 Machine Specific
Lesson 5

MODE 2
VIEW/CLEAR STORED FAULT CODES

AREA/HR SPEED

AREA PTO RPM

% SLIP ENG HR

SET UP START

SELECT STOP
E/M

Fig. 2.5.21

Mode 2: View/Clear Stored Fault Codes

This mode allows the technician to view and clear stored fault codes
that have occurred in the system. A fault code identifies a specific
component or circuit and the reason for the failure. Up to 30
different fault codes that occur can be stored in memory.
The fault information shown on the EMC while in Mode 2 is:
a. The fault codes are displayed sequentially with the most
recent code shown first and the oldest code last.
b. The hour that the fault code last occurred is shown on the
hourmeter.
c. The number of times a fault code occurs (repeating fault
code) is shown on the gear display.

Procedure to View/Clear Stored Fault Codes:


1. Enter the View/Clear Stored Fault Codes Mode (Mode 2):
a. Turn the key start switch from OFF to ON.
b. Press and hold the "Setup/Select" key for three seconds.
c. Press the "Digit Set" key until the display shows "_ _ _ 2."
d. Press and hold the "Setup/Select" key for three seconds to
enter Mode 2.
Unit 2 2-5-29 Machine Specific
Lesson 5

The stored fault codes are displayed sequentially, starting with the
most recent fault. The hour that the fault last occurred will be shown
on the hourmeter. If the fault has occurred more than once, the
number of occurrences will appear on the gear display.
If no fault codes are recorded, the display is blank.
2. To cycle through the fault codes, press the "Setup/Select" key to
view the next code. All fault codes should be reviewed before
troubleshooting any system.
3. After the fault codes have been reviewed and recorded, the fault
codes can be cleared (erased). To clear all the fault codes, press
and hold the "Start/Stop/Reset" key for three seconds. All the
displays will go blank.
Fault codes that cause a shutdown cannot be erased. The shutdown
fault codes are: F386, F387, F394, F400 and F401. If the operator
shuts down the machine prior to the appearance of the word "STOP,"
the shutdown fault code can be erased. If the word "STOP" has been
shown, the Caterpillar Electronic Technician service tool must be
used to erase a shutdown fault code.
After the repairs are made, the machine should again be operated to
ensure that the fault does not reoccur.
4. To return the EMC to Service Mode selection, press the
"Exit/Mode" key once. To return the EMC to normal operation,
press the "Exit/Mode" key twice.
NOTE: If the engine shutdown override switch is activated
within eight seconds of a critical shutdown indication, no fault
code will appear and the engine will not shutdown. No fault code
is given for the engine shutdown override switch. Overriding the
automatic engine shutdown process allows the operator to
continue operating the machine until it can be safely shutdown.
Unit 2 2-5-30 Machine Specific
Lesson 5

MODE 3
ALL MODULE INPUT DIAGNOSTICS

AREA/HR SPEED

AREA PTO RPM

% SLIP ENG HR

SET UP START

SELECT STOP E/M

Fig. 2.5.22

Mode 3: All Module Input Diagnostics

In this mode, the technician can check the input components


(switches, potentiometers and sensors) to all modules without using
additional testing equipment. When the technician operates any
switch, sensor or potentiometer, the display area of the MPM will
identify the input component and indicate if the component is
functioning. All input components are assigned a unique four-digit
parameter identification number (P _ _ _ ).
When a switch or sensor is activated or deactivated (changes state):
a. The alarm horn will emit an audible sound to indicate the
switch and circuit are working.
b. A unique four-digit parameter identification number (P _ _ _ )
that corresponds to the input component being tested will
automatically be shown on the display.
c. The actual status of the input component is shown on the
display.
"Hi" indicates that the sensor voltage is high at the module input. A
pulsating audible tone will sound when "Hi" is shown.
"Lo" indicates that the sensor voltage is low at the module input. A
single audible tone will sound.
Unit 2 2-5-31 Machine Specific
Lesson 5

For potentiometers, a two-digit value "_ _" from 0 to 99 is shown to


indicate the percent of full scale.
d. When the sensor or switch is returned to its original position,
the alarm horn will emit a different tone.

NOTE: A specific parameter identification number (P _ _ _ ) can


also be selected by the technician to be shown on the display. If
no change is noticed when a circuit is activated, an input fault is
present. Troubleshoot that portion of the circuit. Ensure that all
potentiometers have a smooth transition of digits throughout the
range of values.

AREA/HR SPEED

AREA PTO RPM

% SLIP ENG HR

SET UP START

SELECT STOP
E/M

Fig. 2.5.23

After entering Mode 3 and moving the shift control lever to the left
(downshift), the technician should observe the following:
a. The alarm horn will emit an audible tone, which indicates
that an input component has changed state.
b. The display will show "P109" to identify the downshift input
as the component that changed state.
c. The display will show "Hi," which indicates that the voltage
at the downshift input of the module is +12 Volts.

NOTE: The engine must be cranking to perform the input


diagnostics for parameter number P108. The ECM must receive
an engine speed signal before the input component will change
state. Disconnecting the fuel solenoid will allow the engine to
crank without starting.
Unit 2 2-5-32 Machine Specific
Lesson 5

AREA/HR SPEED

AREA PTO RPM

% SLIP ENG HR

SET UP START

SELECT STOP
E/M

Fig. 2.5.24

After entering Mode 3 and turning the draft sensitivity knob


(potentiometer), the technician should observe the following:
a. The alarm horn will emit an audible tone, which indicates
that an input component has changed state.
b. the display will show "P121" to identify the draft sensitivity
input as the component that changed state.
c. The display will show a two-digit value, for example "64,"
which indicates that the potentiometer (in the present
position) is at 64% of full scale.
Unit 2 2-5-33 Machine Specific
Lesson 5

PROCEDURE TO USE MODE 3

AREA/HR SPEED

AREA PTO RPM

% SLIP ENG HR

SET UP START

SELECT STOP
E/M

Fig. 2.5.25

1. Enter the All Module Input Diagnostic Mode (Mode 3):


a. Turn the key start switch from OFF to ON.
b. Press and hold the "Setup/Select" key for three seconds.
c. Press the "Digit Set" key until the display shows "_ _ _ 3."
d. Press and hold the "Setup/Select" key for three seconds to
enter Mode 3. The display will show the parameter
identifier that was viewed when Mode 3 was last exited.

2. The technician can now operate any switch, sensor or


potentiometer to determine if it is functional.
3. To check a specific input component, determine the desired
parameter identification number.
4. Press the "Setup/Select" key. The display will show "P000" with
the first "0" flashing.
5. Enter the desired parameter identification number on the display.
The value of each digit is changed individually. The flashing
digit identifies the digit to be changed. Pressing the "Digit Set"
key increases the numerical value of the flashing digit. Pressing
the "Digit Select" key causes the next digit to flash, which can be
set with the "Digit Set" key.
6. With the desired parameter identification number showing on the
display, activate the circuit. No other switches, senders or
potentiometers will change the display while a specific parameter
identification number is selected.
Unit 2 2-5-34 Machine Specific
Lesson 5

7. To re-select the automatic parameter selection, press the


"Setup/Select" key. To return to the single parameter selection,
again press the "Setup/Select" key. (Pressing the "Setup/Select"
key toggles the operation back and forth between automatic and
single parameter selection.)
8. To return the EMC to Service Mode selection, press the
"Exit/Mode" key once. To return the EMC to normal operation,
press the "Exit/Mode" key twice.

MODE 4
EMC OUTPUT DIAGNOSTICS

AREA/HR SPEED

AREA PTO RPM PARAMETER IDENTIFICATION

ID NO. DESCRIPTION
% SLIP ENG HR
P250 Work Lamp 1 Driver: Front/Mid Side Lamps
P251 Work Lamp 1 Driver: Rear Lower Lamps
P252 Work Lamp 1 Driver: Rear Upper Lamps
SET UP START
P253 Work Lamp 1 Driver: Front Upper Lamps
SELECT STOP
E/M P254 Alarm Horn

Fig. 2.5.26

Mode 4: EMC Output Diagnostics

In this mode, the technician can check the output components of the
Electronic Monitoring Center (EMC) without using additional testing
equipment. The technician selects an output component, and the
display area of the MPM will indicate if the component is
functioning. The technician can turn the output component ON and
OFF. All EMC output components are assigned a unique four-digit
parameter identification number (P _ _ _ ).
When an output component is selected, the actual status of the
component at the EMC is shown on the display.
"Hi" indicates that the output component is ON.
"Lo" indicates that the output component is OFF.
"Hi" and "Lo" indicate only that the EMC is providing the ON or
OFF signals for the output component. The technician must confirm
that the output component is actually turning ON and OFF. If, during
troubleshooting, it is found that an output does turn ON and OFF,
then the corresponding input circuit is probably at fault.
Unit 2 2-5-35 Machine Specific
Lesson 5

Procedure to use Mode 4:


1. Enter the EMC Output Diagnostics Mode (Mode 4):
a. Turn the key start switch from OFF to ON.
b. Press and hold the "Setup/Select" key for three seconds.
c. Press the "Digit Set" key until the display shows "_ _ _ 4."
d. Press and hold the "Setup/Select" key for three seconds to
enter Mode 4.

2. Determine the parameter identification number of the output


component to be checked. Press and release the "Digit Set" key
until the desired parameter identification number shows on the
display.
3. Press the "Start/Stop/Reset" key to turn the output component ON
or OFF.
4. To return the EMC to Service Mode selection, press the
"Exit/Mode" key once. To return the EMC to normal operation,
press the "Exit/Mode" key twice.
NOTE: If a short circuit exists when an output component is
ON, the selected parameter identification number on the display
changes to fault code F201. The F201 fault code is only shown
when the component is ON.
Unit 2 2-5-36 Machine Specific
Lesson 5

MODE 5
RHC OUTPUT DIAGNOSTICS

AREA/HR SPEED

AREA PTO RPM


PARAMETER IDENTIFICATION

ID NO. DESCRIPTION
% SLIP ENG HR
P152 PTO Status Lamp Driver
P153 3-Point Hitch Status Lamp Driver

SET UP START

SELECT STOP
E/M

Fig. 2.5.27

Mode 5: RHC Output Diagnostics

In this mode, the technician can check the output components of the
Right Hand Control (RHC) module without using additional testing
equipment. The technician selects an output component, and the
display area of the MPM will indicate if the component is
functioning. The technician can turn the output component ON and
OFF. All RHC output components are assigned a unique four-digit
parameter identification number (P _ _ _ ).
When an output component is selected, the actual status of the
component at the RHC is shown on the display.
"Hi" indicates that the output component is ON.
"Lo" indicates that the output component is OFF.
As previously stated, the "Hi" and "Lo" indicate only that the RHC is
providing the ON or OFF signals for the output component. The
technician must confirm that the output component is actually turning
ON and OFF. If, during troubleshooting, an output component does
turn ON and OFF, the corresponding input circuit probably is at fault.
Unit 2 2-5-37 Machine Specific
Lesson 5

Procedure to use Mode 5:


1. Enter the RHC Output Diagnostics Mode (Mode 5):
a. Turn the key start switch from OFF to ON.
b. Press and hold the "Setup/Select" key for three seconds.
c. Press the "Digit Set" key until the display shows "_ _ _ 5."
d. Press and hold the "Setup/Select" key for three seconds to
enter Mode 5.
2. Determine the parameter identification number of the output
component to be checked. Press and release the "Digit Set" key
until the desired parameter identification number shows on the
display.
3. Press the "Start/Stop/Reset" key to turn the output component ON
or OFF.
4. To return the EMC to Service Mode selection, press the
"Exit/Mode" key once. To return the EMC to normal operation,
press the "Exit/Mode" key twice.
Unit 2 2-5-38 Machine Specific
Lesson 5

MODE 6
CCM DRAFT CONTROL OUTPUT DIAGNOSTICS

AREA/HR SPEED

AREA PTO RPM PARAMETER IDENTIFICATION

ID NO. DESCRIPTION
% SLIP ENG HR P050 3-Point Raise Solenoid Driver
P051 3-Point Lower Solenoid Driver

SET UP START

SELECT STOP
E/M

Fig. 2.5.28

Mode 6: CCM Draft Control Output Diagnostics

In this mode, the technician can check the draft control output
components of the Chassis Control Module (CCM) without using
additional testing equipment. The technician selects an output
component, and the display area of the MPM will indicate if the
component is functioning. The technician can turn the output
component ON and OFF. All CCM draft control output components
are assigned a unique four-digit parameter identification number
(P _ _ _ ).
When an output component is selected, the actual status of the
component at the CCM is shown on the display.
"Hi" indicates that the output component is ON.
"Lo" indicates that the output component is OFF.
Procedure to use Mode 6:
1. Enter the CCM Draft Control Output Diagnostics Mode
(Mode 6):
a. Turn the key start switch from OFF to ON.
b. Press and hold the "Setup/Select" key for three seconds.
c. Press the "Digit Set" key until the display shows "_ _ _ 6."
d. Press and hold the "Setup/Select" key for three seconds to
enter Mode 6.
Unit 2 2-5-39 Machine Specific
Lesson 5

2. Determine the parameter identification number of the output


component to be checked. Press and release the "Digit Set" key
until the desired parameter identification number shows on the
display.
3. Press the "Start/Stop/Reset" key to turn the output component ON
or OFF.
4. To return the EMC to Service Mode selection, press the
"Exit/Mode" key once. To return the EMC to normal operation,
press the "Exit/Mode" key twice.

MODE 7
CCM TRANSMISSION CONTROL
OUTPUT DIAGNOSTICS

AREA/HR SPEED

AREA PTO RPM

% SLIP ENG HR

SET UP START

SELECT STOP
E/M

Fig. 2.5.29

Mode 7: CCM Transmission Control Output Diagnostics

In this mode, the technician can check the transmission control output
components of the Chassis Control Module (CCM) without using
additional testing equipment. The technician selects an output
component, and the display area of the MPM will indicate if the
component is functioning. The technician can turn the output
component ON and OFF. All CCM transmission control output
components are assigned a unique four-digit parameter identification
number (P _ _ _ ).
When an output component is selected, the actual status of the
component at the CCM is shown on the display.
"Hi" indicates that the output component is ON.
"Lo" indicates that the output component is OFF.
Unit 2 2-5-40 Machine Specific
Lesson 5

Procedure to use Mode 7:


1. Enter the CCM Transmission Control Output Diagnostics Mode
(Mode 7):
a. Turn the key start switch from OFF to ON.
b. Press and hold the "Setup/Select" key for three seconds.
c. Press the "Digit Set" key until the display shows "_ _ _ 7."
d. Press and hold the "Setup/Select" key for three seconds to
enter Mode 7.

2. Determine the parameter identification number of the output


component to be checked. Press and release the "Digit Set" key
until the desired parameter identification number shows on the
display.
3. Press the "Start/Stop/Reset" key to turn the output component ON
or OFF.
4. To return the EMC to Service Mode selection, press the
"Exit/Mode" key once. To return the EMC to normal operation,
press the "Exit/Mode" key twice.
NOTE: The transmission shift lever must be in the proper gear
position to test these parameters.
Unit 2 2-5-41 Machine Specific
Lesson 5

MODE 8
EMC LAMP TEST

INTERCOOLER TRANS TEMP PRG


ALTERNATOR TRANS PRESS
COOL LEVEL FILTERS
COLD START PTO ON UP-SHIFT
AIR FILTER

DOWN-SHIFT

TRAILER BRAKE

1
TRACK TENSION
TRAILER 1 GEAR
2
TRAILER 2

FUEL LEVEL ENG OIL PRESS COOLANT TEMP TRANS TEMP

3 n/min RPM AREA/HR SPEED


4 4

1
2
SERVICE 1000
3 PTO AREA PTO RPM

MPH AREA ON %SLIP 1000


HOUR OFF ALARM PTO
1
km/h IMP WIDTH CAL % SLIP ENG HR

2 DIST FT METERS VOLTS

SET UP START
1 PANEL DIM SYSTEM STATUS P
SELECT STOP
E/M

Fig. 2.5.30

Mode 8: EMC Lamp Test

In this mode, the technician can check each alert indicator and
display segment of the EMC. When this mode is selected, the EMC
will light each alert indicator in succession. Also, all segments of the
bar graphs, Central Display and the MPM will be shown
simultaneously or individually.
Procedure to use Mode 8:
1. Enter the EMC Lamp Test Mode (Mode 8):
a. Turn the key start switch from OFF to ON.
b. Press and hold the "Setup/Select" key for three seconds.
c. Press the "Digit Set" key until the display shows"_ _ _ 8."
d. Press and hold the "Setup/Select" key for three seconds to
enter Mode 8.
2. The alert indicators will start to illuminate individually and all
segments of the bar graphs, Central Display Area and the
Machine Performance Panel should be ON.
3. To view each segment of the bar graphs, Central Display Area and
the Machine Performance Panel individually, press the
"Setup/Select" key. Each segment will turn OFF and turn back
ON until all the segments have been tested. The bar graphs will
cycle first, followed by the Central Display and then the MPM.
Unit 2 2-5-42 Machine Specific
Lesson 5

4. To return the EMC to the Service Mode selection, press the


"Exit/Mode" key once. To return the EMC to normal operation,
press the "Exit/Mode" key twice.
NOTE: The left digit of the hourmeter display consists of two
segments which act as one segment. These two segments turn
OFF and ON simultaneously.

MODE 9
HARDWARE / SOFTWARE
REVISION LEVEL

AREA/HR SPEED

AREA PTO RPM

% SLIP ENG HR

SET UP START

SELECT STOP E/M

Fig. 2.5.31

Mode 9: Hardware/Software Revision Level

In this mode, the technician can sequentially view important


information regarding the electronic control modules on the machine.
Three items of information are shown for each module. The items of
information are:
- Hardware revision level
- Software revision level
- Serial number of the machine in which the module was
originally installed
Unit 2 2-5-43 Machine Specific
Lesson 5

MODE 9
HARDWARE / SOFTWARE
REVISION LEVEL

n/min RPM
AREA/HR SPEED

AREA PTO RPM

% SLIP ENG HR

SET UP START

SELECT STOP E/M

Fig. 2.5.32

The electronic control modules and circuits are:


- Electronic Monitoring Center (EMC)
- Electronic draft control circuits of the Chassis Control Module
(CCM)
- Electronic transmission control circuits of the Chassis Control
Module (CCM)
- Right Hand Control (RHC) module
The engine speed display area shows a four-character code that
represents the electronic control module and the item of information.
The first three characters identify the electronic module that is
selected. The last character identifies the information item ("h" for
hardware, "s" for software and "b" for serial number) that is selected.
The Hardware and Software Revision Levels are shown on the
hourmeter.
The machine serial number has six digits. Both the hourmeter and
the display are used to show the machine serial number. The first
three digits of the machine serial number preceded by the letter "d"
are shown on the hourmeter. The last three digits of the machine
serial number are shown on the display. The first two digits of the
machine serial number identify the sales model. The last four digits
of the machine serial number identify the actual serial number. For
example: "d451 567" identifies a Challenger 45 with Serial Number
1567. If a module has been replaced, the value "_ _ _ _ " for the
machine serial number is shown on the display.
Unit 2 2-5-44 Machine Specific
Lesson 5

Procedure to use Mode 9:


1. Enter the Hardware/Software Revision Level Mode (Mode 9):
a. Turn the key start switch from OFF to ON.
b. Press and hold the "Setup/Select" key for three seconds.
c. Press the "Digit Set" key until the display shows "_ _ _ 9."
d. Press and hold the "Setup/Select" key for three seconds to
enter Mode 9.

2. After entering Mode 9, information is immediately shown on the


engine speed display and the hourmeter. To view the different
items of information, repeatedly press the "Setup/Select" key.
The EMC will cycle through the items of information.
3. To return the EMC to the Service Mode selection, press the
"Exit/Mode" key once. To return the EMC to normal operation,
press the "Exit/Mode" key twice.

MODE 10
TRANSMISSION CALIBRATION REVIEW
AND PROGRAMMING

AREA/HR SPEED

AREA PTO RPM

% SLIP ENG HR

SET UP START

SELECT STOP E/M

Fig. 2.5.33

Mode 10: Transmission Calibration Review And Programming


In this mode, the operator or technician can view the calibration
values for the clutch packs, change the reverse shuttle selections, and
change the programmable upshift and downshift constants.
The available functions are:
C1: The identifier for the low range directional clutch (F1).
C2: The identifier for the high range directional clutch (F2).
C3: The identifier for the reverse directional clutch (REV).
Unit 2 2-5-45 Machine Specific
Lesson 5

The calibration numbers for the C1, C2 and C3 functions are for
viewing only. The possible values are 21 to 99. Mode 10 is not used
to program these functions.
C4: The identifier for the forward to reverse shuttle shift offset. The
possible values are 3, 2, 1, 0, -1, -2, -3 and L. The offset value
determines the gear difference when shifting from forward to reverse.
When the shift control lever is moved from forward to reverse and
the offset value is 0, the machine will engage the same reverse gear
as was selected in forward travel. With an offset value of 2, the
machine will engage a reverse gear two gears higher than the forward
gear that was engaged. With an offset value of -3, the machine will
engage a reverse gear three gears lower than the forward gear that
was engaged. An offset value of L will cause the machine to always
engage R3 (reverse low).
C5: The identifier for the upshift constant used with the
programmable upshift and downshift feature. The possible values are
0, 1, 2 and 3. The upshift constant determines the number of gears to
which the machine will automatically upshift when the programmable
upshift feature is activated by the operator.
C6: The identifier for the downshift constant used with the
programmable upshift and downshift feature. The possible values are
0, 1, 2 and 3. The downshift constant determines the number of gears
to which the machine will automatically downshift when the
programmable downshift feature is activated by the operator.
C7: The identifier for the upshift constant used to "fine tune" the F9
to F10 transmission upshift. The possible values are from 1 to 19.
The value of the upshift constant determines the fill time of the F2
high range clutch.
C8: The identifier for the downshift constant used to "fine tune" the
F8 to F7 transmission downshift. The possible values are from 1 to
19. The value of the downshift constant determines the fill time of
the F1 low range clutch.
Always adjust the C7 or C8 constant by three or more digits to ensure
that the shift quality is noticeably better or worse than the previous
number. The machine must be operated after every adjustment to
evaluate the shift quality. If the machine shift is better, the digits may
be adjusted individually to "fine tune" the shift. If the shift is worse,
change the number by six digits in the opposite direction to improve
the shift. Make sure that the new number is saved after each
adjustment.
This adjustment should be performed only during field conditions
with the oil at normal operating temperature. Cold oil will adversely
affect the transmission shifts.
Unit 2 2-5-46 Machine Specific
Lesson 5

Procedure to use Mode 10:


1. Enter the Transmission Calibration Review and Programming
Mode (Mode 10):
a. Turn the key start switch from OFF to ON.
b. Press and hold the "Setup/Select" key for three seconds.
c. Press the "Digit Set" key until the display shows "_ _ 10."
d. Press and hold the "Setup/Select" key for three seconds to
enter Mode 10.

2. After entering Mode 10, information is immediately shown on the


MPM displays. The upper display shows the function identifier
(C1 to C8). The lower display shows the current value of the
function. To view the different functions (C1 to C8), repeatedly
press the "Setup/Select" key. The EMC will cycle through the
functions.
3. Select the function identifier (C1 to C8). Repeatedly press the
"Setup/Select" key until the desired function identifier is showing
on the display. The present value of the function is shown on the
display.
4. Changing (programming) the value of a selected function is done
in the following manner: each digit of the value showing on the
display is changed individually. The flashing digit identifies the
digit to be changed. Pressing the "Digit Set" key increases the
numerical value of the flashing digit. Pressing the "Digit/Select"
key causes the next digit to flash, and it can be set with the "Digit
Set" key.
5. To save a new (just entered) value shown on the display, press
and hold the "Setup/Select" key for three seconds. The value is
entered into memory, and the display advances to the next
function.
6. To return the EMC to the Service Mode selection, press the
"Exit/Mode" key once. To return the EMC to normal operation,
press the "Exit/Mode" key twice.
Unit 2 2-5-47 Machine Specific
Lesson 5

MODE 11
THREE-POINT HITCH STATUS AND CALIBRATION

AREA/HR SPEED

AREA PTO RPM

% SLIP ENG HR

SET UP START

SELECT STOP E/M

Fig. 2.5.34

Mode 11: Three-Point Hitch Status and Calibration


In this mode, certain functions of the three-point hitch can be viewed,
and the three-point hitch can be calibrated. This mode allows the
technician to:
a. Evaluate the performance while operating in the field.
b. Recalibrate the three-point hitch if any components
(including the CCM) have been repaired or replaced or if a
F024 fault has occurred.
Functions H1 through H4 allow the technician to evaluate the
performance of the three-point hitch while the machine is in
operation. Functions H5 and H6 are part of the three-point hitch
calibration procedure.
Mode 11 can be entered with or without the engine running. If
operating the machine while viewing the functions is desired, start the
engine prior to entering Mode 11.
Unit 2 2-5-48 Machine Specific
Lesson 5

Procedure to View the Three-Point Hitch Status:


This procedure is only for the viewing of the three-point hitch
functions (H1 to H6).
1. Enter the Three-Point Hitch Status and Calibration Mode
(Mode 11):
a. Turn the key start switch from OFF to ON or start the
engine.
b. Press and hold the "Setup/Select" key for three seconds.
c. Press the "Digit Set" key until the display shows "_ _ 1 1."
d. Press and hold the "Setup/Select" key for three seconds to
enter Mode 11.
2. After entering Mode 11, information is immediately shown on the
upper and lower displays of the MPM. The upper display shows
the function identifier (H1 to H6). The lower display shows the
current value of the function. To view the different functions (H1
to H6), repeatedly press the "Setup/Select" key. The EMC will
cycle through the functions.
3. Select the desired function identifier (H1 to H6). Repeatedly
press the "Setup/Select" key until the desired function identifier
shows on the display. The present value of the function is also
shown on the display.
4. Operate the machine while viewing the value of the selected
function. Use the information gathered to evaluate the
performance.
5. To return the EMC to the Service Mode selection, press the
"Exit/Mode" key once. To return the EMC to normal operation,
press the "Exit/Mode" key twice.
Procedure to Calibrate the Three-Point Hitch:
The following procedure must be performed to clear a F024 fault
code.
1. Push the three-point position control lever fully FORWARD.
2. Turn the position/draft sensitivity knob (if equipped) fully
counterclockwise to the POSITION CONTROL position.
3. Turn the height limit control knob fully clockwise to the
MAXIMUM HEIGHT position.
4. Ensure that the raise work switch is in the LOWER position.
5. ENGAGE the parking brake.
6. Start and run the engine at LOW IDLE. The key start switch
must be in the ON position.
Unit 2 2-5-49 Machine Specific
Lesson 5

NOTE: Three-Point Hitch Calibration is best performed without


implements or the quick-hitch coupler installed. Any condition
which prevents the hitch from obtaining full travel will prevent a
proper calibration of the hitch.

MODE 11
THREE-POINT HITCH STATUS AND CALIBRATION

AREA/HR SPEED

AREA PTO RPM

% SLIP ENG HR

SET UP START

SELECT STOP E/M

Fig. 2.5.35

7. Enter the Three-Point Hitch Status and Calibration Mode


(Mode 11):
a. Press and hold the "Setup/Select" key for three seconds.
b. Press the "Digit Set" key until the display shows "_ _ 1 1."
c. Press and hold the "Setup/Select" key for three seconds to
enter Mode 11.
Unit 2 2-5-50 Machine Specific
Lesson 5

AREA/HR SPEED

AREA PTO RPM

% SLIP ENG HR

SET UP START

SELECT STOP E/M

Fig. 2.5.36
8. After entering Mode 11, information is immediately shown on the
display. The "Hitch Disabled" symbol, the function identifier H1
(hitch raise solenoid threshold), and the current value for H1 in
milliamps will be showing on the display.

AREA/HR SPEED

AREA PTO RPM

% SLIP ENG HR

SET UP START

SELECT STOP
E/M

Fig. 2.5.37
9. Repeatedly press the "Setup/Select" key until the H5 function
identifier is showing on the display. H5 is the Memory Reset
function.
10. With H5 showing on the display, press and hold the "Setup/Select"
key for three seconds until a "beep" is heard ("H6" with a "2" will
be briefly shown). The display will then briefly flash "EE" to
indicate that the calibration values have been cleared from memory.
The display will then return to showing H5.
Unit 2 2-5-51 Machine Specific
Lesson 5

AREA/HR SPEED

AREA PTO RPM

% SLIP ENG HR

SET UP START

SELECT STOP
E/M

Fig. 2.5.38

11. This step allows the electronic control modules to establish the
limits of the rockshaft potentiometer and the three-point lever
position potentiometer. The engine must be running and the
hydraulic system must be operational.
a. Slowly move the three-point position control lever rearward
to the FULL RAISE position. This movement captures the
hitch and raises it to the top. Make sure that the lever is
fully to the rear of the slot. The upper limit of the
potentiometer is now established.
b. Move the three-point position control lever fully forward and
hold the lever fully forward for a minimum of 30 seconds.
This movement LOWERS the hitch linkage the maximum
distance. The lower limit of the potentiometer is now
established.

12. This step determines the thresholds of the three-point raise and
three-point lower solenoids.
a. Pull the three-point position control lever fully rearward.
b. Press the "Setup/Select" key until the H6 function identifier
is showing on the display. H6 is the Calibration Status
function.
c. Move the three-point position control lever forward
approximately 19 mm (.75 in.) to LOWER the hitch slightly.
Unit 2 2-5-52 Machine Specific
Lesson 5

AREA/HR SPEED

AREA PTO RPM

% SLIP ENG HR

SET UP START

SELECT STOP
E/M

Fig. 2.5.39
d. Observe the hitch moving a short distance. The hitch will
automatically cycle up and down three times to find the threshold
of the raise and lower solenoids. From one to four minutes are
required to complete the three cycles. After three complete raise
and lower cycles, "H6" and "9" will be shown. The "9" indicates
that the calibration process is complete. The thresholds of the
three-point raise and three-point lower solenoids are now
established.

AREA/HR SPEED

AREA PTO RPM

% SLIP ENG HR

SET UP START

SELECT STOP
E/M

Fig. 2.5.40
13. Press the "Exit/Mode" key twice. The MPM will return to a
normal display. The hitch enable symbol and the relative position
of the hitch will be shown on the display. While the EMC appears
to have exited Mode 11 by returning to the normal display, the
EMC is still in Mode 11.
Unit 2 2-5-53 Machine Specific
Lesson 5

AREA/HR SPEED

AREA PTO RPM

% SLIP ENG HR

SET UP START

SELECT STOP
E/M

Fig. 2.5.41

14. Verify the Hitch Calibration:


a. Push the three-point position control lever fully forward.
Observe that the hitch lift cylinders fully retract.
b. Move the three-point position control lever to the center of the
slot. A value between 25% and 60% should show on the
display.
If either of the above checks cannot be obtained, the hitch calibration
must be repeated. Stop the engine for a minimum of 10 seconds, and
repeat Steps 1 through 15.
15. To save the calibration, turn the key start switch OFF. Wait a
minimum of 10 seconds before restarting the engine.
Unit 2 2-5-54 Machine Specific
Lesson 5

MODE 12
MACHINE FEATURES
CONFIGURATION

n/min RPM
AREA/HR SPEED

AREA PTO RPM

% SLIP ENG HR

SET UP START

SELECT STOP E/M

Fig. 2.5.42

Mode 12: Machine Features Configuration

This mode is used to reconfigure the electronic control modules to


match the features of the machine. For the electronic system to
function correctly, the electronic control modules must be told what
the features or options are. Mode 12 must be used when an
electronic control module has been replaced or an additional option
has been added.
This mode allows the technician to view or change (program) the
value of certain machine features. The engine speed display shows
an identifier that numerically represents the feature. The hourmeter
shows the value of the selected feature.
Procedure to use Mode 12:
1. Enter the Machine Features Configuration Mode (Mode 12):
a. Turn the key start switch from OFF to ON.
b. Press and hold the "Setup/Select" key for three seconds.
c. Press the "Digit Set" key until the display shows "_ _ 1 2."
d. Press and hold the "Setup/Select" key for 15 seconds to enter
Mode 12. Several "beeps" may be heard, but continue to
press the key until the display changes.

2. After entering Mode 12, information is immediately shown on the


displays. The engine speed display shows the feature identifier
selected. The present value of the feature shows on the
hourmeter. To view the different features, repeatedly press the
"Setup/Select" key. The EMC will cycle through the features.
Unit 2 2-5-55 Machine Specific
Lesson 5

3. Changing (programming) the value of a feature is done in the


following manner: repeatedly press the "Setup/Select" key until
the desired feature identifier shows on the engine speed display.
Press the "Digit Set" key to change the value shown on the
hourmeter. Make the necessary changes to the desired feature.
4. To save all the new (just entered) values, press and hold the
"Setup/Select" key for three seconds. The value is then entered
into memory.
5. To return the EMC to the Service Mode selection, press the
"Exit/Mode" key once. To return the EMC to normal operation,
press the "Exit/Mode" key twice.
NOTE: Fault code F205 may be flashing on the display. Two
conditions may cause this fault code:
1. An electronic control module has been replaced.
Communication must be initiated between the different
electronic control modules on the machine. Saving a value
for any feature of Mode 12 initiates the communication.
2. An incorrect value of a feature has been previously saved.
Check all the features and correct the values where
necessary. When the new value is saved, the F205 fault
code will stop flashing.
Fault code F205 will flash when a new value for a feature is
selected. It will clear when the new value is saved in memory and
the electronic control modules (CCM, RHC and EMC) agree.
NOTES
Unit 2 1 Machine Specific
Student Handout 2.5.1

Student Handout: 2.5.1


FUEL LEVEL SPECIFICATIONS
Bars Displayed Fuel Reserve Sensor Resistance
On Bar Graph Percent (%) Ohms (± 5%)
20 Full 22
19 95 44
18 90 66
17 85 88
16 80 110
15 75 132
14 70 154
13 65 176
12 60 198
11 55 220
10 50 242
9 45 264
8 40 286
7 35 308
6 30 330
5 25 352
4 20 374
3 15 396
2 10 418
1 5 440
NOTES
Unit 2 2 Machine Specific
Student Handout 2.5.2

Student Handout: 2.5.2


ENGINE COOLANT TEMPERATURE
SPECIFICATIONS
Bars Displayed Temperature Sensor Resistance
On Bar Graph °C1 (°F2) Ohms (±10%)
20 > 115 (240) < 160
19 113 (235) 163
18 110 (230) 170
17 107 (225) 183
16 104 (220) 193
15 102 (215) 205
14 99 (210) 223
13 96 (205) 235
12 93 (200) 250
11 91 (195) 270
10 88 (190) 290
9 85 (185) 313
8 82 (180) 334
7 79 (175) 358
6 77 (170) 388
5 74 (165) 420
4 71 (160) 458
3 68 (155) 505
2 66 (150) 543
1 < 66 (150) > 560
1 The tolerance for Celsius degrees is +1.5 and -0.
2 The tolerance for Fahrenheit degrees is +5.0 and -0.

WARNING SPECIFICATIONS 1
Bars Displayed Pressure Limit Engine Speed
On Bar Graph kPa (psi) RPM
4 < 55 (8.0) 500 - 1500
7 < 110 (16) 1500 - 2000
8 < 165 (24) 2000 - 3000

1This chart lists the pressure and speed requirements necessary


for the EMC to declare a critical alarm.
The bar graph will flash, the word STOP will appear, the alarm horn
will be continuously activated and the engine will automatically
shutdown within 30 seconds.
NOTES
Unit 2 3 Machine Specific
Student Handout 2.5.3

Student Handout: 2.5.3


ENGINE COOLANT TEMPERATURE
SPECIFICATIONS
Bars Displayed Temperature Sensor Resistance
On Bar Graph °C1 (°F2) Ohms (±10%)
20 > 115 (240) < 160
19 113 (235) 163
18 110 (230) 170
17 107 (225) 183
16 104 (220) 193
15 102 (215) 205
14 99 (210) 223
13 96 (205) 235
12 93 (200) 250
11 91 (195) 270
10 88 (190) 290
9 85 (185) 313
8 82 (180) 334
7 79 (175) 358
6 77 (170) 388
5 74 (165) 420
4 71 (160) 458
3 68 (155) 505
2 66 (150) 543
1 < 66 (150) > 560
1 The tolerance for Celsius degrees is +1.5 and -0.
2 The tolerance for Fahrenheit degrees is +5.0 and -0.
NOTES
Unit 2 4 Machine Specific
Student Handout 2.5.4

Student Handout: 2.5.4


TRANSMISSION OIL TEMPERATURE
SPECIFICATIONS
Bars Displayed Temperature Sensor Resistance
On Bar Graph °C1 (°F2) Ohms
20 ≥ 107 (224) ≤ 185
19 105 (221) 191
18 103 (218) 198
17 102 (215) 205
16 100 (212) 216
15 98 (209) 225
14 97 (206) 233
13 95 (203) 241
12 93 (200) 250
11 90 (194) 274
10 87 (188) 299
9 83 (182) 326
8 80 (176) 353
7 77 (170) 388
6 73 (164) 428
5 70 (158) 477
4 67 (152) 528
3 63 (146) 573
2 60 (140) 619
1 < 60 (140) > 619
1 The tolerance for Celsius degrees is +1.5 and -0.
2 The tolerance for Fahrenheit degrees is +5.0 and -0.
NOTES
Unit 2 5 Machine Specific
Student Handout 2.5.5

Type of Alarm 3

Student Handout: 2.5.5


Function Monitored Description
Air Filter Non-Critical During normal machine operation, switch is open. Alarm triggers when switch
Restriction closes to 5-Volt supply: Water vacuum is 635 mm (25 in.) or greater.
Alternator Charging Non-Critical Varying voltage signal from alternator. Alarm triggers when voltage is:
Improper 11 Volts or less = indicator ON continuously
16 Volts or greater = indicator FLASHES
Coolant Level Low Non-Critical Proximity sensor (5-Volt supply). Low resistance with coolant present, high
w/Alarm resistance w/o coolant.
Coolant Temperature Critical Varying resistance signal from resistance sensor (5-Volt supply). High resistance
High w/Shutdown low temp., low resistance high temp. Room temp. resistance is approx. 2500 ohms.
Alarm triggers when resistance is 163 ohms or less, value corresponds to 112°C
(235°F), or infinite open circuit.
Aftercooler Non-Critical Varying resistance signal from resistance sensor (5-Volt supply). High resistance
Temperature High low temp., low resistance high temp. Alarm triggers when resistance is low:
Value corresponds to 82°C (180°F), or greater.
Engine Oil Pressure Critical Varying voltage signal from pressure sensor (5-Volt supply). Alarm triggers when
Low w/Shutdown voltage value corresponds to:
Approx. 1.7V = 55 kPa (8 psi) or less, with engine rpm from 500 to 1500.
Approx. 2.0V = 110 kPa (16 psi) or less, with engine rpm from 1500 to 2000.
Approx. 2.3V = 165 kPa (24 psi) or less, with engine rpm from 2000 to 3000.
Transmission Oil Critical Varying resistance signal from resistance sensor (5-Volt supply). High resistance
Temperature High w/Shutdown low temp., low resistance high temp. Room temp. resistance is approx. 2500 ohms.
Alarm triggers when resistance is 185 ohms or less, value corresponds to 107°C
(224°F), or infinite open circuit.
Transmission Oil Critical During normal machine operation, switch is open. Alarm triggers when switch
Pressure Low w/Shutdown closes to 12V: 830 kPa (120 psi) or less.

Filter Bypass:

Transmission Filter Non-Critical During normal machine operation, switch is closed to 12V.
Alarm triggers when switch opens: 2 276 kPa (40 psi) or greater.
Pressure High
Pressure must be less than 170 kPa (25 psi) to reset alarm.
Implement Filter Non-Critical During normal machine operation, switch is closed to 12V.
Pressure High Alarm triggers when switch opens: 2 138 kPa (20 psi) or greater.
Pressure must be less than 60 kPa (8.7 psi) to reset alarm.
Steering Filter Critical During normal machine operation, switch is closed to 12V.
Pressure High w/Shutdown 1 Alarm triggers when switch opens: 2 138 kPa (20 psi) or greater.
Pressure must be less than 60 kPa (8.7 psi) to reset alarm.
Fuel Level Low Non-Critical Varying resistance signal from resistance sensor (5-Volt supply). Resistance goes
up as fuel level goes down. Alarm triggers when resistance is approximately
418 ohms (10% volume of tank) or greater.
Track Tension Low Non-Critical During normal machine operation, limit switch is closed to 12V. Alarm triggers
(Right or Left) w/Alarm when limit switch opens; load is approximately 30200 N (6700 lb) or less
PTO Overspeed Non-Critical The PTO speed is calculated from engine rpm at 1.9 to 1 ratio. Alarm triggers when
speed is greater than 1152 rpm.
3-Pt Rockshaft Pot,
Inching Pedal Pot,
3-Pt Lever Pos. Pot, Other 5-Volt Systems
Drop Rate Pot,
Height Limit Pot,
Sensitivity Pot
Draft Pin Sensors: 8-Volt System
Right and Left
Solenoid: Trans Clutch 8-Volt System
Operates on 100 Hz PWM at 67% duty cycle. Will drop 6.5 Volts across solenoid.
Solenoid: 8-Volt System
Trans Modulating Operates on 400 Hz PWM at variable duty cycle and voltage.
Solenoid: 8-Volt System
3-Pt Hitch Operates on 500 Hz PWM at variable duty cycle and voltage.
Solenoid: 12-Volt System
Steering Reversal

1 Condition exists for 90 seconds before auto shutdown occurs.


2 The alarm is triggered but the event is not recorded unless the operating temperature is normal.
3 Condition exists for 8 seconds before alarm or shutdown occurs.
NOTES
Unit 2 6 Machine Specific
Student Handout 2.5.6

Student Handout: 2.5.6


3-Point Hitch and Electronic Draft Functions 3-Point Hitch and Electronic Draft Functions
ID No. Description ID No. Description
P001 Right Draft Pin P300 Radar Speed Sensor
P002 Left Draft Pin P301 2 Transmission Speed Sensor
P003 Rockshaft Potentiometer P302 2 Unassigned
P303 2 Unassigned
Right Control
ID No. Description
Right Control
P106 PTO Start/Stop
ID No. Description
P107 Transmission Enable Engine Coolant Temperature
P400
P108 Neutral P401 Engine Oil Pressure
P109 Downshift P402 Fuel Level
P110 Upshift P405 Transmission Oil Temperature
P111 Reverse P406 Coolant Level
P112 Forward P407 Transmission/Implement Oil Filter
P113 Programmable Downshift P408 Steering Filter
P114 Programmable Upshift P409 Engine Air Filter
P115 Autoshift P410 Transmission Oil Pressure
P119 Work Switch P411 Radar Sense
P120 Raise Switch P412 Seat Switch
P121 3 Sensitivity Potentiometer P413 Remote Implement Status
P122 3 Drop Rate Potentiometer
1 Depending upon the version of software, other
P123 3 Height Limit Potentiometer
parameter ID numbers may appear. Any parameter
P125 3 3-Point Lever Position Potentiometer ID No. that appears on the readout but is not listed
in this chart is not significant and can be ignored.
Electronic Monitoring Center (EMC)
ID No. Description 2 This parameter is only accessible with the Cat ET
P201 Work Lamp Sense Service Tool.
P203 Service Brake 3 The value for setting this potentiometer can only
P204 Park Brake be found in the corresponding fault code chart.
P205 Fender 3PT Raise
P206 Fender 3PT Lower
P207 Main Beam
P208 Right Turn
P209 Left Turn
P210 Creeper
P211 Shut Down Override
P212 Air Inlet Heater
P215 3 Inching Pedal Potentiometer
P216 Park Light Sense
P218 2 1000 PTO
P219 2 Track Slip
P220 2 Area
P221 2 Area/Hour
P222 2 Distance
P223 2 Ground Speed
P224 2 Engine Hours
P225 2 Volts
P226 2 Implement Width
P228 2 Engine rpm
NOTES
Unit 2

Challenger Error Messages

All errors are shown in an error dialog box and are saved to a disk file error.log in
Student Handout 2.5.7-1

the current working directory.

# Error Text Description and possible resolution

1001 Cannot set timer The program could not set the global timer. Quit and rerun the program. If the
error occurs again, close some other windows tasks and try again. If it fails a
third time, restart windows and try again.

1002 File not found The specified file could not be found. Check the file name and try again.

The specified file could not be opened. Check the file name and try again. If
7

1003 Could not open file this is a program generated file, check the preferences, drive capacity, and
paths.

1004 Could not allocate/open The capture pretrigger file could not be opened for write. Check the
pretrigger file preferences and ensure that enough free space is on the drive.

1005 Selected file name The file name selected for saving a capture file has been used already. Select
already exists another name and try to save again.

1006 Selected capture file is The capture file is corrupted. Select another and delete this one as soon as
corrupt possible.

2000 Cannot get EIC, The program could not communicate correctly with the serial multiplexer.
multiplexer error Specifically when trying to talk to the EIC. Check cabling and power source.

2001 Cannot get RHC, The program could not communicate correctly with the serial multiplexer.
multiplexer error Specifically when trying to talk to the RHC. Check cabling and power source.
Machine Specific

Student Handout: 2.5.7-1


NOTES
Unit 2

Challenger Error Messages (continued)


Student Handout 2.5.7-2

2002 Cannot get ETC, The program could not communicate correctly with the serial multiplexer.
multiplexer error Specifically when trying to talk to the ETC. Check cabling and power source.

2003 Cannot get EDC, The program could not communicate correctly with the serial multiplexer.
multiplexer error Specifically when trying to talk to the EDC. Check cabling and power source.

2004 Cannot switch The program could not communicate correctly with the serial multiplexer.
programming power, Specifically when trying to turn on the programming voltage. Check cabling
multiplexer error and power source.

3000 Incorrect number of The command line in the VTL file has too few or too many items in it. Quit the
items in command line program, edit the incorrect line and restart the program.
8

3001 Variable table overflow The internal table that holds all variables is full. Quit the program, edit the VTL
file to remove some variables, and restart the program.

3002 Function redifinition The specified function name has been used before. Quit the program, edit
the VTL file to rename the function, and restart the program.

3003 Function table The internal table that holds all functions is full. Quit the program, edit the
overflow VTL file to remove functions, and restart the program.

3004 An undefined error has occurred on the specified line. Quit the program, edit
Syntax error the VTL file to fix the error, and restart the program.

3005 The number of bytes to read or write specified in the command line equals 0.
Bytes to read/write Quit the program, edit the VTL file to correct the number of bytes field, and
equal 0 restart the program.
Machine Specific

Student Handout: 2.5.7-2


NOTES
Unit 2

Challenger Error Messages (continued)


Student Handout 2.5.7-3

3006 Illegal address The address to read from or write to is less than or equal to 0 or greater than
65535. Quit the program, edit the VTL file to fix the address, and restart the
program.

3007 Function not found The specified function does not exist in the program. Quit the program, edit
the VTL file to fix the function name (check spelling, capitalization), and restart
the program.

3008 Function address is 0


(obsolete)
9

3009 'Endblock' statement The parse encounter an 'endblock' statement before finding a 'block' statement.
without matching Quit the program, edit the VTL file (check for misspelled block statements or
'block' syntax errors in block statements), and restart the program.

3010 Undefined command The command specified in the block does not exist. Quit the program, edit the
(call in block) VTL file, and restart the program.

3011 Syntax error in 'block' The 'block' definition on the specified line does not meet the requirements of
command 'block NAME MODULE'. Quit the program, edit the VTL file, and restart the
program.

3012 Command table The internal table that holds the commands is full. Quit the program, edit the
overflow VTL file to reduce the number of commands, and restart the program.

3013 Command not found The command on the specified line in the specified block does not exist. Quit
the program, edit theVTL file (check for spelling), and restart the program.
Machine Specific

Student Handout: 2.5.7-3


NOTES
Unit 2

Challenger Error Messages (continued)


Student Handout 2.5.7-4

3014 Address must be a The address must be a four-digit hex value, or the variable must be defined as
4-digit hex value a four-digit hex value; e.g., 302 must be written as 0302. Quit the program, edit
the VTL file, and restart the program.

3015 Cannot execute block, The named block could not be found, and could therefore not be executed.
not found This error is usually an internal error. It can also occur if the VTL file has been
edited while the program is running. Quit and restart the program. If it
continues, call tech support.

3016 Must contain read (R) Every command definition must contain a read or write directive. Quit the
or write (W) program, edit the VTL file and fix the specified line, and restart the program.
10

3017 Unknown module type The program has read in a module type from the VTL file that it does not know.
Quit the program, edit the specified line in the VTL file, restart the program.
The program only knows EIC, RHC, EDC and ETC as modules.

3018 Block table overflow The internal table that holds block names is full. Quit the program, edit the VTL
file to remove or combine blocks, restart the program.

3019 Block redifinition The block name on the specified line has been defined already and cannot be
redefined. Quit the program, edit theVTL file to change the block name, restart
the program.

4000 EIC module not The program was able to switch the multiplexer but was unable to
communicating communicate with the module. Check module power and cabling.

4001 RHC module not The program was able to switch the multiplexer but was unable to
communicating communicate with the module. Check module power and cabling.
Machine Specific

Student Handout: 2.5.7-4


NOTES
Unit 2

Challenger Error Messages (continued)


4002 ETC module not The program was able to switch the multiplexer but unable to communicate with
communicating the module. Check module power and cabling.
Student Handout 2.5.7-5

4003 EDC module not The program was able to switch the multiplexer but unable to communicate with
communicating the module. Check module power and cabling.

5000 Checksum Failed - The download process completed but the module failed the checksum
Download Failed verification. Redo the download. The module cannot be trusted after this error
until a download is completed.

5001 Cannot autobaud The download process could not set the baud rate for the module. Retry the
module - download. The module was not changed and can still be used after this error.
Download Failed
11

5002 Cannot set watchdog The download process could not set the watchdog timer in the module. Retry the
timer - Download failed download. The module was not changed and can still be used after this error.

5003 Module never came The download process could not detect that the module ever became ready to
ready - Download Failed receive data. Retry the download. The module was not changed and can still be
used after this error.

5004 Programming Voltage The download process did not get verification of the programming voltage being
bad - Download Failed turned on from the multiplexer. Retry the download. The module was not
changed and can still be used after this error.

5005 Module Erase Failed - The download process has sent the erase program command to the module but
Download Failed never received a reply. Retry the download. The module cannot be trusted after
this error until a download is completed.

5006 Download Failed The download process failed. Retry the download. The module cannot be
trusted after this error until a download is completed.
Machine Specific

Student Handout: 2.5.7-5


NOTES
Unit 2 12 Machine Specific
Student Handout 2.5.8

Student Handout: 2.5.8


CHALLENGER ACRONYMS

CCM - Chassis Control Module


CM - Cab Main
CR - Cab Roof
ET - Electronic Technician
FM - Front Main
FL - Front Light
CT - Challenger Technician
DAM - Diagnostic and Maintenance Connector
EDC - Electronic Draft Control
EMC - Electronic Monitoring Center
ECM - Electronic Control Module
ETC - Electronic Transmission Control
PTO - Power Takeoff
EMC - Electronic Monitoring Center
KAPWR - Keep-Alive Power
KAM - Keep-Alive Memory
MDP - Main Distribution Panel
MFP - Main Fuse Panel
MPM - Machine Performance Monitor
RHC - Right Hand Control
NOTES
Unit 2 -1- Machine Specific
Student Copy Lab 2.5.1

Student Copy: Lab 2.5.1


LAB 2.5.1: ROW CROP CHALLENGER

Given a Challenger 35, 45 or 55 Agricultural Tractor, the student will be able to access and describe the
information available to the operator during normal operation of the Electronic Monitoring Center. The
student will also be able to access and describe the information available using the twelve service
modes of the Electronic Monitoring Center.
Materials Needed
Lab 2.5.1 Worksheets
Pen or Pencil
Service Manual module "Challenger 35/45/55 Agricultural Tractors Electronic Systems Operation,
Testing and Adjusting" (Form SENR5378)

Challenger 35, 45 or 55 Agricultural Tractor


Unit 2 -2- Machine Specific
Student Copy Lab 2.5.1

Lab 2.5.1: Modes of Operation

Directions: Using the Electronic Monitoring Center keyboard, access all the modes on the EMC
beginning with Normal Operation. Write the mode number, mode name, a brief
description of the information that is available to the operator or service technician in
each mode, and record the information currently being displayed.

Mode Number Mode Name

Description:

Current Display:

Mode Number Mode Name

Description:

Current Display:

Mode Number Mode Name

Description:

Current Display:
Unit 2 -3- Machine Specific
Student Copy Lab 2.5.1

Lab 2.5.1: Modes of Operation (continued)

Mode Number Mode Name

Description:

Current Display:

Mode Number Mode Name

Description:

Current Display:

Mode Number Mode Name

Description:

Current Display:
Unit 2 -4- Machine Specific
Student Copy Lab 2.5.1

Lab 2.5.1: Modes of Operation (continued)

Mode Number Mode Name

Description:

Current Display:

Mode Number Mode Name

Description:

Current Display:

Mode Number Mode Name

Description:

Current Display:
Unit 2 -5- Machine Specific
Student Copy Lab 2.5.1

Lab 2.5.1: Modes of Operation (continued)

Mode Number Mode Name

Description:

Current Display:

Mode Number Mode Name

Description:

Current Display:

Mode Number Mode Name

Description:

Current Display:
Unit 2 -6- Machine Specific
Student Copy Lab 2.5.1

Lab 2.5.1: Modes of Operation (continued)

Mode Number Mode Name

Description:

Current Display:

Mode Number Mode Name

Description:

Current Display:

Mode Number Mode Name

Description:

Current Display:
NOTES
NOTES