SAFETY

ICON

WARNING: TO AVOID PERSONAL INJURY OR PROPERTY DAMAGE, READ

AND FOLLOW ALL SAFETY MATERIALS IN THE OPERATORS MANUAL
AND AT THE BEGINNING OF THIS SERVICE MANUAL

This Section covers the electrical system and its components. This section is divided into five groups: Electrical System,
Electrical Diagnosis and Repair, Electrical Schematic Symbols, Schematic Diagrams and Component Locator. In each
topic, if figures are numbered, they are numbered beginning with Fig. 1. Part numbers may be given as a convenience to
the service technician. Always verify part numbers against current parts information.

TABLE OF CONTENTS
ELECTRICAL SYSTEM
GENERAL DESCRIPTION.........................................................................................................
CAB FUSE PANEL.....................................................................................................................
Inside Front Gauge Console .................................................................................................
Inside Rear Dash Panel ........................................................................................................
RELAY PANEL ...........................................................................................................................
ELECTRICAL MASTER DISCONNECT SWITCH .....................................................................
START LADDER FOR VOAC SYSTEM ....................................................................................
JOYSTICK ASSEMBLY..............................................................................................................
ENGINE DISPLAY AND DIAGNOSTIC MODULE (MDDM) ......................................................
General Description...............................................................................................................
Engine Parameters................................................................................................................
Operating Instructions ...........................................................................................................
Main Menu Tree ...............................................................................................................
Selecting Sub Menus .......................................................................................................
Viewing Engine Configuration Data .................................................................................
Viewing Active Engine Service Codes .............................................................................
Viewing Stored Engine Service Codes ............................................................................
Fault Code Information..........................................................................................................
ELECTRICAL DIAGNOSIS & REPAIR ..............................................................................................
ELECTRICAL SCHEMATIC SYMBOLS
AUXILIARY ELECTRICAL CONTROLS ....................................................................................
CHARTS .....................................................................................................................................
SCHEMATIC DIAGRAMS ..................................................................................................................
COMPONENT LOCATOR..................................................................................................................

2003, BLOUNT INC. Information on vended components reprinted by permission. This Manual has been compiled from
materials available at the time of approval for reproduction. BLOUNT reserves the right to improve its products without
giving prior notice or incurring obligation.

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CIRCUIT PROTECTION
GENERAL DESCRIPTION
The electrical system used on the FABTEK 546C Forwarder is a 12 volt negative ground system utilizing two 12 V
batteries connected in parallel.

FUSE PANELS
Fuses are located behind the front gauge console (Fig. 1) and rear dash panel (Fig. 2). They are standard automotive
blade type. They are color coded according to their ampere rating which is also marked on the top of the fuse.
Inside Front Gauge Console

FT546C_15_001
Fig. 1: Fuses front dash panel (shown open)
To access the 34 fuses, remove three screws and pivot the hinged cover down.
Inside Rear Dash Panel

FT546C_15_002
Fig. 2: Fuses rear dash panel (shown open)
To access the 6 fuses, remove the 4 machine screws from the top edge of the dash panel and 3 nuts from the bottom
edge of the panel.

NOTICE Never replace a blown fuse with one having a higher Ampere rating. To do so can cause a fire or damage to the
protected components.

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RELAY/CIRCUIT BREAKER PANEL

In addition to fuses, forwarders are protected by self-resetting thermal circuit breakers. When current through the circuit
breaker exceeds its rated value it will open the overloaded circuit. After a short period the breaker will cool and reset. If
this continues to happen, the reason for the high current should be determined and corrected. This panel is located on the
firewall inside the engine compartment on the left side of the machine (see Fig 3).

FT546C_15_003
Fig. 3: Relay/circuit breaker panel.

MASTER ELECTRICAL DISCONNECT

An electrical master disconnect switch is located on the left side of the machine in the rear of the engine compartment
(Fig. 4). This switch serves as a vandal deterrent, prevents drain of current during periods when the forwarder is not being
operated, and provides a means to disconnect the battery from the electrical system for maintenance or in the event of a
short circuit.

FT546C_15_004
Fig. 4: Master disconnect switch.

CAUTION Accidental contact with live electrical components can cause personal injury or property damage.
Always turn the Master Disconnect Switch off when servicing the electrical system.

NOTICE DO NOT turn off Master Disconnect Switch on or off when the ignition switch is in the On position. Doing this
could result in damage to the engine and/or electronic controls. Removing the ignition key first will assure that it is in the
Off position.

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WARNING: To avoid personal injury or property damage, read and follow all safety materials in the operators
manual and at the beginning of this service manual.

START LADDER FOR VOAC SYSTEM

The description of the start ladder below describes the components and the electronic signal path that occurs between the
time the ignition is turned ON and the engine turns over.
Door Switch Fuse Number 17

FT546C-15-005
Fig. 5: Location of door switch fuse number 17.
The door switch fuse (Fig. 5) allows power to go to the relay board and then to the door switch when the ignition is turned
ON.

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Relay Board

FT546C-15-006
Fig. 6: Location of Door Con On relay board.
The power goes out from the relay board to the door switch through the green plug (Door Con) on (+) and comes back on
(S). See Fig. 6.
Door Switch

FT546C-15-007
Fig. 7: Door switch.
The door closes. The magnet on the door closes the Door Switch (Fig. 7), allowing power to go back to the Door Con.
Relay Board
Power goes from the Relay Board Door Con (Fig. 6) to the Start Relay in the shifter box.

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Shifter Box

FT546C-15-008
Fig. 8: Location of start relay and foot shifter switch.
When the Start Relay is energized, power will go to the Foot shifter switch (Fig. 8). This switch will either send power to
the Foot shifter or the bump shifter.

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Shifter in Neutral

FT546C-15-009
Fig. 9: Shifter and shifter display.
When the shifter is in neutral, it will send a Neutral Start signal to the Neutral Start Relay on the firewall. N or P will appear
on the Shifter Display (Fig. 9).

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Neutral Start Relay

FT546C-15-010
Fig. 10: Location of the neutral start relay and the start solenoid.
The Neutral Start Relay (Fig. 10) is located on the left hand side of the firewall in the engine compartment. When the
Neutral Start Relay is energized by the Neutral Start signal, the Relay will allow the signal sent from the ignition key switch
in start to energize the Start Solenoid.
Start Solenoid Closed

FT546C-15-011
Fig. 11: Power to the starter solenoid from the start solenoid.
When the Start Solenoid (Fig. 11) is energized, it will send power to the Starter Solenoid (Fig. 12) and turn over the
engine.

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FT546C-15-012
Fig. 12: Location of the starter solenoid.
JOYSTICK ASSEMBLY

FT546C-15-013
Fig. 13: Joystick assembly components.
The joystick assembly (Fig. 13) consists of a cap, handle, boot and joystick base. Two micro switches and a rocker are
mounted on a two-piece handle. The handle also has a cavity that encloses the joystick stem block.
Troubleshooting the Joystick Assembly.
If the Electrical Diagnosis & Repair of the display and diagnostic module section identifies a problem with the joystick
assembly, it must be removed from its mount to gain access to the LED indicator lights located on the side of the joystick
assembly next to the wiring terminal, as shown in Fig. 14.

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FT546C-15-020
Fig. 14: Joystick assembly with LED indicator lights.
When the LED indicator light labeled A reads green, the voltage supply is good. When the LED indicator light is out, the
voltage supply is missing.

The LED indicator light labeled B is for status indication. When the system is functioning properly, this LED indicator light
flashes yellow. When an error occurs, this LED indicator light flashes red. See Fig. 15 for an explanation of the red
flashes.
RED FLASHES
1 flash

STATUS INDICATION
Fault on the inputs/outputs or the supply voltage is too low or too high.

2 flashes in a row

Internal temperature in the unit is too low or too high.

3 flashes in a row

Fault is related to the CAN-bus.

4 flashes in a row

Internal Fault on the hardware in the unit. Incorrect level on reference voltage or regulator
voltage.

5 flashes in a row

Fault is related to the address.

Continuous flashing

Fault is related to checksum or software.

Fig. 15: Explanation of red flashes of LED indicator light B.

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Disassembling the joystick assembly handle.

FT546C-15-014
Fig. 16: Removal of cap from handle.
Grasp the handle with one hand and pull cap straight away (see Fig. 16).

FT546C-15 015
Fig. 17: Removal of screws prior to separating halves of handle.
Remove screws (Fig. 17) from the top and bottom of the handle.

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FT546C-15-016
Fig. 18: Separating the halves of handle.
Start at the top of the handle and use a thin blade to separate the halves of handle (Fig.18).

CAUTION Do not pry the halves of the handle apart from the bottom.
FT 546C

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FT546C-15-018
Fig. 19: Viewing the handle guide pin, spring and rocker.
The halves of the handle must remain parallel during separation until the guide pin (Fig. 19) is clear of one of the halves.
Take care not to lose the spring while separating the halves of the handle.
If damaged, remove rocker with spring from guide pin.

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FT546C-15-017
Fig. 20: View of the handle halves separated.
Fig. 20 shows the handle separated into its halves.

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FT546C-15-019
Fig. 21: Wiring of micro switches.
If damaged, disconnect wires shown in Fig. 21 and remove micro switches.
Assembling the joystick assembly handle.
If removed, install micro switches in handle halves and wire as shown in Fig. 21.
If removed, install rocker with spring (Fig. 18) onto guide pin.

NOTICE The spring is retained by the guide pin within the walls of the rocker.
Make sure both legs of the spring are tucked underneath the handle top before installing the mating handle half.
Make sure the joystick stem block fits in the cavity for the joystick stem block as shown in Fig. 20.
Position the mating handle half to accept the guide pin and the joystick stem block (Fig. 18) and install screws (Fig. 17).
Position narrow slots of cap over the guide pin and install the cap (Fig. 16).

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Electrical System

ENGINE DISPLAY and DIAGNOSTIC MODULE

DESCRIPTION
The Murphy Display and Diagnostic Module (MDDM)
is the keystone in a line of components manufactured by FW Murphy as part of its J1939 MurphyLink System. The J1939 MurphyLink System
has been developed to meet the need for instrumentation and control of electronically controlled engines
communicating through the SAE J1939 Controller
Area Network (CAN).
Readout Panel
The MDDM (Fig. 1) is a powerful, easy to use multifunction tool that enables the operator to view many
different engine parameters and engine service
codes. The MDDM includes a two line, eight character back-lit LCD display. The top line of the display
shows a data label, i.e OilPress for Oil Pressure.
The bottom line displays a value in appropriate units,
i.e 80 psi for oil pressure.
Readout Controls
The MDDM has two push buttons (UP and DOWN)
for scrolling through the parameter list and viewing
the menu list. Two LEDs (amber and red) are used
to annunciate active fault messages received by
the MDDM. Other components in the system are a
combination audible alarm and relay unit for warning
and shutdown annunciation.
Additional Components
Up to 32 components may be linked to the MDDM
by an RS485 daisy chained twisted pair cable up to
1,000 meters from the MDDM. The MDDM and all
connected components can be powered by 12 or 24
volt systems, are back-lit using LEDs, and are 100%
environmentally sealed.
ENGINE PARAMETERS

570-276-02

Fig. 1: View of the right dash showing the Tier

2 engine Display & Diagnostic Module
(MDDM).
SPECIFICATIONS
Membrane Switch: Polyester.
Reversed Polarity: Withstands reversed battery
terminal polarity
indefinitely within operating temperatures.
CAN BUS: SAE J1939 Compliant.
Auxiliary Gage Communication: RS485.
Operating Voltage: 8 VDC Minimum to 32 VDC
Maximum.
Operating Temperature: -4 to 158F (-20 to 70C).
Storage Temperature: -40 to 185F (-40 to 85C).
JOHN DEERE

Engine Hours
Engine RPM
System Voltage
% Engine Load at the current RPM
Coolant Temperature
Oil Pressure
Fuel Economy
Throttle Position
Manifold Air Temperature
Current Fuel Consumption
Fuel Pressure
Fuel Temperature
Total Fuel Used
Active Service Codes
Stored Service Codes from the engine
Engine Configuration Parameters (Model, Serial No.)
FT 546/548

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Electrical System

ENGINE DISPLAY and DIAGNOSTIC MODULE

Do not
operate engine if error code has
been displayed. Operating with
MDDM instl.tif

Fig. 2: Installation diagram of Murphy Display and Diagnostic Module to identify components.

SWITCH SHOWN IN
ON POSITION

Failure to disengage battery before working on electrical

system may result in personal injury or
property damage.
Wait 30 seconds after engine shutdown before turning the electrical master disconnect

MDDM wiring.tif

Fig. 3: Wiring diagram of Murphy Display and Diagnostic Module to identify electrical connections.
FT 546/548

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Electrical System

MDDM OPERATION INSTRUCTIONS

The MDDM is simple to use and allows quick and
easy navigation through the menu structure to find
the information needed.
The MDDM Main Menu Tree (below) first displays
engine data parameters, followed by the sub-menu
entry points.
NOTE: When first powered up, some unused parameters may be displayed by the MDDM. These param-

FT 546/548

eters will be automatically removed from the display

after the initialization cycle is complete.
The following two rules are used for accessing the
various items on the main menus:
1. To scroll through the parameter list, press either
the UP or Down push buttons.
2. To select or exit a sub-menu SIMULTANEOUSLY
press the UP and DOWN push buttons.

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Electrical System

MDDM OPERATION INSTRUCTIONS

Selecting Engine Data Parameters
To read any of the engine parameters press either
the UP or DOWN button until the top line of the display shows the desired information.
Selecting Sub-Menus
Press either the UP or DOWN button until the top
line of the display shows the label of the desired
Sub-Menu. Then press BOTH the UP and DOWN
buttons SIMULTANEOUSLY. This action will select
the Sub-Menu and the next screen on the display will
list the Sub-Menu items.
Changing Units of Measure
The MDDM can display engine data in either English
or Metric units.
To select English or Metric, the Units Sub-Menu
must be selected. To select the Units Sub-Menu,

FT 546/548

press the UP or DOWN button until the display

shows the following label:

Press BOTH the UP and DOWN buttons SIMULTANEOUSLY to select the Units Sub-Menu. The
Units Sub-Menu Figure (below) shows the steps for
selecting the desired units of measure. Two options
are available:
1. Press BOTH buttons to retain the current units
designation.
2. Press either UP or DOWN button to toggle the
units selection, then press BOTH buttons to select the desired unit of measure.

110303

Electrical System

MDDM OPERATION INSTRUCTIONS

Viewing Engine Configuration Data
The MDDM can display the engine configuration
data stored in the engine ECM. To select the Engine
Configuration Sub-Menu (shown below), press the
UP or DOWN button until the display shows the following label:

FT 546/548

Press BOTH the UP and DOWN buttons SIMULTANEOUSLY to select the Engine Configuration
Sub-Menu. The MDDM will display the engine
configuration data as shown in Engine Configuration
Sub-Menu. If the Engine Configuration is not available, the display will show:

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Electrical System

MDDM OPERATION INSTRUCTIONS

Viewing Active Engine Service Codes
The MDDM continuously monitors all messages
broadcast over the SAE J1939 Control Area Network
(CAN) and displays all Active Service Codes at the
time the message is broadcast. When a fault occurs
the display will show the message "SrvcCode" every
five seconds interrupting the currently displayed
parameter. In addition, the amber LED will be illuminated during Active Service Code warning faults,
and the red LED will be illuminated during shutdown
faults. These warnings will continue until the fault
clears.
To view the Active Service Codes select the Service
Code Sub-Menu by pressing the UP or DOWN button until the display shows the following label:

Press both the UP and DOWN buttons SIMULTANEOUSLY to select the Service Code Sub-Menu.
The MDDM will display all Active Service Codes as
shown in the Service Codes Menu schematic (below). If Service Codes are not available, the display
will show the following:

Clearing Fault Codes

To clear fault codes after repairs are made:
1. Shut down the engine.
2. Wait two (2) minutes.
3. Restart engine and run two (2) minutes.
4. Shut down the engine.
5 Wait 30 seconds before turning off the master disconnect switch.

EXPLANATION OF SPN & FMI DIAGNOSTIC CODES

SPN refers to Suspect Parameter Number.
FMI refers to Failure Mode Identifier.
Both the SPN and FMI are used in the J 1939 standard for identification of faults
and conditions.
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Electrical System

MDDM OPERATION INSTRUCTIONS

Viewing Service Codes Stored in
The Engine Control Module (ECM)
The MDDM can request Stored Service Codes (DM2)
from the engine. The Stored Service Codes may be
used for diagnostic and service needs. To view the
Stored Service Codes it is necessary to select the
StorCode Sub-Menu by pressing the UP or DOWN
button until the display shows the following label.
Press both the UP and DOWN buttons SIMUL-

TANEOUSLY to select the StorCodes Sub-Menu.

The MDDM will display the Stored Service Codes
according to the menus shown in the schematic
below. If Stored Service Codes are not available, the
display will show:

Clearing Stored Fault

Codes
To clear fault codes after
repairs are made:
1. Shut down the engine.
2. Wait two (2) minutes.
3. Restart engine and run
two (2) minutes.
4. Shut down the engine.
5 Wait 30 seconds before
turning off the master
disconnect switch.

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Electrical System

MDDM FAULT CODE INFORMATION

JOHN DEERE TIER II ENGINE ERROR CODE DEFINITIONS
(With Stanadyne DE10 Pump)
SPN
000028
000029
000084
000091

000097
000100

000105
000110

000111
000158
000160
000174
000189
000190

FMI
03
04
03
04
14
31
03
04
07
10
13
14
03
04
16
01
03
04
18
03
04
16
00
03
04
15
16

2-DIGIT CODES
13
14
15
16
11
12
65
23
24
64
25
26
66
69
18
19
62
63

00
03
04
17
02
03
04
16
00
00
16

54
37
38
81
42
42

DEFINITION
Throttle voltage high
Throttle voltage low
Throttle voltage high
Throttle voltage low
Throttle voltage out of range
Vehicle speed mismatch
Throttle voltage high
Throttle voltage low
Throttle calibration invalid
Throttle voltage low
Throttle calibration invalid
Throttle voltage out of range
Water in fuel input voltage high
Water in fuel input voltage low
Water in fuel detected
Engine oil pressure extremely low
Engine oil pressure input voltage high
Engine oil pressure input voltage low
Engine oil pressure moderately low
Manifold air temperature input voltage high
Manifold air temperature input voltage low
Manifold air temperature moderately high
Engine coolant temperature high most severe
Engine coolant temperature input voltage high
Engine coolant temperature input voltage low
Engine coolant temperature high least severe
Engine coolant temperature high moderately
severe
Loss of coolant temperature extremely high
Loss of coolant temperature input voltage high
Loss of coolant temperature input voltage low
ECU power down error
Wheel speed input noise
Fuel temperature input voltage high
Fuel temperature input voltage low
Fuel temperature moderately high
Engine speed derate
Engine overspeed extreme
Engine overspeed moderate

EXPLANATION OF SPN & FMI DIAGNOSTIC CODES

SPN refers to Suspect Parameter Number.
FMI refers to Failure Mode Identifier.
Both the SPN and FMI are used in the J 1939 standard for identification of faults and conditions.
FT 546/548

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Electrical System

MDDM FAULT CODE INFORMATION

JOHN DEERE TIER II ENGINE ERROR CODE DEFINITIONS
(With Stanadyne DE10 Pump)
SPN
000620

FMI
03
04
04
13
02
10
13
03
05
09
31
31
09
31
00
01
03
05
06
07
10
03
04
31
31
04
31
06
13

2-DIGIT CODES
21
22
28
39
39
55
83
84
71
72
77
73
74
75
76
82
68
79
78

NA

NA

32

NA

NA

33

NA

NA

32

000627
000629
000637
000639
000729
000898
000970
0000971
001069
001076

001079
001109
001110
001568
001569
002000

DEFINITION
Sensor supply voltage high
Sensor supply voltage low
ECU unswitched power missing
ECU error
Crank position input noise
Crank position input pattern error
CAN error
Inlet air heater signal high
Inlet air heater signal low
Vehicle speed invalid/missing
Auxiliary engine shutdown switch active
External engine derate witch active
Tire speed invalid
Tier speed error
Pump control valve
closure too long
Pump control valve
closure too short
Pump solenoid current high
Pump solenoid circuit open
Pump solenoid circuit severely shorted
Pump control valve closure not detected
Pump solenoid circuit moderately shorted
Sensor supply voltage high
Sensor supply voltage low
Engine shutdown warning
Engine shutdown
Torque curve select voltage low
Fuel derate
Internal ECU failure
Security violation
When reading blink codes, signifies the start of
active codes.
When reading blink codes, signifies the start of
perviously active codes.
When reading blink codes, signifies that no fault
codes are in the buffer.

EXPLANATION OF SPN & FMI DIAGNOSTIC CODES

SPN refers to Suspect Parameter Number.
FMI refers to Failure Mode Identifier.
Both the SPN and FMI are used in the J 1939 standard for identification of faults and conditions.
FT 546/548

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Electrical System

MDDM FAULT CODE INFORMATION

JOHN DEERE ENGINE

TROUBLESHOOTING

Trouble Code Diagnostics and Tests

Diagnostic Procedure
Diagnosis of the electronic control system should be
performed according to the following procedure:

5. If no DTC(s) are present, proceed to Group 150

earlier in this Section to find the appropriate
observable diagnostic procedure.

1. Make sure all engine mechanical and other systems

not related to the electronic control system are
operating properly.
2. Using the DST or other code reading tool, read and
record DTC(s).

04
30

3. If code is displayed in 2 or 3-digit, convert the

proper diagnostic procedure using the LISTING OF
DIAGNOSTIC TROUBLE CODES (DTCS) ON ECU
earlier in this Group into an SPN/FMI.

NOTE: Earlier versions of ECUs used different DTCs

in SPN/FMI format than do later ECUs. There
may be some DTCs that are not found within
the table of contents in this manual. In order to
identify earlier DTCs, refer to the index in the
back of the book or to the listing of Diagnostic
Trouble codes above.

6. After any repairs are made, recheck to make sure

all DTC(s) have been eliminated.
IMPORTANT: Care should be used during the
diagnostic procedures to avoid
damaging the terminals of
connectors, sensors, and actuators.
Probes should not be poked into or
around the terminals or damage will
result. Probes should only be
touched against the terminals to
make measurements. It is
recommended that JT07328
Connector Adapter Test Kit be used
to make measurements in
connectors, sensors, and actuators.
These adapters will ensure that
terminal damage does not occur.

4. Go to the diagnostic procedure that the codes

listing page refers to.

EXPLANATION OF SPN & FMI DIAGNOSTIC CODES

SPN refers to Suspect Parameter Number.
FMI refers to Failure Mode Identifier.
Both the
SPN and FMI are used in the J 1939 standard for identification of faults and conditions.
280/384

13-10

FT 546/548

1003

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Electrical System

MDDM FAULT CODE INFORMATION

TROUBLESHOOTING

JOHN DEERE ENGINE

Trouble Code Diagnostics and Tests

Intermittent Fault Diagnostics

Intermittent faults are problems that periodically go
away. A problem such as a loose terminal that
intermittently doesn't make contact is a likely cause of
an intermittent fault. Other intermittent faults may be
set only under certain operating conditions such as
heavy load, extended idle, etc. When diagnosing
intermittent faults, take special note of the condition of
wiring and connectors since a high percentage of
intermittent problems originate here. Check for loose,
dirty, or disconnected connectors. Inspect the wiring
routing looking for possible shorts caused by contact
with external parts (for example, rubbing against sharp
sheet metal edges). Inspect the connector vicinity
looking for wires that have pulled out of connector
terminals, damaged connectors, poorly positioned
terminals, and corroded or damaged terminals. look for
broken wires, damaged splices, and wire-to-wire
shorts. Use good judgement if component replacement
is thought to be required.
NOTE: The ECU is the component LEAST likely
to fail.

If a faulty connection or wire is suspected to be the

cause of the intermittent problem: clear DTCs, then
check the connection or wire by wiggling it while
watching for new fault codes.
To check the connection between the harness and a
sensor or the harness and the ECU, use JT07328
Connector Adapter Test Kit. Insert the male end of
the appropriate test adapter into the female end of
the ECU or sensor connector terminal. There should
be moderate resistance when the test adapter is
inserted into the terminal. If the connection is loose,
replace the female terminal.
Possible causes of intermittent faults:
Faulty connection between sensor or actuator and
harness.
Faulty contact between terminals in connector.
Faulty terminal/wire connection.
Electromagnetic interference (EMI) from an
improperly installed 2-way radio, etc. can cause
faulty signals to be sent to the ECU.

Suggestions for diagnosing intermittent faults:

Appplication
Forwarders

2-Digit Code
15
16
11
12

SPN/FMI Code

Go to page that reads:

29 - 3 - Throttle 2
29 - 4 - Throttle 2
91 - 3 - Throttle 1
91 - 4 - Throttle 1

T5 - Analog Throttle (B) Input High

T6 - Analog Throttle (B) Input Low
T3 - Analog Throttle (A) Input High
T4 - Analog Throttle (A) Input Low

EXPLANATION OF SPN & FMI DIAGNOSTIC CODES

SPN refers to Suspect Parameter Number.
FMI refers to Failure Mode Identifier.
Both 280/384
the SPN and FMI are used in the J 1939 standard
13-11for identification of faults and conditions.
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Electrical System

ELECTRICAL DIAGNOSIS
WARNING: TO AVOID PERSONAL INJURY OR PROPERTY DAMAGE,
READ AND FOLLOW ALL SAFETY MATERIALS IN THE OPERATOR'S
MANUAL AND AT THE BEGINNING OF THIS SERVICE MANUAL.

DIAGNOSTICS
The following diagnostic aids can be useful in trouble shooting the electrical system; although they are by no means all inclusive. As always, sound diagnosis of electrical problems involves testing of the components and tracing of the circuits in order to determine
the malfunction. These aids assume that the circuits have been checked for correctness
of wiring and continuity and that the circuit is question is properly grounded.

SYMPTOM & PROBABLE CAUSE

1. NO POWER TO ANY FUNCTION
corrosion on battery terminals
poor continuity through cable
battery discharged
main cut-off switch turned OFF
faulty main circuit breaker
faulty ground
2. STARTER WILL NOT ENGAGE
poor continuity through cable
faulty ground
defective starter relay
defective starter circuit
defective starter solenoid
defective defective key switch
defective starter

CORRECTIVE ACTION

clean terminals
clean cable ends or replace cable
charge battery
turn switch ON
check for continuity through breaker
- allow breaker to cool down
- try resetting -- replace if necessary
re-establish ground

clean cable ends or replace cable

re-establish ground
repair or replace relay
check and clean starter connections
repair or replace solenoid
replace switch
replace starter

3. STARTER STAYS ENGAGED AFTER

ENGINE STARTS
defective starter relay
defective starter solenoid
defective key switch
FT 546/548

repair or replace relay

repair or replace solenoid
replace switch
110303

Electrical System

ELECTRICAL DIAGNOSIS
WARNING: TO AVOID PERSONAL INJURY OR PROPERTY DAMAGE,
READ AND FOLLOW ALL SAFETY MATERIALS IN THE OPERATOR'S
MANUAL AND AT THE BEGINNING OF THIS SERVICE MANUAL.
SYMPTOM & PROBABLE CAUSE

CORRECTIVE ACTION

ENGINE WILL NOT SHUT DOWN

WITH KEY SWITCH

Disconnect fuel shut-off relay to shut

down engine.

defective key switch

defective fuel shut off switch
defective fuel shut off relay

replace switch
repair or replace switch
repair or replace relay

5. ALTERNATOR WILL NOT CHARGE

BATTERY
defective voltage regulator
loose or defective fan belt
defective key switch
defective key relay
defective excitation diode
defective alternator
faulty ground

repair or replace regulator

tighten or replace
replace switch
repair or replace relay
replace diode
repair or replace alternator
re-establish ground

6. ALTERNATOR OVERCHARGES
BATTERY
defective voltage regulator

repair or replace regulator

7. INDIVIDUAL ELECTRICAL FUNCTION

DOES NOT WORK
defective relay or circuit breaker
defective switch
defective solenoid
defective ground
defective diode

FT 546/548

repair or replace relay and/or breaker

replace switch
repair or replace solenoid
re-establish ground
replace diode

110303

Electrical System

ELECTRICAL DIAGNOSIS
WARNING: TO AVOID PERSONAL INJURY OR PROPERTY DAMAGE,
READ AND FOLLOW ALL SAFETY MATERIALS IN THE OPERATOR'S
MANUAL AND AT THE BEGINNING OF THIS SERVICE MANUAL.

FT 546/548

110303

Electrical System

ELECTRICAL SCHEMATIC SYMBOLS

COMPONENTS:
The relative ease with which electrical energy can
be transmitted from one point to another has made it
a commonly-chosen medium to operate and control
auxiliary functions and to give warning or condition
messages to the operator.
Some of the principal auxiliary control devices, protective equipment and warning or condition indicators are discussed in the following paragraphs.
LAMPS (Fig. 1)
The typical incandescent lamp consists of a tungsten
filament and an enclosing glass envelope. The filament length determines the operating voltage. The
cross sectional area determines the current, and
thus the lamp wattage. The light output goes up with
an increase of voltage on a given lamp, but lamp life
is drastically shortened with an increase of voltage.
The purpose of the envelope is to exclude air from
the filament. At normal operating temperatures, the
filament would be completely oxidized in seconds
if the envelope were absent. Some lamps are filled
with an inert gas, This retards the oxidation of the
filament metal.
The filament of a lamp is in fact a resistor. Being a
resistor, it is subject to a change of resistance with
a change of temperature. Because of the great
change of temperature in a lamp, the resistance
changes drastically from cold to hot. It is not uncommon for a cold filament to have only one tenth the
resistance it has at operating temperature. Thus, the
current at turn-on may be ten times the operating
current.

FT 546/548

lamp sch

Fig. 1: Schematic drawing of a lamp

110303

Electrical System

ELECTRICAL SCHEMATIC SYMBOLS (cont)

SWITCHES (Fig. 2):
The purpose of a switch is to complete a circuit so
current can flow, or to interrupt a circuit to stop current flow.
A typical mechanical switch consists of contacts
and an operator. The contacts have low resistance.
Contacts can be made of several different metals or
alloys. These materials inhibit the formation of high
resistant oxides, and have a high enough melting
point so as not to weld together under rated conditions. The contacts are closed quickly and firmly
to make a good, low resistance connection. They
are also opened quickly to extinguish the arc before
excessive heating and melting can take place. Arc
damage can be reduced by making the contacts
very massive providing sufficient heat sink so that
the arc energy will not raise the surface temperature
appreciably.
The operator consists of combinations of levers,
linkages and springs. In some cases the switch is
operated by rotation of a shaft. When switches are
operated by other means they sometimes have
other names.
A thermostat is a switch that is operated by a
bimetallic bar, or a gas filled bellows whose gas
expands when heated. A pressure switch is actuated by gas or liquid pressure on a diaphragm or
bellows. A float switch is actuated by a float on a
surface of a liquid.
Switches have a voltage and a current rating. However, they may be rated at two or more voltages, with
a different current for each voltage. They can also
be rated for the type of load; e.g., resistive, inductive,
or lamp load. They may also have AC ratings and
DC ratings.
Switches are classified according to the number of
poles and the number of positions.

FT 546/548

contact

contact

operator

Fig. 2: Schematic drawing of a typical switch,

shown in the OPEN position.

110303

Electrical System

ELECTRICAL SCHEMATIC SYMBOLS (cont)

CIRCUIT BREAKERS (Fig. 3)
A circuit breaker is a switch that automatically turns
off (without injury to itself when properly applied)
when the current through the device exceeds its
rated value. Some circuit breakers will automatically
reset after a cooling off period. Others may be
manually reset.
The primary purpose of a circuit breaker is to protect
the circuit it serves by turning off if the current exceeds some predetermined value.
Each circuit breaker has a voltage and a current
rating. If the voltage rating is exceeded, the circuit
breaker may be damaged and may fail to protect its
circuit. When the current rating is exceeded, the operation of the breaker is determined by its construction. There are three basic types of construction:
1. Magnetic
2. Thermal
3. Thermal magnetic
Briefly, the important characteristics of the three
types of circuit breakers are noted below:
1. Magnetic. When the trip value (usually 125% of
rating) of current is exceeded, the breaker trips
instantaneously.
2. Thermal. In this type of breaker, excess current
must flow for some time to cause a trip. In general, the higher the current, the shorter the time.
This breaker is sometimes called an inverse time
breaker.
3. Thermal magnetic. This breaker incorporates the
mechanisms of the two other types. The magnetic (instantaneous) trip is usually 5 to 10 times
rated current.
In addition to voltage and current ratings, circuit
breakers have a maximum current interruption rating.
This is important in protecting wiring during short
circuit conditions. Current is limited by source

FT 546/548

3P brkr sch

Fig. 3: Schematic drawing of a 3-pole circuit

breaker with thermal trip.

110303

Electrical System

ELECTRICAL SCHEMATIC SYMBOLS (cont)

impedance only.
FUSES (Fig. 4)
A fuse is an over-current device with a circuit opening fusible part that melts when heated by the
passage of excessive current through it, thus interrupting current flow.
A fuse consists of two parts: The fusible link and
the housing. The housing serves several purposes.
It protects the links from mechanical damage. It
provides a means of making electrical connection. It
contains the arc and prevents damage to the surroundings when the fuse blows. In some cases,
the housing is filled with special materials to assist in
quenching the arc, thus completing the circuit interruption more quickly.
The fusible link is made of a particular material for
each application. It is also shaped differently for
different applications. The link is designed to fail in a
predictable way, thus making ratings meaningful.
Fuses are rated for maximum voltage on which they
can reliably interrupt. They also carry a current rating. Like some circuit breakers, fuses also have a
current-time relationship for interruption. In general,
fuses are classified as quick-acting, or slow-blow.
Some fuse housings are designed so the link can
be replaced. While this arrangement may hold out
promise of economy, it poses the threat of abuse by
replacing with the wrong fusible link.
Relays and contactors allow the voltage in one cir

FT 546/548

fuse sch

Fig. 4: Schematic drawing of a typical cartridge-type fuse.

110303

Electrical System

ELECTRICAL SCHEMATIC SYMBOLS (cont)

RELAYS AND CONTACTORS (Fig. 5)
Relays and contactors allow the voltage in one circuit to control another different circuit (which usually
operates at higher amperage).
Relays have two main components: a) A coil and
associated parts to carry the magnetic field, and b)
electrical contacts.
The movable part of the magnetic circuit is called
the armature. It supplies the force to operate the
contacts.
The distinction between relays and contactors is not
clear-cut. In general,, an AC relay or contactor coil
may be applied at a higher voltage if frequency is
raised in direct proportion.
Contacts can vary in number and action. That is,
contacts can be either normally open or normally
closed. A popular type of contact arrangement
(called transfer) has movable contact between two
stationary contacts. The movable contact is normally
closed with respect to the other. A relay can have
several sets of contacts of various forms. The most
common contact forms are:
A - normally open
B - normally closed
C - transfer
Relay contacts are rated like switch contacts: voltage, current, AC, DC, type of load.
BATTERIES (Fig. 6)
A battery consists of several cells connected
together, usually in series.
Cells connected in series increase voltage with the
number of cells, as in a flashlight.
Cells connected in parallel increase amperage with
the number of cells, as with automotive batteries.
There are two basic types of cells: primary and
secondary.
Chemicals in primary cells are consumed as they
are used, and primary cells are not recharged.
These are sometimes called dry cell batteries.
The chemical action of a secondary cell can be
reversed by forcing current back through it. This is
called charging. The most common type of secondary cell is the lead acid battery.
Electricity is produced in both primary and secondary cells by chemicals reacting. It should be
borne in mind that these chemicals are very reactive and can react with materials outside the cell,
thus damaging them. In particular, the electrolyte
(whether in liquid or paste form) can react with flesh,
producing severe chemical burns.
FT 546/548

fuse sch

Fig. 5: Schematic drawing of a typical relay or

contactor (many variations are available).

batt sch

Fig. 6: Schematic drawing of a battery.

110303

Electrical System

ELECTRICAL SCHEMATIC SYMBOLS (cont)

elec sym 1

Fig. 7: Chart shows some of the symbols used in electrical schematic drawings.
FT 546/548

110303

Electrical System

ELECTRICAL SCHEMATIC SYMBOLS (cont)

elec sym 2

Fig. 8: Chart shows some of the symbols used in electrical schematic drawings.

FT 546/548

110303

546C Forwarder
Section 15 Electrical

FT 546C

15-37

12005

546C Forwarder
Section 15 Electrical

FT 546C

15-38

12005

546C Forwarder
Section 15 Electrical

FT 546C

15-39

12005

546C Forwarder
Section 15 Electrical

FT 546C

15-40

12005