BUSHING-UPPER 3665134 - Caterpillar

MID 87 - Chassis ECMCID 96 - Fuel Level SensorFMI 3 - Voltage Above Normal
Illustration 1 g01955172
"Fuel Level" sensor
Illustration 2 g01819533
Fuel level sensor circuit
This diagnostic code indicates that the "Chassis ECM" detects the signal voltage of the fuel level sensor voltage is above normal.The following can cause this code:
Sensor failure
Open sensor return circuit
Shorted signal circuit
Open signal circuit
Disconnected sensor
ECM failureNote: The following test procedure may create other diagnostic codes. Ignore these created codes and clear these created codes after the original diagnostic code has been corrected. Ensure that the diagnostic code of CID 96 FMI 3 is active before performing this procedure.Note: Use a calibrated digital multimeter for the measurements in this procedure.System Response:Fuel gauge indication is either:
Continuously empty
Intermittently emptyTest Step 1. CHECK THE SENSOR POWER
At the sensor connector, identify the +24V circuit connector and the Ground circuit connector.
Measure the voltage from contact 1 to contact 2 (ground).Expected Result:The voltage is between 21.3 VDC and 32 VDC.Results:
YES - The voltage is between 21.3 VDC and 32 VDC. Proceed to test step 2.
NO - The voltage is not between 21.3 VDC and 32 VDC. There is an open.Repair: Repair or replace the harness.STOPTest Step 2. CHECK THE SENSOR DUTY CYCLE
Turn on the disconnect switch and the key switch.
Measure the duty cycle from contact 4 to contact 2 (ground).Use a calibrated 9U-7330 Multimeter. Place the multimeter in the 5 VDC range.Expected Result:The duty cycle is between 5% and 95%.Note: If the sensor is functional, but the sensor is not detecting fuel, the duty cycle will be approximately 5%. The duty cycle should increase as the fuel is added.Results:
OK - The duty cycle is between 5% and 95%. Proceed to Test Step 3.
NOT OK - The duty cycle is not between 5% and 95%.Repair: Replace the sensor.STOPTest Step 3. CHECK FOR A SHORT
Turn off the key switch and the disconnect switch.
Disconnect the harness from the monitoring system.
At the monitoring system connector, measure the resistance from contact 24 to all other contacts.Expected Result:The resistance is more than 5000 ohms.Results:
OK - The resistance is more than 5000 ohms. Proceed to test step 4.
NOT OK - The resistance is less than 5000 ohms. The harness is shorted.Repair: Repair or replace the harness.STOPTest Step 4. VERIFY THE DIAGNOSTIC CODE
Inspect the harness.Clean the harness connector contacts.Inspect the harness connector contacts for corrosion or damage.Inspect the wire insulation for damage caused by heat, corrosion, or chafing.
Perform a 45 N (10 lb) pull test on each circuit wire.
Reconnect all harness connectors.Verify that the connectors are fully seated and the clips are fastened.
Check for intermittent problems. Using Cat® Electronic Technician (Cat® ET), perform a wiggle test on the harness.
Turn on the disconnect switch and the key switch.
Operate the machine.
Check the code status.Expected Result:The diagnostic code is not active.Results:
OK - The diagnostic code is not active.Repair: The initial diagnostic code was probably caused by a poor connection at one of the connectors that was checked.Resume normal operation.STOP
NOT OK - The diagnostic code is active. The display module may have failed.Repair: Exit this