SEAL 3530010 - Caterpillar

The PL522 or 523 modules track the machine operating hours for reporting to the office. The Alternator R-Terminal signal is used to detect when the machine is operating. If the input continually receives a voltage signal that is above normal, then machine operation cannot be detected. Also, the reported Service Meter Hours (SMU) would be inaccurate.Test Step 1. CHECK THE R-TERMINAL CABLING FOR SHORT TO BATTERY.
Disconnect the PL522 or 523 cable (P1) from the PL522 or 523 module.
Measure the resistance from the Alternator R-terminal input J1-4 (403MC9-GN(Green) to battery (J1-1). Expected Result:The resistance should be greater than 5000 ohms.Results:
OK - The PL522 or 523 harness is likely correct. Proceed to Test Step 2.
NOT OK - The PL522 or 523 cable has a probable short to battery.Repair: Repair the cable and verify that the fault has been removed.STOPTest Step 2. CHECK THE PL522 AND 523 HARNESS FOR A SHORT TO A VOLTAGE SOURCE.
Disconnect the PL522 or 523 cable (P1) from the PL522 or 523 module.
Start the engine.
Measure the Alternator R-Terminal input (J1-4) to verify that there is an 11 VDC to 32 VDC square-wave. The measurement should range from 5Hz to 2 kHz or a steady DC voltage equivalent to the battery present. Expected Result:The Alternator R-Terminal input does not measure at a steady DC voltage equivalent to the battery voltage.Results:
OK - The signal is an 11 VDC to 32 VDC square-wave. The measurement should range from 0kHz to 2 kHz or a steady DC voltage equivalent to the battery present. The PL522 or 523 harness is likely not faulty. Proceed to Test Step 3.
NOT OK - The PL522 or 523 cable has a possible short to a DC voltage source other than battery voltage.Repair: Repair the cable and verify that the fault has been removed.STOPTest Step 3. CHECK THE MACHINE ALTERNATOR.
Disconnect the PL522 or 523 machine cable from the alternator.
Start the engine.
Using a multimeter and scope, measure the Alternator R-Terminal to verify that there is 11 VDC to 32 VDC square-wave. The measurement should range from 0 kHz to 2 kHz. Expected Result:The alternator R-Terminal should be an 11 VDC to 32 VDC square-wave from 0 kHz to 2 kHz.Results:
OK - The alternator R-Terminal is an 11 VDC to 32 VDC square-wave from 0 kHz to 2 kHz. Proceed to Test Step 4.
NOT OK - The alternator R-Terminal is not an 11 VDC to 32 VDC square-wave from 0 kHz to 2 kHz.Repair: Repair the alternator or replace the alternator.STOPTest Step 4. CHECK IF THE DIAGNOSTIC CODE IS STILL ACTIVE.
Clean the contacts of the harness connectors.
Reconnect all harness connectors.
Turn the key start switch to the ON position and operate the machine.
Determine if "CID 1251 FMI 03" diagnostic code is present by using the Caterpillar Electronic Technician (Cat ET ). Expected Result:A "CID 1251 FMI 03" diagnostic code is present.Results:
YES - The problem has not been corrected. ECM failure is unlikely.Repair: Perform this diagnostic test procedure again. If the cause of the diagnostic code is not found, replace the