966G Wheel Loader 9RS00001-UP (MACHINE) POWERED BY 3306 Engine(SEBP...

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Product:  WHEEL LOADER 
Model:  966G WHEEL LOADER 9RS 
Configuration: 966G Wheel Loader 9RS00001-UP (MACHINE) POWERED BY 3306 Engine 

Tool Operating Manual

Using the 4C-8195 Control Service Tool{0374, 0599, 0709, 7490}
Media Number -NEHS0669-02 Publication Date -16/09/2013 Date Updated -16/09/2013

i05453231

Using the 4C-8195 Control Service Tool{0374, 0599, 0709,

7490}
SMCS - 0374; 0599; 0709; 7490

Caterpillar Products: All

Introduction
European Union Compliant, CE Marked

Important Safety Information

Illustration 1 g02139237

Think Safety

Most accidents that involve product operation, maintenance, and repair are caused by failure to
observe basic safety rules or precautions. An accident can often be avoided by recognizing
potentially hazardous situations before an accident occurs. A person must be alert to potential
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hazards. This person should also have the necessary training, skills, and tools to perform these
functions properly.

Improper operation, lubrication, maintenance, or repair of this product can be dangerous

and could result in injury or death.

Do not operate or perform any lubrication, maintenance, or repair on this product until you
have read and understood the operation, lubrication, maintenance, and repair information.

Safety precautions and warnings are provided in this manual and on the product. If these hazard
warnings are not heeded, bodily injury or death could occur to you or to other persons.

The hazards are identified by the "Safety Alert Symbol" and followed by a "Signal Word" such as
"DANGER","WARNING", or "CAUTION". The Safety Alert "WARNING" label is shown
below.

A non-exhaustive list of operations that may cause product damage are identified by "NOTICE"
labels on the product and in this publication.

Caterpillar cannot anticipate every possible circumstance that might involve a potential
hazard. The warnings in this publication and on the product are, therefore, not all inclusive.
If a tool, procedure, work method, or operating technique that is not recommended by
Caterpillar is used, the operator must be sure that the procedures are safe. The operator
must also be sure that the product will not be damaged or made unsafe by any unspecified
procedures.

The information, specifications, and illustrations in this publication are based on information that
was available at the time that the publication was written. The specifications, torques, pressures,
measurements, adjustments, illustrations, and other items can change at any time. These changes
can affect the service that is given to the product. Obtain the complete and most current
information before you start any job.

When replacement parts are required for this product Caterpillar recommends using
Caterpillar replacement parts or parts with equivalent specifications including, but not
limited to, physical dimensions, type, strength, and material.

Literature Information
This manual contains safety information, operation instructions and maintenance information and
should be stored with the tool group.

Some photographs or illustrations in this publication may show details that can be different from
your service tool. Guards and covers might have been removed for illustrative purposes.

Continuing improvement and advancement of product design might have caused changes to your
service tool, which are not included in this publication.

Whenever a question arises regarding your service tool or this publication, consult Dealer Service
Tools (DST) for the latest available information.

Safety Section

The Safety Section lists basic safety precautions.

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Read and understand the basic precautions listed in the Safety Section before operating or
performing maintenance and repair on this service tool.

General Information Section

The General Information Section describes tooling functions and features. This section provides
useful information on individual parts, additional tooling, and resources.

Operation Section

The Operation Section is a reference for the new operator and a refresher for the experienced
operator.

Photographs and illustrations guide the operator through correct procedures for using the tool
group.

Operating techniques outlined in this publication are basic. Skill and techniques develop as the
operator gains knowledge of the service tool and tool capabilities.

Maintenance Section

The Maintenance Section is a guide to tool inspection, cleaning, storage, and tool disposal.

Safety Section
Safety Icon Nomenclature

Personal Protection/Important Information

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Illustration 2 g02166423

Personal Protection/Important Information

Additional Contact Information

For additional product support questions concerning this tool, contact the Dealer Service Tools
Hotline at:

USA: 800-542-8665, Option 1

International: 1-309-578-7372

Note: Continuing improvement and advancement of product design can mean some photographs
or illustrations in this publication will show details that are different from your service tool.

Introduction
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Illustration 3 g02361576

Control Service Tool and Cables.

(1) 4C-8195 Control Service Tool

(2) 4C-8196 Cable As

(3) 4C-8197 Cable As

(4) 138-7795 Cable As

The 4C-8195 Control Service Tool cancels and replaces the 9U-6665 Service Tool (CMS) . All
the functions performed by the 9U-6665 Service Tool are performed in the same, or similar,
manner using the new 4C-8195 Control Service Tool .

The 4C-8195 Control Service Tool is an aid to the service technician when working with the
Caterpillar Monitoring System (CMS) panel. Sometimes the CMS called CEMS or CMS II. A
several other controls where active and logged faults must be scrolled for viewing and cleared or
other special functions performed. Using this tool, the technician can manipulate the controls with
the flip of a switch. Instead of having to try to manually group pins on the service connector. The
4C-8196 Cable As , 4C-8197 Cable As , and 138-7795 Cable As are part of the 4C-8195 Control
Service Tool . These cables are also available separately. The 6V-3072 Plastic Case and 8T-5267
Foam Insert are available, as options, for storing and carrying the 4C-8195 Control Service Tool .
The 4C-8195 Control Service Tool will also fit into the 9U-5215 Carrying Case

The switches on the 4C-8195 Control Service Tool are labeled in white and yellow. Use the white
Labeling for the CMS and CEMS/CMS II panels, medium, and large wheel loader transmission
controls. Use the yellow labeling for the transmission controls on motor graders, small wheel
loaders, and integrated toolcarriers.

Note: Other modes may be available for specific machine models. For instructions on other
models, refer to the machine, or monitoring panel service Manual.

Table 1
Specifications
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Description Specifications
190 mm (7.5 inch) X
Size 112 mm (4.4 inch) X
40 mm (1.6 inch)

Weight
0.2 kg (0.44 lb)

4C-8196 Cable 250 cm (8 ft) CEMS/CMS II (This cable is used with all other controls,
As except small wheel loader and integrated toolcarrier transmission controls).

4C-8197 Cable
61 cm (2 ft) Wheel Loader Transmission ( This cable is used with small
As
wheel loader and integrated toolcarrier transmission controls).

138-7795 Cable
14 cm (5.5 inch) Motor Grader Transmission Adapter (This cable is used
As
with 4C-8196 Cable As )

Procedure to Connect 4C-8195 Control Service Tool

1. Turn the Start/Stop Key Switch on the machine, OFF.

2. Locate the service connector and disconnect, or remove, the service dust plug or cap. The
service connector is usually under the dash near the CMS control, or near the electronic
control.

3. Using the appropriate cable assembly, connect the 4C-8195 Control Service Tool to the
service connector on the machine being serviced.

Procedure to Use the 4C-8195 with an LCD Version of CMS

Note: Use the white labeling on the 4C-8195 Control Service Tool

Note: The MODE switch is not used in the LCD version of CMS

Table 2
Activation of Display Operations
(Quick Reference)
Display Operation Switch Position
Tattletale Mode
To Enter Scroll Switch Up (after self-test)
To Clear Clear Switch Up and Release
Diagnostic Mode
To Enter and Scroll Hold Scroll Switch Up (before power is applied)
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To Hold Release Scroll Switch (1)

To Clear Clear Switch Up and Release (2)
(1)
Release, when desired information is shown during the scrolling
(2)
A service code can be cleared only while switch is on hold. The service code for a fault that is currently present,
cannot be cleared

Table 3
Description of Operation
Mode
Description

Tattletale Mode
With all switches released on the 4C-8195 Control Service Tool , turn the Start/Stop
To
Key Switch on the machine to ON, to apply power to the CMS Control. After the self-
Enter
test is complete, push the SCROLL ( white ) switch, and release (to ground the
SERVICE line on the CMS control).
To
Push up the CLEAR (white) switch up and release, to momentarily ground the
Clear
CLEAR line on the CMS control.

Turn Start/Stop Key Switch on the machine to OFF, and disconnect 4C-8195 Control
To Service Tool . Reinstall the service connector dust plug. When the Start/Stop Key
Exit Switch on the machine is turned ON, the CMS will again be in the normal operation
mode.
Diagnostic Mode
To
With the SCROLL switch (white) in the up position. turn the Start/Stop Key Switch
Enter
on the machine to ON to apply power to the CMS Control.

Push (or leave) the SCROLL (white) switch up, to ground the SERVICE line on the
To CMS control. The service code for each detected fault will be shown for a brief time
Scroll on the digital display and CMS panel that is most often used for displaying speed. The
list of service codes will be continuously repeated. If no faults are detected, the display
will show 0-00.
Release the SCROLL (white) switch when the desired service code is displayed, to
open the SERVICE line on the CMS control).
To
NOTE: The SERVICE CODE indicator on the display provides additional
Hold
information. If the SERV CODE is FLASHING, the displayed fault IS PRESENT
now. IF SERV CODE is ON CONTINUOUSLY, the displayed fault IS NOT
PRESENT now. The fault either occurred one time, or fault is intermittent
First make sure that the service code is on hold and displayed on the display. Push the
To
CLEAR (white) switch in the UP position and release, to momentarily ground the
Clear
CLEAR line on the CMS control. The digital display will temporarily show 0-00, then
advance and HOLD the next service code.
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To Turn Start/Stop Key Switch on the machine to OFF, and disconnect 4C-8195 Control
Exit Service Tool . Reinstall the service Connector dust plug. When the Start/Stop Key
Switch on the machine is turned ON, the CMS will again be in the normal operation
mode.

Refer to Service Manual, SENR4942, "COMPUTERIZED MONITORING SYSTEM WITH LCD

BARGRAPH GAUGES ", for a full explanation and use of the Tattletale and diagnostic modes.

Procedure to Use the 4C-8195 with a VFD Version of CMS

Note: Use the white labeling on the 4C-8195 Control Service Tool.

Table 4
Activation of Display Operations
(Quick Reference)
Display Operation Switch Position
Changing Mode
To Scroll Hold Mode Switch Up
To Hold Release Mode Switch (1)
Service Mode (Mode 1)
To Scroll Scroll Switch Up
To Hold Release Scroll Switch (1)
To Clear Clear Switch Up and Release (2)
Status Mode (Mode 2)
To Select Contacts 19, 30-40 No Switches Activated
To Select Contacts 5, 6, 20-22, 25-29 Clear Switch Up
Tattletale Mode (Mode 3)
To Clear Clear Switch Up and Release
Numeric Readout Mode (Mode 4)
To Scroll Scroll Switch Up
To Hold Release Scroll Switch (1)
Calibration Mode (mode 5) - Certain models only
Calibrates other electronic controls. Refer to Service Manual for relevant electronic control for
procedures.
(1)
Release, when desired information is shown during the scrolling
(2)
A service code can be cleared only while switch is on hold. The service code for a fault that is currently present,
cannot be cleared
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Note: Refer to the Service Manual, SENR5247 for a full explanation and use of the various
modes.

Procedure to Use the 4C-8195 with CEMS/CMS II

Note: Use the white labeling on the 4C-8195 Control Service Tool

The Procedures are similar for this CMS. Refer to Service Manual SENR6717, for a full
explanation and use of the various modes.

Procedures to Use 4C-8195 with Medium and Large Wheel

Loader Transmission and Track- Type Tractor Power Train
Controls
Note: Use the white labeling on the 4C-8195 Control Service Tool

The procedures are similar for these CMS and CEMS/CMS II. However, additional special
procedures, INCREMENT (+) and DECREMENT (-), are used for calibrations on the track-type
tractor power train. Refer to service Manuals, Medium Wheel Loader - SENR5922, Large Wheel
Loader - SENR5704, and Track-Type Tractor - SENR8367, for a full explanation and use of the
various modes.

Procedures to Use 4C-8195 with Small Wheel Loader, Small

Integrated Toolcarrier, and Motor Grader Transmission
Controls

Illustration 4 g03443298

4C-8197 Wiring Diagram

Note: Use the yellow labeling on the 4C-8195 Control Service Tool . Three updates are required
to early 4C-8195 Control Service Tool to provide all of the functions for these controls. The three
updates are:
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1. Early 4C-8197 Cable As need wires at pin 1 and pin 3 to be interchanged at the 8-pin
connector. So that the connectors are wired, as shown in the diagram. This cable is used for
small wheel loaders and integrated tool carriers.

2. Obtain a 138-7795 Cable As for early 4C-8195 Control Service Tool which did not include
it. This cable is required for Motor Grade transmission procedures, and is used with 4C-
8196 Cable As to connect the 4C-8195 Control Service Tool to the service connector.

3. Replace decals on 4C-8195 Control Service Tool with NEEG2671-01 and NEEG2672-02
decals, which have the correct descriptions for the various switch functions for these
electronic controls, when the above updates (Steps 1 and 2) are completed

For small wheel loader and integrated toolcarrier transmission controls, perform fault diagnostic
and transmission configuration code programming procedures, as described in Service Manual
SENR6982, but using switches on 4C-8195 Control Service Tool, instead of grounding contacts
using jumper wires. The TRANS-1 and TRANS-2 switch functions indicated on the new decal,
enable programming the configuration code first and second digits, respectively

Procedures to Update 9U-6665 Service Tool (CMS) to a 4C-

8195 Control Service Tool

Illustration 5 g02361756

Schematic of 9U-6665 CMS Service Tool .

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Illustration 6 g02361757

Schematic of 4C-8195 Control Service Tool .

1. Replace the CLEAR switch (lower left) on the 9U-6665 Service Tool (CMS) with an SPDT
momentary switch (Single-pole, Double-Throw momentary switch). The 7105SYZQE is the
recommended part available from C&K.

2. Add a wire from the extra contact of the new switch to pin 3 of the connector on the 9U-
6665 Service Tool .

3. Replace the front and rear decals with NEEG2671 (front decal) and NEEG2672 (rear decal).

4. The 9U-6688 CMS Cable Assembly has been canceled, and replaced by 4C-8196. To
update the 9U-6688 CMS Cable Assembly , add a wire between pin 3 of the three
connectors of the 9U-6688 Cable Assembly .

Glossary of Terms

Clear - Clear refers to removing diagnostic information from the memory of the main display
module. Before clearing information, is necessary that the information is placed on hold.

CID (component Identifier) - The CID is a diagnostic code tells that which component or system
faulty. For example, transmission oil temperature, speed sensor, action lamp, or engine boost
pressure. The CID is a three-digit code that is located in the digital readout area when in the
service mode.
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Diagnostic - Diagnostic refers to the showing, monitoring, and/or recording of information other
than normal. Diagnostic information is available from service, status, tattletale, or numeric readout
mode.

Fault - A fault is a failure of a component in the system. For example, open or shorted harness,
faulty switch, sensor, or control.

FMI (Failure Mode Identifier) - The FMI is a diagnostic code that tells what type of failure has
occurred. For example, voltage above normal, and current below normal, or abnormal frequency.
The FMI is a one or two-digit code followed with the letter "F" that is located in the digital
readout area. when the ECM is in the service mode.

Hold or On Hold - Hold pertains to the holding of diagnostic information that is shown in the
digital area when the ECM is in the service mode. On Hold is necessary to hold the set of
diagnostic information before troubleshooting or clearing.

Indicator - An indicator is any of the items within the CMS display area which operate in an ON,
Flashing, or OFF manner to bring attention to a machine condition.

MID (Module Identifier) - The MID is a diagnostic code tells that which electronic control
module diagnosed the fault. For example, main display module, engine control module, or
transmission control module. The MID is a two-digit code that is located in the digital readout
area when in the service mode.

Scroll - Scrolling is the process of showing (within the digital display area) all available sets of
diagnostic information, one set at a time. A set of diagnostic information is shown briefly, and
then the display automatically advances to the next set. After all sets are shown, the sets are
repeated.

Service Code - A code which describes a condition (sometimes a problem) in an electronic

control system. This code is stored in the control for the service technician.

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