Challenger 35, Challenger 45 and Challenger 55 Agricultural Tractors Electronic Systems Caterpillar

Illustration 1	g00566399
(1) Chassis Control Module. (2) Fuel Level Sensor.

This fault code indicates the fuel level sensor has a higher than normal voltage and may be due to an open circuit or a short to positive voltage. Fuel level of 10% gives a resistance of 418 ohms. Resistance goes down as fuel level increases

1. Visually inspect Rear Main harness, Front Main harness and connectors (C002, C008 and C159) for damage or disconnected connectors.

   Expected Result: There is damaged parts or broken parts.

   • YES, repair damage or reconnect connectors as appropriate. Check fault codes. If fault code is not active, repair is complete.

   • NO, go to Step 2.

2. Check sensor for an open circuit between C159-1 and C159-2 (more than 100K ohms).

   Expected Result: There is an open in the circuit.

   • YES, replace fuel level sensor with a new sensor and recheck fault codes. If fault code is not active, repair is complete.

   • NO, go to Step 3.

3. Disconnect connectors C002 and C159. Check for open circuit in Front Main and Rear main harnesses between connector C159-1 and C002-17. Also check between C159-2 and C002-8.

   Expected Result: There is an open in the circuit.

   • YES, go to Step 4.

   • NO, go to Step 6.

4. Disconnect connectors C008. Check for open circuit in Front Main harness between connector C159-1 and C008-M. Also check between C159-2 and C008-X.

   Expected Result: There is an open in the circuit.

   • YES, locate and repair open circuit in Front Main harness. Check fault code and if no longer active the repair is complete.

   • NO, go to Step 5.

5. Check for open circuit in Rear Main harness between connector RM-C008-M and C002-17. Also check between RM-C008-X and C002-8.

   Expected Result: There is an open in the circuit.

   • YES, locate and repair open circuit in Rear Main harness. Check fault code and if no longer active the repair is complete.

   • NO, go to Step 6.

6. Check Front Main and Rear Main harnesses for short circuit to positive voltage from connector C159-1 and C159-2 (positive volts present when key start switch is ON).

   Expected Result: There is a short in the circuit.

   • YES, go to Step 7.

   • NO, go to Step 9.

7. Disconnect connectors C008 and C159. Check Front Main harness for short circuit to positive voltage from connector C159-1 and C159-2 (positive volts present when key start switch is ON).

   Expected Result: There is a short in the circuit.

   • YES, locate and repair short circuit in Front Main harness. Check fault code and if no longer active the repair is complete.

   • NO, go to Step 8.

8. Check Rear Main harness for short circuit to positive voltage from connector C008-M and C008-X.

   Expected Result: There is a short in the circuit.

   • YES, locate and repair short circuit in Rear Main harness. Check fault code and if no longer active the repair is complete.

   • NO, go to Step 9.

9. Download latest control module software into all control modules.

   Expected Result: The fault code is active.

   • YES, go to Step 10.

   • NO, repair is complete. Calibrate transmission and three-point hitch.

10. Replace the Chassis Control Module (CCM).

    Expected Result: The fault code is active.

    • YES, install the original CCM and repeat this troubleshooting procedure.

    • NO, go to Step 11.

11. Install the original CCM.

    Expected Result: The fault code is active.

    • YES, original CCM was faulty. Replace original CCM with new CCM. If fault code is not active, repair is complete. Download latest control module software into all modules. Calibrate transmission and three-point hitch.

    • NO, this fault code may have been caused by faulty connectors. Keep the original on the tractor. Clean all terminals on the CCM and reconnect. If fault code is not active, repair is complete. Download latest control module software into all modules. Calibrate transmission and three-point hitch.