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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.
FT 546C
15-1
12005
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.
FT 546C
15-2
12005
FT546C_15_003
Fig. 3: Relay/circuit breaker panel.
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.
FT 546C
15-3
12005
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.
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.
FT 546C
15-4
12005
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.
FT 546C
15-5
12005
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.
FT 546C
15-6
12005
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).
FT 546C
15-7
12005
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.
FT 546C
15-8
12005
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.
FT 546C
15-9
12005
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
3 flashes in a row
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
Continuous flashing
FT 546C
15-10
12005
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.
FT 546C
15-11
12005
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
15-12
12005
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.
FT 546C
15-13
12005
FT546C-15-017
Fig. 20: View of the handle halves separated.
Fig. 20 shows the handle separated into its halves.
FT 546C
15-14
12005
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).
FT 546C
15-15
12005
Electrical System
570-276-02
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
110303
Electrical System
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
MDDM wiring.tif
Fig. 3: Wiring diagram of Murphy Display and Diagnostic Module to identify electrical connections.
FT 546/548
110303
Electrical System
FT 546/548
110303
Electrical System
FT 546/548
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
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:
110303
Electrical System
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:
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Electrical System
FT 546/548
110303
Electrical System
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
110303
Electrical System
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.
110303
Electrical System
TROUBLESHOOTING
Diagnostic Procedure
Diagnosis of the electronic control system should be
performed according to the following procedure:
04
30
13-10
FT 546/548
1003
110303
Electrical System
Appplication
Forwarders
2-Digit Code
15
16
11
12
SPN/FMI Code
29 - 3 - Throttle 2
29 - 4 - Throttle 2
91 - 3 - Throttle 1
91 - 4 - Throttle 1
1003
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.
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.
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
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
replace switch
repair or replace switch
repair or replace relay
6. ALTERNATOR OVERCHARGES
BATTERY
defective voltage regulator
FT 546/548
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
FT 546/548
lamp sch
110303
Electrical System
FT 546/548
contact
contact
operator
110303
Electrical System
FT 546/548
3P brkr sch
110303
Electrical System
FT 546/548
fuse sch
110303
Electrical System
fuse sch
batt sch
110303
Electrical System
elec sym 1
Fig. 7: Chart shows some of the symbols used in electrical schematic drawings.
FT 546/548
110303
Electrical System
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