02-1 General Electrical N T4 Rev2

N Series Loader Backhoe
General Electrical
Case N series Tier 4 Service Training Manual

General Electrical

General Electrical

General Electrical
Table of Contents
Electrical Theory.............................................................................................................................. 6
Ohms Law.................................................................................................................................... 6
Electrical Circuits ......................................................................................................................... 8
Resistance ................................................................................................................................. 11
Open circuit ............................................................................................................................... 11
Short Circuit .............................................................................................................................. 11
Voltage Drop ............................................................................................................................. 12
Ground connections...................................................................................................................... 13
Batteries ........................................................................................................................................ 17
Electrical Components .................................................................................................................. 20
Capacitors ................................................................................................................................. 20
Diodes ....................................................................................................................................... 22
Resistors .................................................................................................................................... 24
Relays ........................................................................................................................................ 25
Sensors ...................................................................................................................................... 26
Switches .................................................................................................................................... 26
Resistive Sensors ....................................................................................................................... 27
Potentiometers ..................................................................................................................... 27
Thermistor............................................................................................................................. 28
Fixed Resistor Usage with Sensors........................................................................................ 28
Pressure Transducer ............................................................................................................. 29
Inductive Sensors ...................................................................................................................... 30

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Hall Effect Sensors .................................................................................................................... 32
Pulse Width Modulation (PWM) ................................................................................................... 34
CAN bus ......................................................................................................................................... 36
EST Diagnostic Connector ............................................................................................................. 38
N Series Fuse, Relay, and Diode Chart .......................................................................................... 39
Front Console ............................................................................................................................ 39
Side Console .............................................................................................................................. 42
Additional Fuse, Relay, and Diode Locations ............................................................................ 49

General Electrical
Electrical Theory
Electricity, as applied in the operation of construction equipment, is the movement of electrons
through conductors used to perform a task, like generate a magnetic field, generate heat, or
create light. The behavior of electricity is very similar to that of a hydraulic system, where oil
flows through pipes, and whose flow is directed by valves and restrictions to perform useful
work, but in an electrical circuit, electrons are flowing through conductors, directed by switches,
relays and other components, and encountering resistance. When electricity is thought of in
these terms, it is easier to understand.
In electricity the following terms are used to define the nature of the electrical system:
 Amperage is the amount of electron “flow” (current) through an electrical circuit. One
amp is when 6.28 billion billion electrons pass a given point in the circuit.
 Resistance is the propensity for a material to resist the flow of current (amperage).
 Voltage is the difference in electrical potential, or electrical pressure, between two

points measured.
 Wattage is the total power consumed by a circuit. Watts are calculated by multiplying
volts times amps. Therefore a circuit which is using 30 amp alternator in a 12-volt
system is a 360 Watt load. Watts can be calculated into horsepower. 100 kilowatts (1
kilowatt = 1000 watts) is equal to 134.1 horsepower. In a hydraulic system, horsepower
is calculated by multiplying pressure times the flow.
Ohms Law
The basic scientific law which governs electricity and the relationship between the
characteristics of amperage, resistance, and voltage is called Ohm’s Law. In applying Ohms law,
if any two of the three elements are known, the third can be easily calculated. The following
chart shows the equation of this relationship. Ohm’s Law reveals that:
 If resistance increases, amperage will decrease and/or the voltage increases.
 If voltage increases, the amperage will increase and/or the resistance decreases.
 If amperage increases, the resistance decreases and/or the voltage increases.

General Electrical

General Electrical
Electrical Circuits
In order for electricity to perform useful work, it must be routed in the desired path, called a
circuit. The electrical circuit will contain the wires, connections, switches, and a load in a
controlled path which makes a complete route for the electrons to flow from the electron
source (battery) through the circuitry and return to the source again.
There are two types of circuits which are encountered, series and parallel circuits.
Series Circuit
In a series circuit, the electrons must flow through one component before continuing to the
next component in the circuit.
In the example series circuit shown, the current flows:
1. From the + terminal of the battery,
2. Through the fuse,
3. Through the first lamp,
4. Through the second lamp,
5. Through a common ground connection,
6. And back to the - battery terminal.
The fuse, first lamp, second lamp, and ground connection are all in series with each other. If an
open circuit occurs anywhere in the path, no current will flow.

General Electrical
Parallel circuit
In a parallel circuit, the electrons can flow through multiple paths, making each component
independent of the other.
In the example parallel circuit shown below, the current flows:
2. To a junction where the current will split in two directions,
4. And simultaneously through the second lamp,
5. Current from both lamps join back together through a common ground connection,
The two lamps are in parallel with each other, so if an open occurs with one lamp or its wiring
downstream of the junction, the second lamp will still continue to function.

General Electrical
Series - Parallel Circuit
These two types of circuit are combined together to form a series - parallel circuit, which is how
most circuits on construction machinery will be seen.
In the example series - parallel circuit shown below, the current flows:
2. To the switch,
3. To a junction where current will split,
5. And simultaneously through the second lamp,
6. Then through the third lamp,
7. The current from both the first and third lamps will join back together at a common
ground connection,
In this circuit, the switch is in series to the lamps, and so the switch will control current to ALL
lamps. The first lamp is in parallel with the second and third lamps, and the second and third
lamps are in series with each other. If the first lamp goes open, then the second and third lamp
will stay on. If the third lamp goes open, then the second lamp will also go out, but the first
lamp will stay on.
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General Electrical
Resistance
When discussing resistance in a circuit, we must remember that there are two types of
resistance - intended resistance and unintended resistance.
 Intended resistance is the load in the circuit where work is being done, i.e. a light bulb,
electric motor, solenoid valve, etc. There is also a small amount of intended ‘normal’
resistance encountered in wires, connections, switch contacts, etc, but this resistance is
taken into account with the design.
 Unintended resistance is a load in the circuit that is not part of the design, and is a result
of corrosion, loose connections, incorrect components used, broken wires, etc.
Unintended resistance is often the problem when an electrical circuit does not operate
correctly.
Open circuit
An open circuit is infinite resistance in a circuit. An open circuit is measured by an ohm-meter,
continuity tester, or a voltage drop test discussed in the next pages. A broken wire, faulty
switch, and unplugged connector are all examples of an open circuit.
Short Circuit
A short circuit occurs when an unintended path for current to return to the battery is present.
This means the electrons take a ‘shortcut’ back to the battery, which can result in extremely
high current and possible fire or machine damage. Examples are wires rubbing together
exposing the copper conductor, wires rubbing on a metal chassis or other component, or
similar events. Fuses are present on the machine to protect most circuits from the damage
caused by high current resulting from a short circuit. A short circuit is tested by using an ohm-
meter or continuity tester to find the unintended current paths. Often a simple visual
inspection will locate burnt or damaged wires at the short circuit location.
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General Electrical
Voltage Drop
When testing electrical circuits, the power consumption of a component can be tested by
measuring the voltage drop across that component. With a complete circuit, when current
encounters a resistance a voltage drop occurs across the point of resistance, just like an orifice
or restriction in a hydraulic system. Measuring voltage drop is one of the most useful
techniques to find resistive connections or other problems which cannot always be detected by
using an ohm-meter alone.
Using the example circuit below, there is almost no resistance between points A and B (across
the fuse) in the circuit. If a voltmeter is used to measure between points A and B, it would
show 0 volts. However if the fuse were removed or was blown, infinite resistance (open circuit)
would result, and now the voltmeter would show 12 volts between point A and B. Point B is
connected to the - battery terminal through the lamps and ground connection of the circuit.
With the fuse reconnected and a complete circuit, if we measure the voltage between point B
and F, it would show 12 volts. The two bulbs are consuming all 12 volts of the available power.
If the voltmeter were placed between points B and C, then it would show 6 volts (assuming
both bulbs are identical). Measuring between points D and E would also show 6 volts. The sum
of all voltage drops in a circuit will always be the battery voltage of 12 volts.
If an unintended resistance were present at a fuse connection, for example due to corrosion or
a loose terminal, then a voltage drop would result. Now, if a voltmeter were used to measure
between points A and B, it may show 2 volts, and 10 volts would be the voltage drop from B to
F. The voltage drop from A to B shows resistance where there should not be any resistance.
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General Electrical
Ground connections
In construction equipment, a common ground connection is generally used. The negative
battery terminal is connected directly to the machine steel chassis, and the other ground
connections from the electrical components on the machine are also connected to the steel
chassis. The circuit is completed by the electrons flowing through the steel chassis of the
machine. These ground connections are very critical to a correctly functioning electrical system,
and they are often overlooked in the electrical troubleshooting process. If the technician is
experiencing multiple component problems, intermittent problems, and / or very unusual
voltage readings at components, then a loose or corroded ground connection is often the
culprit.
Testing ground connections is most effectively done using the voltage drop measurement
method previously discussed. A resistance check is often inconclusive in showing a ground
connection condition, especially in the case of very high current circuits like the engine starter.
A battery or starter connection and cable may show a resistance of less the 1 ohm, but have a
voltage drop of several volts while cranking the engine. This voltage drop means that some of
the electrical power is being used to cross a resistive connection, not to run the starter motor.
It is difficult to measure extremely low resistance values, but a significant voltage drop may be
present under the electrical load.
Make sure the technician is aware of and checks the integrity of each of the ground
connections for the piece of equipment that is being serviced for an electrical problem.
There are 6 ground locations on the Case N series TLB:
1. Right inside frame rail above and in front of the rear axle mounting.
2. Right frame upright directly adjacent to starter.
3. Cab firewall inside front console.
4. Side console behind loader control handle.
5. Front ROPS / cab header right side facing front.
6. Rear ROPS / cab header right side facing rear.
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General Electrical
1. Right inside frame rail above and in front of the rear axle mounting.
a. Schematic Reference: “CHASSIS GROUND REAR RIGHT CHANNEL”

b. Components grounded at this location:
 SAHR Park Brake Solenoid  Pilot Controls
 Fuel Tank Sending Unit  Return to Dig
 Engine Control Unit (Tier 3 only)  Horn
 Back-up Alarm  Ride Control Solenoids
 Comfort Steer Solenoid  Power Lift Solenoid
 Quick Coupler Solenoids  Cold Start Hyd Pump Solenoid
 Air Filter Restriction Switch  Power Shuttle Trans Solenoids
 Torque Control Solenoid
2. Right frame loader upright directly adjacent to starter.
a. Schematic Reference: “CHASSIS GROUND ON UPRIGHT”

 Negative Battery Cable
 Main Chassis Harness Ground
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General Electrical
3. Cab firewall inside front console.
a. Schematic Reference: “CAB GROUND FIREWALL”

 Front Console Relays  Engine Control Unit (Tier 4 only)
 Front Console Switches (Indicator
Lights)
 Windshield Washer Pumps
4. Side console behind loader control handle. Requires console cover removal to access.
a. Schematic Reference: “CAB GROUND SIDE CONSOLE”

 EST Connector  Side Console Switches (Indicator
 Power Points Lights)
 Vehicle Control Module (VCM)  Side Console Relays
 Radio  EH Clam Controls
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5. Front ROPS / cab header right side facing front.
a. Schematic Reference: “CAB GROUND FRONT OUTSIDE”

 All Front Lights
 Front Wiper Motor
6. Rear ROPS / cab header right side facing rear.
a. Schematic Reference: “CAB GROUND REAR OUTSIDE”

 All Rear and Side Lights
 Rear Wiper Motor
 HVAC Blower Motor
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General Electrical
Batteries
A battery is an electrochemical device that stores chemical energy, which can be released as
electrical energy. In addition to supplying power for various circuits and meeting electrical
demands, the battery acts as a voltage stabilizer or "electrical reservoir". It smoothes out or
temporarily reduces high voltages (transient voltages), to protect sensitive components such as
diodes in the alternator.
All CNH construction equipment uses one or more lead acid 12V batteries for the electrical
system. During normal use of a machine, the battery is constantly being discharged, and then
recharged by the alternator. This process causes evaporation of the battery electrolyte.
Serviceable batteries (conventional, low maintenance, and hybrid) have vent holes to allow the
gases to escape; however this means that the battery electrolyte has to be topped off at
intervals. Maintenance free batteries have condenser channels, which allow the gases to
condense into liquids again. This prevents the gases from escaping through vent holes so there
is no requirement to top off the electrolyte.
Batteries are rated in a couple of ways
 Cold Cranking Amp (CCA) rating is the number of amps (current) that the battery can
deliver for 30 seconds at 0 deg F and maintain a minimum voltage of 1.2V pre cell or 7.2
volts total.
 Reserve Capacity is the number of minutes a fully charged batter at 80 deg F will deliver
25 amps, while maintaining a minimum of 1.75 volts per cell or 10.5 volts total.
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General Electrical
State of Charge
A batteries state of charge is the no load voltage which is measured at 80 deg F. The voltage is
determined by the specific gravity of the cell, which directly corresponds with the voltage of
each cell. The following chart gives the state of charge of the battery for the measured voltage
and specific gravity.
State of Charge Specific Gravity Battery Voltage
100% 1.287 12.6V - 12.8V

75% 1.246 12.4V
50% 1.210 12.2V
25% 1.170 12.0V
Discharged 1.130 11.8V
Battery Load Test

A battery load test is used to determine the health of a battery. Follow the steps below to load
test the battery.
1. Measure the no load battery voltage to ensure that the state of charge is at 75% or
better (battery static voltage greater than 12.4V).
2. Remove any surface charge from the battery caused by recent charging by applying a
load of 50% of the CCA rating for around 15 seconds, then wait 5 minutes
3. Apply a load of 50% of the battery CCA rating for no more than 15 seconds while
monitoring the battery voltage.
4. Compare the voltage reading to the chart below to determine if the battery passes or
fails the test.
Ambient Temperature Load Test Minimum Voltage
70 deg F or above 9.6V

50 deg F 9.4V
30 deg F 9.1V
10 deg F 8.7V
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General Electrical
Series or Parallel Battery Connections

Where more than one battery is used, the batteries can be connected in series or parallel to
achieve 24V or 12V depending on the system used by the machine.
In parallel arrangement, the system voltage will remain 12V, but the battery reserve and
cranking amp capacity is the sum of both batteries.
In series arrangement, the system voltage will become 24V, but the batter reserve and cranking
amp capacity is only that of a single battery.
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General Electrical
Electrical Components
There are many mysterious electrical components used in construction equipment which the
technician will need to be able to identify, understand its function, and be able to test
effectively.
The following components are commonly used in construction equipment circuits:
 Capacitors
 Diodes
 Resistors
 Relays
 Sensors
Capacitors
Capacitors have the ability to absorb and store an electrical charge, and then release it into the
circuit. This is much like the operation of an accumulator in a hydraulic system. Capacitors are
frequently used in timers that keep a circuit or devise in operation for a period of time after the
circuit has been shut off. An example of this is a radio that plays for a period of time after the
vehicle key has been switched off.
A capacitor is constructed from two conducting plates separated by an insulating material

called a dielectric. This material can be paper, plastic, film mica, glass, ceramic, air or a vacuum.
The plates can be aluminum discs, aluminum foil or a thin film of metal applied to the opposite
sides of a solid dielectric. These layered materials are either rolled into a cylinder or left flat.
The operation of a capacitor is fairly simple. When the capacitor is placed in the circuit, a charge
builds on the plates until the plates are at the same potential as the power source. When the
source potential is removed, the capacitor will discharge and cause a current flow in the circuit.
If the potential of the source changes, the capacitor will either charge or discharge to match the
source, thereby smoothing the voltage fluctuation in the circuit.
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General Electrical
Noise suppression
Noise in an audio system is often caused by an AC electrical voltage riding on top of the DC
voltage that supplies power to the radio. A capacitor that is connected into the circuit will filter
out the AC voltage by allowing it to pass to ground.
Spike suppression
A capacitor can absorb voltage spikes in a circuit. This application is used in conventional
ignition systems of a spark ignition engine to prevent an arc between the ignition points when
they open.
Timers
A resistor put in series with a capacitor, that in turn triggers a relay or transistor can keep
current flowing in the circuit for a specified amount of time. A dome light that stays on or
headlights that stay on a specific time period after the key has been shut off are examples of
this usage.
Testing Capacitance
Capacitors are tested using a special capacitance setting on many digital volt ohm-meters.
Capacitors are rated in ‘farads’ which is how many electrons it can store at one time.
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General Electrical
Diodes
Diodes block current flow in one direction and pass current in the opposite direction, like a
check valve in a hydraulic system. In the schematic symbol above current will travel through
the diode when the positive side is on the left, and the negative on the right (current travels in
the direction of the arrow).
The three main uses for diodes in CNH vehicles are rectification, de-spiking, and isolation.
Zener Diodes
A zener diode acts like a regular diode when it is in a forward bias, but it acts differently when
in reverse bias. A zener diode allows the current to flow in reverse bias at a specific voltage
without damage to the diode.
Zener diodes can be useful to regulate voltage in the entire electrical system or in an individual
circuit.
Light Emitting Diodes
LEDs are diodes that are specially designed to produce light. LEDs have advantages over
ordinary (incandescent) bulbs such as longer life, lower operating temperatures, lower voltage
requirements and lower total power consumption.
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General Electrical
Rectification
Because a diode allows current to flow in one direction and not the other, it can be used to turn
alternating current into direct current. This is called rectification.
Diodes can provide either half-wave rectification or full-wave rectification, depending on the
number of diodes and the way they are arranged in the circuit.
Despiking (suppression)
Diodes are used in conjunction with some relay coils or other coils to suppress voltage spikes.
The voltage spike is produced as the magnetic field in the coil collapses when the current flow
through the coil is stopped suddenly. The collapsing magnetic field induces voltage in the coil
similar to the way voltage is induced in an ignition coil. This induced voltage can be several
times system voltage.
A de-spiking diode is connected in parallel with the subject coil. It is reverse biased so that
when the coil is energized, there is no current flow through the diode. When the circuit that
powers the coil is opened current stops flowing through the coil and the magnetic field
collapses. The magnetic lines of force cut through the coil and induce a voltage. Since the circuit
is open, no current flows.
The voltage builds until it reaches about 0.7 volts, which is enough to forward bias the diode
and completes the circuit to the other end of the coil. The current flows around in the coil and
diode circuit until the voltage is dissipated.
Isolation
A diode can be used to separate to circuits, or top allow two circuits to operate together only
under certain circumstances.
Tesing Diodes
Diodes are tested by checking the voltage drop across it. The diode must have one of its
terminals removed from the rest of the circuit. Set the digital volt ohm meter to a diode test
mode. Place each of the meter leads across the two terminals of the diode, then reverse the
leads and check again. Typical meters will show “OL” in one direction and the “0.4 - 0.5 V” in
the other. Smaller diodes may often be checked with a resistance check. They should show
continuity in one direction, and an open circuit in the other.
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General Electrical
Resistors
A resistor is exactly what its name implies, and is rated by how many Ohm’s of resistance it will
create, as well as how many watts of power it can handle.
Hot environments can cause diodes used for spike suppression to fail prematurely. In such
environments a resistor is used in a parallel circuit with the coil. The resistor is more durable
and can suppress voltage spikes in much the same way as a diode can, but the resistor allows
current leakage to flow through it whenever the coil is actuated.
Therefore the resistance of the resistor must be fairly high to prevent too much current flow in
the circuit. Because of this high resistance, resistors are less efficient than diodes at suppressing
voltage spikes.
Ballast resistors are used to control voltage in a portion of a circuit. A common example of a
ballast resistor is the resistor used to reduce the voltage to an ignition coil in a breaker-point
ignition system.
Resistors are checked by placing an ohm-meter across its leads and reading the resistance.
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General Electrical
Relays
A relay is an electrically activated switch, which incorporates two separate circuits. A set of
high current contacts is activated by a small coil in a low current control circuit. Relays have a
magnetic coil that switches the internal contacts when the coil is supplied power and ground.
The high current switched contacts of the relay are the Normally Closed (NC) output which is
spring connected the common terminal when the relay is off. The Normally Open (NO) contact
is magnetically actuated and connects with the common terminal when the coil is energized.
Standard relays have the following terminal nomenclature:
• “85” is typically the coil activation low current terminal
• “86” is typically the coil ground terminal
• “30” is the common high current contact of the relay
• “87a” is the NC contact of the relay
• “87” is the NO contact of the relay
Relays are tested by checking the coil resistance, then checking continuity of the NO and NC
contacts with the coil activated and deactivated. Typical relay terminal locations are shown
below:
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General Electrical
Sensors
Sensors convert temperature, pressure, speed, position and other data into either digital or
analog electrical signals which are used by electronic controllers to make decisions regarding
machine function, inform an operator of machine condition, or directly control another
component. A machine may have many different types of sensors. There are four main
categories of sensors: switches, resistive, inductive, and Hall Effect.
 Switches toggle a reference voltage on (closed) or off (open).
 A resistive sensor reacts to changes in mechanical conditions through changes in its

resistance. An electronic controller supplies a regulated or reference voltage to the
sensor and measures the voltage drop across the sensor to determine the data.
 An inductive sensor generates its own voltage signal in relation to the mechanical
condition it monitors. An electronic controller is used to interpret this voltage signal.
 A Hall Effect sensor generates a signal voltage based on the strength of a magnetic field.
Switches
Several types of switches may be used depending on the data being monitored.
 A reed switch turns on and off based on the presence of a magnetic field or proximity to
a metallic object. Inside a reed switch there are two contacts, one moveable the other
stationary. The moveable contact is suspended by thin flexible material which allows it
to move. The movable contact is pulled toward the stationary contact when a magnet
or metal is placed near the reed switch.
 A bimetallic switch turns on and off based on temperature. It contains a bimetal

element that bends when heated to make contact completing a circuit or to break
contact opening a circuit.
 A pressure switch is comprised of a pair of contacts and a diaphragm. One contact is

attached to the body or housing of the switch (stationary) and the other contact is
attached to the diaphragm (moveable). When the diaphragm is acted upon by pressure
the contacts open or close.
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General Electrical
Resistive Sensors
Like switches, a resistive sensor is used to monitor position, pressure, or temperature. Instead
of turning on or off, they will provide a variable signal which can be used by an electronic
controller or gauge to know how much pressure or temperature in present, not just whether
the condition is on or off.
Potentiometers
The potentiometer is nothing more than a contact sliding along a strip or coil of resistive
material, often called a “pot”.
Potentiometers are a voltage divider which uses the principle of voltage drop to measure
changes in position. A pot has three connections: the reference, signal, and ground. The
reference is at one end of a resistor and the ground is at the other end. Current flows from the
reference through the resistor to ground creating a voltage drop across the resistor. The signal
is a sliding contact (movable wiper arm) that runs across the resistor.
In the above example, 5 volts is supplied to the reference, current flows from the reference (R)
through the entire resistor to ground (G). The Signal wiper slides across the resistor changing
the measured voltage as it moves. As the wiper moves towards the reference (R), the measured
signal voltage at (S) will increase. As the wiper moves away from the Reference (R) towards
ground (G), the measured signal voltage drops.
The main disadvantage of a potentiometer is that it wears out the contact between the resistor
and the signal wiper as it is used, resulting in ‘dead’ spots through the range of motion or an
open circuit. Potentiometers are being replaced by Hall Effect sensors in many applications for
this reason. Hall Effect sensors also provide greater precision.
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General Electrical
Thermistor
Thermistors are variable resistors whose resistance changes in relation to temperature. There
are two types of thermistors:
 Negative Temperature Coefficient (NTC) thermistors vary resistance as the temperature

goes down, the resistance goes up, and as the temperature goes up, the resistance
drops. This type is used today in automotive applications.
 Positive Temperature Coefficient (PTC) thermistors: as the temperature goes down, the
resistance goes down also, and as the temperature goes up, the resistance increases.
Fixed Resistor Usage with Sensors

Fixed resistors are often used in voltage division circuits. One example is the computer sensor
circuit shown below. Notice two resistors, R1 and R2, are placed in series. A fixed resistor R1,
known as a pull-up resistor, is used to create a voltage drop point. As the resistance of water
temp sensor (R2) changes, so does its voltage drop. This change also changes the voltage drop
of R1. A monitor circuit inside the electronic controller measures this voltage drop in between
the two resistors.
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General Electrical
Pressure Transducer
Most pressure measurements are referred to as ‘relative’ because they only record a change in
pressure. Since most measurements originate at atmospheric pressure, this point is often
referred to as "zero" pressure. Absolute pressure measurements are made with respect to
vacuum, while differential pressure is measured between two different points.
The most common form of pressure measurement uses a piezo resistive circuit or a
piezoelectric pressure transducer, (strain gauge connected to a diaphragm).
In order to generate an electrical output from a pressure input, that pressure must first be
converted into a proportional displacement or strain. Physically flexing or distorting a piezo
resistor (strain gauge) a small amount changes its resistance. The change in resistance is then
used to generate a voltage signal. Thus, most pressure transducers are comprised of two main
components, one mechanical, such as the diaphragm, and one electrical, strain gauge.
Diaphragm types may vary for minimal thermal shock error and minimum mass (fast response).
In addition, higher sensitivity can be achieved by increasing the diaphragm size or increasing its
effective area.
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Inductive Sensors
Inductive sensors used in the automotive/agricultural industry are constructed of a coil of wire
wrapped around an iron core and a permanent magnet. The magnet may be stationary or
moveable. These work on the principle of inductance, producing an electrical signal
proportional to a separate moving target. Inductive sensors are non-contacting and provide a
long operational life which is not affected by vibration.
If the magnet is the moving member, as it passes the coil the magnetic lines of force cut
through the coil and a voltage is produced. Since the north and south poles of the magnet
alternate as it passes the coil, the voltage polarity also changes.
If the magnet is stationary, it is attached to the core of the coil. When a tooth or target passes
by the face of the magnet, the magnetic lines of force move and cut through the coil. The lines
of force cutting through the coil will produce the same type of voltage output as when the
magnet was moving. As the speed of the magnet or metal target rotating past the coil is
increased, a larger voltage is produced and the frequency of the voltage polarity change also
increases. Subsequent sophisticated electronics are used to condition this signal to get a digital
waveform that can be more readily counted and timed.
Because the magnitude of the signal developed by an inductive sensor is proportional to target
speed, it is difficult to design circuitry to accommodate very-low-speed signals. A given
inductive sensor has a definite limit as to how slow the target can move and still develop a
usable signal.
This additional complexity is the main reason why inductive sensors have been superseded with
other non-contact sensors such as those based on the Hall Effect which generally cost less and
are simpler to use.
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Hall Effect Sensors
The Hall Effect sensor works on a simple electromagnetic principle. In 1879 Edwin Hall observed
that when a thin sheet of conducting material such as gold foil has current flowing through it, a
separate small voltage could be induced in the foil by passing a magnetic field at right angles to
the foil. This voltage is called the Hall-effect voltage. Hall Effect sensors produce a digital or
analogue output proportional to the magnetic field strength which is amplified to enable
different voltage outputs.
In a Hall-effect speed sensor, the Hall-effect transducer element detects target-induced flux
changes from where it is situated, between the magnet and the target. Unlike an inductive
sensor, however, a Hall transducer is sensitive to the magnitude of flux, not its rate of change.
This feature of Hall-effect technology allows you to make speed sensors that can detect targets
moving at arbitrarily slow speeds, or even the presence or absence of nonmoving targets. For
applications where you must keep track of total revolutions (such as in an odometer), zero-
speed sensing is important because it guarantees the user will not lose count when the target
moves slowly.
Another important feature of Hall-effect speed sensors is that the signal-processing electronics
are often integrated into the same package as the transducer, providing several benefits. The
most important benefit is that little or no additional signal-processing circuitry is required--
most Hall-effect speed sensors directly provide a digital output signal that is directly compatible
with common electronic controllers.
32

General Electrical
Hall Effect sensors are fast becoming an attractive alternative to inductive sensors, offering the
same reliable, virtually unlimited life as a non-contacting technology, but at lower cost as they
do not require sophisticated electronics. The main disadvantage is that they are sensitive to
electromagnetic interference but this can be overcome with the use of appropriate shielding
and good internal circuit design for all but the most demanding environments.
A rotary Hall Effect sensor could be suitable to replace existing potentiometer applications. This
type of sensor combines a set of electronics and a highly accurate Hall Effect rotary sensor
fitted to the selector barrel or disc. As the barrel or disc is rotated the rotary Hall Effect sensor
measures the position change precisely and the electronics in the sensor produces an analog or
digital output relative to the sensor’s position. This offers highly reliable and repeatable results,
compared to a contact potentiometer.
On the Case N series TLB, the foot and hand throttle sensors, pilot control stabilizer switches,
and the yellow buttons in the pilot joysticks for extendahoe and auxiliary controls are all Hall
effect sensors.
Testing Hall Effect sensors can be more difficult than a potentiometer or inductive sensor due
to the need to have current across the Hall element before the signal voltage can be generated.
The best testing method is to use the Electronic Service Tool (EST) to monitor sensor supply and
signal voltages, use a breakout harness, or carefully back-probe electrical connectors to
monitor voltage using a conventional digital voltmeter.
33

General Electrical
Pulse Width Modulation (PWM)

PWM is modulating the duty cycle of a fixed frequency square wave to produce a specific
signal/output. DC voltage is converted to a square-wave signal output, by alternating between
fully on and zero, giving the load a series of power "kicks". At any given instant of time, the full
DC supply is either fully on or fully off. The voltage or source is supplied to the analog load
(solenoid) by means of a repeating series of on and off pulses. The on-time is the time during
which the DC supply is applied to the load, and the off-time is the period during which that
supply is switched off. Given a sufficient bandwidth, any analog load can be driven with PWM.
By adjusting the duty cycle of the signal (modulating the width of the pulse, hence the 'PWM')
ie, the time fraction it is "on", the average current can be varied, and thus the magnetic field
generated by a solenoid varies.
The following figures show three different PWM signals. The first shows a PWM output at a
20% duty cycle. That is, the signal is on for 20% of the period and off the other 80%. The second
and third figures show PWM outputs at 50% and 80% duty cycles, respectively. These three
PWM outputs encode three different analog signal values, at 20%, 50%, and 80% of the full
strength. If, for example, the supply is 12V and the duty cycle is 20%, a 2.4V analog signal
results with an equivalent current of approximately 20% of the full current at 12V. Common
modulating PWM frequencies range from 100Hz to 250Hz.
34

General Electrical
There are several advantages to using PWM instead of a linear voltage control such as a
variable resistor. First, the output transistor used to create the PWM signal is either on or off,
not partly on as with normal voltage regulation, so less power is wasted as heat. Also, the full-
power pulsing action at low duty cycles will run loads at much lower levels than an equivalent
steady voltage.
The magnetic force a coil produces is proportional to the amperage flowing through the coil. As
the temperature of a coil increases, the resistance of the coil also increases. Based on Ohm’s
Law, if the voltage applied to a coil stays the same and the coils resistance increases, the
amperage flowing through the coil will decrease. Therefore the magnetic force the coil
produces will also decrease.
To avoid this phenomenon, modern electronics monitor the amperage flowing through a coil
powered with PWM. The amperage monitored by the electronics becomes the feedback for
the coils output force. With this feedback, a change in the coil’s magnetic force caused by a
change in its resistance which is caused by a change in its temperature can be corrected by
changing the duty cycle of the PWM applied to the coil.
On the Case N series TLB, the solenoids used for the electric pilot controlled functions, as well
as many of the solenoids of the Powershift transmissions use PWM activation.
35

General Electrical
CAN bus
Multiple electronic control units are used on machines to control the operation of the various
systems. An engine control unit (ECU), Transmission Control Unit (TRAX), and Vehicle Control
Module (VCM) are used in the N series TLB. In order for these controllers to be able to
communicate and work together, a system called “CAN bus” is used.
CAN stands for “Controller Area Network”, and was first developed by Bosch and Intel in 1984.
It has been widely used in the automotive and truck industry for many years and has more
recently been implemented in construction equipment. CAN is a network connecting electronic
controllers on a machines which allows information to be shared among all the connected
controllers.
The advantages of a CAN bus system include:
 Replacement of mechanical components and controls with more reliable, better

performing, and cost effective electronic controls.
 More comfort, safety, and features from inside of the vehicle.
 Linking various electronic controllers with data bus gives us less hardware and more
software.
 Reduces the number or wires and the length of the wiring harness.
 Ensure all signal information is available to all controllers on the network.
 Less wiring and fewer connectors increases reliability and durability.
 Use of signal data by multiple controllers results in few sensors needed.
 Improved and more precise diagnostic capabilities.
The CAN bus consists of two wires, called CAN HI and CAN LO, which are connected to all
controllers. These two wires carry the data messages in a ‘language’ understood by all the
connected controllers. This CAN bus backbone contains one or more terminating resistors with
a value of 120 Ohms between the CAN HI and CAN LO wires. There are two terminating
resistors used in Case M series 3 and N series TLB’s. The N series Tier IV CAN bus network is
shown on the following page (M series 3 and N series Tier 3 units are slightly different, refer to
the appropriate wiring schematic for those machines). Note that the CAN HI and CAN LO wires
are a twisted pair of wires in their own loom within the wiring harness.
36

General Electrical
CAN LO = ~2v
120 OHM
/\/\/\/\/\
3 55
4 27
VCM CAN HI = ~3v TRAX
12V+
GND-
A
EST B
DIAGNOSTIC C
CONNECTOR D K-LINE
E
68
S
120 OHM
/\/\/\/\/\
TELEMATICS J
CONNECTOR E
ECU
24
D 25
To test the CAN bus network, use a volt-ohm meter at the EST Diagnostic Connector and check
the following:
 Checking voltage from pin B to pin A should be 12V (battery voltage).
 Checking voltage from pin C to pin A with the key on should be approximately 3.0V
 Checking voltage from pin D to pin A with the key on should be approximately 2.0V
 The difference in voltage from pin C to pin D with the key on must be at least 0.1V
 Checking resistance from pin C to pin D with the key off should be 60 Ohm (due to the
two 120 Ohm resistors in parallel between CAN HI and CAN LO).
37

General Electrical
EST Diagnostic Connector
C
B
PIN FUNCTION
A Ground
B 12V Battery
C CAN HI, approximately 3V when referenced to ground
D CAN LO, approximately 2V when referenced to ground
E K-Line, communication with ECU only
38

General Electrical
N Series Fuse, Relay, and Diode Chart

The fuses and relays are located in the side console near the loader control handle and the left
side of the front console of the N series TLB. The following chart will show the fuse decal icons,
a description of the circuits involved for each component, and the identification number and
schematic page on which they can be found. Note that there are two wiring harness
configurations for these units, for units with either the Power Shuttle or Powershift
transmissions.
Front Console
Powershift Transmission decal:
Power Shuttle Transmission decal:
39

General Electrical
Icon Circuit Schematic Schematic
ID Frame
Headlights F-011 9
Front Work Lights F-006 9
Turn Signals F-014 9
Front Wipers/Washers F-007 11
Brake Lights F-012 17
Rotating Beacon Light F-013 17
Comfort Steer Power Relay (Powershift only) K-007 20
Comfort Steer Cutout Relay (Powershift only) K-014 20
Declutch Relay (Power Shuttle only) K-009 2
40

General Electrical
Shuttle Interlock Relay (Power Shuttle only) K-013 6
Power Relay # 3 K-003 1
ECU Start Relay K-017 2
Reverse Signal Diode (Powershift only) V-007 6
Forward Signal Diode (Powershift only) V-006 6
41

General Electrical
Side Console
Power Shuttle Transmission decal:
10A
20A
20A
42

General Electrical
Powershift Transmission decal:
10A
20A
20A
43

General Electrical
Icon Circuit Schematic Schematic
ID Frame
Diagnostic B+, Telematics F-001 or 25 or 28

F-024
10A
VCM Key On F-003 12
VCM B+ F-004 12
Rear Lights F-005 17
Rear Wipers/Washers F-008 11
Transmission Key On, Differential Lock, Declutch F-009 2
Tail Lights F-010 17
Pilot Controls, Auxiliary Hydraulics F-015 or 22 or 26
F-030
Cigarette Lighter F-016 13
44

General Electrical
Four Wheel Drive, Ride Control F-017 6
Dome Light F-019 10
Radio B+ F-020 16
Horn F-021 19
Heater / Air Conditioning Blower Motor F-022 15
Air Conditioning F-023 15
TRAX controller B+ (Powershift only) F-024 23
Key Switch B+ F-025 2
Air Ride Seat F-026
20A
Engine Starter F-027 2

20A
45

General Electrical
Power Shuttle Trans Speed Sensor for Auto Ride F-001 20
Control (Power Shuttle Only)
Quick Coupler, EH Clam, Radio, Boom Lock F-028 7
SAHR Parking Brake F-029 14
Comfort Steer F-015 or 20
F-030
Power Lift, Torque Control, Return To Dig F-031 21
Side Lights F-032 17
Customer Option B+ F-033 1
Customer Option Key On F-034 2
46

General Electrical
SAHR Parking Brake Relay K-005 14
SAHR Park Brake Transmission Cutout Relay K-006 14
Forward Relay (Power Shuttle only) K-007 6
Air Conditioning Relay K-008 15
Comfort Steer Relay (Power Shuttle only) K-011 20
Reverse Relay (Power Shuttle only) K-014 6
Neutral Relay K-015 2
Start Relay K-016 2
47

General Electrical
Auto Ride Control Relay K-012 20
Rear Light Relay K-019 17
Power Lift Relay K-010 21 or 24
Loader Quick Coupler Retract Logic Diode V-001 7
Backhoe Quick Coupler Retract Logic Diode V-002 7
Quick Coupler LS Coil Suppression Diode V-003 7
Loader Quick Coupler Retract Coil Suppression Diode V-004 7
Backhoe Quick Coupler Retract Coil Suppression Diode V-005 7
Reverse Interlock Logic Diode (Power Shuttle only) V-007 6
48

General Electrical
Forward Interlock Logic Diode (Power Shuttle only) V-008 6
Torque Control Logic Diode V-012 21
Additional Fuse, Relay, and Diode Locations

There are several components which are located independently from the main fuse and relay
blocks at the front and side consoles.
Component Schematic ID Schematic Location

Frame
Pilot Control Enable K-021 9 Above rear axle adjacent to pilot

Relay controller
Pilot Control Diode V-013 8 Pilot control harness near pilot

controller
Engine ECU Power K-023, F-037, F-038, 4 Front console adjacent to ECU
Relay & Fuses F-040
Glow Plug Controller F-035 or F-037 4 Under hood right side at lower
Fuse cab firewall
Return to Dig Diode V-011 21 Harness connector near Torque

Control solenoid
49

02-1 General Electrical N T4 Rev2

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N Series Loader Backhoe

Case N series Tier 4 Service Training Manual

Case N series Tier 4 Service Training Manual

Case N series Tier 4 Service Training Manual

Electrical Circuits ......................................................................................................................... 8

Open circuit ............................................................................................................................... 11

Short Circuit .............................................................................................................................. 11

Voltage Drop ............................................................................................................................. 12

Electrical Components .................................................................................................................. 20

Resistive Sensors ....................................................................................................................... 27

Fixed Resistor Usage with Sensors........................................................................................ 28

Pressure Transducer ............................................................................................................. 29

Inductive Sensors ...................................................................................................................... 30

Case N series Tier 4 Service Training Manual

Pulse Width Modulation (PWM) ................................................................................................... 34

CAN bus ......................................................................................................................................... 36

EST Diagnostic Connector ............................................................................................................. 38

N Series Fuse, Relay, and Diode Chart .......................................................................................... 39

Front Console ............................................................................................................................ 39

Side Console .............................................................................................................................. 42

Additional Fuse, Relay, and Diode Locations ............................................................................ 49

Case N series Tier 4 Service Training Manual

 Voltage is the difference in electrical potential, or electrical pressure, between two

 If resistance increases, amperage will decrease and/or the voltage increases.

 If amperage increases, the resistance decreases and/or the voltage increases.

Case N series Tier 4 Service Training Manual

Case N series Tier 4 Service Training Manual

In the example series circuit shown, the current flows:

1. From the + terminal of the battery,

2. Through the fuse,

3. Through the first lamp,

4. Through the second lamp,

5. Through a common ground connection,

6. And back to the - battery terminal.

Case N series Tier 4 Service Training Manual

In the example parallel circuit shown below, the current flows:

1. From the + terminal of the battery,

2. To a junction where the current will split in two directions,

3. Through the first lamp,

4. And simultaneously through the second lamp,

6. And back to the - battery terminal.

Case N series Tier 4 Service Training Manual

1. From the + terminal of the battery,

3. To a junction where current will split,

4. Through the first lamp,

5. And simultaneously through the second lamp,

6. Then through the third lamp,

8. And back to the - battery terminal.

Case N series Tier 4 Service Training Manual

Case N series Tier 4 Service Training Manual

Case N series Tier 4 Service Training Manual

There are 6 ground locations on the Case N series TLB:

2. Right frame upright directly adjacent to starter.

3. Cab firewall inside front console.

4. Side console behind loader control handle.

5. Front ROPS / cab header right side facing front.

6. Rear ROPS / cab header right side facing rear.

Case N series Tier 4 Service Training Manual

a. Schematic Reference: “CHASSIS GROUND REAR RIGHT CHANNEL”

2. Right frame loader upright directly adjacent to starter.

a. Schematic Reference: “CHASSIS GROUND ON UPRIGHT”

Case N series Tier 4 Service Training Manual

a. Schematic Reference: “CAB GROUND FIREWALL”

a. Schematic Reference: “CAB GROUND SIDE CONSOLE”