Chassis Control Unit (Ccu)/Codes (4000); Testing Oil Level Sensor - Arctic Cat ZR4000 Service Manual

7. Start the engine and allow it to idle. Meter reading
must be within 9-15 AC volts.
4000
1. Remove the right-side access panel; then remove the
lower console from the right-side skid plate and
secure out of the way.
2. Connect the red MaxiClip and meter lead to the
red/blue lead of the connector; then connect the
black MaxiClip and meter lead to the black lead of
the connector.
XM411A
3. Start the engine and allow it to idle. Meter reading
must be within 9-15 DC volts.
NOTE: If tests failed, check all connections, and

fuses, etc., and test again. If no voltage is present,
replace the stator assembly.
Chassis Control Unit
(CCU)/Codes (4000)
The CCU distributes regulated DC power to the chassis
electrical systems and controls the forward/reverse shift-
ing of the ACT drive to ensure safe operation.
The CCU has two DC outputs used for lighting circuits.
Both outputs have a circuit breaker (self resetting
devices) protecting components from over-current and
short circuit situations. If a system stops working, a short
has likely occurred and the system has shut itself off
much like a fuse will blow if a circuit is shorted to
ground. However, unlike a fuse if the short is resolved,
the CCU will reset the output and the system will return
to normal operation.
The first output, labeled the High Power DC Output, sup-
plies power for the headlights and hand-warmers and is
on only while the engine is running. This output is turned
off during shifting to allow maximum power transfer to
the ACT drive.
The second output, labeled the Low Power DC Output,
supplies power to the gauge, speed sensor, taillight,
accessory plugs, and APV servomotor via the Engine
Control Unit. This output is on only while the engine is
running. It is not turned off during shifting.
NOTE: If the engine will not run, the problem is not

related to the CCU.
142
SERVICE ICON
The Service Icon is controlled by the CCU/ECM and
may illuminate for a number of reasons. The icon should
illuminate or illuminates each time the engine is started,
and it should go out after a few seconds. If the icon stays
illuminated while the engine is running, the CCU/ECM is
receiving input that is outside of its established parame-
ters.
Accessing CCU Codes
1. Connect the appropriate harness from CCU Diagnos-
tic Test Kit to the diagnostic port.
2. Start the engine. After approximately 5 seconds, the
service icon on the gauge will begin flashing.
3. The readout screen will display an error code as
CCU followed by a number (refer to the CCU Diag-
nostic Codes chart for descriptions). When all error
codes have been output, the service icon flashes
twice quickly.
CCU Diagnostic Codes
Code Trouble
CCU 32 High power DC output
over current.
CCU 33 High power DC output
shorted.
CCU 34 Low power DC
output over current.
CCU 35 Low power DC output
shorted.
CCU 37 System over voltage. Spike in battery voltage - excessive
CCU 38 Gear shift actuator
failure.
CCU 42 Tachometer input
failure (engine running
- no tachometer signal
present).
CCU 43 Gear position switch
failure.
CCU 44 CCU over
temperature.
Clearing Fault Codes
1. Connect the appropriate harness from CCU Diagnos-
tic Test Kit to the diagnostic port.
2. Start the engine; then press and hold the shift button
for 5 seconds.
NOTE: Two quick flashes of the service icon indi-

cate the codes have been cleared.

Testing Oil Level Sensor

The oil level sensor is a magnetic switch. Its operation is
based on a magnet located in the float. The switch
located in the stem of the sending unit is positioned
through the hole in the float. When the float drops to the
lower part of the stem, the magnet closes the electrical
contacts (located in the stem) allowing the current to pass
on to the warning light.
Cause
Headlight and Hand Warmer
(Red/Black) circuit current greater than
20 Amps.
Headlight and Hand Warmer
(Red/Black) circuit shorted to ground.
Gauge, Taillight, and APV Servo Power
(Red/Blue) circuit current greater than
20 Amps.
Gauge, Taillight, and APV Servo Power
(Red/Blue) circuit shorted to ground.
gear case shifting.
Wires to reverse actuator damaged or
shorted to ground.
Tachometer signal wire shorted to
ground.
Gear position switch damaged or
unplugged - reverse actuator not
working correctly.
Internal CCU temperature over 105° C
(221° F).