[eng][january 2006].pdf

Excavators Electronic System

M316C Material Handlers Excavators Electronic System Systems Operation Index

Introduction General Information (Monitoring System) Keypad Display Gauges

1 2 3 4 5

Fuel Level Coolant Temperature Hydraulic Oil Temperature Throttle Position Monitor

Indicators Powerup Sequence (Monitoring System) Warning Operation

6 7 8

Warning Level 1 Event Codes Warning Level 2 Event Codes Warning Level 3 Event Codes

Diagnostic Operation

9

Communication Errors Monitor Error CAN Data Link (Error)

Main Menu Quick Coupler Menu Preferences Menu

10 11 12

Language Selection Adjusting The Clock Display Adjustment Contrast Brightness

Tool Select Menu Filter Fluid Hours Menu Service Options Menu

13 14 15

MACHINE INFO OPERATING HOURS TOOL INDICATOR

Service Options PW Menu Reset Service Hours Menu Change Password Menu Switch Status Menu Status Menu Active Error Menu Logged Error Menu Logged Events Menu Configuration Menu Tool Adjustment Menu RTC Compensation Interval Menu Soft Switch Panel

16 17 18 19 20 21 22 23 24 25 26 27

Automatic Engine Speed Control Switch (AESC) Power Mode Switch Oscillating Axle Lock Switch Creeper Speed Switch Travel Lock Switch Hydraulic Modulation Control Parking Brake Control Switch Switch (Implement Lockout) Switch (Transmission Speed Control) Travel Alarm Cancel Switch

General Information (Machine Electronic Control System) Automatic Engine Speed Control Function Brake Light Function Creeper Speed Function Engine Start Function Generator Function High Boom Function Hydraulic Activation Control Function Hydraulic Modulation Function Hydraulic Oil Cooling Function Limp Home Function Machine Working Function Oscillating Axle Control Function Parking Brake Function Power Mode Function Powerup Sequence (Machine Electronic Control System) Quick Coupler Function Refueling Function Swing Brake Function Travel Activation Function

28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47

Travel Pedal Operation Position Sensor Auto-Calibration And Operation

Travel Alarm Function Travel Speed Function

48 49

Activation Of The Travel Speed Solenoid Activation Of The Gear Shift Solenoids Travel Motor Control

Travel Speed Lock Function

50

Activation of the Travel Speed Lock

Medium Pressure Hydraulic System

51

Right Joystick Thumbwheel Position Sensor Operation Medium Pressure Enable Joystick Steering Hydraulic Cab Riser Or Offset Boom

Auxiliary Hydraulic System Auxiliary Pedal Forward Pressure Switch Operation Auxiliary Pedal Reverse Pressure Switch Operation Operation With No Switches Actuated

52

Operation With Both Switches Actuated Auxiliary Pedal Position Sensor Operation With The Active Tool As "Hammer" or "Generator" or "No Tool"

Data Link Electronic Control Module (ECM)

53 54

Inputs Outputs Input/Output

Switches

55

Limit Switches Limit Switch (Service Brake Pedal) Limit Switch (Travel Pedal) Limit Switch (Armrest) Limit Switch (Boom) Limit Switch (HCR Door) Level Switches Level Switch (Coolant Level) Level Switch (Hydraulic Oil Level) Pressure Switches Pressure Switch (Multifunction Valve Reverse) Pressure Switch (Multifunction Valve Forward) Pressure Switch (Forward Travel) Pressure Switch (Reverse Travel) Pressure Switch (Swing Pilot) Pressure Switch (Main Pump) Pressure Switch (Brake Oil Accumulator) Pressure Switch (Quick Coupler) Pressure Switch (Service Brake) Switch (Overload Warning) Pressure Switch (Hydraulic Oil Filter) Switch (Air Filter Restriction) Switch (Backup / Limp Home) Switch (Fuel Pump) Medium Pressure Switch

Sensors

56

Sensor (Fuel Level) Position Sensor (Swash plate Angle) Pressure Sensor (Transmission Clutch) Temperature Sensor (Hydraulic Oil) Position Sensor (Travel Pedal) Position Sensor (Auxiliary Hydraulic Pedal) Position Sensor (Right Joystick Thumbwheel) Speed Sensor (Transmission Output)

Solenoid Valves Solenoid (Auxiliary Hydraulic Oil Pressure) Solenoid (Auxiliary Hydraulic Oil Flow) Solenoid (Engine Cooling Fan) Solenoid (Swing Pump)

57

Solenoid (Main Pump) Solenoid (Travel Pilot Pressure) Solenoid (Travel Motor Swash Plate Angle) Solenoids (Medium Pressure 1 And 2) Solenoid (Travel Motor Bypass) Solenoid (Hydraulic Modulation) Solenoids (On/Off Type) Solenoid (Travel Activation) Solenoid (Swing Brake) Solenoid (Parking Brake) Solenoid (Travel Speed) Solenoid (Implement Lockout) Solenoid (Generator) Solenoid (Creeper Speed) Solenoid (Oscillating Axle) Solenoid (Directional Or Hammer) Solenoid (Quick Coupler) Solenoids (Transmission Gear Shift 1 And 2)

Relays

58

Relay (Implement Lockout) Relay (Fuel Pump)

Related Components Travel Lock Magnet Travel Alarm Horn

59

SYSTEMS OPERATION

001

SYSTEMS OPERATION

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Introduction SMCS - 7000-EK; 7490

Illustration 1

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The M300C series of wheeled excavators features electronic control of many machine functions. The Machine ECM controls the manner in which the machine will operate. The ECM communicates with other control modules on the machine in order to coordinate machine control. This communication takes place over the Cat Data Link and the CAN data link. The data link circuits allow the ECM to send and receive machine status data from the other control modules. The ECM receives input data from many types of devices including: The Monitor that is located in the cab via the CAN data link The Soft Switch panel that is located in the cab via the CAN data link

The Engine ECM via the Cat Data Link The MSS ECM (if equipped) via the Cat Data Link Various "hard wired" switches that include operator controlled switches, machine system float switches, machine system pressure switches and machine system sensors. Various "hard wired" sensors that include speed sensors, pressure sensors and temperature sensors The Cat Service Tool through the service tool connector The ECM makes decisions that are based upon the state of these inputs and the operating parameters that are stored in the ECM memory. The ECM will activate outputs in order to energize or de-energize solenoids that will control the different functions of the machine. The Monitor will allow the operator to view the status of the machine systems. The Monitor continuously checks the status of the critical machine systems and will alert the operator or technician if a condition exists that is not within accepted machine parameters. The Monitor will allow the operator to adjust parameters that can customize the operation of the machine. The Monitor can be programmed to control a variety of work tools that require different hydraulic system operation. The operation of the Monitor is explained in this manual.

SYSTEMS OPERATION

002

SYSTEMS OPERATION

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General Information (Monitoring System) SMCS - 7490 The monitoring system on the M300C is an input and an output of the Machine Control System. The Machine Control System communicates back and forth on the CAN data link. The monitoring system consists of the following components: display with numerous screens and menus, keypad, indicators and gauges. These components will be described throughout this section of the manual. The Monitor informs the operators of the status of the machine. The monitor includes a graphic display that allows the operator to view information that pertains to machine functions.

Illustration 1

g01147148

(1) Alert indicator (2) Indicators (3) Gauges (4) Display area (5) Keypad

The monitor communicates with the machine control ECM, the engine control and the soft switch panel via the CAN data link. The CAN data link connects to the machine control ECM at connector contact J1-6 (wire F712-GY) and connector contact J118 (wire F711-GN). The CAN data link connects to the machine interface connector for the engine at connector contact 61 (wire F712-GY) and connector contact 52 (wire F711-GN). The monitor has a DEUTSCH DT 8 pin male connector. The contact description of the connector for the monitor is in table 1. Table 1

Contact

Description

1

+ Battery

2

Key switch ON

3

High beam

4

CAN data link +

5

Ground

6

CAN data link -

7

Right flasher

8

Left flasher

SYSTEMS OPERATION

003

SYSTEMS OPERATION

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Keypad SMCS - 7490 The Keypad allows the operator to access the menus that are available in the display area. The keypad also allows the operator to scroll and select items within the menu displays. The keypad allows the operator to change certain values of selected parameters in order to modify some machine functions. When one of the buttons on the keypad is pressed, the internal chime will sound for a short period.

Illustration 1

g01147160

(1) Upward Key (2) Right Key (3) Set Key (4) Menu Key (5) Left Key (6) Downward Key (7) Cancel Key display (8) OK Key

Upward Key (1) - The Upward Key is used for moving the cursor upward and for inputting the number while the operator is viewing the Graphic Display. Right Key (2) - The Right Key is used in order to scroll the cursor in the right hand direction while the operator is viewing the Graphic Display. Set Key (3) - The Set Key is used to validate or set a selected item. Menu Key (4) - The Menu Key is used to access the main menu. Left Key (5) - The Left key is used for scrolling the cursor in the left hand direction while the operator is viewing the Graphic Display. Downward Key (6) - The Downward Key is used for moving the cursor downward. The Downward Key is also used in order to input the number while the operator is viewing the Graphic Display. Cancel Key (7) - The Cancel Key is used for rejecting a prompt choice. In addition, the Cancel Key is used in order to escape from the menu that is displayed. Pressing this key will return from any other display to the previous display level. OK Key (8) - The OK Key is used in order to select the menu item that is highlighted on the Graphic Display.

SYSTEMS OPERATION

004

SYSTEMS OPERATION

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Display SMCS - 7490 The display on the monitor allows the operator to view information regarding the excavator. Warnings are displayed on the monitor. See Systems Operation, "Warning Operation" for more information. The display shows many different menus that are used by the operator to get information regarding the machine. See Systems Operation, "Menus" for more information. The display also shows information to the operator that is not a menu. These direct messages appear on the display in response to a machine condition. "BOOM ANGLE HIGH" (Attachment) - This display informs the operator that the angle of the boom is high. "BACKUP" - This display informs the operator that the machine is in the backup mode. The backup mode is activated by a switch in the cab. "TRAVEL SPEED LOW" - This display informs the operator that the travel speed that is selected is "LOW". A button on the switch panel causes the display to show this message. "TRAVEL SPEED HIGH" - This display informs the operator that the travel speed that is selected is "HIGH". A button on the switch panel causes the display to show this message. "CREEPER SPEED" - This display informs the operator that the creeper speed is selected. "FUEL PUMP ON" - This display informs the operator that the fuel pump is on.

SYSTEMS OPERATION

005

SYSTEMS OPERATION

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Gauges SMCS - 7490

Fuel Level

Illustration 1

g00827087

(1) Segment 1 (2) Segment 11

The display for the fuel level is divided into 11 segments. The percentage of fuel that is in the tank can be determined by the number of segments that are displayed. Refer to Table 1 for the percentage of fuel that is in the tank. The amount of fuel will vary depending on the size of the fuel tank. Refer to Table 2 for tank capacity according to the machine model. Table 1

Number of Segments that are Displayed

Percentage of Fuel in Tank

1

0 - 0.8

1,2

1.2 - 10.0

1,2,3

10.4 - 20.0

1,2,3,4

20.4 - 30.0

1,2,3,4,5

30.4 - 40.0

1,2,3,4,5,6

40.4 - 50.0

1,2,3,4,5,6,7

50.4 - 60.0

1,2,3,4,5,6,7,8

60.4 - 70.0

1,2,3,4,5,6,7,8,9

70.4 - 80.0

1,2,3,4,5,6,7,8,9,10

80.4 - 90.0

1,2,3,4,5,6,7,8,9,10,11

90.4 - 100.0 Table 2

Model M313C, M315C M316C, M318C MH M318C, M322C, M322C MH

Capacity 240 Liters (63.4 US gal) 310 Liters (81.9 US gal) 380 Liters (100.4 US gal)

Coolant Temperature

Illustration 2

g00827124

(1) Segment 1 (2) Segment 11

The display for the Coolant Temperature is divided into 11 segments. Each segment represents a temperature range. Refer to Table 3 for the range of temperatures that is represented by each segment. Note: Segment 1 is displayed when the system voltage is present. Table 3 Number of Segments Displayed 1 1,2 1,2,3 1,2,3,4 1,2,3,4,5 1,2,3,4,5,6 1,2,3,4,5,6,7 1,2,3,4,5,6,7,8 1,2,3,4,5,6,7,8,9 1,2,3,4,5,6,7,8,9,10 1,2,3,4,5,6,7,8,9,10,11

Temperature Range -40 to 75 °C (-40 to 167.0 °F) 76 to 79 °C (169 to 174 °F) 80 to 82 °C (176 to 179 °F) 83 to 86 °C (181 to 187 °F) 87 to 89 °C (189 to 192 °F) 90 to 93 °C (194 to 199 °F) 94 to 96 °C (201 to 205 °F) 97 to 100 °C (207 to 212 °F) 101 to 103 °C (214 to 217 °F) 104 to 109 °C (219 to 228 °F) 110 to 210 °C (230 to 410 °F)

Hydraulic Oil Temperature

Illustration 3

g00827133

(1) Segment 1 (2) Segment 11

The display for the Hydraulic Oil Temperature is divided into 11 segments. Each segment represents a temperature range. Refer to Table 4 for the range of temperatures that is represented by each segment. Note: Segment 1 is displayed when the system voltage is present. Table 4 Number of Segments Displayed 1 1,2 1,2,3 1,2,3,4 1,2,3,4,5 1,2,3,4,5,6 1,2,3,4,5,6,7 1,2,3,4,5,6,7,8 1,2,3,4,5,6,7,8,9 1,2,3,4,5,6,7,8,9,10

Temperature Range -40 to 30 °C (-40 to 86 °F) 31 to 45 °C (89 to113 °F) 46 to 60 °C (115 to 140 °F) 61 to 74 °C (142 to 165 °F) 75 to 77 °C (167 to 170 °F) 78 to 80 °C (172 to 176 °F) 81 to 83 °C (178 to 181 °F) 84 to 86 °C (183 to 186 °F) 87 to 89 °C (189 to 192 °F) 90 to 92 °C (194 to 197 °F)

1,2,3,4,5,6,7,8,9,10,11

93 to 210 °C (199 to 410 °F)

Throttle Position Monitor

Illustration 4 (1) Throttle Position Monitor

g01147168

The Throttle Position Monitor displays the position that has been set by the throttle position switch. Note: The actual displayed engine speed can be different from the real engine speed when the generator is activated.

SYSTEMS OPERATION

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SYSTEMS OPERATION

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Indicators SMCS - 7490

Illustration 1

g01147067

(1) Left Flasher (2) Parking Brake Indicator (3) High Beam Indicator (4) Low Brake Pressure Indicator (5) Right Flasher

The Low Brake Pressure indicator (4) will be displayed when the engine speed is above 400 rpm and the brake oil accumulator

pressure is below 10000 kPa (1450 psi). A low brake pressure warning is a level 3 warning. The graphic display area on the Monitior will display a "BRAKE PRESSURE LOW" warning. The alert indicator will activate and the action alarm will sound. The Parking Brake indicator (2) will be displayed when the parking brake is ON. The Left Flasher (1) and the Right Flasher (5) are indicators for the turn signals and the emergency flashers. When a flasher is active, an action alarm will sound. Note: The action alarm will not sound when both flashers are active. The High Beam Indicator (3) allows the operator to monitor the state of the headlamps.

SYSTEMS OPERATION

007

SYSTEMS OPERATION

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Powerup Sequence (Monitoring System) SMCS - 7490 The following sequence occurs when the key switch is turned to the ON position. 1. The action alarm sounds for .5 second. The action lamp and all of the gauges illuminate for 3 seconds. The display shows a series of screens that evolve into the "CAT" logo within approximately 2 seconds. 2. If a password is required, the display will show the password menu. 3. The monitor will show "START AID" if the starting aid system is activated. 4. The monitor checks the following items: hydraulic oil level, coolant level, engine RPM and engine oil level. If the three levels are OK, the monitor will show "LEVEL CHECK COMPLETE". If the level switch (engine coolant) is open, the display will show "ENGINE COOLANT LEVEL LOW". If the level switch (engine oil) is open, the display will show "ENGINE OIL LEVEL LOW". If the level switch (hydraulic oil) is open, the display will show "HYDRAULIC OIL LEVEL LOW". If the level check has not been completed and the engine is running, the display will show "LEVEL CHECK CANCELLED". If any of these conditions are detected, the text will show each of the conditions for two seconds. 5. After the level check, the monitor checks the operating hours on the filters and fluids. If one of the fluids or filters is due for changing, the display will show "CHECK FILTER/FLUID HOURS". This display is shown for five seconds. 6. After all checks are complete or when the engine is started, the Monitor will show the default display. The default display is illustrated below.

Illustration 1 Default display

g01147185

Clock (1) - This display indicates the time. Travel Speed Indicator (2) - This display indicates the speed of the machine while the machine is moving. Note: The Travel Speed Indicator will display on machines with the following serial number ranges: BDR2001-UP, BDM2001-UP, BDX2001UP, BCZ2001-UP, BDK2001-UP, BDY2001-UP, BEB2001-UP, H2A1-UP, H2B1-UP, H2C1-UP, H2D1-UP, H2E1-UP, H2F1-UP and H2G1-UP. Selected Tool (3) - This display indicates the tool that has been selected by the operator. Selected Gear (4) - This display features three different transmission gear selections. "TRAVEL SPEED HIGH" and "TRAVEL

SPEED LOW" are displayed when the transmission control switch is pressed. "CREEPER SPEED" is displayed when the creeper speed switch is pressed.

SYSTEMS OPERATION

008

SYSTEMS OPERATION

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Warning Operation SMCS - 7490 The Monitor will activate, display and log events for machine conditions that are not within normal operating parameters. The Monitor will detect some of these events, however, many of these events are detected by the other control modules on the machine. The Monitor receives this event data from the other control modules via the CAN Data Link and will determine what the warning response will be depending on the severity of the problem. The event warnings are classified into three warning levels. The warning level determines what response is required by the operator. Warning level 1 represents the least severe problem and warning level 3 represents the most severe problem. The warning levels, monitor response and the operator action required are given below. Warning Level 1 - Graphic Display - requires operator awareness Warning Level 2 - Graphic Display and Action Indicator - requires a change in the operation of the machine or a change in the maintenance of the machine in order to correct the condition Warning Level 3 - Graphic Display, Action Indicator and Action Alarm - requires immediate shutdown of the machine in order to prevent damage to the machine or personnel Event codes that are logged by the Monitor will have an event identifier number (EID) that will be displayed in the monitor memory under the menu "Logged Events". Refer to System Operation, "Logged Events Menu" for information on viewing these EID's. When multiple warnings are present in the system, the highest level warning is shown first. Press the up key or press the down key in order to view all of the warnings that are logged. If no keys are pressed within five seconds, the display will return to the highest level warning. All event code warnings and EID's that can be displayed by the Monitor are listed below according to their warning level. Events with a warning level higher than level 1 will be logged when activated. For a list of event codes that are activated by the machine ECM, refer to System Operation, "Logged Events Menu". Note: All of the event codes that are listed may not be applicable to all machine models.

Warning Level 1 Event Codes When a warning level 1 event code is active, the Monitor will show a graphic display. Low Engine Oil Pressure, EID 100 - The Monitor will display "ENGINE OIL PRESSURE LOW". This warning appears in the display when the engine oil pressure is low. If this warning appears, stop the machine immediately. Stop the engine and investigate the cause of the problem. Do not operate the machine until the cause of the problem has been corrected. Low Engine Oil Level, EID 171 - The Monitor will display "ENGINE OIL LEVEL LOW". This warning appears in the display when the engine oil level is low. If this warning appears, stop the machine in a safe manner as soon as possible. Stop the engine and check the engine oil level. If needed, add engine oil in order to correct the problem.

Engine Overspeed, EID 190 - When the engine speed is greater than 3300 RPM, the Monitor will display an "ENGINE OVERSPEED" warning.

High Air Filter Restriction, EID 72 - The Monitor will display"AIR FILTER PLUGGED". This warning is displayed when the air filter is restricted. If the air filter is restricted, then engine output will be decreased. High Transmission Clutch Pressure, EID 113 When the pressure of the transmission clutch is greater than 3480 kPa (504.7 psi), the Monitor will display a "TRANSM CLUTCH PRES. HIGH" warning. Low Transmission Clutch Pressure, EID 046 This event code can be activated as a warning level 1 or 3 depending on the severity of the problem. When the pressure of the transmission clutch is less than 2850 kPa (413.4 psi), the Monitor will display a "TRANSM CLUTCH PRES. LOW" warning. Low Quick Coupler Pressure, EID 262 - This event can be activated as a level 1, 2 or 3 warning depending on pressure conditions. This event is activated as a level 1 warning when a command is initiated to LOCK the quick coupler. The Monitor will display a "QUICK COUPLER LOCK" warning. This level 1 event will cancel when the quick coupler pressure switch contacts close indicating hydraulic pressure present. High Quick Coupler Pressure, EID 261 - This event can be activated as a level 1 or 3 warning depending on pressure conditions. This event is activated as a level 1 warning when a command is initiated to UNLOCK the quick coupler. The Monitor will display a "QUICK COUPLER UNLOCK" warning. This level 1 event will cancel when the quick coupler pressure switch contacts open indicating hydraulic pressure is absent. Low Engine Coolant Level, EID 059 - If the engine coolant level is below the specified level, the Monitor will display a "COOLANT WATER LEVEL LOW" warning. Low Hydraulic Oil Level, EID 235 - If the hydraulic oil level is below the specified level, the Monitor will display a "HYDRAULIC OIL LEVEL LOW" warning.

Low Fuel Level, EID 119 - If the fuel in the tank is below the specified level, the Monitor will display a "FUEL LEVEL LOW" warning.

Backup System (NO EID) - If the backup control system is activated, the Monitor will display a "BACKUP" symbol. When the backup system is active the following conditions are disabled:the three gauges, throttle position monitor, the alert indicator, the buzzer, the monitor keypad module and. While the backup system is active, the monitoring system is still fully functional, but the other system conditions are not displayed. Starting Aid (NO EID) - The engine controller is responsible for determining the use of a starting aid. Whenever the starting aid has been activated the Monitor will display a "START AID" symbol. Do not start the engine until the procedure of starting aid has been completed. Once the "START AID" symbol has disappeared from the display monitor, it is safe to start the engine. High Boom Position, EID 260 - The monitoring system is used to monitor the position of the boom. If the boom angle becomes too high, a "BOOM ANGLE HIGH" warning will be displayed.

Refueling Pump (No EID) - The Monitor will display the "FUEL PUMP ON" symbol while the refueling pump is active.

Monitor Error (No EID) - When the monitoring system detects an error in the prestart monitoring function, the Monitor displays a "MONITOR ERROR" warning.

CAN Data Link (No EID) - When the Monitor is not able to communicate via CAN, the Monitor displays a "MONITOR ERROR" warning along with CAN Data Link error symbol. The Monitor automatically repeats an attempt to make contact with the CAN Data Link system.

Axle Lock On (No EID) - This symbol is shown on the fourth line of the default menu in place of the travel speed status when the axle lock is ON.

Warning Level 2 Event Codes When a warning level 2 event code is active, the Monitor will show a graphic display and activate the alert indicator. Auxiliary Valve Pressure, EID 196 - The multifunction auxiliary valve has two pressure switches. These two pressure switches can not be activated simultaneously. When one switch is ON the other switch is OFF. If the ECM for the machine detects both pressure switches are ON, the Monitor will display a "AUX VALVE PRESSURE ERROR". Travel Pedal Pressure Error, EID 195 - The hydraulic circuit for the travel pedal has two pressure switches. These two pressure switches can not be activated simultaneously. When one switch (forward) is ON the other switch (reverse) is OFF. If the ECM for the machine detects both pressure switches in the same state, the Monitor will display a "TRAVEL PEDAL PRES ERROR" warning. High Engine Coolant Temperature, EID 017 This warning indicates excessive coolant temperature. If this warning appears in the display, reduce the operating speed of the machine. Keep the engine at low idle until the engine is cooled down. If the warning stays on after running the engine at low idle, stop the engine. Check the coolant level and check the radiator for debris. Hydraulic Oil Temperature, EID 600 This warning indicates excessive hydraulic oil temperature. If this warning appears in the display, reduce the operating speed of the machine. Keep the engine at low idle until the hydraulic oil temperature decreases to the correct level. If the warning stays on during low idle, stop the engine. Check the hydraulic oil level and check the hydraulic oil cooler for debris.

Alternator Not Charging, EID 179 - The "Battery Charge Error" warning appears in the display in order to indicate that the electrical charging system is malfunctioning. This warning is also displayed during the normal starting procedure. The machine can be operated while this warning is displayed. If this warning does not disappear, check the electrical components of the charging circuit immediately. Perform any necessary repairs. Machine Controller Communication Error (No EID) - In order for the monitoring system to be accurate, the monitoring must keep proper communication with the machine controller. If the Monitor loses communication with the controller, the Monitor will display a "MACHINE CONTROLLER COMMUNICATION ERROR" warning. Engine Controller Communication Error (No EID) - In order for the monitoring system to be accurate, the monitoring system must keep proper communication with the engine controller. If the Monitor loses communication with the controller, the Monitor will display a "ENGINE CONTROLLER COMMUNICATION ERROR" warning. Soft Switch Panel Communication Error (No EID) - In order for the monitoring system to be accurate, the monitoring system must keep proper communication with the soft switch panel. If the Monitor loses communication with the controller, the Monitor will display a "SOFT-SWITCH-PANEL COMMUNICATION ERROR" warning. Power Train (No EID) - The monitoring system is responsible for monitoring the transmission and power train systems. When there is a malfunction in the transmission or the power train systems, the Monitor will display a "POWERTRAIN ERROR" warning. The machine will also display a "POWERTRAIN ERROR" warning when the machine is overspeeding.

Return Hydraulic Filter Plugged, EID 236 - This warning is displayed in the display when the hydraulic return filter (capsule filter) is restricted. A restricted hydraulic return filter will cause hydraulic components to malfunction. Turn the engine start switch to the OFF position and then turn the engine start switch to the ON position. If the warning disappears the filter is good. Operate the machine on flat ground for at least ten minutes. If the warning reappears, replace the return filter cartridge. Refer to Operation and Maintenance Manual, SEBU7945, "Hydraulic System Oil Filter (Return) - Replace". Note: The warning for the restricted hydraulic return filter will disappear from the display after three minutes. Low Quick Coupler Pressure, EID 262 - This event can be activated as a level 1, 2 or 3 warning depending on pressure conditions. A warning level 2 warning will be activated when the quick coupler pressure switch contacts do not close within 60 seconds of a LOCK command when no UNLOCK command has been issued. The Monitor will display a "QUICK COUPLER PRESSURE" warning. Transmission Overspeed, EID 083 - This event is activated when the ground speed is detected to be 7 km/h (4.3 mph) over the defined maximum ground speed. The Monitor will display a "TRANSMISSION OVERSPEED" warning.

Warning Level 3 Event Codes When a warning level 3 event code is active, the Monitor will show a graphic display, activate the alert indicator and sound the action alarm. Low Brake Oil Accumulator Pressure, EID 284 - When the pressure for the brake oil accumulator drops below 10000 kPa (1450 psi), and the engine speed is above 0 rpm, the monitor will display a "BRAKE PRESSURE LOW" warning. Machine Overload, EID 237 - When the system pressure for the machine is too high, the monitor will display a "OVERLOAD HIGH" warning.

Low Quick Coupler Pressure, EID 262 - This event can be activated as a level 1, 2 or 3 warning depending on pressure conditions. This event is activated as a level 3 warning when the quick coupler pressure switch contacts open within 60 seconds of the last contact closing when no UNLOCK command has been given. The monitor will display a "QUICK COUPLER ERROR" warning. High Quick Coupler Pressure, EID 261 - This event can be activated as a level 1 or 3 warning depending on pressure conditions. This event is activated as a level 3 warning when the quick coupler pressure switch contacts close when no LOCK command has been given The Monitor will display a "QUICK COUPLER ERROR" warning. Low Transmission Clutch Pressure, EID 046 This event code can be activated as a warning level 1 or 3 depending on the severity of the problem. When the pressure of the transmission clutch is lower than 2610 kPa (378.5 psi), the monitor will display a "TRANSM CLUTCH PRES. LOW" warning. Coolant Temperature, EID 015 - This warning indicates excessive coolant temperature. If this warning appears in the display, reduce the operating speed of the machine. Keep the engine at low idle until the engine is cooled down. If the warning stays on after running the engine at low idle, stop the engine. Check the coolant level and check the radiator for debris. Hydraulic Oil Temperature, EID 023 This warning indicates excessive hydraulic oil temperature. If this warning appears in the display, reduce the operating speed of the machine. Keep the engine at low idle until the hydraulic oil temperature decreases to the correct level. If the warning stays on during low idle, stop the engine. Check the hydraulic oil level and check the hydraulic oil cooler for debris. Joystick Steering Active (No EID) - This graphic symbol is displayed with the warning "JOYSTICK STEERING ACTIVE" when the joystick steering function is selected. In addition to the graphic symbol, the action alarm will sound a short beep and the alert indicator will illuminate for 3 seconds. The graphic display will be shown until the joystick steering is switch OFF.

Joystick Steering Inactive (No EID) - This graphic symbol is displayed when the joystick steering function is switched OFF. In addition to the graphic symbol, the action alarm will sound a short beep and the alert indicator will illuminate for 3 seconds. The graphic display will disappear three seconds after the function has been turned OFF.

SYSTEMS OPERATION

009

SYSTEMS OPERATION

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Diagnostic Operation SMCS - 7490 The machine control ECM monitors many functions on the excavator. Certain problems with the machine will not record a diagnostic code, but these problems will display a message on the display area. These problems are described below:

Communication Errors The monitor communicates with the following components on the machine: Machine ECM, Engine ECM and Switch Panel. If the monitor loses contact with any of these components, the display shows one of the following messages:

Illustration 1

g00834413

Illustration 2

g00834420

Illustration 3

g00834428

Monitor Error

Illustration 4

g00834432

When the monitor has detected a problem with the monitor, the display will show the symbol for an error with the monitor.

CAN Data Link (Error)

Illustration 5

g00834440

When the monitor is unable to communicate on the CAN data link, the display shows the symbol for an error on the CAN data link.

SYSTEMS OPERATION

010

SYSTEMS OPERATION

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Main Menu SMCS - 7490 The Monitor contains a number of menus that enable the operator or technician to access, select or change machine operating parameters in order to define how the machine will operate. Illustration 1 shows the menus and options that can be accessed on the Monitor. A description of each menu is provided in the following sections of this manual. Note: All of the menus and selections shown may not be available on all machine models depending on the machine configuration and attachments.

Illustration 1

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Illustration 2

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(1) Upward key (2) Right key (3) Set key (4) Menu key (5) Left key (6) Downward key (7) Cancel key (8) OK key

In order to display the main menu, press menu key (4) when the default display is active. Table 1 "MAIN MENU" QUICK COUPLER PREFERENCES SELECT TOOL FILTER/FLUID HOURS SERVICE OPTIONS SERVICE OPTIONS PW (Password Required) After the menu key is pressed the following six options are displayed: "QUICK COUPLER", "PREFERENCES", "TOOL SELECT", "FILTER FLUID HOURS", "SERVICE OPTIONS" and SERVICE OPTIONS PW. The "SERVICE OPTIONS PW" option does not show up until a password has been entered. Press up key (1) or press down key (6) in order to highlight the desired menu. Press OK key (8). Press the cancel key in order to exit the main menu and return to the default display. Note: If no keys are pressed within 30 seconds, the main menu will be cancelled and default display will be shown. "QUICK COUPLER" - This menu allows the operator to lock the quick coupler. This menu also allows the operator to unlock the quick coupler. Refer to Systems Operation, "Quick Coupler Menu" for further information. "PREFERENCES" - This menu allows the operator to customize the display. The operator can change the following items: language, clock, contrast and brightness. Refer to the Systems Operation, "Preferences Menu" for more information. "TOOL SELECT" - This menu allows the operator to select the proper predefined tool. Refer to Systems Operation, "Tool Select Menu" for further information. "FILTER / FLUID HOURS" - This menu allows the operator or the service technician to view the current service hours and the recommended service intervals on a variety of maintenance items. Refer to Systems Operation, "Filter Fluid Hours Menu" for

further information. "SERVICE OPTIONS" - This menu allows the operator to view the machine information and the working hours. This menu also allows the operator to set the indicator for the tool. Refer to Systems Operation, "Service Options Menu" or Systems Operation, "Service Options PW Menu" for further information.

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i02305456

Quick Coupler Menu SMCS - 7490

Illustration 1 (1) Upward key (2) Right key (3) Set key (4) Menu key (5) Left key (6) Downward key (7) Cancel key (8) OK key

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SYSTEMS OPERATION

Illustration 2

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1. Press menu key (4) .

Illustration 3

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2. Press up key (1) or press down key (6) in order to highlight the "QUICK COUPLER" menu. Press OK key (8). The "QUICK COUPLER" menu will appear. If the quick coupler is not installed, the display will show "NOT INSTALLED". 3. Press right key (2) or left key (5) in order to scroll through the options for the quick coupler. Press set key (3) in order to select the desired operation. Note: Press cancel key (7) in order to return the default display.

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Preferences Menu SMCS - 7490

Illustration 1 (1) Upward key (2) Right key (3) Set key (4) Menu key (5) Left key (6) Downward key (7) Cancel key (8) OK key

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SYSTEMS OPERATION

Illustration 2

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1. The menu for the preferences of the monitor can be accessed by pressing the menu key (4) .

Illustration 3

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2. Press up key (1) or press down key (6) in order to highlight the "PREFERENCES" menu. Press OK key (8). After reaching the menu for the preferences, the following items can be changed: Language, Clock and Display.

Language Selection

Illustration 4

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1. Press up key (1) or down key (6) in order to highlight "SELECT LANGUAGE" menu. Press OK key (8) .

Illustration 5

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2. Press right key (2) or left key (5) in order to scroll through the available languages. Press set key (3) in order to select the desired language. Note: Press cancel key (7) in order to return the "PREFERENCES" menu.

Adjusting The Clock

Illustration 6

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Illustration 7

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1. Press up key (1) or press down key (6) in order to highlight the "ADJUST CLOCK" menu. Press OK key (8). The "ADJUST CLOCK" menu will appear. 2. Press left key (5) or press right key (2) in order to select the hour or the minute. Press up key (1) in order to increase the number. Press down key (6) in order to decrease the number. Note: The clock is only a 24 hour clock. 3. When the clock is set to the desired time, press set key (3) . Note: Press cancel key (7) in order to return to the "PREFERENCES" menu.

Display Adjustment The "ADJUST DISPLAY" menu is used in order to adjust the contrast of the message display. This menu is also used to adjust the brightness of the display backlight. There are two settings of the backlight. One setting is for operation during the day when

the lights are off. The other setting is for operation at night when the lights are on.

Contrast

Illustration 8

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1. Press up key (1) or press down key (6) in order to highlight the "ADJUST DISPLAY" menu. Press OK key (8). The "ADJUST DISPLAY" menu will appear.

Illustration 9

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2. Press up key (1) or press down key (6) in order to highlight the "CONTRAST" menu. Press OK key (8) . 3. Press up key (1) or press down key (6) in order to adjust the contrast. Press set key (3) in order to set the contrast. Note: Press cancel key (7) in order to return to the "ADJUST DISPLAY" menu.

Brightness

Illustration 10

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1. Press up key (1) or press down key (6) in order to highlight the "ADJUST DISPLAY" menu. Press OK key (8). The "ADJUST DISPLAY" menu will appear.

Illustration 11

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2. Press up key (1) or press down key (6) in order to highlight the "BRIGHTNESS (DAY)" menu. Press OK key (8). Select this menu in order to change the brightness of the display during the day when the lights are off. 3. Press up key (1) or press down key (6) in order to adjust the brightness. Press set key (5) in order to set the brightness.

Illustration 12

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4. Press up key (1) or press down key (6) in order to highlight the "BRIGHTNESS (NIGHT)" menu. Press OK key (8). Select this menu in order to change the brightness of the display at night when the lights are on. 5. Press up key (1) or press down key (6) in order to adjust the brightness. Press set key (3) in order to set the brightness.

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Tool Select Menu SMCS - 7490

Illustration 1

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(1) Upward key (2) Right key (3) Set key (4) Menu key (5) Left key (6) Downward key (7) Cancel key (8) OK key

1. In order to reach the "Tool Select" menu, press the menu key (4) . 2. Press the up key (1) or press the down key (6) in order to highlight the "TOOL SELECT" menu. Press the OK key (8) . Note: If you only have a Hammer Valve, you can only select "NO TOOL" and "HAMMER".

Illustration 2

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3. Press the left key (5) or press the right key (2) in order to scroll through the options that are available for the tool: Note: "NO TOOL"is the default setting. "NO TOOL" Note: The "TOOL"options are only available if you have a combined function valve. "TOOL #1" "TOOL #2" "TOOL #3" "TOOL #4" "TOOL #5" Note: "HAMMER" is only available if you have a hammer valve. "HAMMER" Note: "GENERATOR" option is available only if you have a generator valve. "GENERATOR" Press the OK key (8) in order to select a tool. Press the cancel key (7) in order to exit the menu. The tool that is active will have "ACTIVE" on the third line of the display.

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Filter Fluid Hours Menu SMCS - 7490 This menu allows the operator and the service technician to view the accumulated service hours and the recommended change intervals for the following filters and lubricants: Engine oil Engine oil filter Engine coolant Fuel/water separator Fuel filter Hydraulic pilot oil filter Return hydraulic oil filter Hydraulic oil

Illustration 1 (1) Upward key (2) Right key (3) Set key (4) Menu key (5) Left key (6) Downward key (7) Cancel key (8) OK key

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Illustration 2

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1. Press menu key (4). The "MAIN MENU" screen will appear.

Illustration 3

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Illustration 4

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2. Press up key (1) or press down key (6) in order to highlight the "FILTER/FLUID HOURS" menu. Press OK key (8). The "FILTER/FLUID HOURS" menu will appear. 3. Press right key (2) or left key (5) in order to scroll through the available service items. Note: Press cancel key (7) in order to return to the "MAIN MENU" menu. The "Filter Fluid Hours" menu cannot be used to reset the service hours.

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Service Options Menu SMCS - 7490

Illustration 1 (1) Upward key (2) Right key (3) Set key (4) Menu key (5) Left key (6) Downward key (7) Cancel key (8) OK key

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SYSTEMS OPERATION

Illustration 2

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1. Press menu key (4). The "MAIN MENU" screen will appear.

Illustration 3

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2. Press up key (1) or press down key (6) in order to highlight the "SERVICE OPTIONS" menu. Press OK key (8). The "SERVICE OPTIONS" menu will appear.

"MACHINE INFO"

Illustration 4

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Press up key (1) or press down key (6) in order to highlight the "MACHINE INFO" menu. Press OK key (8).

Illustration 5

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Different machine information will appear. Press right key (2) or left key (5) in order to scroll through the available service items. The following information is located in this menu: "MACHINE CONTR.""ENGINE CONTR.""MONITOR""SOFT-SWITCHPANEL". The "MACHINE CONTR." shows the following information about the machine ECM: part number, serial number and software version. The "ENGINE CONTR." shows the following information about the engine ECM: part number, serial number and software version. The "MONITOR" shows the following information about the monitor: part number, serial number and software version. The "SWITCH PANEL" shows the following information about the switch panel: part number, serial number and software version.

"OPERATING HOURS"

Illustration 6

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Press the down key (6) until "OPERATING HOURS" is highlighted. Press the OK key (8).

Illustration 7

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Operating hours can be viewed on the following displays:Engine ECM, Machine ECM, Monitor, Switch Panel, Travel, Swing, Tool Number 1, Tool Number 2, Tool Number 3, Tool Number 4 and Tool Number 5. Press right key (2) or left key (5) in order to scroll through the available service items.

"TOOL INDICATOR"

Illustration 8

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Press the down key (6) until "TOOL INDICATOR" is highlighted. Press the OK key (8). Select the "ENABLE" option so the monitor displays the tool that is active on the machine. Select the "DISABLE" option so the monitor does not display the active tool. The default display is the display with the clock. Press the set key (3) in order to save the setting.

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i02305474

Service Options PW Menu SMCS - 7490 The "Service Options PW" menu has a number of submenus. The operator can use these menus in order to modify the operation of the machine. Illustration 1 shows all of the menus that can be listed in the "Service Options PW" menu. A detailed description of each menu is provided in the following sections of this manual. Note: The following block diagram lists all of the possible submenu options for the "Service Options PW" menu that can be displayed. Depending on your machine configuration, some of the listed menu options may not be present on the Monitor. Your machine Monitor will only display the menu options that are applicable to your machine configuration.

Illustration 1

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The "Service Options PW" menu is protected by a password. The "Service Options PW" menu will not appear. After the key is turned on, the menu appears when you have entered the password. In order to access these menus, the following procedure must be performed:

Illustration 2

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1. Turn the key switch to the ON position. 2. While the display shows the "CAT" symbol, press the following three buttons at the same time: Left key (5), Right key (2) and Menu key (4) .

Illustration 3

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3. After the keys are pressed, the above screen will be displayed. The keys for direction are used to input the password. The default password that allows access to the "Service Options PW" menu is "FFF2". Press the LEFT key (5) or RIGHT key (2) in order to change the position of the flashing character. Press the UP key (1) or DOWN key (6) in order to change the value of the flashing character.

Illustration 4

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4. After entering the password, press the "SET" key (3) .

Illustration 5

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5. If an incorrect password is entered, illustration 5 is displayed. After the password is entered, the SERVICE OPTIONS PW menu is available. Follow the steps below in order to reach the menu:

Illustration 6

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(1) Upward key (2) Right key (3) Set key (4) Menu key (5) Left key (6) Downward key (7) Cancel key (8) OK key

Illustration 7

1. Press menu key (4). The "MAIN MENU" screen will appear.

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Illustration 8

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2. Press up key (1) or press down key (6) in order to highlight "SERVICE OPTIONS PW". Press OK key (8). The "SERVICE OPTIONS PW" menu will appear. The following menus are available from the "SERVICE OPTIONS PW" menu: "RESET SERVICE HOURS" "CHANGE PASSWORD" "SWITCH STATUS" "STATUS" "ACTIVE ERROR" "LOGGED ERROR" "LOGGED EVENT" "CONFIGURATION" "TOOL ADJUSTMENT" Each of the preceding menus is explained in the following sections of this manual. Note: The "Service Options Password Menu" remains enabled until the key has been turned off for two minutes.

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Reset Service Hours Menu SMCS - 7490

Illustration 1

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In order to reach the "Reset Service Hours" menu, go to the "Service Option PW" menu. See Systems Operation, "Service Options PW Menu" for more information. After you have reached the menu, press the down key (6) in order to highlight "RESET SERVICE HOURS". Press the OK key (8).

Illustration 2

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Press the left key (5) or press the right key (2) in order to scroll through the items that are available for the service hours. Table 1 lists the items.

Table 1 Service Hours Description

Recommended Change Interval

Engine Oil

500

Engine Oil Filter

500

Engine Coolant

3000

Fuel/Water Separator

500

Fuel Filter

500

Hydraulic Pilot Oil Filter

2000

Return Hydraulic Oil Filter

2000

Hydraulic Oil

2000

After the item that is being reset is located, press the "SET" key (5). The display will request a confirmation. Press the "OK" key (8) in order to confirm the request. The display will return to the "Reset Service Hours" menu. The hours for the item will be reset to zero. If you press the Cancel key (7) the display will return to the "Reset Service Hours" menu and the hours will not change.

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Change Password Menu SMCS - 7490

Illustration 1

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In order to reach the "Change Password" menu, go to the "Service Options PW" menu. See Systems Operation, "Service Options PW Menu" for more information. After you have reached the menu, press the down key (6) in order to highlight "Change Password". Press the OK key (8).

Illustration 2

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Press the left key (5) or press the right key (2) in order to select the desired position for the 8 characters. Press the up key (1) or press the down key (6) in order to change the characters of the current passwords and the new passwords. The passwords are

each 4 characters. The numbers 0 to 9 are available and the letters "A" to "F" are available. Press the Set key (5) in order to complete the password. The display will return to the "Service Options PW" menu. If the wrong current password is entered, the display will allow you to try again or the display will allow you to return to the main menu.

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Switch Status Menu SMCS - 7490

Illustration 1

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Note: The "Switch Status" Menu can be used for troubleshooting. In order to reach the "Switch Status" menu, go to the "Service Option PW" menu. See Systems Operation, "Service Options PW Menu" for more information. After you have reached the menu, press the down key (6) in order to highlight "SWITCH STATUS". Press the OK key (8) . Press the left key (5) or press the right key (2) in order to scroll through the items that are available for the switch status. Table 1 lists the items.

Illustration 2

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Note: Table 1 lists the switch status options that can be displayed for all models. The options that are displayed for your machine will depend on your machine configuration. The Monitor will display the switch status options that are applicable to your machine. Table 1 Switch Status Description

Possible Switch Status

"Attachment Pedal Front"

"OFF" or "ON"

"Attachment Pedal Back"

"OFF" or "ON"

"Swing Pilot Pressure" "Operator Swing Brake Switch"

"LOW" or "HIGH" "NOT DEPRESSED" or "DEPRESSED"

"Forward Travel Pressure Switch"

"OFF" or "ON"

"Reverse Travel Pressure Switch"

"OFF" or "ON"

"Joystick Button Actuation"

"OFF" or "ON"

"Operator Fuel Pump Switch" "Armrest Position" "Forward Travel Pedal Limit Switch" "Operator Service Brake Pressure Switch" "Brake Pedal Limit"

"NOT DEPRESSED" or "DEPRESSED" "NOT DOWN" or "DOWN" "NOT DEPRESSED" or "DEPRESSED" "OFF" or "ON" "RELEASED" or "DEPRESSED"

"Crank w/o Injection"

"OFF" or "ON"

"Hydraulic Modulation"

"OFF" or "ON"

"Cab Door"

"OPEN " or "CLOSED"

"Main Pump"

"LOW " or "HIGH"

"HCR Enable"

"OFF" or "ON"

"Medium Pressure"

"OFF" or "ON"

"Offset Boom"

"OFF" or "ON"

"Left Joystick Front Button"

"OFF" or "ON"

After viewing the item, press the "Cancel" key (7) in order to return to the previous menu. If there is no valid data the display will show five dashes.

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Status Menu SMCS - 7490

Illustration 1

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In order to reach the "Status" menu, go to the "SERVICE OPTIONS PW" menu. See Systems Operation, "Service Options PW Menu" for more information. After you have reached the menu, press the down key (6) in order to highlight "STATUS". Press the OK key (8).

Illustration 2

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Press the left key (5) or press the right key (2) in order to scroll through the items that are available for checking status. Table 1 shows the system components that can be viewed in the "STATUS" menu for machines with the following serial

numbers: (BDX1-2000) (BCZ1-2000) (BEB1-2000) (BDK1-2000) (BDY1-2000) (BDR1-2000) (BDM1-2000)

Table 1 Checking The Status Description

Units

"Auxiliary Hydraulic Flow Solenoid"

mA

"Auxiliary Hydraulic Pressure Solenoid"

mA

"Swash Plate Angle"

deg

"Transmission Clutch Pressure"

kPa

"Hydraulic Oil Temperature"

deg

"Engine Speed"

RPM

"Boost Pressure"

kPa

"Fuel Temperature"

deg

"Coolant Temperature"

deg

"Int Manifold Temperature"

deg

"Engine Oil Pressure"

kPa

"Battery Voltage"

V

"Fuel Per Hour"

L/h

"Total Fuel Used"

Liter

"Desired Engine Speed"

RPM

Table 2 shows the system components that can be viewed in the "STATUS" menu for machines with the following serial numbers: (BDX2001-UP) (BCZ2001-UP) (BEB2001-UP) (BDK2001-UP)

(BDY2001-UP) (BDR2001-UP) (BDM2001-UP) (H2A1-UP) (H2B1-UP) (H2C1-UP) (H2D1-UP) (H2E1-UP) (H2F1-UP) (H2G1-UP)

Table 2 Checking The Status Description

Units

"Auxiliary Hydraulic Flow Solenoid"

mA

"Auxiliary Hydraulic Pressure Solenoid"

mA

"Transmission Clutch Pressure"

kPa

"Hydraulic Oil Temperature"

deg

"Engine Speed"

RPM

"Boost Pressure"

kPa

"Fuel Temperature"

deg

"Coolant Temperature"

deg

"Int Manifold Temperature"

deg

"Engine Oil Pressure"

kPa

"Battery Voltage"

V

"Fuel Per Hour"

L/h

"Fuel Total Used"

Liter

"Desired Engine Speed"

RPM

"Machine Speed (Wheel Based)"

km/h

"Travel Pedal Position"

percent

"Joystick Thumbwheel Position"

percent

Auxiliary Pedal Position

percent

Total Machine Distance

km

When finished viewing the "STATUS" menu, press the "Cancel" key (7). The display will return to the "Service Options PW" menu.

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i01781956

Active Error Menu SMCS - 7490 See Troubleshooting, "Using the Operator Monitor to Determine Diagnostic Codes" for an explanation of the "ACTIVE ERROR" menu.

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Logged Error Menu SMCS - 7490 See Troubleshooting, "Using the Operator Monitor to Determine Diagnostic Codes" for an explanation of the "LOGGED ERROR" menu.

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Logged Events Menu SMCS - 7490

Illustration 1

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In order to reach the "Logged Event" menu, go to the "Service Option PW" menu. See Systems Operation, "Service Options PW Menu" for more information. After you have reached the menu, press the down key (6) in order to highlight "LOGGED EVENT". Press the OK key (8).

Illustration 2

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Press the left key (5) or press the right key (2) in order to scroll through the logged events. The events have a number that corresponds to a condition that is listed in table 1. The "100" in the illustration corresponds to the event for "Low Engine Oil

Pressure". See System Operation, "Warning Operation" for a description of the listed logged events with their warning level. Note: All of the events that are listed may not apply to all machine models depending on machine configurations. Table 1 Logged Events EID

Description

015

Derate Due To High Engine Coolant Temperature

017

Warning For High Engine Coolant Temperature

023

Derate Due To High Hydraulic Oil Temperature

046

Low Transmission Oil Pressure

059

Low Engine Coolant Level

072

High Air Filter Restriction

083

Transmission Overspeed

100

Low Engine Oil Pressure

113

High Transmission Oil Pressure

119

Low Fuel Level

171

Warning Of Low Engine Oil Level

179

Low Alternator Charging

190

Engine Overspeed

195

Error for the Travel Pedal (Pressure)

196

Multifunction Auxiliary Valve Pressure

235

Warning For The Low Hydraulic Oil Level

236

Plugged Return Hydraulic Filter

237

Machine Overload

260

High Boom Position

261

High Pressure For The Quick Coupler

262

Low Pressure For The Quick Coupler

284

Low Pressure For The Brake Oil Accumulator

600

Warning For High Hydraulic Oil Temperature

The "Logged Events" menu will display only the event number. A descriptive explanation of the logged events can be accessed using ET. The description will include the following items: hours number of occurrences explanation of the events

Note: ET must be logged into the CAN data link and the control for the monitor must be selected as the ECM in order to view the logged events.

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Configuration Menu SMCS - 7490

Illustration 1

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In order to reach the "Configuration" menu, go to the "Service Option PW" menu. See Systems Operation, "Service Options PW Menu" for more information. After you have reached the menu, press the down key (6) in order to highlight "CONFIGURATION". Press the OK key (8).

Illustration 2

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Press the left key (5) or press the right key (2) in order to scroll through the configuration screens. The items that are available for configuring are listed in table 1.

Note: Modifications to the configuration must be done via Cat ET. All of the items listed may not apply to all machine models depending on attachments or machine configurations. Table 1 Configuration Menu Description

Possible Values

"Travel Alarm"

Installed / Not Installed

"Boom Angle Switch"

Installed / Not Installed

"Refueling Pump"

Installed / Not Installed

"Quick Coupler"

Installed / Not Installed

"Implement Generator"

Installed / Not Installed

"Aux Tool Control Valve"

Installed / Not Installed

"Hammer"

Installed / Not Installed

Travel Pedal Lock

Installed / Not Installed

Hydraulic Modulation

Installed / Not Installed

Meduim Pressure Attachment

Installed / Not Installed

Hydraulic Cab Riser (HCR)

Installed / Not Installed

Joystick Steering

Installed / Not Installed

"AESC Delay" Max Machine Speed Offset Boom

sec (seconds) km/h Installed / Not Installed

When you reach the item, press the OK key (8). Press the left key (5) or press the right key (2) in order to select the configuration. Note: When the parameter is not available, the bottom row shows "- - - - ".

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Tool Adjustment Menu SMCS - 7490 Note: This is function is not available if your machine is equipped with a "HAMMER VALVE".

Illustration 1

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In order to reach the "Tool Adjust" menu, access the "SERVICE OPTIONS PW" menu. See Systems Operation, "Service Options PW Menu" for more information. After you have reached the menu, press the down key (6) in order to highlight "TOOL ADJUST". Press the OK key (8). You can press the CANCEL key (7) at any time in order to return to the main menu. In order to view configured tools, press the RIGHT key (2) or the LEFT key (5). The Monitor will display all possible tool programs one at a time. In order to configure a tool, perform the following steps. When a tool is selected that has not been configured (all spaces in the tool name line), "NOT CONFIGURED" will be displayed in the tool name area.

Illustration 2

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1. Select the tool to be configured using the RIGHT key or the LEFT key. A tool that has been configured will have the tool name in the tool name area. A tool that has not been configured will have "NOT CONFIGURED" in the tool name area.

1. Press the OK key (8) in order to indicate that this is the tool that is to be configured. See the figure below.

Illustration 3

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2. Enter a tool name of 14 digits or less. The OK key will move the curser to the RIGHT and will wrap to the first digit when the last digit is reached. The Monitor will not allow advancement to the next parameter until a tool name has been entered. To enter a name, use the upward key (1) or the downward key (6) in order to scroll through the possible characters. The possible characters are A through Z, then 0 through 9. Press the SET key (3) when the desired name is in place. Once a tool name is entered, the Monitor will display a RIGHT arrow to enable the rest of the parameters to be displayed. See the figure below.

Illustration 4

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3. Adjust the parameter. The Monitor will display the parameters that are available for the selected tool one at a time. Use the RIGHT key or the LEFT key to scroll the parameters. When the desired parameter is displayed, press the SET key to indicate that this is the one that will be changed. Use the OK key to move the cursor to the right. Adjust the value of the parameter using the upward and downward key to change digits. Press the SET key to save the changed parameter value. The Monitor will only save parameters that are applicable to the selected tool. Use the RIGHT key or the LEFT key to scroll to the next parameters. The following list is the progression of parameters that can be displayed: Tool name - max 14 characters One way / two way mode Maximum pressure - back direction (percent) Maximum flow - back direction (percent) Maximum pressure - front direction (percent) Maximum flow - front direction (percent)

Illustration 5

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If the selected tool is a unidirectional tool, the Monitor will not display the parameters for back direction. Reference: For more information on related tool adjustment topics, refer to Systems Operation, "Auxiliary Hydraulic System."

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RTC Compensation Interval Menu SMCS - 7490

Illustration 1

g00932710

The "RTC COMP INTERVAL" menu allows the technician to program the Monitor to automatically adjust the real time clock (RTC). In extreme temperatures, the Monitor may slowly lose seconds or gain seconds. Over a time period, this may result in the wrong time being displayed on the Monitor. This menu enables the technician to enter a value to compensate for the discrepancy. The value tells the Monitor when to add or subtract one second. A value of +1000 will cause the Monitor to add one second after every 1000 seconds have elapsed. A value of -100 will cause 1 second to be subtracted after 100 seconds. The formula for figuring the value to input is given below: X : RTC Compensation value to be entered D : Number of days of the period that the deviation has been observed T : Number of minutes lost or gained in the period of "D" above

Note: If RTC LOSES time over a period, the value entered must be positive. If RTC GAINS time over a period, the value entered must be negative. Example: The RTC loses 5 minutes in 28 days. The figured value will be positive. The formula is: X = (D x 86400) / (T x 60) X = (28 x 86400) / (5 x 60) X = 8064 Enter 8064 as the NEW value. The RTC will add 1 second after every 8064 seconds. To change the RTC compensation value, perform the following steps. 1. Select the "RTC COMP INTERVAL" menu from the "SERVICE OPTIONS PW" menu. 2. Use the LEFT key or the RIGHT key to select a digit within the six digit value area. 3.

2. 3. Use the UPWARD key or the DOWNWARD key to input the new value 0 through 9. 4. Press the SET key to save the new value. The CANCEL KEY will return to the "SERVICE OPTIONS PW" menu.

SYSTEMS OPERATION

027

SYSTEMS OPERATION

i02293513

Soft Switch Panel SMCS - 7490 The Soft Switch Panel (SSP) is part of the machine's electronic control system. The SSP is located inside the cab on the right hand instrument panel. The SSP allows the operator to control a number of machine functions that are explained below. The switches on the panel are accompanied by LED indicators that show the status of the function that is controlled by the switch. The LED's are controlled by the machine ECM which communicates with the SSP via the CAN data link. The SSP also communicates with the engine ECM and the Monitor over the CAN data link.

Illustration 1

g01148273

Soft switch panel (1) Automatic Engine Speed Switch (2) Power Mode Switch (3) Switch (Oscillating Axle) (4) Creeper Speed Switch (5) Travel Lock Switch (6) Unused on models with the following serial numbers: (BDR1-2000), (BDM1-2000), (BDX1-2000), (BCZ1-2000), (BDK1-2000), (BDY1-2000), (BEB1-2000). (6a) Hydraulic modulation on models with the following serial numbers: (BDR2001-UP), (BDM2001-UP), (BDX2001-UP), (BCZ2001-UP), (BDK2001-UP), (BDY2001-UP), (BEB2001-UP), (H2A1-UP), (H2B1-UP), (H2C1-UP), (H2D1-UP), (H2E1-UP), (H2F1-UP), (H2G1-UP). (7) Parking Brake Switch (8) Implement Lockout (9) Transmission Switch (10) Travel Alarm Cancel Switch

The soft switch panel is part of the machine's electronic control system. The soft switch panel communicates with the machine ECM on the CAN data link. The CAN data link consists of wire F712GY at connector contact J1-6 and wire F711-GN at connector contact J1-18.

Automatic Engine Speed Control Switch (AESC)

Automatic Engine Speed Control switch (AESC) (4) - The AESC functions automatically in order to reduce the engine speed when there is no hydraulic demand. The AESC reduces fuel consumption and noise. The AESC switch is a momentary switch. Depressing the AESC switch will allow the AESC system to toggle from ON to OFF. When this function is enabled the engine speed will be near low idle within one to ten seconds. The LED indicator for the AESC is ON when the function is enabled. The indicator is OFF when the function is disabled. To enable the AESC, push down the switch. Upon activation of a hydraulic circuit, the engine speed will return to the engine speed that is set by the engine speed dial. Note: Disable the AESC during machine travel. See Systems Operation, "Automatic Engine Speed Control Function" for more information on this function.

Power Mode Switch Power Mode Switch (5) - The power mode is selected with the switch on the soft switch panel. On the M316C and M318C, the operator can select "Economy Mode " and "Power Mode". On the M322C, the operator can select any of the modes. LED's on the soft switch panel indicate which mode is selected. On the three models,"Travel Mode" is automatically engaged when either the forward or the reverse travel pressure switch is activated. When one of the modes is selected, the LED that corresponds to that mode is on. If the actual mode becomes different during operation, the new mode indicator will be on and the previously selected mode indicator will blink. Economy - For economy mode, press the switch for the power mode control until the first indicator light turns on. The economy mode provides lower amounts of hydraulic power. The economy mode is suitable for light-duty work such as grading or positioning. This mode provides more precise control and less engine speed. Operating the machine in economy mode will minimize fuel consumption and noise. Power Mode - For power mode, press the switch for the power mode control until the second indicator light turns on. The power mode provides maximum hydraulic power. Power mode is suitable for heavy work such as lifting or excavating.

Travel Mode - For travel mode on the M322C, press the switch for the power mode control until the third indicator light turns on. Use the travel mode when you are roading the machine. You cannot select travel mode by using the soft switch panel on the M313C, M315C, M316C, and M318C. For the M313C, M315C, M316C, and M318C travel mode is automatically turned on when you are roading the machine. Note: On the M322C machine, travel mode can also be engaged while you perform work. Note: When the hydraulic oil temperature is low or high or when the engine coolant temperature is high, the machine hydraulic system is restricted to the economy mode.

Oscillating Axle Lock Switch

NOTICE The oscillating axle must be locked before the boom and the stick are removed to prevent possible tipping of the machine.

Oscillating Axle Lock Switch (6) - Use the oscillating axle lock switch in order to lock and unlock the oscillating axle. Lock the oscillating axle when a load is being carried. The LED indicator for the Oscillating Axle Lock switch is OFF when the solenoid is energized. The indicator is ON when the solenoid is de-energized. When the armrest is down the axle will automatically be unlocked. When the armrest is raised the axle will automatically be locked. If the operator unlocks the axle and the operator raises the armrest, the axle will lock and the LED will blink until the armrest is lowered. See Systems Operation, "Oscillating Axle Control Function" for more information on this function.

Creeper Speed Switch Creeper Speed Switch (7) - Push down on the switch in order to activate the creeper speed. Use the creeper speed when a very low travel speed is desired. When the creeper speed is activated, the indicator light will turn on. Push down on the button in order to deactivate the creeper speed. Creeper speed can be activated when the transmission is in first gear or second gear. See Systems Operation, "Creeper Speed Function" for more information on this function.

Travel Lock Switch

Travel Lock Switch (8) - Use the travel lock switch when you are roading the machine. This will maintain the maximum travel speed over long distances. First attain maximum travel speed by pushing down all the way on the travel speed pedal. Then push down on the switch for the travel lock. The LED indicator will turn on when the travel lock is engaged. Maximum travel speed will be maintained until the operator performs one of the following steps: Push down on the switch for the travel lock. Push down on the wheel brake pedal. Push the travel speed pedal in the reverse direction.

The function of the travel lock is dependent on the position of the armrest. When the armrest is up, the travel lock is disabled. When the armrest is down, the travel lock is enabled. See Systems Operation, "Travel Speed Lock Function" for more information on this function.

Hydraulic Modulation Control Note: The hydraulic Modulation function is available on machines with the following serial numbers: BDR2001-UP, BDM2001UP, BDX2001-UP, BCZ2001-UP, BDK2001-UP, BDY2001-UP, BEB2001-UP, H2A1-UP, H2B1-UP, H2C1-UP, H2D1UP, H2E1-UP, H2F1-UP and H2G1-UP. Hydraulic Modulation Control (6) - The hydraulic modulation control provides adjustable sensitive movement of the work tool. The hydraulic modulation function is enabled when the hydraulic modulation enable switch on the front of the right joystick is pressed. Press the switch again in order to disable the function. When the function is enabled, pressing the soft panel switch will select one of three levels of hydraulic modulation. The levels are low, medium and high. Each level is accompanied by a corresponding LED indicator that will illuminate when the level of modulation is active. Each time the button is pressed, the next level of hydraulic modulation will activate. Each time the soft panel switch is pressed, the Monitor will sound a tone. When the function is disabled either by the enable/disable switch on the joystick or by shutting off the machine, the ECM will activate the last selected modulation level when the function is enabled again. When a hydraulic modulation level is selected, the machine ECM will change the amount of current output that is sent to the hydraulic modulation solenoid. This will limit the amount of hydraulic flow to the work tool. The hydraulic pressure does not change.

Parking Brake Control Switch

Personal injury could result from the sudden stop of the machine. Be prepared for a sudden stop whenever the parking brake indicator comes on and the warning horn sounds. Correct the reason for the loss of oil pressure or any other cause of the automatic application of the parking brake. Machine movement without repair could result in personal injury or death.

NOTICE If the brake system oil pressure drops below normal operating pressure, a warning horn will sound, the brake accumulator error indicator will come on, and the action light will come on. The parking brake will engage automatically.

NOTICE Do not engage the parking brake while the machine is moving unless the wheel brakes fail. The use of the parking brake as a wheel brake in regular operation will cause severe damage to the parking brake system.

Switch (Parking Brake Control) (10) - To engage the parking brake, press the parking brake switch. When the parking brake is in the engaged position, the light that is located on the soft switch panel and the parking brake indicator that is on the monitor will come on. Note: When the left console is in the raised position, the parking brake will engage. Note: The parking brake will not engage when low transmission clutch pressure is detected. However, the travel activation will be deactivated and the parking brake solenoid will not change states. See Systems Operation, "Parking Brake Function" for more information on this function.

Switch (Implement Lockout) Switch (Implement Lockout) (11) - Push the switch for the work tool lockout in order to deactivate any of the work tools. The indicator light will turn on when the switch is pushed. Lock the work tools before roading the machine. Note: The function of the work tool lockout is dependent on the position of the armrest. If the armrest is up, the work tools are disabled. The work tools are enabled when the armrest is down.

Switch (Transmission Speed Control) Switch (Transmission Speed Control) (12) - Push down on the switch in order to select the desired transmission gear. In order to put the transmission in first gear, push the button once. One of the indicator lights will turn on when the transmission is in first gear and the travel speed is LOW. Push down on the switch twice in order to select second gear. Note: The function of the transmission speed control is dependent on the position of the armrest. If the armrest is up, the travel speed is set high. The travel speed is set to low speed with the armrest in the down position. Note: On the M300C excavators, the first LED is illuminated for travel speed low, and the second LED is illuminated for travel speed high. See Systems Operation, "Travel Speed Function" for more information on this function.

Travel Alarm Cancel Switch Travel Alarm Cancel Switch (13) - This switch can be used to stop the travel alarm from sounding. Push down on the switch in order to turn off the alarm. The indicator light above the switch will turn on when the operator has cancelled the travel alarm but the travel alarm is turned off. If the alarm has sounded for more than ten seconds, one of the following will be true: The travel alarm cancel switch was pressed during the ten second period. The travel alarm cancel switch was not pressed during the ten second period. If the switch was pressed during the ten second period, the alarm will stop sounding immediately after the ten second period. If the switch was not pressed during the ten second period the alarm will continue to sound. The alarm will sound until the switch is pressed, or travel is no longer detected. See Systems Operation, "Travel Alarm Function" for more information on this function.

SYSTEMS OPERATION

028

SYSTEMS OPERATION

i02294428

General Information (Machine Electronic Control System) SMCS - 7000-EK The Machine ECM controls many functions on the M300C excavators. The ECM responds to control inputs from the operator. Also, the ECM responds to inputs from various sensors and switches. When the operator commands hydraulic attachments to move, the ECM activates the appropriate solenoid valves. The multifunction valve controls the hydraulic flow to various hydraulic attachments. This manual provides information concerning the machine electronic control system. Some other manuals that may be helpful for testing and adjusting the hydraulic systems on the M300C machines are: Testing and Adjusting, RENR6984, "M313C Excavator Hydraulic System" Testing and Adjusting, RENR6961, "M315C Excavator Hydraulic System" Testing and Adjusting, RENR5565, "M318C Excavator Hydraulic System" Testing and Adjusting, RENR5567, "M316C Excavator Hydraulic System" Testing and Adjusting, RENR7014, "M322C Excavator Hydraulic System"

The following block diagrams illustrate the inputs and the outputs that are associated with the machine ECM. The block diagrams are effective for machines in two serial number ranges in order to show the different components that are equipped on the machines.

Illustration 1

g01148932

Illustration 2

g01166052

SYSTEMS OPERATION

029

SYSTEMS OPERATION

i02305350

Automatic Engine Speed Control Function SMCS - 1915; 7000-EK

Illustration 1

g01154568

Automatic engine speed control function block diagram

The automatic engine speed control (AESC) function will allow the ECM to reduce the speed of the engine to low idle when no hydraulic system activity is detected. This aids in conserving fuel and reducing noise. When the AESC switch on the soft switch panel is pressed, the ECM will monitor the "machine working function" in order to determine if hydraulic activity is needed. The ECM will initiate the AESC function when the machine working function indicates that there has been no hydraulic activity within 1 to 10 seconds. This time period is programmable in ET. The machine ECM sends the request for low idle directly to the engine ECM over the CAN data link. When any of the following functions are activated, the engine will return to the selected engine speed on the engine speed dial: swing, travel, implements (joysticks) and change of the speed dial position. The operator can request that the engine go to low idle mode when the AESC function has not been enabled. When the low idle button on the right hand joystick is pressed, the ECM will check for hydraulic load conditions before sending a request for low idle to the engine ECM. The machine ECM will check the status of the swing pilot pressure switch and the main pump pilot pressure switch in order to determine if a request for hydraulic power is present. When both of these switches are open, the machine ECM will send the request for low idle to the engine ECM. Note: The following paragraphs, which refer to the swash plate angle parameters, apply to machines in the following serial number ranges: BDR2001-UP, BDM2001-UP, BDX2001-UP, BCZ2001-UP, BDK2001-UP, BDY2001-UP, BEB2001UP, H2A1-UP, H2B1-UP, H2C1-UP, H2D1-UP, H2E1-UP, H2F1-UP and H2G1-UP. For machines that are covered in this manual with a different serial number, if there is an active diagnostic code for the main pump pressure switch, the AESC function will be disabled. A programmable parameter controls the deactivation of this function. The value of this parameter relates to the angle of the swash plate. This parameter is called "Main Pump Swash Plate Angle Machine Operating Threshold" in ET. This value is normally 0.8

degrees greater than the angle of the swash plate, when the machine is not working. A change in the angle of the main pump swash plate that is greater than two degrees will deactivate the function. During this time, the idle of the engine will rise to the level that is set by the engine speed dial. If the angle is greater than 2 degrees, the time interval between actuating a control lever and the rise in the level of the engine idle will be delayed. For example, if the value is 4 degrees, check the value (standby or resting) of the main pump. Check the value by using the monitor or ET (status group 3). If this value is 3 degrees, the parameter is programmed at 1 degree above the angle (standby or resting) of the swash plate of the main pump. If there is a diagnostic code for the sensor for the swash plate angle, then the automatic engine speed control does not function. The machine ECM checks the signal wire H783-GN for proper operation. If the machine ECM detects a problem, a diagnostic code is generated.

SYSTEMS OPERATION

030

SYSTEMS OPERATION

i01782222

Brake Light Function SMCS - 7000-EK

Illustration 1

g00915873

Illustration 2

g00830805

The brake lights will be activated when the service brake pressure is greater than 500 kPa (72.5 psi). When the service brake pressure switch detects pressure that is greater than 500 kPa (72.5 psi), the switch closes the contact J1-47 to ground at J1-9. Then, the ECM provides power to the brake lights through contact J2-4 and J2-16. If the left armrest is in the raised position, the brake lights will not illuminate when the pedal is pressed. When the armrest is raised, contact J1-55 is closed to ground through contact J1-9. The ECM does not allow power to go to the brake lights. If the armrest is in the down position, the brake lights will illuminate when the pedal is pressed. When the armrest is down, contact J1-54 is closed to ground at contact J1-9. Then, the ECM does not interrupt the normal operation of the brake lights. When the brake pedal is pressed fully, the pedal is locked in place and the operator service brake limit switch is activated. When the limit switch for the service brake pedal is activated, the service brake is locked and contact J1-57 is closed to ground. When the service brake pedal limit switch is not activated, the service brake is unlocked and contact J1-56 is closed to ground. When the service brake pedal limit switch is activated the ECM starts a 60 second timer. The ECM disables the brake lights after 60 seconds. The ECM assumes that the brake lights are locked because the machine is digging and the brake lights are no longer needed. Note: If the lights remain on for more than 60 seconds, there could be an overheating condition with the housing of the lights.

SYSTEMS OPERATION

031

SYSTEMS OPERATION

i02294504

Creeper Speed Function SMCS - 7000-EK

Illustration 1

g01149026

Illustration 2

g01149034

The creeper speed control allows the operator to operate the machine at a low speed high torque setting. The creeper speed function is selected by pressing the creeper speed switch on the soft switch panel (SSP) in the cab. The SSP communicates with the ECM via the CAN data link. When the creeper speed function is selected, the ECM will energize the creeper speed / travel motor swash plate angle limit solenoid in order to control the travel speed of the machine. The ECM will illuminate the LED above the creeper speed switch in order to indicate that the function is ON. The creeper speed will remain ON until the creeper speed switch is pressed again. The creeper speed function operates

independently of the position of the armrest. Note: If the limp home mode switch is on, the creeper speed will be turned off.

SYSTEMS OPERATION

032

SYSTEMS OPERATION

i01782237

Engine Start Function SMCS - 7000-EK

Illustration 1

g00916682

Illustration 2

g00827655

When the key start switch is turned to the START position, the machine ECM checks the following items: The armrest must be up. The voltage of the system must be less than 32 DCV. There are no diagnostic codes for the brake pedal switch or for the armrest position switch. When these conditions are OK, the starter relay is energized until the speed of the engine is above 400 RPM for 5 seconds. Then, the starter relay is de-energized. If any of the conditions are reversed, the starter relay is IMMEDIATELY de-energized. The key start switch must be placed in the OFF position in order to reset the machine before you attempt to start the machine.

SYSTEMS OPERATION

033

SYSTEMS OPERATION

i02294564

Generator Function SMCS - 7000-EK

Illustration 1

Illustration 2

g00916702

g01149079

Generator function connections for machines in the following serial number ranges: BDR1-2000, BDM1-2000, BDX1-2000, BCZ1-2000, BDK12000, BDY1-2000 and BEB1-2000.

Illustration 3

g01149121

Generator function connections for machines in the following serial number ranges: BDR2001-UP, BDM2001-UP, BDX2001-UP, BCZ2001-UP, BDK2001-UP, BDY2001-UP,, BEB2001-UP, H2A1-UP, H2B1-UP, H2C1-UP, H2D1-UP, H2E1-UP, H2F1-UP and H2G1-UP.

The generator function allows the low flow generator and high flow generator to be used on different machine models. When the generator switch is open, the generator solenoid is de-energized and the generator is activated. When the generator switch is closed, the generator function is always disabled. When the generator switch is closed, contact J129 is closed to ground at J1-9. The generator solenoid is then energized by an ECM output as shown in the illustration above. If the generator function is installed on the machine, the Caterpillar Electronic Technician is used to inform the ECM that the generator is installed. Use Cat ET in order to select the generator as the active tool. Note: See Table 1 for a list of machines that will support a generator. Table 1 Generator Application Model

Low Flow Generator

High Flow Generator

M313C

No

No

M315C

Yes

No

M316C

Yes

No

M318C

Yes

Yes

M322C

Yes

Yes

SYSTEMS OPERATION

034

SYSTEMS OPERATION

i02294652

High Boom Function SMCS - 7000-EK

Illustration 1

g01149143

The high boom function (attachment) warns the operator not to exceed the height of the machine during road travel. The boom angle limit switch sends a signal to the ECM at connector contact J1-14. When the boom is raised this contact is closed to ground. When the implement lockout solenoid is energized which means that the work tools are active, the "BOOM TOO HIGH" message will be shown on the monitor when the switch is closed to ground. This action will not allow the work tools to be activated. This function can be installed or not installed through the Cat ET configuration screen. The default state is not installed. The boom angle status can be boom high, boom low or boom normal.

SYSTEMS OPERATION

035

SYSTEMS OPERATION

i02294658

Hydraulic Activation Control Function SMCS - 7000-EK

Illustration 1 Implement lockout function block diagram

g01149152

Illustration 2

g01149185

Implement circuit connections for machines in the following serial number ranges: BDR1-2000, BDM1-2000, BDX1-2000, BCZ1-2000, BDK1-2000, BDY1-2000 and BEB1-2000.

Illustration 3

g01149187

Implement circuit connections for machines in the following serial number ranges: BDR2001-UP, BDM2001-UP, BDX2001-UP, BCZ2001-UP, BDK2001-UP, BDY2001-UP,, BEB2001-UP, H2A1-UP, H2B1-UP, H2C1-UP, H2D1-UP, H2E1-UP, H2F1-UP and H2G1-UP.

The hydraulics for the implements on the machine can be disabled by the operator with two methods. The operator can raise the left armrest or the operator can press the implement lockout switch on the soft switch panel. When one of these events occurs, the ECM will de-energize the implement lockout solenoid at contact J2-45 (wire K777-GY). The ECM will also de-energize the implement lockout relay at contact J2-33 (wire M927-GN) which will disable the medium pressure functions (if equipped) or the joystick functions. When these two actions take place, all hydraulic controlled functions on the machine will be disabled with the exception of travel, steering and brakes. When the relay and the solenoid are energized, the work tools are active. The machine ECM provides a ground for the relay at J2-33 (wire M927-GN). The ECM de-energizes the relay by removing the ground. The relay provides power to functions that are controlled by the joysticks on certain models or to the medium pressure switch on other models (see illustrations above). The armrest is connected to the machine ECM at contact J1-54 (wire E918-GN) and contact J1-55 (wire E917-WH). When the armrest is raised, the pilot hydraulics are disabled. The pilot hydraulics will return to their prior state when the armrest is lowered. If a diagnostic code for the armrest position switch exists, the implements are locked out. If the status of the implement lockout switch is not known, the implements are locked out. For example, the switch status is not known when an open circuit (broken wire) exists between the machine ECM and the soft switch panel.

SYSTEMS OPERATION

036

SYSTEMS OPERATION

i02301165

Hydraulic Modulation Function SMCS - 7000-EK

Illustration 1 Hydraulic modulation function

Illustration 2 Hydraulic modulation connections

g01152591

g01152513

Note: The hydraulic modulation attachment is available for machines in the following serial number ranges: BDR2001-UP, BDM2001-UP, BDX2001-UP, BCZ2001-UP, BDK2001-UP, BDY2001-UP, BEB2001-UP, H2A1-UP, H2B1-UP, H2C1UP, H2D1-UP, H2E1-UP, H2F1-UP and H2G1-UP The hydraulic modulation function allows the operator to select between three levels of hydraulic sensitivity. The three levels are low, medium or high. The three levels of sensitivity can be selected from the soft switch panel (SSP). When the operator selects a hydraulic modulation level, the ECM will illuminate one of the three LED indicators on the SSP in order to indicate the active level of modulation. When no LED indicators are illuminated, the ECM has disabled the function. When the operator selects a modulation level on the SSP, the hydraulic modulation function is activated by pressing the right

hand joystick trigger switch (hydraulic modulation enable). The ECM will send a corresponding level of output current to the hydraulic modulation solenoid. For each selected level of modulation, the ECM will output a specific current value to the solenoid. A small amount of current is sent to the solenoid when the function is OFF. The current values are: Off - 200 mA Low - 620 mA Medium - 480 mA High - 320 mA

When the hydraulic modulation function is active, the engine ECM will receive this information over the Cat Data Link and will set the swing pump to the economy mode. The machine ECM will disable the hydraulic modulation function if any of the following conditions occur. If the generator is active AND the generator enable switch is ON. If a tool is active AND the left auxiliary pedal is NOT at the zero position (not depressed). If the hammer is active. If the machine is traveling When the ECM disables the hydraulic modulation function, the function will remain OFF until the hydraulic modulation enable switch (joystick trigger) is pressed again. The ECM will activate the function at the level that was last selected. The hydraulic modulation function can be installed or uninstalled in the Cat ET configuration screen.

SYSTEMS OPERATION

037

SYSTEMS OPERATION

i02294823

Hydraulic Oil Cooling Function SMCS - 7000-EK

Illustration 1

Illustration 2

g00916399

g01149295

Hydraulic demand fan connections for machines in the following serial number ranges: BDR1-2000, BDM1-2000, BDX1-2000, BCZ1-2000, BDK12000, BDY1-2000 and BEB1-2000.

Illustration 3

g01149299

Hydraulic demand fan connections for machines in the following serial number ranges: BDR2001-UP, BDM2001-UP, BDX2001-UP, BCZ2001-UP, BDK2001-UP, BDY2001-UP, BEB2001-UP, H2A1-UP, H2B1-UP, H2C1-UP, H2D1-UP, H2E1-UP, H2F1-UP and H2G1-UP.

The hydraulic demand fan helps to prevent overheating of the engine. The ECM will determine the correct fan speed based on the temperature of the engine coolant, the temperature of the hydraulic oil and the speed of the engine. The ECM will control the fan speed by adjusting the output current to the proportional hydraulic demand fan solenoid. This will increase or decrease the amount of hydraulic flow to the fan motor. The machine ECM receives information from the engine coolant temperature sensor via the CAN data link from the engine ECM. The machine ECM receives information from the hydraulic oil temperature sensor at contact J1-61 or J1-60 (wire 442GY) depending on the machine configuration. The fan solenoid is energized through contact J2-24 (wire C411-OR). If there is a diagnostic code problem with the input data from the sensors or the CAN data link, the ECM will default the fan to maximum speed. When the limp home mode switch is ON, the ECM will default the fan to the maximum speed. On the M313C machines, the demand fan configuration can be changed in the Cat ET configuration screen. The available selections are for a Standard Ambient configuration or a High Ambient configuration.

SYSTEMS OPERATION

038

SYSTEMS OPERATION

i02294947

Limp Home Function SMCS - 7000-EK

Illustration 1

g01149415

The limp home mode switch provides a way for the operator to move the machine at reduced speed if a problem forces the ECM into failure mode. When this mode is activated, the proportional reducing valves still receive power from the ECM. The ECM is not bypassed. If the machine ECM FAILS, the limp home mode is inoperative. When the limp home mode switch is turned ON, contact J1-17 is connected to ground and certain functions behave differently. The functions are listed below: The power mode is set to the economy mode. The parking brake will not be engaged. The oscillating axle will not be locked unless the brake pedal is locked and the armrest is raised. The automatic engine speed control is disabled. The creeper speed is always OFF. The travel lock is always OFF. The travel alarm is cancelled after 10 seconds. The travel speed is set to LOW and the travel speed switch is deactivated. The cooling fan is set to the maximum speed. The implement lockout is not allowed. The medium pressure functions (if equipped) are disabled.

The power shift solenoids are disabled The refill pump (fuel tank) is deactivated.

SYSTEMS OPERATION

039

SYSTEMS OPERATION

i02300399

Machine Working Function SMCS - 7000-EK

Illustration 1

g01151926

The machine working function enables the machine ECM to indicate to the engine ECM when more power from the engine is needed or is not needed in order to operate the machine. This information enables the engine ECM to activate the low battery elevated engine idle function when engine power is not required for other systems on the machine. This information from the machine ECM is also used by the engine ECM in order to activate the automatic engine speed control function. When the machine ECM detects that the main pump pilot pressure switch contacts and the swing pilot pressure switch contacts are both open, machine power demand is considered low. This information is sent to the engine ECM over the Cat Data Link. The engine ECM will respond by either activating the low battery elevated engine idle function if needed or the automatic engine speed control function. If the contacts close on either the main pump pilot pressure switch or the swing pilot pressure switch, the machine ECM will indicate an increased machine power demand to the engine ECM.

SYSTEMS OPERATION

040

SYSTEMS OPERATION

i02295035

Oscillating Axle Control Function SMCS - 7000-EK

Illustration 1

g01149509

Illustration 2

g01149519

The ECM illuminates the LED indicator above the oscillating axle switch on the soft switch panel when the axle is locked. When the ECM energizes the oscillating axle solenoid, the oscillating axle is unlocked. The LED indicator will be OFF. If any of the following conditions are met, the ECM will de-energize the oscillating axle solenoid which will cause the oscillating axle to be locked. The armrest is in the UP position. The service brake pedal is locked. The oscillating axle lock is requested from the switch on the soft switch panel. When the axle is locked as a result of the armrest being raised, the axle will unlock when the armrest is lowered. The limit switch for the service brake pedal informs the ECM when the service brake is in the fully depressed position (locked) The signal from the switch for the oscillating axle is sent from the soft switch panel on the CAN data link. If the signal from the switch for the oscillating axle is unknown, the axle will be locked. If there is a diagnostic code for the position switch for the armrest or the brake pedal switch, the axle will be locked.

SYSTEMS OPERATION

041

SYSTEMS OPERATION

i02295175

Parking Brake Function SMCS - 7000-EK The component configuration for the parking brake function has changed from earlier M300C machines. The changes are indicated by the illustrations below. The end result remains the same. When the parking brake is ENGAGED, the machine will not move. This change takes place for the following serial number ranges. (BDX2001-UP) (BCZ2001-UP) (BEB2001-UP) (BDK2001-UP) (BDY2001-UP) (BDR2001-UP) (BDM2001-UP) (H2A1-UP) (H2B1-UP) (H2C1-UP) (H2D1-UP) (H2E1-UP) (H2F1-UP) (H2G1-UP)

Illustration 1

g01149791

Block diagram of the parking brake functionality for machines in the following serial number ranges: BDR1-2000, BDM1-2000, BDX1-2000, BCZ12000, BDK1-2000, BDY1-2000 and BEB1-2000.

Illustration 2

g01149787

Block diagram of the parking brake functionality for machines in the following serial number ranges: BDR2001-UP, BDM2001-UP, BDX2001-UP, BCZ2001-UP, BDK2001-UP, BDY2001-UP, BEB2001-UP, H2A1-UP, H2B1-UP, H2C1-UP, H2D1-UP, H2E1-UP, H2F1-UP and H2G1-UP.

Illustration 3

g01149797

ECM connections for components involved for machines in the following serial number ranges: BDR1-2000, BDM1-2000, BDX1-2000, BCZ12000, BDK1-2000, BDY1-2000 and BEB1-2000.

Illustration 4

g01149890

ECM connections for components involved for machines in the following serial number ranges: BDR2001-UP, BDM2001-UP, BDX2001-UP, BCZ2001-UP, BDK2001-UP, BDY2001-UP, BEB2001-UP, H2A1-UP, H2B1-UP, H2C1-UP, H2D1-UP, H2E1-UP, H2F1-UP and H2G1-UP.

The parking brake is ENGAGED on the machine with the use of a spring force that will lock the transmission in place in order to prevent movement. On machines that are equipped with a parking brake solenoid, The ECM will de-energize the solenoid in order to allow the spring force to ENGAGE the parking brake. On machines that are equipped with the two transmission solenoids, the ECM will de-energize both solenoids in order allow the spring force to ENGAGE the parking brake. When the ECM determines that the parking brake must be DISENGAGED, the ECM will energize either the parking brake solenoid or one of the two transmission gear shift solenoids depending on the machine configuration (see above illustrations). This allows pilot oil to flow to the transmission which allows hydraulic pressure to overcome the force of the springs and DISENGAGE the parking brake. When the parking brake is ENGAGED, the ECM will illuminate the LED indicator above the parking brake switch on the soft switch panel (SSP). The Monitor will illuminate the parking brake indicator. The ECM will ENGAGE the parking brake when any of the following conditions take place: If the service brake limit switch contacts are open (service brake not locked) and the parking brake switch on the soft switch panel is pressed, the parking brake is ENGAGED. If the service brake limit switch contacts are open (service brake not locked) the left armrest is in the UP position, the parking brake is ENGAGED. If the machine hydraulic system pressure is low, the parking brake is ENGAGED.

The ECM will DISENGAGE the parking brake when any of the following conditions take place: If the limp home switch is ON. If the service brake limit switch contacts are closed (service brake locked) the parking brake will be DISENGAGED. If the parking brake is ENGAGED and the service brake limit switch contacts close (service brake pedal depressed), the ECM will DISENGAGE the parking brake until the service brake limit switch contacts open (service brake pedal released), then the ECM will ENGAGE the parking brake again. When the parking brake is ENGAGED and the parking brake switch on the SSP is pressed, The ECM will energize the solenoid(s) in order to DISENGAGE the parking brake. If there is an active diagnostic code for the armrest switch or the service brake limit switch, the parking brake will be ENGAGED unless the service brake is locked or the machine is traveling as indicated to the ECM by the transmission output speed sensor.

SYSTEMS OPERATION

042

SYSTEMS OPERATION

i02296303

Power Mode Function SMCS - 7000-EK

Illustration 1

g01172675

Illustration 2

g01150106

The power mode function enables the operator to select a lower machine hydraulic output level when working conditions do not require full hydraulic power output. The power mode is selected with the power mode switch on the soft switch panel (SSP). The three available power modes are economy mode, power mode and travel mode. The engine ECM controls the power mode operation. When a power mode is selected, the machine ECM will illuminate the LED indicator on the SSP that corresponds to the selected power mode. The machine ECM drives the outputs for the proportional main pump power shift solenoid and the proportional swing pump power shift solenoid that will determine hydraulic power levels from the pumps. The engine ECM sends commands to the machine ECM over the Cat Data Link. The machine ECM sends data for machine travel direction, air filter plugged status and hydraulic oil temp data to the engine ECM. When the operator selects one of the power modes, the engine ECM will command the machine ECM to drive the main pump solenoid at a constant current level in order to produce the correct power shift pressure to the main pump. The machine ECM will drive the swing pump solenoid in the same manner. The engine ECM will compare the current engine speed to a "target" engine speed that is programmed for each throttle position in the selected power mode. If the hydraulic load on the machine causes the current engine speed to fall below the "target" engine speed, the engine ECM will command the machine ECM to reduce the output current to the main pump solenoid in order to de-stroke the pump and reduce the pump pressure. This will decrease the load on the engine. The swing pump will be kept at a constant output level. This condition is known as an "engine under speed condition". When this occurs, a higher engine speed should be selected. If the limp home mode switch is ON or if a diagnostic code is active for one of the solenoids, economy mode will be activated. Power mode output currents are configured using the Cat ET configuration screen.

SYSTEMS OPERATION

043

SYSTEMS OPERATION

i02296515

Powerup Sequence (Machine Electronic Control System) SMCS - 7000-EK When the key switch is in the OFF position, the ECM is in a "sleep" mode and is receiving + battery power. The ECM goes to an active mode when the key start switch is moved from the OFF position to the ON position. When this occurs, most of the outputs for the machine ECM are set to a de-energized state except for the quick coupler solenoid which will be set to the state that the solenoid was in when the key switch was last turned to the OFF position. Most functions that are controlled by the soft switch panel are set to their last known state when the key switch was last turned to the OFF position. The travel lock is the only exception. The travel lock is always OFF when the machine ECM is powered up.

SYSTEMS OPERATION

044

SYSTEMS OPERATION

i02296527

Quick Coupler Function SMCS - 7000-EK

Illustration 1

g00916041

Illustration 2

g01150207

The quick coupler function provides the operator with a quick method of changing attachments. In order to lock an attachment, the operator will properly align the attachment. The request for quick coupler lock is selected from the quick coupler menu in the Monitor. When a quick coupler lock request is received over the CAN data link, the ECM will de-energize the quick coupler solenoid in order to lock the attachment in place. As the hydraulic pressure increases, a warning level 1 event will become active until the quick coupler pressure switch closes. The quick coupler pressure switch will close when the pressure reaches 6000 kPa (870 psi). When the pressure switch closes, the ECM will consider the attachment locked. If the quick coupler pressure switch opens within 60 seconds after a closing, an active warning level 3 event is generated and logged. The Monitor will display a "LOW QUICK COUPLER PRESSURE" message. The ECM will continue to monitor the quick coupler pressure switch. If the switch unexpectedly opens after 60 seconds has passed, a warning level 2 event will be generated. The Monitor will display a "LOW QUICK COUPLER PRESSURE" message. The quick coupler function is deactivated via a command from the menu on the monitor. The ECM will energize the quick coupler solenoid in order to release the hydraulic pressure. As the hydraulic pressure decreases, a level 1 event will be generated until the quick coupler pressure switch has opened. When the quick coupler pressure switch opens, the ECM will consider the attachment unlocked and the Monitor will display a "QUICK COUPLER UNLOCK" message. When the quick coupler pressure switch is open, the pressure will be lower than 6000 kPa (870 psi). If the quick coupler pressure switch is closed when there is no command to lock the quick coupler, a warning level 3 event will be generated. The Monitor will display a "HIGH QUICK COUPLER PRESSURE" message. The quick coupler function can be installed or uninstalled through the Cat ET configuration screen.

SYSTEMS OPERATION

045

SYSTEMS OPERATION

i02296771

Refueling Function SMCS - 7000-EK

Illustration 1 Refueling function block diagram

g01150308

Illustration 2

g01150533

Refueling function connections for machines in the following serial number ranges: BDR1-2000, BDM1-2000, BDX1-2000, BCZ1-2000, BDK12000, BDY1-2000 and BEB1-2000.

Illustration 3

g01150542

Refueling function connections for machines in the following serial number ranges: BDR2001-UP, BDM2001-UP, BDX2001-UP, BCZ2001-UP, BDK2001-UP, BDY2001-UP, BEB2001-UP, H2A1-UP, H2B1-UP, H2C1-UP, H2D1-UP, H2E1-UP, H2F1-UP and H2G1-UP.

The refueling function allows the machine to be refueled in the field. The ECM will cause the refueling pump relay to be energized in one of two methods depending on the machine configuration. For machines equipped with the forward and reverse travel pressure switches (see block diagram), the ECM will energize the relay by enabling +battery power on wire T776-GY to pass through the coil of the relay and return to ECM ground through wire H805-BR. For machines equipped with the travel pedal position sensor (see block diagram), the ECM will energize the coil of the relay by grounding wire T776-GY which will allow +battery power to pass through the coil of the relay from wire 139-OR. When the fuel pump switch is pressed, the machine ECM will allow the coil of the refueling pump relay to energize. The secondary contacts of the relay will close and allow +battery power to activate the refueling pump. All of the following conditions are required in order for the ECM to allow the relay to energize: The fuel pump switch is pressed to the ON position. The left armrest is in the UP position. The fuel level sensor indicates that the fuel level is less than 95 percent. The engine ECM will send the information to the machine ECM that will indicate that the RPM of the engine is zero.

If all of these conditions are not correct when the ECM causes the relay to energize, then the ECM will de-energize the refueling relay. If any of these conditions are changed to a false state when the refueling procedure is taking place, the ECM will deenergize the refueling relay. The ECM will de-energize the relay if any of the following events occur: The time that is required to fill an empty tank is exceeded. This information is programmed into the machine ECM for each machine model. For all M300C models, the time that is programmed is 18 minutes.

120 seconds have passed without the fuel level sensor indicating a change in the fuel level. When the refueling pump relay is activated, all other outputs of the machine ECM are de-energized. If there is an active diagnostic code for the armrest position switch, the ECM will not allow the refueling pump relay to be energized.

SYSTEMS OPERATION

046

SYSTEMS OPERATION

i01782612

Swing Brake Function SMCS - 7000-EK

Illustration 1

g00916075

Illustration 2

g00851965

The swing brake solenoid is normally de-energized. When swing is requested, the solenoid is energized through contact J2-51. In order for the solenoid to energize, the following conditions must be present: The left armrest must be down. The operator is not requesting a lock of the implements. The switch (joystick) for the swing brake is open. Swing must be requested.

When a request for swing is made, the swing pressure switch closes to ground. The solenoid is energized until the request for swing is stopped. At 3.5 seconds after the request for swing has stopped, the solenoid is de-energized. The solenoid is immediately de-energized for the following conditions: The left armrest is raised to the UP position. Implement lockout is requested by the operator. The switch (joystick) for the swing brake is closed to ground. If there is a diagnostic code for the armrest position switch, the solenoid will always be de-energized. If the state of the implement lockout switch is not known, the solenoid will always be de-energized.

SYSTEMS OPERATION

047

SYSTEMS OPERATION

i02297751

Travel Activation Function SMCS - 7000-EK

Illustration 1 Travel activation function block diagram

g01150701

Illustration 2

g01150716

ECM connections for components involved for the travel activation function for machines in the following serial number ranges: BDR1-2000, BDM1-2000, BDX1-2000, BCZ1-2000, BDK1-2000, BDY1-2000 and BEB1-2000.

Illustration 3

g01150719

ECM connections for components involved for the travel activation function for machines in the following serial number ranges: BDR2001-UP, BDM2001-UP, BDX2001-UP, BCZ2001-UP, BDK2001-UP, BDY2001-UP, BEB2001-UP, H2A1-UP, H2B1-UP, H2C1-UP, H2D1-UP, H2E1-UP, H2F1UP and H2G1-UP.

The ECM can enable or disable the travel function by controlling the state of the proportional solenoid for the travel pilot hydraulic circuit. In order for the ECM to enable the travel function, the following conditions must be met: The parking brake is OFF. The left armrest is DOWN. The signal from the transmission pilot pressure sensor (transmission clutch) indicates that the hydraulic pressure is within the correct range. The service brake pedal is unlocked. The machine ECM monitors the state of the service brake pedal limit switch in order to determine if the service brake pedal is depressed.

When above conditions are correct and a travel command is initiated by pressing the travel pedal, the ECM will energize the travel activation / travel pilot pressure solenoid. If any of the required conditions change, the ECM will disable the travel activation / travel pilot pressure solenoid. If a diagnostic code becomes active for the armrest position switch, the brake pedal limit switch or the transmission pressure sensor, the ECM will disable the travel activation / travel pilot pressure solenoid.

Travel Pedal Operation Machines that are equipped with the travel activation solenoid (see illustration for S/N's) are fitted with a limit switch that indicates an actuated / not actuated signal to the ECM in order to indicate the direction of travel. Machines that are equipped with the travel pilot pressure solenoid (see illustration for S/N's) are equipped with a position sensor on the travel pedal. The operation of this sensor is detailed in the following text.

Illustration 4 Pedal position sensor block diagram

g01151695

Illustration 5 Pedal position sensor schematic

g01151754

The travel pedal is mechanically connected to the pilot hydraulic system. When the pedal is depressed, this mechanical connection actuates the pilot valve in order to enable travel. The travel pedal position sensor sends an analogue signal to the ECM. The ECM interprets this voltage signal as a specific pedal position. The ECM uses this information along with information from other sensors and system parameters to determine the output current for the travel motor swash plate angle limit solenoid. This solenoid will control the output of the travel motor. The position sensor allows the speed of the machine to be varied within the select speed range according to the position of the travel pedal.

Position Sensor Auto-Calibration And Operation The analog position signal that is sent to the ECM is calibrated automatically by the ECM every time that the key switch is turned to the ON position. An allowable "zero position" for the pedal is set as a default in the ECM based on where the pedal is expected to be at rest, when there is not pressure of any kind on the pedal. When the rear section of the pedal is completely depressed, the ECM will interpret the signal received as a maximum reverse travel direction command or -100%. When the forward section of the pedal is completely depressed, the ECM will interpret the signal received as a maximum forward travel direction command or +100%. The ECM will interpret the first 20% of pedal travel in either the forward or the backward direction as a 0% command. The ECM will interpret 80% of pedal travel in either direction as a 100% command, consequently, the ECM sees 80% pedal travel in either direction as either a -100% or +100% command. The analogue voltage values for these three positions are shown in Table 1. Table 1 Pedal Position Command

Signal (Voltage)

Initial Zero Position

2.5

Allowable Zero Range (ZP)

2.3 to 2.7

-100% (Reverse)

ZP minus 0.45

+100% (Forward)

ZP plus 0.45

When the key switch is turned to the ON position, the ECM reads the voltage signal from the sensor. If this voltage is within the allowable zero range, then that voltage will become the zero position for the duration of the key switch ON cycle. If the voltage is not within the allowable zero position range, then the ECM will assume that the pedal is pressed and will use the last known zero position voltage for the current zero position voltage. During machine operation, as the travel pedal is depressed further in either direction, the voltage signal to the ECM will result in an increased current output to the travel motor swash plate angle limit solenoid when the other conditions are correct. This will cause increased travel speed for the machine.

SYSTEMS OPERATION

048

SYSTEMS OPERATION

i02297849

Travel Alarm Function SMCS - 7000-EK; 7429 The component configuration for the travel alarm function has changed on the M300C machines. The changes are indicated by the illustrations below and are indicated in the following text.

Illustration 1

g01150849

Block diagram of the travel alarm functionality for machines in the following serial number ranges: BDR1-2000, BDM1-2000, BDX1-2000, BCZ12000, BDK1-2000, BDY1-2000 and BEB1-2000.

Illustration 2

g01150850

ECM connections for the travel alarm function for machines in the following serial number ranges: BDR1-2000, BDM1-2000, BDX1-2000, BCZ12000, BDK1-2000, BDY1-2000 and BEB1-2000.

Illustration 3

g01150851

Block diagram of the travel alarm functionality for machines in the following serial number ranges: BDR2001-UP, BDM2001-UP, BDX2001-UP, BCZ2001-UP, BDK2001-UP, BDY2001-UP, BEB2001-UP, H2A1-UP, H2B1-UP, H2C1-UP, H2D1-UP, H2E1-UP, H2F1-UP and H2G1-UP.

Illustration 4

g01150852

ECM connections for the travel alarm function for machines in the following serial number ranges: BDR2001-UP, BDM2001-UP, BDX2001-UP, BCZ2001-UP, BDK2001-UP, BDY2001-UP, BEB2001-UP, H2A1-UP, H2B1-UP, H2C1-UP, H2D1-UP, H2E1-UP, H2F1-UP and H2G1-UP.

The ECM will activate the travel alarm according to a different set of input conditions depending on the machine configuration. For machines with that are equipped with the forward and revers travel pressure switches (see illustrations for S/N's), the ECM uses the forward travel pressure switch or the reverse travel pressure switch in order to detect machine travel. The ECM will activate the travel alarm when the pressure in either pressure switch causes the switch contacts to close. When this occurs, the ECM will energize the output for the travel alarm in order to sound the travel alarm. The ECM will activate the travel alarm for a minimum of 10 seconds. If the travel alarm cancel switch on the soft switch panel (SSP) is pressed during this time period, the ECM will turn OFF the alarm after 10 seconds. If the travel alarm cancel switch on the SSP is not pressed during the first 10 second time period, the alarm will continue to sound until the travel alarm cancel switch is pressed. If the machine is equipped with a hydraulic cab riser (HCR), the travel alarm will sound when the cab is lowering. For machines with that are equipped with the transmission output speed sensor and the thumbwheel position sensor (see illustrations for S/N's), the functionality of the travel switch is the same as mentioned above. On these machines, the ECM monitors the transmission output speed sensor in order to detect machine movement. The ECM monitors the inputs of the medium pressure switch and the right hand joystick thumbwheel position sensor (if equipped) in order to determine when the

HCR is activated. Note: If the limp home mode is activated, the alarm will sound for a maximum of 10 seconds. The travel alarm function can be installed or uninstalled in the Cat ET configuration screen.

SYSTEMS OPERATION

049

SYSTEMS OPERATION

i02301901

Travel Speed Function SMCS - 7000-EK Note: The following text and illustrations details travel speed control for machines in the in S/N ranges BDR1-2000, BDM1-2000, BDX1-2000, BCZ1-2000, BDK1-2000, BDY1-2000 and BEB1-2000For other serial numbers, see the next section below.

Illustration 1

g01152734

Travel speed control for machines in the following serial number ranges: BDR1-2000, BDM1-2000, BDX1-2000, BCZ1-2000, BDK1-2000, BDY12000 and BEB1-2000.

Illustration 2

g01152735

Travel speed circuit connections for machines in the following serial number ranges: BDR1-2000, BDM1-2000, BDX1-2000, BCZ1-2000, BDK12000, BDY1-2000 and BEB1-2000.

The ECM will allow the operator to select one of two travel speeds. The two travel speeds are high and low. The availability of

two travel speeds offers the operator greater control of the machine. In order for the ECM to enable the travel speed function, the left armrest must be down. The signal for low speed or high speed is sent from the travel speed switch on the soft switch panel (SSP) to the ECM on the CAN data link. When the selected speed is low, the ECM will energize the travel speed solenoid. When the selected travel speed is high, the ECM will de-energize the travel speed solenoid.

Activation Of The Travel Speed Solenoid The travel pedal is mechanically connected to the travel pilot pressure system. When the travel pedal is pressed in either the forward or the rearward direction, travel pilot pressure is enabled. The travel speed will default to high speed. In order to select the low speed, the ECM will determine that the following conditions are correct. 1. The low travel speed is requested by the operator. 2. The parking brake is off. 3. The left console is down. If these conditions are not correct, the ECM will de- energize the travel speed solenoid in order to default to the high speed. The travel speed solenoid will be deactivated when the parking brake is engaged. After the parking brake is disengaged, the machine will return to the previous travel speed. Note: If the limp home mode is activated, the travel speed will be low.

Activation Of The Gear Shift Solenoids Note: The following text and illustrations details travel speed control for machines in the in S/N ranges BDR2001UP, BDM2001-UP, BDX2001-UP, BCZ2001-UP, BDK2001-UP, BDY2001-UP, BEB2001-UP, H2A1-UP, H2B1-UP, H2C1-UP, H2D1-UP, H2E1-UP, H2F1-UP and H2G1-UP.

Illustration 3

g01152749

Travel speed control for machines in the following serial number ranges: BDR2001-UP, BDM2001-UP, BDX2001-UP, BCZ2001-UP, BDK2001-UP, BDY2001-UP, BEB2001-UP, H2A1-UP, H2B1-UP, H2C1-UP, H2D1-UP, H2E1-UP, H2F1-UP and H2G1-UP.

Illustration 4

g01152750

Travel speed circuit connections for machines in the following serial number ranges: BDR2001-UP, BDM2001-UP, BDX2001-UP, BCZ2001-UP, BDK2001-UP, BDY2001-UP, BEB2001-UP, H2A1-UP, H2B1-UP, H2C1-UP, H2D1-UP, H2E1-UP, H2F1-UP and H2G1-UP.

The ECM will allow the operator to select between a high travel speed or low travel speed. The travel speed is selected from the travel speed switch on the SSP. The switch status is supplied to the ECM over the Can data link. The default travel speed is the high speed. In order for the ECM to enable the low travel speed, the following conditions must be correct. 1. The low travel speed is requested by the operator. 2. The parking brake is off. 3. The left console is down. The travel pedal is mechanically connected to the travel pilot pressure system. When the travel pedal is pressed in either the forward or the rearward direction, travel pilot pressure is enabled. When the listed conditions are correct, the ECM will energize transmission gear shift solenoid 1 in order to set the transmission to low speed. When the default high speed is selected and active, the ECM will energize transmission gear shift solenoid 2. If both solenoids are activated at the same time, a diagnostic code will activate. The Monitor will display a "POWERTRAIN ERROR" message and machine travel will be disabled. Reference: For more information on the travel pedal operation and travel motor control, refer to Systems Operation, "Travel Activation Function"

Travel Motor Control Note: This information applies to machines in the following serial number ranges: BDR2001-UP, BDM2001-UP, BDX2001UP, BCZ2001-UP, BDK2001-UP, BDY2001-UP, BEB2001-UP, H2A1-UP, H2B1-UP, H2C1-UP, H2D1-UP, H2E1-UP, H2F1-UP and H2G1-UP

Illustration 5

g01152762

Travel motor control block diagram for machines in the following serial number ranges: BDR2001-UP, BDM2001-UP, BDX2001-UP, BCZ2001-UP, BDK2001-UP, BDY2001-UP, BEB2001-UP, H2A1-UP, H2B1-UP, H2C1-UP, H2D1-UP, H2E1-UP, H2F1-UP and H2G1-UP.

Illustration 6

g01152763

Travel motor control connections for machines in the following serial number ranges: BDR2001-UP, BDM2001-UP, BDX2001-UP, BCZ2001-UP, BDK2001-UP, BDY2001-UP, BEB2001-UP, H2A1-UP, H2B1-UP, H2C1-UP, H2D1-UP, H2E1-UP, H2F1-UP and H2G1-UP.

The ECM controls the speed and torque of the travel motor by sending a variable output current to the travel motor swash plate angle limit solenoid. This solenoid will cause the travel motor swash plate to increase or decrease the hydraulic flow through the travel motor. The ECM will monitor the inputs from the travel pedal position sensor and the transmission output speed sensor in

order to determine the current output. The ECM also looks at the defined maximum machine speed parameter that is programmable in the Monitor or by using Cat ET. The four possible programmable speed settings are: 20 km/h (12.4 mph) 25 km/h (15.5 mph) 30 km/h (18.6 mph) 34 km/h (21.1 mph)

The default speed setting is 20 km/h (12.4 mph). The ECM will use an internal formula calculation in order to determine machine ground speed. This formula takes into consideration the radius of the wheels, the axle ratio and the transmission speed. If the ECM detects that machine ground speed is 7 km/h (4.3 mph) over the defined maximum machine speed parameter, then an 83-2 "TRANSMISSION OVERSPEED" event code will be activated. In order to enable smooth acceleration at the start of travel, the ECM will energize the travel motor bypass solenoid according to set parameters in the software. When this solenoid is energized, a small amount of hydraulic oil is allowed to bypass the travel motor for a short period of time during acceleration. If an active diagnostic code occurs for the transmission speed sensor, the ECM will activate the limp home mode. Engine rpm will be limited. The ECM will also control the braking function of the travel motor by limiting the travel motor swash plate angle with the travel motor swash plate angle limit solenoid. A programmable braking parameter can be changed in the Monitor or by using Cat ET. The three levels of braking and their assigned numbers are: Hard (High) braking Medium braking Soft (Low) braking A travel motor calibration procedure should be performed when the machine is initially put in service or when travel motor performance is not satisfactory. Refer to Testing and Adjusting, "Travel Motor Speed - Calibrate" for this calibration procedure.

SYSTEMS OPERATION

050

SYSTEMS OPERATION

i02298107

Travel Speed Lock Function SMCS - 7000-EK

Illustration 1 Travel lock function block diagram

g01150914

Illustration 2

g01150975

ECM connections for machines in the following serial number ranges: BDR1-2000, BDM1-2000, BDX1-2000, BCZ1-2000, BDK1-2000, BDY1-2000 and BEB1-2000.

Illustration 3

g01150976

ECM connections for machines in the following serial number ranges: BDR2001-UP, BDM2001-UP, BDX2001-UP, BCZ2001-UP, BDK2001-UP, BDY2001-UP, BEB2001-UP, H2A1-UP, H2B1-UP, H2C1-UP, H2D1-UP, H2E1-UP, H2F1-UP and H2G1-UP.

The ability to operate the machine at a set travel speed for an extended period is enabled when the ECM activates the travel lock function. When the ECM activates travel lock, the magnet will hold the travel pedal in the fully depressed position.

Activation of the Travel Speed Lock In order for the ECM to activate the travel lock magnet, the following conditions must be correct. 1. The left armrest must be in the DOWN position as indicated by the armrest limit switch. 2. The service brakes must not be activated as indicated by the service brake pressure switch (open). 3. The travel pedal must be fully depressed as indicated by the travel pedal limit switch or the travel pedal position sensor. 4. The "travel lock control" switch on the SSP must be pressed as indicated from the Monitor on the CAN data link. 5.

4. 5. The parking brake is OFF. 6. The brake system hydraulic pressure must be within the normal range as indicated by the brake oil accumulator pressure switch (switch closed to ECM ground). 7. The transmission hydraulic pressure must be within the normal limits as indicated by the transmission (clutch) pressure sensor. When the ECM detects that these conditions are correct, the ECM will apply + battery power to the travel lock magnet. When ANY ONE of the following conditions occur, the ECM will turn OFF the travel lock magnet. The operator presses the service brake pedal. The operator presses the travel lock control switch on the SSP. The left armrest is raised. DO NOT RAISE THE ARMREST DURING TRAVEL. If an active diagnostic code occurs for the armrest position switch or the travel pedal limit switch / travel pedal position sensor, the travel lock function will be disabled. When the machine limp home mode is active, the travel lock function will be disabled. This function can be installed or uninstalled using the Cat ET configuration screen.

SYSTEMS OPERATION

051

SYSTEMS OPERATION

i02300447

Medium Pressure Hydraulic System SMCS - 7000-EK

Illustration 1

g01151999

Medium pressure hydraulics system connections

The medium pressure function provides the capability to operate attachments that operate at a constant medium hydraulic pressure. Four combinations of medium pressure configurations are possible for a single machine application. These combinations are listed below. Medium pressure function Medium pressure and joystick steering Medium pressure and hydraulic cab riser (HCR) or offset boom Medium pressure and HCR or offset boom and joystick steering

The medium pressure attachment configurations are installed or uninstalled in the Cat ET configuration screen. The operator uses the right hand joystick thumbwheel in order to control the selected medium pressure attachment. For more information on the joystick thumbwheel operation for selected attachments, refer to Operation And Maintenance Manual, SEBU7945. The ECM must see that the armrest position switch is closed to ground at contact J1-54 (wire E917-WH) before the medium

pressure function can be enabled. The ECM must energize the implement lockout relay (implements unlocked) in order to supply +battery power to the medium pressure switch. The position of the medium pressure switch will determine whether the ECM energizes the medium pressure enable solenoid or the HCR/Offset boom enable solenoid. When either of these solenoids is energized, the associated function is enabled. Then, the ECM will output a proportional output current to the appropriate medium pressure solenoid in order to control the hydraulic oil flow for the selected function. The output current from the ECM is dependent on the right hand joystick thumbwheel position sensor signal that is received at contact J1-50 (wire E474-OR). Table 1 indicates the medium pressure switch states for a selected function. Table 1 Medium Pressure Switch States For Selected Functions Function

Sw 1

Sw 2

Sw 3

Medium Press Enabled

Closed (1)

Open (2)

Open

Joystick Steer

Open

Open

Closed

HCR/Offset Boom

Open

Closed

Open

(1) (2)

Closed to + battery from implement lockout relay. Open to + battery from implement lockout relay.

Right Joystick Thumbwheel Position Sensor Operation The pulse width modulated (PWM) signal that is sent to the ECM from the position sensor is calibrated automatically by the ECM every time that the key switch is turned to the ON position. An allowable "zero position" for the thumbwheel is set as a default in the ECM based on where the thumbwheel is expected to be at rest, when there is not pressure of any kind on the thumbwheel. When the left section of the thumbwheel is completely depressed, the ECM will interpret the signal received as a maximum left position command or -100%. When the right section of the thumbwheel is completely depressed, the ECM will interpret the signal received as a maximum right position command or +100%. The ECM will interpret the first 3% of thumbwheel movement in either the left or the right direction as a 0% command. The ECM will interpret 97% of thumbwheel movement in either direction as a 100% command, consequently, the ECM sees a 97% thumbwheel movement in either direction as either a -100% or +100% command. The PWM duty cycle value for these three positions are shown in Table 2. Table 2 Thumbwheel Position Command

PWM Duty Cycle (%)

Initial Zero Position

50

Allowable Zero Range (ZP)

48 to 52

-100% (Full Left)

33

+100% Full Right)

67

When the key switch is turned to the ON position, the ECM reads the duty cycle from the sensor. If the duty cycle is within the allowable zero range, then that duty cycle value will become the zero position for the duration of the key switch ON cycle. If the duty cycle is not within the allowable zero position range, then the ECM will assume that the thumbwheel is pressed and will use the last known zero position duty cycle for the current zero position duty cycle value. During machine operation, as the thumbwheel is depressed further in either direction, the duty cycle signal to the ECM will result in an increased current output to the medium pressure solenoids. This will allow the ECM to increase or decrease the hydraulic flow rate to the tool. For all medium pressure functions that use the right hand thumbwheel for operation, when the thumbwheel is pressed on the right hand side, the ECM will output a proportional signal to medium pressure solenoid 2. When the thumbwheel is pressed on the left hand side, the ECM will output a proportional signal to medium pressure solenoid 1.

Medium Pressure Enable

Illustration 2

g01152481

Medium pressure switch medium pressure enable selection

When the medium pressure switch is in the medium pressure enable position, switch 1 contacts are closed to +battery which will energize the medium pressure enable solenoid. The ECM will receive this input at contact J2-31 (wire L998-OR). The ECM will activate one of the medium pressure solenoids with an output current that is dependent on the right hand thumbwheel position sensor signal that is received at contact J1-50 (wire E474-OR) in order to operate the tool.

Joystick Steering

Illustration 3

g01152486

Medium pressure switch joystick steering selection

Note: In order for the ECM to activate the joystick steering function, the selected machine speed must be low gear. When the medium pressure switch is in the joystick steering position, switch 3 contacts are closed to +battery which will energize the joystick steering protection solenoid. The ECM will receive this input at contact J2-30 (wire 327-PK). The ECM will

activate one of the medium pressure solenoids with an output current that is dependent on the right hand thumbwheel position sensor signal that is received at contact J1-50 (wire E474-OR) in order to operate the steering. When the joystick steering function is active, depressing the trigger switch on the left hand joystick will momentarily enable the medium pressure function and deactivate the joystick steering function. The joystick steering function will reactivate when the trigger switch is released. When the joystick steering is activated, wire 327-PK that is connected to one side of the joystick steering relay coil is charged at + battery power. When the trigger switch on the left hand joystick is pressed, wire 191-WH which is connected to the other side of the joystick steering relay coil is connected to ground through the trigger switch. This energizes the relay which will energize the medium pressure enable solenoid through wire L998-OR. The ECM will disable the joystick steering function while the trigger switch is depressed.

Hydraulic Cab Riser Or Offset Boom

Illustration 4 Medium pressure switch HCR selection

g01152504

Illustration 5

g01152496

Medium pressure switch offset boom selection

Note: The hydraulic cab riser function and the offset boom function can not be installed on the machine at the same time.

When the medium pressure switch is in the hydraulic cab riser position (if installed) or the offset boom position (if installed), switch 2 contacts are closed to +battery which will energize the HCR / offset boom solenoid. The ECM will receive this input at contact J2-38 (wire F864-WH). If the HCR function is installed, the ECM must detect the HCR door switch as being closed to ground at contact J1-44 (wire E997-BR) in order to enable the function. The ECM will activate one of the medium pressure solenoids with an output current that is dependent on the right hand thumbwheel position sensor signal that is received at contact J1-50 (wire E474-OR) in order to operate the HCR function. If the offset boom function is installed, the ECM must detect the input from the medium pressure switch only.

SYSTEMS OPERATION

052

SYSTEMS OPERATION

i02298270

Auxiliary Hydraulic System SMCS - 7000-EK The auxiliary hydraulic system on the machine provides the ability to configure and control the operation of the work tools. The multifunction valve enables unidirectional or bidirectional hydraulic control of the work tool. Seven possible tools can be configured and stored in memory. The tools can be configured or selected using the Monitor or the Caterpillar Electronic Technician (Cat ET). When no tool is selected, the machine ECM will assume that a bucket has been attached to the end of the stick. The seven possible tools that are available are listed below: "Tool #1" "Tool #2" "Tool #3" "Tool #4" "Tool #5" "Generator" "Hammer" "No Tool"

Each tool has eight parameters: Table 1 Tool number

Already programmed

The name of the tool

Programmable

The maximum pressure in the forward direction

Programmable

The maximum pressure in the reverse direction

Programmable

The maximum flow in the forward direction

Programmable

The maximum flow in the reverse direction

Programmable

Flow in one direction or flow in two directions

Programmable

Total operating hours

Automatic

The active tool can be selected by using Caterpillar Electronic Technician or the monitor. See Systems Operation, "Tool Select Menu". Note: The components that are involved in the auxiliary hydraulic system have changed on machines in the following serial number ranges: BDR2001-UP, BDM2001-UP, BDX2001-UP, BCZ2001-UP, BDK2001-UP, BDY2001-UP,, BEB2001UP, H2A1-UP, H2B1-UP, H2C1-UP, H2D1-UP, H2E1-UP, H2F1-UP and H2G1-UP. Most of the functionality remains the same as far as operation and configuration of the tools for the auxiliary hydraulic system. The changes are noted in the following text.

Illustration 1

g01151443

Auxiliary hydraulics effective for machines in the following serial number ranges: BDR1-2000, BDM1-2000, BDX1-2000, BCZ1-2000, BDK1-2000, BDY1-2000 and BEB1-2000.

Illustration 2

g01151445

Auxiliary hydraulics effective for machines in the following serial number ranges: BDR1-2000, BDM1-2000, BDX1-2000, BCZ1-2000, BDK1-2000, BDY1-2000, and BEB1-2000.

The following explanation of the left auxiliary pedal forward pressure switch and the auxiliary pedal reverse pressure switch applies to machines with serial numbers in the following serial number ranges: BDR1-2000, BDM2001-UP, BDX1-2000, BCZ1-2000, BDK1-2000, BDY1-2000 and BEB1-2000. In order to control the selected work tool, the operator uses the left auxiliary pedal. This pedal is attached to the pilot hydraulic lines. Two pressure switches are installed in these lines. The forward pressure switch or the reverse pressure switch will inform the ECM which position the pedal is in. If neither switch is actuated, the machine ECM determines that the pedal is not being pressed. If both switches are actuated at the same time, the machine ECM determines that there is a malfunction.

Auxiliary Pedal Forward Pressure Switch Operation When the operator presses on the forward section of the left auxiliary pedal, the pilot hydraulic pressure will close the forward pressure switch to ECM ground which inputs + battery power to contact J2-30 (wire M745-BU). The ECM then outputs a defined output current for the proportional flow solenoid at contact J2-41 (wire M748-GN) in order to control the flow in the forward direction. If the tool has been programmed for one direction, the ECM will energize the directional solenoid at contact J2-63 (wire M746-GY). If the tool has been programmed for two directions, the ECM will disable the directional solenoid. The ECM also sends a defined output current for the proportional pressure solenoid at contact J2-40 (wire M744-PU) in order to control the pressure in the forward direction. The current output for these solenoids can be programmed in the Monitor menu or by using Cat ET. The solenoid for flow in the forward direction is set to the value that has been programmed or 420 milliamperes (mA). The greater value is used. The current value for the pressure solenoid is set to the maximum value that has been programmed (defined) for the forward direction. The current output for these solenoids can be programmed in the Monitor menu or by using Cat ET. The defined current range is 0 Amps to 65.5 Amps. If the active tool is the generator and the generator enable switch is open, the generator solenoid is de-energized. The total operating hours of the tool will begin counting when the ECM sends output current to either proportional solenoid.

Auxiliary Pedal Reverse Pressure Switch Operation When operator presses on the rear section of the left auxiliary pedal, the pilot hydraulic pressure will close the reverse pressure switch to ECM ground which inputs + battery power to contact J2-31 (wire M747-OR). The ECM then outputs an output current for the proportional flow solenoid at contact J2-41 (wire M748-GN) in order to control the flow in the reverse direction. The solenoid for flow in the reverse direction is set to the value that has been defined or 420 mA. The greater value is used. If the tool has been programmed for one direction, the ECM will energize the directional solenoid at contact J2-63 (wire M746-GY). The ECM also sends a defined output current for the proportional pressure solenoid at contact J2-40 (wire M744-PU) in order to control the pressure in the reverse direction. The solenoid for pressure in the reverse direction is set to the maximum value that has been programmed for the reverse direction. The current output for these solenoids can be programmed in the Monitor menu or by using Cat ET. The defined current range is 0 Amps to 65.5 Amps. If the active tool is the generator and the generator enable switch is open, the generator solenoid is de-energized. The total operating hours of the tool will begin counting.

Operation With No Switches Actuated When no switches are actuated, the machine ECM still sends commands to the solenoids in the multifunction valve. The solenoids for flow are set to the value that has been programmed or 420 mA. The smaller value is used. The solenoid for pressure is set to the maximum value that has been programmed. If the tool has been programmed for one direction, the solenoid for direction is energized. If the tool has been programmed for two directions, the solenoid for direction is de-energized. If the active tool is the generator and the generator enable switch is open, the generator solenoid is de-energized.

The total operating hours of the tool will stop counting.

Operation With Both Switches Actuated When both switches are actuated, a problem exists. The machine ECM still sends commands to the solenoids in the multifunction valve. The solenoids for flow are set to 420 (mA). The solenoid for pressure is set to 0 milliamperes. If the tool has been programmed for one direction, the solenoid for direction is energized. If the tool has been programmed for two directions, the solenoid for direction is de-energized. If the active tool is the generator and the generator enable switch is open, the generator solenoid is de-energized. The total operating hours of the tool will stop counting.

Auxiliary Pedal Position Sensor

Illustration 3

g01151474

Auxiliary hydraulics effective for machines in the following serial number ranges: BDR2001-UP, BDM2001-UP, BDX2001-UP, BCZ2001-UP, BDK2001-UP, BDY2001-UP,, BEB2001-UP, H2A1-UP, H2B1-UP, H2C1-UP, H2D1-UP, H2E1-UP, H2F1-UP and H2G1-UP.

Illustration 4

g01151476

Auxiliary hydraulics effective for machines in the following serial number ranges: BDR2001-UP, BDM2001-UP, BDX2001-UP, BCZ2001-UP, BDK2001-UP, BDY2001-UP,, BEB2001-UP, H2A1-UP, H2B1-UP, H2C1-UP, H2D1-UP, H2E1-UP, H2F1-UP and H2G1-UP.

The left auxiliary pedal position sensor is equipped on machines in the following serial number ranges: BDR2001UP, BDM2001-UP, BDX2001-UP, BCZ2001-UP, BDK2001-UP, BDY2001-UP,, BEB2001-UP, H2A1-UP, H2B1-UP, H2C1-UP, H2D1-UP, H2E1-UP, H2F1-UP and H2G1-UP For machines in the serial number range that is listed above, a position sensor is installed on the left auxiliary pedal. The position sensor indicates to the ECM whether the auxiliary pedal is depressed in the forward direction or the rearward direction. Then, the ECM controls the auxiliary hydraulics by outputting a defined current value to the proportional solenoids and to the directional solenoid when required. The ECM automatically calibrates the position sensor when the key switch is moved to the ON position. When the operator presses on the forward section of the left auxiliary pedal, the ECM outputs a defined output current for the proportional flow solenoid at contact J2-41 (wire M748-GN) in order to set the maximum flow in the forward direction. If the tool has been programmed for one direction, the ECM will energize the directional solenoid at contact J2-63 (wire M746-GY). If the tool has been programmed for two directions, the ECM will disable the directional solenoid. The ECM also sends a defined output current for the proportional pressure solenoid at contact J2-40 (wire M744-PU) in order to set the maximum pressure in the forward direction. The current output for these solenoids can be programmed in the Monitor menu or by using Cat ET. The solenoid for flow in the forward direction is set to the value that has been programmed or 180 milliamperes (mA). The greater value is used. The current value for the pressure solenoid is set to the selected tool's maximum value that has been programmed (defined) for the forward direction. The current output for these solenoids can be programmed in the Monitor menu or by using Cat ET. The defined current range is

0 Amps to 65.5 Amps. If the active tool is the generator and the generator enable switch is open, the generator solenoid is de-energized. The total operating hours of the tool will begin counting when the ECM sends output current to either proportional solenoid. When the operator presses on the rearward section of the left auxiliary pedal, the ECM will respond in the same manner as detailed above. If the tool has been programmed for one direction, the ECM will energize the directional solenoid at contact J263 (wire M746-GY). If the tool has been programmed for two directions, the ECM will disable the directional solenoid.

Operation With The Active Tool As "Hammer" or "Generator" or "No Tool" When the active tool is set to "Hammer", the machine ECM energizes the hammer solenoid. When the active tool is set to "No Tool" the machine ECM assumes that a bucket is mounted. See Systems Operation, "Generator Function" for more information on the generator. For these three functions, the values for all of the parameters are preprogrammed in the monitor. The values are in the following table: Table 2 Generator

Hammer

No Tool

Tool Number

6

7

8

Solenoid (pressure) in the forward direction

100% 0 amperes

100% 0 amperes

100% 0 amperes

Solenoid (pressure) in the reverse direction

100% 0 amperes

100% 0 amperes

100% 0 amperes

Solenoid (flow) in the forward direction

0% 0 amperes

0% 0 amperes

0% 0 amperes

Solenoid (flow) in the reverse direction

0% 0 amperes

0% 0 amperes

0% 0 amperes

Solenoid (direction)

de-energized

de-energized

de-energized

Note: When a Generator, Hammer or "No Tool" is active, the defined current value for the maximum flow solenoid should be 0 mA. The minimum value of 180 mA is only applied when one of the configurable auxiliary tools is active. For more information on selecting and configuring active tools, refer to Systems Operation, "Service Options PW Menu". The multi-function auxiliary hydraulic system or the hammer can be installed or uninstalled in the Cat ET configuration screen. The two functions can not be installed at the same time.

SYSTEMS OPERATION

053

SYSTEMS OPERATION

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Data Link SMCS - 7000-EK The Cat Data Link and the CAN data link are separate inputs and outputs of the ECM. The CAT Data Link is connected to the ECM at connector J1-7 and J1-8. The CAN data link is connected to the ECM at connector J1-6 and J1-18. The data links are designed to communicate with other electronic control modules through the machine harness. The data links are not visible components. The two data link systems consist of internal ECM circuits and the connecting harness wiring. Both of the data links are bidirectional. The data links allow the ECM to receive information, and the data links allow the ECM to send information. Caterpillar Electronic Technician (Cat ET) also communicates with other ECM modules through the Cat Data Link. The Cat ET will list the other ECM modules and the available diagnostic information. Note: All electronic control modules (ECM) that use the data link have a module identifier (MID). The MID is listed for each module: Engine ECM ... 036 Machine ECM ... 039 Monitor ECM ... 256 Soft Switch Panel ECM ... 265

SYSTEMS OPERATION

054

SYSTEMS OPERATION

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Electronic Control Module (ECM) SMCS - 7610-MCH

Illustration 1

g00925940

(3) Fuel Pump Switch (4) Machine ECM

Illustration 2 Electronic Control Module (ECM)

g00554751

The Machine ECM makes decisions based on the information from inputs and information from memory. After the Machine ECM receives the information from inputs and information from memory, the Machine ECM will send a corresponding response through the outputs. The inputs and outputs of the Machine ECM connect to the machine harness by two 70 pin connectors (J1 and J2).

Inputs

The machine has several input devices. The Machine Control ECM receives information from components about machine operations. The machine has switch-type inputs and sensor-type inputs. Switches provide signals to the switch inputs of the ECM. The possible outputs of a switch are listed: an open signal, a grounded signal and + battery signal. Sensors provide a signal to the ECM that constantly changes. The inputs to the Machine Control ECM are listed in the tables for the 70 pin connector.

Outputs The Machine Control ECM sends electrical signals through the outputs. The outputs can create an action or the outputs can provide information to the Machine Control ECM. The outputs for the Machine Control ECM are listed in the tables for the 70 pin connector.

Input/Output The engine ECM and the machine ECM use the Cat Data Link in order to communicate with each other. The data link is bidirectional. The data link allows the ECM to receive information. The data link allows the ECM to send information. The data link allows the sharing of information with other electronic control modules. The Machine ECM, the Monitor, and the Soft Switch Panel use the CAN data link to communicate with each other. The data link is bidirectional. The data link allows the ECM to receive information. The data link allows the ECM to send information. For more information on the data links, see Systems Operation, "Data Link". A module identifier (MID) is assigned to each ECM. The MID for the Machine Control ECM is the number 039. Note: The following table indicates the ECM contact connections for machines with the following serial numbers: (BDX1-2000) (BCZ1-2000) (BEB1-2000) (BDK1-2000) (BDY1-2000) (BDR1-2000) (BDM1-2000)

Table 1 Machine Control ECM - J1 Connections No. (1)

Function

Type

2

Overload Warning Device Switch

Switch Input

3

Hydraulic Oil Clog Switch

Switch Input

5

Alternator R Terminal

Input

6

CAN Data Link -

Input/Output

7

Cat Data Link -

Input/Output

8

Cat Data Link +

Input/Output

9

ECM Ground Return

ECM Ground

10

5 Volt Sensor Supply

Power

11

8 Volt Sensor Supply

Power

12

Analog Sensor Return

ECM Ground

13

10 Volt Sensor Supply

Power

14

Boom Angle Limit Sw

Switch Input (Open / Ground)

15

Coolant Level Sw

Switch Input (Open / Ground)

16

Brake Oil Accumulator Pressure Sw

Switch Input (Open / Ground)

17

Limp Home Mode Sw

Switch Input (Open / Ground)

18

CAN Data Link +

Input/Output

19

CAN Shield

24

Stabilizer Pressure Sw

Switch Input (Open / Ground)

25

Hydraulic Oil Level Sw

Switch Input (Open / Ground)

26

Air Filter Clog Sw

Switch Input (Open / Ground)

28

Forward Travel Pressure Sw

Switch Input (Open / Ground)

29

Generator Enable Sw

Switch Input (Open / Ground)

30

Reverse Travel Pressure Sw

Switch Input (Open / Ground)

36

Swing Brake Joystick Sw

Switch Input (Open / Ground)

37

Quick Coupler Pressure Sw

Switch Input (Open / Ground)

38

Fuel Pump Sw

Switch Input (Open / Ground)

39

Swing Pressure Sw

Switch Input (Open / Ground)

44

Travel Pedal Limit Reached

Switch Input (Open / Ground)

45

Travel Pedal Limit Not Reached

Switch Input (Open / Ground)

46

One Touch Low Idle Sw

Switch Input (Open / Ground)

47

Operator Service Brake Pressure Sw

Switch Input (Open / Ground)

51

Fuel Level Sensor

Sensor Input

52

Transmission Pressure Sensor

Sensor Input

54

Armrest Position Sw (Down)

Switch Input (Open / Ground)

55

Armrest Position Sw (Up)

Switch Input (Open / Ground)

56

Service Brake Pedal Unlocked

Switch Input (Open / Ground)

57

Service Brake Pedal Locked

Switch Input (Open / Ground)

58

Key Sw On

Key Switch Input

61

Hydraulic Oil Temperature Sensor

Sensor Input

62 (1)

Main Pump Swashplate Angle Sensor

Sensor Input

The connector contacts that are not listed are not used. The connector has 70 contacts.

____________________ Table 2 Machine Control ECM - J2 Connections No. (1)

Function

Type

1

+ Battery (24V)

Power

2

- Battery

Ground

4

Brake Light (Right)

Power Output

12

Return

ECM Ground

13

Return

ECM Ground

15

Quick Couple Sol

Proportional Driver

16

Brake Light (Left)

Power Output

17

Fuel Pump Relay

Proportional Driver

22

- Battery

Ground

22

- Battery

Ground

24

Hydraulic Demand Fan Sol

Proportional Driver

25

Generator Sol

Proportional Driver

30

Attachment Pedal Pressure Sw (Back)

Switch To + Battery

31

Attachment Pedal Pressure Sw (Front)

Switch To + Battery

32

AESC Control Line

Sinking Driver

33

Implement Lockout Relay

Sinking Driver

36

Return

ECM Ground

37

Return

ECM Ground

38

Joystick Button Activation

Switch To + Battery

39

Key Start Input

Key Start Switch

40

Auxiliary Hydraulics Sol Number 2

Proportional Driver

41

Auxiliary Hydraulics Sol Number 1

Proportional Driver

44

Travel Alarm

On/Off Driver

45

Implement Lockout Sol

On/Off Driver

46

- Battery

Ground

47

+ Battery

Power

48

Main Pump Sol

Proportional Driver

49

Return

ECM Ground

50

Travel Activation Sol

Proportional Driver

51

Swing Brake Sol

Proportional Driver

52

Return

ECM Ground

55

Parking Brake Sol

Sol Output (On/Off)

56

- Battery

Ground

57

+ Battery

Power

58

Swing Pump Sol

Proportional Driver

59

Return

ECM Ground

60

Travel Lock Magnet

Proportional Driver

61

Travel Speed Sol

Proportional Driver

62

High Pressure Sol

Proportional Driver

63

One-Way or Two-Way Flow Sol or Hammer Sol

Proportional Driver

64

Creeper Speed Sol

Proportional Driver

65

Oscillating Axle Sol

Proportional Driver

68

Starter Relay

On/Off Driver

69

- Battery

Ground

70

+ Battery

Power

(1)

The connector contacts that are not listed are not used. The connector has 70 contacts.

Note: The following table indicates the ECM contact connections for machines with the following serial numbers: (BDX2001-UP) (BCZ2001-UP) (BEB2001-UP) (BDK2001-UP) (BDY2001-UP) (BDR2001-UP) (BDM2001-UP) (H2A1-UP) (H2B1-UP) (H2C1-UP) (H2D1-UP) (H2E1-UP) (H2F1-UP)

(H2G1-UP)

Table 3 Machine Control ECM - J1 Connections No. (1)

Function

Type

2

Overload Warning Device Sw

Freq/ PWM Input

3

Hydraulic Oil Clog Sw

Freq/ PWM Input

4

Limp Home Sw 1

Freq/ PWM Input

5

Alternator R Terminal

Input

6

CAN Data Link -

Input/Output

7

CAT Data Link -

Input/Output

8

CAT Data Link +

Input/Output

9

Switch Return

ECM Ground

10

Trans Press Sensor (5 Volt)

Power

11

Hyd Oil Temp Sensor (8 Volt)

Power

12

Sensor Return

ECM Ground

13

ThmbWhl Pos Sensor (10 Volt)

Power

14

Boom Angle Limit Sw

Freq/ PWM Input

15

Coolant Level Sw

Freq/ PWM Input

16

Brake Oil Accumulator Press Sw

Freq/ PWM Input

17

Limp Home Sw 2

Freq/ PWM Input

18

CAN Data Link +

Input/Output

24

Trans Output Speed Sensor

Freq/ PWM Input

25

Hydraulic Oil Level Sw

Freq/ PWM Input

26

Air Filter Clog Sw

Freq/ PWM Input

28

Forward Travel Pressure Sw

Switch Input (Open / Ground)

29

Generator Enable Sw

Switch Input (Open / Ground)

30

LH Joystick Trigger Sw

Switch Input (Open / Ground)

31

Main Pump Press Sw

Switch Input (Open / Ground)

36

Swing Brake Sw (LH Joystick)

Switch Input (Open / Ground)

37

Quick Coupler Pressure Sw

Switch Input (Open / Ground)

38

Refueling Pump Sw

Switch Input (Open / Ground)

39

Swing Pump Pilot Press Sw

Switch Input (Open / Ground)

44

HCR Door Sw

Switch Input (Open / Ground)

45

Hyd Modulation Enable Sw

Switch Input (Open / Ground)

46

One Touch Low Idle Sw

Switch Input (Open / Ground)

47

Service Brake Pressure Sw

Switch Input (Open / Ground)

51

Fuel Level Sensor

Sensor Input

52

Transmission Pressure Sensor

Sensor Input

54

Armrest Position Sw (Down)

Switch Input (Open / Ground)

55

Armrest Position Sw (Up)

Switch Input (Open / Ground)

56

Service Brake Pedal Unlocked

Switch Input (Open / Ground)

57

Service Brake Pedal Locked

Switch Input (Open / Ground)

58

Key Sw On

Key Switch Input

60

Hyd Oil Temp Sensor

PWM Input

61

Travel Pedal Position Sensor

Analog Input

62

Aux Pedal Position Sensor

Analog Input

(1)

The connector contacts that are not listed are not used. The connector has 70 contacts.

Table 4 Machine Control ECM - J2 Connections No. (1)

Function

Type

1

+ Battery (24V)

Power

2

- Battery

Ground

3

Medium Pressure Sol 2

PWM Driver

4

Brake Light (Right)

Power Output

12

PWM Return 17-20

ECM Ground

13

PWM Return 13-16

ECM Ground

15

Quick Coupler Sol

PWM Driver

16

Brake Light (Left)

Power Output

17

Travel Motor Bypass Sol

PWM Driver

22

- Battery

ECM Ground

23

+ Battery

Power

24

Hydraulic Demand Fan Sol

PWM Driver

25

Hyd Modulation Sol

PWM Driver

30

Medium Pressure Sw 3

Switch To + Battery

31

Medium Pressure Sw 1

Switch To + Battery

33

Implement Lockout Relay

Sinking Driver

36

ON/OFF Drive Return

ECM Ground

37

- Battery

Ground

38

Medium Pressure Sw 2

Switch To + Battery

39

Key Start Input

Key Start Switch

40

Auxiliary Valve Pressure Sol

Proportional Driver

41

Auxiliary Valve Flow Sol

Proportional Driver

44

Travel Alarm Horn

On/Off Driver

45

Implement Lockout Sol

On/Off Driver

46

- Battery

Ground

47

+ Battery

Power

48

Main Pump Sol

Proportional Driver

49

PWM Return 5-8 (ECM Gnd)

ECM Ground

50

Travel Pilot Pressure Sol

Proportional Driver

51

Swing Brake Sol

Proportional Driver

52

PWM Return 1 - 4 (ECM Gnd)

ECM Ground

55

Generator Valve Sol

On/Off Driver

56

- Battery

ECM Ground

57

+ Battery

Power

58

Swing Pump Power Shift Press Sol

PWM Driver

59

PWM Return 5 - 12 (ECM Gnd)

ECM Ground

60

Travel Lock Magnet

Proportional Driver

61

Trans Gear Shift Sol 2

Proportional Driver

62

Trans Gear Shift Sol 1

Proportional Driver

63

Aux Directional or Hammer Sol

Proportional Driver

64

Travel Motor Swash Plate Angle Limit Sw

Proportional Driver

65

Oscillating Axle Sol

Proportional Driver

68

Starter Relay and Limp Home Sw

On/Off Driver

69

- Battery

Ground

70

+ Battery

Power

(1)

The connector contacts that are not listed are not used. The connector has 70 contacts.

SYSTEMS OPERATION

055

SYSTEMS OPERATION

i02299524

Switches SMCS - 1435; 7332

Limit Switches

Illustration 1

Limit Switch (Service Brake Pedal)

g00855687

Illustration 2

g00914468

The limit switch for the service brake pedal has three contacts. The ground wire A235-BK is connected to the ECM at contact J1-9. The normally closed contact on the switch is connected to the ECM at contact J1-56 (wire F790-BR). This indicates that the brake pedal is unlocked. The normally open contact on the switch is connected to the ECM at contact J1-57 (wire F787GN). This switch is closed to ground when the brake pedal is fully depressed.

Limit Switch (Travel Pedal)

Illustration 3

g00920686

Note: The travel pedal limit switch is equipped on machines in serial number range 1 - 2000 for all prefixes covered in this manual. For machines above this S/N range, refer to Systems Operation, "Sensors" for information on updated components on the travel pedal. The limit switch for the travel pedal has three contacts. The ground wire A235-BK is connected to the ECM at contact J1-9. The normally closed contact on the switch is connected to the ECM at contact J1-45 (wire M958-OR). This indicates that the travel pedal has not been pressed. The normally open contact on the switch is connected to the ECM at contact J1-44 (wire M957-GY). This switch is closed to ground when the travel pedal is fully depressed.

Limit Switch (Armrest)

Illustration 4

g00925920

The limit switch for the position of the armrest has three contacts. The ground wire A235-BK is connected to the ECM at contact J1-9. The normally closed contact on the switch is connected to the ECM at contact J1-55 (wire E918-GN). This indicates that the armrest is in the UP position. The normally open contact on the switch is connected to the ECM at contact J154 (wire E917-WH). This switch is closed to ground when the armrest is in the DOWN position.

Limit Switch (Boom) The limit switch for the angle of the boom has three contacts. Two of these contacts are used. The ground wire A235-BK is connected to the ECM at contact J1-9. The normally closed contact on the switch is not connected. The normally open contact on the switch is connected to the ECM at contact J1-14 (wireE441-GN). This switch is closed to ground when the boom is fully lowered.

Limit Switch (HCR Door)

Illustration 5

g01153386

Note: The hydraulic cab riser switch is equipped on machines with the HCR attachment in the following serial number ranges: BDR2001-UP, BDM2001-UP, BDX2001-UP, BCZ2001-UP, BDK2001-UP, BDY2001-UP, BEB2001-UP, H2A1-UP, H2B1-UP, H2C1-UP, H2D1-UP, H2E1-UP, H2F1-UP and H2G1-UP. The hydraulic cab riser door switch provides an input to the ECM that will indicate when the cab door is closed. When the door is closed, the switch is closed to ECM ground at contact J1-44 (wire E997-BR). The common terminal of the switch is connected to ECM ground at contact J1-9 (wire A235-BK). The ECM must detect this condition and other conditions before the cab can be raised.

Level Switches

Level Switch (Coolant Level)

Illustration 6

g00920674

The level switch is connected to the ECM at contact J1-15 (signal wire E452-WH) and contact J1-9 (ground wire A235-BK). When the fluid level drops below the switch, contact J1-15 is opened. The ECM sends the information on the CAN data link to the monitor. The monitor shows the appropriate message on the display.

Level Switch (Hydraulic Oil Level)

Illustration 7

g00986932

The level switch is connected to the ECM at contact J1-25 (signal wire 496-WH) and contact J1-9 (ground wire A235-BK). When the fluid level drops below the switch, contact J1-25 is opened. The ECM sends the information on the CAN data link to the monitor. The monitor shows the appropriate message on the display.

Pressure Switches The following pressure switches are identical. The actuation pressure is 490 ± 49 kPa (71 ± 7 psi). The de-actuation pressure is 290 kPa (42 psi).

Illustration 8

g00855565

Note: The pressure switches for forward and reverse pilot pressure are equipped on machines that have serial numbers in the following ranges: BDR1-2000, BDM1-2000, BDX1-2000, BCZ1-2000, BDK1-2000, BDY1-2000 and BEB1-2000. For machines that are covered by this manual with a different serial number, refer to Systems Operation, "Sensors" or Systems Operation, "Auxiliary Hydraulic System" for information on updated components.

Pressure Switch (Multifunction Valve Reverse)

Illustration 9

g00925934

Forward pressure switch (1) and reverse pressure switch (2) in the multifunction valve (also referred to as the combined function valve)

Note: The pressure switches for multifunction valve forward and multifunction valve reverse are equipped on machines in the following serial number ranges: BDR1-2000, BDM1-2000, BDX1-2000, BCZ1-2000, BDK1-2000, BDY1-2000 and BEB12000. For machines that are covered by this manual with a different serial number, refer to Systems Operation, "Sensors" for information on updated components on the travel pedal. The pressure switch for reverse flow in the multifunction valve is connected to the ECM at contact J2-31 (signal wire M747-OR) and contact J2-23 (ground wire 116-BR).

Pressure Switch (Multifunction Valve Forward)

Illustration 10

g00925934

(1) Forward pressure switch and (2) reverse pressure switch in the multifunction valve (also referred to as the combined function valve)

Note: The pressure switches for multifunction valve forward and multifunction valve reverse are equipped on machines in the following serial number ranges: BDR1-2000, BDM1-2000, BDX1-2000, BCZ1-2000, BDK1-2000, BDY1-2000 and BEB12000. For machines that are covered by this manual with a different serial number, refer to Systems Operation, "Sensors" for information on updated components on the travel pedal. The pressure switch for forward flow in the multifunction valve is connected to the ECM at contact J2-30 (signal wire M748GN) and contact J2-23 (ground wire 116-BR).

Pressure Switch (Forward Travel)

Illustration 11

g00915649

Note: The pressure switches for forward travel and reverse travel are equipped on machines that have serial numbers in the following ranges: BDR1-2000, BDM1-2000, BDX1-2000, BCZ1-2000, BDK1-2000, BDY1-2000 and BEB1-2000. The pressure switch for forward travel is connected to the ECM at contact J1-28 (signal wire E480-BU) and contact J1-9 (ground wire A235-BK).

Pressure Switch (Reverse Travel)

Illustration 12

g00915658

The pressure switch for reverse travel is connected to the ECM at contact J1-30 (signal wire E482-WH) and contact J1-9 (ground wire A235-BK).

Pressure Switch (Swing Pilot)

Illustration 13

g00918410

The pressure switch for the swing circuit is connected to the ECM at contact J1-39 (signal wire G426-WH) and contact J1-9 (ground wire A235-BK). The ECM will use the input from this switch and from the main pump pressure switch in order to detect hydraulic activity. The ECM will use this information to determine when to enable the Automatic Engine Speed Control (AESC). For more information on the AESC function, refer to Systems Operation, "Automatic Engine Speed Control Function".

Pressure Switch (Main Pump)

Illustration 14

g00855565

Illustration 15

g01171832

Main pump pressure switch located on the manifold under the access panel behind the cab

The main pump pressure switch is connected to the ECM contact J1-31 (wire G424-GN) and contact J1-9 (ground wire A235BK). The ECM will use the input from this switch and from the swing pressure switch in order to detect hydraulic activity. The ECM uses this information to determine when to enable the Automatic Engine Speed Control (AESC). For more information on the AESC function, refer to Systems Operation, "Automatic Engine Speed Control Function".

Pressure Switch (Brake Oil Accumulator)

Illustration 16

Illustration 17

g00855587

g00991163

Brake oil accumulator pressure switch location for machines in the following serial number ranges: BDR2001-UP, BDM2001-UP, BDX2001-UP, BCZ2001-UP, BDK2001-UP, BDY2001-UP,, BEB2001-UP, H2A1-UP, H2B1-UP, H2C1-UP, H2D1-UP, H2E1-UP, H2F1-UP and H2G1-UP.

Illustration 18

g01171337

Brake oil accumulator pressure switch location for machines in the following serial number ranges: BDR2001-UP, BDM2001-UP, BDX2001-UP, BCZ2001-UP, BDK2001-UP, BDY2001-UP,, BEB2001-UP, H2A1-UP, H2B1-UP, H2C1-UP, H2D1-UP, H2E1-UP, H2F1-UP and H2G1-UP.

The pressure switch for the brake oil accumulator is connected to the ECM at contact J1-16 (signal wire X778-PU) and contact J1-9 (ground wire A235-BK).

Pressure Switch (Quick Coupler)

Illustration 19

g00855596

Illustration 20

g00918471

The pressure switch for the quick coupler is connected to the ECM at contact J1-37 (signal wire P976-BR) and contact J1-9 (ground wire A235-BK). See Systems Operation, "Quick Coupler Function" for more information.

Pressure Switch (Service Brake)

Illustration 21

g00855612

Illustration 22

g00915673

Service brake pressure switch location for machines in the following serial number ranges: BDR1-2000, BDM1-2000, BDX1-2000, BCZ1-2000, BDK1-2000, BDY1-2000 and BEB1-2000.

Illustration 23

g01171351

Service brake pressure switch location for machines in the following serial number ranges: BDR2001-UP, BDM2001-UP, BDX2001-UP, BCZ2001UP, BDK2001-UP, BDY2001-UP,, BEB2001-UP, H2A1-UP, H2B1-UP, H2C1-UP, H2D1-UP, H2E1-UP, H2F1-UP and H2G1-UP.

The pressure switch for the service brake is connected to the ECM at contact J1-47 (signal wire E973-GY) and contact J1-9 (ground wire A235-BK).

Switch (Overload Warning)

Illustration 24

Illustration 25

g00855620

g00925911

The pressure switch for overload warning is connected to the overload warning switch in the cab by wire H793-PU. The switch in the cab is connected to the machine ECM at contact J1-2 (wire E479-YL) and contact J1-9 (ground wire A235-BK). The overload warning switch can be adjusted. Refer to the following publications for more information: Testing and Adjusting, RENR6984, "M313C Excavator Hydraulic System" Testing and Adjusting, RENR6961, "M315C Excavator Hydraulic System" Testing and Adjusting, RENR5567, "M316C Excavator Hydraulic System" Testing and Adjusting, RENR5565, "M318C Excavator Hydraulic System" Testing and Adjusting, RENR7014, "M322C Excavator Hydraulic System"

Pressure Switch (Hydraulic Oil Filter)

Illustration 26

Illustration 27

g00855630

g00925939

The pressure switch that senses a restriction in the hydraulic oil system is connected to the ECM at contact J1-3 (signal wire E455-BR) and contact J1-9 (ground wire A235-BK).

Switch (Air Filter Restriction)

Illustration 28

g00991208

Illustration 29

g00991251

The pressure switch that senses a restriction in the air filter is connected to the ECM at contact J1-26 (signal wire 430-BU) and contact J1-9 (ground wire A235-BK).

Switch (Backup / Limp Home)

Illustration 30

g00855650

Illustration 31

g00920353

The backup / limp home switch places the machine in the limp home mode. The switch is connected to the ECM at contact J1-4 (signal wire F772-WH), contact J1-17 (signal wire F771-OR) and contact J1-9 (ground wire A235-BK). When the machine is in the limp home mode, power is reduced and many functions are inoperative. See Systems Operation, "Limp Home Function".

Switch (Fuel Pump)

Illustration 32

g00855751

Illustration 33

g00925940

(3) Fuel Pump Switch (4) Machine ECM

The fuel pump switch turns ON the fuel pump. The switch is connected to the ECM at contact J1-38 (signal wire L976-GN) and contact J1-9 (ground wire A235-BK). When the switch is pressed, the ECM checks various conditions before turning on the fuel pump. If the conditions are correct, the fuel pump will turn on. See Systems Operation, "Refueling Function" for more information.

Medium Pressure Switch

Illustration 34 Medium pressure switch

g01154240

Note: The medium pressure switch can be equipped on machines in the following serial number ranges: BDR2001-UP, BDM2001-UP, BDX2001-UP, BCZ2001-UP, BDK2001-UP, BDY2001-UP, BEB2001-UP, H2A1-UP, H2B1-UP, H2C1UP, H2D1-UP, H2E1-UP, H2F1-UP and H2G1-UP. The medium pressure switch is a three position switch that is used to select which function will be active in the medium pressure hydraulics system. The switch sends +battery power to the selected solenoid in order to enable the medium pressure function. The switch also provides a +battery input to the ECM at the same time that the solenoid is energized. The switch provides three inputs to the ECM that correspond to the three positions for the switch. The three ECM inputs are: ECM contact J2-30 - Medium pressure sw 3 (Joystick steer)

ECM contact J2-31 - Medium pressure sw 1 (Med press enable) ECM contact J2-38 - Medium pressure sw 2 (HCR/Offset boom) Reference: For more information on the medium pressure hydraulic system, refer to Systems Operation, "Medium Pressure Hydraulic System".

SYSTEMS OPERATION

056

SYSTEMS OPERATION

i02302373

Sensors SMCS - 1408-NS

Sensor (Fuel Level)

Illustration 1

Illustration 2

g00854441

g00920513

The sensor (fuel level) is connected to the machine ECM at J1-51 (wire 447-PK) and J1-12 (wire G939-PK). The output of the fuel level sender is a resistive signal. The signal varies from 17 ohms to 457 ohms. The machine ECM recognizes a signal from 10 to 465 ohms as a valid signal. If the resistance is below 10 ohms, the machine ECM determines that the sender is shorted to ground. If the resistance is above 465 ohms, the machine ECM determines that the sender is shorted to the + battery circuit. The valid range of 17 ohms to 457 ohms corresponds to a fuel level of 100 to 0 percent.

Position Sensor (Swash plate Angle)

Illustration 3

Illustration 4

g00854479

g00920514

Note: The swash plate angle position sensor is equipped on machines in serial number range 1-2000 for all prefixes covered by this manual. The position sensor (swash plate angle) is connected to the machine ECM at contact J1-62 (signal wire F475-GN). The power supply is +24 DCV. The ground contact is J1-12 (wire G939-PK). The output of the sensor is a analog signal from 0 to 5 volts. The voltage changes as the angle of the swash plate changes. The normal voltage is 2.26 to 4.4 volts. This corresponds to an angle of minus 5 degrees to +40 degrees. If the voltage is 0 to .25, the ECM determines that the sensor is shorted to ground. If the voltage is .26 to 2.25, the ECM determines that the signal is below the normal range. If the voltage is 4.5 to 4.74 volts, the ECM determines that the signal is above the normal range. If the voltage is above 4.75 volts, the ECM determines that the signal is shorted to the + battery circuit.

Pressure Sensor (Transmission Clutch)

Illustration 5

Illustration 6

g00854447

g00918454

The pressure sensor (transmission clutch) is connected to the machine ECM at contact J1-52 (signal wire G428-BU) and J1-10 (power wire 025-WH). The power supply is +5 DCV. The ground contact is J1-12 (wire G939-PK). The output of the sensor (transmission clutch pressure) is an analog signal with a valid signal from 0.46 to 4.4 volts. The voltage changes as the pressure changes. If the voltage is below 0.45 volts, the ECM determines that the sensor is shorted to ground. If the voltage is above 4.5 volts, the ECM determines that the sensor is shorted to the +battery circuit. The input voltage from 0.46 volts to 4.4 volts corresponds to a pressure of 102.1 kPa (14.8 psi) to 5695 kPa (826 psi). A value is normal if the value is within this range.

Temperature Sensor (Hydraulic Oil)

Illustration 7

Illustration 8

g00842499

g00986955

On machines in the following serial number ranges BDR1-2000, BDM1-2000, BDX1-2000, BCZ1-2000, BDK1-2000, BDY1-2000 and BEB1-2000, the temperature sensor (hydraulic oil) is connected to the machine ECM at contact J1-61. On machines in the following serial number ranges: BDR2001-UP, BDM2001-UP, BDX2001-UP, BCZ2001-UP, BDK2001UP, BDY2001-UP, BEB2001-UP, H2A1-UP, H2B1-UP, H2C1-UP, H2D1-UP, H2E1-UP, H2F1-UP and H2G1-UP, the temperature sensor (hydraulic oil) is connected to the machine ECM at contact J1-60. In both applications the signal wire is 442-GY. The ECM 8 volt power supply is at contact J1-11 (wire R800-OR). The ground is contact J1-12 (wire G939-PK). The sensor is a PWM sensor. The output frequency is approximately 5000 Hz. The duty cycle varies from 0 to 100 percent. The duty cycle changes as the temperature changes. The machine ECM recognizes a duty cycle from 3 percent to 97 percent as a valid signal. If the duty cycle is below 3 percent, the ECM determines that the sensor is shorted to ground. If the duty cycle is above 97 percent, the ECM determines that the sensor is shorted to the +battery circuit. The duty cycle of 3 to 97 percent corresponds to a temperature of minus 114 to positive 170 degrees. The ECM will determine that a temperature within this range is normal.

Position Sensor (Travel Pedal) Note: The travel pedal position sensor is equipped on machines in the following serial number ranges: BDR2001-UP, BDM2001-UP, BDX2001-UP, BCZ2001-UP, BDK2001-UP, BDY2001-UP, BEB2001-UP, H2A1-UP, H2B1-UP, H2C1UP, H2D1-UP, H2E1-UP, H2F1-UP and H2G1-UP. The travel pedal position sensor is mounted on the bottom mounting bracket for the travel pedal. This sensor is identical to the position sensor that is used on the auxiliary hydraulic pedal. The sensor receives a +battery power supply from the ECM at

contact J1-58 (wire 308-YL). The sensor is connected to ECM ground at contact J1-12 (wire G939-PK). The sensor sends a 5 volt analogue signal to the ECM at contact J1-61 (wire T993-BR). The ECM is calibrated to correlate this voltage signal to a specific travel pedal position. The ECM automatically calibrates this sensor every time the key switch is turned to the ON position. The allowable voltage range for the sensor signal that the ECM will recognize is listed in the table below. Table 1 Pedal Position Command

Signal (Voltage)

Initial Zero Position

2.5

Allowable Zero Range (ZP)

2.3 to 2.7

-100% (Reverse)

ZP minus 0.45

+100% (Forward)

ZP plus 0.45

If the ECM detects a signal from the travel pedal position sensor that is less than .25 volts or greater than 4.75 volts, then the ECM will activate a diagnostic code for the sensor. Reference: For more information on the travel pedal position sensor, refer to Systems Operation, "Travel Activation Function".

Position Sensor (Auxiliary Hydraulic Pedal) Note: The travel pedal position sensor is equipped on machines in the following serial number ranges: BDR2001-UP, BDM2001-UP, BDX2001-UP, BCZ2001-UP, BDK2001-UP, BDY2001-UP, BEB2001-UP, H2A1-UP, H2B1-UP, H2C1UP, H2D1-UP, H2E1-UP, H2F1-UP and H2G1-UP.. The auxiliary hydraulic pedal position sensor is mounted on the bottom mounting bracket for the auxiliary hydraulic pedal. This sensor is identical to the position sensor that is used on the travel pedal. The sensor receives a +battery power supply from the ECM at contact J1-58 (wire 308-YL). The sensor is connected to ECM ground at contact J1-12 (wire G939-PK). The sensor sends a 5 volt analogue signal to the ECM at contact J1-62 (wire M955-BR). The ECM is calibrated to correlate this voltage signal to a specific travel pedal position. The ECM automatically calibrates this sensor every time the key switch is turned to the ON position. The allowable voltage range for the sensor signal that the ECM will recognize is listed in the table below. Table 2 Pedal Position

Signal (Voltage)

Initial Zero Position

2.5

Allowable Zero Range (ZP)

2.4 to 2.6

-100% (Reverse)

ZP minus 0.4

+100% (Forward)

ZP plus 0.4

If the ECM detects a signal from the auxiliary hydraulic pedal position sensor that is less than .25 volts or greater than 4.75 volts, then the ECM will activate a diagnostic code for the sensor. Reference: For more information on the auxiliary hydraulic pedal position sensor, refer to Systems Operation, "Auxiliary Hydraulic System".

Position Sensor (Right Joystick Thumbwheel) The right joystick thumbwheel position sensor is equipped on machines in the following serial number ranges: BDR2001-UP, BDM2001-UP, BDX2001-UP, BCZ2001-UP, BDK2001-UP, BDY2001-UP, BEB2001-UP, H2A1-UP, H2B1-UP, H2C1UP, H2D1-UP, H2E1-UP, H2F1-UP and H2G1-UP. The right joystick thumbwheel position sensor is located inside the right hand joystick. The sensor indicates the position of the right hand joystick thumbwheel to the ECM. The sensor receives a 10 volt power supply from the ECM at contact J1-13 (wire E472-GN). The sensor is connected to the ECM ground at contact J1-12 (wire G939-PK). The sensor sends a pulse width

modulated (PWM) signal to the ECM at contact J1-50 (wire E474-OR). The ECM monitors the PWM signal duty cycle in order to determine the position of the thumbwheel. The ECM uses this information to control the functions that are associated with the medium hydraulic function. The following table shows the percentage of the PWM duty cycle that the ECM will recognize. Table 3 Thumbwheel Position Command

PWM Duty Cycle (%)

Initial Zero Position

50

Allowable Zero Range (ZP)

48 to 52

-100% (Full Left)

33

+100% Full Right)

67

If the ECM detects a signal from the right hand joystick thumbwheel position sensor that is less than a 5 % duty cycle or greater than a 95 % duty cycle, then the ECM will activate a diagnostic code for the sensor. Reference: For more information on the right hand joystick thumbwheel position sensor, refer to Systems Operation, "Medium Pressure Hydraulic System".

Speed Sensor (Transmission Output) Note: The transmission output speed sensor is equipped on machines in the following serial number ranges: BDR2001-UP, BDM2001-UP, BDX2001-UP, BCZ2001-UP, BDK2001-UP, BDY2001-UP, BEB2001-UP, H2A1-UP, H2B1-UP, H2C1UP, H2D1-UP, H2E1-UP, H2F1-UP and H2G1-UP. The transmission output speed sensor is located on the transmission housing. When installed, the sensor is in the correct position and needs no adjustment. The sensor indicates the output speed of the transmission to the ECM. The ECM uses this information in order to control many functions on the machine including: Travel alarm activation Figure machine speed Parking Brake Function Travel Motor function Figure total distance traveled The transmission output speed sensor receives the +battery power supply from the ECM at contact J1-58 (wire 308-YL). The sensor is grounded to the machine frame ground (wire 200-Bk). The frequency signal is received by the ECM at contact J1-24 (wire 768-OR). The ECM correlates the frequency signal from the sensor to a rpm value for the transmission.

SYSTEMS OPERATION

057

SYSTEMS OPERATION

i02302600

Solenoid Valves SMCS - 5479

Solenoid (Auxiliary Hydraulic Oil Pressure)

Illustration 1

Illustration 2

g00855332

g00920495

(1) Hydraulic Oil Pressure Solenoid (2) Direction Solenoid (Hydraulic Oil) (3) Solenoid (Hydraulic Oil Flow)

This solenoid is located in the multifunction auxiliary valve. This solenoid controls the maximum pressure in the auxiliary hydraulic circuit. The solenoid (hydraulic oil pressure) is connected to the ECM at contact J2-40 (signal wire M744-PU) and contact J259 (ground wire H803-BU). This solenoid is activated proportionally in order to change the relief pressure in the auxiliary circuit. See Systems Operation, "Auxiliary Hydraulic System" for more information.

Solenoid (Auxiliary Hydraulic Oil Flow)

Illustration 3

Illustration 4

g00855350

g00920495

(1) Hydraulic Oil Pressure Solenoid (2) Direction Solenoid (Hydraulic Oil) (3) Solenoid (Hydraulic Oil Flow)

This solenoid is located in the multifunction auxiliary valve. This solenoid controls the maximum pilot pressure in the auxiliary circuit. By limiting the pressure, the amount of oil flow in the auxiliary hydraulic circuit is also reduced. The solenoid (hydraulic oil flow) is connected to the ECM at contact J2-41 (signal wire M745-BU) and contact J2-59 (ground wire H803-BU). This solenoid is proportionally activated in order to limit the amount of oil flow in the circuit. See Systems Operation, "Auxiliary Hydraulic System" for more information.

Solenoid (Engine Cooling Fan)

Illustration 5

g00855362

The solenoid (engine cooling fan) is referred to as the hydraulic demand fan. The solenoid is proportionally energized in order to vary the speed of the cooling fan. The solenoid is turned on when the hydraulic temperature and/or the cooling water is too high. The solenoid is connected to the ECM at contact J2-24 (signal wire C411-OR) and contact J2-13 (ground wire H804-GN). See Systems Operation, "Hydraulic Oil Cooling Function" for more information. Note: The location of some of the existing solenoids and the addition of new solenoids has resulted in a different hydraulic valve manifold equipped on machines the following serial number ranges: BDR2001-UP, BDM2001-UP, BDX2001-UP, BCZ2001UP, BDK2001-UP, BDY2001-UP, BEB2001-UP, H2A1-UP, H2B1-UP, H2C1-UP, H2D1-UP, H2E1-UP, H2F1-UP and H2G1-UP. This manifold is illustrated below. Note: The photographs in the following text indicate solenoid locations for machines in the following serial number ranges: BDR1-2000, BDM1-2000, BDX1-2000, BCZ1-2000, BDK1-2000, BDY1-2000 and BEB1-2000.

Illustration 6

g01171494

Solenoid locations for machines in the following serial number ranges: BDR2001-UP, BDM2001-UP, BDX2001-UP, BCZ2001-UP, BDK2001-UP, BDY2001-UP,, BEB2001-UP, H2A1-UP, H2B1-UP, H2C1-UP, H2D1-UP, H2E1-UP, H2F1-UP and H2G1-UP. Some of the solenoid locations on machines not included in these ranges are the same. (4) Oscillating axle (5) Swing brake (6) Implement lockout (7) Transmission gear shift 1 (8) Transmission gear shift 2 (9) Travel pilot pressure (10) Travel motor swash plate angle limit (11) Swing pump power shift pressure (12) Main pump power shift pressure (13) Medium pressure 1 (left) (14) Medium pressure 2 (right) (15) Medium pressure enable (Not ECM controlled, input only) (16) HCR/offset boom enable (Not ECM controlled, input only)

Solenoid (Swing Pump)

Illustration 7

g00920471

Illustration 8

g00855390

The swing pump solenoid (11) controls the hydraulic oil flow in the circuit for swing. The solenoid is connected to the ECM at contact J2-58 (signal wire K921-GY) and contact J2-57 (ground wire H803-BU).

Solenoid (Main Pump)

Illustration 9

g00920473

Illustration 10

g00855390

This main pump solenoid (12) controls the hydraulic oil flow in the main hydraulic circuit. The solenoid is connected to the ECM at contact J2-48 (signal wire 960-BU) and contact J2-57 (ground wire H803-BU).

Solenoid (Travel Pilot Pressure)

Illustration 11

g01171664

Note: The travel pilot pressure solenoid is equipped on machines in the following serial number ranges: BDR2001-UP, BDM2001-UP, BDX2001-UP, BCZ2001-UP, BDK2001-UP, BDY2001-UP, BEB2001-UP, H2A1-UP, H2B1-UP, H2C1UP, H2D1-UP, H2E1-UP, H2F1-UP and H2G1-UP. The travel pilot pressure solenoid (9) is a proportional solenoid that is energized by a variable current output from the ECM. The ECM drives the solenoid from contact J2-51 (wire A881-YL). The ECM activates this solenoid when the conditions are correct in order to enable machine travel. When the solenoid is energized, pilot hydraulic pressure is supplied to the combination valve. For more information, refer to Systems Operation, "Travel Activation Function"

Solenoid (Travel Motor Swash Plate Angle)

Illustration 12

g01153127

Note: The travel motor swash plate angle solenoid is equipped on machines in the following serial number ranges: BDR2001UP, BDM2001-UP, BDX2001-UP, BCZ2001-UP, BDK2001-UP, BDY2001-UP, BEB2001-UP, H2A1-UP, H2B1-UP, H2C1-UP, H2D1-UP, H2E1-UP, H2F1-UP and H2G1-UP. The travel motor swash plate angle solenoid (10) is a proportional solenoid that is energized by a variable current output from the ECM. The ECM drives the solenoid from contact J2-64 (wire F853-BR). The solenoid is connected to ECM ground at contact J2-52 (wire H801-PU). The ECM activates this solenoid when the conditions are correct in order to increase or decrease the amount of hydraulic oil flow that is available to the travel motor. This will result in an increase or a decrease in machine travel speed within the selected gear.

Solenoids (Medium Pressure 1 And 2)

Illustration 13

g01153127

Note: The medium pressure solenoid 1 and solenoid 2 are equipped on machines in the following serial number ranges: BDR2001-UP, BDM2001-UP, BDX2001-UP, BCZ2001-UP, BDK2001-UP, BDY2001-UP, BEB2001-UP, H2A1-UP, H2B1-UP, H2C1-UP, H2D1-UP, H2E1-UP, H2F1-UP and H2G1-UP. The medium pressure solenoid 1 (13) and solenoid 2 (14) are proportional solenoids that are energized by a defined current output from the ECM. The ECM drives medium pressure solenoid 1 from contact J2-14 (wire P941-WH). The ECM drives medium pressure solenoid 2 from contact J2-3 (wire P942-YL). Medium pressure solenoid 1 is connected to ECM ground at contact J2-13 (wire H804-GN). Medium pressure solenoid 2 is connected to ECM ground at contact J2-12 (wire H805-BR). The ECM uses these solenoids in order to control the medium pressure attachments on the machine. The ECM energizes one solenoid or the other solenoid depending on the input from the right hand joystick thumbwheel sensor. For more information on the medium pressure solenoids, refer to Systems Operation, "Medium Pressure Hydraulic System".

Solenoid (Travel Motor Bypass) Note: The travel motor bypass solenoid is equipped on machines in the following serial number ranges: BDR2001-UP, BDM2001-UP, BDX2001-UP, BCZ2001-UP, BDK2001-UP, BDY2001-UP, BEB2001-UP, H2A1-UP, H2B1-UP, H2C1UP, H2D1-UP, H2E1-UP, H2F1-UP and H2G1-UP. The travel motor bypass solenoid is a proportional solenoid that is energized by a variable current output from the ECM. The ECM drives the solenoid from contact J2-17 (wire J754-OR). The solenoid is connected to ECM ground at contact J2-12 (wire H805-BR). The ECM activates this solenoid during initial acceleration of the travel motor. When this solenoid is energized, some hydraulic flow is allowed to bypass the travel motor. The amount of current that the ECM sends to the solenoid is dependant on the amplitude of the travel command. This enables smoother machine acceleration without sudden, harsh movement of the machine.

Solenoid (Hydraulic Modulation)

Illustration 14

g01153282

The hydraulic modulation solenoid is equipped on machines in the following serial number ranges: BDR2001-UP, BDM2001UP, BDX2001-UP, BCZ2001-UP, BDK2001-UP, BDY2001-UP, BEB2001-UP, H2A1-UP, H2B1-UP, H2C1-UP, H2D1UP, H2E1-UP, H2F1-UP and H2G1-UP. The hydraulic modulation solenoid is a proportional solenoid that is energized by a variable current output from the ECM. The ECM drives the solenoid from contact J2-25 (wire E711-OR). The solenoid is connected to ECM ground at contact J2-13 (wire H804-GN). The ECM will energize this solenoid in according to operator input from the hydraulic modulation enable switch on the right hand joystick and the hydraulic modulation mode switch on the SSP. When the ECM energizes the solenoid, hydraulic flow to the implement is modulated in order to control the operating speed of the implement. Hydraulic pressure for the implement is not affected. For more information on the hydraulic modulation function, refer to Systems Operation, "Hydraulic Modulation Function".

Solenoids (On/Off Type)

Illustration 15

g00855004

Solenoid (Travel Activation)

Illustration 16

g00918381

Note: The travel activation solenoid is equipped on machines in the following serial number ranges: BDR1-2000, BDM1-2000, BDX1-2000, BCZ1-2000, BDK1-2000, BDY1-2000 and BEB1-2000. The travel activation solenoid is connected to the ECM at contact J2-50 (signal wire K923-PU) and contact J2-49 (ground wire H802-GY). See Systems Operation, "Travel Activation Function" for more information.

Solenoid (Swing Brake)

Illustration 17

g00918388

This solenoid is normally de-energized. This solenoid is energized when a request to swing is made. After the swing is completed, the solenoid is de-energized after 3.5 seconds. The solenoid (swing brake) is connected to the ECM at contact J2-51 (signal wire C995-YL) and contact J2-49 (ground wire H802-GY). See Systems Operation, "Swing Brake Function" for more information.

Solenoid (Parking Brake)

Illustration 18

g00918389

Note: The parking brake solenoid is equipped on machines in the following serial number ranges: BDR1-2000, BDM1-2000, BDX1-2000, BCZ1-2000, BDK1-2000, BDY1-2000 and BEB1-2000. The solenoid (parking brake) is connected to the ECM at contact J2-55 (signal wire C744-PU) and contact J2-36 (ground wire H807-YL). This solenoid is energized in order to release the parking brake. This solenoid is energized in order to allow the movement of the machine. See Systems Operation, "Parking Brake Function" for more information.

Solenoid (Travel Speed)

Illustration 19

g00925959

Note: The travel speed solenoid is equipped on machines in the following serial number ranges: BDR1-2000, BDM1-2000, BDX1-2000, BCZ1-2000, BDK1-2000, BDY1-2000 and BEB1-2000. The solenoid (travel speed) is connected to the ECM at contact J2-61 (signal wire R981-YL) and contact J2-49 (ground wire H802-YL). This solenoid is energized in order to enable the low travel speed. See Systems Operation, "Travel Speed Function" for more information.

Solenoid (Implement Lockout)

Illustration 20

g00918391

The solenoid (implement lockout) is connected to the ECM at contact J2-45 (signal wire K777-GY) and contact J2-36 (ground wire H807-YL). This solenoid is energized in order to activate the implements. See Systems Operation, "Hydraulic Activation Control Function" for more information.

Solenoid (Generator) The solenoid (generator) is connected to the ECM at contact J2-25 (signal wire E984-BU) and contact J2-13 (ground wire H804-GN). This solenoid is energized in order to turn off the generator. See Systems Operation, "Generator Function" for more information.

Solenoid (Creeper Speed)

Illustration 21

g00918349

Note: The creeper speed solenoid is equipped on machines in the following serial number ranges: BDR1-2000, BDM1-2000, BDX1-2000, BCZ1-2000, BDK1-2000, BDY1-2000 and BEB1-2000. The solenoid (creeper speed) is connected to the ECM at contact J2-64 (signal wire F853-BR) and contact J2-52 (ground wire H801-PU). This solenoid is energized when the creeper speed is activated. See Systems Operation, "Creeper Speed Function" for more information.

Solenoid (Oscillating Axle)

Illustration 22

g00916760

The solenoid (oscillating axle) is connected to the ECM at contact J2-65 (signal wire K746-PK) and contact J2-52 (ground wire H801-PU). The solenoid is energized in order to unlock the axle and this solenoid is energized in order to allow the axle to oscillate. See Systems Operation, "Oscillating Axle Control Function" for more information.

Solenoid (Directional Or Hammer)

Illustration 23

Illustration 24

g00855357

g00920495

(1) Hydraulic Oil Pressure Solenoid (2) Direction Solenoid (Hydraulic Oil) (3) Solenoid (Hydraulic Oil Flow)

This solenoid is located in the multifunction auxiliary valve. This solenoid controls the direction of the return flow in the auxiliary hydraulic circuit. The direction solenoid (hydraulic oil) is connected to the ECM at contact J2-63 (signal wire M746-GY) and contact J2-52 (ground wire H801-PU). This solenoid is energized in order to force the auxiliary oil flow to return directly to the tank. This solenoid regulates the flow in the following operations: one-way flow and two-way flow. one-way operation allows the regulated oil to flow through the multifunction auxiliary valve in one direction. The other direction will return to the tank. This type of operation is for use with a hammer. Two-way operation allows the regulated oil to flow through the multifunction auxiliary valve in both directions. This type of operation is for use with a rotating consumer. See Systems Operation, "Auxiliary Hydraulic System" for more information.

Solenoid (Quick Coupler)

Illustration 25

Illustration 26

g00855168

g00918285

The solenoid (quick coupler) is connected to the ECM at contact J2-15 (signal wire M743-YL) and contact J2-13 (ground wire H804-GN). See Systems Operation, "Quick Coupler Function" for more information.

Solenoids (Transmission Gear Shift 1 And 2)

Illustration 27

g01153286

Note: The transmission gear shift solenoid 1 (7) and solenoid 2 (8) are equipped on machines in the following serial number ranges: BDR2001-UP, BDM2001-UP, BDX2001-UP, BCZ2001-UP, BDK2001-UP, BDY2001-UP, BEB2001-UP, H2A1UP, H2B1-UP, H2C1-UP, H2D1-UP, H2E1-UP, H2F1-UP and H2G1-UP. The ECM energizes transmission gear shift solenoid 1 from contact J2-62 (wire K923-PU). The ECM drives transmission gear shift solenoid 2 from contact J2-61 (wire K925-PU). Transmission gear shift solenoid 1 is connected to ECM ground at contact J2-52 (wire H801-PU). Transmission gear shift solenoid 2 is connected to ECM ground at contact J2-49 (wire H802-GY). The ECM uses these solenoids in order to activate the low speed gear or activate the high speed gear in the transmission. When the ECM energizes transmission gear shift solenoid 1, the transmission shifts to low gear. When the ECM energizes transmission gear shift solenoid 2, the transmission shifts to high gear. When both solenoids are de-energized, the parking brake is engaged. For more information on the transmission gear shift solenoids, refer to Systems Operation, "Travel Speed Function".

SYSTEMS OPERATION

058

SYSTEMS OPERATION

i01979723

Relays SMCS - 4493

Relay (Implement Lockout)

Illustration 1

Illustration 2

g00581355

g01026301

(1) Fuel Pump Switch (2) Relay (Implement Lockout) (3) Relay (Fuel Pump)

The hydraulics on the machine can be disabled by the operator with two methods: raising the armrest and pressing the implement lockout switch on the joystick. Then, the relay for the implement lockout is de-energized. Power for the coil of the relay comes from contact J2-1 (wire 116-BR). The machine ECM provides a ground for the relay at J2-33 (wire M927-GN). The ECM de-

energizes the relay by removing the ground. The relay provides power to functions that are controlled by the joysticks. Therefore, the following functions are deactivated: rotate clockwise, rotate counterclockwise, cab up and cab down. The main power wire to the relay (wire 140-BU) is connected to the fuse panel. The wire from the relay to the joysticks is L980-GN.

Relay (Fuel Pump)

Illustration 3

Illustration 4

g00853365

g01026301

(1) Fuel Pump Switch (2) Relay (Implement Lockout) (3) Relay (Fuel Pump)

The refueling function allows the machine to be refueled while the machine is in the field. The machine ECM energizes the coil of the relay for the fuel pump through contact J2-17 (wire T776-GY). Ground for the relay is J2-12 (wire H805-BR). The main power wire for the relay is connected to the fuse panel (wire 139-OR). The power is sent from the relay to the fuel pump on wire A893-OR.

SYSTEMS OPERATION

059

SYSTEMS OPERATION

i01797380

Related Components SMCS - 7000-EK

Travel Lock Magnet

Illustration 1

Illustration 2

g00853069

g00920562

The travel lock magnet will hold down the travel pedal in the fully depressed position. The magnet operates in the forward direction. The magnet allows the operator to maintain a request for maximum machine speed without continuously depressing the

pedal. The signal wire for the travel lock magnet is connected to the machine ECM at contact J2-60 (M956-GY). The ground is contact J2-49 (wire H802-GY). See Systems Operation, "Travel Speed Lock Function" for more information.

Travel Alarm Horn

Illustration 3

Illustration 4

g00391203

g00925968

The travel alarm horn sounds when the machine is traveling. The signal wire for the horn is connected to the machine ECM at contact J2-44 (wire 321-BR). The ground is contact J2-36 (wire H807-YL). See Systems Operation, "Travel Alarm Function" for more information.

M316C Material Handlers Excavators Electronic System Testing and Adjusting Index

Configuration Travel Motor Speed - Calibrate Machine Operating Threshold Parameter - Adjust Wiring Harness (Open Circuit) - Test Wiring Harness (Short Circuit) - Test Electrical Connector - Inspect Electronic Control Module (ECM) - Flash Program Electronic Control Module (ECM) - Replace Glossary of Terms System Schematic

1 2 3 4 5 6 7 8 9 10

TESTING AND ADJUSTING

001

TESTING AND ADJUSTING

i01904474

Configuration SMCS - 7610-591-MCH The parameters that are shown in table 1 are available for programming. When a problem is present with any of these functions, check the current value of the parameter. See Systems Operation, "Configuration Menu" for instructions for reaching the menu. This is an example: If your machine has a quick coupler that is inoperative, the coupler may be programmed "Not Installed". Table 1 Events Description

Possible Values

"Travel Alarm"

"Installed" or "Not Installed"

"Travel Lock"

"Installed" or "Not Installed"

"Boom Angle Switch"

"Installed" or "Not Installed"

"Stabilizer"

"Installed" or "Not Installed"

"Fuel Filler Pump"

"Installed" or "Not Installed"

"Machine Overload Pressure Switch Installation Status"

"Installed" or "Not Installed"

"Quick Coupler"

"Installed" or "Not Installed"

"Generator"

"Installed" or "Not Installed"

"Generator Flow"

"High Flow" or "Low Flow"

"Multi-Func Aux"

"Installed" or "Not Installed"

"Hammer"

"Installed" or "Not Installed"

"AESC Delay Time"

"SEC" (seconds)

"Main Pump Swash Plate Angle"

Angle (degrees)

TESTING AND ADJUSTING

002

TESTING AND ADJUSTING

i02304808

Travel Motor Speed - Calibrate SMCS - 4351-524, S/N - BCZ2001-UP, S/N - BDK2001-UP, S/N - BDM2001-UP, S/N - BDR2001-UP, S/N BDX2001-UP, S/N - BDY2001-UP, S/N - BEB2001-UP, S/N - H2A1-UP, S/N - H2B1-UP, S/N - H2C1-UP, S/N H2D1-UP, S/N - H2E1-UP, S/N - H2F1-UP, S/N - H2G1-UP 1. Connect the Electronic Technician (ET) to the service tool connector of the machine. See Troubleshooting, "Diagnostic Capabilities" for more information. 2. Select the Machine ECM from the list of available controls.

Illustration 1

g01154298

3. From the top menu, select "Service". From the pull down menu, select "Calibrations". Then select "Hydraulic Travel Motor Speed".

Illustration 2

g01154319

4. After "Hydraulic Travel Motor Speed" is selected, this warning screen will appear. All of the conditions in this warning MUST be met in order to proceed with the calibration. Failure to met these conditions could result in serious injury or death. All of the following conditions must be met in order to proceed with the calibration. This calibration will cause all of the driving wheels on the machine to rotate. This calibration may be aborted at any time by releasing the travel pedal on the machine or by selecting the "Cancel" button on the ET screen. a. Park the machine in an open area on level ground. b. Clear all personnel from the machine and from the area around the machine. c. Check the visibility and adjust the mirrors for the best vision close to the machine. d. Fasten your seat belt securely. 5. When each of these steps have been met and the implications of performing this calibration are understood, select the "Accept" button.

Illustration 3

g01154356

6. This calibration screen will appear. All of the conditions that are listed in this calibration screen MUST be met in order to start the calibration. When all of the conditions are met, press the "Next" button. If all of the conditions are not met, an error screen will be displayed with the reason that the calibration has failed.

Illustration 4

g01154407

7. As long as the conditions were met in the preceding step, the calibration will begin. Follow the instructions on the highlighted line. The transmission speed will increase to a level at which the increase will stop. The calibration will move on to the next step.

Illustration 5

g01154414

8. Follow the instructions on the highlighted line. The transmission speed will decrease to a level at which the decrease will stop. The following message will be displayed.

Illustration 6

g01154416

9. If the message displays "CALIBRATION SUCCESSFUL", the calibration is complete. Press the "Finish " button. If the

9. message displays "CALIBRATION UNSUCCESSFUL", the calibration must be performed again. Press the "Restart" button and perform this procedure again.

TESTING AND ADJUSTING

003

TESTING AND ADJUSTING

i02305075

Machine Operating Threshold Parameter - Adjust SMCS - 7610-025-MCH, S/N - BCZ1-UP, S/N - BDK1-UP, S/N - BDM1-UP, S/N - BDR1-UP, S/N - BDX1-UP, S/N BDY1-UP, S/N - BEB1-UP This adjustment procedure is applies to machines with the following serial numbers. BEB1-2000 BDK1-2000 BDM1-2000 BDR1-2000 BDX1-2000 BDY1-2000 BCZ1-2000 1. Connect the Electronic Technician (ET) to the service tool connector of the machine. See Troubleshooting, "Diagnostic Capabilities" for more information. 2. Select the Machine ECM from the list of available controls. 3. Go to "Status Group 3" on the ET. While the engine is running ensure that no implements are being used. When the hydraulics are at rest, note the value of the "Main Pump Swash Plate Angle".

Illustration 1

g00991360

4. On the ET, select the button (1) for configuring. 5. Highlight the item "Main Pump Swash Plate Angle Machine Operating Threshold". 6. Click the "Change" button on the bottom of the screen. Enter the new value in the box that appears. The value must be at least 0.8 above the swashplate angle.

TESTING AND ADJUSTING

004

TESTING AND ADJUSTING

i02203144

Wiring Harness (Open Circuit) - Test SMCS - 1408-081 An open is a failure of an electrical circuit that results in no flow of electrical current. An open circuit is usually caused by failed electrical wires or a poor connection of electrical connectors. If an electrical wire or a connection is broken, the flow of electrical current through the circuit is interrupted. A normally closed circuit will have less than 5 ohms of resistance. The following procedure explains the test for an open circuit: Reference: For a complete electrical schematic, refer to Electrical System Schematic for the machine that is being serviced. TEST FOR AN OPEN CIRCUIT. 1. Identify the connectors and the wire numbers of the suspect circuits. Use the Electrical System Schematic of the machine to identify the circuits. 2. Turn the key start switch and the disconnect switch to the OFF position. 3. Disconnect the component and the ECM from the wiring harness. 4. At one of the disconnected harness connections, place a jumper wire from the contact of the suspect wire to frame ground. 5. At the other connector of the machine harness, use the multimeter probes to measure the resistance from the contact of the suspect wire to frame ground. Expected Result: The resistance is less than 5 ohms. OK - The resistance is less than 5 ohms. The harness circuit is correct. Stop. NOT OK - The resistance is greater than 5000 ohms. There is an open in the machine harness. Repair: Repair the machine harness or replace the machine harness. Stop.

TESTING AND ADJUSTING

005

TESTING AND ADJUSTING

i02511516

Wiring Harness (Short Circuit) - Test SMCS - 1408-081 A short circuit is a failure of an electrical circuit that results in undesired electrical current. Usually, a short circuit is a bypass of the circuit across a load. For example, a short across the wires in a circuit for a lamp produces too much current in the wires but no current is felt at the lamp. The lamp is shorted out. The resistance in a normal circuit can vary, but the resistance between a particular circuit and other unrelated circuits is always greater than 5000 ohms. The following procedure explains the test for a short circuit: ReferenceFor a complete electrical schematic, refer to Electrical System Schematic for the machine that is being serviced. TEST FOR A SHORT CIRCUIT. 1. Identify the connectors and the wire numbers of the suspect circuits. Use the Electrical System Schematic of the machine to identify the circuits. 2. Turn the key start switch and the disconnect switch to the OFF position. 3. Disconnect the component and the ECM from the wiring harness. 4. At the machine harness connector for the ECM, place one of the multimeter probes on the contact of the suspect wire. 5. Use the other multimeter probe to check the resistance across all other contacts in the connector(s) of the ECM and frame ground. Expected Result: The resistance is greater than 5000 ohms for all the measurements. OK - The resistance is greater than 5000 ohms for all the measurements. The harness circuits are correct. Stop. NOT OK - The resistance is less than 5 ohms. There is a short in the machine harness. The short is between the suspected wire and the wire with the lowest resistance measurement. Repair: Repair the machine harness or replace the machine harness. Stop.

TESTING AND ADJUSTING

006

TESTING AND ADJUSTING

i02203138

Electrical Connector - Inspect SMCS - 7553-040-WW Reference: Special Instruction, SEHS9615, "Servicing DT Connectors". Reference: Special Instruction, REHS0148, "Listing Of Deutsch Connector Components" Reference: Special Instruction, SEHS9065, "Use Of CE Connector Tools". Reference: Service Magazine, SEPD034227 January 97, "Field Repair Of Single Wire Breaks In Harnesses (Sealed Splice)". Reference: Service Magazine, SEPD037128 July 97, "Protection Of Unsealed Electrical Terminations For Machines In Corrosive Applications". Reference: Service Magazine, SEPD047324 May 99, "New DT Connector Plugs With Improved Seal Retention". Reference: Service Magazine, SEPD054509 October 00, "Dielectric Grease Should Not Be Used In Electrical Connectors". Reference: Pocket Guide, SEBD0402, "Guidelines For Routing And Installing Wire Harness Assemblies". Use this procedure under the following situation: Use the following steps to help determine if the connector is the cause of the problem. If a problem is found in the electrical connector, repair the connector and verify that the problem has been corrected. The following background information is related to this procedure: Many of the operational procedures and the diagnostic code procedures in this troubleshooting guide will instruct you to check a specific electrical connector. Intermittent electrical problems are often caused by poor connections. Always check for an active diagnostic code before breaking any connections. Also, always check for an active diagnostic code after the connector is reconnected in order to verify that the problem disappears. Simply disconnecting the connectors and then reconnecting the connectors can temporarily solve a problem at times. If this occurs, likely causes are loose terminals, bent terminals, improperly crimped terminals, corrosion, or harness routing that is improper. The original source of the problem must then be identified in order to ensure that the problem does not reoccur. Follow this procedure to thoroughly inspect the connectors in order to determine if the connectors are the cause of the problem.

Illustration 1

g01135980

Correct way to route a harness and insert a plug

Illustration 2 Proper Installation of Plug

g00690571

Illustration 3

g00828600

DT Type sealing plug The 8T-8729 Connector Pin (2) and the 8T-8730 Connector Socket (1) is designed to accept only one 16/18 AWG wire. Do not insert multiple wires of a smaller wire size. An incorrect method would be using two 24 AWG wires. The 9W-0852 Connector Pin and the 9W-0844 Connector Socket is designed to accept only one 14 AWG wire. Do not insert multiple wires of a smaller wire size. An example of an incorrect method is the use of two 20 AWG wires.

1. CHECK THE CONNECTORS. a. Ensure that the connector is properly locked. Also, ensure that the two halves of the connector can not be pulled apart. b. Verify that the latch tab of the connector is properly latched. Verify that the latch tab of the connector is fully latched. Expected Result: The connector will securely lock. The connector and the locking mechanism are without cracks or breaks. Results: OK - The connector will securely lock. The connector and the locking mechanism are without cracks or breaks. Proceed to test step 2. NOT OK - A problem exists with the connector. Repair: Repair the connector or replace the connector, as required. STOP. 2. CHECK THE ALLEN HEAD SCREW ON THE HARNESS CONNECTOR OF THE ECM. a. Ensure that the connector bolt is properly tightened. Be careful not to tighten the bolt too much. The bolt may break. b. Do not exceed 6.0 N·m (53.0 lb in) of torque on the connector bolt of the harness when the connector is being installed on the ECM. Expected Result: The harness connector is secure and the connector bolt of the ECM is properly torqued. Results: OK - The harness connector is secure and the connector is properly torqued. Proceed to test step 3. NOT OK - A problem exists with the connector. Repair: Secure the harness connector of the ECM. Ensure that the connector bolt is properly torqued. STOP.

3. PERFORM A PULL TEST ON EACH CONNECTOR CONTACT. a. Each connector contact should withstand 45 N (10 lb) of pull. Each wire should remain in the connector body. This test checks whether the wire was properly crimped in the contact and whether the contact was properly inserted into the connector. b. The DT connectors use an orange wedge to lock the terminals in place. c. Check in order to ensure that the orange wedge is not missing and that the orange wedge is installed properly on the DT connectors. Note: A Crimp Tool should ALWAYS be used in order to crimp wires on connector contacts. Do not solder the terminals. Use the proper Crimp Tool. Expected Result: Each connector contact should withstand 45 N (10 lb) of pull. Each wire remains in the connector body. Results: OK - Each connector contact withstands 45 N (10 lb) of pull. Each wire remains in the connector body. Proceed to test step 4. NOT OK - A problem exists with the connector. Repair: Repair the wiring or replace the connector contact. STOP. 4. CHECK THE WIRES FOR NICKS OR ABRASIONS IN THE INSULATION. a. Carefully inspect each wire for signs of abrasion, nicks, or cuts. The following areas are locations that should be checked: Exposed insulation Points of rubbing wire b. Check all of the hold down clamps for the harness in order to verify that the harness is properly clamped. Also check all of the hold down clamps for the harness in order to verify that the harness is not compressed by the clamp. Pull back the harness sleeves in order to check for a flattened portion of wire. The flattened portion of wire is caused by the clamp that holds the harness. Expected Result: The wires are free of abrasion, nicks, or cuts and the harness is properly clamped. Results: OK - The wires are free of abrasion, nicks, or cuts and the harness is properly clamped. Proceed to test step 5. NOT OK - A problem exists with the wiring. Repair: Repair the wires or replace the wires, as required. STOP. 5. CHECK THE CONNECTORS FOR MOISTURE OR CORROSION. a. Ensure that the connector seals and the white sealing plugs are in place. If any of the seals or plugs are missing, replace the seal or plug. If necessary, replace the connector. b. Check all of the wiring harnesses in order to verify that the harness does not make a sharp bend out of a connector. This will deform the connector seal and this will create a path for the entrance of moisture. See Illustration 1. Note: It is normal to see some minor seal abrasion on the ECM connector seals. Minor seal abrasion will not allow the entry of moisture. c. Thoroughly inspect ECM connectors for evidence of moisture entry. If moisture or corrosion is evident in the connector, the source of the moisture entry must be found and the source of the moisture entry must be repaired. If the source of the moisture entry is not repaired, the problem will reoccur. Simply drying the connector will not fix the problem. Likely paths for the entrance of moisture are from missing seals, improperly installed seals, nicks in exposed insulation, and improperly mated connectors. Note: Moisture can also travel from one connector through the inside of a wire to the ECM Connector. If moisture is found in the ECM connector, thoroughly check all connectors and wires on the harness that connect to the ECM.

The ECM is not the source of the moisture. Do not replace an ECM if moisture is found in either ECM connector. Note: If corrosion is evident on the contacts or the connector, use only denatured alcohol to remove the corrosion. Use a cotton swab or a soft brush to remove the corrosion. Do not use cleaners that contain trichloro-ethylene because trichloro-ethylene may damage the connector. Expected Result: All of the connectors should be completely coupled and all of the seals should be completely inserted. The harness and the wiring should be free of corrosion, moisture, abrasion or pinch points. Results: OK - All of the connectors are completely coupled and all of the seals are completely inserted. The harness and the wiring are free of corrosion, moisture, abrasions or pinch points. Proceed to test step 6. NOT OK - A problem exists with the connector, the wiring or the wiring harness. Moisture is present. Repair: Repair the connectors or wiring and/or replace the connectors or wiring. Ensure that all of the seals are properly in place and ensure that the connectors are completely coupled. Verify that the repair eliminates the problem by operating the machine for several minutes and by checking again for moisture. STOP. 6. INSPECT THE CONNECTOR CONTACTS. a. Verify that the contacts are not damaged. Verify that the contacts are properly aligned in the connector and verify that the contacts are properly located in the connector. Expected Result: The contacts are properly aligned and the contacts appear undamaged. Results: OK - The contacts are properly aligned and the contacts appear undamaged. Proceed to test step 7. NOT OK - A problem exists with the connector contacts. Repair: Repair the contacts and wiring and/or replace the contacts and wiring. STOP. 7. CHECK THE FIT OF THE CONTACTS.

Illustration 4

g00838765

Retention of the Connector (1) Pin Contact (2) Socket Contact

Note: This is especially important for intermittent problems. a. Use a new pin contact. Insert the pin contact into each socket contact one at a time in order to check for a good grip on the pin contact by the socket contact. b. Use a new socket contact. Insert the pin contact into each socket contact one at a time in order to check for a good grip on the pin contact by the socket contact. The pin contact are located on the mating side of the connector. c. The connector contact should stay connected when the connector is held in the position shown in Illustration 4. The connector contact is the pin contact or the socket contact. Expected Result: The pin contacts and the socket contacts appear to be OK. Results: OK - The pin contacts and the socket contacts appear to be OK. STOP. NOT OK - A problem exists with the connector terminal. Repair: Replace the connector contact.

STOP.

TESTING AND ADJUSTING

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Electronic Control Module (ECM) - Flash Program SMCS - 7610-591-MCH Perform the following procedure in order to flash program the ECM. The ECM is flashed in order to upgrade the software. Flash programming of the ECM must also be done if the ECM has been replaced. The Caterpillar Electronic Technician (ET) contains the program WinFlash. WinFlash is used in order to load software into the ECM. The following procedure is used in order to FLASH software into the ECM. Note: Two communications adapters are available to flash electronic control modules. The 7X-1700 Communications Adapter can be used to flash the machine ECM and engine ECM, but NOT the soft switch panel or monitor. The 171-4400 Communication Adapter II is much faster than the previous adapter. This version can be used to flash ALL components on the machine. 1. Procedure a. Connect the Data Link Cable between the Communication Adapter and the Electronic Technician. b. Connect the Data Link Cable between the Communication Adapter and the diagnostic connector of the machine. c. Use WinFlash in order to load the software.

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Electronic Control Module (ECM) - Replace SMCS - 7610-510-MCH Before the ECM is replaced, ensure that replacement is absolutely necessary. The ECM is seldom the cause of a fault. Always check that power is available to the ECM. Battery voltage is required between contacts J1-1 and J1-2 of the machine harness connector for the ECM. Continue ONLY if all other attempts to isolate the problem have failed. Always consult your dealership's Technical Communicator for possible consultation with Caterpillar. This consultation may greatly reduce the time that is required for a repair. 1. Turn the disconnect switch and the key start switch to the OFF position. Disconnect the machine harness from the ECM. 2. Remove the ECM. 3. Make sure that the replacement ECM is the correct part number. 4. Connect the machine harness to the ECM. 5. Install the replacement ECM.

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Glossary of Terms SMCS - 7000 Abuse - A machine or a engine is operated in a way that could possibly damage the machine. Also see "Operational Event". Abnormal - The condition of a machine system is not normal or a signal of a machine system is not within expected limits. An abnormal condition or a abnormal signal means that a problem exists. The operator should be notified with a warning when an abnormal condition exists. Absolute Pressure (PSIA) - The pressure is measured with respect to the atmospheric pressure. Atmospheric pressure is approximately 101 kPa (14.7 psi). See "Gauge Pressure". Active - This pertains to the status of a fault or to the status of a service code. When the fault is active, the fault is currently present. Active Fault - This is a type of diagnostic maintenance event. The maintenance event identifies a specific failure in an electronic control system. See "Event" and "Fault". Active Sensor - The sensor is externally powered. The sensor must have at least three lead wires. See "Passive Sensor". Advanced Diesel Engine Management (ADEM) - This electronic engine control is used by Caterpillar gas engines and diesel engines. Air Gap - This is the distance between a gear tooth and the tip of a magnetic pickup. This is also the distance between the rotor and the stator of an alternator or a generator. Alert Indicator - This is the red indicator lamp that is located in the monitor. The lamp flashes when a problem exists. The associated warning indicator pictograph is shown on the display area to identify the abnormal condition of a machine system. This is part of the monitoring system. The indicator typically means that the machine needs attention. However, the machine is able to continue operation. The abnormal condition must be checked in accordance with the machine's Operation and Maintenance Manual. Alternator - This is a electromechanical device that converts rotating mechanical energy into electrical energy in the form of alternating current. Alternating Current (AC) - This is a flow of current that flows in both directions. This process repeats continuously. The number of such cycles per second is called the frequency. American Wire Gauge (AWG) - This is a measure of the diameter of electrical wire. As the AWG number becomes smaller, the wire diameter becomes larger. Thicker wires handle more current. Ampere "I" - The standard unit of measure for current flow in a circuit. Analog Display - A type of readout that shows information with a needle that sweeps across a dial face. See "Digital Display". Analog Sensor Power Supply - This is a power source in a Caterpillar electronic control system, that powers analog sensors. The power source is usually rated at 5 DCV. Analog Signal - This is a signal voltage from an analog sensor. The signal varies smoothly over time. The variations are caused by the changing conditions that are sensed. Analog Sensor - This is a device that generates a DC signal between +0.2 and 4.8 Volts. The sensor signal is proportional to the mechanical system that is being monitored. Analog sensors are most often used with electronic engine controls. See "Digital Sensor". Atmospheric Pressure Sensor - This is a device that generates a signal that is proportional to atmospheric pressure. This is usually an analog sensor. Automatic Engine Speed Control (AESC) - This is used by excavators in order to reduce the engine speed to about 950 rpm. This is used in order to save fuel during periods when the hydraulic system is not being used. Battery - This is a device that stores electrical energy. The typical battery that is used in Caterpillar electrical systems is the 12 Volt lead acid. The batteries are used to start the engine. Each battery is made up of six cells. +Battery - This is the voltage that is found on all wiring harnesses that connect to the positive battery post of the electrical system. The +Battery voltage is also known as the "system voltage". -Battery - This term is sometimes used to designate the chassis ground or the negative side of the battery. See "Ground". Breakout T-Harness - This is a test harness that connects into a machine harness or a engine harness. The breakout T-harness connector cable allows the normal operation of the system. The cable also provides a connector that allows the hookup of test

equipment. Bypass Circuit - This is a circuit that temporarily replaces the existing circuit during a test. Calibration - This is the adjustment of an electrical signal that is related to a mechanical linkage or a component. For example, the small differences that occur between the output of the atmospheric pressure sensor and the boost pressure sensor can be corrected by calibration. CAN Data Link (CAN) - The CAN data link is an electrical connection for communication with onboard devices. Devices that use the CAN Data Link include the following items: Machine ECM, Soft Switch Panel and Monitor. CAT Data Link (CDL) - The CAT data link is an electrical connection for communication with onboard devices. Devices that use the CAT data link include the following items: Machine ECM, Engine ECM and service tools such as Caterpillar Electronic Technician. The CAT data link is also the medium that is used for programming with Caterpillar service tools and for troubleshooting with Caterpillar service tools. Category 1 Warning - This is a red alert indicator that flashes in order to warn the operator that a "Category 1 Warning" condition exists. The indicator also indicates the failed machine system. The "Category 1" condition needs attention by the end of the shift. Category 2 Warning - This is a red alert indicator that flashes in order to warn the operator that a "Category 2" condition exists. The indicator also indicates the failed machine system. The action lamp also flashes in order to indicate "Category 2 warning". The presence of this category usually indicates that the operator must alter the operation of the machine or that the service technician must perform maintenance. This warning most often relates to a system temperature that is too high. Category 3 Warning - This is a red alert indicator that flashes in order to warn the operator that a "Category 3" condition exists. The indicator also indicates the failed machine system. The action lamp also flashes in order to indicate a "Category 3 warning". The action alarm sounds ON and OFF. This warns the operator to safely shut down the machine. There is an exception to this warning. When the parking brake is turned ONand the transmission is in gear. Caterpillar Electronic Technician (ET) - This is a Windows based program, that is used to service Caterpillar products. The software operates on a service tool (personal computer). CDL - See "CAT Data Link". CID - See "Component Identifier". Circuit - This is a path for the continuous flow of electrical current. The current will flow from a power source through various conductors and back to the source. Clear - This is the removal of diagnostic information that is stored in the memory of an electronic control. Before clearing a failure, the failure must be on hold and the failure must not be present. This has the same meaning as "Reset". "Clear" is the preferred term. See "Reset". Communication Adapter - This is a device that allows the service tool to communicate with an electronic control over the CAT Data Link and the ATA Data Link. "The communication adapter converts the CAT Data Link Communications and the ATA Data Link communications to RS-232and vice versa". Component Identifier (CID) - This is a diagnostic code that identifies a component or a system that is faulty. This is a four digit diagnostic code. The code is sometimes preceded by a C or CID. Conductor - This is any material that can carry an electrical current. An example of a conductor would be a wire in a wiring harness. Connector - This is a device that is usually constructed of two pieces that mate. A connector provides a way to easily disconnect circuits or separate circuits. Connectors are also used for hydraulic circuits or pneumatic circuits. Connector Contact - This is a component of a harness connector that actually makes the electrical connection. Connector contacts can be either pins (male) or sockets (female). Continuity - This is one property of a complete electrical circuit. The correct resistance depends on the circuit that is being tested. Control - See "Electronic Control". Coolant Temperature Sensor (CTS) - This is a device that generates a signal that is proportional to the engine coolant temperature. Current - This is the flow of electrons in a circuit. Current is measured in Amperes. The standard symbol for current is the letter "I". Data Event - This is an abnormal machine or engine condition. These conditions can affect the machine or the engine life. Data Link - This is a circuit that is used for digital communications. The communications occur between electronic controls or the communications occur between electronic controls and a service tool. Default - This is the initial value of a parameter prior to programming by the customer. This is also the value of the parameter after the system has been reset. Derate - This is the operation of the system at a setting that is below a desired limit. Detected Fault - See "System Event" and "Diagnostic Code".

Diagnostic - This is a process that takes place within an electronic control. The control senses the abnormal machine information. The control displays the abnormal machine information. The control stores the abnormal machine information. This stored information can aid the service technician. Diagnostic Code - This is a code that is generated from a diagnostic type of maintenance event. This code relates to an abnormal condition in an electrical system that has been detected by an electronic control. See "Service Code". Diagnostic Connector - This is a service connector. This is normally a CE connector that contains 20 sockets. The connector brings the test points that are required in testing the starting and charging circuits to a common point. This permits testing with either a multimeter or dedicated 6V-2150 Starting/Charging Analyzer. A Deutsch connector with 12 contacts is used on products that use only one starter. Diagnostic Event - This is a type of maintenance event. This event is displayed when an electronic control detects an abnormal condition in the electrical system. Sometimes abnormal conditions in the mechanical system can be detected through the electrical system. Diagnostic Event Code - See "Event" and "Diagnostic Code". Diagnostic Fault Code - See "Diagnostic Code". Digital Display - This is a type of readout that shows information in the digital format ("numbers and letters"). See "Analog Display". Digital Power Supply - This is a power source that powers digital sensors in a control system. This is usually 8 Volts DC power supply. Digital Sensor - This is a device that generates an output signal that oscillates between two different voltage levels. Either the frequency of the signal or the duty cycle of the signal changes in order to carry the sensed information. The digital sensor can be powered by voltages that are between 8 and 28 DCV. The voltage that is used depends on the sensor. See "Analog Sensor". Digital Voltmeter (DVM) - This is a voltmeter with a digital display. Direct Current (DC) - This is flow of electrons (current) in a closed circuit, that moves in only one direction through a conductor. Disconnect Switch - This is a battery disconnect switch that is connected between the battery's negative terminal and frame ground (chassis). This switch is most often a keyswitch. This switch may be controlled electronically on some machines. The switch is used in order to disconnect the electrical system from the machine for service. The switch is used when a machine is placed in storage for periods longer than one month. Display - A gauge, indicator and digital readout. The display is used to view the status of a machine. Download - The process of moving or transferring stored information from an electronic control to an off-board system such as a service tool. See "Upload". Driver - This is the electrical circuit that powers an output of an electronic control. The "driver" turns on lamps, solenoids, relays, etc. Duty Cycle - This is the ratio of "ON"time to the total time of a digital signal. An example of duty cycle of 50 percent is a signal that is "ON" for one second and "Off" for one second. See "Pulse Width Modulation". Electromagnet - This is a temporary magnet that consists of a coil of wire that is wrapped around an iron core. The assembly becomes a magnet only when a magnetic field is produced by an electric current passing through the coil. Relays work on this principle. Electromagnetic Interference (EMI) - This is the response of an electronic component or system to electromagnetic radiation. The interference usually causes a reduction of performance. Electronic Control Module (ECM) - This is an electronic control. The control monitors machine systems. The control also outputs commands to drive components. The term was formerly used to specifically describe an electronic engine control. Electromagnetic Pickup - This is a permanent magnet that is wrapped with many turns of small wire that becomes a pickup coil. The pickup coil will generate an electrical pulse whenever a gear tooth passes the tip of the magnet. The sensor does not require a power wire. Electrostatic Discharge (ESD) - This is the release of electrical energy that is caused by the buildup of static between two components. Engine Speed/Timing Sensor - This is a device that generates a signal that is based on the characteristics of the crankshaft: position, speed and direction of rotation. Erasable Programmable Read Only Memory (EPROM) - This is a type of computer memory that requires special equipment in order to erase stored data. After the device is programmed and then installed the computer can only READ the software program. See "Electrically Erasable Programmable Read Only Memory". Error - This is a type of operator warning that results from a system event. See "System Event". ET - See "Caterpillar Electronic Technician". Event - This is a detected failure. The failure may be caused by a sensor that is out of range or an abnormal condition. Events are separated into two basic categories "DATA events" and "MAINTENANCE events". A stored event has a fixed duration

("start and end time"). An active event is present at the time of troubleshooting. This event has not yet ended so the event has no duration. The conditions that define this event will determine if the event will be stored and/or displayed. Event Category Indicator (ECI) - This is a designation that shows the "event warning category". This is a direct indication of the severity of the event. An example of the indicators are listed here: 1, 2, and 3 Event Count - This is the number of occurrences for a "particular event"since the last reset of the on board data. See "Occurrence Count" which is the preferred term. Event Duration - This is the recorded duration of an event that was active. Failure - This is a malfunction of a component or an incorrect calibration of an electronic control system. This condition can occur during normal operation of the engine or machine and AFTER a period of known correct operation. Failures are detected by an electronic control when a signal does not exist or a signal is outside a valid range. Failures usually cause diagnostic information to be stored. However, not all maintenance information represents a failure. A "failure" is often referred to as a "fault". This is an incorrect use of the term. See "Fault", "Event" and "Diagnostic Event". Failure Mode Identifier (FMI) - This is a portion of the total diagnostic code. The FMI identifies a type of failure that is detected by an electronic control. The FMI is a two digit code. The code describes the failure mode of the component that is described by the Component Identifier. A Component Identifier (CID) is always displayed in conjunction with the FMI. Fault - This is a "pre-existing" defect in a component or a system. The fault is identified at the initial assembly or at the time of purchase. See "Failure". An example of a fault is a PWM sensor that will not function at the time of initial installation. Flash Files - These Software programs contain instructions on the operation of electronic controls. The programs are transferred from the off-board service tool to any on board electronic control. See "Flash Programming". Flash Memory - This is "solid state memory" that is used in electronic controls. The memory can be reprogrammed with an offboard service tool through a data link without being removed from the control. Other types of memory can only be programmed outside of the control. Flash Programming - This is a means of "programming, reprogramming or updating (uploading) an electronic control with an off-board service tool instead of replacing the control or personality module". This process involves the transfer of configuration software from the service tool to the electronic control. Communication is done over a data link. See "Flash Memory" and "Uploading". Floating - This describes the end of a circuit that is open. The circuit is not connected to any other component. Fuse - This is a replaceable safety device for an electrical circuit. Gage - See "Gauge". Gauge - This is a type of "display device". The gauge is usually a circular shape with a indicator needle. The gauge can be a mechanical device or a solid state device. Gauge Pressure (PSIG) - This is the pressure that is measured with respect to atmospheric pressure. See "Absolute Pressure". Ground (B-) - This is the reference point for the electrical system. On CAT products, ground is the machine frame or the engine. This is the connection point for the negative side of the battery. Grounded Circuit - This is the connection point of any electrical circuit to the machine frame, engine or any part of the machine. This is considered to be the ground reference point for the electrical system. This connection can be either "wanted" or "unwanted" (fault). Ground Level Shutdown - This is a remote means of shutting down the engine without turning off the key switch. This lever can usually be reached from the ground without entering the operator's station (cab). Hall Effect Speed Sensor (HESS) - This is an active sensor for sensing the speed of slow moving gears or targets. This sensor uses a silicon chip that is called a "Hall Cell" to sense a moving target. Hardware (H/W) - This is the electrical components and electronic components that make up an electrical system. Hard Wired - These permanent connections are made within the wiring harness. These "soldered or crimped" connections are not meant to be altered. Harness - This is an "assembly or bundle" of two or more wires that electrically connect system components. Harness Code - This refers to the grounded condition or open condition of the harness code inputs. The harness code provides the characteristics of the machine such as engine oil pressure, maximum engine speed, etc. This code is usually "model specific". The machine ECM uses this hard wired code in order to determine the module identifier (MID) that is used for data link communications. Hertz (Hz) - This is a measure of frequency. The units are cycles per second. Histogram - This is a bar graph that shows the number of occurrences for a given range. Hysteresis - This is a measure of the "lag time that occurs between the turn ON and turn OFF values of a switch or a sensor". An example would be "the EUI oil pressure warning lamp may turn on at 40 psi with decreasing pressure and turn off at 45 psi with increasing pressure". The hysteresis is 5 psi. I - This is the standard symbol for current. The unit of measure is the Ampere. Icon - This is a symbol that is used instead of words in order to convey a message in any language.

Indicator - This is a lamp, gauge, etc. The indicator calls attention to service related conditions regarding a machine. Information System Builder (ISB) - This is a "software tool" that is used to generate configurations for the Vital Information Management System. The software can also modify existing configuration software. The software can also be used in order to view the items that are listed here: parameters and limits of the parameters. The software can also be used to change the "customer values" in the "Large Wheel Loader Payload portion" of the configuration. Input/Output (I/O) - This describes "the electronic circuits within an electronic control that are used for inputs (such as sensors and switches) to the control and the outputs from the control to the external circuits (such as horns, lamps and solenoids)". Jumper - This is a piece of wire that is used to make a temporary electrical connection during troubleshooting. Keypad - This is a panel of keys that is similar to the one that is used on a "push button telephone". The keypad is used as an interface to the on board electrical system. Key Start Switch - This is a "key actuated, automotive type, engine cranking/starting switch including functions such as the ON (relay), CRANK and, sometimes, ACCESSORY". Kilopascal (kPa) - This is a Metric unit of pressure. The force that is applied to one square meter is one Newton (6.89 kPa (1.000 psi)). kPa - See "Kilopascal". Lamp - This is a component of the machine electrical system that emits light by converting electrical energy into light. Large Hydraulic Excavator (LHEX) - This is a machine that is usually propelled on tracks. The machine uses hydraulic power to travel. The machine uses hydraulic power to dig up material with a bucket. Light Emitting Diode (LED) - This is a solid state device. The device emits light that is visible to the human eye when an electrical current is passed through the device. the LED is used as a "lamp" in electronic controls because the device is very reliable. Liquid Crystal Display (LCD) - This is a display that uses a liquid crystalline material that is sealed between two glass sheets. An electrical signal causes segments of the crystal material to be visible to the eye. Load - This is a device that is connected to the electrical system. The load consumes power or the load dissipates power. Log (Logged) - This is the process of saving information ("stored or recorded") within an electronic control. See "Store". Machine Event - This is an event that describes an abnormal MACHINE condition. Machine events relate to any system except the events that deal with the electrical system. Machine Service Connector - This is a harness connector for the machine or engine electrical systems that allow the connection of a service tool. Module - This is a shortened term that is used in place of the electronic control module. See "electronic control module". Module Identifier (MID) - This is a three digit number that identifies an electronic control. Monitor - The monitor is an electronic control module that is mounted in the cab of the machine. The monitor has a display that allows the operator to view information about the machine. Also, switches on the monitor are used for accessing the various menus of the monitor. Normal Condition - "Normal" describes the contact position of a switch or relay. This is the condition when the component is not controlled by the application of the conditions that are listed here:force, temperature, pressure and electricity. This is usually the condition that is found when the component is installed on a machine. This condition can be different when the component has been removed from the machine prior to testing. The Electrical System Schematic shows the condition of the components as the component is installed on a machine. "Normal" also describes the status of a machine system. Occurrence Count - This is the number of occurrences for a "particular event"since the last reset of the on board data. This is the preferred term. See "Event Count"and "Event". Off-Board - This refers to hardware and software that is located off the machine. The hardware and software can be temporarily connected to the electrical system. Ohm - This is the standard unit for measuring resistance. This is represented by the letter "R". On Board - This refers to hardware and software that is located on the machine as part of the electrical system. Open Circuit - This is a condition that exists when an electrical circuit is broken. Parameter - This is a value or a limit that is sometimes programmable. The parameter determines the characteristics or behavior of the engine and/or machine electrical system. See "Protected Parameter". A parameter can also refer to the "gauge functions" and/or the "monitored channels" of information (Vital Information Management System). Parameter Identifier (PID) - This is a code that is assigned to each packet of digital information. This code is shared between controls over the CAT Data Link and the American Trucking Association data link. Passive Sensor - This is a sensor that does not require external power in order to operate. See "Active Sensor". Password - This is a group of numeric characters or letters that restrict the access to information in a control system. A password is required by Caterpillar electronic service tools in order to change information. Plug - This is the male end of a connector. The plug makes an electrical connection to a circuit by inserting into a receptacle. Polled Data - This is data that is requested by an electronic control. The data is not brought in automatically.

Potentiometer (Pot) - This is a variable resistor that has three terminals. The potentiometer can be easily adjusted by using a knob or a screwdriver. Pounds per square inch (psi) - This is an English unit of pressure measurement. The measurement represents the force that is applied to one square inch. The value is measured in pounds. 6.89 kPa (1 psi) Pressure Sensor - This is a device that generates a signal that is proportional to the pressure that is sensed. Pressure Switch - This is a device that senses pressure. The pressure causes the switch contacts to open or the pressure causes the switch contacts to close. This signal can be used by an electronic control. The signal can also be used with a "signalling device" such as a lamp. Problem - This is an abnormal "machine/engine" condition. Pull up Voltage - This is the voltage that is measured on the input of an electronic control when the input device has been disconnected. (sensor, switch, etc.) Pulse Width Modulation (PWM) - This is a signal that is made up of a string of pulses that vary in width. The "time on" versus "time off" varies according to the system that is being sensed. The frequency of the signal ("repetition rate") of the pulses and the height of the signal ("amplitude") remain constant. Radio Frequency (RF) - "Frequencies that are between about 150 kHz and infrared (invisible light)". This range of frequencies are capable of carrying data via radio telemetry systems. Real Time - This term is used to describe the relationship of information (events) that is based on a true clock "24 hours represents one day". Real Time Clock (RTC) - This is the method that is used by electronic controls to measure time. The time is based upon true clock hours. See "Diagnostic Clock", "Service Meter Hours" and "Service Meter Units". Receptacle - This is a female component of the connector that makes an electrical connection to a circuit. The receptacle will receive a plug assembly. Rectifier - This is an electrical device that converts alternating current into pulsating dc current. Relay - This is an electromechanical device. The relay uses an electromagnet in order to actuate the electrical contacts. The contacts switch large currents with a relatively small amount of control current to the electromagnet. Reset - This is a command that restores memory to a default state. The default state is usually "zero". This means that all of the data has been removed or erased. See "Clear". Resistor - This is an electrical component. The resistor is usually made of "resistance wire" or of carbon that has a resistance. Resistance opposes the flow of current. Rheostat - This is a variable resistor. The rheostat is usually a "two terminal version" of the potentiometer. The rheostat is often used in applications that require a higher dissipation of power than a potentiometer. RS-232 Data Link - This is a serial data link that transfers data between electronic devices such as a personal computer and a printer. See "Serial Data Link". Sample Rate - This is the "rate or frequency that data is captured and/or stored". This is usually measured in samples per second. Scroll - This is the process of showing all available sets of "event information"within a digital display area. The information is shown one set at a time. A set of "event information" is shown briefly. The display will automatically advance to the next set. After all the sets are shown the process is repeated. Some controls will show the message "END" before the control repeats the process. Sender - This is a device that changes resistance according to a physical condition. The sender then sends a signal to a gauge. A single connection provides the signal and the power. Sensor - This is a device that monitors the physical condition of a machine system. The sensors can monitor the conditions that are listed here: pressure, temperature, flow and mechanical movement. The sensors convert the condition into an electrical signal that can be understood by an electronic control. Also see "Transducer" and "Sender". Serial Data Link - This is a type of data link that transfers one bit of data at a time. The data link is used to transfer information between devices. Service Code - This is a diagnostic code that describes a condition that has been identified by an ECM. The code indicates when "service" is required. This code is stored in the control for the service technician. This term was previously referred to as a "fault code". This code is now referred to as a diagnostic code. See "Event" and "Diagnostic Code". Service Event - This is a type of maintenance event that requires a service technician to perform service. This is usually routine service that is performed on the machine. Examples of "service" are changing the engine oil or transmission filters. See "Event". Service Hour Meter (SHM) - This is a meter on the machine that totals the "engine running hours". Service Meter Hours (SMH) - This meter increments time only when the engine is running. This meter is most often used in order to determine the intervals for servicing the machine. This meter is also used to identify the time of occurrence of an event. This is used as part of the diagnostic process. Also see "Service Meter Units". Service Program Code (SPC) - These codes are entered into the electrical system by the user through the keypad. The codes

initiate the requested operation. Service Tool - This is a tool that is used in order to service Caterpillar machines. This term most often refers to the service equipment that is listed here: Electronic Control Analyzer Programmer (ECAP), Caterpillar Electronic Technician (ET), a digital multimeter and laptop computer This may also refer to any other dedicated service equipment. Service Tool Connector - See "Machine Service Connector". Short Circuit - A connection between two points in a circuit that is normally unwanted. Signal - This is the changing voltage that is used to carry information. A signal is typically sent from a sensor to an electronic control. For example, a signal is sent from the transmission output speed sensor (TOS) to the transmission control. Signal Wire - This is the harness wire that carries the signal voltage to the electronic control. The signal is sent by any of the components that are listed here: a sensor, a switch and any other similar components. Soft Switch Panel - This panel contains switches for controlling various functions on the machine. This panel communicates with the machine ECM on the CAN data link. Software (S/W) - This is a step-by-step instruction that defines the operation of a computer system. This is often called a program. Solenoid - This is a coil assembly that is used to perform some type of mechanical work. The solenoid converts electrical energy into linear mechanical motion with an electrical coil (electromagnet) that produces a magnetic field around an armature (slug or plunger). Solenoid Valve - This is a device that uses a solenoid in order to actuate a valve ("hydraulic or pneumatic"). The valve is used to control the flow or pressure of a liquid or gas. Solid State - This refers to circuits or components that use semiconductors. Examples of solid state devices: transistors, diodes and integrated circuits (IC). Source Software - This is software that contains detailed operating instruction for the on board system. This is software that is similar to the operating system that is used with a personal computer. Sourcing Driver - This is a type of output of an electronic control. When the output is ON, power is supplied to the load. The other connection must be connected to ground. This is sometimes referred to as a high side driver. Speed Burp - This is a sudden unwanted change in engine speed. Speedometer/Tachometer Module - This is a display module that contains the components that are listed here: speedometer for machine ground speed, a tachometer for engine speed and a display for actual gear. Store - This is the process that is used to record the "event information" in an electronic control. See "Log". Subsystem - This is a system that is part of a larger system. Supply Voltage - This is a constant voltage that is supplied to a component such as a sensor. The supply voltage provides the electrical power for the operation of the component. The voltage may be generated by the electronic control or supplied from the machine electrical system. Sure-Seal Connector - This is a multi-contact connector that holds pins and sockets in a rubber housing. Suspension Cylinder Pressure Sensor - This is a device that generates a signal that is proportional to suspension cylinder pressure. This sensor is a digital type. The signal changes frequency as the pressure changes. Switch - This is a device with electrical contacts that opens under specified conditions. This is a device with electrical contacts that closes under specified conditions. Switch Input - This is a connection on an ECM. The signal that is received by this connection is one of the following types: ground, open and +Battery. System Clock - "This is a device within a machine or engine electrical system, usually in the monitoring system if present, that synchronizes or forces the clock within each electronic control module on a data link to display the same machine or engine hours. The primary use of this clock is for time stamping of events used for service, maintenance and/or warranty, etc." System Event - This is an abnormal condition in the ELECTRICAL SYSTEM that has been detected by the machine ECM or the Monitor. This term is now called a diagnostic type of "maintenance" event. See "Event" and "Diagnostic Code". System Voltage - This is the actual voltage that exists between the positive battery post and frame ground. This is sometimes referred to as +Battery voltage. Temperature Sensor - This is a device that generates a signal that is proportional to the change in temperature. Temperature Switch - This is a switch that monitors temperature. The switch sends a signal to an electronic control or signal lamp. Telemetry Signal - This is a method of broadcasting data between two points. This method most often uses a radio. The mobile unit transfers the data to the "data collection area". Test Probe - This is a device for connecting a service tool in order to test a circuit. The probe provides access to a circuit that is being tested. The probes provide access to the circuit without disconnecting the circuit. Trend - This is a type of graph that shows the changes of a parameter value over time. Trigger point - This is the starting point in the process of storing a snapshot. This is also the beginning of an event.

Undetected Fault - This is a system event that cannot be detected by the electronic control. The fault must be detected by the operator or a service technician. Upload - This is the process of transferring a program and/or configuration into an electronic control from an off-board service tool. See "Flash Programming "and "Download". +V - This is a constant voltage that is supplied to a component that provides electrical power for the operation of the component. The voltage is provided by an electronic control module. Volatile Memory (VM) - This is a type of "data storage" that is lost with a interruption of power. Warning Category - This describes the severity of an operator warning. This is based on one of three categories. Wiring Harness - See "Harness". Zener Diode - This is a special diode that conducts current in the reverse direction when this reverse voltage becomes higher than a specified value. When this specified value is reached, the voltage across this diode remains constant.

TESTING AND ADJUSTING

010

TESTING AND ADJUSTING

i02305114

System Schematic SMCS - 7566-MCH These simplified schematics for the M300C Excavators Machine Electronic Control System are electrically correct. The schematics show the inputs and outputs of the ECM. The schematics do not show all possible harness connectors. The schematics do not show all related electrical systems on the machine. For a complete electrical system schematic of a particular machine, always refer to the Electrical System Schematic in the machine Service Manual. The following schematics for the ECM connector J1 and J2 connections are for machines with the following serial numbers: BEB1-2000 BDK1-2000 BDM1-2000 BDR1-2000 BDX1-2000 BDY1-2000 BCZ1-2000

Illustration 1

g00986652

Illustration 2

g00987922

The following schematics for the ECM connector J1 and J2 connections are for machines with the following serial numbers: (BDX2001-UP) (BCZ2001-UP) (BEB2001-UP) (BDK2001-UP) (BDY2001-UP) (BDR2001-UP) (BDM2001-UP) (H2A1-UP) (H2B1-UP) (H2C1-UP)

(H2D1-UP) (H2E1-UP) (H2F1-UP) (H2G1-UP)

Illustration 3

g01154463

Illustration 4

g01154465

M316C Material Handlers Excavators Electronic System Troubleshooting Index

General Information Service Tools Electrical Component and Connector Locations Diagnostic Capabilities

1 2 3 4

Operator Monitor The Caterpillar Electronic Technician (ET) Logged Event Codes Status Groups For The Electronic Technician

Diagnostic Code List Using the Operator Monitor to Determine Diagnostic Codes

5 6

Module Identifier (MID) Failure Mode Identifier Detailed FMI Explanation

Using Caterpillar Electronic Technician to Determine Diagnostic Codes MID 039 - CID 0096 - FMI 03 MID 039 - CID 0096 - FMI 04 MID 039 - CID 0127 - FMI 03 MID 039 - CID 0127 - FMI 04 MID 039 - CID 0191 - FMI 02 MID 039 - CID 0191 - FMI 11 MID 039 - CID 0291 - FMI 03 MID 039 - CID 0291 - FMI 05 MID 039 - CID 0291 - FMI 06 MID 039 - CID 0298 - FMI 04 MID 039 - CID 0298 - FMI 05 MID 039 - CID 0374 - FMI 03 MID 039 - CID 0374 - FMI 05 MID 039 - CID 0374 - FMI 06 MID 039 - CID 0376 - FMI 03 MID 039 - CID 0376 - FMI 05 MID 039 - CID 0376 - FMI 06 MID 039 - CID 0444 - FMI 03 MID 039 - CID 0444 - FMI 05 MID 039 - CID 0444 - FMI 06 MID 039 - CID 0590 - FMI 02 MID 039 - CID 0590 - FMI 09 MID 039 - CID 0590 - FMI 12 MID 039 - CID 0598 - FMI 03 MID 039 - CID 0598 - FMI 05 MID 039 - CID 0598 - FMI 06 MID 039 - CID 0600 - FMI 03 MID 039 - CID 0600 - FMI 04 MID 039 - CID 0681 - FMI 03 MID 039 - CID 0681 - FMI 05 MID 039 - CID 0681 - FMI 06

7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38

MID 039 - CID 0727 - FMI 03 MID 039 - CID 0727 - FMI 05 MID 039 - CID 0727 - FMI 06 MID 039 - CID 0736 - FMI 03 MID 039 - CID 0736 - FMI 06 MID 039 - CID 0882 - FMI 03 MID 039 - CID 0882 - FMI 05 MID 039 - CID 0882 - FMI 06 MID 039 - CID 1130 - FMI 03 MID 039 - CID 1130 - FMI 04 MID 039 - CID 1180 - FMI 03 MID 039 - CID 1180 - FMI 05 MID 039 - CID 1180 - FMI 06 MID 039 - CID 1181 - FMI 03 MID 039 - CID 1181 - FMI 05 MID 039 - CID 1181 - FMI 06 MID 039 - CID 1401 - FMI 03 MID 039 - CID 1401 - FMI 05 MID 039 - CID 1401 - FMI 06 MID 039 - CID 1402 - FMI 03 MID 039 - CID 1402 - FMI 05 MID 039 - CID 1402 - FMI 06 MID 039 - CID 1486 - FMI 03 MID 039 - CID 1486 - FMI 05 MID 039 - CID 1486 - FMI 06 MID 039 - CID 1530 - FMI 03 MID 039 - CID 1530 - FMI 05 MID 039 - CID 1530 - FMI 06 MID 039 - CID 1615 - FMI 03 MID 039 - CID 1615 - FMI 05 MID 039 - CID 1615 - FMI 06 MID 039 - CID 1616 - FMI 03 MID 039 - CID 1616 - FMI 05 MID 039 - CID 1616 - FMI 06 MID 039 - CID 1617 - FMI 03 MID 039 - CID 1617 - FMI 05 MID 039 - CID 1617 - FMI 06 MID 039 - CID 1618 - FMI 00 MID 039 - CID 1618 - FMI 01 MID 039 - CID 1618 - FMI 03 MID 039 - CID 1618 - FMI 04 MID 039 - CID 1621 - FMI 03 MID 039 - CID 1621 - FMI 05 MID 039 - CID 1621 - FMI 06 MID 039 - CID 1622 - FMI 03 MID 039 - CID 1622 - FMI 05 MID 039 - CID 1622 - FMI 06 MID 039 - CID 1623 - FMI 03

39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86

MID 039 - CID 1623 - FMI 05 MID 039 - CID 1623 - FMI 06 MID 039 - CID 1624 - FMI 03 MID 039 - CID 1624 - FMI 05 MID 039 - CID 1624 - FMI 06 MID 039 - CID 1628 - FMI 04 MID 039 - CID 1628 - FMI 05 MID 039 - CID 1629 - FMI 03 MID 039 - CID 1629 - FMI 05 MID 039 - CID 1629 - FMI 06 MID 039 - CID 1630 - FMI 03 MID 039 - CID 1630 - FMI 05 MID 039 - CID 1630 - FMI 06 MID 039 - CID 1657 - FMI 03 MID 039 - CID 1657 - FMI 04 MID 039 - CID 1670 - FMI 04 MID 039 - CID 1670 - FMI 05 MID 039 - CID 1683 - FMI 03 MID 039 - CID 1683 - FMI 05 MID 039 - CID 1683 - FMI 06 MID 039 - CID 1739 - FMI 03 MID 039 - CID 1739 - FMI 05 MID 039 - CID 1739 - FMI 06 MID 039 - CID 1842 - FMI 03 MID 039 - CID 1842 - FMI 05 MID 039 - CID 1842 - FMI 06 MID 039 - CID 1843 - FMI 03 MID 039 - CID 1843 - FMI 05 MID 039 - CID 1843 - FMI 06 MID 039 - CID 2104 - FMI 03 MID 039 - CID 2104 - FMI 05 MID 039 - CID 2104 - FMI 06 MID 039 - CID 2142 - FMI 03 MID 039 - CID 2142 - FMI 04 MID 039 - CID 2149 - FMI 03 MID 039 - CID 2149 - FMI 05 MID 039 - CID 2149 - FMI 06 MID 039 - CID 2184 - FMI 03 MID 039 - CID 2184 - FMI 05 MID 039 - CID 2184 - FMI 06 MID 039 - CID 2198 - FMI 02 MID 039 - CID 2256 - FMI 03 MID 039 - CID 2256 - FMI 05 MID 039 - CID 2256 - FMI 06 MID 039 - CID 2447 - FMI 03 MID 039 - CID 2447 - FMI 05 MID 039 - CID 2447 - FMI 06 Engine Does Not Start

87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 121 122 123 124 125 126 127 128 129 130 131 132 133 134

Engine Stalls Automatic Engine Speed Control Never Activates Engine Speed Does Not Change Engine Speed Increase Is Delayed During Hydraulic Demand Hydraulic Response Is Poor Machine Only Operates in Economy Mode Machine Only Operates in Power Mode Machine Only Operates in Travel Mode

135 136 137 139 140 141 142 143

TROUBLESHOOTING

001

TROUBLESHOOTING

i01900973

General Information SMCS - 7000-EK; 7490 Troubleshooting the electronic control system will require additional information from the Service Manual of the machine. The reference material should be consulted: the Electrical System Schematic, the Parts Manual and the Operation And Maintenance Manual. As a reference, a typical system schematic is included at the end of this manual. For an accurate representation of the machine that is being diagnosed, see the Testing And Adjusting, "System Schematic". You should use the Electrical System Schematic in the Service Manual of the machine in order to trace the circuit, if a troubleshooting procedure instructs you to "REPAIR THE HARNESS". The continuity checks and resistance checks should be performed at the connectors in order to locate a failure in the harness. At a component connector, always check the ground circuit. Less than five ohms of resistance is required from the ground contacts to frame ground. A problem can be incorrectly diagnosed, if an excessive resistance that is greater than 5 ohms is present in the ground circuit. During a troubleshooting procedure, you should inspect all component and harness connections before a component is replaced. If these connections are not clean and tight, the connection can cause an electrical problem. The problem can be permanent or the problem can be intermittent. Ensure that the wires are pushed into the connectors completely. Make sure that the connections are tight before other tests are performed. A failure of an electrical component can cause a failure of another component or a failure can be caused by the failure of other components. You should always attempt to find a failure and you should correct the cause of a failure in the electrical system before you replace a component.

TROUBLESHOOTING

002

TROUBLESHOOTING

i01789043

Service Tools SMCS - 0785 The following service tools should be used to aid in troubleshooting the electrical system. Table 1 Service Tools Part Number

Part Caterpillar Electronic Technician (ET)

(1)

6V-7070

Digital Multimeter (Heavy Duty)

9U-7330

Digital Multimeter (1)

146-4080

Digital Multimeter (RS-232) (1)

8T-3224

Needle Tip Group

7X-1710

Multimeter Probe Group

8T-8726

3 Pin Cable Assembly

6V-3000

Connector Repair Kit (Sure Seal)

9U-7246

Connector Repair Kit (Deutsch DT Type)

4C-3406

Connector Repair Kit (Deutsch)

4C-8195

Control Service Tool (Switch Box)

This tool can be used to measure the duty cycle and the frequency.

For instructions on servicing Sure Seal connectors, see Special Instruction, SMHS7531. For instructions on servicing the Deutsch "DT" Type connectors, see Special Instruction, SEHS9615. Use the digital multimeter for making continuity checks or for measuring voltage. For instructions about the use of the 6V-7070 Digital Multimeter, see Special Instruction, SEHS7734. The 7X-1710 Multimeter Cable is used for measuring the voltage at the connectors without needing to disconnect the connectors. The probe cables are pushed into the back of the connector along the wire. The 8T-8726 Adapter Cable has a 3 pin breakout. The adapter cable is used for measurements in the sensor circuits. Note: Except for harness tests, using continuity testers such as the 8T-0500 Continuity Tester or voltage testers such as the 5P7277 Voltage Tester is not recommended for today's Caterpillar electrical circuits.

TROUBLESHOOTING

003

TROUBLESHOOTING

i01789046

Electrical Component and Connector Locations SMCS - 7553-546-WW The following references should be used to locate the components and connectors for the machine that is being serviced: Electrical System Schematic, Parts Manual and Operation And Maintenance Manual. The following information is found on the back of the Electrical System Schematic: the "Harness Connector and Component Locations", the machine profile and area view. The following information explains the use of the information on the back of the System Schematic. "Component Locations"

The component location chart uses white circles as location labels in the machine profile and the area view. Alphanumeric letters are used in the columns for the connector location. Alphanumeric characters are used in the machine location column. These identifiers are used in order to indicate the location in the area view. "Connector Locations" The chart for the location of a harness connector uses white circles for the location labels in the general view and the area view. Alphanumeric characters are used in the column for connector locations. These identifiers are used in order to indicate the location in the area view.

TROUBLESHOOTING

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TROUBLESHOOTING

i02303593

Diagnostic Capabilities SMCS - 7000-EK; 7490

Operator Monitor The monitor will display the following information that can be used for diagnostics: Active diagnostic codes are viewed in the "Service Options PW" menu under the "ACTIVE ERROR" heading. See Troubleshooting, "Using the Operator Monitor to Determine Diagnostic Codes". Inactive diagnostic codes and logged diagnostic codes are viewed in the "Service Options PW" menu under the heading "LOGGED ERROR". See Troubleshooting, "Using the Operator Monitor to Determine Diagnostic Codes". Events that are not diagnostic codes are viewed in the "Service Options PW" menu under the "LOGGED EVENTS" heading. See Systems Operation, "Logged Events Menu" for more information. See Troubleshooting, " Using the Operator Monitor to Determine Diagnostic Codes". This manual provides step-by-step instructions that are used for troubleshooting the ECM.

The Caterpillar Electronic Technician (ET)

Illustration 1

g00917650

The Caterpillar Electronic Technician (ET) is a software program that is used to access data. The service technician will use the ET in order to perform the maintenance on the machine. Some of the options that are available with the Caterpillar Electronic Technician are listed below: Diagnosis of problems. Viewing diagnostic codes. Viewing active event codes and logged event codes. View the status of parameters. Clear active diagnostic codes and clear logged diagnostic codes. Perform calibration of machine systems. Program the ECM (Flash). This is done with the "WINflash" program. See Testing and Adjusting, "Electronic Control Module (ECM) - Flash Program". Print reports.

See Troubleshooting, "Using the Caterpillar Electronic Technician to Determine Diagnostic Codes". Diagnostic information is accessed with the following drop down menus:

Active diagnostic codes Logged diagnostic codes

Logged Event Codes

Illustration 2

g00918221

Logged events are provided with an indicator which is used to keep track of recurring or intermittent events. The data for the logged event shall include the following items: an event identifier (EID), a text description of the event, the number of occurrences of the event, a time stamp that shows the time that the event first occurred and a time stamp that shows the time that the event has most recently occurred. Reference: For a complete list of the event codes that can be activated, refer to Systems Operation, "Logged Events Menu".

Status Groups For The Electronic Technician

Illustration 3

g00873997

Status groups that are available through the ET

The Status groups are lists of machine parameters. The status of the parameters are shown in real time. The following tables contain the descriptions of the ten different status group of the machine parameters. Note: Some of the ET status group options have changed on machines in the following serial number ranges: BDR2001-UP, BDM2001-UP, BDX2001-UP, BCZ2001-UP, BDK2001-UP, BDY2001-UP, BEB2001-UP, H2A1-UP, H2B1-UP, H2C1-UP, H2D1-UP, H2E1-UP, H2F1-UP and H2G1-UP. In the group tables below, the changes are noted. Some tables are repeated in order to show the numerous differences. The items in Group 1 displayed below cover all machines with one exception which is noted. Table 1 Machine ECM "Group 1" Description

Value

"AESC Enable Momentary Switch"

"Depressed" or "Not Depressed"

"Oscillating Axle Momentary Switch"

"Depressed" or "Not Depressed"

"Creeper Mode Momentary Switch Status"

"Depressed" or "Not Depressed"

"Travel Pedal Lock Momentary Switch"

"Depressed" or "Not Depressed"

"Parking Brake Momentary Switch"

"Depressed" or "Not Depressed"

"Implement Lockout Momentary Switch"

"Depressed" or "Not Depressed"

"Travel Speed Momentary Switch"

"Depressed" or "Not Depressed"

"Travel Alarm Cancel Momentary Switch"

"Depressed" or "Not Depressed"

"Hydraulic Modulation Mode Switch Status" (1)

"Depressed" or "Not Depressed"

"Power Mode Momentary Switch"

"Depressed" or "Not Depressed"

(1)

Displayed only for machines in S/N ranges: BDR2001-UP, BDM2001-UP, BDX2001-UP, BCZ2001-UP, BDK2001-UP, BDY2001-UP, BEB2001UP, H2A1-UP, H2B1-UP, H2C1-UP, H2D1-UP, H2E1-UP, H2F1-UP and H2G1-UP.

The items in Group 2 cover all machines except for the noted exceptions. Table 2 Machine ECM "Group 2" Description

Value

"Attachment Pedal Front Pressure" (2)

"On" or "Off"

"Attachment Pedal Back Pressure" (2)

"On" or "Off"

"Left Attachment Pedal Position" (1)

"-100%" to "+100%"

"Implement Generator Operator Enable Switch Status"

"Installed" or "Not Installed"

"Generator Valve Solenoid Command"

"Installed" or "Not Installed"

"One Way / Two Way Valve Solenoid Status"

"One Way" or "Two Way"

"Auxiliary Valve Pressure Solenoid Current Command"

Amperes

"Auxiliary Valve Flow Solenoid Current Command"

Amperes

"Hammer Enable Solenoid Status"

"Installed" or "Not Installed"

(2) (1)

Displayed only for machines in S/N ranges: BDR1-2000, BDM1-2000, BDX1-2000, BCZ1-2000, BDK1-2000, BDY1-2000 and BEB1-2000. Displayed only for machines in S/N ranges: BDR2001-UP, BDM2001-UP, BDX2001-UP, BCZ2001-UP, BDK2001-UP, BDY2001-UP, BEB2001UP, H2A1-UP, H2B1-UP, H2C1-UP, H2D1-UP, H2E1-UP, H2F1-UP and H2G1-UP.

Note: Table 3 below for Group 3 applies to machines in S/N ranges BDR1-2000, BDM1-2000, BDX1-2000, BCZ1-2000, BDK1-2000, BDY1-2000 and BEB1-2000. Table 3 Machine ECM "Group 3" Description

Value

"Boom Angle Status"

"Installed" or "Not Installed"

"Machine Overload Pressure Status"

"On" or "Off"

"Stabilizer Extend Pressure Status"

"Installed" or "Not Installed"

"Stabilizer High Pressure Solenoid Command"

"Installed" or "Not Installed"

"Implement Lockout Solenoid Status"

"On" or "Off"

"Oscillating Axle Solenoid Command"

"On" or "Off"

"Main Pump Swash Plate Angle"

Degrees

"Main Pump Power Shift Pressure Solenoid Current"

Amperes

"Swing Pump Power Shift Pressure Solenoid Current"

Amperes

Note: Table 4 below for Group 3 applies to machines in S/N ranges BDR2001-UP, BDM2001-UP, BDX2001-UP, BCZ2001-UP, BDK2001-UP, BDY2001-UP, BEB2001-UP, H2A1-UP, H2B1-UP, H2C1-UP, H2D1-UP, H2E1-UP, H2F1-UP and H2G1-UP. Table 4

Machine ECM "Group 3" Description

Value

"Swing Pilot Pressure Switch"

"High" or "Low"

"Operator Swing Brake Momentary Switch Status"

"Energized" or "Not Energized"

"Swing Brake Solenoid Status"

"Energized" or "Not Energized"

"Boom Angle Status"

"Installed" or "Not Installed"

"Machine Overload Pressure Status"

"On" or "Off"

"Implement Lockout solenoid Status"

"On" or "Off"

"Oscillating Axle Solenoid Command"

"On" or "Off"

"Main Pump Power Shift Pressure Solenoid Current"

Amperes

"Swing Pump Power Shift Pressure Solenoid Current"

Amperes

"Main Pump Pressure Switch Status"

"On" or "Off"

The items in Group 4 cover all machines. Table 5 Machine ECM "Group 4" Description

Value

"Hydraulic Oil Level"

"OK" or "Not OK"

"Return Hydraulic Oil Filter"

"OK" or "Not OK"

"Hydraulic Oil Temperature"

Degrees

"Hydraulic Fan Speed Percentage"

Percentage

"Hydraulic Fan Bypass Solenoid Current Command"

Amperes

"Engine Coolant Temperature"

Degrees

Note: Table 6 below for Group 5 applies to machines in S/N ranges BDR1-2000, BDM1-2000, BDX1-2000, BCZ1-2000, BDK1-2000, BDY1-2000 and BEB1-2000. Table 6 Machine ECM "Group 5" Description

Value

"Swing Pilot Pressure Switch"

"High" or "Low"

"Operator Swing Brake Momentary Switch Status"

"Depressed" or "Not Depressed"

"Swing Brake Solenoid Status"

"On" or "Off"

"Swing Pump Power Shift Pressure Solenoid Current"

Amperes

Note: Table 7 below for Group 5 applies to machines in S/N ranges BDR2001-UP, BDM2001-UP, BDX2001-UP, BCZ2001-UP, BDK2001-UP, BDY2001-UP, BEB2001-UP, H2A1-UP, H2B1-UP, H2C1-UP, H2D1-UP, H2E1-UP, H2F1-UP and H2G1-UP.

Table 7 Machine ECM "Group 5" Description

Value

"Hyd. Modulation Enable Switch Status"

"Depressed" or "Not Depressed"

"Hyd. Modulation Mode Status"

"Normal/Low/Medium/High"

"Hyd. Modulation Solenoid Current Status"

"Milliampere (mA)"

"Medium Pressure Hyd. Solenoid 1 Current Status"

"Milliampere (mA)"

"Medium Pressure Hyd. Solenoid 2 Current Status"

"Milliampere (mA)"

"Medium Pressure Hyd. Selector Switch Position"

"Offset Boom/Cab Riser/ Steering/Attachment/Not Installed"

"Service Door Position"

"Open" or "Closed"

"Right Joystick Thumbwheel Position"

"-100%" to "+100%"

Left Joystick Trigger Switch Position

"Depressed" or "Not Depressed"

Note: Table 8 below for Group 6 applies to machines in S/N ranges BDR1-2000, BDM1-2000, BDX1-2000, BCZ1-2000, BDK1-2000, BDY1-2000 and BEB1-2000. Table 8 Machine ECM "Group 6" Description

Value

"Travel Solenoid Status"

"On" or "Off"

"Transmission Creeper Gear Solenoid Status"

"Energized" or "Not Energized"

"Travel Enable Solenoid Command"

"On" or "Off"

"Forward Travel Pressure Switch Status"

"On" or "Off"

"Reverse Travel Pressure Switch Status"

"On" or "Off"

"Travel Alarm Command"

"On" or "Off"

"Travel Pedal Lock Command"

"Locked" or "Not Locked"

"Brake Light Status"

"On" or "Off"

Note: Table 9 below for Group 6 applies to machines in S/N ranges BDR2001-UP, BDM2001-UP, BDX2001-UP, BCZ2001-UP, BDK2001-UP, BDY2001-UP, BEB2001-UP, H2A1-UP, H2B1-UP, H2C1-UP, H2D1-UP, H2E1-UP, H2F1-UP and H2G1-UP. Table 9

Machine ECM "Group 6" Description

Value

"Transmission Gear"

"Gear 1/Gear2/Park/Neutral"

"Transmission Creep Function Status"

"Active" or "Inactive"

"Transmission Solenoid 1 Status"

"On" or "Off"

"Transmission Solenoid 2 Status"

"On" or "Off"

"Travel Motor Swash Plate Angle Limit Solenoid Current Status"

"0 Amp" to "65.5 Amp"

"Intended Machine Travel Direction"

"Forward/Reverse/Stop"

"Straight Travel Pedal Position"

"-100%" to "+100%"

"Transmission Output Speed"

"-32736 rpm" to "32767 rpm"

"Ground Speed / Direction"

"-117.8 km/h" to "117.9 km/h"

"Travel Pilot Solenoid Current Status"

"Milliampere (mA)"

"Travel Pedal Lock Command"

"Locked" or "Unlocked"

The items in Group 7 cover all machines with two exceptions which are noted. Table 10 Machine ECM "Group 7" Description

Value

"Low Idle Switch"

"On" or "Off"

"Joystick Button Actuation Status" (2)

"On" or "Off"

"AESC Indicator Enable Status"

"On" or "Off"

"AESC Control Line" (2)

"Active" or "Not Active"

"Operator Fuel Pump Momentary Switch Status"

"Depressed" or "Not Depressed"

"Refueling Pump Relay Command"

"On" or "Off"

"Fuel Gauge"

Percentage

"Power Mode Status"

Mode

(2)

Displayed only for machines in S/N ranges BDR1-2000, BDM1-2000, BDX1-2000, BCZ1-2000, BDK1-2000, BDY1-2000 and BEB1-2000.

The items in Group 8 cover all machines except for noted exceptions. Table 11

Machine ECM "Group 8" Description

Value

"Armrest Position Status"

Down / Not Down

"Forward Travel Pedal Status"

"Depressed" or "Not Depressed"

"Travel Alarm Status" (1)

"On" or "Off"

"Limp Home Switch Status"

"On" or "Off"

"Ignition Switch"

Start / Run / Off

"Parking Brake Solenoid" (1)

"Energized" or "Not Energized"

"Operator Service Brake Pressure Switch Status"

"On" or "Off"

"Brake Pedal"

Released / Not Released

"Brake Light Status"

"On" or "Off"

"Brake Oil Accumulator Pressure Switch"

High / Low / Normal

"Transmission Oil Pressure"

PSI

"Transmission Oil Pressure Status"

High / Low / Normal

(1)

Displayed only for machines in S/N ranges BDR2001-UP, BDM2001-UP, BDX2001-UP, BCZ2001-UP, BDK2001-UP, BDY2001-UP, BEB2001UP, H2A1-UP, H2B1-UP, H2C1-UP, H2D1-UP, H2E1-UP, H2F1-UP and H2G1-UP..

The items in Group 9 cover all machines except for one noted exception. Table 12 Machine ECM "Group 9" Description

Value

"Hydraulic Oil Type" (2)

Type

"Hydraulic Oil Level"

OK / Not OK

"Hydraulic Oil Temperature"

Degrees

"Coolant Level"

OK / Not OK

"Return Hydraulic Oil Filter"

OK / Not OK

"Air Filter Restriction Status"

OK / Not OK

"Machine Overload Pressure Status"

"On" or "Off"

"Engine Coolant Temperature"

Degrees

"Engine Oil Level"

High / Low / Normal

"Engine Oil Pressure Status"

Available / Unavailable

(2)

Displayed only for machines in S/N ranges BDR1-2000, BDM1-2000, BDX1-2000, BCZ1-2000, BDK1-2000, BDY1-2000 and BEB1-2000.

The items in Group 10 cover all machines except for one noted exception. Table 13

Machine ECM "Group 10" Description

Value

"Starter Relay"

"On" or "Off"

"Quick Coupler Pin Engagement Status"

Engaged / Not Engaged

"Quick Coupler Solenoid Status"

"On" or "Off"

"Alternator R Terminal Speed" (1)

Frequency

"Throttle Switch Position"

Percentage

"Engine Speed"

RPM

(1)

Displayed only for machines in S/N ranges BDR2001-UP, BDM2001-UP, BDX2001-UP, BCZ2001-UP, BDK2001-UP, BDY2001-UP, BEB2001UP, H2A1-UP, H2B1-UP, H2C1-UP, H2D1-UP, H2E1-UP, H2F1-UP and H2G1-UP..

TROUBLESHOOTING

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Diagnostic Code List SMCS - 7000-EK; 7490 When the ECM detects an abnormal condition for a certain component in the system, a diagnostic code will be activated for the component. When the ECM activates a diagnostic code for your machine, refer to the corresponding procedure in the Troubleshooting section of this manual for the specific troubleshooting procedure. The following diagnostic code list is for machines with serial number ranges: BEB1-2000 BDK1-2000 BDM1-2000 BDR1-2000 BDX1-2000 BDY1-2000 BCZ1-2000

Table 1 Diagnostic Codes For The Machine ECM MID 039 CID 0096 Fuel Level Sensor FMI 03

Voltage above normal, shorted high

FMI 04

Voltage below normal, shorted low

CID 0127 Transmission Pressure Sensor FMI 03

Voltage above normal, shorted high

FMI 04

Voltage below normal, shorted low

CID 0291 Solenoid (Engine Cooling Fan) FMI 03

Voltage above normal, shorted high

FMI 05

Current below normal, open circuit

FMI 06

Current above normal, grounded circuit

CID 0298 Switch (Service Brake Pedal) FMI 04

Voltage below normal, shorted low

FMI 05

Current below normal, open circuit

CID 0374 Solenoid Valve (Swing Brake)

FMI 03

Voltage above normal, shorted high

FMI 05

Current below normal, open circuit

FMI 06

Current above normal, grounded circuit

CID 0376 Travel Alarm FMI 03

Voltage above normal, shorted high

FMI 05

Current below normal, open circuit

FMI 06

Current above normal, grounded circuit

CID 0444 Magnetic Switch (Start Relay) FMI 03

Voltage above normal, shorted high

FMI 05

Current below normal, open circuit

FMI 06

Current above normal, grounded circuit

CID 0590 Engine Electronic Control Module (ECM) FMI 02

Incorrect, intermittent, erratic data

FMI 09

Abnormal update

FMI 12

Bad device or component

CID 0598 Solenoid Valve (Travel Speed) FMI 03

Voltage above normal, shorted high

FMI 05

Current below normal, open circuit

FMI 06

Current above normal, grounded circuit

CID 0600 Hydraulic Oil Temperature Sensor FMI 03

Voltage above normal, shorted high

FMI 04

Voltage below normal, shorted low

CID 0681 Solenoid Valve (Parking Brake) FMI 03

Voltage above normal, shorted high

FMI 05

Current below normal, open circuit

FMI 06

Current above normal, grounded circuit

CID 0736 Signal for Automatic Engine Speed Control FMI 03

Voltage above normal, shorted high

FMI 06

Current above normal, grounded circuit

CID 0882 Solenoid Valve (Hydraulic Activation) FMI 03

Voltage above normal, shorted high

FMI 05

Current below normal, open circuit

FMI 06

Current above normal, grounded circuit

CID 1180 Solenoid (Auxiliary Hydraulic Number 1) FMI 03

Voltage above normal, shorted high

FMI 05

Voltage below normal, shorted low

FMI 06

Current above normal, grounded circuit

CID 1181 Solenoid (Auxiliary Hydraulic Number 2) FMI 03

Voltage above normal, shorted high

FMI 05

Voltage below normal, shorted low

FMI 06

Current above normal, grounded circuit

CID 1486 Solenoid Valve (Creeper Speed) FMI 03

Voltage above normal, shorted high

FMI 05

Current below normal, open circuit

FMI 06

Current above normal, grounded circuit

CID 1530 Solenoid Valve (Quick Coupler) FMI 03

Voltage above normal, shorted high

FMI 05

Current below normal, open circuit

FMI 06

Current above normal, grounded circuit

CID 1615 Solenoid Valve (One-Way Flow or Two-Way Flow) FMI 03

Voltage above normal, shorted high

FMI 05

Current below normal, open circuit

FMI 06

Current above normal, grounded circuit

CID 1616 Solenoid Valve (Stabilizer) (High Pressure Solenoid) FMI 03

Voltage above normal, shorted high

FMI 05

Current below normal, open circuit

FMI 06

Current above normal, grounded circuit

CID 1617 Solenoid Valve (Oscillating Axle) FMI 03

Voltage above normal, shorted high

FMI 05

Current below normal, open circuit

FMI 06

Current above normal, grounded circuit

CID 1618 Position Sensor (Swashplate Angle) FMI 00

Data Above normal range

FMI 01

Data Below normal range

FMI 03

Voltage above normal, shorted high

FMI 04

Voltage below normal, shorted low

CID 1621 Solenoid Valve (Generator) FMI 03

Voltage above normal, shorted high

FMI 05

Current below normal, open circuit

FMI 06

Current above normal, grounded circuit

CID 1622 Travel Lock Magnet FMI 03

Voltage above normal, shorted high

FMI 05

Current below normal, open circuit

FMI 06

Current above normal, grounded circuit

CID 1623 Brake Lights FMI 03

Voltage above normal, shorted high

FMI 05

Current below normal, open circuit

FMI 06

Current above normal, grounded circuit

CID 1624 Solenoid (Travel) FMI 03

Voltage above normal, shorted high

FMI 05

Current below normal, open circuit

FMI 06

Current above normal, grounded circuit

CID 1628 Armrest Switch FMI 04

Voltage below normal, shorted low

FMI 05

Current below normal, open circuit

CID 1629 Solenoid (Power Shift Pressure for the Main Pump) FMI 03

Voltage above normal, shorted high

FMI 05

Current below normal, open circuit

FMI 06

Current above normal, grounded circuit

CID 1630 Solenoid (Swing Pump) FMI 03

Voltage above normal, shorted high

FMI 05

Current below normal, open circuit

FMI 06

Current above normal, grounded circuit

CID 1670 Limit Switch (Travel Pedal) FMI 04

Voltage below normal, shorted low

FMI 05

Current below normal, open circuit

CID 1683 Relay (Refueling Pump) FMI 03

Voltage above normal, shorted high

FMI 05

Current below normal, open circuit

FMI 06

Current above normal, grounded circuit

CID 1739 Solenoid (Hammer) FMI 03

Voltage above normal, shorted high

FMI 05

Current below normal, open circuit

FMI 06

Current above normal, grounded circuit

The following diagnostic code list is for machines with serial number ranges: (BDX2001-UP) (BCZ2001-UP) (BEB2001-UP) (BDK2001-UP) (BDY2001-UP) (BDR2001-UP) (BDM2001-UP) (H2A1-UP) (H2B1-UP) (H2C1-UP) (H2D1-UP) (H2E1-UP) (H2F1-UP) (H2G1-UP)

Table 2 Diagnostic Codes For The Machine ECM MID 039 CID 0096 Fuel Level Sensor FMI 03

Voltage above normal, shorted high

FMI 04

Voltage below normal, shorted low

CID 0127 Transmission Pressure Sensor FMI 03

Voltage above normal, shorted high

FMI 04

Voltage below normal, shorted low

CID0191 Transmission Output Speed Sensor FMI 02

Data erratic, intermittent or incorrect

FMI 11

Failure mode not identifiable

CID 0291 Solenoid (Engine Cooling Fan) FMI 03

Voltage above normal, shorted high

FMI 05

Current below normal, open circuit

FMI 06

Current above normal, grounded circuit

CID 0298 Switch (Service Brake Pedal) FMI 04

Voltage below normal, shorted low

FMI 05

Current below normal, open circuit

CID 0374 Solenoid Valve (Swing Brake) FMI 03

Voltage above normal, shorted high

FMI 05

Current below normal, open circuit

FMI 06

Current above normal, grounded circuit

CID 0444 Magnetic Switch (Start Relay) FMI 03

Voltage above normal, shorted high

FMI 05

Current below normal, open circuit

FMI 06

Current above normal, grounded circuit

CID 0600 Hydraulic Oil Temperature Sensor FMI 03

Voltage above normal, shorted high

FMI 04

Voltage below normal, shorted low

CID 0727 Medium Pressure Hydraulic Solenoid No. 2 FMI 03

Voltage above normal, shorted high

FMI 05

Current below normal, open circuit

FMI 06

Current above normal, grounded circuit

CID 0882 Solenoid Valve (Hydraulic Activation) FMI 03

Voltage above normal, shorted high

FMI 05

Current below normal, open circuit

FMI 06

Current above normal, grounded circuit

CID 1130 Auxiliary Pedal Position Sensor FMI 03

Voltage above normal, shorted high

FMI 04

Voltage below normal, shorted low

CID 1401 Transmission Solenoid No. 1 FMI 03

Voltage above normal, shorted high

FMI 05

Current below normal, open circuit

FMI 06

Current above normal, grounded circuit

CID 1402 Transmission Solenoid No. 2 FMI 03

Voltage above normal, shorted high

FMI 05

Current below normal, open circuit

FMI 06

Current above normal, grounded circuit

CID 1530 Solenoid Valve (Quick Coupler) FMI 03

Voltage above normal, shorted high

FMI 05

Current below normal, open circuit

FMI 06

Current above normal, grounded circuit

CID 1615 Solenoid Valve (One-Way Flow or Two-Way Flow) FMI 03

Voltage above normal, shorted high

FMI 05

Current below normal, open circuit

FMI 06

Current above normal, grounded circuit

CID 1617 Solenoid Valve (Oscillating Axle) FMI 03

Voltage above normal, shorted high

FMI 05

Current below normal, open circuit

FMI 06

Current above normal, grounded circuit

CID 1621 Solenoid Valve (Generator) FMI 03

Voltage above normal, shorted high

FMI 05

Current below normal, open circuit

FMI 06

Current above normal, grounded circuit

CID 1622 Travel Lock Magnet FMI 03

Voltage above normal, shorted high

FMI 05

Current below normal, open circuit

FMI 06

Current above normal, grounded circuit

CID 1623 Brake Lights FMI 03

Voltage above normal, shorted high

FMI 05

Current below normal, open circuit

FMI 06

Current above normal, grounded circuit

CID 1628 Armrest Switch FMI 04

Voltage below normal, shorted low

FMI 05

Current below normal, open circuit

CID 1629 Solenoid (Power Shift Pressure for the Main Pump) FMI 03

Voltage above normal, shorted high

FMI 05

Current below normal, open circuit

FMI 06

Current above normal, grounded circuit

CID 1630 Solenoid (Swing Pump) FMI 03

Voltage above normal, shorted high

FMI 05

Current below normal, open circuit

FMI 06

Current above normal, grounded circuit

CID 1657 Right Joystick Thumbwheel FMI 03

Voltage above normal, shorted high

FMI 04

Voltage below normal, shorted low

CID 1670 Travel Pedal Limit Switch FMI 04

Voltage below normal, shorted low

FMI 05

Current below normal, open circuit

CID 1739 Solenoid (Hammer) FMI 03

Voltage above normal, shorted high

FMI 05

Current below normal, open circuit

FMI 06

Current above normal, grounded circuit

CID 1842 Auxiliary Valve Pressure Solenoid (Aux Sol. No. 2) FMI 03

Voltage above normal, shorted high

FMI 05

Current below normal, open circuit

FMI 06

Current above normal, grounded circuit

CID 1843 Auxiliary Valve Flow Solenoid (Aux Sol. No. 1) FMI 03

Voltage above normal, shorted high

FMI 05

Current below normal, open circuit

FMI 06

Current above normal, grounded circuit

CID 2104 Travel Motor Swash Plate Angle Limit Solenoid FMI 03

Voltage above normal, shorted high

FMI 05

Current below normal, open circuit

FMI 06

Current above normal, grounded circuit

CID 2142 Straight Travel Pedal Position Sensor FMI 03

Voltage above normal, shorted high

FMI 04

Voltage below normal, shorted low

CID 2149 Travel Pilot Pressure Solenoid FMI 03

Voltage above normal, shorted high

FMI 05

Current below normal, open circuit

FMI 06

Current above normal, grounded circuit

CID 2184 Medium Pressure Hydraulic Solenoid No. 1 FMI 03

Voltage above normal, shorted high

FMI 05

Current below normal, open circuit

FMI 06

Current above normal, grounded circuit

CID 2198 Medium Pressure Switches No. 1, No. 2, No. 3 FMI 02

Data erratic, intermittent or incorrect

CID 2256 Hydraulic Modulation Solenoid FMI 03

Voltage above normal, shorted high

FMI 05

Current below normal, open circuit

FMI 06

Current above normal, grounded circuit

CID 2447 Travel Motor Bypass Solenoid FMI 03

Voltage above normal, shorted high

FMI 05

Current below normal, open circuit

FMI 06

Current above normal, grounded circuit

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Using the Operator Monitor to Determine Diagnostic Codes SMCS - 7490 Active diagnostic codes can be displayed on the monitor. Also, logged diagnostic codes can be displayed. The diagnostic codes correspond to an abnormal condition that is detected by the machine ECM. Active diagnostic codes are recorded in the "ACTIVE ERROR" menu. When a problem is no longer active, the diagnostic code is recorded in the "LOGGED ERROR" menu.

Illustration 1

g00790675

1. In order to view diagnostic codes, enter the password protected service mode. See Systems Operation, "Passwords" for more information. Use the direction keys to select the "ACTIVE ERROR" option on the second line. Note: In order to view logged codes, press the right key (2) when "ACTIVE ERROR" is highlighted. The display will show "LOGGED ERROR".

Illustration 2

g00790676

2. The area that is highlighted in the illustration is showing the number of the error out of the total number of errors that are present.

Illustration 3

g00833798

3. The left arrow key and the right arrow key is used to display the error codes that are active. These keys are used to scroll through the codes. The illustration above shows the "MID-CID-FMI". The "39" is the MID. The "0291" is the CID and the "03" is the FMI. The arrow keys are used to scroll through the active diagnostic codes.

Module Identifier (MID) The module identifier (MID) identifies the electronic control module that detected the diagnostic code. Each electronic control module on the machine has a unique MID. The chart for the Module Identifier (MID) is located on the Electrical System Schematic for your machine. Table 1

Module Identification (MID) Number For The Module 27

Module Power Train ECM

Failure Mode Identifier The codes for the Failure Mode Identifier are defined by the SAE standards. The following list contains a CAT version of definitions. The diagram that follows will help you understand the use of FMI with sensors.

Illustration 4

g00835584

Table 2 Failure Mode Identifier and Message Center Displays FMI

Description of Failure

00

"Data valid but above normal operating range"

01

"Data valid but below normal operating range"

02

"Data erratic, intermittent or incorrect"

03

"Voltage above normal or shorted high"

04

"Voltage below normal or shorted low"

05

"Current below normal or open circuit"

06

"Current above normal or grounded circuit"

07

"Mechanical system not responding properly"

08

"Abnormal frequency, pulse, or period"

09

"Abnormal update"

10

"Abnormal rate of change"

11

"Failure mode not identifiable"

12

"Bad device or component"

13

"Out of calibration"

14

"Not used"

15

"Not used"

16

"Parameter not available"

17

"Module not responding"

18

"Sensor supply fault"

19

"Condition not met"

20

"Not used"

Detailed FMI Explanation FMI 00 "Data Valid But Above Normal Operating Range" - Every electronic control system sets a high limit for the expected operating range of the signal. The high limit includes over range signals. This could be a high temperature. A sensor that is still operating but sending a signal above the expected limit will cause a FMI 00 to be stored. Some of the possible causes of a FMI 00 diagnostic code are listed below. The signal is above normal. The signal is shorted to the +battery. The sensor needs to be calibrated.

This is an example of a sensor that needs calibration. A PWM signal that is at a duty cycle of 80 percent is a valid signal. If the PWM signal has a duty cycle of 81 percent the sensor is still working, but the sensor signal is above the expected signal limits. FMI 01 "Data Valid But Below Normal Operating Range" - Every electronic control system sets a low limit for the expected operating range of the signal. The limit includes signals that are under the lower limit. The low signal could be the oil pressure signal. The sensor is still working but sending a signal below the expected limit will cause a FMI 01 to be stored. Some of the possible causes of a FMI 01 diagnostic code are listed below. The signal is below the normal range. The timing is retarded.

This is an example of a PWM sensor. This sensor is not expected to generate a PWM signal below a duty cycle of 5 percent with zero air pressure. If the sensor generates a signal with a duty cycle of 4 percent when the engine is shutdown. The sensor is still working but sending a signal below the expected limit will cause a FMI 01 to be stored. FMI 02 "Data Erratic, Intermittent or Incorrect" - The signal from a component is present. The control that reads the diagnostic information can not read the signal properly. The signal appears to be gone, unstable or invalid. The data can be correct or incorrect intermittently. Also, this condition relates to communication between controls. This is an example of communication between controls. When the monitoring system is looking for the engine speed from the engine ECM over the CAT Data Link.

There is a faulty connection. The signal is intermittent or erratic. The software has been changed. The signal is noisy. The signal is out of range.

FMI 03 "Voltage Above Normal or Shorted High" - The component or system voltage is higher than the limit. FMI 03 most often relates to a signal circuit. Some of the components that could cause a FMI 03 diagnostic code are listed below. The sensor or the switch is faulty. The harness is damaged. The electronic control has failed.

Some of the possible causes of a FMI 03 diagnostic code are listed below. A sensor that has failed and the voltage output is high. Any wiring harness that has a sensor signal wire shorted to a high voltage. A high voltage is any voltage that is greater than the sensor supply voltage. A wiring harness that has an open circuit in the sensor signal wire will cause the control to pull up. When this occurs the input circuit is pulled up to the supply voltage. A faulty control will also cause a FMI 03. This is very unlikely.

FMI 04 "Voltage Below Normal or Shorted Low" - The component or system voltage is lower than the limit. FMI 04 most often relates to a signal circuit. Some of the components that could cause a FMI 03 diagnostic code are listed below. The sensor or the switch is faulty. The harness is damaged. The electronic control has failed.

Some of the possible causes of a FMI 04 diagnostic code are listed below. A sensor that has failed and the voltage output is low. Any wiring harness that has a sensor signal wire shorted to ground. A faulty control will also cause a FMI 04. This is very unlikely.

FMI 05 "Current Below Normal or Open Circuit" - The current through the component or the system is lower than the limit. FMI 05 is most often related to a driver circuit. Some of the possible causes of a FMI 05 diagnostic code are listed below.

There is an open circuit or a poor harness connection. There is an open relay. There is a switch in the open position.

FMI 06 "Current Above Normal or Grounded Circuit" - The current through the component or the system is higher than the limit. FMI 06 is most often related to a driver circuit. This fault is very similar to FMI 04. Some of the possible causes of a FMI 06 diagnostic code are listed below. There is a short to ground in the harness connection. There is a shorted relay. A faulty control will also cause a FMI 06. This is very unlikely.

FMI 07 "Mechanical System Not Responding Properly" - The control detects a signal that is sent to a mechanical system and the response is not correct. Some of the possible causes of a FMI 07 diagnostic code are listed below. The component responds improperly. The component is stuck in a position. The component has failed. The engine is shut down. The machine is being used improperly.

FMI 08 "Abnormal Frequency, Pulse Width or Period" - This occurs when the signal is not in the expected range. FMI 08 can also relate to a faulty sensor. Some of the possible causes of a FMI 08 diagnostic code are listed below. The harness connections are intermittent or poor. The engine misfired. The signal is noisy due to nearby interference. There are loose mechanical devices.

FMI 09 "Abnormal Update" - This relates to communications on the data link. FMI 09 occurs when a control is not able to get information from another control. Some of the possible causes of a FMI 09 diagnostic code are listed below. The control module is not communicating on the data link correctly. The rate of data transmission is abnormal. The data link has failed. There is a mismatch of software.

FMI 10 "Abnormal Rate of Change" - This relates to a signal that changes too fast. The rate of change is outside of the expected limit. FMI 11 "Failure Mode Not Identifiable" - The control identifies more than one FMI as being responsible for a single failure. Some of the possible causes of a FMI 11 diagnostic code are listed below. There is a mechanical failure. There is damage to multiple circuits.

FMI 12 "Bad Device or Component" - The electronic control sends a signal and the electronic control expects a response. The control receives no response or the response is incorrect. Some of the possible causes of a FMI 12 diagnostic code are listed below. There is a failure of the electronic control. There is a failure on the data link. There are one or more controls with mismatched software.

FMI 13 "Out of Calibration" - The electrical signal is not within limits for a specific mechanical condition. Some of the possible causes of a FMI 13 diagnostic code are listed below. Calibration is required. The data is out of range. FMI 14, 15, and 20 - These codes are not active. FMI 16 "Parameter Not Available" - The control does not support the requested parameter. FMI 17 "Module Not Responding" - The control does not respond to the request for data. FMI 18 "Sensor Supply Failure" - The sensor power supply in the control has failed. FMI 19 "Condition Not Met" - The conditions that are defined by the software were not met.

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Using Caterpillar Electronic Technician to Determine Diagnostic Codes SMCS - 0785-UE Connect the ET to the machine. Turn the key switch to the RUN position. Start the ET. The ET will initiate communications with the Electronic Control Modules on the machine. After communication has been established, the ET will list the Electronic Control Modules on the machine. Choose the desired Electronic Control Module. After the diagnostic codes have been determined with the CAT ET, see the test procedure for the corresponding diagnostic code. Reference: Troubleshooting, "Service Tools" Active Diagnostic Codes

Illustration 1

g00859671

Typical ET screen for active diagnostic codes

The following procedures may cause new diagnostic codes to be logged. Therefore, before any procedures are performed make a list of all the active diagnostic codes in order to determine the system problems. Clear the diagnostic codes that were caused by the procedure, when each procedure is complete. Note: Before performing a procedure, always check all the circuit breakers. Repair the cause of any circuit breaker that is tripped. A screen is provided in ET for active diagnostic codes. The screen will display the diagnostic codes that are active. Active diagnostic information shall include a component identifier (CID), a failure mode identifier (FMI) and a text description of the

problem. Logged Diagnostic Codes

Illustration 2

g00859762

Typical ET screen for logged diagnostic codes

A screen is provided in ET for logged diagnostic codes. The screen will display diagnostic codes that are logged. The ET will log diagnostic codes that are intermittent. The logged diagnostic data shall include a component identifier (CID), a failure mode identifier (FMI), and a text description of the problem. Also, the logged diagnostic data shall include the number of occurrences of the problem and two time stamps. The time stamp displays the first occurrence of the problem and the time stamp displays the most recent occurrence of the problem. Diagnostics are logged in non-volatile memory. On powerup, the ECM will clear any diagnostic codes that have not been detected or active within the last 150 hours of machine operation.

TROUBLESHOOTING

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TROUBLESHOOTING

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MID 039 - CID 0096 - FMI 03 SMCS - 1273-038-UN Conditions Which Generate This Code:

Illustration 1 Schematic of the fuel level sender

g00840560

This diagnostic code is recorded when the machine ECM reads the signal voltage of the fuel level sender and the voltage is too high. The possible causes of this diagnostic code are listed here: The sender has failed. The return circuit of the sender is open in the machine harness. The signal circuit in the machine harness is shorted to a source of positive voltage. The signal circuit in the machine harness is open or the sender is disconnected. The machine ECM has failed. This is unlikely.

System Response: This failure causes the fuel gauge to always indicate an empty fuel tank or the fuel gauge may intermittently indicate an empty fuel tank. Test Step 1. CHECK THE CONTROL AND THE HARNESS. A. Turn the disconnect switch and the key start switch to the ON position. B. Disconnect the machine harness connector from the fuel level sender. C. At the machine harness connector for the sender, measure the voltage (DCV) between the signal contact 1 (wire 447-PK) and the return contact 2 (wire G939-PK).

Expected Result: The voltage is between 4.5 and 8.0 DCV. Results: OK - The voltage is between 4.5 and 8.0 DCV. The machine ECM and the harness are correct. Repair: Replace the sender. Stop. NOT OK - The voltage is not between 4.5 and 8.0 DCV. The machine ECM or the harness has failed. Proceed to Test Step 2. Test Step 2. CHECK THE RETURN CIRCUIT OF THE HARNESS. A. The sender remains disconnected. B. Turn the disconnect switch (if equipped) and the key start switch to the OFF position. C. Disconnect the J1 and J2 machine harness connectors from the machine ECM. D. Measure the resistance of the return circuit between contact 2 (wire G939-PK) of the machine harness for the sender and contact J1-12 of the machine harness for the machine ECM. Expected Result: The resistance is less than 5.0 ohms. Results: OK - The resistance is less than 5.0 ohms. The harness resistance is correct. Proceed to Test Step 3. NOT OK - The resistance is greater than 5.0 ohms. The ground circuit in the harness has failed. There is an open circuit between the ground contact and frame ground. Repair: Repair the machine harness or replace the machine harness. Stop. Test Step 3. CHECK FOR A SHORTED HARNESS. A. The sender and the machine ECM remain disconnected from the machine harness. B. The disconnect switch and the key start switch remain in the OFF position. C. At the machine harness connector for the sender, measure the resistance between the signal contact 1 (wire 447-PK) and the +battery circuit at the contact J1-51 of the machine harness connector for the machine ECM. Expected Result: The resistance is greater than 5000 ohms. Results: OK - The resistance is greater than 5000 ohms. The machine ECM has failed. Repair: It is unlikely that an ECM has failed. Exit this procedure. Perform this CID 0096 FMI 03 procedure again. If the failure is not found, replace the machine ECM. Refer to the Testing and Adjusting, "Electronic Control Module (ECM) Replace". Stop. NOT OK - The resistance is less than 5000 ohms. The machine harness has failed. There is a short between the +battery circuit and the signal circuit in the machine harness. Repair: Repair the machine harness or replace the machine harness.

Stop.

TROUBLESHOOTING

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TROUBLESHOOTING

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MID 039 - CID 0096 - FMI 04 SMCS - 1273-038-UN Conditions Which Generate This Code:

Illustration 1

g00840560

This diagnostic code is recorded when the machine ECM reads the signal voltage of the fuel level sender and the voltage is too low. The possible causes of this failure are listed here: The senderhas failed. The signal circuit in the machine harness is shorted to ground. The machine ECM has failed. This is unlikely.

This failure causes the fuel gauge to always indicate an empty fuel tank or the fuel gauge may intermittently indicate an empty fuel tank. Test Step 1. CHECK THE SENDER. A. Disconnect the machine harness from the sender. Expected Result: The diagnostic code changes from CID 0096 FMI 04 to CID 0096 FMI 03. Results: OK - The diagnostic code changed from CID 0096 FMI 04 to CID 0096 FMI 03. This indicates that the failure is no longer present. The sender has failed. Repair: Replace the sender. Stop.

NOT OK - The diagnostic code remains. The failure remains present. The sender is not causing the failure. Proceed to test step 2. Test Step 2. CHECK THE HARNESS. A. The sender remains disconnected from the machine harness. B. Turn the disconnect switch and the key start switch to the OFF position. C. Disconnect the J1 and J2 machine harness connectors from the machine ECM. D. At the machine harness connector for the sender, measure the resistance between the signal contact 1 (wire 447-PK) and frame ground. Expected Result: The resistance is greater than 5000 ohms. Results: OK - The resistance is greater than 5000 ohms. The harness circuit resistance is correct. The machine ECM has failed. Repair: It is unlikely that the ECM has failed. Exit this procedure, and perform this procedure again. If the failure is not found, replace the ECM. See Testing and Adjusting, "Electronic Control Module (ECM) - Replace". Stop. NOT OK - The resistance is less than 5000 ohms. The machine harness has failed. There is a short between frame ground and the signal circuit in the machine harness. Repair: Repair the machine harness or replace the machine harness. Stop.

TROUBLESHOOTING

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MID 039 - CID 0127 - FMI 03 SMCS - 3080-038-PXS Conditions Which Generate This Code:

Illustration 1

g00840570

Schematic of the Sensor (transmission oil pressure)

This diagnostic code is associated with the Sensor (transmission oil pressure). The FMI 03 means that the machine ECM has determined that the voltage of the circuit for the sensor is above normal. Refer to Systems Operation, "Sensors" for information regarding the operation of the sensor and the location. The output of the transmission oil pressure sensor is an analog signal from 0.45 to 4.5 DCV. The voltage changes as the pressure changes. The machine ECM recognizes a voltage in the range of 0.45 DCV to 4.5 DCV as valid input from the sensor. If the voltage is below 0.45 DCV, the machine ECM determines that the sensor is shorted to ground. If the voltage is above 4.5 DCV, the machine ECM determines that the sensor is shorted to the + battery. The possible causes of this diagnostic code are listed below: The signal circuit for the sensor is open. The signal circuit for the sensor is shorted to the +battery circuit. The sensor has failed. The power circuit or the ground circuit has failed. The machine ECM has failed. This is unlikely.

Note: The following test procedure may create other diagnostic codes. Ignore these created diagnostic codes and clear the diagnostic codes when the original diagnostic code has been corrected. Ensure that the diagnostic code of CID 0127 FMI 03 is active before performing this procedure.

Note: Use the 146-4080 Digital Multimeter for the measurements in this procedure. System Response: When this diagnostic code occurs, the machine ECM will disable travel. The machine ECM will disable the travel pedal's lock by not energizing the magnet that locks the travel pedal. The Electronic Technician will display"Abnormal/Incorrect Data" parameter for the Transmission Oil Pressure. Test Step 1. CHECK FOR POWER AT THE SENSOR. A. Do not disconnect the harness connector from the sensor. B. Turn the key start switch and the disconnect switch to the ON position. C. At the back of the harness connector for the sensor, insert a 7X-1710 Multimeter Probe along the voltage supply wire (contact A). D. Measure the voltage from contact 1 to frame ground. Expected Result: The voltage is +5 DCV. Results: OK - The voltage is +5 DCV. Proceed to Test Step 2. NOT OK - The voltage is not +5 DCV. The + battery circuit in the machine harness has failed. Repair: Replace the machine harness or repair the machine harness. Stop. Test Step 2. CHECK FOR PROPER GROUND AT THE SENSOR. A. The machine harness remains connected to the sensor. B. Turn the key start switch and the disconnect switch to the OFF position. C. Remove the 7X-1710 Multimeter Probe from the voltage supply wire (contact A). D. At the back of the harness connector for the sensor, insert a 7X-1710 Multimeter Probe along the ground wire (contact B). E. Measure the resistance from contact B to frame ground. Expected Result: The resistance is less than 5 ohms. Results: OK - The resistance is less than 5 ohms. The ground circuit is correct. Proceed to Test Step 3. NOT OK - The resistance is greater than 5 ohms. The ground circuit in the machine harness has failed. Repair: Replace the machine harness or repair the machine harness. Stop. Test Step 3. CHECK THE WIRING HARNESS OF THE SENSOR FOR AN OPEN CIRCUIT. A. The key start switch and the disconnect switch remain in the OFF position. B. Disconnect the machine harness from the sensor. C. At the harness connector for the sensor, connect a jumper wire between contact B and contact C. D. Disconnect the machine harness connector(s) from the machine ECM.

D. E. At the harness connector for the machine ECM, measure the resistance between contact J1-52 (wire G428-BU) and contact J1-12 (wire G939-PK). Expected Result: The resistance measurement is less than 5 ohms. Results: OK - The resistance measurement is less than 5 ohms. The circuit is correct. Proceed to Test Step 4. NOT OK - The resistance is greater than 5 ohms. The circuit is not correct. There is an open circuit in the wiring harness. Repair: There is an open circuit in the wiring harness. Repair the wiring harness or replace the wiring harness. Stop. Test Step 4. CHECK THE WIRING HARNESS OF THE SENSOR FOR A SHORT TO THE +BATTERY CIRCUIT. A. The key start switch and the disconnect switch remain in the OFF position. B. The machine harness remains disconnected from the sensor. Remove the jumper wire that was installed in the previous step. C. The machine harness connector(s) remains disconnected from the machine ECM. D. At the machine harness connector for the machine ECM, measure the resistance from the signal contact J1-52 (wire G428BU) of the machine harness to all contacts that are used in the machine harness connectors for the machine ECM. Expected Result: Each resistance measurement is greater than 5000 ohms. Results: OK - Each resistance measurement is greater than 5000 ohms. The machine harness is correct. Proceed to Test Step 5. NOT OK - One or more resistance measurements is not correct. There is a short in the machine harness. Repair: The short is between signal contact J1-52 (wire G428-BU) and the circuit with the low resistance measurement. Repair the machine harness or replace the machine harness. Stop. Test Step 5. CHECK THE OUTPUT OF THE SENSOR. A. Reconnect the machine harness connectors to the machine ECM. Reconnect the machine harness connector to the sensor. B. At the back of the harness connector for the sensor, insert a 7X-1710 Multimeter Probe along the signal wire (contact C). C. At the back of the harness connector for the sensor, insert a 7X-1710 Multimeter Probe along the ground wire (contact B). D. Turn the disconnect switch and the key start switch to the ON position. E. Measure the signal of the sensor. The proper signal is described at the beginning of this procedure. Expected Result: The signal from the sensor is valid. Results: OK - The signal from the sensor is valid. Proceed to Test Step 6.

NOT OK - The signal from the sensor is not valid. Repair: The sensor has failed. Replace the sensor. Stop. Test Step 6. CHECK IF THE DIAGNOSTIC CODE REMAINS. A. Inspect the contacts of the harness connectors and clean the connectors. B. Reconnect all harness connectors. C. Turn the disconnect switch and the key start switch to the ON position. D. Operate the machine. E. Check the status of the CID 0127 FMI 03. Expected Result: The CID 0127 FMI 03 is active. Results: YES - The CID 0127 FMI 03 is active. The diagnostic code has not been corrected. The machine ECM may have failed. Repair: It is unlikely that the machine ECM has failed. Exit this procedure and perform this procedure again. If the cause of the diagnostic code is not found, replace the machine ECM. See Testing and Adjusting, "Electronic Control Module (ECM) - Replace". Stop. NO - The CID 0127 FMI 03 is not active. The diagnostic code does not exist at this time. Repair: The initial diagnostic code was probably caused by a poor electrical connection or a short at one of the harness connectors that was disconnected and reconnected. Resume normal machine operation. Stop.

TROUBLESHOOTING

011

TROUBLESHOOTING

i01901013

MID 039 - CID 0127 - FMI 04 SMCS - 3080-038-PXS Conditions Which Generate This Code:

Illustration 1

g00840570

Schematic of the Sensor (transmission oil pressure)

This diagnostic code is associated with the Sensor (transmission oil pressure). The FMI 04 means that the machine ECM has determined that the voltage of the circuit for the position sensor is below normal. The input voltage of 0.45 DCV to 4.5 DCV from the sensor corresponds to a pressure of 102.1 kPa to 5694.9 kPa. Any pressure in the range will be recognized by the machine ECM. The machine ECM will consider the pressure to be within the normal operating range. The possible causes of this diagnostic code are listed below: The signal circuit for the sensor is shorted to ground. The sensor has failed. The machine ECM has failed. This is unlikely.

Note: The following test procedure may create other diagnostic codes. Ignore these created diagnostic codes and clear the diagnostic codes when the original diagnostic code has been corrected. Ensure that the diagnostic code of CID 0127 FMI 04 is active before performing this procedure. Note: Use the 146-4080 Digital Multimeter for the measurements in this procedure. System Response: When this diagnostic code occurs, the machine ECM will disable travel. The machine ECM will not supply power to the solenoid (travel). The machine ECM will disable the travel pedal's lock by not energizing the magnet that locks the travel pedal. The Electronic Technician will display "Abnormal/Incorrect Data" parameter for the Transmission Oil Pressure. Test Step 1. CHECK THE SENSOR.

A. Turn the disconnect switch and the key start switch to the ON position. B. Ensure that the diagnostic code is active. C. Observe the status of the diagnostic code. Disconnect the sensor from the machine harness. Expected Result: The CID 0127 FMI 04 remains active. The FMI has not changed and the "04" is still active. Results: OK - The diagnostic code remains active. The sensor is correct. Proceed to Test Step 2. NOT OK - The diagnostic code is no longer active. The sensor has failed. Repair: Replace the sensor. Stop. Test Step 2. CHECK THE WIRING HARNESS OF THE SENSOR FOR A SHORT TO GROUND. A. Turn the key start switch and the disconnect switch to the OFF position. B. Disconnect the machine harness from the sensor. C. Disconnect the machine harness connector(s) from the machine ECM. D. At the machine harness connector for the machine ECM, measure the resistance from the signal contact J1-52 (wire G428BU) of the machine harness to all possible sources of ground. Measure the resistance to all contacts of the machine harness connectors for the machine ECM. Expected Result: Each resistance measurement is greater than 5000 ohms. Results: OK - Each resistance measurement is greater than 5000 ohms. The machine harness is correct. Proceed to Test Step 3. NOT OK - One or more resistance measurements is not correct. There is a short in the machine harness. Repair: The short is between signal contact J1-52 (wire G428-BU) and the circuit with the low resistance measurement. Repair the machine harness or replace the machine harness. Stop. Test Step 3. CHECK IF THE DIAGNOSTIC CODE REMAINS. A. Inspect the contacts of the harness connectors and clean the contacts. B. Reconnect all harness connectors. C. Turn the disconnect switch and the key start switch to the ON position. D. Operate the machine. E. Check the status of the CID 0127 FMI 04. Expected Result: The CID 0127 FMI 04 is active. Results:

YES - The CID 0127 FMI 04 is active. The diagnostic code has not been corrected. The machine ECM may have failed. Repair: It is unlikely that the machine ECM has failed. Exit this procedure and perform this procedure again. If the cause of the diagnostic code is not found, replace the machine ECM. See Testing and Adjusting, "Electronic Control Module (ECM) - Replace". Stop. NO - The CID 0127 FMI 04 is not active. The diagnostic code does not exist at this time. Repair: The initial diagnostic code was probably caused by a poor electrical connection or a short at one of the harness connectors that was disconnected and reconnected. Resume normal machine operation. Stop.

TROUBLESHOOTING

012

TROUBLESHOOTING

i02282343

MID 039 - CID 0191 - FMI 02 SMCS - 3175-038 Conditions Which Generate This Code:

Illustration 1

g01142298

Schematic of the speed sensor (transmission output)

This diagnostic code is recorded when the ECM compares certain machine conditions and the data received from the sensor. The ECM will issue this diagnostic code if the sensor data is not within certain parameters. Sensor Data must be outside of the expected parameters for at least 10 seconds in order for this diagnostic code to be issued. If the transmission speed is between 0 rpm and 200 rpm when the sensor fails, then a CID 0191 FMI 11 code will be logged. If the transmission speed is above 200 rpm when the sensor fails, then a CID 0191 FMI 02 code will be logged. Possible sensor conditions that can cause this diagnostic code are listed: The signal circuit is shorted to ground. The transmission output speed sensor is not installed correctly. The transmission output speed sensor has failed. The ECM has failed. This is unlikely.

System Response: When the CID 0191 FMI 02 diagnostic code is active. Machine response will be: The warning indicator on the Monitor will flash. The machine "Limp Home Mode" will be activated. The transmission will only operate in first gear.

Machine functions will be limited.

Note: Before performing the following Test Steps, check to see that the speed sensor is mounted securely. If the speed sensor mount is correct and the CID 0191 FMI 02 code is active, proceed to Test Step 1. Test Step 1. CHECK THE RESISTANCE OF THE CASE OF THE SENSOR . A. Turn the key start switch and the disconnect switch (if equipped) to the OFF position. B. Disconnect the machine harness connector from the sensor. C. Measure the resistance from contact 2 (wire 768-OR) and from contact 1 (wire 308-YL) to the case of the sensor. Expected Result: The resistance is greater than 10,000 ohms. Results: OK - The resistance is greater than 10,000 ohms. Proceed to Test Step 2. NOT OK - The resistance is NOT greater than 10,000 ohms. The speed sensor has failed. Repair: Replace the sensor. Stop. Test Step 2. CHECK THE RESISTANCE OF THE SENSOR. A. The machine harness connector remains disconnected. B. Measure the resistance between contact 2 (wire 768-OR) and contact 1 (wire 308-YL) of the connector of the sensor. Expected Result: The resistance is approximately 140 ohms. Results: OK - The resistance is approximately 140 ohms. The resistance is correct. Proceed to Test Step 3. NOT OK - The resistance is NOT approximately 140 ohms. The resistance is not correct. The sensor has failed. Repair: Replace the sensor. Stop. Test Step 3. CHECK FOR AN OPEN WIRE IN THE MACHINE HARNESS. A. The key start switch and the disconnect switch (if equipped) remain in the OFF position. B. Reconnect the machine harness connector to the sensor. C. Disconnect the machine harness ECM connector J1 from the ECM. D. At the machine harness ECM connector, measure the resistance from contact J1-24 (wire 768-OR) to J1-58 (wire 308YL). Expected Result: The resistance is approximately 140 ohms. Results:

OK - The resistance is approximately 140 ohms. The circuit is correct. Proceed to Test Step 4. NOT OK - The resistance is NOT approximately 140 ohms. The circuit is open in the machine harness. Repair: Repair the machine harness or replace the machine harness. Stop. Test Step 4. CHECK FOR A SHORT IN THE RETURN CIRCUIT OF THE MACHINE HARNESS. A. The key start switch and the disconnect switch (if equipped) remain in the OFF position. B. Disconnect the machine harness from the sensor. C. At the machine harness connector, measure the resistance between contacts J1-24 and J1-58 to all sources of ground. Expected Result: Each resistance measurement is greater than 5000 ohms. Results: OK - Each resistance measurement is greater than 5000 ohms. Proceed to Test Step 5. NOT OK - There is a short in the machine harness. Repair: Repair the machine harness or replace the machine harness. Stop. Test Step 5. CHECK THE SENSOR GROUND The sensor remains disconnected from the machine harness. The key start switch and the disconnect switch (if equipped) remain in the OFF position. A. At the machine harness connector for the sensor, check the resistance between ground contact 3 (wire 200-BK) and frame ground. Expected Result: The resistance should measure 5 ohms or less. Results: OK - The resistance measurement is 5 ohms or less. Proceed to Test Step 6. NOT OK - The resistance measurement is GREATER than 5 ohms. Repair: The ground circuit for the speed sensor is not correct. The ground connection is faulty. Repair the machine harness or replace the machine harness. Stop. Test Step 6. CHECK IF THE DIAGNOSTIC CODE REMAINS A. Inspect the contacts of the harness connectors and clean the contacts. B. Reconnect all harness connectors. C. Turn the disconnect switch (if equipped) and the key start switch to the ON position. D. Operate the machine. E. Check for an active diagnostic code of CID 0191 FMI 02.

Expected Result: The diagnostic code of CID 0191 FMI 02 is not active. Results: OK - The diagnostic code of CID 0191 FMI 02 is not active. The failure is no longer present. Repair: The diagnostic code was probably caused by a poor electrical connection or a short at one of the harness connections that was disconnected and reconnected. Resume normal machine operation. Stop. NOT OK - The diagnostic code of CID 0191 FMI 02 is active. The failure has not been corrected. The ECM has failed. Repair: It is unlikely that the ECM has failed. Exit this procedure and perform this procedure again. If the cause of the failure is not found then replace the ECM. Stop.

TROUBLESHOOTING

013

TROUBLESHOOTING

i02282490

MID 039 - CID 0191 - FMI 11 SMCS - 3175-038 Conditions Which Generate This Code:

Illustration 1

g01142367

Schematic of the speed sensor (transmission output)

This diagnostic code is recorded when the ECM compares certain machine conditions and the data received from the sensor. The ECM will issue this diagnostic code if the sensor data is not within certain parameters. Sensor Data must be outside of the expected parameters for at least 10 seconds in order for this diagnostic code to be issued. If the transmission speed is between 0 rpm and 200 rpm when the sensor fails, then a CID 0191 FMI 11 code will be logged. If the transmission speed is above 200 rpm when the sensor fails, then a CID 0191 FMI 02 code will be logged. Possible sensor conditions that can cause this diagnostic code are listed: The signal circuit is shorted to ground. The transmission output speed sensor is not installed correctly. The transmission output speed sensor has failed. The ECM has failed. This is unlikely.

System Response: When the CID 0191 FMI 11 diagnostic code is active. Machine response will be: The warning indicator on the Monitor will flash. The machine "Limp Home Mode" will be activated. The transmission will only operate in first gear.

Machine functions will be limited.

If the diagnostic code for the sensor supply is present, correct the diagnostic code prior to troubleshooting the CID 0191 FMI 11. Before the diagnostic code becomes active, the machine must be operated in second gear. Ensure that the CID 0191 FMI 11 is active. Test Step 1. CHECK THE RESISTANCE OF THE CASE OF THE SENSOR A. Turn the key start switch and the disconnect switch (if equipped) to the OFF position. B. Disconnect the machine harness connector from the sensor. C. Measure the resistance from contact 2 (wire 768-OR) and from contact 1 (wire 308-YL) to the case of the sensor. Expected Result: The resistance is greater than 10,000 ohms. Results: OK - The resistance is greater than 10,000 ohms. Proceed to Test Step 2. NOT OK - The resistance is NOT greater than 10,000 ohms. The speed sensor has failed. Repair: Replace the sensor. Stop. Test Step 2. CHECK THE RESISTANCE OF THE SENSOR A. The machine harness connector remains disconnected. B. Measure the resistance between contact 2 (wire 768-OR) and contact 1 (wire 308-YL) of the connector of the sensor. Expected Result: The resistance is approximately 140 ohms. Results: OK - The resistance is approximately 140 ohms. The resistance is correct. Proceed to Test Step 3. NOT OK - The resistance is NOT approximately 140 ohms. The resistance is not correct. The sensor has failed. Repair: Replace the sensor. Stop. Test Step 3. CHECK FOR AN OPEN WIRE IN THE MACHINE HARNESS A. The key start switch and the disconnect switch (if equipped) remain in the OFF position. B. Reconnect the machine harness connector to the sensor. C. Disconnect the machine harness connector J1 from the ECM. D. At the machine harness ECM connector, measure the resistance from contact J1-24 (wire 768-OR) to J1-58 (wire 308YL). Expected Result: The resistance is approximately 140 ohms. Results:

OK - The resistance is approximately 140 ohms. The circuit is correct. Proceed to Test Step 4. NOT OK - The resistance is NOT approximately 140 ohms. The circuit is open in the machine harness. Repair: Repair the machine harness or replace the machine harness. Stop. Test Step 4. CHECK FOR A SHORT IN THE RETURN CIRCUIT OF THE MACHINE HARNESS A. The key start switch and the disconnect switch (if equipped) remain in the OFF position. B. Disconnect the machine harness from the sensor. C. At the machine harness connector, measure the resistance between contacts J1-24 and J1-58 to all sources of ground. Expected Result: Each resistance measurement is greater than 5000 ohms. Results: OK - Each resistance measurement is greater than 5000 ohms. Proceed to Test Step 5. NOT OK - One or more of the resistance measurements is less than 5000 ohms. There is a short in the machine harness. Repair: Repair the machine harness or replace the machine harness. Stop. Test Step 5. CHECK THE SENSOR GROUND CIRCUIT The sensor remains disconnected from the machine harness. The key start switch and the disconnect switch (if equipped) remain in the OFF position. A. At the machine harness connector for the sensor, check the resistance between ground contact 3 (wire 200-BK) and frame ground. Expected Result: The resistance should measure 5 ohms or less. Results: OK - The resistance measurement is 5 ohms or less. Proceed to Test Step 6. NOT OK - The resistance measurement is GREATER than 5 ohms. Repair: The ground circuit for the speed sensor is not correct. The ground connection is faulty. Repair the machine harness or replace the machine harness. Stop. Test Step 6. CHECK IF THE DIAGNOSTIC CODE REMAINS A. Inspect the contacts of the harness connectors that are used in the solenoid circuit. Ensure that the contacts are secure. Clean all of the contacts in the harness connectors. B. Reconnect all harness connectors. C. Turn the disconnect switch (if equipped) and the key start switch to the ON position. D. Operate the machine. E. Check for an active diagnostic code of CID 0191 FMI 11.

E. Expected Result: The diagnostic code of CID 0191 FMI 11 is not active. Results: OK - The diagnostic code of CID 0191 FMI 11 is not active. The failure is no longer present. Repair: The diagnostic code was probably caused by a poor electrical connection or a short at one of the harness connections that was disconnected and reconnected. Resume normal machine operation. Stop. NOT OK - The diagnostic code of CID 0191 FMI 11 is active. The failure has not been corrected. The ECM has failed. Repair: It is unlikely that the ECM has failed. Exit this procedure and perform this procedure again. If the cause of the failure is not found then replace the ECM. Stop.

TROUBLESHOOTING

014

TROUBLESHOOTING

i01792692

MID 039 - CID 0291 - FMI 03 SMCS - 1359-038-OD Conditions Which Generate This Code:

Illustration 1

g00840395

Schematic of the Solenoid (engine cooling fan)

This diagnostic code is associated with the Solenoid (engine cooling fan). The FMI 03 means that the machine ECM has determined that the voltage of the solenoid circuit is above normal. The possible causes of the diagnostic code are listed: The solenoid has failed. The energize circuit of the solenoid is shorted to the +battery circuit. The machine ECM has failed. This is unlikely.

Note: The following test procedure may create other diagnostic codes. Ignore these created diagnostic codes and clear these diagnostic codes when the original diagnostic code has been corrected. Ensure that the diagnostic code of CID 0291 FMI 03 is active before performing this procedure. Note: Use the 146-4080 Digital Multimeter for the measurements in this procedure. System Response: When this diagnostic code is active, the machine ECM will not be able to control the solenoid. The engine cooling fan solenoid will receive maximum current. This current causes the engine cooling fan to rotate at minimum fan speed. Test Step 1. CHECK THE ENERGIZE CIRCUIT OF THE SOLENOID FOR A SHORT TO THE +BATTERY CIRCUIT. A. Turn the key start switch and the disconnect switch to the OFF position. B.

A. B. Disconnect the machine harness connectors from the solenoid and the machine ECM. C. At the machine harness connector for the machine ECM, measure the resistance from contact J2-24 (wire C411-OR) to all contacts that are used in the machine harness connectors for the machine ECM. Expected Result: Each resistance measurement is greater than 5000 ohms. Results: OK - Each resistance measurement is greater than 5000 ohms. The machine harness is correct. Proceed to Test Step 2. NOT OK - Each resistance measurement is not greater than 5000 ohms. There is a short in the machine harness. The short is between J2-24 (C411-OR) and the circuit that has a low resistance measurement. Repair: Repair the machine harness or replace the machine harness. Stop. Test Step 2. CHECK IF THE DIAGNOSTIC CODE IS STILL ACTIVE. A. Inspect the contacts and clean the contacts of the harness connectors. B. Reconnect all harness connectors. C. Turn the disconnect switch and the key start switch to the ON position. D. Operate the machine. E. Determine if the CID 0291 FMI 03 is active. Expected Result: The CID 0291 FMI 03 is active. Results: YES - The CID 0291 FMI 03 is active. The problem has not been corrected. The machine ECM may have failed. Repair: It is unlikely that the machine ECM has failed. Exit this procedure and perform this procedure again. If the cause of the diagnostic code is not found, replace the machine ECM. See Testing and Adjusting, "Electronic Control Module (ECM) - Replace". Stop. NO - The CID 0291 FMI 03 is not active. The problem does not exist at this time. Repair: The initial diagnostic code was probably caused by a poor electrical connection or a short at one of the harness connectors that was disconnected and reconnected. Resume normal machine operation. Stop.

TROUBLESHOOTING

015

TROUBLESHOOTING

i01792703

MID 039 - CID 0291 - FMI 05 SMCS - 1359-038-OD Conditions Which Generate This Code:

Illustration 1

g00840395

Schematic of the Solenoid (engine cooling fan)

This diagnostic code is associated with the Solenoid (engine cooling fan). The FMI 05 means that the machine ECM has determined that the current of the solenoid is below normal. The possible causes of this diagnostic code are listed below: The energize circuit of the solenoid is open. The return circuit of the solenoid is open. The solenoid has failed. The machine ECM has failed. This is unlikely.

Note: The following test procedure may create other diagnostic codes. Ignore these created diagnostic codes and clear these diagnostic codes when the original diagnostic code has been corrected. Ensure that the diagnostic code of CID 0291 FMI 05 is active before performing this procedure. Note: Use the 146-4080 Digital Multimeter for the measurements in this procedure. System Response: When this diagnostic code is active, the machine ECM will not be able to control the solenoid. The solenoid (demand fan) will not receive current. This causes the demand fan to rotate at maximum fan speed. Test Step 1. CHECK THE SOLENOID. A. Turn the disconnect switch and the key start switch to the ON position. Do not start the engine. B.

A. B. Disconnect the solenoid with the active diagnostic code from the machine harness. C. At the machine harness connector for the solenoid, place a jumper wire from contact 1 (wire C411-OR) to contact 2 (wire H804-GN). D. Observe the status of the CID 0291 FMI 05. Expected Result: The CID 0291 FMI 05 remains active. The FMI has not changed and the "05" is still active. Results: YES - The diagnostic code remains active. The jumper wire does not affect the diagnostic code. Proceed to Test Step 2. NO - The diagnostic is no longer active. The solenoid has failed. Repair: The solenoid has failed. Repeat this Test Step "CHECK THE SOLENOID" in order to verify the solenoid failure. Replace the solenoid. Verify that the new solenoid corrects the problem. Stop. Test Step 2. CHECK THE HARNESS FOR AN OPEN. A. Turn the key start switch and the disconnect switch to the OFF position. B. Disconnect the machine harness connector(s) from the machine ECM. C. The jumper wire that was installed in the previous Test Step remains in place. D. At the machine harness connector, measure the resistance from signal contact J2-24 (wire C411-OR) to contact J2-13 (wire H804-GN). Expected Result: The resistance is less than 5.0 ohms. Results: OK - The resistance is less than 5.0 ohms. The machine harness is correct. Proceed to Test Step 3. NOT OK - The resistance is greater than 5000 ohms. The resistance measurement is not correct. There is an open circuit in the machine harness. Repair: The open is in wire C411-OR or in wire H804-GN of the machine harness. Repair the machine harness or replace the machine harness. Stop. Test Step 3. CHECK IF THE DIAGNOSTIC CODE REMAINS. A. Inspect the contacts of the harness connectors and clean the harness connectors. B. Reconnect all harness connectors. C. Turn the disconnect switch and the key start switch to the ON position. D. Operate the machine. E. Check the status of the CID 0291 FMI 05. Expected Result: The CID 0291 FMI 05 is active.

Results: YES - The CID 0291 FMI 05 is active. The diagnostic code has not been corrected. The machine ECM may have failed. Repair: It is unlikely that the machine ECM has failed. Exit this procedure and perform this procedure again. If the cause of the diagnostic code is not found, replace the machine ECM. See Testing and Adjusting, "Electronic Control Module (ECM) - Replace". Stop. NO - The CID 0291 FMI 05 is not active. The diagnostic code does not exist at this time. Repair: The initial diagnostic code was probably caused by a poor electrical connection or a short at one of the harness connectors that was disconnected and reconnected. Resume normal machine operation. Stop.

TROUBLESHOOTING

016

TROUBLESHOOTING

i01792711

MID 039 - CID 0291 - FMI 06 SMCS - 1359-038-OD Conditions Which Generate This Code:

Illustration 1

g00840395

Schematic of the Solenoid (engine cooling fan)

This diagnostic code is associated with the Solenoid (engine cooling fan). The FMI 06 means that the machine ECM has determined that the current of the solenoid is above normal. The possible causes of this diagnostic code are listed: The energize circuit of the solenoid is shorted to ground. The solenoid has failed. The machine ECM has failed. This is unlikely.

Note: The following test procedure may create other diagnostic codes. Ignore these created diagnostic codes and clear these diagnostic codes when the original diagnostic code has been corrected. Ensure that the diagnostic code of CID 0291 FMI 06 is active before performing this procedure. Note: Use the 146-4080 Digital Multimeter for the measurements in this procedure. System Response: When this diagnostic code is active, the machine ECM will not be able to control the solenoid. The solenoid (demand fan) will not receive current. This causes the demand fan to rotate at the maximum fan speed. Test Step 1. CHECK THE SOLENOID. A. Turn the disconnect switch and the key start switch to the ON position. Do not start the engine. B. Observe the status of the diagnostic code. C.

B. C. Disconnect the solenoid with the active diagnostic code from the machine harness. Expected Result: CID 0291 FMI 06 changes to CID 0291 FMI 05 when the solenoid is disconnected. Results: YES - CID 0291 FMI 06 changes to CID 0291 FMI 05 when the solenoid is disconnected. The circuit is correct. Repair: The solenoid has failed. Repeat this test "CHECK THE SOLENOID" in order to verify the solenoid failure. Replace the solenoid. Stop. NO - CID 0291 FMI 06 remains active. Proceed to Test Step 2. Test Step 2. CHECK THE ENERGIZE CIRCUIT OF THE SOLENOID FOR A SHORT TO GROUND. A. Turn the key start switch and the disconnect switch to the OFF position. B. The solenoid remains disconnected from the machine harness. C. Disconnect the machine harness connector(s) from the machine ECM. D. At the machine harness connector, measure the resistance from the signal contact J2-24 (wire C411-OR) to all contacts that are used in the machine harness connectors for the machine ECM. Expected Result: Each resistance measurement is greater than 5000 ohms. Results: OK - Each resistance measurement is greater than 5000 ohms. The machine harness is correct. Proceed to Test Step 3. NOT OK - Each resistance measurement is not greater than 5000 ohms. There is a short in the machine harness. The short is between J2-24 (wire C411-OR) and the circuit with the low resistance measurement. Repair: Repair the machine harness or replace the machine harness. Stop. Test Step 3. CHECK IF THE DIAGNOSTIC CODE REMAINS. A. Inspect the harness connectors and clean the contacts of the harness connectors. B. Reconnect all harness connectors. C. Turn the disconnect switch and the key start switch to the ON position. D. Operate the machine. E. Check the status of the CID 0291 FMI 06. Expected Result: The CID 0291 FMI 06 is active. Results: YES - The CID 0291 FMI 06 is active. The diagnostic code has not been corrected. The machine ECM may have failed. Repair: It is unlikely that the machine ECM has failed. Exit this procedure and perform this procedure again. If the cause of the diagnostic code is not found, replace the machine ECM. See Testing and Adjusting, "Electronic Control Module (ECM) - Replace". Stop.

NO - The CID 0291 FMI 06 is not active. The diagnostic code does not exist at this time. Repair: The initial diagnostic code was probably caused by a poor electrical connection or a short at one of the harness connectors that was disconnected and reconnected. Resume normal machine operation. Stop.

TROUBLESHOOTING

017

TROUBLESHOOTING

i01901016

MID 039 - CID 0298 - FMI 04 SMCS - 1435-038-P9 Conditions Which Generate This Code:

Illustration 1

g00840403

Schematic of the Switch (service brake pedal)

This diagnostic code is associated with the Switch (service brake pedal). The switch is connected to two inputs of the machine ECM. The inputs are "Normally Open" and "Normally Closed". One of the inputs is open and the other input is grounded during proper operation. The FMI 04 means that the machine ECM has determined that the "Normally Open" and "Normally Closed" circuits are grounded. Note: The following test procedure may create other diagnostic codes. Ignore these diagnostic codes and clear these diagnostic codes when the original diagnostic code has been corrected.Ensure that the diagnostic code of CID 0298 FMI 04 is active before performing this procedure. System Response: When this diagnostic code is active, the machine ECM will not be able to determine the state of the switch. The parking brake will be engaged only if there is no request for travel. The brake lights will shut off. The oscillating axle will be locked. The pilot hydraulics for the travel function will be disabled. Test Step 1. CHECK THE SWITCH. A. Turn the key start switch and the disconnect switch to the OFF position. B. Disconnect the machine harness from the switch. C. Turn the key start switch and the disconnect switch to the ON position. Expected Result: The CID 0298 FMI 04 has been replaced by CID 0298 FMI 05. Results:

OK - The CID 0298 FMI 04 has been replaced by CID 0298 FMI 05. The machine harness and the machine ECM are correct. Proceed to Test Step 3. NOT OK - The CID 0298 FMI 04 is still active. Proceed to Test Step 2. Test Step 2. CHECK THE HARNESS. A. Turn the disconnect switch and the key start switch to the OFF position. B. The machine harness remains disconnected from the switch. C. Disconnect the machine harness connector(s) from the machine ECM. D. Measure the resistance between contacts J1-56 (wire F790-BR) and J1-57 (wire F787-GN) of the machine harness to all the contacts that are used in machine harness connectors for the machine ECM. Expected Result: Each resistance measurement is greater than 5000 ohms. Results: YES - Each resistance measurement is greater than 5000 ohms. The machine ECM has failed. Repair: It is unlikely that the machine ECM has failed. Exit this procedure and perform this procedure again. If the cause of the diagnostic code is not found, replace the machine ECM. See Testing And Adjusting, "Electronic Control Module (ECM) - Replace". Stop. NO - One or more of the resistance measurements are less than 5 ohms. The harness has failed. The short is between J156 (wire F790-BR) and the circuit with the lowest resistance or the short is between J1-57 (wire F787-GN) and the circuit with the lowest resistance. Repair: Repair the wiring harness or replace the wiring harness. Stop. Test Step 3. CHECK THE OPERATION OF THE SWITCH. A. The machine harness remains disconnected from the switch. B. Connect one lead from a multimeter to contact A (wire A235-BK) of the harness connector for the switch. C. Connect the other lead from a multimeter to contact C (wire F790-BR) of the harness connector for the switch. D. Measure the resistance between contact A (wire A235-BK) and contact C (wire F790-BR). Note the resistance. E. Disconnect the lead from contact C (wire F790-BR) and connect the lead to contact B (wire F787-GN). F. Measure the resistance between contact A (wire A235-BK) and contact B (wire F787-GN). Expected Result: The resistance from contact A (wire A235-BK) to contact B (wire F787-GN) is less than 5 ohms, and the resistance from contact A (wire A235-BK) to contact C (wire F790-BR) is greater than 5000 ohms. Results: YES - The resistance from contact A (wire A235-BK) to contact B (wire F787-GN) is less than 5 ohms, and the resistance from contact A (wire A235-BK) to contact C (wire F790-BR) is greater than 5000 ohms. Proceed to Test Step 4. NO - The resistance measurements do not differ. The switch has failed.

Repair: Replace the switch. Stop. Test Step 4. CHECK THE OPERATION OF THE SWITCH. A. The machine harness remains disconnected from the switch. B. Press and hold the switch. C. Press and lock the service brake pedal. D. Connect one lead from a multimeter to contact A (wire A235-BK) of the harness connector for the switch. E. Connect the other lead from a multimeter to contact C (wire F790-BR) of the harness connector for the switch. F. Measure the resistance between contact A (wire A235-BK) and contact C (wire F790-BR). Note the resistance. G. Disconnect the lead from contact C (wire F790-BR) and connect the lead to contact B (wire F787-GN). H. Measure the resistance between contact A (wire A235-BK) and contact B (wire F787-GN). Expected Result: The resistance from contact A (wire A235-BK) to contact C (wire F790-BR) is less than 5 ohms, and the resistance from contact A (wire A235-BK) and contact B (wire F787-GN) is greater than 5000 ohms. These measurements are opposite of the measurements from the previous Test Step. Results: YES - The resistance from contact A (wire A235-BK) to contact C (wire F790-BR) is less than 5 ohms, and the resistance from contact A (wire A235-BK) and contact B (wire F787-GN) is greater than 5000 ohms. These measurements are opposite of the measurements from the previous Test Step. The switch is operating correctly. Proceed to Test Step 5. NO - The resistance measurements do not differ for both contacts, or the measurements have not changed from the previous Test Step. The switch has failed. Repair: Replace the switch. Stop. Test Step 5. CHECK IF THE DIAGNOSTIC CODE REMAINS. A. Inspect the contacts of the harness connectors and clean the connectors. B. Reconnect all harness connectors. C. Turn the disconnect switch and the key start switch to the ON position. D. Operate the machine. E. Determine if CID 0298 FMI 04 is present. Expected Result: The CID 0298 FMI 04 is active. Results: YES - The CID 0298 FMI 04 is active. The diagnostic code has not been corrected. The machine ECM may have failed. Repair: It is unlikely that the machine ECM has failed. Exit this procedure and perform this procedure again. If the cause of the diagnostic code is not found, replace the machine ECM. See Testing and Adjusting, "Electronic Control Module

(ECM) - Replace". Stop. NO - The CID 0298 FMI 04 is not active. The diagnostic code is NOT present. The diagnostic code does not exist at this time. Repair: The initial diagnostic code was probably caused by a poor electrical connection or a short at one of the harness connectors that was disconnected and reconnected. Resume normal machine operation. Stop.

TROUBLESHOOTING

018

TROUBLESHOOTING

i01901018

MID 039 - CID 0298 - FMI 05 SMCS - 1435-038-P9 Conditions Which Generate This Code:

Illustration 1

g00840403

Schematic of the Switch (service brake pedal)

This diagnostic code is associated with the Switch (service brake pedal). The switch is connected to two inputs of the machine ECM. One contact is open and the other contact is grounded during proper operation. The possible causes of this diagnostic code are listed: The normally open contact and the normally closed contact are open. The contact that is currently closed to ground is shorted to the +battery circuit.

Note: The following test procedure may create other diagnostic codes. Ignore these diagnostic codes and clear the diagnostic codes when the original diagnostic code has been corrected. Ensure that the diagnostic code of CID 0298 FMI 05 is active before performing this procedure. System Response: When this diagnostic code is active, the machine ECM will be unable to determine the state of the switch. The parking brake will be engaged if there is no request for travel. The brake lights will shut off. The oscillating axle will be locked. The pilot hydraulics for the travel function will be disabled. Test Step 1. CHECK THE GROUND CIRCUIT OF THE SWITCH IN THE HARNESS. A. Turn the key start switch and the disconnect switch to the OFF position. B. Disconnect the machine harness connector(s) from the machine ECM. C. Measure the resistance between contact J1-9 (wire A235-BK) of the machine harness for the machine ECM and contact

C. A (wire A235-BK) at the switch. Expected Result: The resistance is less than 5 ohms. Results: OK - The resistance is less than 5 ohms. The circuit is correct. Proceed to Test Step 2. NOT OK - The resistance is greater than 5000 ohms. The circuit is open. The machine harness has failed. Repair: Repair the machine harness or replace the machine harness. Stop. Test Step 2. CHECK THE SWITCH CIRCUITS FOR A SHORT TO THE +BATTERY CIRCUIT. A. The machine harness connector(s) remains disconnected from the machine ECM. B. The disconnect switch and the key start switch remain in the OFF position. C. Disconnect contact C (wire F790-BR) and contact B (wire F787-GN) from the connector of the switch. D. At the machine harness connector for the machine ECM, measure the resistance from contact C (wire F790-J1-56) and contact B (wire F787-GN) of the machine harness to all the contacts that are used in the machine harness connectors for the machine ECM. Expected Result: Each resistance measurement is greater than 5000 ohms. Results: OK - Each resistance measurement is greater than 5000 ohms. The harness is correct. Proceed to Test Step 3. NO - One or more of the measurements were less than 5 ohms. There is a short in the machine harness. Repair: The short is between wire F790-BR and the circuit with the lowest resistance measurement or the short is between wire F787-GN and the circuit with the lowest resistance measurement. Repair the machine harness or replace the machine harness. Stop. Test Step 3. CHECK THE SWITCH CIRCUITS IN THE HARNESS. A. The machine harness remains disconnected from the machine ECM and the switch. B. At the harness connector for the switch, connect a jumper wire between contact C (wire F790-BR) and contact B (wire F787-GN). C. At the harness connector for the machine ECM, measure the resistance from contact J1-56 (wire F790-BR) to contact J157 (wire F787-GN). Expected Result: The resistance is less than 5 ohms. Results: OK - The resistance is less than 5 ohms. Proceed to Test Step 4. NOT OK - The resistance is greater than 5000 ohms. The circuit is open. Repair: The machine harness has failed. Repair the machine harness or replace the machine harness.

Stop. Test Step 4. CHECK THE OPERATION OF THE SWITCH. A. Remove the jumper that was installed in the previous Test Step. B. The machine harness remains disconnected from the switch. C. Connect one lead from a multimeter to contact A (wire A235-BK) of the harness connector for the switch. D. Connect the other lead from a multimeter to contact C (wire F790-BR) of the harness connector for the switch. E. Measure the resistance between contact A (wire A235-BK) and contact C (wire F790-BR). Note the resistance. F. Disconnect the lead from contact C (wire F790-BR) and connect the lead to contact B (wire F787-GN). G. Measure the resistance between contact A (wire A235-BK) and contact B (wire F787-GN). Expected Result: The resistance from contact A to contact B is less than 5 ohms, and the resistance from contact A to contact C is greater than 5000 ohms. Results: YES - The resistance from contact A to contact A is less than 5 ohms, and the resistance from contact A to contact C is greater than 5000 ohms. The switch is operating correctly. Proceed to Test Step 5. NO - The resistance measurements do not differ for both contacts, or the measurements have not changed from the previous Test Step. The switch has failed. Repair: Replace the switch. Stop. Test Step 5. CHECK THE OPERATION OF THE SWITCH. A. The machine harness remains disconnected from the switch. B. Press and hold the switch. C. Press and lock the service brake pedal. D. Connect one lead from a multimeter to contact A (wire A235-BK) of the harness connector for the switch. E. Connect the other lead from a multimeter to contact C (wire F790-BR) of the harness connector for the switch. F. Measure the resistance between contact A (wire A235-BK) and contact C (wire F790-BR). Note the resistance. G. Disconnect the lead from contact C (wire F790-BR) and connect the lead to contact B (wire F787-GN). H. Measure the resistance between contact A (wire A235F790-BKBR) and contact B (wire F787-GN). Note the resistance. Expected Result: The resistance from contact A (wire A235-BK) to contact C (wire F790-BR) is less than 5 ohms, and the resistance from contact A (wire A235-BK) and contact B (wire F787-GN) is greater than 5000 ohms. These measurements are opposite of the measurements from the previous Test Step. Results: YES - The resistance from contact A to contact C is less than 5 ohms, and the resistance from contact A and contact B is greater than 5000 ohms. These measurements are opposite of the measurements from the previous Test Step. The switch is operating correctly. Proceed to Test Step 6.

NO - The resistance measurements do not differ for both contacts, or the measurements have not changed from the previous Test Step. The switch has failed. Repair: Replace the switch. Stop. Test Step 6. CHECK IF THE DIAGNOSTIC CODE REMAINS. A. Inspect the contacts of the harness connectors and clean the harness connectors. B. Reconnect all the harness connectors. C. Turn the disconnect switch and the key start switch to the ON position. D. Operate the machine. E. Check the status of the CID 0298 FMI 05. Expected Result: The CID 0298 FMI 05 is active. Results: YES - The CID 0298 FMI 05 is active. The diagnostic code has not been corrected. The machine ECM may have failed. Repair: It is unlikely that the machine ECM has failed. Exit this procedure and perform this procedure again. If the cause of the diagnostic code is not found, replace the machine ECM. See Testing and Adjusting, "Electronic Control Module (ECM) - Replace". Stop. NO - The CID 0298 FMI 05 is not active. The diagnostic code does not exist at this time. Repair: The initial diagnostic code was probably caused by a poor electrical connection or a short at one of the harness connectors that was disconnected and reconnected. Resume normal machine operation. Stop.

TROUBLESHOOTING

019

TROUBLESHOOTING

i01792736

MID 039 - CID 0374 - FMI 03 SMCS - 5479-038-ZWB Conditions Which Generate This Code:

Illustration 1

g00840422

Schematic of the Solenoid valve (swing brake)

This diagnostic code is associated with the Solenoid valve (swing brake). The FMI 03 means that the machine ECM has determined that the voltage of the solenoid circuit is above normal. The possible causes of the diagnostic code are listed: The solenoid has failed. The energize circuit of the solenoid is shorted to the +battery circuit. The machine ECM has failed. This is unlikely.

Note: The following test procedure may create other diagnostic codes. Ignore these created diagnostic codes and clear these diagnostic codes when the original diagnostic code has been corrected. Ensure that the diagnostic code of CID 0374 FMI 03 is active before performing this procedure. Note: Use the 146-4080 Digital Multimeter for the measurements in this procedure. System Response: When this diagnostic code is active, the machine ECM will be unable to control the swing brake. The swing brake will never be activated. Test Step 1. CHECK THE ENERGIZE CIRCUIT OF THE SOLENOID FOR A SHORT TO THE +BATTERY CIRCUIT. A. Turn the key start switch and the disconnect switch to the OFF position. B.

A. B. Disconnect the machine harness connectors from the solenoid and the machine ECM. C. At the machine harness connector for the machine ECM, measure the resistance from contact J2-51 (wire C995-YL) to all contacts that are used in the machine harness connectors for the machine ECM. Expected Result: Each resistance measurement is greater than 5000 ohms. Results: OK - Each resistance measurement is greater than 5000 ohms. The machine harness is correct. Proceed to Test Step 2. NOT OK - Each resistance measurement is not greater than 5000 ohms. There is a short in the machine harness. The short is between J2-51 (C995-YL) and the circuit that has a low resistance measurement. Repair: Repair the machine harness or replace the machine harness. Stop. Test Step 2. CHECK IF THE DIAGNOSTIC CODE IS STILL ACTIVE. A. Inspect the contacts and clean the contacts of the harness connectors. B. Reconnect all harness connectors. C. Turn the disconnect switch and the key start switch to the ON position. D. Operate the machine. E. Determine if the CID 0374 FMI 03 is active. Expected Result: The CID 0374 FMI 03 is active. Results: YES - The CID 0374 FMI 03 is active. The problem has not been corrected. The machine ECM may have failed. Repair: It is unlikely that the machine ECM has failed. Exit this procedure and perform this procedure again. If the cause of the diagnostic code is not found, replace the machine ECM. See Testing and Adjusting, "Electronic Control Module (ECM) - Replace". Stop. NO - The CID 0374 FMI 03 is not active. The problem does not exist at this time. Repair: The initial diagnostic code was probably caused by a poor electrical connection or a short at one of the harness connectors that was disconnected and reconnected. Resume normal machine operation. Stop.

TROUBLESHOOTING

020

TROUBLESHOOTING

i01792754

MID 039 - CID 0374 - FMI 05 SMCS - 5479-038-ZWB Conditions Which Generate This Code:

Illustration 1

g00840422

Schematic of the Solenoid valve (swing brake)

This diagnostic code is associated with the Solenoid valve (swing brake). The FMI 05 means that the machine ECM has determined that the current of the solenoid is below normal. The possible causes of this diagnostic code are listed below: The energize circuit of the solenoid is open. The return circuit of the solenoid is open. The solenoid has failed. The machine ECM has failed. This is unlikely.

Note: The following test procedure may create other diagnostic codes. Ignore these created diagnostic codes and clear these diagnostic codes when the original diagnostic code has been corrected. Ensure that the diagnostic code of CID 0374 FMI 05 is active before performing this procedure. Note: Use the 146-4080 Digital Multimeter for the measurements in this procedure. System Response: When this diagnostic code is active, the machine ECM will be unable to control the swing brake. The swing brake will always be activated. Test Step 1. CHECK THE SOLENOID. A. Turn the disconnect switch and the key start switch to the ON position. Do not start the engine. B.

A. B. Disconnect the solenoid with the active diagnostic code from the machine harness. C. At the machine harness connector for the solenoid, place a jumper wire from contact 1 (wire C995-YL) to contact 2 (wire H802-GY). D. Observe the status of the CID 0374 FMI 05. Expected Result: The CID 0374 FMI 05 remains active. The FMI has not changed and the "05" is still active. Results: YES - The diagnostic code remains active. The jumper wire does not affect the diagnostic code. Proceed to Test Step 2. NO - The diagnostic is no longer active. The solenoid has failed. Repair: The solenoid has failed. Repeat this Test Step "CHECK THE SOLENOID" in order to verify the solenoid failure. Replace the solenoid. Verify that the new solenoid corrects the problem. Stop. Test Step 2. CHECK THE HARNESS FOR AN OPEN. A. Turn the key start switch and the disconnect switch to the OFF position. B. Disconnect the machine harness connector(s) from the machine ECM. C. The jumper wire that was installed in the previous Test Step remains in place. D. At the machine harness connector, measure the resistance from signal contact J2-51 (wire C995-YL) to contact J2-49 (wire H802-GY). Expected Result: The resistance is less than 5.0 ohms. Results: OK - The resistance is less than 5.0 ohms. The machine harness is correct. Proceed to Test Step 3. NOT OK - The resistance is greater than 5000 ohms. The resistance measurement is not correct. There is an open circuit in the machine harness. Repair: The open is in wire C995-YL or in wire H802-GY of the machine harness. Repair the machine harness or replace the machine harness. Stop. Test Step 3. CHECK IF THE DIAGNOSTIC CODE REMAINS. A. Inspect the contacts of the harness connectors and clean the harness connectors. B. Reconnect all harness connectors. C. Turn the disconnect switch and the key start switch to the ON position. D. Operate the machine. E. Check the status of the CID 0374 FMI 05. Expected Result: The CID 0374 FMI 05 is active.

Results: YES - The CID 0374 FMI 05 is active. The diagnostic code has not been corrected. The machine ECM may have failed. Repair: It is unlikely that the machine ECM has failed. Exit this procedure and perform this procedure again. If the cause of the diagnostic code is not found, replace the machine ECM. See Testing and Adjusting, "Electronic Control Module (ECM) - Replace". Stop. NO - The CID 0374 FMI 05 is not active. The diagnostic code does not exist at this time. Repair: The initial diagnostic code was probably caused by a poor electrical connection or a short at one of the harness connectors that was disconnected and reconnected. Resume normal machine operation. Stop.

TROUBLESHOOTING

021

TROUBLESHOOTING

i01792740

MID 039 - CID 0374 - FMI 06 SMCS - 5479-038-ZWB Conditions Which Generate This Code:

Illustration 1

g00840422

Schematic of the Solenoid valve (swing brake)

This diagnostic code is associated with the Solenoid valve (swing brake). The FMI 06 means that the machine ECM has determined that the current of the solenoid is above normal. The possible causes of this diagnostic code are listed: The energize circuit of the solenoid is shorted to ground. The solenoid has failed. The machine ECM has failed. This is unlikely.

Note: The following test procedure may create other diagnostic codes. Ignore these created diagnostic codes and clear these diagnostic codes when the original diagnostic code has been corrected. Ensure that the diagnostic code of CID 0374 FMI 06 is active before performing this procedure. Note: Use the 146-4080 Digital Multimeter for the measurements in this procedure. System Response: When this diagnostic code is active, the machine ECM will be unable to control the swing brake. The swing brake will always be activated. Test Step 1. CHECK THE SOLENOID. A. Turn the disconnect switch and the key start switch to the ON position. Do not start the engine. B. Observe the status of the diagnostic code. C.

B. C. Disconnect the solenoid with the active diagnostic code from the machine harness. Expected Result: CID 0374 FMI 06 changes to CID 0374 FMI 05 when the solenoid is disconnected. Results: YES - CID 0374 FMI 06 changes to CID 0374 FMI 05 when the solenoid is disconnected. The circuit is correct. Repair: The solenoid has failed. Repeat this test "CHECK THE SOLENOID" in order to verify the solenoid failure. Replace the solenoid. Stop. NO - CID 0374 FMI 06 remains active. Proceed to Test Step 2. Test Step 2. CHECK THE ENERGIZE CIRCUIT OF THE SOLENOID FOR A SHORT TO GROUND. A. Turn the key start switch and the disconnect switch to the OFF position. B. The solenoid remains disconnected from the machine harness. C. Disconnect the machine harness connector(s) from the machine ECM. D. At the machine harness connector, measure the resistance from the signal contact J2-51 (wire C995-YL) to all contacts that are used in the machine harness connectors for the machine ECM. Expected Result: Each resistance measurement is greater than 5000 ohms. Results: OK - Each resistance measurement is greater than 5000 ohms. The machine harness is correct. Proceed to Test Step 3. NOT OK - Each resistance measurement is not greater than 5000 ohms. There is a short in the machine harness. The short is between J2-51 (wire C995-YL) and the circuit with the low resistance measurement. Repair: Repair the machine harness or replace the machine harness. Stop. Test Step 3. CHECK IF THE DIAGNOSTIC CODE REMAINS. A. Inspect the harness connectors and clean the contacts of the harness connectors. B. Reconnect all harness connectors. C. Turn the disconnect switch and the key start switch to the ON position. D. Operate the machine. E. Check the status of the CID 0374 FMI 06. Expected Result: The CID 0374 FMI 06 is active. Results: YES - The CID 0374 FMI 06 is active. The diagnostic code has not been corrected. The machine ECM may have failed. Repair: It is unlikely that the machine ECM has failed. Exit this procedure and perform this procedure again. If the cause of the diagnostic code is not found, replace the machine ECM. See Testing and Adjusting, "Electronic Control Module (ECM) - Replace". Stop.

NO - The CID 0374 FMI 06 is not active. The diagnostic code does not exist at this time. Repair: The initial diagnostic code was probably caused by a poor electrical connection or a short at one of the harness connectors that was disconnected and reconnected. Resume normal machine operation. Stop.

TROUBLESHOOTING

022

TROUBLESHOOTING

i01897261

MID 039 - CID 0376 - FMI 03 SMCS - 7429-038 Conditions Which Generate This Code:

Illustration 1 Schematic of the Travel Alarm

g00865970

This diagnostic code is associated with the Travel Alarm. The FMI 03 means that the ECM has determined that the voltage of the circuit is above normal. The possible causes of the diagnostic code are listed: The alarm has failed. The energize circuit is shorted to the +battery circuit. The ECM has failed. This is unlikely.

Note: The following test procedure may create other diagnostic codes. Ignore these created diagnostic codes and clear these diagnostic codes when the original diagnostic code has been corrected. Ensure that the diagnostic code of CID 0376 FMI 03 is active before performing this procedure. Note: Use the 146-4080 Digital Multimeter for the measurements in this procedure. System Response: When this failure occurs, a warning is displayed on the message center and the travel alarm will sound continuously. Test Step 1. CHECK THE ENERGIZE CIRCUIT FOR A SHORT TO THE +BATTERY CIRCUIT. A. Turn the key start switch and the disconnect switch to the OFF position. B. Disconnect the machine harness connectors from the alarm and the ECM. C. At the machine harness connector for the ECM, measure the resistance from contact J2-44 (wire 321-BR) to all contacts that are used in the machine harness connectors for the ECM.

C.

Expected Result: Each resistance measurement is greater than 5000 ohms. Results: OK - Each resistance measurement is greater than 5000 ohms. The machine harness is correct. Proceed to Test Step 2. NOT OK - Each resistance measurement is not greater than 5000 ohms. There is a short in the machine harness. The short is between J2-44 (321-BR) and the circuit that has a low resistance measurement. Repair: Repair the machine harness or replace the machine harness. Stop. Test Step 2. CHECK IF THE DIAGNOSTIC CODE IS STILL ACTIVE. A. Inspect the contacts and clean the contacts of the harness connectors. B. Reconnect all harness connectors. C. Turn the disconnect switch and the key start switch to the ON position. D. Operate the machine. E. Determine if the CID 0376 FMI 03 is active. Expected Result: The CID 0376 FMI 03 is active. Results: YES - The CID 0376 FMI 03 is active. The problem has not been corrected. The ECM may have failed. Repair: It is unlikely that the ECM has failed. Exit this procedure and perform this procedure again. If the cause of the diagnostic code is not found, replace the ECM. See Testing and Adjusting, "Electronic Control Module (ECM) - Replace". Stop. NO - The CID 0376 FMI 03 is not active. The problem does not exist at this time. Repair: The initial diagnostic code was probably caused by a poor electrical connection or a short at one of the harness connectors that was disconnected and reconnected. Resume normal machine operation. Stop.

TROUBLESHOOTING

023

TROUBLESHOOTING

i01897287

MID 039 - CID 0376 - FMI 05 SMCS - 7429-038 Conditions Which Generate This Code:

Illustration 1 Schematic of the Travel Alarm

g00865970

This diagnostic code is associated with the Travel Alarm. The FMI 05 means that the ECM has determined that the current of the circuit is below normal. The possible causes of this diagnostic code are listed below: The alarm has failed. The energize circuit is open. The return circuit is open. The ECM has failed. This is unlikely.

Note: The following test procedure may create other diagnostic codes. Ignore these created diagnostic codes and clear these diagnostic codes when the original diagnostic code has been corrected. Ensure that the diagnostic code of CID 0376 FMI 05 is active before performing this procedure. Note: Use the 146-4080 Digital Multimeter for the measurements in this procedure. System Response: When this failure occurs, a warning is displayed on the message center and the travel alarm will sound continuously. Test Step 1. CHECK THE ALARM. A. Turn the disconnect switch and the key start switch to the ON position. Do not start the engine. B. Disconnect the alarm from the machine harness. C.

B. C. At the machine harness connector for the alarm, place a jumper wire from contact 1 (wire 321-BR) to contact 2 (wire H807-YL). D. Observe the status of the CID 0376 FMI 05. Expected Result: The CID 0376 FMI 05 remains active. The FMI has not changed and the "05" is still active. Results: YES - The diagnostic code remains active. The jumper wire does not affect the diagnostic code. Proceed to Test Step 2. NO - The diagnostic is no longer active. The alarm has failed. Repair: The alarm has failed. Repeat this Test Step "CHECK THE ALARM" in order to verify that the alarm has failed. Replace the alarm. Verify that the new alarm corrects the problem. Stop. Test Step 2. CHECK THE HARNESS FOR AN OPEN. A. Turn the key start switch and the disconnect switch to the OFF position. B. Disconnect the machine harness connector(s) from the ECM. C. The jumper wire that was installed in the previous Test Step remains in place. D. At the machine harness connector, measure the resistance from signal contact J2-44 (wire 321-BR) to contact J2-36 (wire H807-YL). Expected Result: The resistance is less than 5.0 ohms. Results: OK - The resistance is less than 5.0 ohms. The machine harness is correct. Proceed to Test Step 3. NOT OK - The resistance is greater than 5000 ohms. The resistance measurement is not correct. There is an open circuit in the machine harness. Repair: The open is in wire 321-BR or in wire H807-YL of the machine harness. Repair the machine harness or replace the machine harness. Stop. Test Step 3. CHECK IF THE DIAGNOSTIC CODE REMAINS. A. Inspect the contacts of the harness connectors and clean the harness connectors. B. Reconnect all harness connectors. C. Turn the disconnect switch and the key start switch to the ON position. D. Operate the machine. E. Check the status of the CID 0376 FMI 05. Expected Result: The CID 0376 FMI 05 is active. Results:

YES - The CID 0376 FMI 05 is active. The diagnostic code has not been corrected. The ECM may have failed. Repair: It is unlikely that the ECM has failed. Exit this procedure and perform this procedure again. If the cause of the diagnostic code is not found, replace the ECM. See Testing and Adjusting, "Electronic Control Module (ECM) - Replace". Stop. NO - The CID 0376 FMI 05 is not active. The diagnostic code does not exist at this time. Repair: The initial diagnostic code was probably caused by a poor electrical connection at one of the harness connectors that was disconnected and reconnected. Resume normal machine operation. Stop.

TROUBLESHOOTING

024

TROUBLESHOOTING

i01897304

MID 039 - CID 0376 - FMI 06 SMCS - 7429-038 Conditions Which Generate This Code:

Illustration 1 Schematic of the Travel Alarm

g00865970

This diagnostic code is associated with the Travel Alarm. The FMI 06 means that the ECM has determined that the current is above normal. The possible causes of this diagnostic code are listed: The energize circuit is shorted to ground. The alarm has failed. The ECM has failed. This is unlikely.

Note: The following test procedure may create other diagnostic codes. Ignore these created diagnostic codes and clear these diagnostic codes when the original diagnostic code has been corrected. Ensure that the diagnostic code of CID 0376 FMI 06 is active before performing this procedure. Note: Use the 146-4080 Digital Multimeter for the measurements in this procedure. System Response: When this failure occurs, a warning is displayed on the message center. The travel alarm will not sound when this failure is present. Test Step 1. CHECK THE ALARM. A. Turn the disconnect switch and the key start switch to the ON position. Do not start the engine. B. Observe the status of the diagnostic code. C. Disconnect the alarm with the active diagnostic code from the machine harness.

C. Expected Result: CID 0376 FMI 06 changes to CID 0376 FMI 05 when the alarm is disconnected. Results: YES - CID 0376 FMI 06 changes to CID 0376 FMI 05 when the alarm is disconnected. The circuit is correct. Repair: The alarm has failed. Repeat this test "CHECK THE ALARM" in order to verify that the alarm has failed. Replace the alarm. Stop. NO - CID 0376 FMI 06 remains active. Proceed to Test Step 2. Test Step 2. CHECK THE ENERGIZE CIRCUIT OF THE ALARM FOR A SHORT TO GROUND. A. Turn the key start switch and the disconnect switch to the OFF position. B. The alarm remains disconnected from the machine harness. C. Disconnect the machine harness connector(s) from the ECM. D. At the machine harness connector, measure the resistance from the signal contact J2-44 (wire 321-BR) to all contacts that are used in the machine harness connectors for the ECM. Expected Result: Each resistance measurement is greater than 5000 ohms. Results: OK - Each resistance measurement is greater than 5000 ohms. The machine harness is correct. Proceed to Test Step 3. NOT OK - Each resistance measurement is not greater than 5000 ohms. There is a short in the machine harness. The short is between J2-44 (wire 321-BR) and the circuit with the low resistance measurement. Repair: Repair the machine harness or replace the machine harness. Stop. Test Step 3. CHECK IF THE DIAGNOSTIC CODE REMAINS. A. Inspect the harness connectors and clean the contacts of the harness connectors. B. Reconnect all harness connectors. C. Turn the disconnect switch and the key start switch to the ON position. D. Operate the machine. E. Check the status of the CID 0376 FMI 06. Expected Result: The CID 0376 FMI 06 is active. Results: YES - The CID 0376 FMI 06 is active. The diagnostic code has not been corrected. The ECM may have failed. Repair: It is unlikely that the ECM has failed. Exit this procedure and perform this procedure again. If the cause of the diagnostic code is not found, replace the ECM. See Testing and Adjusting, "Electronic Control Module (ECM) - Replace". Stop. NO - The CID 0376 FMI 06 is not active. The diagnostic code does not exist at this time.

Repair: The initial diagnostic code was probably caused by a poor electrical connection or a short at one of the harness connectors that was disconnected and reconnected. Resume normal machine operation. Stop.

TROUBLESHOOTING

025

TROUBLESHOOTING

i01792786

MID 039 - CID 0444 - FMI 03 SMCS - 1426-038 Conditions Which Generate This Code:

Illustration 1 Schematic of the Start Relay

g00840434

This diagnostic code is associated with the Magnetic switch (start relay). The FMI 03 means that the machine ECM has determined that the voltage of the relay circuit is above normal. The possible causes of the diagnostic code are listed: The relay has failed. The power circuit of the relay is shorted to the +battery circuit. The machine ECM has failed. This is unlikely.

Note: The following test procedure may create other diagnostic codes. Ignore these created diagnostic codes and clear these diagnostic codes when the original diagnostic code has been corrected. Ensure that the diagnostic code of CID 0444 FMI 03 is active before performing this procedure. Note: Use the 146-4080 Digital Multimeter for the measurements in this procedure. System Response: When this diagnostic code is active, the machine ECM will be unable to control the starter relay. The starter relay will always be activated. Test Step 1. CHECK THE POWER CIRCUIT OF THE RELAY FOR A SHORT TO THE +BATTERY CIRCUIT. A. Turn the key start switch and the disconnect switch to the OFF position. B. Disconnect the machine harness connectors from the relay and the machine ECM. C. At the machine harness connector for the machine ECM, measure the resistance from contact J2-68 (wire 306-GN) to all

C. contacts that are used in the machine harness connectors for the machine ECM. Expected Result: Each resistance measurement is greater than 5000 ohms. Results: OK - Each resistance measurement is greater than 5000 ohms. The machine harness is correct. Proceed to Test Step 2. NOT OK - Each resistance measurement is not greater than 5000 ohms. There is a short in the machine harness. The short is between J1-10 (751-GN) and the circuit that has a low resistance measurement. Repair: Repair the machine harness or replace the machine harness. Stop. Test Step 2. CHECK IF THE DIAGNOSTIC CODE IS STILL ACTIVE. A. Inspect the contacts and clean the contacts of the harness connectors. B. Reconnect all harness connectors. C. Turn the disconnect switch and the key start switch to the ON position. D. Operate the machine. E. Determine if the CID 0444 FMI 03 is active. Expected Result: The CID 0444 FMI 03 is active. Results: YES - The CID 0444 FMI 03 is active. The problem has not been corrected. The machine ECM may have failed. Repair: It is unlikely that the machine ECM has failed. Exit this procedure and perform this procedure again. If the cause of the diagnostic code is not found, replace the machine ECM. See Testing and Adjusting, "Electronic Control Module (ECM) - Replace". Stop. NO - The CID 0444 FMI 03 is not active. The problem does not exist at this time. Repair: The initial diagnostic code was probably caused by a poor electrical connection or a short at one of the harness connectors that was disconnected and reconnected. Resume normal machine operation. Stop.

TROUBLESHOOTING

026

TROUBLESHOOTING

i01792791

MID 039 - CID 0444 - FMI 05 SMCS - 1426-038 Conditions Which Generate This Code:

Illustration 1 Schematic of the Start Relay

g00840434

This diagnostic code is associated with the Magnetic switch (start relay). The FMI 05 means that the machine ECM has determined that the current of the relay is below normal. The possible causes of this diagnostic code are listed below: The power circuit of the relay is open. The return circuit of the relay is open. The relay has failed. The machine ECM has failed. This is unlikely.

Note: The following test procedure may create other diagnostic codes. Ignore these created diagnostic codes and clear these diagnostic codes when the original diagnostic code has been corrected. Ensure that the diagnostic code of CID 0444 FMI 05 is active before performing this procedure. Note: Use the 146-4080 Digital Multimeter for the measurements in this procedure. System Response: When this diagnostic code is active, the machine ECM will be unable to control the starter relay. The machine will be unable to start. On an operating engine, this failure has no effect. The engine will continue to operate normally. Test Step 1. CHECK THE RELAY. A. Turn the disconnect switch and the key start switch to the ON position. Do not start the engine. B. Disconnect the relay with the active diagnostic code from the machine harness.

B. C. At the machine harness connector for the relay, place a jumper wire from contact 1 (wire 306-GN) to contact 2 (wire H807-YL). D. Observe the status of the CID 0444 FMI 05. Expected Result: The CID 0444 FMI 05 remains active. The FMI has not changed and the "05" is still active. Results: YES - The diagnostic code remains active. The jumper wire does not affect the diagnostic code. Proceed to Test Step 2. NO - The diagnostic is no longer active. The relay has failed. Repair: The relay has failed. Repeat this Test Step "CHECK THE RELAY" in order to verify the failure of the relay. Replace the relay. Verify that the new relay corrects the problem. Stop. Test Step 2. CHECK THE HARNESS FOR AN OPEN. A. Turn the key start switch and the disconnect switch to the OFF position. B. Disconnect the machine harness connector(s) from the machine ECM. C. The jumper wire that was installed in the previous test remains in place. D. At the machine harness connector, measure the resistance from signal contact J2-68 (wire 306-GN) to contact J2-36 (wire H807-YL). Expected Result: The resistance is less than 5.0 ohms. Results: OK - The resistance is less than 5.0 ohms. The machine harness is correct. Proceed to Test Step 3. NOT OK - The resistance is greater than 5000 ohms. The resistance measurement is not correct. There is an open circuit in the machine harness. Repair: The open is in wire 751-GN or in wire 921-WH of the machine harness. Repair the machine harness or replace the machine harness. Stop. Test Step 3. CHECK IF THE DIAGNOSTIC CODE REMAINS. A. Inspect the contacts of the harness connectors and clean the harness connectors. B. Reconnect all harness connectors. C. Turn the disconnect switch and the key start switch to the ON position. D. Operate the machine. E. Check the status of the CID 0444 FMI 05. Expected Result: The CID 0444 FMI 05 is active. Results:

YES - The CID 0444 FMI 05 is active. The diagnostic code has not been corrected. The machine ECM may have failed. Repair: It is unlikely that the machine ECM has failed. Exit this procedure and perform this procedure again. If the cause of the diagnostic code is not found, replace the machine ECM. See Testing and Adjusting, "Electronic Control Module (ECM) - Replace". Stop. NO - The CID 0444 FMI 05 is not active. The diagnostic code does not exist at this time. Repair: The initial diagnostic code was probably caused by a poor electrical connection or a short at one of the harness connectors that was disconnected and reconnected. Resume normal machine operation. Stop.

TROUBLESHOOTING

027

TROUBLESHOOTING

i01792796

MID 039 - CID 0444 - FMI 06 SMCS - 1426-038 Conditions Which Generate This Code:

Illustration 1

g00840434

Schematic of the Magnetic Switch (start relay)

This diagnostic code is associated with the Magnetic switch (start relay). The FMI 06 means that the machine ECM has determined that the current of the relay is above normal. The possible causes of this diagnostic code are listed: The power circuit of the relay is shorted to ground. The relay has failed. The machine ECM has failed. This is unlikely.

Note: The following test procedure may create other diagnostic codes. Ignore these created diagnostic codes and clear these diagnostic codes when the original diagnostic code has been corrected. Ensure that the diagnostic code of CID 0444 FMI 06 is active before performing this procedure. Note: Use the 146-4080 Digital Multimeter for the measurements in this procedure. System Response: When this diagnostic code is active, the machine ECM will be unable to control the starter relay. The machine will be unable to start. On an operating engine, this failure has no effect. The engine will continue to operate normally. Test Step 1. CHECK THE RELAY. A. Turn the disconnect switch and the key start switch to the ON position. Do not start the engine. B. Observe the status of the diagnostic code. C.

B. C. Disconnect the relay with the active diagnostic code from the machine harness. Expected Result: CID 0444 FMI 06 changes to CID 0444 FMI 05 when the relay is disconnected. Results: YES - CID 0444 FMI 06 changes to CID 0444 FMI 05 when the relay is disconnected. The circuit is correct. Repair: The relay has failed. Repeat this test "CHECK THE RELAY" in order to verify the failure of the relay. Replace the relay. Stop. NO - CID 0444 FMI 06 remains active. Proceed to Test Step 2. Test Step 2. CHECK THE POWER CIRCUIT OF THE RELAY FOR A SHORT TO GROUND. A. Turn the key start switch and the disconnect switch to the OFF position. B. The relay remains disconnected from the machine harness. C. Disconnect the machine harness connector(s) from the machine ECM. D. At the machine harness connector, measure the resistance from the signal contact J2-68 (wire 306-GN) to all contacts that are used in the machine harness connectors for the machine ECM. Expected Result: Each resistance measurement is greater than 5000 ohms. Results: OK - Each resistance measurement is greater than 5000 ohms. The machine harness is correct. Proceed to Test Step 3. NOT OK - Each resistance measurement is not greater than 5000 ohms. There is a short in the machine harness. The short is between J2-68 (wire 306-GN) and the circuit with the low resistance measurement. Repair: Repair the machine harness or replace the machine harness. Stop. Test Step 3. CHECK IF THE DIAGNOSTIC CODE REMAINS. A. Inspect the harness connectors and clean the contacts of the harness connectors. B. Reconnect all harness connectors. C. Turn the disconnect switch and the key start switch to the ON position. D. Operate the machine. E. Check the status of the CID 0444 FMI 06. Expected Result: The CID 0444 FMI 06 is active. Results: YES - The CID 0444 FMI 06 is active. The diagnostic code has not been corrected. The machine ECM may have failed. Repair: It is unlikely that the machine ECM has failed. Exit this procedure and perform this procedure again. If the cause of the diagnostic code is not found, replace the machine ECM. See Testing and Adjusting, "Electronic Control Module (ECM) - Replace". Stop.

NO - The CID 0444 FMI 06 is not active. The diagnostic code does not exist at this time. Repair: The initial diagnostic code was probably caused by a poor electrical connection or a short at one of the harness connectors that was disconnected and reconnected. Resume normal machine operation. Stop.

TROUBLESHOOTING

028

TROUBLESHOOTING

i02303963

MID 039 - CID 0590 - FMI 02 SMCS - 1901-038 Conditions Which Generate This Code:

Illustration 1 Schematic of the Cat Data Link

g00852693

This failure results in events that are logged against an ECM that can not be explained. The Machine ECM cannot communicate with the Engine ECM or the ECM appears to work intermittently. Test Step 1. VERIFY THE HARDWARE AND THE SOFTWARE PART NUMBERS. A. Verify that the following information is correct: The part number of the software of the machine ECM The part number of the "engine ECM flash software" The part number of the machine ECM The part number of the engine ECM Note: Consult the Business Unit that produces the product for the correct part numbers of the configuration software. Expected Result: All part numbers are correct. Results: OK - All part numbers are correct. Proceed to test step 2. NOT OK - All part numbers are NOT correct. The part number of the machine ECM may be incorrect. The part number of the Engine ECM may be incorrect. The incorrect configuration software may also be installed. Repair: Replace the incorrect ECM with an ECM that has the correct part number. Flash the correct configuration

software. See Testing and Adjusting, "Electronic Control Module (ECM) - Flash Program". Stop. Test Step 2. INSPECT THE HARNESS CONNECTIONS. A. Turn the disconnect switch to the OFF position. B. Inspect all harness connections that are related to the Cat Data Link. Make sure that the connectors are clean and tight. C. Check the connectors for proper mating. D. Check the wires at the connector. E. Check each wire for nicks or signs of abrasion in the insulation. F. Check for moisture at the connector. G. Check the connectors for dirty contacts or corroded contacts. H. Check each pin and each socket of the machine harness connectors. Expected Result: The machine harness connectors are tight and free of corrosion. Results: OK - The machine harness connectors are tight and free of corrosion. Proceed to test step 3. NOT OK - The machine harness connectors are in need of repair. Repair: Repair the machine harness or replace the machine harness. Stop. Test Step 3. CHECK FOR SHORTS TO GROUND. A. The disconnect switch remains in the OFF position. B. Disconnect the machine harness from all electronic control modules that use the CatData Link. C. At the machine harness for the machine ECM, measure the resistance between frame ground and connector contacts J1-8 (wire 882-PK) and J1-7 (wire 883-GY) of the Cat Data Link circuit. Expected Result: The resistance is greater than 5000 ohms. Results: OK - The resistance is greater than 5000 ohms. The harness circuit resistance is correct. Proceed to test step 4. NOT OK - The resistance is less than 5000 ohms. The machine harness has failed. Repair: There is a short between frame ground and the Cat Data Link circuit in the machine harness. Repair the machine harness or replace the machine harness. Stop. Test Step 4. CHECK FOR A SHORT TO THE +BATTERY CIRCUIT. A. The disconnect switch remains in the OFF position. B.

A. B. All related electronic control modules remain disconnected from the machine harness. C. At the machine harness connector for the machine ECM, perform the checks that are listed here: Measure the resistance between the connector contact J2-1 (wire 116-BR) and connector contact J1-8 (wire 883GY). Measure the resistance between connector contact J2-1 (wire 116-BR) and connector contact J1-7(wire 882-PK).

Expected Result: The resistance is greater than 5000 ohms. Results: OK - The harness circuit resistance is correct. Proceed to test step 5. NOT OK - The resistance is less than 5000 ohms. The machine harness has failed. Repair: There is a short between the +battery circuit and the Cat Data Link circuit in the machine harness. Repair the machine harness or replace the machine harness. Stop. Test Step 5. CHECK FOR A OPEN HARNESS. A. The disconnect switch remains in the OFF position. B. All related electronic control modules remain disconnected from the machine harness. C. Check the continuity of the Cat Data Link circuit in the machine harness: Measure the resistance between connector contact J1-8 (wire 883-GY) of the machine ECM and connector contact J1-4 (wire 883-GY) of the engine ECM. Measure the resistance between connector contact J1-7 (wire 882-PK) of the machine ECM and connector contact J1-5 (wire 882-PK) of the engine ECM.

Expected Result: The resistance measures less than 5 ohms. Results: OK - The resistance is less than 5 ohms. The Cat Data Link circuit in the machine harness is correct. Proceed to test step 6. NOT OK - The resistance is greater than 5 Ohms. The machine harness has failed. Repair: The Cat Data Link circuit is open in the machine harness. Repair the machine harness or replace the machine harness. Stop. Test Step 6. CHECK FOR ADDITIONAL DIAGNOSTIC CODES FOR THE OTHER ELECTRONIC CONTROL MODULES. A. Reconnect all the electronic control modules that use the Cat Data Link. B. Turn the disconnect switch and the key start switch to the ON position. C. After each of the electronic control modules has been reconnected, check the Event List for diagnostic codes that are logged against the electronic control module.

Expected Result: Diagnostic codes are not present for the other electronic control modules (ECM) in the event list. Results: OK - Diagnostic codes are not present for the other electronic control modules (ECM) in the event list. Repair: The engine ECM has failed. It is unlikely that the ECM has failed. Exit this procedure. Perform this procedure again. If the failure is not found, replace the ECM. Stop. NOT OK - Diagnostic codes are present for the other electronic control modules (ECM) in the event list. Repair: The machine ECM may have failed. It is unlikely that the ECM has failed. Exit this procedure. Perform this procedure again. If the failure is not found, replace the ECM. See the Testing and Adjusting, "Electronic Control Module (ECM) - Replace". Stop.

TROUBLESHOOTING

029

TROUBLESHOOTING

i02303966

MID 039 - CID 0590 - FMI 09 SMCS - 1901-038 Conditions Which Generate This Code:

Illustration 1 Schematic of the Cat Data Link

g00852693

This diagnostic code is recorded when the machine ECM does not receive the expected information on the Cat Data Link. The possible causes of this diagnostic code are listed below: There is a poor electrical connection on the Cat Data Link. The Cat Data Link has shorted to ground. The Cat Data Link has shorted to the + Battery. The Cat Data Link circuit has an open circuit.

Test Step 1. VERIFY THE HARDWARE AND THE SOFTWARE PART NUMBERS. A. Verify that the following information is correct: The part number of the software of the machine ECM The part number of the "engine ECM flash software" The part number of the machine ECM The part number of the engine ECM Note: Consult the Business Unit that produces the product for the correct part numbers of the configuration software.

Expected Result: All part numbers are correct. Results: OK - All part numbers are correct. Proceed to test step 2. NOT OK - All part numbers are NOT correct. The part number of the machine ECM may be incorrect. The part number of the Engine ECM may be incorrect. The incorrect configuration software may also be installed. Repair: Replace the incorrect ECM with an ECM that has the correct part number. Flash the correct configuration software. See Testing and Adjusting, "Electronic Control Module (ECM) - Flash Program". Stop. Test Step 2. INSPECT THE HARNESS CONNECTIONS. A. Turn the disconnect switch to the OFF position. B. Inspect all harness connections that are related to the Cat Data Link. Make sure that the connectors are clean and tight. C. Check the connectors for proper mating. D. Check the wires at the connector. E. Check each wire for nicks or signs of abrasion in the insulation. F. Check for moisture at the connector. G. Check the connectors for dirty contacts or corroded contacts. H. Check each pin and check each socket of the machine harness connectors. Expected Result: The machine harness connectors are tight and free of corrosion. Results: OK - The machine harness connectors are tight and free of corrosion. Proceed to test step 3. NOT OK - The machine harness connectors are in need of repair. Repair: Repair the machine harness or replace the machine harness. Stop. Test Step 3. CHECK FOR SHORTS TO GROUND. A. The disconnect switch remains in the OFF position. B. Disconnect the machine harness from all electronic control modules that use the CatData Link. C. At the machine harness for the machine ECM, measure the resistance between frame ground and connector contacts J1-8 (wire 882-PK) and J1-7 (wire 883-GY) of the Cat Data Link circuit. Expected Result: The resistance is greater than 5000 ohms. Results: OK - The resistance is greater than 5000 ohms. The harness circuit resistance is correct. Proceed to test step 4. NOT OK - The resistance is less than 5000 ohms. The machine harness has failed.

Repair: There is a short between frame ground and the Cat Data Link circuit in the machine harness. Repair the machine harness or replace the machine harness. Stop. Test Step 4. CHECK FOR A SHORT TO THE +BATTERY CIRCUIT. A. The disconnect switch remains in the OFF position. B. All related electronic control modules remain disconnected from the machine harness. C. At the machine harness connector for the machine ECM, perform the checks that are listed here: Measure the resistance between the connector contact J2-1 (wire 116-BR) and connector contact J1-8 (wire 883GY). Measure the resistance between connector contact J2-1 (wire 116-BR) and connector contact J1-7(wire 882-PK).

Expected Result: The resistance is greater than 5000 ohms. Results: OK - The harness circuit resistance is correct. Proceed to test step 5. NOT OK - The resistance is less than 5000 ohms. The machine harness has failed. Repair: There is a short between the +battery circuit and the Cat Data Link circuit in the machine harness. Repair the machine harness or replace the machine harness. Stop. Test Step 5. CHECK FOR A OPEN HARNESS. A. The disconnect switch remains in the OFF position. B. All related electronic control modules remain disconnected from the machine harness. C. Check the continuity of the Cat Data Link circuit in the machine harness: Measure the resistance between connector contact J1-8 (wire 883-GY) of the machine ECM and connector contact J1-4 (wire 883-GY) of the engine ECM. Measure the resistance between connector contact J1-7 (wire 882-PK) of the machine ECM and connector contact J1-5 (wire 882-PK) of the engine ECM.

Expected Result: The resistance measures less than 5 ohms. Results: OK - The resistance is less than 5 ohms. The Cat Data Link circuit in the machine harness is correct. Proceed to test step 6. NOT OK - The resistance is greater than 5 Ohms. The machine harness has failed. Repair: The Cat Data Link circuit is open in the machine harness. Repair the machine harness or replace the machine harness. Stop.

Test Step 6. CHECK FOR ADDITIONAL DIAGNOSTIC CODES FOR THE OTHER ELECTRONIC CONTROL MODULES. A. Reconnect all the electronic control modules that use the Cat Data Link. B. Turn the disconnect switch and the key start switch to the ON position. C. After each of the electronic control modules has been reconnected, check the Event List for diagnostic codes that are logged against the electronic control module. Expected Result: Diagnostic codes are not present for the other electronic control modules (ECM) in the event list. Results: OK - Diagnostic codes are not present for the other electronic control modules (ECM) in the event list. Repair: The engine ECM has failed. It is unlikely that the ECM has failed. Exit this procedure. Perform this procedure again. If the failure is not found, replace the ECM. Stop. NOT OK - Diagnostic codes are present for the other electronic control modules (ECM) in the event list. Repair: The machine ECM may have failed. It is unlikely that the ECM has failed. Exit this procedure. Perform this procedure again. If the failure is not found, replace the ECM. See the Testing and Adjusting, "Electronic Control Module (ECM) - Replace". Stop.

TROUBLESHOOTING

030

TROUBLESHOOTING

i02303968

MID 039 - CID 0590 - FMI 12 SMCS - 1901-038 Conditions Which Generate This Code:

Illustration 1 Schematic of the Cat Data Link circuit

g00852693

This diagnostic code is recorded when the Machine ECM does not receive the expected information from the Engine ECM. The likely possible causes of this diagnostic code are listed below: The software that is installed on the engine ECM is incorrect. The software that is installed on the machine ECM is incorrect.

Test Step 1. VERIFY THE HARDWARE AND THE SOFTWARE PART NUMBERS. A. Verify that the following information is correct: The part number of the software of the machine ECM The part number of the "engine ECM flash software" The part number of the machine ECM The part number of the engine ECM Note: Consult the Business Unit that produces the product for the correct part numbers of the configuration software. Expected Result: All part numbers are correct.

Results: OK - All part numbers are correct. Proceed to test step 2. NOT OK - All part numbers are NOT correct. The part number of the machine ECM may be incorrect. The part number of the Engine ECM may be incorrect. The incorrect configuration software may also be installed. Repair: Replace the incorrect ECM with an ECM that has the correct part number. Flash the correct configuration software. See Testing and Adjusting, "Electronic Control Module (ECM) - Flash Program". Stop. Test Step 2. INSPECT THE HARNESS CONNECTIONS. A. Turn the disconnect switch to the OFF position. B. Inspect all harness connections that are related to the Cat Data Link. Make sure that the connectors are clean and tight. C. Check the connectors for proper mating. D. Check the wires at the connector. E. Check each wire for nicks or signs of abrasion in the insulation. F. Check for moisture at the connector. G. Check the connectors for dirty contacts or corroded contacts. H. Check each pin and check each socket of the machine harness connectors. Expected Result: The machine harness connectors are tight and free of corrosion. Results: OK - The machine harness connectors are tight and free of corrosion. Proceed to test step 3. NOT OK - The machine harness connectors are in need of repair. Repair: Repair the machine harness or replace the machine harness. Stop. Test Step 3. CHECK FOR SHORTS TO GROUND. A. The disconnect switch remains in the OFF position. B. Disconnect the machine harness from all electronic control modules that use the Cat Data Link. C. At the machine harness for the machine ECM, measure the resistance between frame ground and connector contacts J1-8 (wire 882-PK) and J1-7 (wire 883-GY) of the Cat Data Link circuit. Expected Result: The resistance is greater than 5000 ohms. Results: OK - The resistance is greater than 5000 ohms. The harness circuit resistance is correct. Proceed to test step 4. NOT OK - The resistance is less than 5000 ohms. The machine harness has failed. Repair: There is a short between frame ground and the Cat Data Link circuit in the machine harness. Repair the machine harness or replace the machine harness.

Stop. Test Step 4. CHECK FOR A SHORT TO THE +BATTERY CIRCUIT. A. The disconnect switch remains in the OFF position. B. All related electronic control modules remain disconnected from the machine harness. C. At the machine harness connector for the machine ECM, perform the checks that are listed here: Measure the resistance between the connector contact J2-1 (wire 116-BR) and connector contact J1-8 (wire 883GY). Measure the resistance between connector contact J2-1 (wire 116-BR) and connector contact J1-7(wire 882-PK).

Expected Result: The resistance is greater than 5000 ohms. Results: OK - The harness circuit resistance is correct. Proceed to test step 5. NOT OK - The resistance is less than 5000 ohms. The machine harness has failed. Repair: There is a short between the +battery circuit and the Cat Data Link circuit in the machine harness. Repair the machine harness or replace the machine harness. Stop. Test Step 5. CHECK FOR A OPEN HARNESS. A. The disconnect switch remains in the OFF position. B. All related electronic control modules remain disconnected from the machine harness. C. Check the continuity of the Cat Data Link circuit in the machine harness: Measure the resistance between connector contact J1-8 (wire 883-GY) of the machine ECM and connector contact J1-4 (wire 883-GY) of the engine ECM. Measure the resistance between connector contact J1-7 (wire 882-PK) of the machine ECM and connector contact J1-5 (wire 882-PK) of the engine ECM.

Expected Result: The resistance measures less than 5 ohms. Results: OK - The resistance is less than 5 ohms. The Cat Data Link circuit in the machine harness is correct. Proceed to test step 6. NOT OK - The resistance is greater than 5 Ohms. The machine harness has failed. Repair: The Cat Data Link circuit is open in the machine harness. Repair the machine harness or replace the machine harness. Stop. Test Step 6. CHECK FOR ADDITIONAL DIAGNOSTIC CODES FOR THE OTHER ELECTRONIC CONTROL MODULES. A.

A. Reconnect all the electronic control modules that use the Cat Data Link. B. Turn the disconnect switch and the key start switch to the ON position. C. After each of the electronic control modules has been reconnected, check the Event List for diagnostic codes that are logged against the electronic control module. Expected Result: Diagnostic codes are not present for the other electronic control modules (ECM) in the event list. Results: OK - Diagnostic codes are not present for the other electronic control modules (ECM) in the event list. Repair: The engine ECM has failed. It is unlikely that the ECM has failed. Exit this procedure. Perform this procedure again. If the failure is not found, replace the ECM. Stop. NOT OK - Diagnostic codes are present for the other electronic control modules (ECM) in the event list. Repair: The machine ECM may have failed. It is unlikely that the ECM has failed. Exit this procedure. Perform this procedure again. If the failure is not found, replace the ECM. See the Testing and Adjusting, "Electronic Control Module (ECM) - Replace". Stop.

TROUBLESHOOTING

031

TROUBLESHOOTING

i01792822

MID 039 - CID 0598 - FMI 03 SMCS - 5479-038-V6 Conditions Which Generate This Code:

Illustration 1

g00840442

Schematic of the Solenoid valve (travel speed)

This diagnostic code is associated with the Solenoid valve (travel speed). The FMI 03 means that the machine ECM has determined that the voltage of the solenoid circuit is above normal. The possible causes of the diagnostic code are listed: The solenoid has failed. The energize circuit of the solenoid is shorted to the +battery circuit. The machine ECM has failed. This is unlikely.

Note: The following test procedure may create other diagnostic codes. Ignore these created diagnostic codes and clear these diagnostic codes when the original diagnostic code has been corrected. Ensure that the diagnostic code of CID 0598 FMI 03 is active before performing this procedure. Note: Use the 146-4080 Digital Multimeter for the measurements in this procedure. System Response: When this diagnostic code is active, the machine ECM will be unable to control the travel speed. The travel speed will always be set to low speed. Test Step 1. CHECK THE ENERGIZE CIRCUIT OF THE SOLENOID FOR A SHORT TO THE +BATTERY CIRCUIT. A. Turn the key start switch and the disconnect switch to the OFF position. B.

A. B. Disconnect the machine harness connectors from the solenoid and the machine ECM. C. At the machine harness connector for the machine ECM, measure the resistance from contact J2-61 (wire R981-YL) to all contacts that are used in the machine harness connectors for the machine ECM. Expected Result: Each resistance measurement is greater than 5000 ohms. Results: OK - Each resistance measurement is greater than 5000 ohms. The machine harness is correct. Proceed to Test Step 2. NOT OK - Each resistance measurement is not greater than 5000 ohms. There is a short in the machine harness. The short is between J2-61 (R981-YL) and the circuit that has a low resistance measurement. Repair: Repair the machine harness or replace the machine harness. Stop. Test Step 2. CHECK IF THE DIAGNOSTIC CODE IS STILL ACTIVE. A. Inspect the contacts and clean the contacts of the harness connectors. B. Reconnect all harness connectors. C. Turn the disconnect switch and the key start switch to the ON position. D. Operate the machine. E. Determine if the CID 0598 FMI 03 is active. Expected Result: The CID 0598 FMI 03 is active. Results: YES - The CID 0598 FMI 03 is active. The problem has not been corrected. The machine ECM may have failed. Repair: It is unlikely that the machine ECM has failed. Exit this procedure and perform this procedure again. If the cause of the diagnostic code is not found, replace the machine ECM. See Testing and Adjusting, "Electronic Control Module (ECM) - Replace". Stop. NO - The CID 0598 FMI 03 is not active. The problem does not exist at this time. Repair: The initial diagnostic code was probably caused by a poor electrical connection or a short at one of the harness connectors that was disconnected and reconnected. Resume normal machine operation. Stop.

TROUBLESHOOTING

032

TROUBLESHOOTING

i01792825

MID 039 - CID 0598 - FMI 05 SMCS - 5479-038-V6 Conditions Which Generate This Code:

Illustration 1

g00840442

Schematic of the Solenoid valve (travel speed)

This diagnostic code is associated with the Solenoid valve (travel speed). The FMI 05 means that the machine ECM has determined that the current of the solenoid is below normal. The possible causes of this diagnostic code are listed below: The energize circuit of the solenoid is open. The return circuit of the solenoid is open. The solenoid has failed. The machine ECM has failed. This is unlikely.

Note: The following test procedure may create other diagnostic codes. Ignore these created diagnostic codes and clear these diagnostic codes when the original diagnostic code has been corrected. Ensure that the diagnostic code of CID 0598 FMI 05 is active before performing this procedure. Note: Use the 146-4080 Digital Multimeter for the measurements in this procedure. System Response: When this diagnostic code is active, the machine ECM will be unable to control the travel speed. The travel speed will always be set to high speed. Test Step 1. CHECK THE SOLENOID. A. Turn the disconnect switch and the key start switch to the ON position. Do not start the engine. B.

A. B. Disconnect the solenoid with the active diagnostic code from the machine harness. C. At the machine harness connector for the solenoid, place a jumper wire from contact 1 (wire R981-YL) to contact 2 (wire H802-GY). D. Observe the status of the CID 0598 FMI 05. Expected Result: The CID 0598 FMI 05 remains active. The FMI has not changed and the "05" is still active. Results: YES - The diagnostic code remains active. The jumper wire does not affect the diagnostic code. Proceed to Test Step 2. NO - The diagnostic is no longer active. The solenoid has failed. Repair: The solenoid has failed. Repeat this Test Step "CHECK THE SOLENOID" in order to verify the solenoid failure. Replace the solenoid. Verify that the new solenoid corrects the problem. Stop. Test Step 2. CHECK THE HARNESS FOR AN OPEN. A. Turn the key start switch and the disconnect switch to the OFF position. B. Disconnect the machine harness connector(s) from the machine ECM. C. The jumper wire that was installed in the previous Test Step remains in place. D. At the machine harness connector, measure the resistance from signal contact J2-61 (wire R981-YL) to contact J2-49 (wire H802-GY). Expected Result: The resistance is less than 5.0 ohms. Results: OK - The resistance is less than 5.0 ohms. The machine harness is correct. Proceed to Test Step 3. NOT OK - The resistance is greater than 5000 ohms. The resistance measurement is not correct. There is an open circuit in the machine harness. Repair: The open is in wire R981-YL or in wire H802-GY of the machine harness. Repair the machine harness or replace the machine harness. Stop. Test Step 3. CHECK IF THE DIAGNOSTIC CODE REMAINS. A. Inspect the contacts of the harness connectors and clean the harness connectors. B. Reconnect all harness connectors. C. Turn the disconnect switch and the key start switch to the ON position. D. Operate the machine. E. Check the status of the CID 0598 FMI 05. Expected Result: The CID 0598 FMI 05 is active.

Results: YES - The CID 0598 FMI 05 is active. The diagnostic code has not been corrected. The machine ECM may have failed. Repair: It is unlikely that the machine ECM has failed. Exit this procedure and perform this procedure again. If the cause of the diagnostic code is not found, replace the machine ECM. See Testing and Adjusting, "Electronic Control Module (ECM) - Replace". Stop. NO - The CID 0598 FMI 05 is not active. The diagnostic code does not exist at this time. Repair: The initial diagnostic code was probably caused by a poor electrical connection or a short at one of the harness connectors that was disconnected and reconnected. Resume normal machine operation. Stop.

TROUBLESHOOTING

033

TROUBLESHOOTING

i01792833

MID 039 - CID 0598 - FMI 06 SMCS - 5479-038-V6 Conditions Which Generate This Code:

Illustration 1

g00840442

Schematic of the Solenoid valve (travel speed)

This diagnostic code is associated with the Solenoid valve (travel speed). The FMI 06 means that the machine ECM has determined that the current of the solenoid is above normal. The possible causes of this diagnostic code are listed: The energize circuit of the solenoid is shorted to ground. The solenoid has failed. The machine ECM has failed. This is unlikely.

Note: The following test procedure may create other diagnostic codes. Ignore these created diagnostic codes and clear these diagnostic codes when the original diagnostic code has been corrected. Ensure that the diagnostic code of CID 0598 FMI 06 is active before performing this procedure. Note: Use the 146-4080 Digital Multimeter for the measurements in this procedure. System Response: When this diagnostic code is active, the machine ECM will be unable to control the travel speed. The travel speed will always be set to high speed. Test Step 1. CHECK THE SOLENOID. A. Turn the disconnect switch and the key start switch to the ON position. Do not start the engine. B. Observe the status of the diagnostic code. C.

B. C. Disconnect the solenoid with the active diagnostic code from the machine harness. Expected Result: CID 0598 FMI 06 changes to CID 0598 FMI 05 when the solenoid is disconnected. Results: YES - CID 0598 FMI 06 changes to CID 0598 FMI 05 when the solenoid is disconnected. The circuit is correct. Repair: The solenoid has failed. Repeat this test "CHECK THE SOLENOID" in order to verify the solenoid failure. Replace the solenoid. Stop. NO - CID 0598 FMI 06 remains active. Proceed to Test Step 2. Test Step 2. CHECK THE ENERGIZE CIRCUIT OF THE SOLENOID FOR A SHORT TO GROUND. A. Turn the key start switch and the disconnect switch to the OFF position. B. The solenoid remains disconnected from the machine harness. C. Disconnect the machine harness connector(s) from the machine ECM. D. At the machine harness connector, measure the resistance from the signal contact J2-61 (wire R981-YL) to all contacts that are used in the machine harness connectors for the machine ECM. Expected Result: Each resistance measurement is greater than 5000 ohms. Results: OK - Each resistance measurement is greater than 5000 ohms. The machine harness is correct. Proceed to Test Step 3. NOT OK - Each resistance measurement is not greater than 5000 ohms. There is a short in the machine harness. The short is between J2-61 (wire R981-YL) and the circuit with the low resistance measurement. Repair: Repair the machine harness or replace the machine harness. Stop. Test Step 3. CHECK IF THE DIAGNOSTIC CODE REMAINS. A. Inspect the harness connectors and clean the contacts of the harness connectors. B. Reconnect all harness connectors. C. Turn the disconnect switch and the key start switch to the ON position. D. Operate the machine. E. Check the status of the CID 0598 FMI 06. Expected Result: The CID 0598 FMI 06 is active. Results: YES - The CID 0598 FMI 06 is active. The diagnostic code has not been corrected. The machine ECM may have failed. Repair: It is unlikely that the machine ECM has failed. Exit this procedure and perform this procedure again. If the cause of the diagnostic code is not found, replace the machine ECM. See Testing and Adjusting, "Electronic Control Module (ECM) - Replace". Stop.

NO - The CID 0598 FMI 06 is not active. The diagnostic code does not exist at this time. Repair: The initial diagnostic code was probably caused by a poor electrical connection or a short at one of the harness connectors that was disconnected and reconnected. Resume normal machine operation. Stop.

TROUBLESHOOTING

034

TROUBLESHOOTING

i01792835

MID 039 - CID 0600 - FMI 03 SMCS - 5095-038-NS Conditions Which Generate This Code:

Illustration 1

g00840581

Schematic of the Sensor (hydraulic oil temperature)

This diagnostic code is associated with the Sensor (hydraulic oil temperature). The FMI 03 means that the machine ECM has determined that the voltage of the circuit for the sensor is above normal. Refer to Systems Operation, "Sensors" for information regarding the operation of the sensor and the location. The output of the sensor (hydraulic oil temperature) is a 500 Hz PWM signal. The signal varies in the duty cycle from 0 to 100 percent. The duty cycle changes as the temperature changes. The machine ECM recognizes a duty cycle in the range of 3 percent to 97 percent as valid input from the sensor. If the duty cycle is below 3 percent, the machine ECM determines that the sensor is shorted to ground. If the voltage is above 97 percent, the machine ECM will determine that the sensor is shorted to the battery. The possible causes of this diagnostic code are listed below: The signal circuit for the sensor is open. The signal circuit for the sensor is shorted to the +battery circuit. The sensor has failed. The power circuit or the ground circuit has failed. The machine ECM has failed. This is unlikely.

Note: The following test procedure may create other diagnostic codes. Ignore these created diagnostic codes and clear the diagnostic codes when the original diagnostic code has been corrected. Ensure that the diagnostic code of CID 0600 FMI

03 is active before performing this procedure. Note: Use the 146-4080 Digital Multimeter for the measurements in this procedure. System Response: When this diagnostic code occurs, the machine ECM will not consider this input for calculating the fan speed. The Electronic Technician will display"Abnormal/Incorrect Data" parameter for the Hydraulic Oil Temperature. Test Step 1. CHECK FOR POWER AT THE SENSOR. A. Do not disconnect the harness connector from the sensor. B. Turn the key start switch and the disconnect switch to the ON position. C. At the back of the harness connector for the sensor, insert a 7X-1710 Multimeter Probe along the voltage supply wire (contact A). D. Measure the voltage from contact 1 to frame ground. Expected Result: The voltage is +8 DCV. Results: OK - The voltage is +8 DCV. Proceed to Test Step 2. NOT OK - The voltage is not +8 DCV. The + battery circuit in the machine harness has failed. Repair: Replace the machine harness or repair the machine harness. Stop. Test Step 2. CHECK FOR PROPER GROUND AT THE SENSOR. A. The machine harness remains connected to the sensor. B. Turn the key start switch and the disconnect switch to the OFF position. C. Remove the 7X-1710 Multimeter Probe from the voltage supply wire (contact A). D. At the back of the harness connector for the sensor, insert a 7X-1710 Multimeter Probe along the ground wire (contact B). E. Measure the resistance from contact B to frame ground. Expected Result: The resistance is less than 5 ohms. Results: OK - The resistance is less than 5 ohms. The ground circuit is correct. Proceed to Test Step 3. NOT OK - The resistance is greater than 5 ohms. The ground circuit in the machine harness has failed. Repair: Replace the machine harness or repair the machine harness. Stop. Test Step 3. CHECK THE WIRING HARNESS OF THE SENSOR FOR AN OPEN CIRCUIT. A. The key start switch and the disconnect switch remain in the OFF position. B. Disconnect the machine harness from the sensor. C. At the harness connector for the sensor, connect a jumper wire between contact B and contact C. D. Disconnect the machine harness connector(s) from the machine ECM.

D. E. At the harness connector for the machine ECM, measure the resistance between contact J1-61 (wire 442-GY) and contact J1-12 (wire G939-PK). Expected Result: The resistance measurement is less than 5 ohms. Results: OK - The resistance measurement is less than 5 ohms. The circuit is correct. Proceed to Test Step 4. NOT OK - The resistance is greater than 5 ohms. The circuit is not correct. There is an open circuit in the wiring harness. Repair: There is an open circuit in the wiring harness. Repair the wiring harness or replace the wiring harness. Stop. Test Step 4. CHECK THE WIRING HARNESS OF THE SENSOR FOR A SHORT TO THE +BATTERY CIRCUIT. A. The key start switch and the disconnect switch remain in the OFF position. B. The machine harness remains disconnected from the sensor. Remove the jumper wire that was installed in the previous step. C. The machine harness connector(s) remains disconnected from the machine ECM. D. At the machine harness connector for the machine ECM, measure the resistance from the signal contact J1-61 (wire 442GY) of the machine harness to all contacts that are used in the machine harness connectors for the machine ECM. Expected Result: Each resistance measurement is greater than 5000 ohms. Results: OK - Each resistance measurement is greater than 5000 ohms. The machine harness is correct. Proceed to Test Step 5. NOT OK - One or more resistance measurements is not correct. There is a short in the machine harness. Repair: The short is between signal contact J1-61 (wire 442-GY) and the circuit with the low resistance measurement. Repair the machine harness or replace the machine harness. Stop. Test Step 5. CHECK THE OUTPUT OF THE SENSOR. A. Reconnect the machine harness connectors to the machine ECM. Reconnect the machine harness connector to the sensor. B. At the back of the harness connector for the sensor, insert a 7X-1710 Multimeter Probe along the signal wire (contact C). C. At the back of the harness connector for the sensor, insert a 7X-1710 Multimeter Probe along the ground wire (contact B). D. Turn the disconnect switch and the key start switch to the ON position. E. Measure the signal of the sensor. The proper signal is described at the beginning of this procedure. Expected Result: The signal from the sensor is valid. Results: OK - The signal from the sensor is valid. Proceed to Test Step 6.

NOT OK - The signal from the sensor is not valid. Repair: The sensor has failed. Replace the sensor. Stop. Test Step 6. CHECK IF THE DIAGNOSTIC CODE REMAINS. A. Inspect the contacts of the harness connectors and clean the connectors. B. Reconnect all harness connectors. C. Turn the disconnect switch and the key start switch to the ON position. D. Operate the machine. E. Check the status of the CID 0600 FMI 03. Expected Result: The CID 0600 FMI 03 is active. Results: YES - The CID 0600 FMI 03 is active. The diagnostic code has not been corrected. The machine ECM may have failed. Repair: It is unlikely that the machine ECM has failed. Exit this procedure and perform this procedure again. If the cause of the diagnostic code is not found, replace the machine ECM. See Testing and Adjusting, "Electronic Control Module (ECM) - Replace". Stop. NO - The CID 0600 FMI 03 is not active. The diagnostic code does not exist at this time. Repair: The initial diagnostic code was probably caused by a poor electrical connection or a short at one of the harness connectors that was disconnected and reconnected. Resume normal machine operation. Stop.

TROUBLESHOOTING

035

TROUBLESHOOTING

i01901036

MID 039 - CID 0600 - FMI 04 SMCS - 5095-038-NS Conditions Which Generate This Code:

Illustration 1

g00840581

Schematic of the Sensor (hydraulic oil temperature)

This diagnostic code is associated with the Sensor (hydraulic oil temperature). The FMI 04 means that the machine ECM has determined that the voltage of the circuit for the position sensor is below normal. The duty cycle of 3 percent to 97 percent from the sensor corresponds to a temperature of -114 degrees to 170 degrees. Any temperature in that range will be recognized by the machine ECM. The machine ECM will consider temperatures in the range to be within normal operating limits. The possible causes of this diagnostic code are listed below: The signal circuit for the sensor is shorted to ground. The sensor has failed. The machine ECM has failed. This is unlikely.

Note: The following test procedure may create other diagnostic codes. Ignore these created diagnostic codes and clear the diagnostic codes when the original diagnostic code has been corrected. Ensure that the diagnostic code of CID 0600 FMI 04 is active before performing this procedure. Note: Use the 146-4080 Digital Multimeter for the measurements in this procedure. System Response: When this diagnostic code occurs, the machine ECM will no longer consider this input for calculating the fan speed. The Electronic Technician will display "Abnormal/Incorrect Data" parameter for the Hydraulic Oil Temperature. Test Step 1. CHECK THE SENSOR. A.

A. Turn the disconnect switch and the key start switch to the ON position. B. Ensure that the diagnostic code is active. C. Observe the status of the diagnostic code. Disconnect the sensor from the machine harness. Expected Result: The CID 0600 FMI 04 remains active. The FMI has not changed and the "04" is still active. Results: OK - The diagnostic code remains active. The sensor is correct. Proceed to Test Step 2. NOT OK - The diagnostic code is no longer active. The sensor has failed. Repair: Replace the sensor. Stop. Test Step 2. CHECK THE WIRING HARNESS OF THE SENSOR FOR A SHORT TO GROUND. A. Turn the key start switch and the disconnect switch to the OFF position. B. Disconnect the machine harness from the sensor. C. Disconnect the machine harness connector(s) from the machine ECM. D. At the machine harness connector for the machine ECM, measure the resistance from the signal contact J1-61 (wire 442GY) of the machine harness to all possible sources of ground. Measure the resistance to all contacts of the machine harness connectors for the machine ECM. Expected Result: Each resistance measurement is greater than 5000 ohms. Results: OK - Each resistance measurement is greater than 5000 ohms. The machine harness is correct. Proceed to Test Step 3. NOT OK - One or more resistance measurements is not correct. There is a short in the machine harness. Repair: The short is between signal contact J1-61 (wire 442-GY) and the circuit with the low resistance measurement. Repair the machine harness or replace the machine harness. Stop. Test Step 3. CHECK IF THE DIAGNOSTIC CODE REMAINS. A. Inspect the contacts of the harness connectors and clean the contacts. B. Reconnect all harness connectors. C. Turn the disconnect switch and the key start switch to the ON position. D. Operate the machine. E. Check the status of the CID 0600 FMI 04. Expected Result: The CID 0600 FMI 04 is active. Results: YES - The CID 0600 FMI 04 is active. The diagnostic code has not been corrected. The machine ECM may have failed.

Repair: It is unlikely that the machine ECM has failed. Exit this procedure and perform this procedure again. If the cause of the diagnostic code is not found, replace the machine ECM. See Testing and Adjusting, "Electronic Control Module (ECM) - Replace". Stop. NO - The CID 0600 FMI 04 is not active. The diagnostic code does not exist at this time. Repair: The initial diagnostic code was probably caused by a poor electrical connection or a short at one of the harness connectors that was disconnected and reconnected. Resume normal machine operation. Stop.

TROUBLESHOOTING

036

TROUBLESHOOTING

i01792876

MID 039 - CID 0681 - FMI 03 SMCS - 5479-038-BRK Conditions Which Generate This Code:

Illustration 1

g00840451

Schematic of the Solenoid valve (parking brake)

This diagnostic code is associated with the Solenoid valve (parking brake). The FMI 03 means that the machine ECM has determined that the voltage of the solenoid circuit is above normal. The possible causes of the diagnostic code are listed: The solenoid has failed. The energize circuit of the solenoid is shorted to the +battery circuit. The machine ECM has failed. This is unlikely.

Note: The following test procedure may create other diagnostic codes. Ignore these created diagnostic codes and clear these diagnostic codes when the original diagnostic code has been corrected. Ensure that the diagnostic code of CID 0681 FMI 03 is active before performing this procedure. Note: Use the 146-4080 Digital Multimeter for the measurements in this procedure. System Response: When this diagnostic code is active, the machine ECM will be unable to control the parking brake solenoid. The parking brake will never be activated. Test Step 1. CHECK THE ENERGIZE CIRCUIT OF THE SOLENOID FOR A SHORT TO THE +BATTERY CIRCUIT. A. Turn the key start switch and the disconnect switch to the OFF position. B.

A. B. Disconnect the machine harness connectors from the solenoid and the machine ECM. C. At the machine harness connector for the machine ECM, measure the resistance from contact J2-55 (wire C744-PU) to all contacts that are used in the machine harness connectors for the machine ECM. Expected Result: Each resistance measurement is greater than 5000 ohms. Results: OK - Each resistance measurement is greater than 5000 ohms. The machine harness is correct. Proceed to Test Step 2. NOT OK - Each resistance measurement is not greater than 5000 ohms. There is a short in the machine harness. The short is between J2-55 (C744-PU) and the circuit that has a low resistance measurement. Repair: Repair the machine harness or replace the machine harness. Stop. Test Step 2. CHECK IF THE DIAGNOSTIC CODE IS STILL ACTIVE. A. Inspect the contacts and clean the contacts of the harness connectors. B. Reconnect all harness connectors. C. Turn the disconnect switch and the key start switch to the ON position. D. Operate the machine. E. Determine if the CID 0681 FMI 03 is active. Expected Result: The CID 0681 FMI 03 is active. Results: YES - The CID 0681 FMI 03 is active. The problem has not been corrected. The machine ECM may have failed. Repair: It is unlikely that the machine ECM has failed. Exit this procedure and perform this procedure again. If the cause of the diagnostic code is not found, replace the machine ECM. See Testing and Adjusting, "Electronic Control Module (ECM) - Replace". Stop. NO - The CID 0681 FMI 03 is not active. The problem does not exist at this time. Repair: The initial diagnostic code was probably caused by a poor electrical connection or a short at one of the harness connectors that was disconnected and reconnected. Resume normal machine operation. Stop.

TROUBLESHOOTING

037

TROUBLESHOOTING

i01792877

MID 039 - CID 0681 - FMI 05 SMCS - 5479-038-BRK Conditions Which Generate This Code:

Illustration 1

g00840451

Schematic of the Solenoid valve (parking brake)

This diagnostic code is associated with the Solenoid valve (parking brake). The FMI 05 means that the machine ECM has determined that the current of the solenoid is below normal. The possible causes of this diagnostic code are listed below: The energize circuit of the solenoid is open. The return circuit of the solenoid is open. The solenoid has failed. The machine ECM has failed. This is unlikely.

Note: The following test procedure may create other diagnostic codes. Ignore these created diagnostic codes and clear these diagnostic codes when the original diagnostic code has been corrected. Ensure that the diagnostic code of CID 0681 FMI 05 is active before performing this procedure. Note: Use the 146-4080 Digital Multimeter for the measurements in this procedure. System Response: When this diagnostic code is active, the machine ECM will be unable to control the parking brake solenoid. The parking brake will always be activated. Test Step 1. CHECK THE SOLENOID. A. Turn the disconnect switch and the key start switch to the ON position. Do not start the engine. B.

A. B. Disconnect the solenoid with the active diagnostic code from the machine harness. C. At the machine harness connector for the solenoid, place a jumper wire from contact 1 (wire C744-PU) to contact 2 (wire H807-YL). D. Observe the status of the CID 0681 FMI 05. Expected Result: The CID 0681 FMI 05 remains active. The FMI has not changed and the "05" is still active. Results: YES - The diagnostic code remains active. The jumper wire does not affect the diagnostic code. Proceed to Test Step 2. NO - The diagnostic is no longer active. The solenoid has failed. Repair: The solenoid has failed. Repeat this Test Step "CHECK THE SOLENOID" in order to verify the solenoid failure. Replace the solenoid. Verify that the new solenoid corrects the problem. Stop. Test Step 2. CHECK THE HARNESS FOR AN OPEN. A. Turn the key start switch and the disconnect switch to the OFF position. B. Disconnect the machine harness connector(s) from the machine ECM. C. The jumper wire that was installed in the previous Test Step remains in place. D. At the machine harness connector, measure the resistance from signal contact J2-55 (wire C744-PU) to contact J2-36 (wire H807-YL). Expected Result: The resistance is less than 5.0 ohms. Results: OK - The resistance is less than 5.0 ohms. The machine harness is correct. Proceed to Test Step 3. NOT OK - The resistance is greater than 5000 ohms. The resistance measurement is not correct. There is an open circuit in the machine harness. Repair: The open is in wire C744-PU or in wire H807-YL of the machine harness. Repair the machine harness or replace the machine harness. Stop. Test Step 3. CHECK IF THE DIAGNOSTIC CODE REMAINS. A. Inspect the contacts of the harness connectors and clean the harness connectors. B. Reconnect all harness connectors. C. Turn the disconnect switch and the key start switch to the ON position. D. Operate the machine. E. Check the status of the CID 0681 FMI 05. Expected Result: The CID 0681 FMI 05 is active.

Results: YES - The CID 0681 FMI 05 is active. The diagnostic code has not been corrected. The machine ECM may have failed. Repair: It is unlikely that the machine ECM has failed. Exit this procedure and perform this procedure again. If the cause of the diagnostic code is not found, replace the machine ECM. See Testing and Adjusting, "Electronic Control Module (ECM) - Replace". Stop. NO - The CID 0681 FMI 05 is not active. The diagnostic code does not exist at this time. Repair: The initial diagnostic code was probably caused by a poor electrical connection or a short at one of the harness connectors that was disconnected and reconnected. Resume normal machine operation. Stop.

TROUBLESHOOTING

038

TROUBLESHOOTING

i01792878

MID 039 - CID 0681 - FMI 06 SMCS - 5479-038-BRK Conditions Which Generate This Code:

Illustration 1

g00840451

Schematic of the Solenoid valve (parking brake)

This diagnostic code is associated with the Solenoid valve (parking brake). The FMI 06 means that the machine ECM has determined that the current of the solenoid is above normal. The possible causes of this diagnostic code are listed: The energize circuit of the solenoid is shorted to ground. The solenoid has failed. The machine ECM has failed. This is unlikely.

Note: The following test procedure may create other diagnostic codes. Ignore these created diagnostic codes and clear these diagnostic codes when the original diagnostic code has been corrected. Ensure that the diagnostic code of CID 0681 FMI 06 is active before performing this procedure. Note: Use the 146-4080 Digital Multimeter for the measurements in this procedure. System Response: When this diagnostic code is active, the machine ECM will be unable to control the parking brake solenoid. The parking brake will always be activated. Test Step 1. CHECK THE SOLENOID. A. Turn the disconnect switch and the key start switch to the ON position. Do not start the engine. B. Observe the status of the diagnostic code. C.

B. C. Disconnect the solenoid with the active diagnostic code from the machine harness. Expected Result: CID 0681 FMI 06 changes to CID 0681 FMI 05 when the solenoid is disconnected. Results: YES - CID 0681 FMI 06 changes to CID 0681 FMI 05 when the solenoid is disconnected. The circuit is correct. Repair: The solenoid has failed. Repeat this test "CHECK THE SOLENOID" in order to verify the solenoid failure. Replace the solenoid. Stop. NO - CID 0681 FMI 06 remains active. Proceed to Test Step 2. Test Step 2. CHECK THE ENERGIZE CIRCUIT OF THE SOLENOID FOR A SHORT TO GROUND. A. Turn the key start switch and the disconnect switch to the OFF position. B. The solenoid remains disconnected from the machine harness. C. Disconnect the machine harness connector(s) from the machine ECM. D. At the machine harness connector, measure the resistance from the signal contact J2-55 (wire C744-PU) to all contacts that are used in the machine harness connectors for the machine ECM. Expected Result: Each resistance measurement is greater than 5000 ohms. Results: OK - Each resistance measurement is greater than 5000 ohms. The machine harness is correct. Proceed to Test Step 3. NOT OK - Each resistance measurement is not greater than 5000 ohms. There is a short in the machine harness. The short is between J2-55 (wire C744-PU) and the circuit with the low resistance measurement. Repair: Repair the machine harness or replace the machine harness. Stop. Test Step 3. CHECK IF THE DIAGNOSTIC CODE REMAINS. A. Inspect the harness connectors and clean the contacts of the harness connectors. B. Reconnect all harness connectors. C. Turn the disconnect switch and the key start switch to the ON position. D. Operate the machine. E. Check the status of the CID 0681 FMI 06. Expected Result: The CID 0681 FMI 06 is active. Results: YES - The CID 0681 FMI 06 is active. The diagnostic code has not been corrected. The machine ECM may have failed. Repair: It is unlikely that the machine ECM has failed. Exit this procedure and perform this procedure again. If the cause of the diagnostic code is not found, replace the machine ECM. See Testing and Adjusting, "Electronic Control Module (ECM) - Replace". Stop.

NO - The CID 0681 FMI 06 is not active. The diagnostic code does not exist at this time. Repair: The initial diagnostic code was probably caused by a poor electrical connection or a short at one of the harness connectors that was disconnected and reconnected. Resume normal machine operation. Stop.

TROUBLESHOOTING

039

TROUBLESHOOTING

i02282772

MID 039 - CID 0727 - FMI 03 SMCS - 5479-038-ZH Conditions Which Generate This Code:

Illustration 1

g01142533

Schematic of the Medium Pressure Solenoid 2 (attachment)

This diagnostic code is associated with the medium pressure solenoid 2. The FMI 03 means that the ECM has determined that the voltage of the solenoid circuit is above normal. Some possible causes of the diagnostic code are listed: The solenoid has failed. The energize circuit of the solenoid is shorted to the +battery circuit. The ECM has failed. This is unlikely.

System Response: When the CID 0727 FMI 03 diagnostic code is active, the machine response will be: The warning indicator on the Monitor will illuminate. The medium pressure functions that are controlled by the right hand joystick thumbwheel will be disabled.

Note: The following test procedure may create other diagnostic codes. Ignore these created diagnostic codes and clear these diagnostic codes when the original diagnostic code has been corrected. Ensure that the diagnostic code of CID 0727 FMI 03 is active before performing this procedure. Test Step 1. CHECK THE ENERGIZE CIRCUIT OF THE SOLENOID FOR A SHORT TO THE +BATTERY

CIRCUIT A. Turn the key start switch and the disconnect switch to the OFF position. B. Disconnect the machine harness connector from the solenoid. Disconnect the machine harness connectors J-1 and J-2 from the ECM. C. At the machine harness ECM connector J2, measure the resistance from contact J2-3 (wire P942-YL) to all J-1 and J2 contacts that are connected to +battery. The J-1 contact is J1-58. The J2 contacts are: J2-1, J2-23, J2-47, J2-57 and J270. Expected Result: Each resistance measurement is greater than 5000 ohms. Results: OK - Each resistance measurement is greater than 5000 ohms. The machine harness is correct. Proceed to Test Step 2. NOT OK - Each resistance measurement is not greater than 5000 ohms. There is a short in the machine harness. The short is between J2-3 (P942-YL) and the circuit that has a low resistance measurement. Repair: Repair the machine harness or replace the machine harness. Stop. Test Step 2. CHECK IF THE DIAGNOSTIC CODE IS STILL ACTIVE A. Inspect the contacts of the harness connectors that are used in the solenoid circuit. Ensure that the contacts are secure. Clean all of the contacts in the harness connectors. B. Reconnect all harness connectors. C. Turn the disconnect switch and the key start switch to the ON position. D. Operate the machine. E. Determine if the CID 0727 FMI 03 is active. Expected Result: The CID 0727 FMI 03 is active. Results: YES - The CID 0727 FMI 03 is active. Repair: Replace the medium pressure solenoid 2. After solenoid replacement, repeat this Test Step again. If the diagnostic code is still active, the ECM may be faulty. It is unlikely that the ECM has failed. Exit this procedure and perform this procedure again. If the cause of the diagnostic code is not found, replace the ECM. See Testing and Adjusting, "Electronic Control Module (ECM) - Replace". Stop. NO - The CID 0727 FMI 03 is not active. The problem does not exist at this time. Repair: The initial diagnostic code was probably caused by a poor electrical connection or a short at one of the harness connectors that was disconnected and reconnected. Resume normal machine operation. Stop.

TROUBLESHOOTING

040

TROUBLESHOOTING

i02282778

MID 039 - CID 0727 - FMI 05 SMCS - 5479-038-ZH Conditions Which Generate This Code:

Illustration 1

g01142604

Schematic of the Medium Pressure Solenoid 2 (attachment)

This diagnostic code is associated with the medium pressure solenoid 2. The FMI 05 means that the ECM has determined that the current for the solenoid is below normal. An open may exist in the circuit for the solenoid. Some possible causes of this diagnostic code are listed below: The energize circuit of the solenoid is open. The return circuit of the solenoid is open. The solenoid has failed. The ECM has failed. This is unlikely.

System Response: When the CID 0727 FMI 03 diagnostic code is active, the machine response will be: The warning indicator on the Monitor will illuminate. The medium pressure functions that are controlled by the right hand joystick thumbwheel will be disabled.

Note: The following test procedure may create other diagnostic codes. Ignore these created diagnostic codes and clear these diagnostic codes when the original diagnostic code has been corrected. Ensure that the diagnostic code of CID 0727 FMI

05 is active before performing this procedure. Test Step 1. CHECK THE SOLENOID A. Disconnect the solenoid with the active diagnostic code from the machine harness. B. At the machine harness connector for the solenoid, place a jumper wire from contact 1 (wire P942-YL) to contact 2 (wire H805-BR). C. Turn the disconnect switch and the key start switch to the ON position. Do not start the engine. D. Observe the status of the CID 0727 FMI 05. Expected Result: The CID 0727 FMI 05 remains active. Results: YES - The diagnostic code remains active. The jumper wire does not affect the diagnostic code. Proceed to Test Step 2. NO - The diagnostic is no longer active. The solenoid has failed. Repair: The solenoid has failed. Repeat this Test Step "CHECK THE SOLENOID" in order to verify the solenoid failure. Replace the solenoid. Verify that the new solenoid corrects the problem. Stop. Test Step 2. CHECK THE HARNESS FOR AN OPEN A. Turn the key start switch and the disconnect switch to the OFF position. B. Disconnect the machine harness ECM connector J2 from the ECM. C. The jumper wire that was installed in the previous Test Step remains in place. D. At the machine harness connector J2 for the ECM, measure the resistance from contact J2-3 (wire P942-YL) to contact J2-12 (wire H805-BR). Expected Result: The resistance is less than 5 ohms. Results: OK - The resistance is less than 5 ohms. The machine harness is correct. Proceed to Test Step 3. NOT OK - The resistance is greater than 5000 ohms. The resistance measurement is not correct. There is an open circuit in the machine harness. A resistance measurement that is much greater than 5 ohms but less than 5000 ohms could indicate that one of the connection points in the circuit is not open but is not a good connection. Repair: The open or possible bad connection is in wire P942-YL or in wire H805-BR of the machine harness. Repair the machine harness or replace the machine harness. Stop. Test Step 3. CHECK IF THE DIAGNOSTIC CODE REMAINS A. Inspect the contacts of the harness connectors that are used in the solenoid circuit. Ensure that the contacts are secure. Clean all of the contacts in the harness connectors. B. Reconnect all harness connectors. C. Turn the disconnect switch and the key start switch to the ON position. D.

C. D. Operate the machine. E. Check the status of the CID 0727 FMI 05. Expected Result: The CID 0727 FMI 05 is active. Results: YES - The CID 0727 FMI 05 is active. The diagnostic code has not been corrected. The ECM may have failed. Repair: It is unlikely that the ECM has failed. Exit this procedure and perform this procedure again. If the cause of the diagnostic code is not found, replace the ECM. See Testing and Adjusting, "Electronic Control Module (ECM) - Replace". Stop. NO - The CID 0727 FMI 05 is not active. The diagnostic code does not exist at this time. Repair: The initial diagnostic code was probably caused by a poor electrical connection at one of the harness connectors that was disconnected and reconnected. Resume normal machine operation. Stop.

TROUBLESHOOTING

041

TROUBLESHOOTING

i02282779

MID 039 - CID 0727 - FMI 06 SMCS - 5479-038-ZH Conditions Which Generate This Code:

Illustration 1

g01142624

Schematic of the Medium Pressure Solenoid 2 (attachment)

This diagnostic code is associated with the medium pressure solenoid 2. The FMI 06 means that the ECM has determined that the current for the solenoid is above normal. There may be a short to ground in the solenoid circuit. Some possible causes of this diagnostic code are listed: The energize circuit of the solenoid is shorted to ground. The solenoid has failed. The ECM has failed. This is unlikely.

System Response: When the CID 0727 FMI 03 diagnostic code is active, the machine response will be: The warning indicator on the Monitor will illuminate. The medium pressure functions that are controlled by the right hand joystick thumbwheel will be disabled.

Note: The following test procedure may create other diagnostic codes. Ignore these created diagnostic codes and clear these diagnostic codes when the original diagnostic code has been corrected. Ensure that the diagnostic code of CID 0727 FMI 06 is active before performing this procedure. Test Step 1. CHECK THE SOLENOID A.

A. Turn the disconnect switch and the key start switch to the ON position. Do not start the engine. B. Observe the status of the diagnostic code. C. Disconnect the solenoid with the active diagnostic code from the machine harness. Expected Result: CID 0727 FMI 06 changes to CID 0727 FMI 05 when the solenoid is disconnected. Results: YES - CID 0727 FMI 06 changes to CID 0727 FMI 05 when the solenoid is disconnected. The circuit is correct. Repair: The solenoid has failed. Repeat this test "CHECK THE SOLENOID" in order to verify the solenoid failure. Replace the solenoid. Stop. NO - CID 0727 FMI 06 remains active. Proceed to Test Step 2. Test Step 2. CHECK THE ENERGIZE CIRCUIT OF THE SOLENOID FOR A SHORT TO GROUND A. Turn the key start switch and the disconnect switch to the OFF position. B. The solenoid remains disconnected from the machine harness. C. Disconnect the machine harness ECM connectors J1 and J2 from the ECM. D. At the machine harness ECM connectors, measure the resistance from the signal contact J2-3 (wire P942-YL) to all ground contacts on connectors J1 and J2. The ground contacts on connector J2 are J2-2, J2-12, J2-13, J2-22, J2-36, J237, J2-46, J2-49, J2-52, J2-56, J2-59 and J2-69. The ground contact on connector J1 is J1-9. Expected Result: Each resistance measurement is greater than 5000 ohms. Results: OK - Each resistance measurement is greater than 5000 ohms. The machine harness is correct. Proceed to Test Step 3. NOT OK - Each resistance measurement is not greater than 5000 ohms. There is a short in the machine harness. The short is between J2-3 (wire P942-YL) and the circuit with the low resistance measurement. Repair: Repair the machine harness or replace the machine harness. Stop. Test Step 3. CHECK IF THE DIAGNOSTIC CODE REMAINS A. Inspect the contacts of the harness connectors that are used in the solenoid circuit. Ensure that the contacts are secure. Clean all of the contacts in the harness connectors. B. Reconnect all harness connectors. C. Turn the disconnect switch and the key start switch to the ON position. D. Operate the machine. E. Check the status of the CID 0727 FMI 06. Expected Result: The CID 0727 FMI 06 is active. Results:

YES - The CID 0727 FMI 06 is active. The diagnostic code has not been corrected. The ECM may have failed. Repair: It is unlikely that the ECM has failed. Exit this procedure and perform this procedure again. If the cause of the diagnostic code is not found, replace the ECM. See Testing and Adjusting, "Electronic Control Module (ECM) - Replace". Stop. NO - The CID 0727 FMI 06 is not active. The diagnostic code does not exist at this time. Repair: The initial diagnostic code was probably caused by a poor electrical connection or a short at one of the harness connectors that was disconnected and reconnected. Resume normal machine operation. Stop.

TROUBLESHOOTING

042

TROUBLESHOOTING

i02304003

MID 039 - CID 0736 - FMI 03 SMCS - 1915-038 Conditions Which Generate This Code:

Illustration 1

g01158309

Schematic of the automatic engine speed control circuit

This diagnostic code is associated with the automatic engine speed control. The FMI 03 means that the machine ECM has commanded the circuit to be grounded but the engine ECM determines that the circuit is open. This information is sent from the engine ECM to the machine ECM on the Cat Data Link. The possible causes of the diagnostic code are listed: The circuit is open. The circuit is shorted to the +battery circuit. The engine ECM has failed. This is unlikely. The machine ECM has failed. This is unlikely.

Note: The following test procedure may create other diagnostic codes. Ignore these created diagnostic codes and clear these diagnostic codes when the original diagnostic code has been corrected. Ensure that the diagnostic code of CID 736 FMI 03 is active before performing this procedure. Note: Use the 146-4080 Digital Multimeter for the measurements in this procedure. System Response: When this diagnostic code is active, the automatic engine speed control is inoperative.

Test Step 1. CHECK THE WIRING HARNESS OF THE SENSOR FOR A SHORT TO THE +BATTERY CIRCUIT. A. Turn the key start switch and the disconnect switch to the OFF position. B. Disconnect the machine harness from the machine ECM. Disconnect the harness from the engine ECM. C. At the machine harness connector for the machine ECM, measure the resistance from contact J2-32 (wire H783-GN) of the machine harness to all contacts that are used in the machine harness connectors for the machine ECM. Expected Result: Each resistance measurement is greater than 5000 ohms. Results: OK - Each resistance measurement is greater than 5000 ohms. The machine harness is correct. Proceed to Test Step 2. NOT OK - One or more resistance measurements is not correct. There is a short in the machine harness. Repair: The short is between contact J2-32 (wire H783-GN) and the circuit with the low resistance measurement. Repair the machine harness or replace the machine harness. Stop. Test Step 2. CHECK THE WIRING HARNESS FOR AN OPEN CIRCUIT. A. The key start switch and the disconnect switch remain in the OFF position. The machine harness remains disconnected from the engine ECM and the machine ECM. B. Connect a jumper wire to contact 30 of the engine ECM. C. At the harness connector for the machine ECM, measure the resistance between contact J2-32 (wire H783-GN) and the jumper wire. Expected Result: The resistance measurement is less than 5 ohms. Results: OK - The resistance measurement is less than 5 ohms. The circuit is correct. Proceed to Test Step 1. NOT OK - The resistance is greater than 5 ohms. The circuit is not correct. There is an open circuit in the wiring harness. Repair: There is an open circuit in the wiring harness. Repair the wiring harness or replace the wiring harness. Stop. Test Step 3. CHECK THE OPERATION OF THE ENGINE ECM. A. Reconnect the machine harness connectors to the machine ECM. B. At the machine harness connector for the engine ECM, remove the H783-GN wire (contact 30). Use the proper extraction tool. C. Insert a jumper wire into the empty contact 30. Ensure that the other end of the jumper wire does not contact any part of the machine. D. Reconnect the machine harness connector to the engine ECM. E. Turn the disconnect switch and the key start switch to the ON position. F. Operate the machine. Turn on the automatic engine speed control. Move the boom and then stop all movement. Wait for

F. the reduction of the RPM to idle. Expected Result: The engine never goes to low idle. Results: OK - The engine never goes to low idle. Proceed to Test Step 5. NOT OK - The engine goes to low idle. The engine ECM has determined that contact 30 is grounded when the contact is open. Repair: The engine ECM may have failed. Reconnect wire H783-GN to contact 30 of the engine ECM. It is unlikely that the engine ECM has failed. Exit this procedure and perform this procedure again. If the cause of the diagnostic code is not found see the service manual for the engine for more troubleshooting information. Stop. Test Step 4. CHECK THE ENGINE ECM. A. While the engine is running, connect the jumper wire that is connected to contact 30 of the engine ECM to frame ground. Expected Result: The engine goes to low idle. Results: OK - The engine goes to low idle. The engine ECM is operating correctly. Proceed to Test Step 5. NOT OK - The engine never goes to low idle. The engine ECM may have failed. Reconnect wire H783-GN to contact 30 of the engine ECM. It is unlikely that the engine ECM has failed. Exit this procedure and perform this procedure again. If the cause of the diagnostic code is not found see the service manual for the engine for more troubleshooting information. Stop. Test Step 5. CHECK IF THE DIAGNOSTIC CODE REMAINS. A. Inspect the contacts of the harness connectors and clean the connectors. B. Reconnect all harness connectors. C. Turn the disconnect switch and the key start switch to the ON position. D. Operate the machine. E. Check the status of the CID 0736 FMI 03. Expected Result: The CID 0736 FMI 03 is active. Results: YES - The CID 0736 FMI 03 is active. The diagnostic code has not been corrected. The machine ECM may have failed. Repair: It is unlikely that the machine ECM has failed. Exit this procedure and perform this procedure again. If the cause of the diagnostic code is not found, replace the machine ECM. See Testing and Adjusting, "Electronic Control Module (ECM) - Replace". Stop. NO - The CID 0736 FMI 03 is not active. The diagnostic code does not exist at this time. Repair: The initial diagnostic code was probably caused by a poor electrical connection or a short at one of the harness connectors that was disconnected and reconnected. Resume normal machine operation.

Stop.

TROUBLESHOOTING

043

TROUBLESHOOTING

i02304006

MID 039 - CID 0736 - FMI 06 SMCS - 1915-038 Conditions Which Generate This Code:

Illustration 1

g01158309

Schematic of the automatic engine speed control circuit

This diagnostic code is associated with the automatic engine speed control. The FMI 06 means that the machine ECM has commanded the circuit to be open but the engine ECM determines that the circuit is grounded. This information is sent from the engine ECM to the machine ECM on the Cat Data Link. The possible causes of the diagnostic code are listed: The circuit is shorted to ground. The engine ECM has failed. This is unlikely. The machine ECM has failed. This is unlikely.

Note: The following test procedure may create other diagnostic codes. Ignore these created diagnostic codes and clear these diagnostic codes when the original diagnostic code has been corrected. Ensure that the diagnostic code of CID 736 FMI 06 is active before performing this procedure. Note: Use the 146-4080 Digital Multimeter for the measurements in this procedure. System Response: When this diagnostic code is active, the automatic engine speed control is inoperative. Test Step 1. CHECK THE WIRING HARNESS OF THE SENSOR FOR A SHORT TO GROUND. A.

A. Turn the key start switch and the disconnect switch to the OFF position. B. Disconnect the machine harness from the machine ECM. Disconnect the harness from the engine ECM. C. At the machine harness connector for the machine ECM, measure the resistance from contact J2-32 (wire H783-GN) to all contacts that are used in the machine harness connectors for the machine ECM. Expected Result: Each resistance measurement is greater than 5000 ohms. Results: OK - Each resistance measurement is greater than 5000 ohms. The machine harness is correct. Proceed to Test Step 2. NOT OK - One or more resistance measurements is not correct. There is a short in the machine harness. Repair: The short is between contact J2-32 (wire H783-GN) and the circuit with the low resistance measurement. Repair the machine harness or replace the machine harness. Stop. Test Step 2. CHECK THE OPERATION OF THE ENGINE ECM. A. Reconnect the machine harness connectors to the machine ECM. B. At the machine harness connector for the engine ECM, remove the H783-GN wire (contact 30). Use the proper extraction tool. C. Insert a jumper wire into the empty contact 30. Ensure that the other end of the jumper wire does not contact any part of the machine. D. Reconnect the machine harness connector to the engine ECM. E. Turn the disconnect switch and the key start switch to the ON position. F. Operate the machine. Turn on the automatic engine speed control. Move the boom and then stop all movement. Wait for the reduction of the RPM to idle. Expected Result: The engine never goes to low idle. Results: OK - The engine never goes to low idle. Proceed to Test Step 3. NOT OK - The engine goes to low idle. The engine ECM has determined that contact 30 is grounded when the contact is open. Repair: The engine ECM may have failed. Reconnect wire H783-GN to contact 30 of the engine ECM. It is unlikely that the engine ECM has failed. Exit this procedure and perform this procedure again. If the cause of the diagnostic code is not found see the service manual for the engine for more troubleshooting information. Stop. Test Step 3. CHECK THE ENGINE ECM. A. While the engine is running, connect the jumper wire that is connected to contact 30 of the engine ECM to frame ground. Expected Result: The engine goes to low idle. Results:

OK - The engine goes to low idle. The engine ECM is operating correctly. Proceed to Test Step 4. NOT OK - The engine never goes to low idle. The engine ECM may have failed. Reconnect wire H783-GN to contact 30 of the engine ECM. It is unlikely that the engine ECM has failed. Exit this procedure and perform this procedure again. If the cause of the diagnostic code is not found see the service manual for the engine for more troubleshooting information. Stop. Test Step 4. CHECK IF THE DIAGNOSTIC CODE REMAINS. A. Inspect the contacts of the harness connectors and clean the connectors. B. Reconnect all harness connectors. C. Turn the disconnect switch and the key start switch to the ON position. D. Operate the machine. E. Check the status of the CID 0736 FMI 06. Expected Result: The CID 0736 FMI 06 is active. Results: YES - The CID 0736 FMI 06 is active. The diagnostic code has not been corrected. The machine ECM may have failed. Repair: It is unlikely that the machine ECM has failed. Exit this procedure and perform this procedure again. If the cause of the diagnostic code is not found, replace the machine ECM. See Testing and Adjusting, "Electronic Control Module (ECM) - Replace". Stop. NO - The CID 0736 FMI 06 is not active. The diagnostic code does not exist at this time. Repair: The initial diagnostic code was probably caused by a poor electrical connection or a short at one of the harness connectors that was disconnected and reconnected. Resume normal machine operation. Stop.

TROUBLESHOOTING

044

TROUBLESHOOTING

i01792906

MID 039 - CID 0882 - FMI 03 SMCS - 5479-038-HR Conditions Which Generate This Code:

Illustration 1

g00840458

Schematic of the Solenoid valve (implement lockout)

This diagnostic code is associated with the Solenoid valve (implement lockout). The FMI 03 means that the machine ECM has determined that the voltage of the solenoid circuit is above normal. The possible causes of the diagnostic code are listed: The solenoid has failed. The energize circuit of the solenoid is shorted to the +battery circuit. The machine ECM has failed. This is unlikely.

Note: The following test procedure may create other diagnostic codes. Ignore these created diagnostic codes and clear these diagnostic codes when the original diagnostic code has been corrected. Ensure that the diagnostic code of CID 0882 FMI 03 is active before performing this procedure. Note: Use the 146-4080 Digital Multimeter for the measurements in this procedure. System Response: When this diagnostic code is active, the machine ECM will be unable to control the implement lockout solenoid. The solenoid will always be energized. Pilot hydraulics for implements will be always activated. Test Step 1. CHECK THE ENERGIZE CIRCUIT OF THE SOLENOID FOR A SHORT TO THE +BATTERY CIRCUIT. A. Turn the key start switch and the disconnect switch to the OFF position. B.

A. B. Disconnect the machine harness connectors from the solenoid and the machine ECM. C. At the machine harness connector for the machine ECM, measure the resistance from contact J2-45 (wire K777-GY) to all contacts that are used in the machine harness connectors for the machine ECM. Expected Result: Each resistance measurement is greater than 5000 ohms. Results: OK - Each resistance measurement is greater than 5000 ohms. The machine harness is correct. Proceed to Test Step 2. NOT OK - Each resistance measurement is not greater than 5000 ohms. There is a short in the machine harness. The short is between J2-45 (K777-GY) and the circuit that has a low resistance measurement. Repair: Repair the machine harness or replace the machine harness. Stop. Test Step 2. CHECK IF THE DIAGNOSTIC CODE IS STILL ACTIVE. A. Inspect the contacts and clean the contacts of the harness connectors. B. Reconnect all harness connectors. C. Turn the disconnect switch and the key start switch to the ON position. D. Operate the machine. E. Determine if the CID 0882 FMI 03 is active. Expected Result: The CID 0882 FMI 03 is active. Results: YES - The CID 0882 FMI 03 is active. The problem has not been corrected. The machine ECM may have failed. Repair: It is unlikely that the machine ECM has failed. Exit this procedure and perform this procedure again. If the cause of the diagnostic code is not found, replace the machine ECM. See Testing and Adjusting, "Electronic Control Module (ECM) - Replace". Stop. NO - The CID 0882 FMI 03 is not active. The problem does not exist at this time. Repair: The initial diagnostic code was probably caused by a poor electrical connection or a short at one of the harness connectors that was disconnected and reconnected. Resume normal machine operation. Stop.

TROUBLESHOOTING

045

TROUBLESHOOTING

i01792910

MID 039 - CID 0882 - FMI 05 SMCS - 5479-038-HR Conditions Which Generate This Code:

Illustration 1

g00840458

Schematic of the Solenoid valve (implement lockout)

This diagnostic code is associated with the Solenoid valve (implement lockout). The FMI 05 means that the machine ECM has determined that the current of the solenoid is below normal. The possible causes of this diagnostic code are listed below: The energize circuit of the solenoid is open. The return circuit of the solenoid is open. The solenoid has failed. The machine ECM has failed. This is unlikely.

Note: The following test procedure may create other diagnostic codes. Ignore these created diagnostic codes and clear these diagnostic codes when the original diagnostic code has been corrected. Ensure that the diagnostic code of CID 0882 FMI 05 is active before performing this procedure. Note: Use the 146-4080 Digital Multimeter for the measurements in this procedure. System Response: When this diagnostic code is active, the machine ECM will be unable to control the implement lockout solenoid. The solenoid will never be energized. Pilot hydraulics for implements will never be activated. Implements will not be functional. Test Step 1. CHECK THE SOLENOID. A. Turn the disconnect switch and the key start switch to the ON position. Do not start the engine. B.

A. B. Disconnect the solenoid with the active diagnostic code from the machine harness. C. At the machine harness connector for the solenoid, place a jumper wire from contact 1 (wire K777-GY) to contact 2 (wire H807-YL). D. Observe the status of the CID 0882 FMI 05. Expected Result: The CID 0882 FMI 05 remains active. The FMI has not changed and the "05" is still active. Results: YES - The diagnostic code remains active. The jumper wire does not affect the diagnostic code. Proceed to Test Step 2. NO - The diagnostic is no longer active. The solenoid has failed. Repair: The solenoid has failed. Repeat this Test Step "CHECK THE SOLENOID" in order to verify the solenoid failure. Replace the solenoid. Verify that the new solenoid corrects the problem. Stop. Test Step 2. CHECK THE HARNESS FOR AN OPEN. A. Turn the key start switch and the disconnect switch to the OFF position. B. Disconnect the machine harness connector(s) from the machine ECM. C. The jumper wire that was installed in the previous Test Step remains in place. D. At the machine harness connector, measure the resistance from signal contact J2-45 (wire K777-GY) to contact J2-36 (wire H807-YL). Expected Result: The resistance is less than 5.0 ohms. Results: OK - The resistance is less than 5.0 ohms. The machine harness is correct. Proceed to Test Step 3. NOT OK - The resistance is greater than 5000 ohms. The resistance measurement is not correct. There is an open circuit in the machine harness. Repair: The open is in wire K777-GY or in wire H807-YL of the machine harness. Repair the machine harness or replace the machine harness. Stop. Test Step 3. CHECK IF THE DIAGNOSTIC CODE REMAINS. A. Inspect the contacts of the harness connectors and clean the harness connectors. B. Reconnect all harness connectors. C. Turn the disconnect switch and the key start switch to the ON position. D. Operate the machine. E. Check the status of the CID 0882 FMI 05. Expected Result: The CID 0882 FMI 05 is active.

Results: YES - The CID 0882 FMI 05 is active. The diagnostic code has not been corrected. The machine ECM may have failed. Repair: It is unlikely that the machine ECM has failed. Exit this procedure and perform this procedure again. If the cause of the diagnostic code is not found, replace the machine ECM. See Testing and Adjusting, "Electronic Control Module (ECM) - Replace". Stop. NO - The CID 0882 FMI 05 is not active. The diagnostic code does not exist at this time. Repair: The initial diagnostic code was probably caused by a poor electrical connection or a short at one of the harness connectors that was disconnected and reconnected. Resume normal machine operation. Stop.

TROUBLESHOOTING

046

TROUBLESHOOTING

i01792917

MID 039 - CID 0882 - FMI 06 SMCS - 5479-038-HR Conditions Which Generate This Code:

Illustration 1

g00840458

Schematic of the Solenoid valve (implement lockout)

This diagnostic code is associated with the Solenoid valve (implement lockout). The FMI 06 means that the machine ECM has determined that the current of the solenoid is above normal. The possible causes of this diagnostic code are listed: The energize circuit of the solenoid is shorted to ground. The solenoid has failed. The machine ECM has failed. This is unlikely.

Note: The following test procedure may create other diagnostic codes. Ignore these created diagnostic codes and clear these diagnostic codes when the original diagnostic code has been corrected. Ensure that the diagnostic code of CID 0882 FMI 06 is active before performing this procedure. Note: Use the 146-4080 Digital Multimeter for the measurements in this procedure. System Response: When this diagnostic code is active, the machine ECM will be unable to control the implement lockout solenoid. The solenoid will never be energized. Pilot hydraulics for implements will never be activated. Implements will not be functional. Test Step 1. CHECK THE SOLENOID. A. Turn the disconnect switch and the key start switch to the ON position. Do not start the engine. B. Observe the status of the diagnostic code. C.

B. C. Disconnect the solenoid with the active diagnostic code from the machine harness. Expected Result: CID 0882 FMI 06 changes to CID 0882 FMI 05 when the solenoid is disconnected. Results: YES - CID 0882 FMI 06 changes to CID 0882 FMI 05 when the solenoid is disconnected. The circuit is correct. Repair: The solenoid has failed. Repeat this test "CHECK THE SOLENOID" in order to verify the solenoid failure. Replace the solenoid. Stop. NO - CID 0882 FMI 06 remains active. Proceed to Test Step 2. Test Step 2. CHECK THE ENERGIZE CIRCUIT OF THE SOLENOID FOR A SHORT TO GROUND. A. Turn the key start switch and the disconnect switch to the OFF position. B. The solenoid remains disconnected from the machine harness. C. Disconnect the machine harness connector(s) from the machine ECM. D. At the machine harness connector, measure the resistance from the signal contact J2-45 (wire K777-GY) to all contacts that are used in the machine harness connectors for the machine ECM. Expected Result: Each resistance measurement is greater than 5000 ohms. Results: OK - Each resistance measurement is greater than 5000 ohms. The machine harness is correct. Proceed to Test Step 3. NOT OK - Each resistance measurement is not greater than 5000 ohms. There is a short in the machine harness. The short is between J2-45 (wire K777-GY) and the circuit with the low resistance measurement. Repair: Repair the machine harness or replace the machine harness. Stop. Test Step 3. CHECK IF THE DIAGNOSTIC CODE REMAINS. A. Inspect the harness connectors and clean the contacts of the harness connectors. B. Reconnect all harness connectors. C. Turn the disconnect switch and the key start switch to the ON position. D. Operate the machine. E. Check the status of the CID 0882 FMI 06. Expected Result: The CID 0882 FMI 06 is active. Results: YES - The CID 0882 FMI 06 is active. The diagnostic code has not been corrected. The machine ECM may have failed. Repair: It is unlikely that the machine ECM has failed. Exit this procedure and perform this procedure again. If the cause of the diagnostic code is not found, replace the machine ECM. See Testing and Adjusting, "Electronic Control Module (ECM) - Replace". Stop.

NO - The CID 0882 FMI 06 is not active. The diagnostic code does not exist at this time. Repair: The initial diagnostic code was probably caused by a poor electrical connection or a short at one of the harness connectors that was disconnected and reconnected. Resume normal machine operation. Stop.

TROUBLESHOOTING

047

TROUBLESHOOTING

i02283023

MID 039 - CID 1130 - FMI 03 SMCS - 5574-038-P9 Conditions Which Generate This Code:

Illustration 1

g01142736

Schematic of the Auxiliary Pedal Position Sensor (attachment)

This diagnostic code is associated with the auxiliary pedal position sensor. The FMI 03 means that the ECM has determined that the signal voltage from the sensor is above 4.75 VDC. Some possible causes of the diagnostic code are listed: The sensor has failed. The signal circuit of the sensor is shorted to +battery. The ECM has failed. This is unlikely.

System Response: When the CID 1130 FMI 03 diagnostic code is active, the machine response will be: The warning indicator on the Monitor will illuminate. The attachment that is controlled by the left attachment pedal will not operate.

Note: The following test procedure may create other diagnostic codes. Ignore these created diagnostic codes and clear these diagnostic codes when the original diagnostic code has been corrected. Ensure that the diagnostic code of CID 1130 FMI 03 is active before performing this procedure. Test Step 1. CHECK THE SIGNAL CIRCUIT OF THE SENSOR FOR A SHORT TO THE +BATTERY CIRCUIT A.

A. Turn the key start switch and the disconnect switch to the OFF position. B. Disconnect the machine harness connector from the sensor. Disconnect the machine harness connectors J-1 and J2 from the ECM. C. At the machine harness ECM connector J1, measure the resistance from signal contact J1-62 (wire M955-BR) to all J-1 and J2 contacts that are connected to +battery. The J-1 contact is J1-58. The J2 contacts are: J2-1, J2-23, J2-47, J2-57 and J2-70. Expected Result: Each resistance measurement is greater than 5000 ohms. Results: OK - Each resistance measurement is greater than 5000 ohms. The machine harness is correct. Proceed to Test Step 2. NOT OK - Each resistance measurement is not greater than 5000 ohms. There is a short in the machine harness. The short is between J1-62 (wire M955-BR) and the circuit that has a low resistance measurement. Repair: Repair the machine harness or replace the machine harness. Stop. Test Step 2. CHECK IF THE DIAGNOSTIC CODE IS STILL ACTIVE A. Inspect the contacts of the harness connectors that are used in the solenoid circuit. Ensure that the contacts are secure. Clean all of the contacts in the harness connectors. B. Reconnect all harness connectors. C. Turn the disconnect switch and the key start switch to the ON position. D. Operate the machine. E. Determine if the CID 1130 FMI 03 is active. Expected Result: The CID 1130 FMI 03 is active. Results: YES - The CID 1130 FMI 03 is active. Repair: Replace the auxiliary pedal position sensor. After sensor replacement, repeat this Test Step again. If the diagnostic code is still active, the ECM may be faulty. It is unlikely that the ECM has failed. Exit this procedure and perform this procedure again. If the cause of the diagnostic code is not found, replace the ECM. See Testing and Adjusting, "Electronic Control Module (ECM) - Replace". Stop. NO - The CID 1130 FMI 03 is not active. The problem does not exist at this time. Repair: The initial diagnostic code was probably caused by a poor electrical connection or a short at one of the harness connectors that was disconnected and reconnected. Resume normal machine operation. Stop.

TROUBLESHOOTING

048

TROUBLESHOOTING

i02283025

MID 039 - CID 1130 - FMI 04 SMCS - 5574-038-P9 Conditions Which Generate This Code:

Illustration 1

g01142799

Schematic of the Auxiliary Pedal Position Sensor (attachment)

This diagnostic code is associated with the auxiliary pedal position sensor. The FMI 04 means that the ECM has determined that the voltage of the signal circuit for the position sensor is below .25 VDC. The possible causes of this diagnostic code are listed below: The signal circuit for the sensor is shorted to ground. The sensor has failed. The ECM has failed. This is unlikely.

Note: The following test procedure may create other diagnostic codes. Ignore these created diagnostic codes and clear the diagnostic codes when the original diagnostic code has been corrected. Ensure that the diagnostic code of CID 1130 FMI 04 is active before performing this procedure. System Response: When the CID 1130 FMI 04 diagnostic code is active, the machine response will be: The warning indicator on the Monitor will illuminate. The attachment that is controlled by the left attachment pedal will not operate.

Test Step 1. CHECK THE SENSOR A.

A. Turn the disconnect switch and the key start switch to the ON position. B. Observe the status of the diagnostic code. Disconnect the sensor from the machine harness. Expected Result: The CID 1130 FMI 04 remains active. The FMI 04 code has not changed and is still active. Results: OK - The diagnostic code remains active. The sensor is correct. Proceed to Test Step 2. NOT OK - The diagnostic code is no longer active. The sensor has failed. Repair: Replace the auxiliary pedal position sensor. Stop. Test Step 2. CHECK THE WIRING HARNESS OF THE SENSOR FOR A SHORT TO GROUND. A. Turn the key start switch and the disconnect switch to the OFF position. B. Disconnect the machine harness from the sensor. C. Disconnect the machine harness connectors from the ECM. D. At the machine harness connector for the ECM, measure the resistance from the signal contact J1-62 (wire M955-BR) to all other ECM connector ground contacts. The ground contacts on connector J2 are J2-2, J2-12, J2-13, J2-22, J2-36, J2-37, J2-46, J2-49, J2-52, J2-56, J2-59 and J2-69. The ground contact on connector J1 is J1-9. Expected Result: Each resistance measurement is greater than 5000 ohms. Results: OK - Each resistance measurement is greater than 5000 ohms. The machine harness is correct. Proceed to Test Step 3. NOT OK - One or more resistance measurements is not correct. There is a short in the machine harness. Repair: The short is between signal contact J1-62 (wire M955-BR) and the circuit with the low resistance measurement. Repair the machine harness or replace the machine harness. Stop. Test Step 3. CHECK IF THE DIAGNOSTIC CODE REMAINS. A. Inspect the contacts of the harness connectors and clean the contacts. B. Reconnect all harness connectors. C. Turn the disconnect switch and the key start switch to the ON position. D. Operate the machine. E. Check the status of the CID 1130 FMI 04. Expected Result: The CID 1130 FMI 04 is active. Results: YES - The CID 1130 FMI 04 is active. The diagnostic code has not been corrected. The ECM may have failed. Repair: It is unlikely that the ECM has failed. Exit this procedure and perform this procedure again. If the cause of the

diagnostic code is not found, replace the ECM. See Testing and Adjusting, "Electronic Control Module (ECM) - Replace". Stop. NO - The CID 1130 FMI 04 is not active. The diagnostic code does not exist at this time. Repair: The initial diagnostic code was probably caused by a poor electrical connection or a short at one of the harness connectors that was disconnected and reconnected. Resume normal machine operation. Stop.

TROUBLESHOOTING

049

TROUBLESHOOTING

i01792925

MID 039 - CID 1180 - FMI 03 SMCS - 5479-038-HR Conditions Which Generate This Code:

Illustration 1

g00840583

Schematic of the Solenoid (oil flow) in the Work Tool Control Valve

This diagnostic code is associated with the Solenoid (oil flow) in the work tool control valve. The FMI 03 means that the machine ECM has determined that the voltage of the solenoid circuit is above normal. The possible causes of the diagnostic code are listed: The solenoid has failed. The energize circuit of the solenoid is shorted to the +battery circuit. The machine ECM has failed. This is unlikely.

Note: The following test procedure may create other diagnostic codes. Ignore these created diagnostic codes and clear these diagnostic codes when the original diagnostic code has been corrected. Ensure that the diagnostic code of CID 1180 FMI 03 is active before performing this procedure. Note: Use the 146-4080 Digital Multimeter for the measurements in this procedure. System Response: When the Auxiliary Flow Solenoid (number 1) is shorted to the battery, maximum flow is allowed to the tool. The tool will be activated. The machine ECM will not take any action when this diagnostic code is detected. Test Step 1. CHECK THE ENERGIZE CIRCUIT OF THE SOLENOID FOR A SHORT TO THE +BATTERY CIRCUIT. A. Turn the key start switch and the disconnect switch to the OFF position. B.

A. B. Disconnect the machine harness connectors from the solenoid and the machine ECM. C. At the machine harness connector for the machine ECM, measure the resistance from contact J2-41 (wire M745-BU) to all contacts that are used in the machine harness connectors for the machine ECM. Expected Result: Each resistance measurement is greater than 5000 ohms. Results: OK - Each resistance measurement is greater than 5000 ohms. The machine harness is correct. Proceed to Test Step 2. NOT OK - Each resistance measurement is not greater than 5000 ohms. There is a short in the machine harness. The short is between J2-41 (M745-BU) and the circuit that has a low resistance measurement. Repair: Repair the machine harness or replace the machine harness. Stop. Test Step 2. CHECK IF THE DIAGNOSTIC CODE IS STILL ACTIVE. A. Inspect the contacts and clean the contacts of the harness connectors. B. Reconnect all harness connectors. C. Turn the disconnect switch and the key start switch to the ON position. D. Operate the machine. E. Determine if the CID 1180 FMI 03 is active. Expected Result: The CID 1180 FMI 03 is active. Results: YES - The CID 1180 FMI 03 is active. The problem has not been corrected. The machine ECM may have failed. Repair: It is unlikely that the machine ECM has failed. Exit this procedure and perform this procedure again. If the cause of the diagnostic code is not found, replace the machine ECM. See Testing and Adjusting, "Electronic Control Module (ECM) - Replace". Stop. NO - The CID 1180 FMI 03 is not active. The problem does not exist at this time. Repair: The initial diagnostic code was probably caused by a poor electrical connection or a short at one of the harness connectors that was disconnected and reconnected. Resume normal machine operation. Stop.

TROUBLESHOOTING

050

TROUBLESHOOTING

i01792926

MID 039 - CID 1180 - FMI 05 SMCS - 5479-038-HR Conditions Which Generate This Code:

Illustration 1

g00840583

Schematic of the Solenoid (oil flow) in the Work Tool Control Valve

This diagnostic code is associated with the Solenoid (oil flow) in the work tool control valve. The FMI 05 means that the machine ECM has determined that the current of the solenoid is below normal. The possible causes of this diagnostic code are listed below: The energize circuit of the solenoid is open. The return circuit of the solenoid is open. The solenoid has failed. The machine ECM has failed. This is unlikely.

Note: The following test procedure may create other diagnostic codes. Ignore these created diagnostic codes and clear these diagnostic codes when the original diagnostic code has been corrected. Ensure that the diagnostic code of CID 1180 FMI 05 is active before performing this procedure. Note: Use the 146-4080 Digital Multimeter for the measurements in this procedure. System Response: When the Auxiliary Flow Solenoid (number 1) is an open circuit, no flow is allowed to the tool. The tool will be disabled. The machine ECM will not take any action when this diagnostic code is detected. Test Step 1. CHECK THE SOLENOID. A. Turn the disconnect switch and the key start switch to the ON position. Do not start the engine. B.

A. B. Disconnect the solenoid with the active diagnostic code from the machine harness. C. At the machine harness connector for the solenoid, place a jumper wire from contact 1 (wire M745-BU) to contact 2 (wire H803-BU). D. Observe the status of the CID 1180 FMI 05. Expected Result: The CID 1180 FMI 05 remains active. The FMI has not changed and the "05" is still active. Results: YES - The diagnostic code remains active. The jumper wire does not affect the diagnostic code. Proceed to Test Step 2. NO - The diagnostic is no longer active. The solenoid has failed. Repair: The solenoid has failed. Repeat this Test Step "CHECK THE SOLENOID" in order to verify the solenoid failure. Replace the solenoid. Verify that the new solenoid corrects the problem. Stop. Test Step 2. CHECK THE HARNESS FOR AN OPEN. A. Turn the key start switch and the disconnect switch to the OFF position. B. Disconnect the machine harness connector(s) from the machine ECM. C. The jumper wire that was installed in the previous Test Step remains in place. D. At the machine harness connector, measure the resistance from signal contact J2-41 (wire M745-BU) to contact J2-59 (wire H803-BU). Expected Result: The resistance is less than 5.0 ohms. Results: OK - The resistance is less than 5.0 ohms. The machine harness is correct. Proceed to Test Step 3. NOT OK - The resistance is greater than 5000 ohms. The resistance measurement is not correct. There is an open circuit in the machine harness. Repair: The open is in wire M745-BU or in wire H803-BU of the machine harness. Repair the machine harness or replace the machine harness. Stop. Test Step 3. CHECK IF THE DIAGNOSTIC CODE REMAINS. A. Inspect the contacts of the harness connectors and clean the harness connectors. B. Reconnect all harness connectors. C. Turn the disconnect switch and the key start switch to the ON position. D. Operate the machine. E. Check the status of the CID 1180 FMI 05. Expected Result: The CID 1180 FMI 05 is active.

Results: YES - The CID 1180 FMI 05 is active. The diagnostic code has not been corrected. The machine ECM may have failed. Repair: It is unlikely that the machine ECM has failed. Exit this procedure and perform this procedure again. If the cause of the diagnostic code is not found, replace the machine ECM. See Testing and Adjusting, "Electronic Control Module (ECM) - Replace". Stop. NO - The CID 1180 FMI 05 is not active. The diagnostic code does not exist at this time. Repair: The initial diagnostic code was probably caused by a poor electrical connection or a short at one of the harness connectors that was disconnected and reconnected. Resume normal machine operation. Stop.

TROUBLESHOOTING

051

TROUBLESHOOTING

i01792928

MID 039 - CID 1180 - FMI 06 SMCS - 5479-038-HR Conditions Which Generate This Code:

Illustration 1

g00840583

Schematic of the Solenoid (oil flow) in the Work Tool Control Valve

This diagnostic code is associated with the Solenoid (oil flow) in the work tool control valve. The FMI 06 means that the machine ECM has determined that the current of the solenoid is above normal. The possible causes of this diagnostic code are listed: The energize circuit of the solenoid is shorted to ground. The solenoid has failed. The machine ECM has failed. This is unlikely.

Note: The following test procedure may create other diagnostic codes. Ignore these created diagnostic codes and clear these diagnostic codes when the original diagnostic code has been corrected. Ensure that the diagnostic code of CID 1180 FMI 06 is active before performing this procedure. Note: Use the 146-4080 Digital Multimeter for the measurements in this procedure. System Response: When the Auxiliary Flow Solenoid (number 1) is shorted to ground, no flow is allowed to the tool. The tool will be disabled. The machine ECM does not take any action when this diagnostic code is detected. Test Step 1. CHECK THE SOLENOID. A. Turn the disconnect switch and the key start switch to the ON position. Do not start the engine. B. Observe the status of the diagnostic code. C.

B. C. Disconnect the solenoid with the active diagnostic code from the machine harness. Expected Result: CID 1180 FMI 06 changes to CID 1180 FMI 05 when the solenoid is disconnected. Results: YES - CID 1180 FMI 06 changes to CID 1180 FMI 05 when the solenoid is disconnected. The circuit is correct. Repair: The solenoid has failed. Repeat this test "CHECK THE SOLENOID" in order to verify the solenoid failure. Replace the solenoid. Stop. NO - CID 1180 FMI 06 remains active. Proceed to Test Step 2. Test Step 2. CHECK THE ENERGIZE CIRCUIT OF THE SOLENOID FOR A SHORT TO GROUND. A. Turn the key start switch and the disconnect switch to the OFF position. B. The solenoid remains disconnected from the machine harness. C. Disconnect the machine harness connector(s) from the machine ECM. D. At the machine harness connector, measure the resistance from the signal contact J2-41 (wire M745-BU) to all contacts that are used in the machine harness connectors for the machine ECM. Expected Result: Each resistance measurement is greater than 5000 ohms. Results: OK - Each resistance measurement is greater than 5000 ohms. The machine harness is correct. Proceed to Test Step 3. NOT OK - Each resistance measurement is not greater than 5000 ohms. There is a short in the machine harness. The short is between J2-41 (wire M745-BU) and the circuit with the low resistance measurement. Repair: Repair the machine harness or replace the machine harness. Stop. Test Step 3. CHECK IF THE DIAGNOSTIC CODE REMAINS. A. Inspect the harness connectors and clean the contacts of the harness connectors. B. Reconnect all harness connectors. C. Turn the disconnect switch and the key start switch to the ON position. D. Operate the machine. E. Check the status of the CID 1180 FMI 06. Expected Result: The CID 1180 FMI 06 is active. Results: YES - The CID 1180 FMI 06 is active. The diagnostic code has not been corrected. The machine ECM may have failed. Repair: It is unlikely that the machine ECM has failed. Exit this procedure and perform this procedure again. If the cause of the diagnostic code is not found, replace the machine ECM. See Testing and Adjusting, "Electronic Control Module (ECM) - Replace". Stop.

NO - The CID 1180 FMI 06 is not active. The diagnostic code does not exist at this time. Repair: The initial diagnostic code was probably caused by a poor electrical connection or a short at one of the harness connectors that was disconnected and reconnected. Resume normal machine operation. Stop.

TROUBLESHOOTING

052

TROUBLESHOOTING

i01792949

MID 039 - CID 1181 - FMI 03 SMCS - 5479-038-HR Conditions Which Generate This Code:

Illustration 1

g00840591

Schematic of the Solenoid (oil pressure) in the Work Tool Control Valve

This diagnostic code is associated with the Solenoid (oil pressure) in the work tool control valve. The FMI 03 means that the machine ECM has determined that the voltage of the solenoid circuit is above normal. The possible causes of the diagnostic code are listed: The solenoid has failed. The energize circuit of the solenoid is shorted to the +battery circuit. The machine ECM has failed. This is unlikely.

Note: The following test procedure may create other diagnostic codes. Ignore these created diagnostic codes and clear these diagnostic codes when the original diagnostic code has been corrected. Ensure that the diagnostic code of CID 1181 FMI 03 is active before performing this procedure. Note: Use the 146-4080 Digital Multimeter for the measurements in this procedure. System Response: When this diagnostic code is active, no pressure is applied to the tool. The tool will be activated. The machine ECM does not take any action when this diagnostic code is detected. Test Step 1. CHECK THE ENERGIZE CIRCUIT OF THE SOLENOID FOR A SHORT TO THE +BATTERY CIRCUIT. A. Turn the key start switch and the disconnect switch to the OFF position. B.

A. B. Disconnect the machine harness connectors from the solenoid and the machine ECM. C. At the machine harness connector for the machine ECM, measure the resistance from contact J2-40 (wire M744-PU) to all contacts that are used in the machine harness connectors for the machine ECM. Expected Result: Each resistance measurement is greater than 5000 ohms. Results: OK - Each resistance measurement is greater than 5000 ohms. The machine harness is correct. Proceed to Test Step 2. NOT OK - Each resistance measurement is not greater than 5000 ohms. There is a short in the machine harness. The short is between J2-40 (M744-PU) and the circuit that has a low resistance measurement. Repair: Repair the machine harness or replace the machine harness. Stop. Test Step 2. CHECK IF THE DIAGNOSTIC CODE IS STILL ACTIVE. A. Inspect the contacts and clean the contacts of the harness connectors. B. Reconnect all harness connectors. C. Turn the disconnect switch and the key start switch to the ON position. D. Operate the machine. E. Determine if the CID 1181 FMI 03 is active. Expected Result: The CID 1181 FMI 03 is active. Results: YES - The CID 1181 FMI 03 is active. The problem has not been corrected. The machine ECM may have failed. Repair: It is unlikely that the machine ECM has failed. Exit this procedure and perform this procedure again. If the cause of the diagnostic code is not found, replace the machine ECM. See Testing and Adjusting, "Electronic Control Module (ECM) - Replace". Stop. NO - The CID 1181 FMI 03 is not active. The problem does not exist at this time. Repair: The initial diagnostic code was probably caused by a poor electrical connection or a short at one of the harness connectors that was disconnected and reconnected. Resume normal machine operation. Stop.

TROUBLESHOOTING

053

TROUBLESHOOTING

i01792950

MID 039 - CID 1181 - FMI 05 SMCS - 5479-038-HR Conditions Which Generate This Code:

Illustration 1

g00840591

Schematic of the Solenoid (oil pressure) in the Work Tool Control Valve

This diagnostic code is associated with the Solenoid (oil pressure) in the work tool control valve. The FMI 05 means that the machine ECM has determined that the current of the solenoid is below normal. The possible causes of this diagnostic code are listed below: The energize circuit of the solenoid is open. The return circuit of the solenoid is open. The solenoid has failed. The machine ECM has failed. This is unlikely.

Note: The following test procedure may create other diagnostic codes. Ignore these created diagnostic codes and clear these diagnostic codes when the original diagnostic code has been corrected. Ensure that the diagnostic code of CID 1181 FMI 05 is active before performing this procedure. Note: Use the 146-4080 Digital Multimeter for the measurements in this procedure. System Response: When this diagnostic code is active, maximum pressure is applied to the tool. The tool will be disabled. The machine ECM does not take any action when this diagnostic code is detected. Test Step 1. CHECK THE SOLENOID. A. Turn the disconnect switch and the key start switch to the ON position. Do not start the engine. B.

A. B. Disconnect the solenoid with the active diagnostic code from the machine harness. C. At the machine harness connector for the solenoid, place a jumper wire from contact 1 (wire M744-PU) to contact 2 (wire H803-BU). D. Observe the status of the CID 1181 FMI 05. Expected Result: The CID 1181 FMI 05 remains active. The FMI has not changed and the "05" is still active. Results: YES - The diagnostic code remains active. The jumper wire does not affect the diagnostic code. Proceed to Test Step 2. NO - The diagnostic is no longer active. The solenoid has failed. Repair: The solenoid has failed. Repeat this Test Step "CHECK THE SOLENOID" in order to verify the solenoid failure. Replace the solenoid. Verify that the new solenoid corrects the problem. Stop. Test Step 2. CHECK THE HARNESS FOR AN OPEN. A. Turn the key start switch and the disconnect switch to the OFF position. B. Disconnect the machine harness connector(s) from the machine ECM. C. The jumper wire that was installed in the previous Test Step remains in place. D. At the machine harness connector, measure the resistance from signal contact J2-40 (wire M744-PU) to contact J2-59 (wire H803-BU). Expected Result: The resistance is less than 5.0 ohms. Results: OK - The resistance is less than 5.0 ohms. The machine harness is correct. Proceed to Test Step 3. NOT OK - The resistance is greater than 5000 ohms. The resistance measurement is not correct. There is an open circuit in the machine harness. Repair: The open is in wire M744-PU or in wire H803-BU of the machine harness. Repair the machine harness or replace the machine harness. Stop. Test Step 3. CHECK IF THE DIAGNOSTIC CODE REMAINS. A. Inspect the contacts of the harness connectors and clean the harness connectors. B. Reconnect all harness connectors. C. Turn the disconnect switch and the key start switch to the ON position. D. Operate the machine. E. Check the status of the CID 1181 FMI 05. Expected Result: The CID 1181 FMI 05 is active.

Results: YES - The CID 1181 FMI 05 is active. The diagnostic code has not been corrected. The machine ECM may have failed. Repair: It is unlikely that the machine ECM has failed. Exit this procedure and perform this procedure again. If the cause of the diagnostic code is not found, replace the machine ECM. See Testing and Adjusting, "Electronic Control Module (ECM) - Replace". Stop. NO - The CID 1181 FMI 05 is not active. The diagnostic code does not exist at this time. Repair: The initial diagnostic code was probably caused by a poor electrical connection or a short at one of the harness connectors that was disconnected and reconnected. Resume normal machine operation. Stop.

TROUBLESHOOTING

054

TROUBLESHOOTING

i01792951

MID 039 - CID 1181 - FMI 06 SMCS - 5479-038-HR Conditions Which Generate This Code:

Illustration 1

g00840591

Schematic of the Solenoid (oil pressure) in the Work Tool Control Valve

This diagnostic code is associated with the Solenoid (oil pressure) in the work tool control valve. The FMI 06 means that the machine ECM has determined that the current of the solenoid is above normal. The possible causes of this diagnostic code are listed: The energize circuit of the solenoid is shorted to ground. The solenoid has failed. The machine ECM has failed. This is unlikely.

Note: The following test procedure may create other diagnostic codes. Ignore these created diagnostic codes and clear these diagnostic codes when the original diagnostic code has been corrected. Ensure that the diagnostic code of CID 1181 FMI 06 is active before performing this procedure. Note: Use the 146-4080 Digital Multimeter for the measurements in this procedure. System Response: When this diagnostic code is active, maximum pressure is applied to the tool. The tool will be disabled. The machine ECM does not take any action when this diagnostic code is detected. Test Step 1. CHECK THE SOLENOID. A. Turn the disconnect switch and the key start switch to the ON position. Do not start the engine. B. Observe the status of the diagnostic code. C.

B. C. Disconnect the solenoid with the active diagnostic code from the machine harness. Expected Result: CID 1181 FMI 06 changes to CID 1181 FMI 05 when the solenoid is disconnected. Results: YES - CID 1181 FMI 06 changes to CID 1181 FMI 05 when the solenoid is disconnected. The circuit is correct. Repair: The solenoid has failed. Repeat this test "CHECK THE SOLENOID" in order to verify the solenoid failure. Replace the solenoid. Stop. NO - CID 1181 FMI 06 remains active. Proceed to Test Step 2. Test Step 2. CHECK THE ENERGIZE CIRCUIT OF THE SOLENOID FOR A SHORT TO GROUND. A. Turn the key start switch and the disconnect switch to the OFF position. B. The solenoid remains disconnected from the machine harness. C. Disconnect the machine harness connector(s) from the machine ECM. D. At the machine harness connector, measure the resistance from the signal contact J2-40 (wire M744-PU) to all contacts that are used in the machine harness connectors for the machine ECM. Expected Result: Each resistance measurement is greater than 5000 ohms. Results: OK - Each resistance measurement is greater than 5000 ohms. The machine harness is correct. Proceed to Test Step 3. NOT OK - Each resistance measurement is not greater than 5000 ohms. There is a short in the machine harness. The short is between J2-40 (wire M744-PU) and the circuit with the low resistance measurement. Repair: Repair the machine harness or replace the machine harness. Stop. Test Step 3. CHECK IF THE DIAGNOSTIC CODE REMAINS. A. Inspect the harness connectors and clean the contacts of the harness connectors. B. Reconnect all harness connectors. C. Turn the disconnect switch and the key start switch to the ON position. D. Operate the machine. E. Check the status of the CID 1181 FMI 06. Expected Result: The CID 1181 FMI 06 is active. Results: YES - The CID 1181 FMI 06 is active. The diagnostic code has not been corrected. The machine ECM may have failed. Repair: It is unlikely that the machine ECM has failed. Exit this procedure and perform this procedure again. If the cause of the diagnostic code is not found, replace the machine ECM. See Testing and Adjusting, "Electronic Control Module (ECM) - Replace". Stop.

NO - The CID 1181 FMI 06 is not active. The diagnostic code does not exist at this time. Repair: The initial diagnostic code was probably caused by a poor electrical connection or a short at one of the harness connectors that was disconnected and reconnected. Resume normal machine operation. Stop.

TROUBLESHOOTING

055

TROUBLESHOOTING

i02283691

MID 039 - CID 1401 - FMI 03 SMCS - 5479-038-T3 Conditions Which Generate This Code:

Illustration 1

g01142938

Schematic of the Transmission Solenoid No.1

This diagnostic code is associated with the transmission solenoid 1. The FMI 03 means that the ECM has determined that the voltage of the solenoid circuit is above normal. Some possible causes of the diagnostic code are listed: The solenoid has failed. The energize circuit of the solenoid is shorted to the +battery circuit. The ECM has failed. This is unlikely.

System Response: When the CID 1401 FMI 03 diagnostic code is active, the machine response will be: The warning indicator on the Monitor will illuminate. The transmission low speed function will not operate. The transmission will default to high speed.

Note: The following test procedure may create other diagnostic codes. Ignore these created diagnostic codes and clear these diagnostic codes when the original diagnostic code has been corrected. Ensure that the diagnostic code of CID 1401 FMI 03 is active before performing this procedure. Test Step 1. CHECK THE ENERGIZE CIRCUIT OF THE SOLENOID FOR A SHORT TO THE +BATTERY

CIRCUIT A. Turn the key start switch and the disconnect switch to the OFF position. B. Disconnect the machine harness connector from the solenoid. Disconnect the machine harness connectors J-1 and J-2 from the ECM. C. At the machine harness ECM connector J2, measure the resistance from contact J2-62 (wire K923-PU) to all J-1 and J2 contacts that are connected to +battery. The J-1 contact is J1-58. The J2 contacts are: J2-1, J2-23, J2-47, J2-57 and J270. Expected Result: Each resistance measurement is greater than 5000 ohms. Results: OK - Each resistance measurement is greater than 5000 ohms. The machine harness is correct. Proceed to Test Step 2. NOT OK - Each resistance measurement is not greater than 5000 ohms. There is a short in the machine harness. The short is between J2-62 (wire K923-PU) and the circuit that has a low resistance measurement. Repair: Repair the machine harness or replace the machine harness. Stop. Test Step 2. CHECK IF THE DIAGNOSTIC CODE IS STILL ACTIVE A. Inspect the contacts of the harness connectors that are used in the solenoid circuit. Ensure that the contacts are secure. Clean all of the contacts in the harness connectors. B. Reconnect all harness connectors. C. Turn the disconnect switch and the key start switch to the ON position. D. Operate the machine. E. Determine if the CID 1401 FMI 03 is active. Expected Result: The CID 1401 FMI 03 is active. Results: YES - The CID 1401 FMI 03 is active. Repair: Replace the transmission solenoid no. 1. After solenoid replacement, repeat this Test Step again. If the diagnostic code is still active, the ECM may be faulty. It is unlikely that the ECM has failed. Exit this procedure and perform this procedure again. If the cause of the diagnostic code is not found, replace the ECM. See Testing and Adjusting, "Electronic Control Module (ECM) - Replace". Stop. NO - The CID 1401 FMI 03 is not active. The problem does not exist at this time. Repair: The initial diagnostic code was probably caused by a poor electrical connection or a short at one of the harness connectors that was disconnected and reconnected. Resume normal machine operation. Stop.

TROUBLESHOOTING

056

TROUBLESHOOTING

i02283699

MID 039 - CID 1401 - FMI 05 SMCS - 5479-038-T3 Conditions Which Generate This Code:

Illustration 1

g01142938

Schematic of the Transmission Solenoid No.1

This diagnostic code is associated with the transmission solenoid 1. The FMI 05 means that the ECM has determined that the current for the solenoid is below normal. An open may exist in the circuit for the solenoid. Some possible causes of this diagnostic code are listed below: The energize circuit of the solenoid is open. The return circuit of the solenoid is open. The solenoid has failed. The ECM has failed. This is unlikely.

System Response: When the CID 1401 FMI 03 diagnostic code is active, the machine response will be: The warning indicator on the Monitor will illuminate. The transmission low speed function will not operate. The transmission will default to high speed.

Note: The following test procedure may create other diagnostic codes. Ignore these created diagnostic codes and clear these diagnostic codes when the original diagnostic code has been corrected. Ensure that the diagnostic code of CID 1401 FMI

05 is active before performing this procedure. Test Step 1. CHECK THE SOLENOID A. Disconnect the solenoid with the active diagnostic code from the machine harness. B. At the machine harness connector for the solenoid, place a jumper wire from contact 1 (wire K923-PU) to contact 2 (wire H801-PU). C. Turn the disconnect switch and the key start switch to the ON position. Do not start the engine. D. Observe the status of the CID 1401 FMI 05. Expected Result: The CID 1401 FMI 05 remains active. Results: YES - The diagnostic code remains active. The jumper wire does not affect the diagnostic code. Proceed to Test Step 2. NO - The diagnostic is no longer active. The solenoid has failed. Repair: The solenoid has failed. Repeat this Test Step "CHECK THE SOLENOID" in order to verify the solenoid failure. Replace the solenoid. Verify that the new solenoid corrects the problem. Stop. Test Step 2. CHECK THE HARNESS FOR AN OPEN A. Turn the key start switch and the disconnect switch to the OFF position. B. Disconnect the machine harness ECM connector J2 from the ECM. C. The jumper wire that was installed in the previous Test Step remains in place. D. At the machine harness connector J2 for the ECM, measure the resistance from contact J2-62 (wire K923-PU) to contact J2-52 (wire H801-PU). Expected Result: The resistance is less than 5 ohms. Results: OK - The resistance is less than 5 ohms. The machine harness is correct. Proceed to Test Step 3. NOT OK - The resistance is greater than 5000 ohms. The resistance measurement is not correct. There is an open circuit in the machine harness. A resistance measurement that is much greater than 5 ohms but less than 5000 ohms could indicate that one of the connection points is not open but is not a good connection. Repair: The open or possible bad connection is in wire K923-PU or in wire H801-PU of the machine harness. Repair the machine harness or replace the machine harness. Stop. Test Step 3. CHECK IF THE DIAGNOSTIC CODE REMAINS A. Inspect the contacts of the harness connectors that are used in the solenoid circuit. Ensure that the contacts are secure. Clean all of the contacts in the harness connectors. B. Reconnect all harness connectors. C. Turn the disconnect switch and the key start switch to the ON position. D.

C. D. Operate the machine. E. Check the status of the CID 1401 FMI 05. Expected Result: The CID 1401 FMI 05 is active. Results: YES - The CID 1401 FMI 05 is active. The diagnostic code has not been corrected. The ECM may have failed. Repair: It is unlikely that the ECM has failed. Exit this procedure and perform this procedure again. If the cause of the diagnostic code is not found, replace the ECM. See Testing and Adjusting, "Electronic Control Module (ECM) - Replace". Stop. NO - The CID 1401 FMI 05 is not active. The diagnostic code does not exist at this time. Repair: The initial diagnostic code was probably caused by a poor electrical connection at one of the harness connectors that was disconnected and reconnected. Resume normal machine operation. Stop.

TROUBLESHOOTING

057

TROUBLESHOOTING

i02283677

MID 039 - CID 1401 - FMI 06 SMCS - 5479-038-T3 Conditions Which Generate This Code:

Illustration 1

g01142938

Schematic of the Transmission Solenoid No. 1

This diagnostic code is associated with the transmission solenoid 1. The FMI 06 means that the ECM has determined that the current for the solenoid is above normal. There may be a short to ground in the solenoid circuit. Some possible causes of this diagnostic code are listed: The energize circuit of the solenoid is shorted to ground. The solenoid has failed. The ECM has failed. This is unlikely.

System Response: When the CID 1401 FMI 06 diagnostic code is active, the machine response will be: The warning indicator on the Monitor will illuminate. The transmission low speed function will not operate. The transmission will default to high speed.

Note: The following test procedure may create other diagnostic codes. Ignore these created diagnostic codes and clear these diagnostic codes when the original diagnostic code has been corrected. Ensure that the diagnostic code of CID 1401 FMI 06 is active before performing this procedure. Test Step 1. CHECK THE SOLENOID A.

A. Turn the disconnect switch and the key start switch to the ON position. Do not start the engine. B. Observe the status of the diagnostic code. C. Disconnect the solenoid with the active diagnostic code from the machine harness. Expected Result: CID 1401 FMI 06 changes to CID 1401 FMI 05 when the solenoid is disconnected. Results: YES - CID 1401 FMI 06 changes to CID 1401 FMI 05 when the solenoid is disconnected. The circuit is correct. Repair: The solenoid has failed. Repeat this test "CHECK THE SOLENOID" in order to verify the solenoid failure. Replace the solenoid. Stop. NO - CID 1401 FMI 06 remains active. Proceed to Test Step 2. Test Step 2. CHECK THE ENERGIZE CIRCUIT OF THE SOLENOID FOR A SHORT TO GROUND A. Turn the key start switch and the disconnect switch to the OFF position. B. The solenoid remains disconnected from the machine harness. C. Disconnect the machine harness ECM connectors J1 and J2 from the ECM. D. At the machine harness ECM connectors, measure the resistance from the signal contact J2-62 (wire K923-PU) to all ground contacts on connectors J1 and J2. The ground contacts on connector J2 are J2-2, J2-12, J2-13, J2-22, J2-36, J237, J2-46, J2-49, J2-52, J2-56, J2-59 and J2-69. The ground contact on connector J1 is J1-9. Expected Result: Each resistance measurement is greater than 5000 ohms. Results: OK - Each resistance measurement is greater than 5000 ohms. The machine harness is correct. Proceed to Test Step 3. NOT OK - Each resistance measurement is not greater than 5000 ohms. There is a short in the machine harness. The short is between J2-62 (wire K923-PU) and the circuit with the low resistance measurement. Repair: Repair the machine harness or replace the machine harness. Stop. Test Step 3. CHECK IF THE DIAGNOSTIC CODE REMAINS A. Inspect the contacts of the harness connectors that are used in the solenoid circuit. Ensure that the contacts are secure. Clean all of the contacts in the harness connectors. B. Reconnect all harness connectors. C. Turn the disconnect switch and the key start switch to the ON position. D. Operate the machine. E. Check the status of the CID 1401 FMI 06. Expected Result: The CID 1401 FMI 06 is active. Results:

YES - The CID 1401 FMI 06 is active. The diagnostic code has not been corrected. The ECM may have failed. Repair: It is unlikely that the ECM has failed. Exit this procedure and perform this procedure again. If the cause of the diagnostic code is not found, replace the ECM. See Testing and Adjusting, "Electronic Control Module (ECM) - Replace". Stop. NO - The CID 1401 FMI 06 is not active. The diagnostic code does not exist at this time. Repair: The initial diagnostic code was probably caused by a poor electrical connection or a short at one of the harness connectors that was disconnected and reconnected. Resume normal machine operation. Stop.

TROUBLESHOOTING

058

TROUBLESHOOTING

i02283678

MID 039 - CID 1402 - FMI 03 SMCS - 5479-038-T3 Conditions Which Generate This Code:

Illustration 1

g01142992

Schematic of the Transmission Solenoid No.2

This diagnostic code is associated with the transmission solenoid 2. The FMI 03 means that the ECM has determined that the voltage of the solenoid circuit is above normal. Some possible causes of the diagnostic code are listed: The solenoid has failed. The energize circuit of the solenoid is shorted to the +battery circuit. The ECM has failed. This is unlikely.

System Response: When the CID 1402 FMI 03 diagnostic code is active, the machine response will be: The warning indicator on the Monitor will illuminate. The transmission high speed function will not operate.

Note: The following test procedure may create other diagnostic codes. Ignore these created diagnostic codes and clear these diagnostic codes when the original diagnostic code has been corrected. Ensure that the diagnostic code of CID 1402 FMI 03 is active before performing this procedure. Test Step 1. CHECK THE ENERGIZE CIRCUIT OF THE SOLENOID FOR A SHORT TO THE +BATTERY

CIRCUIT A. Turn the key start switch and the disconnect switch to the OFF position. B. Disconnect the machine harness connector from the solenoid. Disconnect the machine harness connectors J-1 and J-2 from the ECM. C. At the machine harness ECM connector J2, measure the resistance from contact J2-61 (wire K925-PU) to all J-1 and J2 contacts that are connected to +battery. The J-1 contact is J1-58. The J2 contacts are: J2-1, J2-23, J2-47, J2-57 and J270 Expected Result: Each resistance measurement is greater than 5000 ohms. Results: OK - Each resistance measurement is greater than 5000 ohms. The machine harness is correct. Proceed to Test Step 2. NOT OK - Each resistance measurement is not greater than 5000 ohms. There is a short in the machine harness. The short is between J2-62 (wire K925-PU) and the circuit that has a low resistance measurement. Repair: Repair the machine harness or replace the machine harness. Stop. Test Step 2. CHECK IF THE DIAGNOSTIC CODE IS STILL ACTIVE A. Inspect the contacts of the harness connectors that are used in the solenoid circuit. Ensure that the contacts are secure. Clean all of the contacts in the harness connectors. B. Reconnect all harness connectors. C. Turn the disconnect switch and the key start switch to the ON position. D. Operate the machine. E. Determine if the CID 1402 FMI 03 is active. Expected Result: The CID 1402 FMI 03 is active. Results: YES - The CID 1402 FMI 03 is active. Repair: Replace the transmission solenoid no. 2. After solenoid replacement, repeat this Test Step again. If the diagnostic code is still active, the ECM may be faulty. It is unlikely that the ECM has failed. Exit this procedure and perform this procedure again. If the cause of the diagnostic code is not found, replace the ECM. See Testing and Adjusting, "Electronic Control Module (ECM) - Replace". Stop. NO - The CID 1402 FMI 03 is not active. The problem does not exist at this time. Repair: The initial diagnostic code was probably caused by a poor electrical connection or a short at one of the harness connectors that was disconnected and reconnected. Resume normal machine operation. Stop.

TROUBLESHOOTING

059

TROUBLESHOOTING

i02283767

MID 039 - CID 1402 - FMI 05 SMCS - 5479-038-T3 Conditions Which Generate This Code:

Illustration 1

g01142992

Schematic of the Transmission Solenoid No.2

This diagnostic code is associated with the transmission solenoid 2. The FMI 05 means that the ECM has determined that the current for the solenoid is below normal. An open may exist in the circuit for the solenoid. Some possible causes of this diagnostic code are listed below: The energize circuit of the solenoid is open. The return circuit of the solenoid is open. The solenoid has failed. The ECM has failed. This is unlikely.

System Response: When the CID 1402 FMI 05 diagnostic code is active, the machine response will be: The warning indicator on the Monitor will illuminate. The transmission high speed function will not operate.

Note: The following test procedure may create other diagnostic codes. Ignore these created diagnostic codes and clear these diagnostic codes when the original diagnostic code has been corrected. Ensure that the diagnostic code of CID 1402 FMI

05 is active before performing this procedure. Test Step 1. CHECK THE SOLENOID A. Disconnect the solenoid with the active diagnostic code from the machine harness. B. At the machine harness connector for the solenoid, place a jumper wire from contact 1 (wire K925-PU) to contact 2 (wire H802-GY). C. Turn the disconnect switch and the key start switch to the ON position. Do not start the engine. D. Observe the status of the CID 1402 FMI 05. Expected Result: The CID 1402 FMI 05 remains active. Results: YES - The diagnostic code remains active. The jumper wire does not affect the diagnostic code. Proceed to Test Step 2. NO - The diagnostic is no longer active. The solenoid has failed. Repair: The solenoid has failed. Repeat this Test Step "CHECK THE SOLENOID" in order to verify the solenoid failure. Replace the solenoid. Verify that the new solenoid corrects the problem. Stop. Test Step 2. CHECK THE HARNESS FOR AN OPEN A. Turn the key start switch and the disconnect switch to the OFF position. B. Disconnect the machine harness ECM connector J2 from the ECM. C. The jumper wire that was installed in the previous Test Step remains in place. D. At the machine harness connector J2 for the ECM, measure the resistance from contact J2-61 (wire K925-PU) to contact J2-49 (wire H802-GY). Expected Result: The resistance is less than 5 ohms. Results: OK - The resistance is less than 5 ohms. The machine harness is correct. Proceed to Test Step 3. NOT OK - The resistance is greater than 5000 ohms. The resistance measurement is not correct. There is an open circuit in the machine harness. A resistance measurement that is much greater than 5 ohms but less than 5000 ohms could indicate that one of the connection points is not open but is not a good connection. Repair: The open or possible bad connection is in wire K925-PU or in wire H802-PU of the machine harness. Repair the machine harness or replace the machine harness. Stop. Test Step 3. CHECK IF THE DIAGNOSTIC CODE REMAINS A. Inspect the contacts of the harness connectors that are used in the solenoid circuit. Ensure that the contacts are secure. Clean all of the contacts in the harness connectors. B. Reconnect all harness connectors. C. Turn the disconnect switch and the key start switch to the ON position. D.

C. D. Operate the machine. E. Check the status of the CID 1402 FMI 05. Expected Result: The CID 1402 FMI 05 is active. Results: YES - The CID 1402 FMI 05 is active. The diagnostic code has not been corrected. The ECM may have failed. Repair: It is unlikely that the ECM has failed. Exit this procedure and perform this procedure again. If the cause of the diagnostic code is not found, replace the ECM. See Testing and Adjusting, "Electronic Control Module (ECM) - Replace". Stop. NO - The CID 1402 FMI 05 is not active. The diagnostic code does not exist at this time. Repair: The initial diagnostic code was probably caused by a poor electrical connection at one of the harness connectors that was disconnected and reconnected. Resume normal machine operation. Stop.

TROUBLESHOOTING

060

TROUBLESHOOTING

i02283772

MID 039 - CID 1402 - FMI 06 SMCS - 5479-038-T3 Conditions Which Generate This Code:

Illustration 1

g01142992

Schematic of the Transmission Solenoid No. 2

This diagnostic code is associated with the transmission solenoid 2. The FMI 06 means that the ECM has determined that the current for the solenoid is above normal. There may be a short to ground in the solenoid circuit. Some possible causes of this diagnostic code are listed: The energize circuit of the solenoid is shorted to ground. The solenoid has failed. The ECM has failed. This is unlikely.

System Response: When the CID 1402 FMI 03 diagnostic code is active, the machine response will be: The warning indicator on the Monitor will illuminate. The transmission high speed function will not operate.

Note: The following test procedure may create other diagnostic codes. Ignore these created diagnostic codes and clear these diagnostic codes when the original diagnostic code has been corrected. Ensure that the diagnostic code of CID 1402 FMI 06 is active before performing this procedure. Test Step 1. CHECK THE SOLENOID A.

A. Turn the disconnect switch and the key start switch to the ON position. Do not start the engine. B. Observe the status of the diagnostic code. C. Disconnect the solenoid with the active diagnostic code from the machine harness. Expected Result: CID 1402 FMI 06 changes to CID 1402 FMI 05 when the solenoid is disconnected. Results: YES - CID 1402 FMI 06 changes to CID 1402 FMI 05 when the solenoid is disconnected. The circuit is correct. Repair: The solenoid has failed. Repeat this test "CHECK THE SOLENOID" in order to verify the solenoid failure. Replace the solenoid. Stop. NO - CID 1402 FMI 06 remains active. Proceed to Test Step 2. Test Step 2. CHECK THE ENERGIZE CIRCUIT OF THE SOLENOID FOR A SHORT TO GROUND A. Turn the key start switch and the disconnect switch to the OFF position. B. The solenoid remains disconnected from the machine harness. C. Disconnect the machine harness ECM connectors J1 and J2 from the ECM. D. At the machine harness ECM connectors, measure the resistance from the signal contact J2-61 (wire K925-PU) to all ground contacts on connectors J1 and J2. The ground contacts on connector J2 are J2-2, J2-12, J2-13, J2-22, J2-36, J237, J2-46, J2-49, J2-52, J2-56, J2-59 and J2-69. The ground contact on connector J1 is J1-9. Expected Result: Each resistance measurement is greater than 5000 ohms. Results: OK - Each resistance measurement is greater than 5000 ohms. The machine harness is correct. Proceed to Test Step 3. NOT OK - Each resistance measurement is not greater than 5000 ohms. There is a short in the machine harness. The short is between J2-61 (wire K925-PU) and the circuit with the low resistance measurement. Repair: Repair the machine harness or replace the machine harness. Stop. Test Step 3. CHECK IF THE DIAGNOSTIC CODE REMAINS A. Inspect the contacts of the harness connectors that are used in the solenoid circuit. Ensure that the contacts are secure. Clean all of the contacts in the harness connectors. B. Reconnect all harness connectors. C. Turn the disconnect switch and the key start switch to the ON position. D. Operate the machine. E. Check the status of the CID 1402 FMI 06. Expected Result: The CID 1402 FMI 06 is active. Results:

YES - The CID 1402 FMI 06 is active. The diagnostic code has not been corrected. The ECM may have failed. Repair: It is unlikely that the ECM has failed. Exit this procedure and perform this procedure again. If the cause of the diagnostic code is not found, replace the ECM. See Testing and Adjusting, "Electronic Control Module (ECM) - Replace". Stop. NO - The CID 1402 FMI 06 is not active. The diagnostic code does not exist at this time. Repair: The initial diagnostic code was probably caused by a poor electrical connection or a short at one of the harness connectors that was disconnected and reconnected. Resume normal machine operation. Stop.

TROUBLESHOOTING

061

TROUBLESHOOTING

i01792962

MID 039 - CID 1486 - FMI 03 SMCS - 5479-038-T3 Conditions Which Generate This Code:

Illustration 1

g00840461

Schematic of the Solenoid valve (creeper speed)

This diagnostic code is associated with the Solenoid valve (creeper speed). The FMI 03 means that the machine ECM has determined that the voltage of the solenoid circuit is above normal. The possible causes of the diagnostic code are listed: The solenoid has failed. The energize circuit of the solenoid is shorted to the +battery circuit. The machine ECM has failed. This is unlikely.

Note: The following test procedure may create other diagnostic codes. Ignore these created diagnostic codes and clear these diagnostic codes when the original diagnostic code has been corrected. Ensure that the diagnostic code of CID 1486 FMI 03 is active before performing this procedure. Note: Use the 146-4080 Digital Multimeter for the measurements in this procedure. System Response: When this diagnostic code is active, the machine ECM will be unable to control the solenoid (creeper speed). The creeper speed will always be on. Test Step 1. CHECK THE ENERGIZE CIRCUIT OF THE SOLENOID FOR A SHORT TO THE +BATTERY CIRCUIT. A. Turn the key start switch and the disconnect switch to the OFF position. B.

A. B. Disconnect the machine harness connectors from the solenoid and the machine ECM. C. At the machine harness connector for the machine ECM, measure the resistance from contact J2-64 (wire F853-BR) to all contacts that are used in the machine harness connectors for the machine ECM. Expected Result: Each resistance measurement is greater than 5000 ohms. Results: OK - Each resistance measurement is greater than 5000 ohms. The machine harness is correct. Proceed to Test Step 2. NOT OK - Each resistance measurement is not greater than 5000 ohms. There is a short in the machine harness. The short is between J2-64 (F853-BR) and the circuit that has a low resistance measurement. Repair: Repair the machine harness or replace the machine harness. Stop. Test Step 2. CHECK IF THE DIAGNOSTIC CODE IS STILL ACTIVE. A. Inspect the contacts and clean the contacts of the harness connectors. B. Reconnect all harness connectors. C. Turn the disconnect switch and the key start switch to the ON position. D. Operate the machine. E. Determine if the CID 1486 FMI 03 is active. Expected Result: The CID 1486 FMI 03 is active. Results: YES - The CID 1486 FMI 03 is active. The problem has not been corrected. The machine ECM may have failed. Repair: It is unlikely that the machine ECM has failed. Exit this procedure and perform this procedure again. If the cause of the diagnostic code is not found, replace the machine ECM. See Testing and Adjusting, "Electronic Control Module (ECM) - Replace". Stop. NO - The CID 1486 FMI 03 is not active. The problem does not exist at this time. Repair: The initial diagnostic code was probably caused by a poor electrical connection or a short at one of the harness connectors that was disconnected and reconnected. Resume normal machine operation. Stop.

TROUBLESHOOTING

062

TROUBLESHOOTING

i01792963

MID 039 - CID 1486 - FMI 05 SMCS - 5479-038-T3 Conditions Which Generate This Code:

Illustration 1

g00840461

Schematic of the Solenoid valve (creeper speed)

This diagnostic code is associated with the Solenoid valve (creeper speed). The FMI 05 means that the machine ECM has determined that the current of the solenoid is below normal. The possible causes of this diagnostic code are listed below: The energize circuit of the solenoid is open. The return circuit of the solenoid is open. The solenoid has failed. The machine ECM has failed. This is unlikely.

Note: The following test procedure may create other diagnostic codes. Ignore these created diagnostic codes and clear these diagnostic codes when the original diagnostic code has been corrected. Ensure that the diagnostic code of CID 1486 FMI 05 is active before performing this procedure. Note: Use the 146-4080 Digital Multimeter for the measurements in this procedure. System Response: When this diagnostic code is active, the machine ECM will be unable to control the solenoid (creeper speed). The creeper speed will always be off. Test Step 1. CHECK THE SOLENOID. A. Turn the disconnect switch and the key start switch to the ON position. Do not start the engine. B.

A. B. Disconnect the solenoid with the active diagnostic code from the machine harness. C. At the machine harness connector for the solenoid, place a jumper wire from contact 1 (wire F853-BR) to contact 2 (wire H801-PU). D. Observe the status of the CID 1486 FMI 05. Expected Result: The CID 1486 FMI 05 remains active. The FMI has not changed and the "05" is still active. Results: YES - The diagnostic code remains active. The jumper wire does not affect the diagnostic code. Proceed to Test Step 2. NO - The diagnostic is no longer active. The solenoid has failed. Repair: The solenoid has failed. Repeat this Test Step "CHECK THE SOLENOID" in order to verify the solenoid failure. Replace the solenoid. Verify that the new solenoid corrects the problem. Stop. Test Step 2. CHECK THE HARNESS FOR AN OPEN. A. Turn the key start switch and the disconnect switch to the OFF position. B. Disconnect the machine harness connector(s) from the machine ECM. C. The jumper wire that was installed in the previous Test Step remains in place. D. At the machine harness connector, measure the resistance from signal contact J2-64 (wire F853-BR) to contact J2-52 (wire H801-PU). Expected Result: The resistance is less than 5.0 ohms. Results: OK - The resistance is less than 5.0 ohms. The machine harness is correct. Proceed to Test Step 3. NOT OK - The resistance is greater than 5000 ohms. The resistance measurement is not correct. There is an open circuit in the machine harness. Repair: The open is in wire F853-BR or in wire H801-PU of the machine harness. Repair the machine harness or replace the machine harness. Stop. Test Step 3. CHECK IF THE DIAGNOSTIC CODE REMAINS. A. Inspect the contacts of the harness connectors and clean the harness connectors. B. Reconnect all harness connectors. C. Turn the disconnect switch and the key start switch to the ON position. D. Operate the machine. E. Check the status of the CID 1486 FMI 05. Expected Result: The CID 1486 FMI 05 is active.

Results: YES - The CID 1486 FMI 05 is active. The diagnostic code has not been corrected. The machine ECM may have failed. Repair: It is unlikely that the machine ECM has failed. Exit this procedure and perform this procedure again. If the cause of the diagnostic code is not found, replace the machine ECM. See Testing and Adjusting, "Electronic Control Module (ECM) - Replace". Stop. NO - The CID 1486 FMI 05 is not active. The diagnostic code does not exist at this time. Repair: The initial diagnostic code was probably caused by a poor electrical connection or a short at one of the harness connectors that was disconnected and reconnected. Resume normal machine operation. Stop.

TROUBLESHOOTING

063

TROUBLESHOOTING

i01792964

MID 039 - CID 1486 - FMI 06 SMCS - 5479-038-T3 Conditions Which Generate This Code:

Illustration 1

g00840461

Schematic of the Solenoid valve (creeper speed)

This diagnostic code is associated with the Solenoid valve (creeper speed). The FMI 06 means that the machine ECM has determined that the current of the solenoid is above normal. The possible causes of this diagnostic code are listed: The energize circuit of the solenoid is shorted to ground. The solenoid has failed. The machine ECM has failed. This is unlikely.

Note: The following test procedure may create other diagnostic codes. Ignore these created diagnostic codes and clear these diagnostic codes when the original diagnostic code has been corrected. Ensure that the diagnostic code of CID 1486 FMI 06 is active before performing this procedure. Note: Use the 146-4080 Digital Multimeter for the measurements in this procedure. System Response: When this diagnostic code is active, the machine ECM will be unable to control the solenoid (creeper speed). The creeper speed will always be off. Test Step 1. CHECK THE SOLENOID. A. Turn the disconnect switch and the key start switch to the ON position. Do not start the engine. B. Observe the status of the diagnostic code. C.

B. C. Disconnect the solenoid with the active diagnostic code from the machine harness. Expected Result: CID 1486 FMI 06 changes to CID 1486 FMI 05 when the solenoid is disconnected. Results: YES - CID 1486 FMI 06 changes to CID 1486 FMI 05 when the solenoid is disconnected. The circuit is correct. Repair: The solenoid has failed. Repeat this test "CHECK THE SOLENOID" in order to verify the solenoid failure. Replace the solenoid. Stop. NO - CID 1486 FMI 06 remains active. Proceed to Test Step 2. Test Step 2. CHECK THE ENERGIZE CIRCUIT OF THE SOLENOID FOR A SHORT TO GROUND. A. Turn the key start switch and the disconnect switch to the OFF position. B. The solenoid remains disconnected from the machine harness. C. Disconnect the machine harness connector(s) from the machine ECM. D. At the machine harness connector, measure the resistance from the signal contact J2-64 (wire F853-BR) to all contacts that are used in the machine harness connectors for the machine ECM. Expected Result: Each resistance measurement is greater than 5000 ohms. Results: OK - Each resistance measurement is greater than 5000 ohms. The machine harness is correct. Proceed to Test Step 3. NOT OK - Each resistance measurement is not greater than 5000 ohms. There is a short in the machine harness. The short is between J2-64 (wire F853-BR) and the circuit with the low resistance measurement. Repair: Repair the machine harness or replace the machine harness. Stop. Test Step 3. CHECK IF THE DIAGNOSTIC CODE REMAINS. A. Inspect the harness connectors and clean the contacts of the harness connectors. B. Reconnect all harness connectors. C. Turn the disconnect switch and the key start switch to the ON position. D. Operate the machine. E. Check the status of the CID 1486 FMI 06. Expected Result: The CID 1486 FMI 06 is active. Results: YES - The CID 1486 FMI 06 is active. The diagnostic code has not been corrected. The machine ECM may have failed. Repair: It is unlikely that the machine ECM has failed. Exit this procedure and perform this procedure again. If the cause of the diagnostic code is not found, replace the machine ECM. See Testing and Adjusting, "Electronic Control Module (ECM) - Replace". Stop.

NO - The CID 1486 FMI 06 is not active. The diagnostic code does not exist at this time. Repair: The initial diagnostic code was probably caused by a poor electrical connection or a short at one of the harness connectors that was disconnected and reconnected. Resume normal machine operation. Stop.

TROUBLESHOOTING

064

TROUBLESHOOTING

i01792973

MID 039 - CID 1530 - FMI 03 SMCS - 5479-038-QCH Conditions Which Generate This Code:

Illustration 1

g00840463

Schematic of the Solenoid valve (quick coupler)

This diagnostic code is associated with the Solenoid valve (quick coupler). The FMI 03 means that the machine ECM has determined that the voltage of the solenoid circuit is above normal. The possible causes of the diagnostic code are listed: The solenoid has failed. The energize circuit of the solenoid is shorted to the +battery circuit. The machine ECM has failed. This is unlikely.

Note: The following test procedure may create other diagnostic codes. Ignore these created diagnostic codes and clear these diagnostic codes when the original diagnostic code has been corrected. Ensure that the diagnostic code of CID 1530 FMI 03 is active before performing this procedure. Note: Use the 146-4080 Digital Multimeter for the measurements in this procedure. System Response: When this diagnostic code is active, the machine ECM will be unable to control the solenoid (quick coupler). The quick coupler will command an attachment to unlock. Test Step 1. CHECK THE ENERGIZE CIRCUIT OF THE SOLENOID FOR A SHORT TO THE +BATTERY CIRCUIT. A. Turn the key start switch and the disconnect switch to the OFF position. B.

A. B. Disconnect the machine harness connectors from the solenoid and the machine ECM. C. At the machine harness connector for the machine ECM, measure the resistance from contact J2-15 (wire M743-YL) to all contacts that are used in the machine harness connectors for the machine ECM. Expected Result: Each resistance measurement is greater than 5000 ohms. Results: OK - Each resistance measurement is greater than 5000 ohms. The machine harness is correct. Proceed to Test Step 2. NOT OK - Each resistance measurement is not greater than 5000 ohms. There is a short in the machine harness. The short is between J2-15 (M743-YL) and the circuit that has a low resistance measurement. Repair: Repair the machine harness or replace the machine harness. Stop. Test Step 2. CHECK IF THE DIAGNOSTIC CODE IS STILL ACTIVE. A. Inspect the contacts and clean the contacts of the harness connectors. B. Reconnect all harness connectors. C. Turn the disconnect switch and the key start switch to the ON position. D. Operate the machine. E. Determine if the CID 1530 FMI 03 is active. Expected Result: The CID 1530 FMI 03 is active. Results: YES - The CID 1530 FMI 03 is active. The problem has not been corrected. The machine ECM may have failed. Repair: It is unlikely that the machine ECM has failed. Exit this procedure and perform this procedure again. If the cause of the diagnostic code is not found, replace the machine ECM. See Testing and Adjusting, "Electronic Control Module (ECM) - Replace". Stop. NO - The CID 1530 FMI 03 is not active. The problem does not exist at this time. Repair: The initial diagnostic code was probably caused by a poor electrical connection or a short at one of the harness connectors that was disconnected and reconnected. Resume normal machine operation. Stop.

TROUBLESHOOTING

065

TROUBLESHOOTING

i01792974

MID 039 - CID 1530 - FMI 05 SMCS - 5479-038-QCH Conditions Which Generate This Code:

Illustration 1

g00840463

Schematic of the Solenoid valve (quick coupler)

This diagnostic code is associated with the Solenoid valve (quick coupler). The FMI 05 means that the machine ECM has determined that the current of the solenoid is below normal. The possible causes of this diagnostic code are listed below: The energize circuit of the solenoid is open. The return circuit of the solenoid is open. The solenoid has failed. The machine ECM has failed. This is unlikely.

Note: The following test procedure may create other diagnostic codes. Ignore these created diagnostic codes and clear these diagnostic codes when the original diagnostic code has been corrected. Ensure that the diagnostic code of CID 1530 FMI 05 is active before performing this procedure. Note: Use the 146-4080 Digital Multimeter for the measurements in this procedure. System Response: When this diagnostic code is active, the machine ECM will be unable to control the solenoid (quick coupler). The quick coupler will command an attachment to lock. Test Step 1. CHECK THE SOLENOID. A. Turn the disconnect switch and the key start switch to the ON position. Do not start the engine. B.

A. B. Disconnect the solenoid with the active diagnostic code from the machine harness. C. At the machine harness connector for the solenoid, place a jumper wire from contact 1 (wire M743-YL) to contact 2 (wire H804-GN). D. Observe the status of the CID 1530 FMI 05. Expected Result: The CID 1530 FMI 05 remains active. The FMI has not changed and the "05" is still active. Results: YES - The diagnostic code remains active. The jumper wire does not affect the diagnostic code. Proceed to Test Step 2. NO - The diagnostic is no longer active. The solenoid has failed. Repair: The solenoid has failed. Repeat this Test Step "CHECK THE SOLENOID" in order to verify the solenoid failure. Replace the solenoid. Verify that the new solenoid corrects the problem. Stop. Test Step 2. CHECK THE HARNESS FOR AN OPEN. A. Turn the key start switch and the disconnect switch to the OFF position. B. Disconnect the machine harness connector(s) from the machine ECM. C. The jumper wire that was installed in the previous Test Step remains in place. D. At the machine harness connector, measure the resistance from signal contact J2-15 (wire M743-YL) to contact J2-13 (wire H804-GN). Expected Result: The resistance is less than 5.0 ohms. Results: OK - The resistance is less than 5.0 ohms. The machine harness is correct. Proceed to Test Step 3. NOT OK - The resistance is greater than 5000 ohms. The resistance measurement is not correct. There is an open circuit in the machine harness. Repair: The open is in wire M743-YL or in wire H804-GN of the machine harness. Repair the machine harness or replace the machine harness. Stop. Test Step 3. CHECK IF THE DIAGNOSTIC CODE REMAINS. A. Inspect the contacts of the harness connectors and clean the harness connectors. B. Reconnect all harness connectors. C. Turn the disconnect switch and the key start switch to the ON position. D. Operate the machine. E. Check the status of the CID 1530 FMI 05. Expected Result: The CID 1530 FMI 05 is active.

Results: YES - The CID 1530 FMI 05 is active. The diagnostic code has not been corrected. The machine ECM may have failed. Repair: It is unlikely that the machine ECM has failed. Exit this procedure and perform this procedure again. If the cause of the diagnostic code is not found, replace the machine ECM. See Testing and Adjusting, "Electronic Control Module (ECM) - Replace". Stop. NO - The CID 1530 FMI 05 is not active. The diagnostic code does not exist at this time. Repair: The initial diagnostic code was probably caused by a poor electrical connection or a short at one of the harness connectors that was disconnected and reconnected. Resume normal machine operation. Stop.

TROUBLESHOOTING

066

TROUBLESHOOTING

i01792975

MID 039 - CID 1530 - FMI 06 SMCS - 5479-038-QCH Conditions Which Generate This Code:

Illustration 1

g00840463

Schematic of the Solenoid valve (quick coupler)

This diagnostic code is associated with the Solenoid valve (quick coupler). The FMI 06 means that the machine ECM has determined that the current of the solenoid is above normal. The possible causes of this diagnostic code are listed: The energize circuit of the solenoid is shorted to ground. The solenoid has failed. The machine ECM has failed. This is unlikely.

Note: The following test procedure may create other diagnostic codes. Ignore these created diagnostic codes and clear these diagnostic codes when the original diagnostic code has been corrected. Ensure that the diagnostic code of CID 1530 FMI 06 is active before performing this procedure. Note: Use the 146-4080 Digital Multimeter for the measurements in this procedure. System Response: When this diagnostic code is active, the machine ECM will be unable to control the solenoid (quick coupler). The quick coupler will command an attachment to lock. Test Step 1. CHECK THE SOLENOID. A. Turn the disconnect switch and the key start switch to the ON position. Do not start the engine. B. Observe the status of the diagnostic code. C.

B. C. Disconnect the solenoid with the active diagnostic code from the machine harness. Expected Result: CID 1530 FMI 06 changes to CID 1530 FMI 05 when the solenoid is disconnected. Results: YES - CID 1530 FMI 06 changes to CID 1530 FMI 05 when the solenoid is disconnected. The circuit is correct. Repair: The solenoid has failed. Repeat this test "CHECK THE SOLENOID" in order to verify the solenoid failure. Replace the solenoid. Stop. NO - CID 1530 FMI 06 remains active. Proceed to Test Step 2. Test Step 2. CHECK THE ENERGIZE CIRCUIT OF THE SOLENOID FOR A SHORT TO GROUND. A. Turn the key start switch and the disconnect switch to the OFF position. B. The solenoid remains disconnected from the machine harness. C. Disconnect the machine harness connector(s) from the machine ECM. D. At the machine harness connector, measure the resistance from the signal contact J2-15 (wire M743-YL) to all contacts that are used in the machine harness connectors for the machine ECM. Expected Result: Each resistance measurement is greater than 5000 ohms. Results: OK - Each resistance measurement is greater than 5000 ohms. The machine harness is correct. Proceed to Test Step 3. NOT OK - Each resistance measurement is not greater than 5000 ohms. There is a short in the machine harness. The short is between J2-15 (wire M743-YL) and the circuit with the low resistance measurement. Repair: Repair the machine harness or replace the machine harness. Stop. Test Step 3. CHECK IF THE DIAGNOSTIC CODE REMAINS. A. Inspect the harness connectors and clean the contacts of the harness connectors. B. Reconnect all harness connectors. C. Turn the disconnect switch and the key start switch to the ON position. D. Operate the machine. E. Check the status of the CID 1530 FMI 06. Expected Result: The CID 1530 FMI 06 is active. Results: YES - The CID 1530 FMI 06 is active. The diagnostic code has not been corrected. The machine ECM may have failed. Repair: It is unlikely that the machine ECM has failed. Exit this procedure and perform this procedure again. If the cause of the diagnostic code is not found, replace the machine ECM. See Testing and Adjusting, "Electronic Control Module (ECM) - Replace". Stop.

NO - The CID 1530 FMI 06 is not active. The diagnostic code does not exist at this time. Repair: The initial diagnostic code was probably caused by a poor electrical connection or a short at one of the harness connectors that was disconnected and reconnected. Resume normal machine operation. Stop.

TROUBLESHOOTING

067

TROUBLESHOOTING

i01792976

MID 039 - CID 1615 - FMI 03 SMCS - 5467-038 Conditions Which Generate This Code:

Illustration 1

g00840465

Schematic of the Solenoid valve (one-way / two-way)

This diagnostic code is associated with the Solenoid valve (one-way / two-way). The FMI 03 means that the machine ECM has determined that the voltage of the solenoid circuit is above normal. The possible causes of the diagnostic code are listed: The solenoid has failed. The energize circuit of the solenoid is shorted to the +battery circuit. The machine ECM has failed. This is unlikely.

Note: The following test procedure may create other diagnostic codes. Ignore these created diagnostic codes and clear these diagnostic codes when the original diagnostic code has been corrected. Ensure that the diagnostic code of CID 1615 FMI 03 is active before performing this procedure. Note: Use the 146-4080 Digital Multimeter for the measurements in this procedure. System Response: When this diagnostic code is active, the machine ECM will be unable to control the solenoid. The solenoid will be constantly energized and set for the bidirectional tool. Test Step 1. CHECK THE ENERGIZE CIRCUIT OF THE SOLENOID FOR A SHORT TO THE +BATTERY CIRCUIT. A. Turn the key start switch and the disconnect switch to the OFF position. B.

A. B. Disconnect the machine harness connectors from the solenoid and the machine ECM. C. At the machine harness connector for the machine ECM, measure the resistance from contact J2-63 (wire M746-GY) to all contacts that are used in the machine harness connectors for the machine ECM. Expected Result: Each resistance measurement is greater than 5000 ohms. Results: OK - Each resistance measurement is greater than 5000 ohms. The machine harness is correct. Proceed to Test Step 2. NOT OK - Each resistance measurement is not greater than 5000 ohms. There is a short in the machine harness. The short is between J2-63 (M746-GY) and the circuit that has a low resistance measurement. Repair: Repair the machine harness or replace the machine harness. Stop. Test Step 2. CHECK IF THE DIAGNOSTIC CODE IS STILL ACTIVE. A. Inspect the contacts and clean the contacts of the harness connectors. B. Reconnect all harness connectors. C. Turn the disconnect switch and the key start switch to the ON position. D. Operate the machine. E. Determine if the CID 1615 FMI 03 is active. Expected Result: The CID 1615 FMI 03 is active. Results: YES - The CID 1615 FMI 03 is active. The problem has not been corrected. The machine ECM may have failed. Repair: It is unlikely that the machine ECM has failed. Exit this procedure and perform this procedure again. If the cause of the diagnostic code is not found, replace the machine ECM. See Testing and Adjusting, "Electronic Control Module (ECM) - Replace". Stop. NO - The CID 1615 FMI 03 is not active. The problem does not exist at this time. Repair: The initial diagnostic code was probably caused by a poor electrical connection or a short at one of the harness connectors that was disconnected and reconnected. Resume normal machine operation. Stop.

TROUBLESHOOTING

068

TROUBLESHOOTING

i01792990

MID 039 - CID 1615 - FMI 05 SMCS - 5479-038 Conditions Which Generate This Code:

Illustration 1

g00840465

Schematic of the Solenoid valve (one-way / two-way)

This diagnostic code is associated with the Solenoid valve (one-way / two-way). The FMI 05 means that the machine ECM has determined that the current of the solenoid is below normal. The possible causes of this diagnostic code are listed below: The energize circuit of the solenoid is open. The return circuit of the solenoid is open. The solenoid has failed. The machine ECM has failed. This is unlikely.

Note: The following test procedure may create other diagnostic codes. Ignore these created diagnostic codes and clear these diagnostic codes when the original diagnostic code has been corrected. Ensure that the diagnostic code of CID 1615 FMI 05 is active before performing this procedure. Note: Use the 146-4080 Digital Multimeter for the measurements in this procedure. System Response: When this diagnostic code is active, the machine ECM will be unable to control the solenoid. The solenoid will be constantly deenergized and constantly set for a unidirectional tool. Test Step 1. CHECK THE SOLENOID. A. Turn the disconnect switch and the key start switch to the ON position. Do not start the engine. B.

A. B. Disconnect the solenoid with the active diagnostic code from the machine harness. C. At the machine harness connector for the solenoid, place a jumper wire from contact 1 (wire M746-GY) to contact 2 (wire H801-PU). D. Observe the status of the CID 1615 FMI 05. Expected Result: The CID 1615 FMI 05 remains active. The FMI has not changed and the "05" is still active. Results: YES - The diagnostic code remains active. The jumper wire does not affect the diagnostic code. Proceed to Test Step 2. NO - The diagnostic is no longer active. The solenoid has failed. Repair: The solenoid has failed. Repeat this Test Step "CHECK THE SOLENOID" in order to verify the solenoid failure. Replace the solenoid. Verify that the new solenoid corrects the problem. Stop. Test Step 2. CHECK THE HARNESS FOR AN OPEN. A. Turn the key start switch and the disconnect switch to the OFF position. B. Disconnect the machine harness connector(s) from the machine ECM. C. The jumper wire that was installed in the previous Test Step remains in place. D. At the machine harness connector, measure the resistance from signal contact J2-63 (wire M746-GY) to contact J2-52 (wire H801-PU). Expected Result: The resistance is less than 5.0 ohms. Results: OK - The resistance is less than 5.0 ohms. The machine harness is correct. Proceed to Test Step 3. NOT OK - The resistance is greater than 5000 ohms. The resistance measurement is not correct. There is an open circuit in the machine harness. Repair: The open is in wire M746-GY or in wire H801-PU of the machine harness. Repair the machine harness or replace the machine harness. Stop. Test Step 3. CHECK IF THE DIAGNOSTIC CODE REMAINS. A. Inspect the contacts of the harness connectors and clean the harness connectors. B. Reconnect all harness connectors. C. Turn the disconnect switch and the key start switch to the ON position. D. Operate the machine. E. Check the status of the CID 1615 FMI 05. Expected Result: The CID 1615 FMI 05 is active.

Results: YES - The CID 1615 FMI 05 is active. The diagnostic code has not been corrected. The machine ECM may have failed. Repair: It is unlikely that the machine ECM has failed. Exit this procedure and perform this procedure again. If the cause of the diagnostic code is not found, replace the machine ECM. See Testing and Adjusting, "Electronic Control Module (ECM) - Replace". Stop. NO - The CID 1615 FMI 05 is not active. The diagnostic code does not exist at this time. Repair: The initial diagnostic code was probably caused by a poor electrical connection or a short at one of the harness connectors that was disconnected and reconnected. Resume normal machine operation. Stop.

TROUBLESHOOTING

069

TROUBLESHOOTING

i01792991

MID 039 - CID 1615 - FMI 06 SMCS - 5479-038 Conditions Which Generate This Code:

Illustration 1

g00840465

Schematic of the Solenoid valve (one-way / two-way)

This diagnostic code is associated with the Solenoid valve (one-way / two-way). The FMI 06 means that the machine ECM has determined that the current of the solenoid is above normal. The possible causes of this diagnostic code are listed: The energize circuit of the solenoid is shorted to ground. The solenoid has failed. The machine ECM has failed. This is unlikely.

Note: The following test procedure may create other diagnostic codes. Ignore these created diagnostic codes and clear these diagnostic codes when the original diagnostic code has been corrected. Ensure that the diagnostic code of CID 1615 FMI 06 is active before performing this procedure. Note: Use the 146-4080 Digital Multimeter for the measurements in this procedure. System Response: When this diagnostic code is active, the machine ECM will be unable to control the solenoid. The solenoid will be constantly deenergized, set for a unidirectional tool. Test Step 1. CHECK THE SOLENOID. A. Turn the disconnect switch and the key start switch to the ON position. Do not start the engine. B. Observe the status of the diagnostic code. C.

B. C. Disconnect the solenoid with the active diagnostic code from the machine harness. Expected Result: CID 1615 FMI 06 changes to CID 1615 FMI 05 when the solenoid is disconnected. Results: YES - CID 1615 FMI 06 changes to CID 1615 FMI 05 when the solenoid is disconnected. The circuit is correct. Repair: The solenoid has failed. Repeat this test "CHECK THE SOLENOID" in order to verify the solenoid failure. Replace the solenoid. Stop. NO - CID 1615 FMI 06 remains active. Proceed to Test Step 2. Test Step 2. CHECK THE ENERGIZE CIRCUIT OF THE SOLENOID FOR A SHORT TO GROUND. A. Turn the key start switch and the disconnect switch to the OFF position. B. The solenoid remains disconnected from the machine harness. C. Disconnect the machine harness connector(s) from the machine ECM. D. At the machine harness connector, measure the resistance from the signal contact J2-63 (wire M746-GY) to all contacts that are used in the machine harness connectors for the machine ECM. Expected Result: Each resistance measurement is greater than 5000 ohms. Results: OK - Each resistance measurement is greater than 5000 ohms. The machine harness is correct. Proceed to Test Step 3. NOT OK - Each resistance measurement is not greater than 5000 ohms. There is a short in the machine harness. The short is between J2-63 (wire M746-GY) and the circuit with the low resistance measurement. Repair: Repair the machine harness or replace the machine harness. Stop. Test Step 3. CHECK IF THE DIAGNOSTIC CODE REMAINS. A. Inspect the harness connectors and clean the contacts of the harness connectors. B. Reconnect all harness connectors. C. Turn the disconnect switch and the key start switch to the ON position. D. Operate the machine. E. Check the status of the CID 1615 FMI 06. Expected Result: The CID 1615 FMI 06 is active. Results: YES - The CID 1615 FMI 06 is active. The diagnostic code has not been corrected. The machine ECM may have failed. Repair: It is unlikely that the machine ECM has failed. Exit this procedure and perform this procedure again. If the cause of the diagnostic code is not found, replace the machine ECM. See Testing and Adjusting, "Electronic Control Module (ECM) - Replace". Stop.

NO - The CID 1615 FMI 06 is not active. The diagnostic code does not exist at this time. Repair: The initial diagnostic code was probably caused by a poor electrical connection or a short at one of the harness connectors that was disconnected and reconnected. Resume normal machine operation. Stop.

TROUBLESHOOTING

070

TROUBLESHOOTING

i01792992

MID 039 - CID 1616 - FMI 03 SMCS - 5479-038-SCY Conditions Which Generate This Code:

Illustration 1

g00840466

Schematic of the Solenoid valve (stabilizer)

This diagnostic code is associated with the Solenoid valve (stabilizer). The FMI 03 means that the machine ECM has determined that the voltage of the solenoid circuit is above normal. The possible causes of the diagnostic code are listed: The solenoid has failed. The energize circuit of the solenoid is shorted to the +battery circuit. The machine ECM has failed. This is unlikely.

Note: The following test procedure may create other diagnostic codes. Ignore these created diagnostic codes and clear these diagnostic codes when the original diagnostic code has been corrected. Ensure that the diagnostic code of CID 1616 FMI 03 is active before performing this procedure. Note: Use the 146-4080 Digital Multimeter for the measurements in this procedure. System Response: When this diagnostic code is active, the machine ECM will be unable to control the solenoid. The solenoid will be constantly energized. This activates the high pressure. Test Step 1. CHECK THE ENERGIZE CIRCUIT OF THE SOLENOID FOR A SHORT TO THE +BATTERY CIRCUIT. A. Turn the key start switch and the disconnect switch to the OFF position. B.

A. B. Disconnect the machine harness connectors from the solenoid and the machine ECM. C. At the machine harness connector for the machine ECM, measure the resistance from contact J2-62 (wire G422-BU) to all contacts that are used in the machine harness connectors for the machine ECM. Expected Result: Each resistance measurement is greater than 5000 ohms. Results: OK - Each resistance measurement is greater than 5000 ohms. The machine harness is correct. Proceed to Test Step 2. NOT OK - Each resistance measurement is not greater than 5000 ohms. There is a short in the machine harness. The short is between J2-62 (G422-BU) and the circuit that has a low resistance measurement. Repair: Repair the machine harness or replace the machine harness. Stop. Test Step 2. CHECK IF THE DIAGNOSTIC CODE IS STILL ACTIVE. A. Inspect the contacts and clean the contacts of the harness connectors. B. Reconnect all harness connectors. C. Turn the disconnect switch and the key start switch to the ON position. D. Operate the machine. E. Determine if the CID 1616 FMI 03 is active. Expected Result: The CID 1616 FMI 03 is active. Results: YES - The CID 1616 FMI 03 is active. The problem has not been corrected. The machine ECM may have failed. Repair: It is unlikely that the machine ECM has failed. Exit this procedure and perform this procedure again. If the cause of the diagnostic code is not found, replace the machine ECM. See Testing and Adjusting, "Electronic Control Module (ECM) - Replace". Stop. NO - The CID 1616 FMI 03 is not active. The problem does not exist at this time. Repair: The initial diagnostic code was probably caused by a poor electrical connection or a short at one of the harness connectors that was disconnected and reconnected. Resume normal machine operation. Stop.

TROUBLESHOOTING

071

TROUBLESHOOTING

i01792993

MID 039 - CID 1616 - FMI 05 SMCS - 5479-038-SCY Conditions Which Generate This Code:

Illustration 1

g00840466

Schematic of the Solenoid valve (stabilizer)

This diagnostic code is associated with the Solenoid valve (stabilizer). The FMI 05 means that the machine ECM has determined that the current of the solenoid is below normal. The possible causes of this diagnostic code are listed below: The energize circuit of the solenoid is open. The return circuit of the solenoid is open. The solenoid has failed. The machine ECM has failed. This is unlikely.

Note: The following test procedure may create other diagnostic codes. Ignore these created diagnostic codes and clear these diagnostic codes when the original diagnostic code has been corrected. Ensure that the diagnostic code of CID 1616 FMI 05 is active before performing this procedure. Note: Use the 146-4080 Digital Multimeter for the measurements in this procedure. System Response: When this diagnostic code is active, the machine ECM will be unable to control the solenoid. The solenoid will be constantly deenergized. This disables the high pressure. Test Step 1. CHECK THE SOLENOID. A. Turn the disconnect switch and the key start switch to the ON position. Do not start the engine. B.

A. B. Disconnect the solenoid with the active diagnostic code from the machine harness. C. At the machine harness connector for the solenoid, place a jumper wire from contact 1 (wire G422-BU) to contact 2 (wire H801-PU). D. Observe the status of the CID 1616 FMI 05. Expected Result: The CID 1616 FMI 05 remains active. The FMI has not changed and the "05" is still active. Results: YES - The diagnostic code remains active. The jumper wire does not affect the diagnostic code. Proceed to Test Step 2. NO - The diagnostic is no longer active. The solenoid has failed. Repair: The solenoid has failed. Repeat this Test Step "CHECK THE SOLENOID" in order to verify the solenoid failure. Replace the solenoid. Verify that the new solenoid corrects the problem. Stop. Test Step 2. CHECK THE HARNESS FOR AN OPEN. A. Turn the key start switch and the disconnect switch to the OFF position. B. Disconnect the machine harness connector(s) from the machine ECM. C. The jumper wire that was installed in the previous Test Step remains in place. D. At the machine harness connector, measure the resistance from signal contact J2-62 (wire G422-BU) to contact J2-52 (wire H801-PU). Expected Result: The resistance is less than 5.0 ohms. Results: OK - The resistance is less than 5.0 ohms. The machine harness is correct. Proceed to Test Step 3. NOT OK - The resistance is greater than 5000 ohms. The resistance measurement is not correct. There is an open circuit in the machine harness. Repair: The open is in wire G422-BU or in wire H801-PU of the machine harness. Repair the machine harness or replace the machine harness. Stop. Test Step 3. CHECK IF THE DIAGNOSTIC CODE REMAINS. A. Inspect the contacts of the harness connectors and clean the harness connectors. B. Reconnect all harness connectors. C. Turn the disconnect switch and the key start switch to the ON position. D. Operate the machine. E. Check the status of the CID 1616 FMI 05. Expected Result: The CID 1616 FMI 05 is active.

Results: YES - The CID 1616 FMI 05 is active. The diagnostic code has not been corrected. The machine ECM may have failed. Repair: It is unlikely that the machine ECM has failed. Exit this procedure and perform this procedure again. If the cause of the diagnostic code is not found, replace the machine ECM. See Testing and Adjusting, "Electronic Control Module (ECM) - Replace". Stop. NO - The CID 1616 FMI 05 is not active. The diagnostic code does not exist at this time. Repair: The initial diagnostic code was probably caused by a poor electrical connection or a short at one of the harness connectors that was disconnected and reconnected. Resume normal machine operation. Stop.

TROUBLESHOOTING

072

TROUBLESHOOTING

i01792996

MID 039 - CID 1616 - FMI 06 SMCS - 5479-038-SCY Conditions Which Generate This Code:

Illustration 1

g00840466

Schematic of the Solenoid valve (stabilizer)

This diagnostic code is associated with the Solenoid valve (stabilizer). The FMI 06 means that the machine ECM has determined that the current of the solenoid is above normal. The possible causes of this diagnostic code are listed: The energize circuit of the solenoid is shorted to ground. The solenoid has failed. The machine ECM has failed. This is unlikely.

Note: The following test procedure may create other diagnostic codes. Ignore these created diagnostic codes and clear these diagnostic codes when the original diagnostic code has been corrected. Ensure that the diagnostic code of CID 1616 FMI 06 is active before performing this procedure. Note: Use the 146-4080 Digital Multimeter for the measurements in this procedure. System Response: When this diagnostic code is active, the machine ECM will be unable to control the solenoid. The solenoid will be constantly deenergized. This disables the high pressure. Test Step 1. CHECK THE SOLENOID. A. Turn the disconnect switch and the key start switch to the ON position. Do not start the engine. B. Observe the status of the diagnostic code. C.

B. C. Disconnect the solenoid with the active diagnostic code from the machine harness. Expected Result: CID 1616 FMI 06 changes to CID 1616 FMI 05 when the solenoid is disconnected. Results: YES - CID 1616 FMI 06 changes to CID 1616 FMI 05 when the solenoid is disconnected. The circuit is correct. Repair: The solenoid has failed. Repeat this test "CHECK THE SOLENOID" in order to verify the solenoid failure. Replace the solenoid. Stop. NO - CID 1616 FMI 06 remains active. Proceed to Test Step 2. Test Step 2. CHECK THE ENERGIZE CIRCUIT OF THE SOLENOID FOR A SHORT TO GROUND. A. Turn the key start switch and the disconnect switch to the OFF position. B. The solenoid remains disconnected from the machine harness. C. Disconnect the machine harness connector(s) from the machine ECM. D. At the machine harness connector, measure the resistance from the signal contact J2-62 (wire G422-BU) to all contacts that are used in the machine harness connectors for the machine ECM. Expected Result: Each resistance measurement is greater than 5000 ohms. Results: OK - Each resistance measurement is greater than 5000 ohms. The machine harness is correct. Proceed to Test Step 3. NOT OK - Each resistance measurement is not greater than 5000 ohms. There is a short in the machine harness. The short is between J2-62 (wire G422-BU) and the circuit with the low resistance measurement. Repair: Repair the machine harness or replace the machine harness. Stop. Test Step 3. CHECK IF THE DIAGNOSTIC CODE REMAINS. A. Inspect the harness connectors and clean the contacts of the harness connectors. B. Reconnect all harness connectors. C. Turn the disconnect switch and the key start switch to the ON position. D. Operate the machine. E. Check the status of the CID 1616 FMI 06. Expected Result: The CID 1616 FMI 06 is active. Results: YES - The CID 1616 FMI 06 is active. The diagnostic code has not been corrected. The machine ECM may have failed. Repair: It is unlikely that the machine ECM has failed. Exit this procedure and perform this procedure again. If the cause of the diagnostic code is not found, replace the machine ECM. See Testing and Adjusting, "Electronic Control Module (ECM) - Replace". Stop.

NO - The CID 1616 FMI 06 is not active. The diagnostic code does not exist at this time. Repair: The initial diagnostic code was probably caused by a poor electrical connection or a short at one of the harness connectors that was disconnected and reconnected. Resume normal machine operation. Stop.

TROUBLESHOOTING

073

TROUBLESHOOTING

i01901060

MID 039 - CID 1617 - FMI 03 SMCS - 5479-038-ZX Conditions Which Generate This Code:

Illustration 1

g00840471

Schematic of the Solenoid valve (oscillating axle)

This diagnostic code is associated with the Solenoid valve (oscillating axle). The FMI 03 means that the machine ECM has determined that the voltage of the solenoid circuit is above normal. The possible causes of the diagnostic code are listed: The solenoid has failed. The energize circuit of the solenoid is shorted to the +battery circuit. The machine ECM has failed. This is unlikely.

Note: The following test procedure may create other diagnostic codes. Ignore these created diagnostic codes and clear these diagnostic codes when the original diagnostic code has been corrected. Ensure that the diagnostic code of CID 1617 FMI 03 is active before performing this procedure. Note: Use the 146-4080 Digital Multimeter for the measurements in this procedure. System Response: When this diagnostic code is active, the machine ECM will be unable to control the solenoid (oscillating axle). The oscillating axle will always be locked. Test Step 1. CHECK THE ENERGIZE CIRCUIT OF THE SOLENOID FOR A SHORT TO THE +BATTERY CIRCUIT. A. Turn the key start switch and the disconnect switch to the OFF position. B.

A. B. Disconnect the machine harness connectors from the solenoid and the machine ECM. C. At the machine harness connector for the machine ECM, measure the resistance from contact J2-65 (wire K746-PK) to all contacts that are used in the machine harness connectors for the machine ECM. Expected Result: Each resistance measurement is greater than 5000 ohms. Results: OK - Each resistance measurement is greater than 5000 ohms. The machine harness is correct. Proceed to Test Step 2. NOT OK - Each resistance measurement is not greater than 5000 ohms. There is a short in the machine harness. The short is between J2-65 (K746-PK) and the circuit that has a low resistance measurement. Repair: Repair the machine harness or replace the machine harness. Stop. Test Step 2. CHECK IF THE DIAGNOSTIC CODE IS STILL ACTIVE. A. Inspect the contacts and clean the contacts of the harness connectors. B. Reconnect all harness connectors. C. Turn the disconnect switch and the key start switch to the ON position. D. Operate the machine. E. Determine if the CID 1617 FMI 03 is active. Expected Result: The CID 1617 FMI 03 is active. Results: YES - The CID 1617 FMI 03 is active. The problem has not been corrected. The machine ECM may have failed. Repair: It is unlikely that the machine ECM has failed. Exit this procedure and perform this procedure again. If the cause of the diagnostic code is not found, replace the machine ECM. See Testing and Adjusting, "Electronic Control Module (ECM) - Replace". Stop. NO - The CID 1617 FMI 03 is not active. The problem does not exist at this time. Repair: The initial diagnostic code was probably caused by a poor electrical connection or a short at one of the harness connectors that was disconnected and reconnected. Resume normal machine operation. Stop.

TROUBLESHOOTING

074

TROUBLESHOOTING

i01793019

MID 039 - CID 1617 - FMI 05 SMCS - 5479-038-ZX Conditions Which Generate This Code:

Illustration 1

g00840471

Schematic of the Solenoid valve (oscillating axle)

This diagnostic code is associated with the Solenoid valve (oscillating axle). The FMI 05 means that the machine ECM has determined that the current of the solenoid is below normal. The possible causes of this diagnostic code are listed below: The energize circuit of the solenoid is open. The return circuit of the solenoid is open. The solenoid has failed. The machine ECM has failed. This is unlikely.

Note: The following test procedure may create other diagnostic codes. Ignore these created diagnostic codes and clear these diagnostic codes when the original diagnostic code has been corrected. Ensure that the diagnostic code of CID 1617 FMI 05 is active before performing this procedure. Note: Use the 146-4080 Digital Multimeter for the measurements in this procedure. System Response: When this diagnostic code is active, the machine ECM will be unable to control the solenoid (oscillating axle). The oscillating axle will never be locked. Test Step 1. CHECK THE SOLENOID. A. Turn the disconnect switch and the key start switch to the ON position. Do not start the engine. B.

A. B. Disconnect the solenoid with the active diagnostic code from the machine harness. C. At the machine harness connector for the solenoid, place a jumper wire from contact 1 (wire K746-PK) to contact 2 (wire H801-PU). D. Observe the status of the CID 1617 FMI 05. Expected Result: The CID 1617 FMI 05 remains active. The FMI has not changed and the "05" is still active. Results: YES - The diagnostic code remains active. The jumper wire does not affect the diagnostic code. Proceed to Test Step 2. NO - The diagnostic is no longer active. The solenoid has failed. Repair: The solenoid has failed. Repeat this Test Step "CHECK THE SOLENOID" in order to verify the solenoid failure. Replace the solenoid. Verify that the new solenoid corrects the problem. Stop. Test Step 2. CHECK THE HARNESS FOR AN OPEN. A. Turn the key start switch and the disconnect switch to the OFF position. B. Disconnect the machine harness connector(s) from the machine ECM. C. The jumper wire that was installed in the previous Test Step remains in place. D. At the machine harness connector, measure the resistance from signal contact J2-65 (wire K746-PK) to contact J2-52 (wire H801-PU). Expected Result: The resistance is less than 5.0 ohms. Results: OK - The resistance is less than 5.0 ohms. The machine harness is correct. Proceed to Test Step 3. NOT OK - The resistance is greater than 5000 ohms. The resistance measurement is not correct. There is an open circuit in the machine harness. Repair: The open is in wire K746-PK or in wire H801-PU of the machine harness. Repair the machine harness or replace the machine harness. Stop. Test Step 3. CHECK IF THE DIAGNOSTIC CODE REMAINS. A. Inspect the contacts of the harness connectors and clean the harness connectors. B. Reconnect all harness connectors. C. Turn the disconnect switch and the key start switch to the ON position. D. Operate the machine. E. Check the status of the CID 1617 FMI 05. Expected Result: The CID 1617 FMI 05 is active.

Results: YES - The CID 1617 FMI 05 is active. The diagnostic code has not been corrected. The machine ECM may have failed. Repair: It is unlikely that the machine ECM has failed. Exit this procedure and perform this procedure again. If the cause of the diagnostic code is not found, replace the machine ECM. See Testing and Adjusting, "Electronic Control Module (ECM) - Replace". Stop. NO - The CID 1617 FMI 05 is not active. The diagnostic code does not exist at this time. Repair: The initial diagnostic code was probably caused by a poor electrical connection or a short at one of the harness connectors that was disconnected and reconnected. Resume normal machine operation. Stop.

TROUBLESHOOTING

075

TROUBLESHOOTING

i01793020

MID 039 - CID 1617 - FMI 06 SMCS - 5479-038-ZX Conditions Which Generate This Code:

Illustration 1

g00840471

Schematic of the Solenoid valve (oscillating axle)

This diagnostic code is associated with the Solenoid valve (oscillating axle). The FMI 06 means that the machine ECM has determined that the current of the solenoid is above normal. The possible causes of this diagnostic code are listed: The energize circuit of the solenoid is shorted to ground. The solenoid has failed. The machine ECM has failed. This is unlikely.

Note: The following test procedure may create other diagnostic codes. Ignore these created diagnostic codes and clear these diagnostic codes when the original diagnostic code has been corrected. Ensure that the diagnostic code of CID 1617 FMI 06 is active before performing this procedure. Note: Use the 146-4080 Digital Multimeter for the measurements in this procedure. System Response: When this diagnostic code is active, the machine ECM will be unable to control the solenoid (oscillating axle). The oscillating axle will never be locked. Test Step 1. CHECK THE SOLENOID. A. Turn the disconnect switch and the key start switch to the ON position. Do not start the engine. B. Observe the status of the diagnostic code. C.

B. C. Disconnect the solenoid with the active diagnostic code from the machine harness. Expected Result: CID 1617 FMI 06 changes to CID 1617 FMI 05 when the solenoid is disconnected. Results: YES - CID 1617 FMI 06 changes to CID 1617 FMI 05 when the solenoid is disconnected. The circuit is correct. Repair: The solenoid has failed. Repeat this test "CHECK THE SOLENOID" in order to verify the solenoid failure. Replace the solenoid. Stop. NO - CID 1617 FMI 06 remains active. Proceed to Test Step 2. Test Step 2. CHECK THE ENERGIZE CIRCUIT OF THE SOLENOID FOR A SHORT TO GROUND. A. Turn the key start switch and the disconnect switch to the OFF position. B. The solenoid remains disconnected from the machine harness. C. Disconnect the machine harness connector(s) from the machine ECM. D. At the machine harness connector, measure the resistance from the signal contact J2-65 (wire K746-PK) to all contacts that are used in the machine harness connectors for the machine ECM. Expected Result: Each resistance measurement is greater than 5000 ohms. Results: OK - Each resistance measurement is greater than 5000 ohms. The machine harness is correct. Proceed to Test Step 3. NOT OK - Each resistance measurement is not greater than 5000 ohms. There is a short in the machine harness. The short is between J2-65 (wire K746-PK) and the circuit with the low resistance measurement. Repair: Repair the machine harness or replace the machine harness. Stop. Test Step 3. CHECK IF THE DIAGNOSTIC CODE REMAINS. A. Inspect the harness connectors and clean the contacts of the harness connectors. B. Reconnect all harness connectors. C. Turn the disconnect switch and the key start switch to the ON position. D. Operate the machine. E. Check the status of the CID 1617 FMI 06. Expected Result: The CID 1617 FMI 06 is active. Results: YES - The CID 1617 FMI 06 is active. The diagnostic code has not been corrected. The machine ECM may have failed. Repair: It is unlikely that the machine ECM has failed. Exit this procedure and perform this procedure again. If the cause of the diagnostic code is not found, replace the machine ECM. See Testing and Adjusting, "Electronic Control Module (ECM) - Replace". Stop.

NO - The CID 1617 FMI 06 is not active. The diagnostic code does not exist at this time. Repair: The initial diagnostic code was probably caused by a poor electrical connection or a short at one of the harness connectors that was disconnected and reconnected. Resume normal machine operation. Stop.

TROUBLESHOOTING

076

TROUBLESHOOTING

i01901066

MID 039 - CID 1618 - FMI 00 SMCS - 5070-038-PSN Conditions Which Generate This Code:

Illustration 1

g00840478

Schematic of the position Sensor (swashplate angle)

This diagnostic code is associated with the position sensor (swashplate angle). The FMI 00 means that the machine ECM has determined that the signal of the sensor is above the normal range. The output of the sensor (main pump swashplate angle) is an analog signal from 0.25 to 4.75 DCV. The voltage changes as the angle of the swashplate changes. The machine ECM recognizes a voltage in the range of 0.25 DCV to 4.75 DCV as valid input from the sensor. If the voltage is below 0.25 DCV, the machine ECM determines that the sensor is shorted to ground. If the voltage is above 4.75 DCV, the machine ECM determines that the sensor is shorted to the + battery. The possible causes of this diagnostic code are listed below: The sensor has failed. The signal circuit of the sensor is shorted to the + battery circuit. The sensor needs to be calibrated. The machine ECM has failed. This is unlikely.

Note: The following test procedure may create other diagnostic codes. Ignore these created diagnostic codes and clear the diagnostic codes when the original diagnostic code has been corrected. Note: Use the 146-4080 Digital Multimeter for the measurements in this procedure. System Response: When this diagnostic code is active, the machine ECM does not take any action after logging the code. Test Step 1. INSPECT THE SENSOR. A.

A. Perform a visual inspection of the sensor, the wiring for the sensor and the hardware that is associated with the sensor. Expected Result: There is no apparent damage to the sensor, the wiring for the sensor or the hardware that is associated with the sensor. Results: OK - There is no apparent damage to the sensor, the wiring for the sensor or the hardware that is associated with the sensor. Proceed to Test Step 2. NOT OK - There is apparent damage to the sensor, the wiring for the sensor or the hardware that is associated with the sensor. Repair: Replace the damaged part. Proceed to Test Step 8. Test Step 2. CHECK FOR POWER AT THE SENSOR. A. Do not disconnect the harness connector from the sensor. B. At the back of the harness connector for the sensor, insert a 7X-1710 Multimeter Probe along the voltage supply wire (contact B). C. Turn the key start switch and the disconnect switch to the ON position. D. Measure the voltage from contact B to frame ground. Expected Result: The voltage is +24 DCV. Results: OK - The voltage is +24 DCV. Proceed to Test Step 3. NOT OK - The voltage is not +24 DCV. The circuit is open. Repair: Repair the machine harness or replace the machine harness. Stop. Test Step 3. CHECK FOR PROPER GROUND AT THE SENSOR. A. The machine harness remains connected to the sensor. B. Turn the key start switch and the disconnect switch to the OFF position. C. Remove the 7X-1710 Multimeter Probe from the voltage supply wire (contact B). D. At the back of the harness connector for the sensor, insert a 7X-1710 Multimeter Probe along the ground wire (contact A). E. Measure the resistance from contact A to frame ground. Expected Result: The resistance is less than 5 ohms. Results: OK - The resistance is less than 5 ohms. The ground circuit is correct. Proceed to Test Step 4. NOT OK - The resistance is greater than 5 ohms. The ground circuit in the machine harness has failed.

Repair: Replace the machine harness or repair the machine harness. Stop. Test Step 4. CHECK THE SIGNAL OF THE SENSOR. A. Turn the key start switch and the disconnect switch to the OFF position. B. The 7X-1710 Multimeter Probe remains along the ground wire (contact A). C. At the back of the harness connector for the sensor, insert the other 7X-1710 Multimeter Probe along the signal wire (contact C). D. Turn the disconnect switch and the key start switch to the ON position. E. Monitor the signal of the sensor with the 146-4080 Digital Multimeter . F. Without disconnecting the sensor or the hardware that is associated with the sensor from the machine, take the sensor through the full operating range of the sensor. Note: On some machines, it may be necessary to start the engine in order to take the sensor through the full operating range of the sensor. Expected Result: The sensor's signal responds in the manner that is described at the beginning of this procedure. The CID 1618 FMI 00 is not active at the maximum range of the sensor. Results: OK - The sensor's signal responds correctly. The sensor is operating correctly. Proceed to Test Step 5. NOT OK - The sensor's signal does not respond correctly. The sensor is NOT operating correctly. Repair: Replace the sensor. Stop. Test Step 5. CHECK THE SIGNAL AT THE MACHINE ECM. A. Turn the key start switch and the disconnect switch to the OFF position. B. Insert the 7X-1710 Multimeter Probes into the back of the ECM connector along J1-62 (wire F475-GN) and J1-12 (wire G939-PK). C. Turn the disconnect switch and the key start switch to the ON position. D. Monitor the signal of the sensor with the 146-4080 Digital Multimeter . E. Without disconnecting the sensor or the hardware that is associated with the sensor from the machine, take the sensor through the full operating range of the sensor. Note: On some machines, it may be necessary to start the engine in order to take the sensor through the full operating range of the sensor. Expected Result: The sensor's signal responds in the manner that is described at the beginning of this procedure. The CID 1618 FMI 00 is not active at the maximum range of the sensor. Results: OK - The sensor's signal responds correctly. The sensor is operating correctly. Proceed to Test Step 6. NOT OK - The sensor's signal does not respond correctly. The harness has failed.

Repair: Repair the machine harness or replace the machine harness. Stop. Test Step 6. CHECK THE SIGNAL CIRCUIT FOR A SHORT IN THE HARNESS. A. The key start switch and the disconnect switch remain in the OFF position. B. Disconnect the machine harness connectors from the sensor and the machine ECM. C. Measure the resistance between contact J1-62 (wire F475-GN) and all contacts that are used in the machine harness connectors for the machine ECM. Expected Result: Each resistance measurement is greater than 5000 ohms. Results: OK - Each of the resistance measurements are greater than 5000 ohms. The circuit is correct. Proceed to Test Step 7. NOT OK - The resistance is less than 5 ohms. The signal circuit is shorted to another circuit in the harness. Repair: Repair the machine harness or replace the machine harness. Stop. Test Step 7. CHECK IF THE DIAGNOSTIC CODE REMAINS. A. Inspect the harness connectors and clean the contacts of the machine harness connectors. B. Reconnect all harness connectors. C. Turn the disconnect switch and the key start switch to the ON position. D. Operate the machine and take the sensor through the operating range of the sensor. E. Check the status of the CID 1618 FMI 00. Expected Result: The CID 1618 FMI 00 is not active at the maximum range of the sensor. Results: OK - The CID 1618 FMI 00 is not active at the maximum range of the sensor. The diagnostic code does not exist at this time. The initial diagnostic code was probably caused by a poor connection or a short at one of the connectors that was disconnected and reconnected. Resume normal operation. Stop. NOT OK - The CID 1618 FMI 00 is active at the maximum range of the sensor. The diagnostic code has not been corrected. The machine ECM may have failed. Repair: It is unlikely that the machine ECM has failed. Exit this procedure. Perform the adjustment procedure for the sensor, if necessary. Then perform the calibration procedure for the sensor. Perform this procedure again. If the cause of the failure is not found, replace the machine ECM. See the Testing and Adjusting, "Electronic Control Module -(ECM) Replace". Stop. Test Step 8. CHECK THE ADJUSTMENT AND/OR THE CALIBRATION OF THE SENSOR. A. Turn the disconnect switch and the key start switch to the ON position. B.

A. B. Perform the adjustment procedure for the position sensor, if necessary. Then perform the calibration of the position sensor. Refer to the Testing and Adjusting section of the manual for additional information on these procedures. C. Without disconnecting the sensor or the hardware that is associated with the sensor, move the sensor through the entire range of motion. Note: On some machines, it may be necessary to start the engine in order to move the sensor through the entire range of motion. D. Check the status of the diagnostic code. Expected Result: The CID 1618 FMI 00 is not active. Results: OK - The diagnostic is not active. The adjustment and/or the calibration has corrected the failure. Resume normal operation. Stop. NOT OK - CID 1618 FMI 00 is still active. Repair: Exit this procedure. Perform this procedure again. Stop.

TROUBLESHOOTING

077

TROUBLESHOOTING

i01901074

MID 039 - CID 1618 - FMI 01 SMCS - 5070-038-PSN Conditions Which Generate This Code:

Illustration 1

g00840478

Schematic of the Position Sensor (swashplate angle)

This diagnostic code is associated with the Position sensor (swashplate angle). The FMI 01 means that the machine ECM has determined that the signal of the sensor is below the normal range. The output of the sensor (main pump swashplate angle) is an analog signal from 0.25 to 4.75 DCV. The voltage changes as the angle of the swashplate changes. The machine ECM recognizes a voltage in the range of 0.25 DCV to 4.75 DCV as valid input from the sensor. If the voltage is below 0.25 DCV, the machine ECM determines that the sensor is shorted to ground. If the voltage is above 4.75 DCV, the machine ECM determines that the sensor is shorted to the + battery. The possible causes of this failure are listed below: The position sensor has failed. The signal circuit of the sensor is shorted to the ground. The sensor needs to be calibrated. The machine ECM has failed. This is unlikely.

Note: The following test procedure may create other diagnostic codes. Ignore these created diagnostic codes and clear the diagnostic codes when the original diagnostic code has been corrected. Note: Use the 146-4080 Digital Multimeter for the measurements in this procedure. System Response: When this diagnostic code is active, the machine ECM does not take any action after logging the code. Test Step 1. INSPECT THE SENSOR. A.

A. Perform a visual inspection of the sensor, the wiring for the sensor and the hardware that is associated with the sensor. Expected Result: There is no apparent damage to the sensor, the wiring for the sensor or the hardware that is associated with the sensor. Results: OK - There is no apparent damage to the sensor, the wiring for the sensor or the hardware that is associated with the sensor. Proceed to Test Step 2. NOT OK - There is apparent damage to the sensor, the wiring for the sensor or the hardware that is associated with the sensor. Repair: Replace the damaged part. Proceed to Test Step 8. Test Step 2. CHECK FOR POWER AT THE SENSOR. A. Do not disconnect the harness connector from the sensor. B. At the back of the harness connector for the sensor, insert a 7X-1710 Multimeter Probe along the voltage supply wire (contact B). C. Turn the key start switch and the disconnect switch to the ON position. D. Measure the voltage from contact B to frame ground. Expected Result: The voltage is +24 DCV. Results: OK - The voltage is +24 DCV. Proceed to Test Step 3. NOT OK - The voltage is not +24 DCV. The circuit is open. Repair: Repair the machine harness or replace the machine harness. Stop. Test Step 3. CHECK FOR PROPER GROUND AT THE SENSOR. A. The machine harness remains connected to the sensor. B. Turn the key start switch and the disconnect switch to the OFF position. C. Remove the 7X-1710 Multimeter Probe from the voltage supply wire (contact B). D. At the back of the harness connector for the sensor, insert a 7X-1710 Multimeter Probe along the ground wire (contact A). E. Measure the resistance from contact A to frame ground. Expected Result: The resistance is less than 5 ohms. Results: OK - The resistance is less than 5 ohms. The ground circuit is correct. Proceed to Test Step 4. NOT OK - The resistance is greater than 5 ohms. The ground circuit in the machine harness has failed.

Repair: Replace the machine harness or repair the machine harness. Stop. Test Step 4. CHECK THE SIGNAL OF THE SENSOR. A. Turn the key start switch and the disconnect switch to the OFF position. B. At the back of the harness connector for the sensor, remove the 7X-1710 Multimeter Probe from contact B and insert the probe along the signal wire (contact C). C. At the back of the harness connector for the sensor, insert the 7X-1710 Multimeter Probe along the ground wire (contact A). D. Turn the disconnect switch and the key start switch to the ON position. E. Monitor the signal of the sensor with the 146-4080 Digital Multimeter . F. Without disconnecting the sensor or the hardware that is associated with the sensor from the machine, take the sensor through the full operating range of the sensor. Note: On some machines, it may be necessary to start the engine in order to take the sensor through the full operating range of the sensor. Expected Result: The sensor's signal responds in the manner that is described at the beginning of this procedure. The CID 1618 FMI 01 is not active at the maximum range of the sensor. Results: OK - The sensor's signal responds correctly. The sensor is operating correctly. Proceed to Test Step 5. NOT OK - The sensor's signal does not respond correctly. The sensor is NOT operating correctly. Repair: Replace the sensor. Stop. Test Step 5. CHECK THE SIGNAL AT THE machine ECM. A. Turn the key start switch and the disconnect switch to the OFF position. B. Insert the 7X-1710 Multimeter Probes into the back of the ECM connector along J1-62 (wire F475-GN) and J1-12 (wire G939-PK). C. Turn the disconnect switch and the key start switch to the ON position. D. Monitor the signal of the sensor with the 146-4080 Digital Multimeter . E. Without disconnecting the sensor or the hardware that is associated with the sensor from the machine, take the sensor through the full operating range of the sensor. Note: On some machines, it may be necessary to start the engine in order to take the sensor through the full operating range of the sensor. Expected Result: The sensor's signal responds in the manner that is described at the beginning of this procedure. The CID 1618 FMI 01 is not active at the maximum range of the sensor. Results: OK - The sensor's signal responds correctly. The sensor is operating correctly. Proceed to Test Step 6.

NOT OK - The sensor's signal does not respond correctly. The harness has failed. Repair: Repair the machine harness or replace the machine harness. Stop. Test Step 6. CHECK THE SIGNAL CIRCUIT FOR A SHORT IN THE HARNESS. A. The key start switch and the disconnect switch remain in the OFF position. B. Disconnect the machine harness connectors from the sensor and the machine ECM. C. Measure the resistance between contact J1-62 (wire F475-GN) and all contacts that are used in the machine harness connectors for the machine ECM. Expected Result: Each resistance measurement is greater than 5000 ohms. Results: OK - Each of the resistance measurements are greater than 5000 ohms. The circuit is correct. Proceed to Test Step 7. NOT OK - The resistance is less than 5 ohms. The signal circuit is shorted to another circuit in the harness. Repair: Repair the machine harness or replace the machine harness. Stop. Test Step 7. CHECK IF THE DIAGNOSTIC CODE REMAINS. A. Inspect the harness connectors and clean the contacts of the machine harness connectors. B. Reconnect all harness connectors. C. Turn the disconnect switch and the key start switch to the ON position. D. Operate the machine and take the sensor through the operating range of the sensor. E. Check the status of the CID 1618 FMI 01. Expected Result: The CID 1618 FMI 01 is not active at the minimum range of the sensor. Results: OK - The CID 1618 FMI 01 is not active at the minimum range of the sensor. The diagnostic code does not exist at this time. The initial diagnostic code was probably caused by a poor connection or a short at one of the connectors that was disconnected and reconnected. Resume normal operation. Stop. NOT OK - The CID 1618 FMI 01 is active at the minimum range of the sensor. The diagnostic code has not been corrected. The machine ECM may have failed. Repair: It is unlikely that the machine ECM has failed. Exit this procedure. Perform the adjustment procedure for the sensor, if necessary. Then perform the calibration procedure for the sensor. Perform this procedure again. If the cause of the failure is not found, replace the machine ECM. See the Testing and Adjusting, "Electronic Control Module (ECM) Replace". Stop. Test Step 8. CHECK THE ADJUSTMENT AND/OR THE CALIBRATION OF THE SENSOR. A. Turn the disconnect switch and the key start switch to the ON position. B.

A. B. Perform the adjustment procedure for the position sensor, if necessary. Then perform the calibration of the position sensor. Refer to the Testing and Adjusting section of the manual for additional information on these procedures. C. Without disconnecting the sensor or the hardware that is associated with the sensor, move the sensor through the entire range of motion. Note: On some machines, it may be necessary to start the engine in order to move the sensor through the entire range of motion. D. Check the status of the diagnostic code. Expected Result: The CID 1618 FMI 01 is not active. Results: OK - The diagnostic is not active. The adjustment and/or the calibration has corrected the failure. Resume normal operation. Stop. NOT OK - CID 1618 FMI 01 is still active. Repair: Exit this procedure. Perform this procedure again. Stop.

TROUBLESHOOTING

078

TROUBLESHOOTING

i01793022

MID 039 - CID 1618 - FMI 03 SMCS - 5070-038-PSN Conditions Which Generate This Code:

Illustration 1

g00840478

Schematic of the Position sensor (swashplate angle)

This diagnostic code is associated with the Position sensor (swashplate angle). The FMI 03 means that the machine ECM has determined that the voltage of the circuit for the sensor is above normal. Refer to Systems Operation, "Sensors" for information regarding the operation of the sensor and the location. The input voltage of 0.25 DCV to 4.75 DCV from the sensor corresponds to a swashplate angle of -45 degrees to 45 degrees. The machine ECM recognizes a swashplate angle in the range of -5 degrees to 40 degrees as a valid swashplate angle. If the angle is less than -5 degrees, the machine ECM determines that the value is below the normal operational range. If the angle is greater than 40 degrees, the machine ECM determines that the value is above the normal operational range. The possible causes of this diagnostic code are listed below: The signal circuit for the sensor is open. The signal circuit for the sensor is shorted to the +battery circuit. The sensor has failed. The power circuit or the ground circuit has failed. The machine ECM has failed. This is unlikely.

Note: The following test procedure may create other diagnostic codes. Ignore these created diagnostic codes and clear the diagnostic codes when the original diagnostic code has been corrected. Ensure that the diagnostic code of CID 1618 FMI 03 is active before performing this procedure.

Note: Use the 146-4080 Digital Multimeter for the measurements in this procedure. System Response: When this diagnostic code is active, the machine ECM will disable the AESC. The AESC will never be activated. The machine ECM will also disable the High Pressure Solenoid. High Pressure will never be provided to the stabilizer system. The Electronic Technician will display "Abnormal/Incorrect Data " parameter for the Main Pump Swashplate. Test Step 1. CHECK FOR POWER AT THE SENSOR. A. Do not disconnect the harness connector from the sensor. B. Turn the key start switch and the disconnect switch to the ON position. C. At the back of the harness connector for the sensor, insert a 7X-1710 Multimeter Probe along the voltage supply wire (contact B). D. Measure the voltage from contact B to frame ground. Expected Result: The voltage is +24 DCV. Results: OK - The voltage is +24 DCV. Proceed to Test Step 2. NOT OK - The voltage is not +24 DCV. The + battery circuit in the machine harness has failed. Repair: Replace the machine harness or repair the machine harness. Stop. Test Step 2. CHECK FOR PROPER GROUND AT THE SENSOR. A. The machine harness remains connected to the sensor. B. Turn the key start switch and the disconnect switch to the OFF position. C. Remove the 7X-1710 Multimeter Probe from the voltage supply wire (contact B). D. At the back of the harness connector for the sensor, insert a 7X-1710 Multimeter Probe along the ground wire (contact A). E. Measure the resistance from contact A to frame ground. Expected Result: The resistance is less than 5 ohms. Results: OK - The resistance is less than 5 ohms. The ground circuit is correct. Proceed to Test Step 3. NOT OK - The resistance is greater than 5 ohms. The ground circuit in the machine harness has failed. Repair: Replace the machine harness or repair the machine harness. Stop. Test Step 3. CHECK THE WIRING HARNESS OF THE SENSOR FOR AN OPEN CIRCUIT. A. The key start switch and the disconnect switch remain in the OFF position. B. Disconnect the machine harness from the sensor. C. At the harness connector for the sensor, connect a jumper wire between contact A and contact C. D.

C. D. Disconnect the machine harness connector(s) from the machine ECM. E. At the harness connector for the machine ECM, measure the resistance between contact J1-62 (wire F475-GN) and contact J1-12 (wire G939-PK). Expected Result: The resistance measurement is less than 5 ohms. Results: OK - The resistance measurement is less than 5 ohms. The circuit is correct. Proceed to Test Step 4. NOT OK - The resistance is greater than 5 ohms. The circuit is not correct. There is an open circuit in the wiring harness. Repair: There is an open circuit in the wiring harness. Repair the wiring harness or replace the wiring harness. Stop. Test Step 4. CHECK THE WIRING HARNESS OF THE SENSOR FOR A SHORT TO THE +BATTERY CIRCUIT. A. The key start switch and the disconnect switch remain in the OFF position. B. The machine harness remains disconnected from the sensor. Remove the jumper wire that was installed in the previous step. C. The machine harness connector(s) remains disconnected from the machine ECM. D. At the machine harness connector for the machine ECM, measure the resistance from the signal contact J1-62 (wire F475GN) of the machine harness to all contacts that are used in the machine harness connectors for the machine ECM. Expected Result: Each resistance measurement is greater than 5000 ohms. Results: OK - Each resistance measurement is greater than 5000 ohms. The machine harness is correct. Proceed to Test Step 5. NOT OK - One or more resistance measurements is not correct. There is a short in the machine harness. Repair: The short is between signal contact J1-62 (wire F475-GN) and the circuit with the low resistance measurement. Repair the machine harness or replace the machine harness. Stop. Test Step 5. CHECK THE OUTPUT OF THE SENSOR. A. Reconnect the machine harness connectors to the machine ECM. Reconnect the machine harness connector to the sensor. B. At the back of the harness connector for the sensor, insert a 7X-1710 Multimeter Probe along the signal wire (contact C). C. At the back of the harness connector for the sensor, insert a 7X-1710 Multimeter Probe along the ground wire (contact A). D. Turn the disconnect switch and the key start switch to the ON position. E. Measure the signal of the sensor. The proper signal is described at the beginning of this procedure. Expected Result: The signal from the sensor is valid. Results:

OK - The signal from the sensor is valid. Proceed to Test Step 6. NOT OK - The signal from the sensor is not valid. Repair: The sensor has failed. Replace the sensor. Stop. Test Step 6. CHECK IF THE DIAGNOSTIC CODE REMAINS. A. Inspect the contacts of the harness connectors and clean the connectors. B. Reconnect all harness connectors. C. Turn the disconnect switch and the key start switch to the ON position. D. Operate the machine. E. Check the status of the CID 1618 FMI 03. Expected Result: The CID 1618 FMI 03 is active. Results: YES - The CID 1618 FMI 03 is active. The diagnostic code has not been corrected. The machine ECM may have failed. Repair: It is unlikely that the machine ECM has failed. Exit this procedure and perform this procedure again. If the cause of the diagnostic code is not found, replace the machine ECM. See Testing and Adjusting, "Electronic Control Module (ECM) - Replace". Stop. NO - The CID 1618 FMI 03 is not active. The diagnostic code does not exist at this time. Repair: The initial diagnostic code was probably caused by a poor electrical connection or a short at one of the harness connectors that was disconnected and reconnected. Resume normal machine operation. Stop.

TROUBLESHOOTING

079

TROUBLESHOOTING

i01901116

MID 039 - CID 1618 - FMI 04 SMCS - 5070-038-PSN Conditions Which Generate This Code:

Illustration 1

g00840478

Schematic of the Position sensor (swashplate angle)

This diagnostic code is associated with the Position sensor (swashplate angle). The FMI 04 means that the ECM has determined that the voltage of the circuit for the position sensor is below normal. The input voltage of 0.25 DCV to 4.75 DCV from the sensor corresponds to a swashplate angle of -45 degrees to 45 degrees. The ECM recognizes a swashplate angle in the range of -5 degrees to 40 degrees as a valid swashplate angle. If the angle is less than -5 degrees, the ECM determines that the value is below the normal operational range. If the angle is greater than 40 degrees, the ECM determines that the value is above the normal operational range. The possible causes of this diagnostic code are listed below: The signal circuit for the sensor is shorted to ground. The sensor has failed. The ECM has failed. This is unlikely.

Note: The following test procedure may create other diagnostic codes. Ignore these created diagnostic codes and clear the diagnostic codes when the original diagnostic code has been corrected. Ensure that the diagnostic code of CID 1618 FMI 04 is active before performing this procedure. Note: Use the 146-4080 Digital Multimeter for the measurements in this procedure. System Response: When this diagnostic code is active, the Machine ECM will disable the AESC. The AESC will never be activated. Also, the Machine ECM will disable the Solenoid (High Pressure). High Pressure will never be provided to the stabilizer system. The Electronic Technician will display "Abnormal/Incorrect Data" parameter for the Main Pump Swashplate Angle.

Test Step 1. CHECK THE SENSOR. A. Turn the disconnect switch and the key start switch to the ON position. B. Ensure that the diagnostic code is active. C. Observe the status of the diagnostic code. Disconnect the sensor from the machine harness. Expected Result: The CID 1618 FMI 04 remains active. The FMI has not changed and the "04" is still active. Results: OK - The diagnostic code remains active. The sensor is correct. Proceed to Test Step 2. NOT OK - The diagnostic code is no longer active. The sensor has failed. Repair: Replace the sensor. Stop. Test Step 2. CHECK THE WIRING HARNESS OF THE SENSOR FOR A SHORT TO GROUND. A. Turn the key start switch and the disconnect switch to the OFF position. B. Disconnect the machine harness from the sensor. C. Disconnect the machine harness connector(s) from the ECM. D. At the machine harness connector for the ECM, measure the resistance from the signal contact J1-62 (wire F475-GN) of the machine harness to all possible sources of ground. Measure the resistance to all contacts of the machine harness connectors for the ECM. Expected Result: Each resistance measurement is greater than 5000 ohms. Results: OK - Each resistance measurement is greater than 5000 ohms. The machine harness is correct. Proceed to Test Step 3. NOT OK - One or more resistance measurements is not correct. There is a short in the machine harness. Repair: The short is between signal contact J1-62 (wire F475-GN) and the circuit with the low resistance measurement. Repair the machine harness or replace the machine harness. Stop. Test Step 3. CHECK IF THE DIAGNOSTIC CODE REMAINS. A. Inspect the contacts of the harness connectors and clean the contacts. B. Reconnect all harness connectors. C. Turn the disconnect switch and the key start switch to the ON position. D. Operate the machine. E. Check the status of the CID 1618 FMI 04. Expected Result: The CID 1618 FMI 04 is active. Results:

YES - The CID 1618 FMI 04 is active. The diagnostic code has not been corrected. The ECM may have failed. Repair: It is unlikely that the ECM has failed. Exit this procedure and perform this procedure again. If the cause of the diagnostic code is not found, replace the ECM. See Testing and Adjusting, "Electronic Control Module (ECM) - Replace". Stop. NO - The CID 1618 FMI 04 is not active. The diagnostic code does not exist at this time. Repair: The initial diagnostic code was probably caused by a poor electrical connection or a short at one of the harness connectors that was disconnected and reconnected. Resume normal machine operation. Stop.

TROUBLESHOOTING

080

TROUBLESHOOTING

i02304087

MID 039 - CID 1621 - FMI 03 SMCS - 5479-038-DRV Conditions Which Generate This Code: Note: The ECM connections for the generator solenoid have changed for machines in the following serial number ranges: BDR2001-UP, BDM2001-UP, BDX2001-UP, BCZ2001-UP, BDK2001-UP, BDY2001-UP,, BEB2001-UP, H2A1-UP, H2B1-UP, H2C1-UP, H2D1-UP, H2E1-UP, H2F1-UP and H2G1-UP. The connections for these machines and the other machines that are covered by this manual are illustrated below.

Illustration 1

g01153697

Generator valve solenoid ECM connections for machines in the following serial number ranges: BDR1-2000, BDM1-2000, BDX1-2000, BCZ12000, BDK1-2000, BDY1-2000 and BEB1-2000.

Illustration 2

g01153698

Generator valve solenoid ECM connections for machines in the following serial number ranges: BDR2001-UP, BDM2001-UP, BDX2001-UP, BCZ2001-UP, BDK2001-UP, BDY2001-UP,, BEB2001-UP, H2A1-UP, H2B1-UP, H2C1-UP, H2D1-UP, H2E1-UP, H2F1-UP and H2G1-UP

This diagnostic code is associated with the generator solenoid valve. The FMI 03 means that the machine ECM has determined that the voltage of the solenoid circuit is above normal. The possible causes of the diagnostic code are listed: The solenoid has failed. The energize circuit of the solenoid is shorted to the +battery circuit. The machine ECM has failed. This is unlikely.

System Response: The alert indicator on the Monitor will illuminate. When this diagnostic code is active, the machine ECM will be unable to control the solenoid. The solenoid will be constantly energized, and the generator will be on. Note: The following test procedure may create other diagnostic codes. Ignore these created diagnostic codes and clear these diagnostic codes when the original diagnostic code has been corrected. Ensure that the diagnostic code of CID 1621 FMI 03 is active before performing this procedure. Note: Use the 146-4080 Digital Multimeter for the measurements in this procedure. Test Step 1. CHECK THE ENERGIZE CIRCUIT OF THE SOLENOID FOR A SHORT TO THE +BATTERY CIRCUIT. A. Turn the key start switch and the disconnect switch to the OFF position. B. Disconnect the machine harness connector from the solenoid. Disconnect the machine harness connectors J-1 and J-2 from the ECM. C. At the machine harness ECM connector J2, depending on your machine configuration, measure the resistance from either contact J2-25 or J2-55 (wire E984-BU) to all J-1 and J2 contacts that are connected to +battery. The J-1 contact is J158. The J2 contacts are: J2-1, J2-23, J2-47, J2-57 and J2-70. Expected Result: Each resistance measurement is greater than 5000 ohms. Results:

OK - Each resistance measurement is greater than 5000 ohms. The machine harness is correct. Proceed to Test Step 2. NOT OK - Each resistance measurement is not greater than 5000 ohms. There is a short in the machine harness. The short is between wire E984-BU and the circuit that has a low resistance measurement. Repair: Repair the machine harness or replace the machine harness. Stop. Test Step 2. CHECK IF THE DIAGNOSTIC CODE IS STILL ACTIVE. A. Inspect the contacts and clean the contacts of the harness connectors. B. Reconnect all harness connectors. C. Turn the disconnect switch and the key start switch to the ON position. D. Operate the machine. E. Determine if the CID 1621 FMI 03 is active. Expected Result: The CID 1621 FMI 03 is active. Results: YES - The CID 1621 FMI 03 is active. The problem has not been corrected. The machine ECM may have failed. Repair: It is unlikely that the machine ECM has failed. Exit this procedure and perform this procedure again. If the cause of the diagnostic code is not found, replace the machine ECM. See Testing and Adjusting, "Electronic Control Module (ECM) - Replace". Stop. NO - The CID 1621 FMI 03 is not active. The problem does not exist at this time. Repair: The initial diagnostic code was probably caused by a poor electrical connection or a short at one of the harness connectors that was disconnected and reconnected. Resume normal machine operation. Stop.

TROUBLESHOOTING

081

TROUBLESHOOTING

i02304184

MID 039 - CID 1621 - FMI 05 SMCS - 5479-038-DRV Conditions Which Generate This Code: Note: The ECM connections for the generator solenoid have changed for machines in the following serial number ranges: BDR2001-UP, BDM2001-UP, BDX2001-UP, BCZ2001-UP, BDK2001-UP, BDY2001-UP,, BEB2001-UP, H2A1-UP, H2B1-UP, H2C1-UP, H2D1-UP, H2E1-UP, H2F1-UP and H2G1-UP. The connections for these machines and the other machines that are covered by this manual are illustrated below.

Illustration 1

g01153697

Generator valve solenoid ECM connections for machines in the following serial number ranges: BDR1-2000, BDM1-2000, BDX1-2000, BCZ12000, BDK1-2000, BDY1-2000 and BEB1-2000.

Illustration 2

g01153698

Generator valve solenoid ECM connections for machines in the following serial number ranges: BDR2001-UP, BDM2001-UP, BDX2001-UP, BCZ2001-UP, BDK2001-UP, BDY2001-UP,, BEB2001-UP, H2A1-UP, H2B1-UP, H2C1-UP, H2D1-UP, H2E1-UP, H2F1-UP and H2G1-UP.

This diagnostic code is associated with the generator solenoid valve. The FMI 05 means that the machine ECM has determined that the current of the solenoid is below normal. The possible causes of this diagnostic code are listed below: The energize circuit of the solenoid is open. The return circuit of the solenoid is open. The solenoid has failed. The machine ECM has failed. This is unlikely.

System Response: The alert indicator on the Monitor will illuminate. When this diagnostic code is active, the machine ECM will be unable to control the solenoid. The solenoid will be constantly deenergized, and the generator will be off. Note: The following test procedure may create other diagnostic codes. Ignore these created diagnostic codes and clear these diagnostic codes when the original diagnostic code has been corrected. Ensure that the diagnostic code of CID 1621 FMI 05 is active before performing this procedure. Note: Use the 146-4080 Digital Multimeter for the measurements in this procedure. Test Step 1. CHECK THE SOLENOID. A. Turn the disconnect switch and the key start switch to the ON position. Do not start the engine. B. Disconnect the solenoid with the active diagnostic code from the machine harness. C. At the machine harness connector for the solenoid, place a jumper wire from contact 1 (wire E984-BU) to contact 2 (wire H804-GN) or (wire H807-YL) depending on your machine configuration. D. Observe the status of the CID 1621 FMI 05. Expected Result: The CID 1621 FMI 05 remains active. The FMI has not changed and the "05" is still active.

Results: YES - The diagnostic code remains active. The jumper wire does not affect the diagnostic code. Proceed to Test Step 2. NO - The diagnostic is no longer active. The solenoid has failed. Repair: The solenoid has failed. Repeat this Test Step "CHECK THE SOLENOID" in order to verify the solenoid failure. Replace the solenoid. Verify that the new solenoid corrects the problem. Stop. Test Step 2. CHECK THE HARNESS FOR AN OPEN. A. Turn the key start switch and the disconnect switch to the OFF position. B. Disconnect the machine harness connector(s) from the machine ECM. C. The jumper wire that was installed in the previous Test Step remains in place. D. At the machine harness connector, measure the resistance from signal contact J2-25 or J2-55 (wire E984-BU) to the ECM ground wire at either contact J2-13 (wire H804-GN) or J2-36 (wire H807-YL). Expected Result: The resistance is less than 5.0 ohms. Results: OK - The resistance is less than 5.0 ohms. The machine harness is correct. Proceed to Test Step 3. NOT OK - The resistance is greater than 5000 ohms. The resistance measurement is not correct. There is an open circuit in the machine harness. Repair: The open is in wire E984-BU or in the ECM ground wire, either H804-GN or H807-YL of the machine harness. Repair the machine harness or replace the machine harness. Stop. Test Step 3. CHECK IF THE DIAGNOSTIC CODE REMAINS. A. Inspect the contacts of the harness connectors and clean the harness connectors. B. Reconnect all harness connectors. C. Turn the disconnect switch and the key start switch to the ON position. D. Operate the machine. E. Check the status of the CID 1621 FMI 05. Expected Result: The CID 1621 FMI 05 is active. Results: YES - The CID 1621 FMI 05 is active. The diagnostic code has not been corrected. The machine ECM may have failed. Repair: It is unlikely that the machine ECM has failed. Exit this procedure and perform this procedure again. If the cause of the diagnostic code is not found, replace the machine ECM. See Testing and Adjusting, "Electronic Control Module (ECM) - Replace". Stop. NO - The CID 1621 FMI 05 is not active. The diagnostic code does not exist at this time. Repair: The initial diagnostic code was probably caused by a poor electrical connection or a short at one of the harness

connectors that was disconnected and reconnected. Resume normal machine operation. Stop.

TROUBLESHOOTING

082

TROUBLESHOOTING

i02304206

MID 039 - CID 1621 - FMI 06 SMCS - 5479-038-DRV Conditions Which Generate This Code: Note: The ECM connections for the generator solenoid have changed for machines in the following serial number ranges: BDR2001-UP, BDM2001-UP, BDX2001-UP, BCZ2001-UP, BDK2001-UP, BDY2001-UP,, BEB2001-UP, H2A1-UP, H2B1-UP, H2C1-UP, H2D1-UP, H2E1-UP, H2F1-UP and H2G1-UP. The connections for these machines and the other machines that are covered by this manual are illustrated below.

Illustration 1

g01153697

Generator valve solenoid ECM connections for machines in the following serial number ranges: BDR1-2000, BDM1-2000, BDX1-2000, BCZ12000, BDK1-2000, BDY1-2000 and BEB1-2000.

Illustration 2

g01153698

Generator valve solenoid ECM connections for machines in the following serial number ranges: BDR2001-UP, BDM2001-UP, BDX2001-UP, BCZ2001-UP, BDK2001-UP, BDY2001-UP,, BEB2001-UP, H2A1-UP, H2B1-UP, H2C1-UP, H2D1-UP, H2E1-UP, H2F1-UP and H2G1-UP

This diagnostic code is associated with the Solenoid valve (generator drive). The FMI 06 means that the machine ECM has determined that the current of the solenoid is above normal. The possible causes of this diagnostic code are listed: The energize circuit of the solenoid is shorted to ground. The solenoid has failed. The machine ECM has failed. This is unlikely.

System Response: The alert indicator on the Monitor will illuminate. When this diagnostic code is active, the machine ECM will be unable to control the solenoid. The solenoid will be constantly deenergized, and the generator will be off. Note: The following test procedure may create other diagnostic codes. Ignore these created diagnostic codes and clear these diagnostic codes when the original diagnostic code has been corrected. Ensure that the diagnostic code of CID 1621 FMI 06 is active before performing this procedure. Note: Use the 146-4080 Digital Multimeter for the measurements in this procedure. Test Step 1. CHECK THE SOLENOID. A. Turn the disconnect switch and the key start switch to the ON position. Do not start the engine. B. Observe the status of the diagnostic code. C. Disconnect the solenoid with the active diagnostic code from the machine harness. Expected Result: CID 1621 FMI 06 changes to CID 1621 FMI 05 when the solenoid is disconnected. Results: YES - CID 1621 FMI 06 changes to CID 1621 FMI 05 when the solenoid is disconnected. The circuit is correct. Repair: The solenoid has failed. Repeat this test "CHECK THE SOLENOID" in order to verify the solenoid failure. Replace the solenoid.

Stop. NO - CID 1621 FMI 06 remains active. Proceed to Test Step 2. Test Step 2. CHECK THE ENERGIZE CIRCUIT OF THE SOLENOID FOR A SHORT TO GROUND. A. Turn the key start switch and the disconnect switch to the OFF position. B. The solenoid remains disconnected from the machine harness. C. Disconnect the machine harness connector(s) from the machine ECM. D. At the machine harness connector, measure the resistance from the signal contact J2-25 or J2-55 depending on your machine configuration (wire E984-BU) to all ground contacts on connectors J1 and J2. The ground contacts on connector J2 are J2-2, J2-12, J2-13, J2-22, J2-36, J2-37, J2-46, J2-49, J2-52, J2-56, J2-59 and J2-69. The ground contact on connector J1 is J1-9. Expected Result: Each resistance measurement is greater than 5000 ohms. Results: OK - Each resistance measurement is greater than 5000 ohms. The machine harness is correct. Proceed to Test Step 3. NOT OK - Each resistance measurement is not greater than 5000 ohms. There is a short in the machine harness. The short is between wire E984-BU and the circuit with the low resistance measurement. Repair: Repair the machine harness or replace the machine harness. Stop. Test Step 3. CHECK IF THE DIAGNOSTIC CODE REMAINS. A. Inspect the harness connectors and clean the contacts of the harness connectors. B. Reconnect all harness connectors. C. Turn the disconnect switch and the key start switch to the ON position. D. Operate the machine. E. Check the status of the CID 1621 FMI 06. Expected Result: The CID 1621 FMI 06 is active. Results: YES - The CID 1621 FMI 06 is active. The diagnostic code has not been corrected. The machine ECM may have failed. Repair: It is unlikely that the machine ECM has failed. Exit this procedure and perform this procedure again. If the cause of the diagnostic code is not found, replace the machine ECM. See Testing and Adjusting, "Electronic Control Module (ECM) - Replace". Stop. NO - The CID 1621 FMI 06 is not active. The diagnostic code does not exist at this time. Repair: The initial diagnostic code was probably caused by a poor electrical connection or a short at one of the harness connectors that was disconnected and reconnected. Resume normal machine operation. Stop.

TROUBLESHOOTING

083

TROUBLESHOOTING

i02304010

MID 039 - CID 1622 - FMI 03 SMCS - 3225-038-P9 Conditions Which Generate This Code:

Illustration 1 Schematic of the Travel Lock Magnet

g01156447

This diagnostic code is associated with the Travel Lock Magnet. The FMI 03 means that the ECM has determined that the voltage of the circuit for the magnet is above normal. The possible causes of the diagnostic code are listed: The magnet has failed. The energize circuit of the magnet is shorted to the +battery circuit. The ECM has failed. This is unlikely.

Note: The following test procedure may create other diagnostic codes. Ignore these created diagnostic codes and clear these diagnostic codes when the original diagnostic code has been corrected. Ensure that the diagnostic code of CID 1622 FMI 03 is active before performing this procedure. Note: Use the 146-4080 Digital Multimeter for the measurements in this procedure. Test Step 1. CHECK THE ENERGIZE CIRCUIT OF THE MAGNET FOR A SHORT TO THE +BATTERY CIRCUIT. A. Turn the key start switch and the disconnect switch to the OFF position. B. Disconnect the machine harness connectors from the magnet and the ECM. C. At the machine harness connector for the ECM, measure the resistance from contact J2-60 (wire M956-GN) to all contacts that are used in the machine harness connectors for the ECM.

Expected Result: Each resistance measurement is greater than 5000 ohms. Results: OK - Each resistance measurement is greater than 5000 ohms. The machine harness is correct. Proceed to Test Step 2. NOT OK - Each resistance measurement is not greater than 5000 ohms. There is a short in the machine harness. The short is between J2-60 (M956-GN) and the circuit that has a low resistance measurement. Repair: Repair the machine harness or replace the machine harness. Stop. Test Step 2. CHECK IF THE DIAGNOSTIC CODE IS STILL ACTIVE. A. Inspect the contacts and clean the contacts of the harness connectors. B. Reconnect all harness connectors. C. Turn the disconnect switch and the key start switch to the ON position. D. Operate the machine. E. Determine if the CID 1622 FMI 03 is active. Expected Result: The CID 1622 FMI 03 is active. Results: YES - The CID 1622 FMI 03 is active. The problem has not been corrected. The ECM may have failed. Repair: It is unlikely that the ECM has failed. Exit this procedure and perform this procedure again. If the cause of the diagnostic code is not found, replace the ECM. See Testing and Adjusting, "Electronic Control Module (ECM) - Replace". Stop. NO - The CID 1622 FMI 03 is not active. The problem does not exist at this time. Repair: The initial diagnostic code was probably caused by a poor electrical connection or a short at one of the harness connectors that was disconnected and reconnected. Resume normal machine operation. Stop.

TROUBLESHOOTING

084

TROUBLESHOOTING

i02304015

MID 039 - CID 1622 - FMI 05 SMCS - 3225-038-P9 Conditions Which Generate This Code:

Illustration 1 Schematic of the Travel Lock Magnet

g01156447

This diagnostic code is associated with the Travel Lock Magnet. The FMI 05 means that the ECM has determined that the current of the magnet is below normal. The possible causes of this diagnostic code are listed below: The energize circuit of the magnet is open. The return circuit of the magnet is open. The magnet has failed. The ECM has failed. This is unlikely.

Note: The following test procedure may create other diagnostic codes. Ignore these created diagnostic codes and clear these diagnostic codes when the original diagnostic code has been corrected. Ensure that the diagnostic code of CID 1622 FMI 05 is active before performing this procedure. Note: Use the 146-4080 Digital Multimeter for the measurements in this procedure. Test Step 1. CHECK THE MAGNET. A. Turn the disconnect switch and the key start switch to the ON position. Do not start the engine. B. Disconnect the magnet with the active diagnostic code from the machine harness. C. At the machine harness connector for the magnet, place a jumper wire from contact 1 (wire M956-GN) to contact 2 (wire H802-GY).

D. Observe the status of the CID 1622 FMI 05. Expected Result: The CID 1622 FMI 05 remains active. The FMI has not changed and the "05" is still active. Results: YES - The diagnostic code remains active. The jumper wire does not affect the diagnostic code. Proceed to Test Step 2. NO - The diagnostic is no longer active. The magnet has failed. Repair: The magnet has failed. Repeat this Test Step "CHECK THE MAGNET" in order to verify the failure of the magnet. Replace the magnet. Verify that the new magnet corrects the problem. Stop. Test Step 2. CHECK THE HARNESS FOR AN OPEN. A. Turn the key start switch and the disconnect switch to the OFF position. B. Disconnect the machine harness connector(s) from the ECM. C. The jumper wire that was installed in the previous Test Step remains in place. D. At the machine harness connector, measure the resistance from signal contact J2-60 (wire M956-GN) to contact J2-49 (wire H802-GY). Expected Result: The resistance is less than 5.0 ohms. Results: OK - The resistance is less than 5.0 ohms. The machine harness is correct. Proceed to Test Step 3. NOT OK - The resistance is greater than 5000 ohms. The resistance measurement is not correct. There is an open circuit in the machine harness. Repair: The open is in wire M956-GN or in wire H802-GY of the machine harness. Repair the machine harness or replace the machine harness. Stop. Test Step 3. CHECK IF THE DIAGNOSTIC CODE REMAINS. A. Inspect the contacts of the harness connectors and clean the harness connectors. B. Reconnect all harness connectors. C. Turn the disconnect switch and the key start switch to the ON position. D. Operate the machine. E. Check the status of the CID 1622 FMI 05. Expected Result: The CID 1622 FMI 05 is active. Results: YES - The CID 1622 FMI 05 is active. The diagnostic code has not been corrected. The ECM may have failed. Repair: It is unlikely that the ECM has failed. Exit this procedure and perform this procedure again. If the cause of the diagnostic code is not found, replace the ECM. See Testing and Adjusting, "Electronic Control Module (ECM) - Replace".

Stop. NO - The CID 1622 FMI 05 is not active. The diagnostic code does not exist at this time. Repair: The initial diagnostic code was probably caused by a poor electrical connection at one of the harness connectors that was disconnected and reconnected. Resume normal machine operation. Stop.

TROUBLESHOOTING

085

TROUBLESHOOTING

i02304016

MID 039 - CID 1622 - FMI 06 SMCS - 3225-038-P9 Conditions Which Generate This Code:

Illustration 1 Schematic of the Travel Lock Magnet

g01156447

This diagnostic code is associated with the Travel Lock Magnet. The FMI 06 means that the ECM has determined that the current of the magnet is above normal. The possible causes of this diagnostic code are listed: The energize circuit of the magnet is shorted to ground. The magnet has failed. The ECM has failed. This is unlikely.

Note: The following test procedure may create other diagnostic codes. Ignore these created diagnostic codes and clear these diagnostic codes when the original diagnostic code has been corrected. Ensure that the diagnostic code of CID 1622 FMI 06 is active before performing this procedure. Note: Use the 146-4080 Digital Multimeter for the measurements in this procedure. Test Step 1. CHECK THE MAGNET. A. Turn the disconnect switch and the key start switch to the ON position. Do not start the engine. B. Observe the status of the diagnostic code. C. Disconnect the magnet with the active diagnostic code from the machine harness. Expected Result:

CID 1622 FMI 06 changes to CID 1622 FMI 05 when the magnet is disconnected. Results: YES - CID 1622 FMI 06 changes to CID 1622 FMI 05 when the magnet is disconnected. The circuit is correct. Repair: The magnet has failed. Repeat this test "CHECK THE MAGNET" in order to verify the failure of the magnet. Replace the magnet. Stop. NO - CID 1622 FMI 06 remains active. Proceed to Test Step 2. Test Step 2. CHECK THE ENERGIZE CIRCUIT OF THE SOLENOID FOR A SHORT TO GROUND. A. Turn the key start switch and the disconnect switch to the OFF position. B. The magnet remains disconnected from the machine harness. C. Disconnect the machine harness connector(s) from the ECM. D. At the machine harness connector, measure the resistance from the signal contact J2-60 (wire M956-GN) to all contacts that are used in the machine harness connectors for the ECM. Expected Result: Each resistance measurement is greater than 5000 ohms. Results: OK - Each resistance measurement is greater than 5000 ohms. The machine harness is correct. Proceed to Test Step 3. NOT OK - Each resistance measurement is not greater than 5000 ohms. There is a short in the machine harness. The short is between J2-60 (wire M956-GN) and the circuit with the low resistance measurement. Repair: Repair the machine harness or replace the machine harness. Stop. Test Step 3. CHECK IF THE DIAGNOSTIC CODE REMAINS. A. Inspect the harness connectors and clean the contacts of the harness connectors. B. Reconnect all harness connectors. C. Turn the disconnect switch and the key start switch to the ON position. D. Operate the machine. E. Check the status of the CID 1622 FMI 06. Expected Result: The CID 1622 FMI 06 is active. Results: YES - The CID 1622 FMI 06 is active. The diagnostic code has not been corrected. The ECM may have failed. Repair: It is unlikely that the ECM has failed. Exit this procedure and perform this procedure again. If the cause of the diagnostic code is not found, replace the ECM. See Testing and Adjusting, "Electronic Control Module (ECM) - Replace". Stop. NO - The CID 1622 FMI 06 is not active. The diagnostic code does not exist at this time. Repair: The initial diagnostic code was probably caused by a poor electrical connection or a short at one of the harness connectors that was disconnected and reconnected. Resume normal machine operation.

Stop.

TROUBLESHOOTING

086

TROUBLESHOOTING

i02304019

MID 039 - CID 1623 - FMI 03 SMCS - 1432-038-BRK Conditions Which Generate This Code:

Illustration 1 Schematic of the Brake Lights

g00865910

This diagnostic code is associated with the Brake Lights. The FMI 03 means that the ECM has determined that the voltage of the lamp circuit is above normal. The possible causes of the diagnostic code are listed: The indicator lamp has failed. The energize circuit of the indicator lamp is shorted to the +battery circuit. The ECM has failed. This is unlikely.

Note: The following test procedure may create other diagnostic codes. Ignore these created diagnostic codes and clear these diagnostic codes when the original diagnostic code has been corrected. Ensure that the diagnostic code of CID 1623 FMI 03 is active before performing this procedure. Note: Use the 146-4080 Digital Multimeter for the measurements in this procedure. Test Step 1. CHECK THE ENERGIZE CIRCUIT OF THE INDICATOR LAMP FOR A SHORT TO THE +BATTERY CIRCUIT. A. Turn the key start switch and the disconnect switch to the OFF position. B. Disconnect the machine harness connectors from the indicator lamp and the ECM. C. At the machine harness connector for the ECM, measure the resistance from contact J2-4 (wire A618-OR) and J2-16 (wire 604-OR) to all contacts that are used in the machine harness connectors for the ECM.

Expected Result: Each resistance measurement is greater than 5000 ohms. Results: OK - Each resistance measurement is greater than 5000 ohms. The machine harness is correct. Proceed to Test Step 2. NOT OK - Each resistance measurement is not greater than 5000 ohms. There is a short in the machine harness. The short is between the circuit that has a low resistance measurement and either the contact J2-4 (A618-OR) or the contact J2-16 (wire 604-OR). Repair: Repair the machine harness or replace the machine harness. Stop. Test Step 2. CHECK IF THE DIAGNOSTIC CODE IS STILL ACTIVE. A. Inspect the contacts and clean the contacts of the harness connectors. B. Reconnect all harness connectors. C. Turn the disconnect switch and the key start switch to the ON position. D. Operate the machine. E. Determine if the CID 1623 FMI 03 is active. Expected Result: The CID 1623 FMI 03 is active. Results: YES - The CID 1623 FMI 03 is active. The problem has not been corrected. The ECM may have failed. Repair: It is unlikely that the ECM has failed. Exit this procedure and perform this procedure again. If the cause of the diagnostic code is not found, replace the ECM. See Testing and Adjusting, "Electronic Control Module (ECM) - Replace". Stop. NO - The CID 1623 FMI 03 is not active. The problem does not exist at this time. Repair: The initial diagnostic code was probably caused by a poor electrical connection or a short at one of the harness connectors that was disconnected and reconnected. Resume normal machine operation. Stop.

TROUBLESHOOTING

087

TROUBLESHOOTING

i02304022

MID 039 - CID 1623 - FMI 05 SMCS - 1432-038-BRK Conditions Which Generate This Code:

Illustration 1 Schematic of the Brake Lights

g00865910

This diagnostic code is associated with the Brake Lights. The FMI 05 means that the ECM has determined that the current of the lamp circuit is below normal. The possible causes of this diagnostic code are listed below: The energize circuit of the indicator lamp is open. The return circuit of the indicator lamp is open. The indicator lamp has failed. The ECM has failed. This is unlikely.

Note: The following test procedure may create other diagnostic codes. Ignore these created diagnostic codes and clear these diagnostic codes when the original diagnostic code has been corrected. Ensure that the diagnostic code of CID 1623 FMI 05 is active before performing this procedure. Note: Use the 146-4080 Digital Multimeter for the measurements in this procedure. Test Step 1. CHECK THE INDICATOR LAMP. A. Turn the disconnect switch and the key start switch to the ON position. Do not start the engine. B. Disconnect the indicator lamp with the active diagnostic code from the machine harness. C. At the machine harness connector for the indicator lamp, place a jumper wire from contact 1 (wire 604-OR or wire A618OR) to contact 2 (wire 200-BK).

D. Observe the status of the CID 1623 FMI 05. Expected Result: The CID 1623 FMI 05 remains active. The FMI has not changed and the "05" is still active. Results: YES - The diagnostic code remains active. The jumper wire does not affect the diagnostic code. Proceed to Test Step 2. NO - The diagnostic is no longer active. The indicator lamp has failed. Repair: The indicator lamp has failed. Repeat this Test Step "CHECK THE INDICATOR LAMP" in order to verify the failure of the indicator lamp. Replace the indicator lamp. Verify that the new indicator lamp corrects the problem. Stop. Test Step 2. CHECK THE HARNESS FOR AN OPEN. A. Turn the key start switch and the disconnect switch to the OFF position. B. Disconnect the machine harness connector(s) from the ECM. C. The jumper wire that was installed in the previous test remains in place. D. At the machine harness connector, measure the resistance from signal contact J2 (wire A618-OR or wire 604-OR) to the ground contact on the housing of the machine ECM (wire 200-BK). Expected Result: The resistance is less than 5.0 ohms. Results: OK - The resistance is less than 5.0 ohms. The machine harness is correct. Proceed to Test Step 3. NOT OK - The resistance is greater than 5000 ohms. The resistance measurement is not correct. There is an open circuit in the machine harness. Repair: The open is in wire A618-OR or in wire 604-OR or in wire 200-BK of the machine harness. Repair the machine harness or replace the machine harness. Stop. Test Step 3. CHECK IF THE DIAGNOSTIC CODE REMAINS. A. Inspect the contacts of the harness connectors and clean the harness connectors. B. Reconnect all harness connectors. C. Turn the disconnect switch and the key start switch to the ON position. D. Operate the machine. E. Check the status of the CID 1623 FMI 05. Expected Result: The CID 1623 FMI 05 is active. Results: YES - The CID 1623 FMI 05 is active. The diagnostic code has not been corrected. The ECM may have failed. Repair: It is unlikely that the ECM has failed. Exit this procedure and perform this procedure again. If the cause of the diagnostic code is not found, replace the ECM. See Testing and Adjusting, "Electronic Control Module (ECM) - Replace".

Stop. NO - The CID 1623 FMI 05 is not active. The diagnostic code does not exist at this time. Repair: The initial diagnostic code was probably caused by a poor electrical connection at one of the harness connectors that was disconnected and reconnected. Resume normal machine operation. Stop.

TROUBLESHOOTING

088

TROUBLESHOOTING

i02304024

MID 039 - CID 1623 - FMI 06 SMCS - 1432-038-BRK Conditions Which Generate This Code:

Illustration 1 Schematic of the Brake Lights

g00865910

This diagnostic code is associated with the Brake Lights. The FMI 06 means that the ECM has determined that the current of the lamp circuit is above normal. The possible causes of this diagnostic code are listed: The energize circuit of the indicator lamp is shorted to ground. The indicator lamp has failed. The ECM has failed. This is unlikely.

Note: The following test procedure may create other diagnostic codes. Ignore these created diagnostic codes and clear these diagnostic codes when the original diagnostic code has been corrected. Ensure that the diagnostic code of CID 1623 FMI 06 is active before performing this procedure. Note: Use the 146-4080 Digital Multimeter for the measurements in this procedure. Test Step 1. CHECK THE INDICATOR LAMP. A. Turn the disconnect switch and the key start switch to the ON position. Do not start the engine. B. Observe the status of the diagnostic code. C. Disconnect the indicator lamp with the active diagnostic code from the machine harness. Expected Result:

CID 1623 FMI 06 changes to CID 1623 FMI 05 when the indicator lamp is disconnected. Results: YES - CID 1623 FMI 06 changes to CID 1623 FMI 05 when the indicator lamp is disconnected. The circuit is correct. Repair: The indicator lamp has failed. Repeat this test "CHECK THE INDICATOR LAMP" in order to verify the failure of the indicator lamp. Replace the indicator lamp. Stop. NO - CID 1623 FMI 06 remains active. Proceed to Test Step 2. Test Step 2. CHECK THE ENERGIZE CIRCUIT OF THE INDICATOR LAMP FOR A SHORT TO GROUND. A. Turn the key start switch and the disconnect switch to the OFF position. B. The indicator lamp remains disconnected from the machine harness. C. Disconnect the machine harness connector(s) from the ECM. D. At the machine harness connector, measure the resistance from the signal contact J2 (wire A618-OR or wire 604-OR) to all contacts that are used in the machine harness connectors for the ECM. Expected Result: Each resistance measurement is greater than 5000 ohms. Results: OK - Each resistance measurement is greater than 5000 ohms. The machine harness is correct. Proceed to Test Step 3. NOT OK - Each resistance measurement is not greater than 5000 ohms. There is a short in the machine harness. The short is between J2 (wire A618-OR or wire 604-OR) and the circuit with the low resistance measurement. Repair: Repair the machine harness or replace the machine harness. Stop. Test Step 3. CHECK IF THE DIAGNOSTIC CODE REMAINS. A. Inspect the harness connectors and clean the contacts of the harness connectors. B. Reconnect all harness connectors. C. Turn the disconnect switch and the key start switch to the ON position. D. Operate the machine. E. Check the status of the CID 1623 FMI 06. Expected Result: The CID 1623 FMI 06 is active. Results: YES - The CID 1623 FMI 06 is active. The diagnostic code has not been corrected. The ECM may have failed. Repair: It is unlikely that the ECM has failed. Exit this procedure and perform this procedure again. If the cause of the diagnostic code is not found, replace the ECM. See Testing and Adjusting, "Electronic Control Module (ECM) - Replace". Stop. NO - The CID 1623 FMI 06 is not active. The diagnostic code does not exist at this time. Repair: The initial diagnostic code was probably caused by a poor electrical connection or a short at one of the harness connectors that was disconnected and reconnected. Resume normal machine operation.

Stop.

TROUBLESHOOTING

089

TROUBLESHOOTING

i02308987

MID 039 - CID 1624 - FMI 03 SMCS - 5479-038-V6 Conditions Which Generate This Code:

Illustration 1

g00840487

Schematic of the Solenoid valve (travel activation)

This diagnostic code is associated with the solenoid valve (travel activation). The FMI 03 means that the machine ECM has determined that the voltage of the solenoid circuit is above normal. The possible causes of the diagnostic code are listed: The solenoid has failed. The energize circuit of the solenoid is shorted to the +battery circuit. The machine ECM has failed. This is unlikely.

Note: The following test procedure may create other diagnostic codes. Ignore these created diagnostic codes and clear these diagnostic codes when the original diagnostic code has been corrected. Ensure that the diagnostic code of CID 1624 FMI 03 is active before performing this procedure. Note: Use the 146-4080 Digital Multimeter for the measurements in this procedure. System Response: When this diagnostic code is active, the machine ECM will be unable to control the pilot hydraulics for the travel function. The travel function will always be enabled. Test Step 1. CHECK THE ENERGIZE CIRCUIT OF THE SOLENOID FOR A SHORT TO THE +BATTERY CIRCUIT. A. Turn the key start switch and the disconnect switch to the OFF position. B.

A. B. Disconnect the machine harness connectors from the solenoid and the machine ECM. C. At the machine harness connector for the machine ECM, measure the resistance from contact J2-50 (wire K923-PU) to all contacts that are used in the machine harness connectors for the machine ECM. Expected Result: Each resistance measurement is greater than 5000 ohms. Results: OK - Each resistance measurement is greater than 5000 ohms. The machine harness is correct. Proceed to Test Step 2. NOT OK - Each resistance measurement is not greater than 5000 ohms. There is a short in the machine harness. The short is between J2-50 (K923-PU) and the circuit that has a low resistance measurement. Repair: Repair the machine harness or replace the machine harness. Stop. Test Step 2. CHECK IF THE DIAGNOSTIC CODE IS STILL ACTIVE. A. Inspect the contacts and clean the contacts of the harness connectors. B. Reconnect all harness connectors. C. Turn the disconnect switch and the key start switch to the ON position. D. Operate the machine. E. Determine if the CID 1624 FMI 03 is active. Expected Result: The CID 1624 FMI 03 is active. Results: YES - The CID 1624 FMI 03 is active. The problem has not been corrected. The machine ECM may have failed. Repair: It is unlikely that the machine ECM has failed. Exit this procedure and perform this procedure again. If the cause of the diagnostic code is not found, replace the machine ECM. See Testing and Adjusting, "Electronic Control Module (ECM) - Replace". Stop. NO - The CID 1624 FMI 03 is not active. The problem does not exist at this time. Repair: The initial diagnostic code was probably caused by a poor electrical connection or a short at one of the harness connectors that was disconnected and reconnected. Resume normal machine operation. Stop.

TROUBLESHOOTING

090

TROUBLESHOOTING

i01793424

MID 039 - CID 1624 - FMI 05 SMCS - 5479-038-V6 Conditions Which Generate This Code:

Illustration 1

g00840487

Schematic of the Solenoid valve (travel activation)

This diagnostic code is associated with the Solenoid valve (travel activation). The FMI 05 means that the machine ECM has determined that the current of the solenoid is below normal. The possible causes of this diagnostic code are listed below: The energize circuit of the solenoid is open. The return circuit of the solenoid is open. The solenoid has failed. The machine ECM has failed. This is unlikely.

Note: The following test procedure may create other diagnostic codes. Ignore these created diagnostic codes and clear these diagnostic codes when the original diagnostic code has been corrected. Ensure that the diagnostic code of CID 1624 FMI 05 is active before performing this procedure. Note: Use the 146-4080 Digital Multimeter for the measurements in this procedure. System Response: When this diagnostic code is active, the machine ECM will be unable to control the pilot hydraulics for the travel function. The travel function will always be disabled. Test Step 1. CHECK THE SOLENOID. A. Turn the disconnect switch and the key start switch to the ON position. Do not start the engine. B.

A. B. Disconnect the solenoid with the active diagnostic code from the machine harness. C. At the machine harness connector for the solenoid, place a jumper wire from contact 1 (wire K923-PU) to contact 2 (wire H802-GY). D. Observe the status of the CID 1624 FMI 05. Expected Result: The CID 1624 FMI 05 remains active. The FMI has not changed and the "05" is still active. Results: YES - The diagnostic code remains active. The jumper wire does not affect the diagnostic code. Proceed to Test Step 2. NO - The diagnostic is no longer active. The solenoid has failed. Repair: The solenoid has failed. Repeat this Test Step "CHECK THE SOLENOID" in order to verify the solenoid failure. Replace the solenoid. Verify that the new solenoid corrects the problem. Stop. Test Step 2. CHECK THE HARNESS FOR AN OPEN. A. Turn the key start switch and the disconnect switch to the OFF position. B. Disconnect the machine harness connector(s) from the machine ECM. C. The jumper wire that was installed in the previous Test Step remains in place. D. At the machine harness connector, measure the resistance from signal contact J2-50 (wire K923-PU) to contact J2-49 (wire H802-GY). Expected Result: The resistance is less than 5.0 ohms. Results: OK - The resistance is less than 5.0 ohms. The machine harness is correct. Proceed to Test Step 3. NOT OK - The resistance is greater than 5000 ohms. The resistance measurement is not correct. There is an open circuit in the machine harness. Repair: The open is in wire K923-PU or in wire H802-GY of the machine harness. Repair the machine harness or replace the machine harness. Stop. Test Step 3. CHECK IF THE DIAGNOSTIC CODE REMAINS. A. Inspect the contacts of the harness connectors and clean the harness connectors. B. Reconnect all harness connectors. C. Turn the disconnect switch and the key start switch to the ON position. D. Operate the machine. E. Check the status of the CID 1624 FMI 05. Expected Result: The CID 1624 FMI 05 is active.

Results: YES - The CID 1624 FMI 05 is active. The diagnostic code has not been corrected. The machine ECM may have failed. Repair: It is unlikely that the machine ECM has failed. Exit this procedure and perform this procedure again. If the cause of the diagnostic code is not found, replace the machine ECM. See Testing and Adjusting, "Electronic Control Module (ECM) - Replace". Stop. NO - The CID 1624 FMI 05 is not active. The diagnostic code does not exist at this time. Repair: The initial diagnostic code was probably caused by a poor electrical connection or a short at one of the harness connectors that was disconnected and reconnected. Resume normal machine operation. Stop.

TROUBLESHOOTING

091

TROUBLESHOOTING

i02308989

MID 039 - CID 1624 - FMI 06 SMCS - 5479-038-V6 Conditions Which Generate This Code:

Illustration 1

g00840487

Schematic of the Solenoid valve (travel activation)

This diagnostic code is associated with the Solenoid valve (travel activation). The FMI 06 means that the machine ECM has determined that the current of the solenoid is above normal. The possible causes of this diagnostic code are listed: The energize circuit of the solenoid is shorted to ground. The solenoid has failed. The machine ECM has failed. This is unlikely.

Note: The following test procedure may create other diagnostic codes. Ignore these created diagnostic codes and clear these diagnostic codes when the original diagnostic code has been corrected. Ensure that the diagnostic code of CID 1624 FMI 06 is active before performing this procedure. Note: Use the 146-4080 Digital Multimeter for the measurements in this procedure. System Response: When this diagnostic code is active, the machine ECM will be unable to control the pilot hydraulics for the travel function. The travel function will always be disabled. Test Step 1. CHECK THE SOLENOID. A. Turn the disconnect switch and the key start switch to the ON position. Do not start the engine. B. Observe the status of the diagnostic code. C.

B. C. Disconnect the solenoid with the active diagnostic code from the machine harness. Expected Result: CID 1624 FMI 06 changes to CID 1624 FMI 05 when the solenoid is disconnected. Results: YES - CID 1624 FMI 06 changes to CID 1624 FMI 05 when the solenoid is disconnected. The circuit is correct. Repair: The solenoid has failed. Repeat this test "CHECK THE SOLENOID" in order to verify the solenoid failure. Replace the solenoid. Stop. NO - CID 1624 FMI 06 remains active. Proceed to Test Step 2. Test Step 2. CHECK THE ENERGIZE CIRCUIT OF THE SOLENOID FOR A SHORT TO GROUND. A. Turn the key start switch and the disconnect switch to the OFF position. B. The solenoid remains disconnected from the machine harness. C. Disconnect the machine harness connector(s) from the machine ECM. D. At the machine harness connector, measure the resistance from the signal contact J2-50 (wire K923-PU) to all contacts that are used in the machine harness connectors for the machine ECM. Expected Result: Each resistance measurement is greater than 5000 ohms. Results: OK - Each resistance measurement is greater than 5000 ohms. The machine harness is correct. Proceed to Test Step 3. NOT OK - Each resistance measurement is not greater than 5000 ohms. There is a short in the machine harness. The short is between J2-50 (wire K923-PU) and the circuit with the low resistance measurement. Repair: Repair the machine harness or replace the machine harness. Stop. Test Step 3. CHECK IF THE DIAGNOSTIC CODE REMAINS. A. Inspect the harness connectors and clean the contacts of the harness connectors. B. Reconnect all harness connectors. C. Turn the disconnect switch and the key start switch to the ON position. D. Operate the machine. E. Check the status of the CID 1624 FMI 06. Expected Result: The CID 1624 FMI 06 is active. Results: YES - The CID 1624 FMI 06 is active. The diagnostic code has not been corrected. The machine ECM may have failed. Repair: It is unlikely that the machine ECM has failed. Exit this procedure and perform this procedure again. If the cause of the diagnostic code is not found, replace the machine ECM. See Testing and Adjusting, "Electronic Control Module (ECM) - Replace". Stop.

NO - The CID 1624 FMI 06 is not active. The diagnostic code does not exist at this time. Repair: The initial diagnostic code was probably caused by a poor electrical connection or a short at one of the harness connectors that was disconnected and reconnected. Resume normal machine operation. Stop.

TROUBLESHOOTING

092

TROUBLESHOOTING

i02309001

MID 039 - CID 1628 - FMI 04 SMCS - 1435-038-AN Conditions Which Generate This Code:

Illustration 1

g00840492

Schematic of the Switch (position of the armrest)

This diagnostic code is associated with the Switch (position of the armrest). The switch is connected to two inputs of the machine ECM. The inputs are "Normally Open" and "Normally Closed". One of the inputs is open and the other input is grounded during proper operation. The FMI 04 means that the machine ECM has determined that the "Normally Open" and "Normally Closed" circuits are grounded. Note: The following test procedure may create other diagnostic codes. Ignore these diagnostic codes and clear these diagnostic codes when the original diagnostic code has been corrected. Ensure that the diagnostic code of CID 1628 FMI 04 is active before performing this procedure. System Response: When this diagnostic code is active, the machine ECM will be unable to determine the state of the switch. Pilot hydraulics for implements will be deactivated. The parking brake will be engaged only if there is no request for travel. The brake lights will be turned off. The oscillating axle will be locked. Travel speed is set to travel speed high. Travel lock is disengaged. The swing brake is turned on. The pilot hydraulics for travel function will be disabled. The fuel pump will be disabled. If all other functions are enabled, the machine will start. On an operating machine, the function of the starter relay is not affected. Test Step 1. CHECK THE SWITCH. A. Turn the key start switch and the disconnect switch to the OFF position. B. Disconnect the machine harness from the switch. C. Turn the key start switch and the disconnect switch to the ON position. Expected Result:

The CID 1628 FMI 04 has been replaced by CID 1628 FMI 05. Results: OK - The CID 1628 FMI 04 has been replaced by CID 1628 FMI 05. The machine harness and the machine ECM are correct. Proceed to Test Step 3. NOT OK - The CID 1628 FMI 04 is still active. Proceed to Test Step 2. Test Step 2. CHECK THE HARNESS. A. Turn the disconnect switch and the key start switch to the OFF position. B. The machine harness remains disconnected from the switch. C. Disconnect the machine harness connector(s) from the machine ECM. D. Measure the resistance between contacts J1-54 (wire E917-WH) and J1-55 (wire E918-GN) of the machine harness to all the contacts that are used in machine harness connectors for the machine ECM. Expected Result: Each resistance measurement is greater than 5000 ohms. Results: YES - Each resistance measurement is greater than 5000 ohms. The machine ECM has failed. Repair: It is unlikely that the machine ECM has failed. Exit this procedure and perform this procedure again. If the cause of the diagnostic code is not found, replace the machine ECM. See Testing And Adjusting, "Electronic Control Module (ECM) - Replace". Stop. NO - One or more of the resistance measurements are less than 5 ohms. The harness has failed. The short is between J154 (wire E917-WH) and the circuit with the lowest resistance or the short is between J1-55 (wire E918-GN) and the circuit with the lowest resistance. Repair: Repair the wiring harness or replace the wiring harness. Stop. Test Step 3. CHECK THE OPERATION OF THE SWITCH. A. The machine harness remains disconnected from the switch. B. Connect one lead from a multimeter to contactA (wire A235-BK) of the harness connector for the switch. C. Connect the other lead from a multimeter to contact C (wire E917-WH) of the harness connector for the switch. D. Measure the resistance between contact A (wire A235-BK) and contact C (wire E917-WH). Note the resistance. E. Disconnect the lead from contact C (wire E917-WH) and connect the lead to contact B (wire E918-GN). F. Measure the resistance between contact A (wire A235-BK) and contact B (wire E918-GN). Expected Result: The resistance from contact A (wire A235-BK) to contact B (wire E918-GN) is less than 5 ohms, and the resistance from contact A (wire A235-BK) to contact C (wire E917-WH) is greater than 5000 ohms. Results: YES - The resistance from contact A (wire A235-BK) to contact B (wire E918-GN) is less than 5 ohms, and the resistance from contact A (wire A235-BK) to contact C (wire E917-WH) is greater than 5000 ohms. Proceed to Test Step 4.

NO - The resistance measurements do not differ. The switch has failed. Repair: Replace the switch. Stop. Test Step 4. CHECK THE OPERATION OF THE SWITCH. A. The machine harness remains disconnected from the switch. B. Press and hold the switch. C. Connect one lead from a multimeter to contact A (wire A235-BK) of the harness connector for the switch. D. Connect the other lead from a multimeter to contact C (wire E917-WH) of the harness connector for the switch. E. Measure the resistance between contact A (wire A235-BK) and contact C (wire E917-WH). Note the resistance. F. Disconnect the lead from contact C (wire E917-WH) and connect the lead to contact B (wire E918-GN). G. Measure the resistance between contact A (wire A235-BK) and contact B (wire E918-GN). Expected Result: The resistance from contact A (wire A235-BK) to contact C (wire E917-WH) is less than 5 ohms, and the resistance from contact A (wire A235-BK) and contact B (wire E918-GN) is greater than 5000 ohms. These measurements are opposite of the measurements from the previous Test Step. Results: YES - The resistance from contact A (wire A235-BK) to contact C (wire E917-WH) is less than 5 ohms, and the resistance from contact A (wire A235-BK) and contact B (wire E918-GN) is greater than 5000 ohms. These measurements are opposite of the measurements from the previous Test Step. The switch is operating correctly. Proceed to Test Step 5. NO - The resistance measurements do not differ for both contacts, or the measurements have not changed from the previous Test Step. The switch has failed. Repair: Replace the switch. Stop. Test Step 5. CHECK IF THE DIAGNOSTIC CODE REMAINS. A. Inspect the contacts of the harness connectors and clean the connectors. B. Reconnect all harness connectors. C. Turn the disconnect switch and the key start switch to the ON position. D. Operate the machine. E. Determine if CID 1628 FMI 04 is present. Expected Result: The CID 1628 FMI 04 is active. Results: YES - The CID 1628 FMI 04 is active. The diagnostic code has not been corrected. The machine ECM may have failed. Repair: It is unlikely that the machine ECM has failed. Exit this procedure and perform this procedure again. If the cause of the diagnostic code is not found, replace the machine ECM. See Testing and Adjusting, "Electronic Control Module

(ECM) - Replace". Stop. NO - The CID 1628 FMI 04 is not active. The diagnostic code is NOT present. The diagnostic code does not exist at this time. Repair: The initial diagnostic code was probably caused by a poor electrical connection or a short at one of the harness connectors that was disconnected and reconnected. Resume normal machine operation. Stop.

TROUBLESHOOTING

093

TROUBLESHOOTING

i01793439

MID 039 - CID 1628 - FMI 05 SMCS - 1435-038-AN Conditions Which Generate This Code:

Illustration 1

g00840492

Schematic of the Switch (position of the armrest)

This diagnostic code is associated with the Switch (position of the armrest). The switch is connected to two inputs of the machine ECM. One contact is open and the other contact is grounded during proper operation. The possible causes of this diagnostic code are listed: The normally open contact and the normally closed contact are open. The contact that is currently closed to ground is shorted to the +battery circuit.

Note: The following test procedure may create other diagnostic codes. Ignore these diagnostic codes and clear the diagnostic codes when the original diagnostic code has been corrected. Ensure that the diagnostic code of CID 1628 FMI 05 is active before performing this procedure. System Response: When this diagnostic code is active, the machine ECM will be unable to determine the state of the switch. Pilot hydraulics for implements will be deactivated. The parking brake will be engaged only if there is no request for travel. The brake lights will be turned off. The oscillating axle will be locked. Travel speed is set to travel speed high. Travel lock is disengaged. The swing brake is turned on. The pilot hydraulics for travel function will be disabled. The fuel pump will be disabled. The machine may be started, if all other requirements are met. On an operating machine, the function of the starter relay will not be affected. Test Step 1. CHECK THE GROUND CIRCUIT OF THE SWITCH IN THE HARNESS. A. Turn the key start switch and the disconnect switch to the OFF position. B. Disconnect the machine harness connector(s) from the machine ECM. C.

B. C. Measure the resistance between the contact J1-9 (wire A235-BK) of the machine harness for the machine ECM and the contact A (wire A235-BK) at the switch. Expected Result: The resistance is less than 5 ohms. Results: OK - The resistance is less than 5 ohms. The circuit is correct. Proceed to Test Step 2. NOT OK - The resistance is greater than 5000 ohms. The circuit is open. The machine harness has failed. Repair: Repair the machine harness or replace the machine harness. Stop. Test Step 2. CHECK THE SWITCH CIRCUITS FOR A SHORT TO THE +BATTERY CIRCUIT. A. The machine harness connector(s) remains disconnected from the machine ECM. B. The disconnect switch and the key start switch remain in the OFF position. C. Disconnect contact C (wire E917-WH) and contact B (wire E918-GN) from the connector of the switch. D. At the machine harness connector for the machine ECM, measure the resistance from contact C (wire E917-J1-54) and contact B (wire E918-GN) of the machine harness to all the contacts that are used in the machine harness connectors for the machine ECM. Expected Result: Each resistance measurement is greater than 5000 ohms. Results: OK - Each resistance measurement is greater than 5000 ohms. The harness is correct. Proceed to Test Step 3. NO - One or more of the measurements were less than 5 ohms. There is a short in the machine harness. Repair: The short is between wire E917-WH and the circuit with the lowest resistance measurement or the short is between wire E918-GN and the circuit with the lowest resistance measurement. Repair the machine harness or replace the machine harness. Stop. Test Step 3. CHECK THE SWITCH CIRCUITS IN THE HARNESS. A. The machine harness remains disconnected from the machine ECM and the switch. B. At the harness connector for the switch, connect a jumper wire between contact C (wire E917-WH) and contact B (wire E918-GN). C. At the harness connector for the machine ECM, measure the resistance from contact J1-54 (wire E917-WH) to contact J1-55 (wire E918-GN). Expected Result: The resistance is less than 5 ohms. Results: OK - The resistance is less than 5 ohms. Proceed to Test Step 4. NOT OK - The resistance is greater than 5000 ohms. The circuit is open. Repair: The machine harness has failed. Repair the machine harness or replace the machine harness.

Stop. Test Step 4. CHECK THE OPERATION OF THE SWITCH. A. Remove the jumper that was installed in the previous Test Step. B. The machine harness remains disconnected from the switch. C. Connect one lead from a multimeter to contact A (wire A235-BK) of the harness connector for the switch. D. Connect the other lead from a multimeter to contact C (wire E917-WH) of the harness connector for the switch. E. Measure the resistance between contact A (wire A235-BK) and contact C (wire E917-WH). Note the resistance. F. Disconnect the lead from contact C (wire E917-WH) and connect the lead to contact B (wire E918-GN). G. Measure the resistance between contact A (wire A235-BK) and contact B (wire E918-GN). Expected Result: The resistance from contact A to contact B is less than 5 ohms, and the resistance from contact A to contact C is greater than 5000 ohms. Results: YES - The resistance from contact A to contact A is less than 5 ohms, and the resistance from contact A to contact C is greater than 5000 ohms. The switch is operating correctly. Proceed to Test Step 5. NO - The resistance measurements do not differ for both contacts, or the measurements have not changed from the previous Test Step. The switch has failed. Repair: Replace the switch. Stop. Test Step 5. CHECK THE OPERATION OF THE SWITCH A. The machine harness remains disconnected from the switch. B. Press and hold the switch. C. Connect one lead from a multimeter to contact A (wire A235-BK) of the harness connector for the switch. D. Connect the other lead from a multimeter to contact C (wire E917-WH) of the harness connector for the switch. E. Measure the resistance between contact A (wire A235-BK) and contact C (wire E917-WH). Note the resistance. F. Disconnect the lead from contact C (wire E917-WH) and connect the lead to contact B (wire E918-GN). G. Measure the resistance between contact A (wire A235E917-BKWH) and contact B (wire E918-GN). Note the resistance. Expected Result: The resistance from contact A (wire A235-BK) to contact C (wire E917-WH) is less than 5 ohms, and the resistance from contact A (wire A235-BK) and contact B (wire E918-GN) is greater than 5000 ohms. These measurements are opposite of the measurements from the previous Test Step. Results: YES - The resistance from contact A to contact C is less than 5 ohms, and the resistance from contact A and contact B is greater than 5000 ohms. These measurements are opposite of the measurements from the previous Test Step. The switch is operating correctly. Proceed to Test Step 6.

NO - The resistance measurements do not differ for both contacts, or the measurements have not changed from the previous Test Step. The switch has failed. Repair: Replace the switch. Stop. Test Step 6. CHECK IF THE DIAGNOSTIC CODE REMAINS. A. Inspect the contacts of the harness connectors and clean the harness connectors. B. Reconnect all the harness connectors. C. Turn the disconnect switch and the key start switch to the ON position. D. Operate the machine. E. Check the status of the CID 1628 FMI 05. Expected Result: The CID 1628 FMI 05 is active. Results: YES - The CID 1628 FMI 05 is active. The diagnostic code has not been corrected. The machine ECM may have failed. Repair: It is unlikely that the machine ECM has failed. Exit this procedure and perform this procedure again. If the cause of the diagnostic code is not found, replace the machine ECM. See Testing and Adjusting, "Electronic Control Module (ECM) - Replace". Stop. NO - The CID 1628 FMI 05 is not active. The diagnostic code does not exist at this time. Repair: The initial diagnostic code was probably caused by a poor electrical connection or a short at one of the harness connectors that was disconnected and reconnected. Resume normal machine operation. Stop.

TROUBLESHOOTING

094

TROUBLESHOOTING

i01793460

MID 039 - CID 1629 - FMI 03 SMCS - 5479-038-PM Conditions Which Generate This Code:

Illustration 1

g00840496

Schematic of the Solenoid valve (powershift pressure)

This diagnostic code is associated with the Solenoid valve (powershift pressure). The FMI 03 means that the machine ECM has determined that the voltage of the solenoid circuit is above normal. The possible causes of the diagnostic code are listed: The solenoid has failed. The energize circuit of the solenoid is shorted to the +battery circuit. The machine ECM has failed. This is unlikely.

Note: The following test procedure may create other diagnostic codes. Ignore these created diagnostic codes and clear these diagnostic codes when the original diagnostic code has been corrected. Ensure that the diagnostic code of CID 1629 FMI 03 is active before performing this procedure. Note: Use the 146-4080 Digital Multimeter for the measurements in this procedure. System Response: When this diagnostic code is active, the machine ECM will be unable to control the solenoid (main pump). Test Step 1. CHECK THE ENERGIZE CIRCUIT OF THE SOLENOID FOR A SHORT TO THE +BATTERY CIRCUIT. A. Turn the key start switch and the disconnect switch to the OFF position. B. Disconnect the machine harness connectors from the solenoid and the machine ECM. C.

B. C. At the machine harness connector for the machine ECM, measure the resistance from contact J2-48 (wire 960-BU) to all contacts that are used in the machine harness connectors for the machine ECM. Expected Result: Each resistance measurement is greater than 5000 ohms. Results: OK - Each resistance measurement is greater than 5000 ohms. The machine harness is correct. Proceed to Test Step 2. NOT OK - Each resistance measurement is not greater than 5000 ohms. There is a short in the machine harness. The short is between J2-48 (960-BU) and the circuit that has a low resistance measurement. Repair: Repair the machine harness or replace the machine harness. Stop. Test Step 2. CHECK IF THE DIAGNOSTIC CODE IS STILL ACTIVE. A. Inspect the contacts and clean the contacts of the harness connectors. B. Reconnect all harness connectors. C. Turn the disconnect switch and the key start switch to the ON position. D. Operate the machine. E. Determine if the CID 1629 FMI 03 is active. Expected Result: The CID 1629 FMI 03 is active. Results: YES - The CID 1629 FMI 03 is active. The problem has not been corrected. The machine ECM may have failed. Repair: It is unlikely that the machine ECM has failed. Exit this procedure and perform this procedure again. If the cause of the diagnostic code is not found, replace the machine ECM. See Testing and Adjusting, "Electronic Control Module (ECM) - Replace". Stop. NO - The CID 1629 FMI 03 is not active. The problem does not exist at this time. Repair: The initial diagnostic code was probably caused by a poor electrical connection or a short at one of the harness connectors that was disconnected and reconnected. Resume normal machine operation. Stop.

TROUBLESHOOTING

095

TROUBLESHOOTING

i01793461

MID 039 - CID 1629 - FMI 05 SMCS - 5479-038-PM Conditions Which Generate This Code:

Illustration 1

g00840496

Schematic of the Solenoid valve (powershift pressure)

This diagnostic code is associated with the Solenoid valve (powershift pressure). The FMI 05 means that the machine ECM has determined that the current of the solenoid is below normal. The possible causes of this diagnostic code are listed below: The energize circuit of the solenoid is open. The return circuit of the solenoid is open. The solenoid has failed. The machine ECM has failed. This is unlikely.

Note: The following test procedure may create other diagnostic codes. Ignore these created diagnostic codes and clear these diagnostic codes when the original diagnostic code has been corrected. Ensure that the diagnostic code of CID 1629 FMI 05 is active before performing this procedure. Note: Use the 146-4080 Digital Multimeter for the measurements in this procedure. System Response: When this diagnostic code is active, the machine ECM will be unable to control the solenoid (main pump). Test Step 1. CHECK THE SOLENOID. A. Turn the disconnect switch and the key start switch to the ON position. Do not start the engine. B. Disconnect the solenoid with the active diagnostic code from the machine harness.

B. C. At the machine harness connector for the solenoid, place a jumper wire from contact 1 (wire 960-BU) to contact 2 (wire H803-BU). D. Observe the status of the CID 1629 FMI 05. Expected Result: The CID 1629 FMI 05 remains active. The FMI has not changed and the "05" is still active. Results: YES - The diagnostic code remains active. The jumper wire does not affect the diagnostic code. Proceed to Test Step 2. NO - The diagnostic is no longer active. The solenoid has failed. Repair: The solenoid has failed. Repeat this Test Step "CHECK THE SOLENOID" in order to verify the solenoid failure. Replace the solenoid. Verify that the new solenoid corrects the problem. Stop. Test Step 2. CHECK THE HARNESS FOR AN OPEN. A. Turn the key start switch and the disconnect switch to the OFF position. B. Disconnect the machine harness connector(s) from the machine ECM. C. The jumper wire that was installed in the previous Test Step remains in place. D. At the machine harness connector, measure the resistance from signal contact J2-48 (wire 960-BU) to contact J2-59 (wire H803-BU). Expected Result: The resistance is less than 5.0 ohms. Results: OK - The resistance is less than 5.0 ohms. The machine harness is correct. Proceed to Test Step 3. NOT OK - The resistance is greater than 5000 ohms. The resistance measurement is not correct. There is an open circuit in the machine harness. Repair: The open is in wire 960-BU or in wire H803-BU of the machine harness. Repair the machine harness or replace the machine harness. Stop. Test Step 3. CHECK IF THE DIAGNOSTIC CODE REMAINS. A. Inspect the contacts of the harness connectors and clean the harness connectors. B. Reconnect all harness connectors. C. Turn the disconnect switch and the key start switch to the ON position. D. Operate the machine. E. Check the status of the CID 1629 FMI 05. Expected Result: The CID 1629 FMI 05 is active. Results:

YES - The CID 1629 FMI 05 is active. The diagnostic code has not been corrected. The machine ECM may have failed. Repair: It is unlikely that the machine ECM has failed. Exit this procedure and perform this procedure again. If the cause of the diagnostic code is not found, replace the machine ECM. See Testing and Adjusting, "Electronic Control Module (ECM) - Replace". Stop. NO - The CID 1629 FMI 05 is not active. The diagnostic code does not exist at this time. Repair: The initial diagnostic code was probably caused by a poor electrical connection or a short at one of the harness connectors that was disconnected and reconnected. Resume normal machine operation. Stop.

TROUBLESHOOTING

096

TROUBLESHOOTING

i01793462

MID 039 - CID 1629 - FMI 06 SMCS - 5479-038-PM Conditions Which Generate This Code:

Illustration 1

g00840496

Schematic of the Solenoid valve (powershift pressure)

This diagnostic code is associated with the Solenoid valve (powershift pressure). The FMI 06 means that the machine ECM has determined that the current of the solenoid is above normal. The possible causes of this diagnostic code are listed: The energize circuit of the solenoid is shorted to ground. The solenoid has failed. The machine ECM has failed. This is unlikely.

Note: The following test procedure may create other diagnostic codes. Ignore these created diagnostic codes and clear these diagnostic codes when the original diagnostic code has been corrected. Ensure that the diagnostic code of CID 1629 FMI 06 is active before performing this procedure. Note: Use the 146-4080 Digital Multimeter for the measurements in this procedure. System Response: When this diagnostic code is active, the machine ECM will be unable to control the solenoid (main pump). Test Step 1. CHECK THE SOLENOID. A. Turn the disconnect switch and the key start switch to the ON position. Do not start the engine. B. Observe the status of the diagnostic code. C. Disconnect the solenoid with the active diagnostic code from the machine harness.

C. Expected Result: CID 1629 FMI 06 changes to CID 1629 FMI 05 when the solenoid is disconnected. Results: YES - CID 1629 FMI 06 changes to CID 1629 FMI 05 when the solenoid is disconnected. The circuit is correct. Repair: The solenoid has failed. Repeat this test "CHECK THE SOLENOID" in order to verify the solenoid failure. Replace the solenoid. Stop. NO - CID 1629 FMI 06 remains active. Proceed to Test Step 2. Test Step 2. CHECK THE ENERGIZE CIRCUIT OF THE SOLENOID FOR A SHORT TO GROUND. A. Turn the key start switch and the disconnect switch to the OFF position. B. The solenoid remains disconnected from the machine harness. C. Disconnect the machine harness connector(s) from the machine ECM. D. At the machine harness connector, measure the resistance from the signal contact J2-48 (wire 960-BU) to all contacts that are used in the machine harness connectors for the machine ECM. Expected Result: Each resistance measurement is greater than 5000 ohms. Results: OK - Each resistance measurement is greater than 5000 ohms. The machine harness is correct. Proceed to Test Step 3. NOT OK - Each resistance measurement is not greater than 5000 ohms. There is a short in the machine harness. The short is between J2-48 (wire 960-BU) and the circuit with the low resistance measurement. Repair: Repair the machine harness or replace the machine harness. Stop. Test Step 3. CHECK IF THE DIAGNOSTIC CODE REMAINS. A. Inspect the harness connectors and clean the contacts of the harness connectors. B. Reconnect all harness connectors. C. Turn the disconnect switch and the key start switch to the ON position. D. Operate the machine. E. Check the status of the CID 1629 FMI 06. Expected Result: The CID 1629 FMI 06 is active. Results: YES - The CID 1629 FMI 06 is active. The diagnostic code has not been corrected. The machine ECM may have failed. Repair: It is unlikely that the machine ECM has failed. Exit this procedure and perform this procedure again. If the cause of the diagnostic code is not found, replace the machine ECM. See Testing and Adjusting, "Electronic Control Module (ECM) - Replace". Stop.

NO - The CID 1629 FMI 06 is not active. The diagnostic code does not exist at this time. Repair: The initial diagnostic code was probably caused by a poor electrical connection or a short at one of the harness connectors that was disconnected and reconnected. Resume normal machine operation. Stop.

TROUBLESHOOTING

097

TROUBLESHOOTING

i01793463

MID 039 - CID 1630 - FMI 03 SMCS - 5479-038-PM Conditions Which Generate This Code:

Illustration 1

g00840497

Schematic of the Solenoid valve (swing pump)

This diagnostic code is associated with the Solenoid valve (swing pump). The FMI 03 means that the machine ECM has determined that the voltage of the solenoid circuit is above normal. The possible causes of the diagnostic code are listed: The solenoid has failed. The energize circuit of the solenoid is shorted to the +battery circuit. The machine ECM has failed. This is unlikely.

Note: The following test procedure may create other diagnostic codes. Ignore these created diagnostic codes and clear these diagnostic codes when the original diagnostic code has been corrected. Ensure that the diagnostic code of CID 1630 FMI 03 is active before performing this procedure. Note: Use the 146-4080 Digital Multimeter for the measurements in this procedure. System Response: When this diagnostic code is active, the machine ECM will be unable to control the solenoid (swing pump). The swashplate angle and the hydraulic pressure for swing will be at the maximum. Test Step 1. CHECK THE ENERGIZE CIRCUIT OF THE SOLENOID FOR A SHORT TO THE +BATTERY CIRCUIT. A. Turn the key start switch and the disconnect switch to the OFF position. B.

A. B. Disconnect the machine harness connectors from the solenoid and the machine ECM. C. At the machine harness connector for the machine ECM, measure the resistance from contact J2-58 (wire K921-GY) to all contacts that are used in the machine harness connectors for the machine ECM. Expected Result: Each resistance measurement is greater than 5000 ohms. Results: OK - Each resistance measurement is greater than 5000 ohms. The machine harness is correct. Proceed to Test Step 2. NOT OK - Each resistance measurement is not greater than 5000 ohms. There is a short in the machine harness. The short is between J2-58 (K921-GY) and the circuit that has a low resistance measurement. Repair: Repair the machine harness or replace the machine harness. Stop. Test Step 2. CHECK IF THE DIAGNOSTIC CODE IS STILL ACTIVE. A. Inspect the contacts and clean the contacts of the harness connectors. B. Reconnect all harness connectors. C. Turn the disconnect switch and the key start switch to the ON position. D. Operate the machine. E. Determine if the CID 1630 FMI 03 is active. Expected Result: The CID 1630 FMI 03 is active. Results: YES - The CID 1630 FMI 03 is active. The problem has not been corrected. The machine ECM may have failed. Repair: It is unlikely that the machine ECM has failed. Exit this procedure and perform this procedure again. If the cause of the diagnostic code is not found, replace the machine ECM. See Testing and Adjusting, "Electronic Control Module (ECM) - Replace". Stop. NO - The CID 1630 FMI 03 is not active. The problem does not exist at this time. Repair: The initial diagnostic code was probably caused by a poor electrical connection or a short at one of the harness connectors that was disconnected and reconnected. Resume normal machine operation. Stop.

TROUBLESHOOTING

098

TROUBLESHOOTING

i01793464

MID 039 - CID 1630 - FMI 05 SMCS - 5479-038-PM Conditions Which Generate This Code:

Illustration 1

g00840497

Schematic of the Solenoid valve (swing pump)

This diagnostic code is associated with the Solenoid valve (swing pump). The FMI 05 means that the machine ECM has determined that the current of the solenoid is below normal. The possible causes of this diagnostic code are listed below: The energize circuit of the solenoid is open. The return circuit of the solenoid is open. The solenoid has failed. The machine ECM has failed. This is unlikely.

Note: The following test procedure may create other diagnostic codes. Ignore these created diagnostic codes and clear these diagnostic codes when the original diagnostic code has been corrected. Ensure that the diagnostic code of CID 1630 FMI 05 is active before performing this procedure. Note: Use the 146-4080 Digital Multimeter for the measurements in this procedure. System Response: When this diagnostic code is active, the machine ECM will be unable to control the solenoid (swing pump). The swashplate angle will be small, and there will be no hydraulic pressure for the swing. Test Step 1. CHECK THE SOLENOID. A. Turn the disconnect switch and the key start switch to the ON position. Do not start the engine. B.

A. B. Disconnect the solenoid with the active diagnostic code from the machine harness. C. At the machine harness connector for the solenoid, place a jumper wire from contact 1 (wire K921-GY) to contact 2 (wire H803-BU). D. Observe the status of the CID 1630 FMI 05. Expected Result: The CID 1630 FMI 05 remains active. The FMI has not changed and the "05" is still active. Results: YES - The diagnostic code remains active. The jumper wire does not affect the diagnostic code. Proceed to Test Step 2. NO - The diagnostic is no longer active. The solenoid has failed. Repair: The solenoid has failed. Repeat this Test Step "CHECK THE SOLENOID" in order to verify the solenoid failure. Replace the solenoid. Verify that the new solenoid corrects the problem. Stop. Test Step 2. CHECK THE HARNESS FOR AN OPEN. A. Turn the key start switch and the disconnect switch to the OFF position. B. Disconnect the machine harness connector(s) from the machine ECM. C. The jumper wire that was installed in the previous Test Step remains in place. D. At the machine harness connector, measure the resistance from signal contact J2-58 (wire K921-GY) to contact J2-59 (wire H803-BU). Expected Result: The resistance is less than 5.0 ohms. Results: OK - The resistance is less than 5.0 ohms. The machine harness is correct. Proceed to Test Step 3. NOT OK - The resistance is greater than 5000 ohms. The resistance measurement is not correct. There is an open circuit in the machine harness. Repair: The open is in wire K921-GY or in wire H803-BU of the machine harness. Repair the machine harness or replace the machine harness. Stop. Test Step 3. CHECK IF THE DIAGNOSTIC CODE REMAINS. A. Inspect the contacts of the harness connectors and clean the harness connectors. B. Reconnect all harness connectors. C. Turn the disconnect switch and the key start switch to the ON position. D. Operate the machine. E. Check the status of the CID 1630 FMI 05. Expected Result: The CID 1630 FMI 05 is active.

Results: YES - The CID 1630 FMI 05 is active. The diagnostic code has not been corrected. The machine ECM may have failed. Repair: It is unlikely that the machine ECM has failed. Exit this procedure and perform this procedure again. If the cause of the diagnostic code is not found, replace the machine ECM. See Testing and Adjusting, "Electronic Control Module (ECM) - Replace". Stop. NO - The CID 1630 FMI 05 is not active. The diagnostic code does not exist at this time. Repair: The initial diagnostic code was probably caused by a poor electrical connection or a short at one of the harness connectors that was disconnected and reconnected. Resume normal machine operation. Stop.

TROUBLESHOOTING

099

TROUBLESHOOTING

i01793465

MID 039 - CID 1630 - FMI 06 SMCS - 5479-038-PM Conditions Which Generate This Code:

Illustration 1

g00840497

Schematic of the Solenoid valve (swing pump)

This diagnostic code is associated with the Solenoid valve (swing pump). The FMI 06 means that the machine ECM has determined that the current of the solenoid is above normal. The possible causes of this diagnostic code are listed: The energize circuit of the solenoid is shorted to ground. The solenoid has failed. The machine ECM has failed. This is unlikely.

Note: The following test procedure may create other diagnostic codes. Ignore these created diagnostic codes and clear these diagnostic codes when the original diagnostic code has been corrected. Ensure that the diagnostic code of CID 1630 FMI 06 is active before performing this procedure. Note: Use the 146-4080 Digital Multimeter for the measurements in this procedure. System Response: When this diagnostic code is active, the machine ECM will be unable to control the solenoid (swing pump). The swashplate angle will be small, and there will be no hydraulic pressure for the swing. Test Step 1. CHECK THE SOLENOID. A. Turn the disconnect switch and the key start switch to the ON position. Do not start the engine. B. Observe the status of the diagnostic code. C.

B. C. Disconnect the solenoid with the active diagnostic code from the machine harness. Expected Result: CID 1630 FMI 06 changes to CID 1630 FMI 05 when the solenoid is disconnected. Results: YES - CID 1630 FMI 06 changes to CID 1630 FMI 05 when the solenoid is disconnected. The circuit is correct. Repair: The solenoid has failed. Repeat this test "CHECK THE SOLENOID" in order to verify the solenoid failure. Replace the solenoid. Stop. NO - CID 1630 FMI 06 remains active. Proceed to Test Step 2. Test Step 2. CHECK THE ENERGIZE CIRCUIT OF THE SOLENOID FOR A SHORT TO GROUND. A. Turn the key start switch and the disconnect switch to the OFF position. B. The solenoid remains disconnected from the machine harness. C. Disconnect the machine harness connector(s) from the machine ECM. D. At the machine harness connector, measure the resistance from the signal contact J2-58 (wire K921-GY) to all contacts that are used in the machine harness connectors for the machine ECM. Expected Result: Each resistance measurement is greater than 5000 ohms. Results: OK - Each resistance measurement is greater than 5000 ohms. The machine harness is correct. Proceed to Test Step 3. NOT OK - Each resistance measurement is not greater than 5000 ohms. There is a short in the machine harness. The short is between J2-58 (wire K921-GY) and the circuit with the low resistance measurement. Repair: Repair the machine harness or replace the machine harness. Stop. Test Step 3. CHECK IF THE DIAGNOSTIC CODE REMAINS. A. Inspect the harness connectors and clean the contacts of the harness connectors. B. Reconnect all harness connectors. C. Turn the disconnect switch and the key start switch to the ON position. D. Operate the machine. E. Check the status of the CID 1630 FMI 06. Expected Result: The CID 1630 FMI 06 is active. Results: YES - The CID 1630 FMI 06 is active. The diagnostic code has not been corrected. The machine ECM may have failed. Repair: It is unlikely that the machine ECM has failed. Exit this procedure and perform this procedure again. If the cause of the diagnostic code is not found, replace the machine ECM. See Testing and Adjusting, "Electronic Control Module (ECM) - Replace". Stop.

NO - The CID 1630 FMI 06 is not active. The diagnostic code does not exist at this time. Repair: The initial diagnostic code was probably caused by a poor electrical connection or a short at one of the harness connectors that was disconnected and reconnected. Resume normal machine operation. Stop.

TROUBLESHOOTING

100

TROUBLESHOOTING

i02283853

MID 039 - CID 1657 - FMI 03 SMCS - 5705-038-PSN Conditions Which Generate This Code:

Illustration 1

g01143160

Schematic of the Right Joystick Thumbwheel Sensor

This diagnostic code is associated with the right hand joystick thumbwheel position sensor. The FMI 03 means that the ECM has determined that the PWM (Pulse Width Modulated) duty signal for the sensor is above normal. Some possible causes of the diagnostic code are listed: The sensor has failed. The signal circuit of the sensor is shorted to the +battery circuit. The energize circuit of the sensor is shorted to the +battery circuit. The ECM has failed. This is unlikely.

System Response: When the CID 1657 FMI 03 diagnostic code is active, the machine response will be: The warning indicator on the Monitor will illuminate. The medium pressure attachment that is controlled by the thumbwheel will not operate.

Note: The following test procedure may create other diagnostic codes. Ignore these created diagnostic codes and clear these diagnostic codes when the original diagnostic code has been corrected. Ensure that the diagnostic code of CID 1657 FMI

03 is active before performing this procedure. Test Step 1. CHECK THE THUMBWHEEL SENSOR A. Turn the key start switch and the disconnect switch to the OFF position B. Access the three contact joystick connector for the thumbwheel position sensor and disconnect the sensor from the machine harness. C. Turn the disconnect switch and the key switch to the ON position. D. Check the status of the CID 1657 FMI 04 diagnostic code. Expected Result: The CID 1657 FMI 03 diagnostic code is no longer active. A CID 1657 FMI 04 diagnostic code is now active. Results: YES - The active diagnostic code has changed to a CID 1657 FMI 04 diagnostic code. Repair: The thumbwheel sensor on the right hand joystick has failed. Replace the right hand joystick. Stop. NO - The active diagnostic code has not changed. The CID 1657 FMI 03 code is still active. Proceed to Test Step 2. Test Step 2. CHECK THE SIGNAL CIRCUIT OF THE SENSOR FOR A SHORT TO THE +BATTERY CIRCUIT A. Turn the key start switch and the disconnect switch to the OFF position. B. The thumbwheel sensor remains disconnected from the machine harness. Disconnect the machine harness connectors J-1 and J-2 from the ECM. C. At the machine harness ECM connector J1, measure the resistance from PWM signal contact J1-50 (wire E474-OR) to all J-1 and J2 contacts that are connected to +battery. The J-1 contact is J1-58. The J2 contacts are: J2-1, J2-23, J2-47, J257 and J2-70. Expected Result: Each resistance measurement is greater than 5000 ohms. Results: OK - Each resistance measurement is greater than 5000 ohms. The signal circuit in the machine harness is correct. Proceed to Test Step 3. NOT OK - Each resistance measurement is not greater than 5000 ohms. There is a short in the machine harness. The short is between J1-50 (wire E474-OR) and the circuit that has a low resistance measurement. Repair: Repair the machine harness or replace the machine harness. Stop. Test Step 3. CHECK THE ENERGIZE VOLTAGE AT THE SENSOR A. Reconnect machine harness connectors J-1 and J-2 to the ECM. B. Turn the disconnect switch and the key start switch to the ON position. C. At the disconnected machine harness connector for the thumbwheel sensor, measure the DC voltage between energize contact A (wire E472-GN) and ground contact B (wire G939-PK). Expected Result: The voltage measurement should be approximately 10 DC volts.

Results: OK - The voltage measurement is approximately 10 DC volts. The energize circuit is correct. Proceed to Test Step 5. NOT OK - The voltage measurement is ABOVE 10 DC volts. The energize circuit could be shorted to a + battery circuit. Proceed to Test Step 4. Test Step 4. CHECK THE ENERGIZE CIRCUIT OF THE SENSOR FOR A SHORT TO THE +BATTERY CIRCUIT A. Turn the key start switch and the disconnect switch to the OFF position. B. The thumbwheel sensor remains disconnected from the machine harness. Disconnect the machine harness connectors J-1 and J-2 from the ECM. C. At the machine harness ECM connector J1, measure the resistance from the sensor supply contact J1-13 (wire E472-GN) to all J-1 and J2 contacts that are connected to +battery. The J-1 contact is J1-58. The J2 contacts are: J2-1, J2-23, J247, J2-57 and J2-70. Expected Result: Each resistance measurement is greater than 5000 ohms. Results: OK - Each resistance measurement is greater than 5000 ohms. The energize circuit in the machine harness is correct. Proceed to Test Step 5. NOT OK - Each resistance measurement is not greater than 5000 ohms. There is a short in the machine harness. The short is between J1-13 (wire E472-GN) and the circuit that has a low resistance measurement. Repair: Repair the machine harness or replace the machine harness. Stop. Test Step 5. CHECK IF THE DIAGNOSTIC CODE IS STILL ACTIVE A. Inspect the contacts and clean the contacts of the harness connectors. B. Reconnect all harness connectors. C. Turn the disconnect switch and the key start switch to the ON position. D. Operate the machine. E. Determine if the CID 1657 FMI 03 is active. Expected Result: The CID 1657 FMI 03 is still active. Results: YES - The CID 1657 FMI 03 is still active. Repair: Repeat this entire test procedure again. If the diagnostic code is still active, the ECM may be faulty. It is unlikely that the ECM has failed. If the cause of the diagnostic code is not found, replace the ECM. See Testing and Adjusting, "Electronic Control Module (ECM) - Replace". Stop. NO - The CID 1401 FMI 03 is not active. The problem does not exist at this time. Repair: The initial diagnostic code was probably caused by a poor electrical connection or a short at one of the harness connectors that was disconnected and reconnected. Resume normal machine operation.

Stop.

TROUBLESHOOTING

101

TROUBLESHOOTING

i02283860

MID 039 - CID 1657 - FMI 04 SMCS - 5705-038-PSN Conditions Which Generate This Code:

Illustration 1

g01143160

Schematic of the Right Joystick Thumbwheel Sensor

This diagnostic code is associated with the right hand joystick thumbwheel sensor. The FMI 04 means that the ECM has determined that the voltage of the PWM (Pulse Width Modulated) signal circuit for the thumbwheel sensor is below normal. The possible causes of this diagnostic code are listed below: The signal circuit for the sensor is open. The energize circuit for the sensor is open. The sensor has failed. The ECM has failed. This is unlikely.

Note: The following test procedure may create other diagnostic codes. Ignore these created diagnostic codes and clear the diagnostic codes when the original diagnostic code has been corrected. Ensure that the diagnostic code of CID 1657 FMI 04 is active before performing this procedure. System Response: When the CID 1657 FMI 04 diagnostic code is active, the machine response will be: The warning indicator on the Monitor will illuminate. The medium pressure attachment that is controlled by the thumbwheel will not operate.

Note: The following test procedure may create other diagnostic codes. Ignore these created diagnostic codes and clear these diagnostic codes when the original diagnostic code has been corrected. Ensure that the diagnostic code of CID 1657 FMI 04 is active before performing this procedure. Test Step 1. CHECK THE SENSOR SIGNAL CIRCUIT FOR AN OPEN A. Turn the disconnect switch and the key switch to the OFF position B. Access the thumbwheel sensor three contact machine harness connector below the right hand joystick. Disconnect the sensor connector from the machine harness. C. At the machine harness three contact connector for the sensor, place a jumper between contact A (wire E472-GN) and contact C (wire E474-OR). D. Disconnect machine harness connector J1 from the ECM. E. At the machine harness connector J1 for the ECM, measure the resistance between signal contact J1-50 (wire E474-OR) and supply contact J1-13 (wire E472-GN). Expected Result: The resistance measurement is 5 ohms or less. Results: OK - The resistance measurement is 5 ohms or less. The machine harness circuit for the sensor signal is correct. Proceed to Test Step 2. NOT OK - The resistance measurement is greater than 5 ohms. There is a problem in the machine harness. Repair: There is an open or a faulty connection in the sensor signal circuit for the thumbwheel sensor. The problem is either in the sensor signal wire E474-OR or sensor supply contact J1-13 (wire E472-GN). Repair the machine harness or replace the machine harness. Stop. Test Step 2. CHECK THE SENSOR SUPPLY CIRCUIT FOR AN OPEN The machine wiring harness remains disconnected from the sensor. The machine harness connector J1 remains disconnected from the ECM. A. Turn the key start switch and the disconnect switch to the OFF position. B. At the machine harness three contact connector for the sensor, place a jumper between contact A (wire E472-GN) and contact B (wire G939-PK). C. At the machine harness connector J1 for the ECM, measure the resistance between supply contact J1-50 (wire E474-OR) and ground contact J1-12 (wire G939-PK). Expected Result: The resistance measurement is 5 ohms or less. Results: OK - The resistance measurement is 5 ohms or less. The machine harness circuit for the sensor supply is correct. Proceed to Test Step 3. NOT OK - The resistance measurement is greater than 5 ohms. There is a problem in the machine harness. Repair: There is an open or a faulty connection in the sensor ground circuit for the thumbwheel sensor. The problem is in the ground circuit wire G939-PK. Repair the machine harness or replace the machine harness. Stop.

Test Step 3. CHECK SENSOR SUPPLY VOLTAGE The machine wiring harness remains disconnected from the sensor. A. Connect machine harness J1 to the ECM. B. Turn the key start switch and the disconnect switch to the ON position C. At the machine harness for the sensor, measure the DC voltage between contact A (wire E472-GN) and contact B (wire G939-PK). Expected Result: The voltage measurement should be between 9 to 11 DCV. Results: OK - The voltage measurement is between 9 to 11 DCV. The supply voltage is correct. The sensor is not working correctly. Repair: Replace the right hand joystick. Stop. NOT OK - The voltage measurement is NOT between 9 to 11 DCV. The ECM may be faulty. Proceed to Test Step 4. Test Step 4. CHECK IF THE DIAGNOSTIC CODE REMAINS. A. Inspect the contacts of all of the machine harness connectors that are used in the thumbwheel sensor circuit. Clean the contacts of the connectors. B. Reconnect all harness connectors. C. Turn the disconnect switch and the key start switch to the ON position. D. Operate the machine. E. Check the status of the CID 1657 FMI 04 diagnostic code. Expected Result: The CID 1657 FMI 04 code is still active. Results: YES - The CID 1657 FMI 04 still is active. The diagnostic code has not been corrected. The ECM may have failed. Repair: It is unlikely that the ECM has failed. Exit this procedure and perform this procedure again. If the cause of the diagnostic code is not found, replace the ECM. See Testing and Adjusting, "Electronic Control Module (ECM) - Replace". Stop. NO - The CID 1657 FMI 04 is not active. The diagnostic code does not exist at this time. Repair: The initial diagnostic code was probably caused by a poor electrical connection or a short at one of the harness connectors that was disconnected and reconnected. Resume normal machine operation. Stop.

TROUBLESHOOTING

102

TROUBLESHOOTING

i02304028

MID 039 - CID 1670 - FMI 04 SMCS - 7332-038-P9 Conditions Which Generate This Code:

Illustration 1

g00866031

Schematic of the Travel Pedal Limit Switch

The diagnostic code is associated with the Travel Pedal Limit Switch. The switch is connected to two inputs of the ECM. The inputs are "Normally Open" and "Normally Closed". One of the inputs is open and the other input is grounded during proper operation. The FMI 04 means that the ECM has determined that the "Normally Open" and "Normally Closed" circuits are grounded. Note: The following test procedure may create other diagnostic codes. Ignore these diagnostic codes and clear these diagnostic codes when the original diagnostic code has been corrected. Ensure that the diagnostic code of CID 1670 FMI 04 is active before performing this procedure. Test Step 1. CHECK THE SWITCH. A. Turn the key start switch and the disconnect switch to the OFF position. B. Disconnect the machine harness from the switch. C. Turn the key start switch and the disconnect switch to the ON position. Expected Result: The CID 1670 FMI 04 has been replaced by CID 1670 FMI 05. Results: OK - The CID 1670 FMI 04 has been replaced by CID 1670 FMI 05. The machine harness and the ECM are correct. Proceed to Test Step 3. NOT OK - The CID 1670 FMI 04 is still active. Proceed to Test Step 2.

Test Step 2. CHECK THE HARNESS. A. Turn the disconnect switch and the key start switch to the OFF position. B. The machine harness remains disconnected from the switch. C. Disconnect the machine harness connector(s) from the ECM. D. Measure the resistance between contacts J1-44 (wire M957-GY) and J1-45 (wire M958-OR) of the machine harness to all the contacts that are used in machine harness connectors for the ECM. Expected Result: Each resistance measurement is greater than 5000 ohms. Results: YES - Each resistance measurement is greater than 5000 ohms. The ECM has failed. Repair: It is unlikely that the ECM has failed. Exit this procedure and perform this procedure again. If the cause of the diagnostic code is not found, replace the ECM. See Testing And Adjusting, "Electronic Control Module (ECM) Replace". Stop. NO - One or more of the resistance measurements are less than 5 ohms. The harness has failed. The short is between J144 (wire M957-GY) and the circuit with the lowest resistance or the short is between J1-45 (wire M958-OR) and the circuit with the lowest resistance. Repair: Repair the wiring harness or replace the wiring harness. Stop. Test Step 3. CHECK THE OPERATION OF THE SWITCH. A. The machine harness remains disconnected from the switch. B. Connect one lead from a multimeter to contactA (wire A235-BK) of the harness connector for the switch. C. Connect the other lead from a multimeter to contact B (wire M957-GY) of the harness connector for the switch. D. Measure the resistance between contact A (wire A235-BK) and contact B (wire M957-GY). Note the resistance. E. Disconnect the lead from contact B (wire M957-GY) and connect the lead to contact C (wire M958-OR). F. Measure the resistance between contact A (wire A235-BK) and contact C (wire M958-OR). Expected Result: The resistance from contact A (wire A235-BK) to contact B (wire M957-GY) is less than 5 ohms, and the resistance from contact A (wire A235-BK) to contact C (wire M958-OR) is greater than 5000 ohms. Results: YES - The resistance from contact A (wire A235-BK) to contact B (wire M957-GY) is less than 5 ohms, and the resistance from contact A (wire A235-BK) to contact C (wire M958-OR) is greater than 5000 ohms. Proceed to Test Step 4. NO - The resistance measurements do not differ. The switch has failed. Repair: Replace the switch. Stop. Test Step 4. CHECK THE OPERATION OF THE SWITCH.

A. The machine harness remains disconnected from the switch. B. Press and hold the switch. C. Connect one lead from a multimeter to contact A (wire A235-BK) of the harness connector for the switch. D. Connect the other lead from a multimeter to contact B (wire M957-GY) of the harness connector for the switch. E. Measure the resistance between contact A (wire A235-BK) and contact B (wire M957-GY). Note the resistance. F. Disconnect the lead from contact B (wire M957-GY) and connect the lead to contact C (wire M958-OR). G. Measure the resistance between contact A (wire A235-BK) and contact C (wire M958-OR). Expected Result: The resistance from contact A (wire A235-BK) to contact B (wire M957-GY) is less than 5 ohms, and the resistance from contact A (wire A235-BK) and contact C (wire M958-OR) is greater than 5000 ohms. These measurements are opposite of the measurements from the previous Test Step. Results: YES - The resistance from contact A (wire A235-BK) to contact B (wire M957-GY) is less than 5 ohms, and the resistance from contact A (wire A235-BK) and contact C (wire M958-OR) is greater than 5000 ohms. These measurements are opposite of the measurements from the previous Test Step. The switch is operating correctly. Proceed to Test Step 5. NO - The resistance measurements do not differ for both contacts, or the measurements have not changed from the previous Test Step. The switch has failed. Repair: Replace the switch. Stop. Test Step 5. CHECK IF THE DIAGNOSTIC CODE REMAINS. A. Inspect the contacts of the harness connectors and clean the connectors. B. Reconnect all harness connectors. C. Turn the disconnect switch and the key start switch to the ON position. D. Operate the machine. E. Determine if CID 1670 FMI 04 is present. Expected Result: The CID 1670 FMI 04 is active. Results: YES - The CID 1670 FMI 04 is active. The diagnostic code has not been corrected. The ECM may have failed. Repair: It is unlikely that the ECM has failed. Exit this procedure and perform this procedure again. If the cause of the diagnostic code is not found, replace the ECM. See Testing and Adjusting, "Electronic Control Module (ECM) - Replace". Stop. NO - The CID 1670 FMI 04 is not active. The diagnostic code is NOT present. The diagnostic code does not exist at this time. Repair: The initial diagnostic code was probably caused by a poor electrical connection or a short at one of the harness connectors that was disconnected and reconnected. Resume normal machine operation. Stop.

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MID 039 - CID 1670 - FMI 05 SMCS - 7332-038-P9 Conditions Which Generate This Code:

Illustration 1

g00866031

Schematic of the limit switch for the travel pedal

This diagnostic code is associated with the limit switch for the travel pedal. The switch is connected to two inputs of the ECM. One contact is open and the other contact is grounded during proper operation. The possible causes of this diagnostic code are listed: The normally open contact and the normally closed contact are open. The contact that is currently closed to ground is shorted to the +battery circuit.

Note: The following test procedure may create other diagnostic codes. Ignore these diagnostic codes and clear the diagnostic codes when the original diagnostic code has been corrected. Ensure that the diagnostic code of CID 1670 FMI 05 is active before performing this procedure. Test Step 1. CHECK THE GROUND CIRCUIT OF THE SWITCH IN THE HARNESS. A. Turn the key start switch and the disconnect switch to the OFF position. B. Disconnect the machine harness connector(s) from the ECM. C. Measure the resistance between contact J1-9 (wire A235-BK) of the machine harness for the ECM and contact A (wire A235-BK) at the switch. Expected Result: The resistance is less than 5 ohms.

Results: OK - The resistance is less than 5 ohms. The circuit is correct. Proceed to Test Step 2. NOT OK - The resistance is greater than 5000 ohms. The circuit is open. The machine harness has failed. Repair: Repair the machine harness or replace the machine harness. Stop. Test Step 2. CHECK THE SWITCH CIRCUITS FOR A SHORT TO THE +BATTERY CIRCUIT. A. The machine harness connector(s) remains disconnected from the ECM. B. The disconnect switch and the key start switch remain in the OFF position. C. Disconnect contact B (wire M957-GY) and contact C (wire M958-OR) from the connector of the switch. D. At the machine harness connector for the ECM, measure the resistance from contact B (wire M957-GY) and contact C (wire M958-OR) of the machine harness to all the contacts that are used in the machine harness connectors for the ECM. Expected Result: Each resistance measurement is greater than 5000 ohms. Results: OK - Each resistance measurement is greater than 5000 ohms. The harness is correct. Proceed to Test Step 3. NO - One or more of the measurements were less than 5 ohms. There is a short in the machine harness. Repair: The short is between wire M957-GY and the circuit with the lowest resistance measurement or the short is between wire M958-OR and the circuit with the lowest resistance measurement. Repair the machine harness or replace the machine harness. Stop. Test Step 3. CHECK THE SWITCH CIRCUITS IN THE HARNESS. A. The machine harness remains disconnected from the ECM and the switch. B. At the harness connector for the switch, connect a jumper wire between contact B (wire M957-GY) and contact C (wire M958-OR). C. At the harness connector for the ECM, measure the resistance from contact J1-44 (wire M957-GY) to contact J1-45 (wire M958-OR). Expected Result: The resistance is less than 5 ohms. Results: OK - The resistance is less than 5 ohms. Proceed to Test Step 4. NOT OK - The resistance is greater than 5000 ohms. The circuit is open. Repair: The machine harness has failed. Repair the machine harness or replace the machine harness. Stop. Test Step 4. CHECK THE OPERATION OF THE SWITCH. A. Remove the jumper that was installed in the previous Test Step. B.

A. B. The machine harness remains disconnected from the switch. C. Connect one lead from a multimeter to contact A (wire A235-BK) of the harness connector for the switch. D. Connect the other lead from a multimeter to contact B (wire M957-GY) of the harness connector for the switch. E. Measure the resistance between contact A (wire A235-BK) and contact B (wire M957-GY). Note the resistance. F. Disconnect the lead from contact B (wire M957-GY) and connect the lead to contact C (wire M958-OR). G. Measure the resistance between contact A (wire A235-BK) and contact C (wire M958-OR). Expected Result: The resistance from contact A to contact B is less than 5 ohms, and the resistance from contact A to contact C is greater than 5000 ohms. Results: YES - The resistance from contact A to contact B is less than 5 ohms, and the resistance from contact A to contact C is greater than 5000 ohms. The switch is operating correctly. Proceed to Test Step 5. NO - The resistance measurements do not differ for both contacts, or the measurements have not changed from the previous Test Step. The switch has failed. Repair: Replace the switch. Stop. Test Step 5. CHECK THE OPERATION OF THE SWITCH. A. The machine harness remains disconnected from the switch. B. Press and hold the switch. C. Connect one lead from a multimeter to contact A (wire A235-BK) of the harness connector for the switch. D. Connect the other lead from a multimeter to contact B (wire M957-GY) of the harness connector for the switch. E. Measure the resistance between contact A (wire A235-BK) and contact B (wire M957-GY). Note the resistance. F. Disconnect the lead from contact B (wire M957-GY) and connect the lead to contact C (wire M958-OR). G. Measure the resistance between contact A (wire A235-BK) and contact C (wire M958-OR). Note the resistance. Expected Result: The resistance from contact A (wire A235-BK) to contact B (wire M957-GY) is less than 5 ohms, and the resistance from contact A (wire A235-BK) and contact C (wire M958-OR) is greater than 5000 ohms. These measurements are opposite of the measurements from the previous Test Step. Results: YES - The resistance from contact A to contact B is less than 5 ohms, and the resistance from contact A and contact C is greater than 5000 ohms. These measurements are opposite of the measurements from the previous Test Step. The switch is operating correctly. Proceed to Test Step 6. NO - The resistance measurements do not differ for both contacts, or the measurements have not changed from the previous Test Step. The switch has failed. Repair: Replace the switch. Stop.

Test Step 6. CHECK IF THE DIAGNOSTIC CODE REMAINS. A. Inspect the contacts of the harness connectors and clean the harness connectors. B. Reconnect all the harness connectors. C. Turn the disconnect switch and the key start switch to the ON position. D. Operate the machine. E. Check the status of the CID 1670 FMI 03. Expected Result: The CID 1670 FMI 03 is active. Results: YES - The CID 1670 FMI 03 is active. The diagnostic code has not been corrected. The ECM may have failed. Repair: It is unlikely that the ECM has failed. Exit this procedure and perform this procedure again. If the cause of the diagnostic code is not found, replace the ECM. See Testing and Adjusting, "Electronic Control Module (ECM) - Replace". Stop. NO - The CID 1670 FMI 03 is not active. The diagnostic code does not exist at this time. Repair: The initial diagnostic code was probably caused by a poor electrical connection or a short at one of the harness connectors that was disconnected and reconnected. Resume normal machine operation. Stop.

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MID 039 - CID 1683 - FMI 03 SMCS - 7499-038-NP Conditions Which Generate This Code:

Illustration 1

g00866076

Schematic of the Relay for the Refueling Pump

This diagnostic code is associated with the Relay for the Refueling Pump. The FMI 03 means that the ECM has determined that the voltage of the relay circuit is above normal. The possible causes of the diagnostic code are listed: The relay has failed. The energize circuit of the relay is shorted to the + battery circuit. The ECM has failed. This is unlikely.

Note: The following test procedure may create other diagnostic codes. Ignore these created diagnostic codes and clear these diagnostic codes when the original diagnostic code has been corrected. Ensure that the diagnostic code of CID 1683 FMI 03 is active before performing this procedure. Note: Use the 146-4080 Digital Multimeter for the measurements in this procedure. Test Step 1. CHECK THE ENERGIZE CIRCUIT OF THE RELAY FOR A SHORT TO THE +BATTERY CIRCUIT A. Turn the key start switch and the disconnect switch to the OFF position. B. Disconnect the machine harness connectors from the relay and the ECM. C. At the machine harness connector for the ECM, measure the resistance from contact J2-17 (wire T776-GY) to all contacts that are used in the machine harness connectors for the ECM.

Expected Result: Each resistance measurement is greater than 5000 ohms. Results: OK - Each resistance measurement is greater than 5000 ohms. The machine harness is correct. Proceed to Test Step 2. NOT OK - Each resistance measurement is not greater than 5000 ohms. There is a short in the machine harness. The short is between J2-17 (wire T776-GY) and the circuit that has a low resistance measurement. Repair: Repair the machine harness or replace the machine harness. Stop. Test Step 2. CHECK IF THE DIAGNOSTIC CODE IS STILL ACTIVE A. Inspect the contacts and clean the contacts of the harness connectors. B. Reconnect all harness connectors. C. Turn the disconnect switch and the key start switch to the ON position. D. Operate the machine. E. Determine if the CID 1683 FMI 03 is active. Expected Result: The CID 1683 FMI 03 is active. Results: YES - The CID 1683 FMI 03 is active. The problem has not been corrected. The ECM may have failed. Repair: It is unlikely that the ECM has failed. Exit this procedure and perform this procedure again. If the cause of the diagnostic code is not found, replace the ECM. See Testing and Adjusting, "Electronic Control Module (ECM) - Replace". Stop. NO - The CID 1683 FMI 03 is not active. The problem does not exist at this time. Repair: The initial diagnostic code was probably caused by a poor electrical connection or a short at one of the harness connectors that was disconnected and reconnected. Resume normal machine operation. Stop.

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MID 039 - CID 1683 - FMI 05 SMCS - 7499-038-NP Conditions Which Generate This Code:

Illustration 1

g00866076

Schematic of the Relay for the Refueling Pump

This diagnostic code is associated with the Relay for the Refueling Pump. The FMI 05 means that the ECM has determined that the current of the relay is below normal. The possible causes of this diagnostic code are listed below: The energize circuit of the relay is open. The return circuit of the relay is open. The relay has failed. The ECM has failed. This is unlikely.

Note: The following test procedure may create other diagnostic codes. Ignore these created diagnostic codes and clear these diagnostic codes when the original diagnostic code has been corrected. Ensure that the diagnostic code of CID 1683 FMI 05 is active before performing this procedure. Note: Use the 146-4080 Digital Multimeter for the measurements in this procedure. Test Step 1. CHECK THE RELAY A. Turn the disconnect switch and the key start switch to the ON position. Do not start the engine. B. Disconnect the relay with the active diagnostic code from the machine harness. C. At the machine harness connector for the relay, place a jumper wire from contact 86 (wire T776-GY) to contact 85 (wire

C. H805-BR). D. Observe the status of the CID 1683 FMI 05. Expected Result: The CID 1683 FMI 05 remains active. The FMI has not changed and the "05" is still active. Results: YES - The diagnostic code remains active. The jumper wire does not affect the diagnostic code. Proceed to Test Step 2. NO - The diagnostic is no longer active. The relay has failed. Repair: The relay has failed. Repeat this Test Step "CHECK THE RELAY" in order to verify the failure of the relay. Replace the relay. Verify that the new relay corrects the problem. Stop. Test Step 2. CHECK THE HARNESS FOR AN OPEN A. Turn the key start switch and the disconnect switch to the OFF position. B. Disconnect the machine harness connector(s) from the ECM. C. The jumper wire that was installed in the previous test remains in place. D. At the machine harness connector, measure the resistance from signal contact J2-17 (wire T776-GY) to contact J2-12 (wire H805-BR). Expected Result: The resistance is less than 5.0 ohms. Results: OK - The resistance is less than 5.0 ohms. The machine harness is correct. Proceed to Test Step 3. NOT OK - The resistance is greater than 5000 ohms. The resistance measurement is not correct. There is an open circuit in the machine harness. Repair: The open is in wire 751-GN or in wire wire H805-BR of the machine harness. Repair the machine harness or replace the machine harness. Stop. Test Step 3. CHECK IF THE DIAGNOSTIC CODE REMAINS. A. Inspect the contacts of the harness connectors and clean the harness connectors. B. Reconnect all harness connectors. C. Turn the disconnect switch and the key start switch to the ON position. D. Operate the machine. E. Check the status of the CID 1683 FMI 05. Expected Result: The CID 1683 FMI 05 is active. Results: YES - The CID 1683 FMI 05 is active. The diagnostic code has not been corrected. The ECM may have failed.

Repair: It is unlikely that the ECM has failed. Exit this procedure and perform this procedure again. If the cause of the diagnostic code is not found, replace the ECM. See Testing and Adjusting, "Electronic Control Module (ECM) - Replace". Stop. NO - The CID 1683 FMI 05 is not active. The diagnostic code does not exist at this time. Repair: The initial diagnostic code was probably caused by a poor electrical connection at one of the harness connectors that was disconnected and reconnected. Resume normal machine operation. Stop.

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MID 039 - CID 1683 - FMI 06 SMCS - 7499-038-NP Conditions Which Generate This Code:

Illustration 1

g00866076

Schematic of the Relay for the Refueling Pump

This diagnostic code is associated with the Relay for the Refueling Pump. The FMI 06 means that the ECM has determined that the current of the relay is above normal. The possible causes of this diagnostic code are listed: The energize circuit of the relay is shorted to ground. The relay has failed. The ECM has failed. This is unlikely.

Note: The following test procedure may create other diagnostic codes. Ignore these created diagnostic codes and clear these diagnostic codes when the original diagnostic code has been corrected. Ensure that the diagnostic code of CID 1683 FMI 06 is active before performing this procedure. Note: Use the 146-4080 Digital Multimeter for the measurements in this procedure. Test Step 1. CHECK THE RELAY A. Turn the disconnect switch and the key start switch to the ON position. Do not start the engine. B. Observe the status of the diagnostic code. C. Disconnect the relay with the active diagnostic code from the machine harness.

Expected Result: CID 1683 FMI 06 changes to CID 1683 FMI 05 when the relay is disconnected. Results: YES - CID 1683 FMI 06 changes to CID 1683 FMI 05 when the relay is disconnected. The circuit is correct. Repair: The relay has failed. Repeat this test "CHECK THE RELAY" in order to verify the failure of the relay. Replace the relay. Stop. NO - CID 1683 FMI 06 remains active. Proceed to Test Step 2. Test Step 2. CHECK THE ENERGIZE CIRCUIT OF THE RELAY FOR A SHORT TO GROUND A. Turn the key start switch and the disconnect switch to the OFF position. B. The relay remains disconnected from the machine harness. C. Disconnect the machine harness connector(s) from the ECM. D. At the machine harness connector, measure the resistance from the signal contact J2-17 (wire T776-GY) to all contacts that are used in the machine harness connectors for the ECM. Expected Result: Each resistance measurement is greater than 5000 ohms. Results: OK - Each resistance measurement is greater than 5000 ohms. The machine harness is correct. Proceed to Test Step 3. NOT OK - Each resistance measurement is not greater than 5000 ohms. There is a short in the machine harness. The short is between J2-17 (wire T776-GY) and the circuit with the low resistance measurement. Repair: Repair the machine harness or replace the machine harness. Stop. Test Step 3. CHECK IF THE DIAGNOSTIC CODE REMAINS A. Inspect the harness connectors and clean the contacts of the harness connectors. B. Reconnect all harness connectors. C. Turn the disconnect switch and the key start switch to the ON position. D. Operate the machine. E. Check the status of the CID 1683 FMI 06. Expected Result: The CID 1683 FMI 06 is active. Results: YES - The CID 1683 FMI 06 is active. The diagnostic code has not been corrected. The ECM may have failed. Repair: It is unlikely that the ECM has failed. Exit this procedure and perform this procedure again. If the cause of the diagnostic code is not found, replace the ECM. See Testing and Adjusting, "Electronic Control Module (ECM) - Replace". Stop. NO - The CID 1683 FMI 06 is not active. The diagnostic code does not exist at this time. Repair: The initial diagnostic code was probably caused by a poor electrical connection or a short at one of the harness connectors that was disconnected and reconnected. Resume normal machine operation.

Stop.

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MID 039 - CID 1739 - FMI 03 SMCS - 5479-038-HR Conditions Which Generate This Code:

Illustration 1 Schematic of the Solenoid (hammer)

g00840635

This diagnostic code is associated with the Solenoid (Hammer). The FMI 03 means that the machine ECM has determined that the voltage of the solenoid circuit is above normal. The possible causes of the diagnostic code are listed: The solenoid has failed. The energize circuit of the solenoid is shorted to the +battery circuit. The machine ECM has failed. This is unlikely.

Note: The following test procedure may create other diagnostic codes. Ignore these created diagnostic codes and clear these diagnostic codes when the original diagnostic code has been corrected. Ensure that the diagnostic code of CID 1739 FMI 03 is active before performing this procedure. Note: Use the 146-4080 Digital Multimeter for the measurements in this procedure. System Response: When this diagnostic code is active, the hammer is enabled. The hammer will be activated when the operator depresses the attachment pedal. The machine ECM does not take any action when this diagnostic code is detected. Test Step 1. CHECK THE ENERGIZE CIRCUIT OF THE SOLENOID FOR A SHORT TO THE +BATTERY CIRCUIT. A. Turn the key start switch and the disconnect switch to the OFF position. B. Disconnect the machine harness connectors from the solenoid and the machine ECM. C.

B. C. At the machine harness connector for the machine ECM, measure the resistance from contact J2-63 (wire M746-GY) to all contacts that are used in the machine harness connectors for the machine ECM. Expected Result: Each resistance measurement is greater than 5000 ohms. Results: OK - Each resistance measurement is greater than 5000 ohms. The machine harness is correct. Proceed to Test Step 2. NOT OK - Each resistance measurement is not greater than 5000 ohms. There is a short in the machine harness. The short is between J2-63 (M746-GY) and the circuit that has a low resistance measurement. Repair: Repair the machine harness or replace the machine harness. Stop. Test Step 2. CHECK IF THE DIAGNOSTIC CODE IS STILL ACTIVE. A. Inspect the contacts and clean the contacts of the harness connectors. B. Reconnect all harness connectors. C. Turn the disconnect switch and the key start switch to the ON position. D. Operate the machine. E. Determine if the CID 1739 FMI 03 is active. Expected Result: The CID 1739 FMI 03 is active. Results: YES - The CID 1739 FMI 03 is active. The problem has not been corrected. The machine ECM may have failed. Repair: It is unlikely that the machine ECM has failed. Exit this procedure and perform this procedure again. If the cause of the diagnostic code is not found, replace the machine ECM. See Testing and Adjusting, "Electronic Control Module (ECM) - Replace". Stop. NO - The CID 1739 FMI 03 is not active. The problem does not exist at this time. Repair: The initial diagnostic code was probably caused by a poor electrical connection or a short at one of the harness connectors that was disconnected and reconnected. Resume normal machine operation. Stop.

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MID 039 - CID 1739 - FMI 05 SMCS - 5479-038-HR Conditions Which Generate This Code:

Illustration 1 Schematic of the Solenoid (hammer)

g00840635

This diagnostic code is associated with the Solenoid (Hammer). The FMI 05 means that the machine ECM has determined that the current of the solenoid is below normal. The possible causes of this diagnostic code are listed below: The energize circuit of the solenoid is open. The return circuit of the solenoid is open. The solenoid has failed. The machine ECM has failed. This is unlikely.

Note: The following test procedure may create other diagnostic codes. Ignore these created diagnostic codes and clear these diagnostic codes when the original diagnostic code has been corrected. Ensure that the diagnostic code of CID 1739 FMI 05 is active before performing this procedure. Note: Use the 146-4080 Digital Multimeter for the measurements in this procedure. System Response: When this diagnostic code is active, the hammer is disabled. The hammer will never be activated. The machine ECM does not take any action when this diagnostic code is detected. Test Step 1. CHECK THE SOLENOID. A. Turn the disconnect switch and the key start switch to the ON position. Do not start the engine. B. Disconnect the solenoid with the active diagnostic code from the machine harness.

B. C. At the machine harness connector for the solenoid, place a jumper wire from contact 1 (wire M746-GY) to contact 2 (wire H801-PU). D. Observe the status of the CID 1739 FMI 05. Expected Result: The CID 1739 FMI 05 remains active. The FMI has not changed and the "05" is still active. Results: YES - The diagnostic code remains active. The jumper wire does not affect the diagnostic code. Proceed to Test Step 2. NO - The diagnostic is no longer active. The solenoid has failed. Repair: The solenoid has failed. Repeat this Test Step "CHECK THE SOLENOID" in order to verify the solenoid failure. Replace the solenoid. Verify that the new solenoid corrects the problem. Stop. Test Step 2. CHECK THE HARNESS FOR AN OPEN. A. Turn the key start switch and the disconnect switch to the OFF position. B. Disconnect the machine harness connector(s) from the machine ECM. C. The jumper wire that was installed in the previous Test Step remains in place. D. At the machine harness connector, measure the resistance from signal contact J2-63 (wire M746-GY) to contact J2-52 (wire H801-PU). Expected Result: The resistance is less than 5.0 ohms. Results: OK - The resistance is less than 5.0 ohms. The machine harness is correct. Proceed to Test Step 3. NOT OK - The resistance is greater than 5000 ohms. The resistance measurement is not correct. There is an open circuit in the machine harness. Repair: The open is in wire M746-GY or in wire H801-PU of the machine harness. Repair the machine harness or replace the machine harness. Stop. Test Step 3. CHECK IF THE DIAGNOSTIC CODE REMAINS. A. Inspect the contacts of the harness connectors and clean the harness connectors. B. Reconnect all harness connectors. C. Turn the disconnect switch and the key start switch to the ON position. D. Operate the machine. E. Check the status of the CID 1739 FMI 05. Expected Result: The CID 1739 FMI 05 is active. Results:

YES - The CID 1739 FMI 05 is active. The diagnostic code has not been corrected. The machine ECM may have failed. Repair: It is unlikely that the machine ECM has failed. Exit this procedure and perform this procedure again. If the cause of the diagnostic code is not found, replace the machine ECM. See Testing and Adjusting, "Electronic Control Module (ECM) - Replace". Stop. NO - The CID 1739 FMI 05 is not active. The diagnostic code does not exist at this time. Repair: The initial diagnostic code was probably caused by a poor electrical connection or a short at one of the harness connectors that was disconnected and reconnected. Resume normal machine operation. Stop.

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MID 039 - CID 1739 - FMI 06 SMCS - 5479-038-HR Conditions Which Generate This Code:

Illustration 1 Schematic of the Solenoid (hammer)

g00840635

This diagnostic code is associated with the Solenoid (hammer). The FMI 06 means that the machine ECM has determined that the current of the solenoid is above normal. The possible causes of this diagnostic code are listed: The energize circuit of the solenoid is shorted to ground. The solenoid has failed. The machine ECM has failed. This is unlikely.

Note: The following test procedure may create other diagnostic codes. Ignore these created diagnostic codes and clear these diagnostic codes when the original diagnostic code has been corrected. Ensure that the diagnostic code of CID 1739 FMI 06 is active before performing this procedure. Note: Use the 146-4080 Digital Multimeter for the measurements in this procedure. System Response: When this diagnostic code is active, the hammer is disabled. The hammer will never be activated. The machine ECM does not take any action when this diagnostic code is detected. Test Step 1. CHECK THE SOLENOID. A. Turn the disconnect switch and the key start switch to the ON position. Do not start the engine. B. Observe the status of the diagnostic code. C. Disconnect the solenoid with the active diagnostic code from the machine harness.

C. Expected Result: CID 1739 FMI 06 changes to CID 1739 FMI 05 when the solenoid is disconnected. Results: YES - CID 1739 FMI 06 changes to CID 1739 FMI 05 when the solenoid is disconnected. The circuit is correct. Repair: The solenoid has failed. Repeat this test "CHECK THE SOLENOID" in order to verify the solenoid failure. Replace the solenoid. Stop. NO - CID 1739 FMI 06 remains active. Proceed to Test Step 2. Test Step 2. CHECK THE ENERGIZE CIRCUIT OF THE SOLENOID FOR A SHORT TO GROUND. A. Turn the key start switch and the disconnect switch to the OFF position. B. The solenoid remains disconnected from the machine harness. C. Disconnect the machine harness connector(s) from the machine ECM. D. At the machine harness connector, measure the resistance from the signal contact J2-63 (wire M746-GY) to all contacts that are used in the machine harness connectors for the machine ECM. Expected Result: Each resistance measurement is greater than 5000 ohms. Results: OK - Each resistance measurement is greater than 5000 ohms. The machine harness is correct. Proceed to Test Step 3. NOT OK - Each resistance measurement is not greater than 5000 ohms. There is a short in the machine harness. The short is between J2-63 (wire M746-GY) and the circuit with the low resistance measurement. Repair: Repair the machine harness or replace the machine harness. Stop. Test Step 3. CHECK IF THE DIAGNOSTIC CODE REMAINS. A. Inspect the harness connectors and clean the contacts of the harness connectors. B. Reconnect all harness connectors. C. Turn the disconnect switch and the key start switch to the ON position. D. Operate the machine. E. Check the status of the CID 1739 FMI 06. Expected Result: The CID 1739 FMI 06 is active. Results: YES - The CID 1739 FMI 06 is active. The diagnostic code has not been corrected. The machine ECM may have failed. Repair: It is unlikely that the machine ECM has failed. Exit this procedure and perform this procedure again. If the cause of the diagnostic code is not found, replace the machine ECM. See Testing and Adjusting, "Electronic Control Module (ECM) - Replace". Stop.

NO - The CID 1739 FMI 06 is not active. The diagnostic code does not exist at this time. Repair: The initial diagnostic code was probably caused by a poor electrical connection or a short at one of the harness connectors that was disconnected and reconnected. Resume normal machine operation. Stop.

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MID 039 - CID 1842 - FMI 03 SMCS - 5479-038-QV Conditions Which Generate This Code:

Illustration 1

g01143425

Schematic of the Auxiliary Hydraulic Valve Pressure Solenoid (aux sol. 2) (attachment)

This diagnostic code is associated with the auxiliary hydraulic valve pressure solenoid (aux sol. 2). The FMI 03 means that the ECM has determined that the voltage of the solenoid circuit is above normal. Some possible causes of the diagnostic code are listed: The solenoid has failed. The energize circuit of the solenoid is shorted to the +battery circuit. The ECM has failed. This is unlikely.

System Response: When the CID 1842 FMI 03 diagnostic code is active, the machine response will be: The warning indicator on the Monitor will illuminate. The tool that is controlled by the left auxiliary hydraulic attachment pedal will not operate.

Note: The following test procedure may create other diagnostic codes. Ignore these created diagnostic codes and clear these diagnostic codes when the original diagnostic code has been corrected. Ensure that the diagnostic code of CID 1842 FMI 03 is active before performing this procedure. Test Step 1. CHECK THE ENERGIZE CIRCUIT OF THE SOLENOID FOR A SHORT TO THE +BATTERY

CIRCUIT A. Turn the key start switch and the disconnect switch to the OFF position. B. Disconnect the machine harness connector from the solenoid. Disconnect the machine harness connectors J-1 and J-2 from the ECM. C. At the machine harness ECM connector J2, measure the resistance from contact J2-40 (wire M744-WH) to all J-1 and J2 contacts that are connected to +battery. The J-1 contact is J1-58. The J2 contacts are: J2-1, J2-23, J2-47, J2-57 and J270. Expected Result: Each resistance measurement is greater than 5000 ohms. Results: OK - Each resistance measurement is greater than 5000 ohms. The machine harness is correct. Proceed to Test Step 2. NOT OK - Each resistance measurement is not greater than 5000 ohms. There is a short in the machine harness. The short is between J2-40 (wire M744-WH) and the circuit that has a low resistance measurement. Repair: Repair the machine harness or replace the machine harness. Stop. Test Step 2. CHECK IF THE DIAGNOSTIC CODE IS STILL ACTIVE A. Inspect the contacts of the harness connectors that are used in the solenoid circuit. Ensure that the contacts are secure. Clean all of the contacts in the harness connectors. B. Reconnect all harness connectors. C. Turn the disconnect switch and the key start switch to the ON position. D. Operate the machine. E. Determine if the CID 1842 FMI 03 is active. Expected Result: The CID 1842 FMI 03 is active. Results: YES - The CID 1842 FMI 03 is active. Repair: Replace the auxiliary valve pressure solenoid. After solenoid replacement, repeat this Test Step again. If the diagnostic code is still active, the ECM may be faulty. It is unlikely that the ECM has failed. Exit this procedure and perform this procedure again. If the cause of the diagnostic code is not found, replace the ECM. See Testing and Adjusting, "Electronic Control Module (ECM) - Replace". Stop. NO - The CID 1842 FMI 03 is not active. The problem does not exist at this time. Repair: The initial diagnostic code was probably caused by a poor electrical connection or a short at one of the harness connectors that was disconnected and reconnected. Resume normal machine operation. Stop.

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MID 039 - CID 1842 - FMI 05 SMCS - 5479-038-QV Conditions Which Generate This Code:

Illustration 1

g01143425

Schematic of the Auxiliary Hydraulic Valve Pressure Solenoid (aux sol. 2) (attachment)

This diagnostic code is associated with the auxiliary hydraulic valve pressure solenoid (aux sol. 2). The FMI 05 means that the ECM has determined that the current for the solenoid is below normal. An open may exist in the circuit for the solenoid. Some possible causes of this diagnostic code are listed below: The energize circuit of the solenoid is open. The return circuit of the solenoid is open. The solenoid has failed. The ECM has failed. This is unlikely.

System Response: When the CID 1842 FMI 03 diagnostic code is active, the machine response will be: The warning indicator on the Monitor will illuminate. The tool that is controlled by the left attachment pedal will not operate.

Note: The following test procedure may create other diagnostic codes. Ignore these created diagnostic codes and clear these diagnostic codes when the original diagnostic code has been corrected. Ensure that the diagnostic code of CID 1842 FMI

05 is active before performing this procedure. Test Step 1. CHECK THE SOLENOID A. Disconnect the solenoid with the active diagnostic code from the machine harness. B. At the machine harness connector for the solenoid, place a jumper wire from contact 1 (wire M744-WH) to contact 2 (wire H803-BU). C. Turn the disconnect switch and the key start switch to the ON position. Do not start the engine. D. Observe the status of the CID 1842 FMI 05 diagnostic code. Expected Result: The CID 1842 FMI 05 diagnostic code remains active. Results: YES - The diagnostic code remains active. The jumper wire does not affect the diagnostic code. Proceed to Test Step 2. NO - The diagnostic is no longer active. The solenoid has failed. Repair: The solenoid has failed. Repeat this Test Step "CHECK THE SOLENOID" in order to verify the solenoid failure. Replace the solenoid. Verify that the new solenoid corrects the problem. Stop. Test Step 2. CHECK THE HARNESS FOR AN OPEN A. Turn the key start switch and the disconnect switch to the OFF position. B. Disconnect the machine harness ECM connector J2 from the ECM. C. The jumper wire that was installed in the previous Test Step remains in place. D. At the machine harness connector J2 for the ECM, measure the resistance from contact J2-40 (wire M744-WH) to contact J2-59 (wire H803-BU). Expected Result: The resistance is less than 5 ohms. Results: OK - The resistance is less than 5 ohms. The machine harness is correct. Proceed to Test Step 3. NOT OK - The resistance is greater than 5000 ohms. The resistance measurement is not correct. There is an open circuit in the machine harness. A resistance measurement that is much greater than 5 ohms but less than 5000 ohms could indicate that one of the connection points in the circuit is not open but is not a good connection. Repair: The open or possible bad connection is in wire M744-WH or in wire H803-BU of the machine harness. Repair the machine harness or replace the machine harness. Stop. Test Step 3. CHECK IF THE DIAGNOSTIC CODE REMAINS A. Inspect the contacts of the harness connectors that are used in the solenoid circuit. Ensure that the contacts are secure. Clean all of the contacts in the harness connectors. B. Reconnect all harness connectors. C. Turn the disconnect switch and the key start switch to the ON position. D.

C. D. Operate the machine. E. Check the status of the CID 1842 FMI 05. Expected Result: The CID 1842 FMI 05 is active. Results: YES - The CID 1842 FMI 05 is active. The diagnostic code has not been corrected. The ECM may have failed. Repair: It is unlikely that the ECM has failed. Exit this procedure and perform this procedure again. If the cause of the diagnostic code is not found, replace the ECM. See Testing and Adjusting, "Electronic Control Module (ECM) - Replace". Stop. NO - The CID 1842 FMI 05 is not active. The diagnostic code does not exist at this time. Repair: The initial diagnostic code was probably caused by a poor electrical connection at one of the harness connectors that was disconnected, cleaned and reconnected. Resume normal machine operation. Stop.

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MID 039 - CID 1842 - FMI 06 SMCS - 5479-038-QV Conditions Which Generate This Code:

Illustration 1

g01143425

Schematic of the Auxiliary HydraulicValve Pressure Solenoid (aux sol. 2) (attachment)

This diagnostic code is associated with the auxiliary hydraulic valve pressure solenoid (aux sol. 2). The FMI 06 means that the ECM has determined that the current for the solenoid is above normal. There may be a short to ground in the solenoid circuit. Some possible causes of this diagnostic code are listed: The energize circuit of the solenoid is shorted to ground. The solenoid has failed. The ECM has failed. This is unlikely.

System Response: When the CID 1842 FMI 03 diagnostic code is active, the machine response will be: The warning indicator on the Monitor will illuminate. The tool that is controlled by the left attachment pedal will not operate.

Note: The following test procedure may create other diagnostic codes. Ignore these created diagnostic codes and clear these diagnostic codes when the original diagnostic code has been corrected. Ensure that the diagnostic code of CID 1842 FMI 06 is active before performing this procedure. Test Step 1. CHECK THE SOLENOID A.

A. Turn the disconnect switch and the key start switch to the ON position. Do not start the engine. B. Observe the status of the diagnostic code. C. Disconnect the solenoid with the active diagnostic code from the machine harness. Expected Result: CID 1842 FMI 06 code changes to CID 1842 FMI 05 code when the solenoid is disconnected. Results: YES - CID 1842 FMI 06 code changes to CID 1842 FMI 05 code when the solenoid is disconnected. The circuit is correct. Repair: The solenoid has failed. Repeat this test "CHECK THE SOLENOID" in order to verify the solenoid failure. Replace the solenoid. Stop. NO - CID 1842 FMI 06 remains active. Proceed to Test Step 2. Test Step 2. CHECK THE ENERGIZE CIRCUIT OF THE SOLENOID FOR A SHORT TO GROUND A. Turn the key start switch and the disconnect switch to the OFF position. B. The solenoid remains disconnected from the machine harness. C. Disconnect the machine harness ECM connectors J1 and J2 from the ECM. D. At the machine harness ECM connectors, measure the resistance from the signal contact J2-40 (wire M744-WH) to all ground contacts on connectors J1 and J2. The ground contacts on connector J2 are J2-2, J2-12, J2-13, J2-22, J2-36, J237, J2-46, J2-49, J2-52, J2-56, J2-59 and J2-69. The ground contact on connector J1 is J1-9. Expected Result: Each resistance measurement is greater than 5000 ohms. Results: OK - Each resistance measurement is greater than 5000 ohms. The machine harness is correct. Proceed to Test Step 3. NOT OK - Each resistance measurement is not greater than 5000 ohms. There is a short in the machine harness. The short is between J2-40 (wire M744-WH) and the circuit with the low resistance measurement. Repair: Repair the machine harness or replace the machine harness. Stop. Test Step 3. CHECK IF THE DIAGNOSTIC CODE REMAINS A. Inspect the contacts of the harness connectors that are used in the solenoid circuit. Ensure that the contacts are secure. Clean all of the contacts in the harness connectors. B. Reconnect all harness connectors. C. Turn the disconnect switch and the key start switch to the ON position. D. Operate the machine. E. Check the status of the CID 1842 FMI 06. Expected Result: The CID 1842 FMI 06 is active.

Results: YES - The CID 1842 FMI 06 is active. The diagnostic code has not been corrected. The ECM may have failed. Repair: It is unlikely that the ECM has failed. Exit this procedure and perform this procedure again. If the cause of the diagnostic code is not found, replace the ECM. See Testing and Adjusting, "Electronic Control Module (ECM) - Replace". Stop. NO - The CID 1842 FMI 06 is not active. The diagnostic code does not exist at this time. Repair: The initial diagnostic code was probably caused by a poor electrical connection or a short at one of the harness connectors that was disconnected and reconnected. Resume normal machine operation. Stop.

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i02284869

MID 039 - CID 1843 - FMI 03 SMCS - 5479-038-FW Conditions Which Generate This Code:

Illustration 1

g01143517

Schematic of the Auxiliary Hydraulic Valve Flow Solenoid (aux sol. 1) (attachment)

This diagnostic code is associated with the auxiliary hydraulic valve flow solenoid (aux sol. 1). The FMI 03 means that the ECM has determined that the voltage of the solenoid circuit is above normal. Some possible causes of the diagnostic code are listed: The solenoid has failed. The energize circuit of the solenoid is shorted to the +battery circuit. The ECM has failed. This is unlikely.

System Response: When the CID 1843 FMI 03 diagnostic code is active, the machine response will be: The warning indicator on the Monitor will illuminate. The tool that is controlled by the left attachment pedal will not operate.

Note: The following test procedure may create other diagnostic codes. Ignore these created diagnostic codes and clear these diagnostic codes when the original diagnostic code has been corrected. Ensure that the diagnostic code of CID 1843 FMI 03 is active before performing this procedure. Test Step 1. CHECK THE ENERGIZE CIRCUIT OF THE SOLENOID FOR A SHORT TO THE +BATTERY

CIRCUIT A. Turn the key start switch and the disconnect switch to the OFF position. B. Disconnect the machine harness connector from the solenoid. Disconnect the machine harness connectors J-1 and J-2 from the ECM. C. At the machine harness ECM connector J2, measure the resistance from contact J2-41 (wire M745-GY) to all J-1 and J2 contacts that are connected to +battery. The J-1 contact is J1-58. The J2 contacts are: J2-1, J2-23, J2-47, J2-57 and J270. Expected Result: Each resistance measurement is greater than 5000 ohms. Results: OK - Each resistance measurement is greater than 5000 ohms. The machine harness is correct. Proceed to Test Step 2. NOT OK - Each resistance measurement is not greater than 5000 ohms. There is a short in the machine harness. The short is between J2-41 (wire M745-GY) and the circuit that has a low resistance measurement. Repair: Repair the machine harness or replace the machine harness. Stop. Test Step 2. CHECK IF THE DIAGNOSTIC CODE IS STILL ACTIVE A. Inspect the contacts of the harness connectors that are used in the solenoid circuit. Ensure that the contacts are secure. Clean all of the contacts in the harness connectors. B. Reconnect all harness connectors. C. Turn the disconnect switch and the key start switch to the ON position. D. Operate the machine. E. Determine if the CID 1843 FMI 03 is active. Expected Result: The CID 1843 FMI 03 is active. Results: YES - The CID 1843 FMI 03 is active. Repair: Replace the auxiliary valve flow solenoid. After solenoid replacement, repeat this Test Step again. If the diagnostic code is still active, the ECM may be faulty. It is unlikely that the ECM has failed. Exit this procedure and perform this procedure again. If the cause of the diagnostic code is not found, replace the ECM. See Testing and Adjusting, "Electronic Control Module (ECM) - Replace". Stop. NO - The CID 1843 FMI 03 is not active. The problem does not exist at this time. Repair: The initial diagnostic code was probably caused by a poor electrical connection or a short at one of the harness connectors that was disconnected and reconnected. Resume normal machine operation. Stop.

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i02284909

MID 039 - CID 1843 - FMI 05 SMCS - 5479-038-FW Conditions Which Generate This Code:

Illustration 1

g01143517

Schematic of the Auxiliary Hydraulic Valve Flow Solenoid (aux sol. 1) (attachment)

This diagnostic code is associated with the auxiliary hydraulic valve flow solenoid (aux sol. 1). The FMI 05 means that the ECM has determined that the current for the solenoid is below normal. An open may exist in the circuit for the solenoid. Some possible causes of this diagnostic code are listed below: The energize circuit of the solenoid is open. The return circuit of the solenoid is open. The solenoid has failed. The ECM has failed. This is unlikely.

System Response: When the CID 1843 FMI 05 diagnostic code is active, the machine response will be: The warning indicator on the Monitor will illuminate. The tool that is controlled by the left attachment pedal will not operate.

Note: The following test procedure may create other diagnostic codes. Ignore these created diagnostic codes and clear these diagnostic codes when the original diagnostic code has been corrected. Ensure that the diagnostic code of CID 1843 FMI

05 is active before performing this procedure. Test Step 1. CHECK THE SOLENOID A. Disconnect the solenoid with the active diagnostic code from the machine harness. B. At the machine harness connector for the solenoid, place a jumper wire from contact 1 (wire M745-GY) to contact 2 (wire H803-BU). C. Turn the disconnect switch and the key start switch to the ON position. Do not start the engine. D. Observe the status of the CID 1843 FMI 05 diagnostic code. Expected Result: The CID 1843 FMI 05 diagnostic code remains active. Results: YES - The diagnostic code remains active. The jumper wire does not affect the diagnostic code. Proceed to Test Step 2. NO - The diagnostic is no longer active. The solenoid has failed. Repair: The solenoid has failed. Repeat this Test Step "CHECK THE SOLENOID" in order to verify the solenoid failure. Replace the solenoid. Verify that the new solenoid corrects the problem. Stop. Test Step 2. CHECK THE HARNESS FOR AN OPEN A. Turn the key start switch and the disconnect switch to the OFF position. B. Disconnect the machine harness ECM connector J2 from the ECM. C. The jumper wire that was installed in the previous Test Step remains in place. D. At the machine harness connector J2 for the ECM, measure the resistance from contact J2-41 (wire M745-GY) to contact J2-59 (wire H803-BU). Expected Result: The resistance is less than 5 ohms. Results: OK - The resistance is less than 5 ohms. The machine harness is correct. Proceed to Test Step 3. NOT OK - The resistance is greater than 5000 ohms. The resistance measurement is not correct. There is an open circuit in the machine harness. A resistance measurement that is much greater than 5 ohms but less than 5000 ohms could indicate that one of the connection points in the circuit is not open but is not a good connection. Repair: The open or possible bad connection is in wire M745-GY or in wire H803-BU of the machine harness. Repair the machine harness or replace the machine harness. Stop. Test Step 3. CHECK IF THE DIAGNOSTIC CODE REMAINS A. Inspect the contacts of the harness connectors that are used in the solenoid circuit. Ensure that the contacts are secure. Clean all of the contacts in the harness connectors. B. Reconnect all harness connectors. C. Turn the disconnect switch and the key start switch to the ON position. D.

C. D. Operate the machine. E. Check the status of the CID 1843 FMI 05. Expected Result: The CID 1843 FMI 05 is active. Results: YES - The CID 1843 FMI 05 is active. The diagnostic code has not been corrected. The ECM may have failed. Repair: It is unlikely that the ECM has failed. Exit this procedure and perform this procedure again. If the cause of the diagnostic code is not found, replace the ECM. See Testing and Adjusting, "Electronic Control Module (ECM) - Replace". Stop. NO - The CID 1843 FMI 05 is not active. The diagnostic code does not exist at this time. Repair: The initial diagnostic code was probably caused by a poor electrical connection at one of the harness connectors that was disconnected, cleaned and reconnected. Resume normal machine operation. Stop.

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MID 039 - CID 1843 - FMI 06 SMCS - 5479-038-FW Conditions Which Generate This Code:

Illustration 1

g01143517

Schematic of the Auxiliary Hydraulic Valve Flow Solenoid (aux sol. 1) (attachment)

This diagnostic code is associated with the auxiliary hydraulic valve flow solenoid (aux sol. 1). The FMI 06 means that the ECM has determined that the current for the solenoid is above normal. There may be a short to ground in the solenoid circuit. Some possible causes of this diagnostic code are listed: The energize circuit of the solenoid is shorted to ground. The solenoid has failed. The ECM has failed. This is unlikely.

System Response: When the CID 1843 FMI 06 diagnostic code is active, the machine response will be: The warning indicator on the Monitor will illuminate. The tool that is controlled by the left attachment pedal will not operate.

Note: The following test procedure may create other diagnostic codes. Ignore these created diagnostic codes and clear these diagnostic codes when the original diagnostic code has been corrected. Ensure that the diagnostic code of CID 1843 FMI 06 is active before performing this procedure. Test Step 1. CHECK THE SOLENOID A.

A. Turn the disconnect switch and the key start switch to the ON position. Do not start the engine. B. Observe the status of the diagnostic code. C. Disconnect the solenoid with the active diagnostic code from the machine harness. Expected Result: CID 1843 FMI 06 code changes to CID 1843 FMI 05 code when the solenoid is disconnected. Results: YES - CID 1843 FMI 06 code changes to CID 1843 FMI 05 code when the solenoid is disconnected. The circuit is correct. Repair: The solenoid has failed. Repeat this test "CHECK THE SOLENOID" in order to verify the solenoid failure. Replace the solenoid. Stop. NO - CID 1843 FMI 06 remains active. Proceed to Test Step 2. Test Step 2. CHECK THE ENERGIZE CIRCUIT OF THE SOLENOID FOR A SHORT TO GROUND A. Turn the key start switch and the disconnect switch to the OFF position. B. The solenoid remains disconnected from the machine harness. C. Disconnect the machine harness ECM connectors J1 and J2 from the ECM. D. At the machine harness ECM connectors, measure the resistance from the signal contact J2-41 (wire M745-GY) to all ground contacts on connectors J1 and J2. The ground contacts on connector J2 are J2-2, J2-12, J2-13, J2-22, J2-36, J237, J2-46, J2-49, J2-52, J2-56, J2-59 and J2-69. The ground contact on connector J1 is J1-9. Expected Result: Each resistance measurement is greater than 5000 ohms. Results: OK - Each resistance measurement is greater than 5000 ohms. The machine harness is correct. Proceed to Test Step 3. NOT OK - Each resistance measurement is not greater than 5000 ohms. There is a short in the machine harness. The short is between J2-41 (wire M745-GY) and the circuit with the low resistance measurement. Repair: Repair the machine harness or replace the machine harness. Stop. Test Step 3. CHECK IF THE DIAGNOSTIC CODE REMAINS A. Inspect the contacts of the harness connectors that are used in the solenoid circuit. Ensure that the contacts are secure. Clean all of the contacts in the harness connectors. B. Reconnect all harness connectors. C. Turn the disconnect switch and the key start switch to the ON position. D. Operate the machine. E. Check the status of the CID 1843 FMI 06. Expected Result: The CID 1843 FMI 06 is active.

Results: YES - The CID 1843 FMI 06 is active. The diagnostic code has not been corrected. The ECM may have failed. Repair: It is unlikely that the ECM has failed. Exit this procedure and perform this procedure again. If the cause of the diagnostic code is not found, replace the ECM. See Testing and Adjusting, "Electronic Control Module (ECM) - Replace". Stop. NO - The CID 1843 FMI 06 is not active. The diagnostic code does not exist at this time. Repair: The initial diagnostic code was probably caused by a poor electrical connection or a short at one of the harness connectors that was disconnected and reconnected. Resume normal machine operation. Stop.

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i02285196

MID 039 - CID 2104 - FMI 03 SMCS - 5479-038-MQ Conditions Which Generate This Code:

Illustration 1

g01143552

Schematic of the Travel Motor Swash Plate Angle Limit Solenoid

This diagnostic code is associated with the travel motor swash plate angle limit solenoid. The FMI 03 means that the ECM has determined that the voltage of the solenoid circuit is above normal. Some possible causes of the diagnostic code are listed: The solenoid has failed. The energize circuit of the solenoid is shorted to the +battery circuit. The ECM has failed. This is unlikely.

System Response: When the CID 2104 FMI 03 diagnostic code is active, the machine response will be: The warning indicator on the Monitor will illuminate. The ECM will default to the limp home mode.

Note: The following test procedure may create other diagnostic codes. Ignore these created diagnostic codes and clear these diagnostic codes when the original diagnostic code has been corrected. Ensure that the diagnostic code of CID 2104 FMI 03 is active before performing this procedure. Test Step 1. CHECK THE ENERGIZE CIRCUIT OF THE SOLENOID FOR A SHORT TO THE +BATTERY

CIRCUIT A. Turn the key start switch and the disconnect switch to the OFF position. B. Disconnect the machine harness connector from the solenoid. Disconnect the machine harness connectors J-1 and J-2 from the ECM. C. At the machine harness ECM connector J2, measure the resistance from contact J2-64 (wire F853-BR) to all J-1 and J2 contacts that are connected to +battery. The J-1 contact is J1-58. The J2 contacts are: J2-1, J2-23, J2-47, J2-57 and J270. Expected Result: Each resistance measurement is greater than 5000 ohms. Results: OK - Each resistance measurement is greater than 5000 ohms. The machine harness is correct. Proceed to Test Step 2. NOT OK - Each resistance measurement is not greater than 5000 ohms. There is a short in the machine harness. The short is between J2-64 (wire F853-BR) and the circuit that has a low resistance measurement. Repair: Repair the machine harness or replace the machine harness. Stop. Test Step 2. CHECK IF THE DIAGNOSTIC CODE IS STILL ACTIVE A. Inspect the contacts of the harness connectors that are used in the solenoid circuit. Ensure that the contacts are secure. Clean all of the contacts in the harness connectors. B. Reconnect all harness connectors. C. Turn the disconnect switch and the key start switch to the ON position. D. Operate the machine. E. Determine if the CID 2104 FMI 03 is active. Expected Result: The CID 2104 FMI 03 is active. Results: YES - The CID 2104 FMI 03 is active. Repair: Replace the travel motor swash plate angle limit solenoid. After solenoid replacement, repeat this Test Step again. If the diagnostic code is still active, the ECM may be faulty. It is unlikely that the ECM has failed. Exit this procedure and perform this procedure again. If the cause of the diagnostic code is not found, replace the ECM. See Testing and Adjusting, "Electronic Control Module (ECM) - Replace". Stop. NO - The CID 2104 FMI 03 is not active. The problem does not exist at this time. Repair: The initial diagnostic code was probably caused by a poor electrical connection or a short at one of the harness connectors that was disconnected and reconnected. Resume normal machine operation. Stop.

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i02285209

MID 039 - CID 2104 - FMI 05 SMCS - 5479-038-MQ Conditions Which Generate This Code:

Illustration 1

g01143552

Schematic of the Travel Motor Swash Plate Angle Limit Solenoid

This diagnostic code is associated with the travel motor swash plate angle limit solenoid. The FMI 05 means that the ECM has determined that the current for the solenoid is below normal. An open may exist in the circuit for the solenoid. Some possible causes of this diagnostic code are listed below: The energize circuit of the solenoid is open. The return circuit of the solenoid is open. The solenoid has failed. The ECM has failed. This is unlikely.

System Response: When the CID 2104 FMI 05 diagnostic code is active, the machine response will be: The warning indicator on the Monitor will Illuminate. The ECM will default to the limp home mode.

Note: The following test procedure may create other diagnostic codes. Ignore these created diagnostic codes and clear these diagnostic codes when the original diagnostic code has been corrected. Ensure that the diagnostic code of CID 2104 FMI

05 is active before performing this procedure. Test Step 1. CHECK THE SOLENOID A. Disconnect the solenoid with the active diagnostic code from the machine harness. B. At the machine harness connector for the solenoid, place a jumper wire from contact 1 (wire F853-BR) to contact 2 (wire H801-PU). C. Turn the disconnect switch and the key start switch to the ON position. Do not start the engine. D. Observe the status of the CID 2104 FMI 05 diagnostic code. Expected Result: The CID 2104 FMI 05 diagnostic code remains active. Results: YES - The diagnostic code remains active. The jumper wire does not affect the diagnostic code. Proceed to Test Step 2. NO - The diagnostic is no longer active. The solenoid has failed. Repair: The solenoid has failed. Repeat this Test Step "CHECK THE SOLENOID" in order to verify the solenoid failure. Replace the solenoid. Verify that the new solenoid corrects the problem. Stop. Test Step 2. CHECK THE HARNESS FOR AN OPEN A. Turn the key start switch and the disconnect switch to the OFF position. B. Disconnect the machine harness ECM connector J2 from the ECM. C. The jumper wire that was installed in the previous Test Step remains in place. D. At the machine harness connector J2 for the ECM, measure the resistance from contact J2-64 (wire F853-BR) to contact J2-52 (wire H801-PU). Expected Result: The resistance is less than 5 ohms. Results: OK - The resistance is less than 5 ohms. The machine harness is correct. Proceed to Test Step 3. NOT OK - The resistance is greater than 5000 ohms. The resistance measurement is not correct. There is an open circuit in the machine harness. A resistance measurement that is much greater than 5 ohms but less than 5000 ohms could indicate that one of the connection points in the circuit is not open but is not a good connection. Repair: The open or possible bad connection is in wire M745-GY or in wire H803-BU of the machine harness. Repair the machine harness or replace the machine harness. Stop. Test Step 3. CHECK IF THE DIAGNOSTIC CODE REMAINS A. Inspect the contacts of the harness connectors that are used in the solenoid circuit. Ensure that the contacts are secure. Clean all of the contacts in the harness connectors. B. Reconnect all harness connectors. C. Turn the disconnect switch and the key start switch to the ON position. D.

C. D. Operate the machine. E. Check the status of the CID 2104 FMI 05. Expected Result: The CID 2104 FMI 05 is active. Results: YES - The CID 2104 FMI 05 is active. The diagnostic code has not been corrected. The ECM may have failed. Repair: It is unlikely that the ECM has failed. Exit this procedure and perform this procedure again. If the cause of the diagnostic code is not found, replace the ECM. See Testing and Adjusting, "Electronic Control Module (ECM) - Replace". Stop. NO - The CID 2104 FMI 05 is not active. The diagnostic code does not exist at this time. Repair: The initial diagnostic code was probably caused by a poor electrical connection at one of the harness connectors that was disconnected, cleaned and reconnected. Resume normal machine operation. Stop.

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MID 039 - CID 2104 - FMI 06 SMCS - 5479-038-MQ Conditions Which Generate This Code:

Illustration 1

g01143552

Schematic of the Travel Motor Swash Plate Angle Limit Solenoid

This diagnostic code is associated with the travel motor swash plate angle limit solenoid. The FMI 06 means that the ECM has determined that the current for the solenoid is above normal. There may be a short to ground in the solenoid circuit. Some possible causes of this diagnostic code are listed: The energize circuit of the solenoid is shorted to ground. The solenoid has failed. The ECM has failed. This is unlikely.

System Response: When the CID 2104 FMI 06 diagnostic code is active, the machine response will be: The warning indicator on the Monitor will illuminate. The ECM will default to the limp home mode.

Note: The following test procedure may create other diagnostic codes. Ignore these created diagnostic codes and clear these diagnostic codes when the original diagnostic code has been corrected. Ensure that the diagnostic code of CID 2104 FMI 06 is active before performing this procedure. Test Step 1. CHECK THE SOLENOID A.

A. Turn the disconnect switch and the key start switch to the ON position. Do not start the engine. B. Observe the status of the diagnostic code. C. Disconnect the solenoid with the active diagnostic code from the machine harness. Expected Result: CID 2104 FMI 06 code changes to CID 2104 FMI 05 code when the solenoid is disconnected. Results: YES - CID 2104 FMI 06 code changes to CID 2104 FMI 05 code when the solenoid is disconnected. The circuit is correct. Repair: The solenoid has failed. Repeat this test "CHECK THE SOLENOID" in order to verify the solenoid failure. Replace the solenoid. Stop. NO - CID 2104 FMI 06 remains active. Proceed to Test Step 2. Test Step 2. CHECK THE ENERGIZE CIRCUIT OF THE SOLENOID FOR A SHORT TO GROUND A. Turn the key start switch and the disconnect switch to the OFF position. B. The solenoid remains disconnected from the machine harness. C. Disconnect the machine harness ECM connectors J1 and J2 from the ECM. D. At the machine harness ECM connectors, measure the resistance from the signal contact J2-64 (wire F853-BR) to all ground contacts on connectors J1 and J2. The ground contacts on connector J2 are J2-2, J2-12, J2-13, J2-22, J2-36, J237, J2-46, J2-49, J2-52, J2-56, J2-59 and J2-69. The ground contact on connector J1 is J1-9. Expected Result: Each resistance measurement is greater than 5000 ohms. Results: OK - Each resistance measurement is greater than 5000 ohms. The machine harness is correct. Proceed to Test Step 3. NOT OK - Each resistance measurement is not greater than 5000 ohms. There is a short in the machine harness. The short is between J2-64 (wire F853-BR) and the circuit with the low resistance measurement. Repair: Repair the machine harness or replace the machine harness. Stop. Test Step 3. CHECK IF THE DIAGNOSTIC CODE REMAINS A. Inspect the contacts of the harness connectors that are used in the solenoid circuit. Ensure that the contacts are secure. Clean all of the contacts in the harness connectors. B. Reconnect all harness connectors. C. Turn the disconnect switch and the key start switch to the ON position. D. Operate the machine. E. Check the status of the CID 2104 FMI 06. Expected Result: The CID 2104 FMI 06 is active.

Results: YES - The CID 2104 FMI 06 is active. The diagnostic code has not been corrected. The ECM may have failed. Repair: It is unlikely that the ECM has failed. Exit this procedure and perform this procedure again. If the cause of the diagnostic code is not found, replace the ECM. See Testing and Adjusting, "Electronic Control Module (ECM) - Replace". Stop. NO - The CID 2104 FMI 06 is not active. The diagnostic code does not exist at this time. Repair: The initial diagnostic code was probably caused by a poor electrical connection or a short at one of the harness connectors that was disconnected and reconnected. Resume normal machine operation. Stop.

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MID 039 - CID 2142 - FMI 03 SMCS - 5574-038-P9 Conditions Which Generate This Code:

Illustration 1

g01145839

Schematic of the Travel Pedal Position Sensor

This diagnostic code is associated with the travel pedal position sensor. The FMI 03 means that the ECM has determined that the signal voltage from the sensor circuit is above 4.75 VDC. Some possible causes of the diagnostic code are listed: The sensor has failed. The signal circuit of the sensor is shorted to +battery. The ECM has failed. This is unlikely.

System Response: When the CID 2142 FMI 03 diagnostic code is active, the machine response will be: The warning indicator on the Monitor will illuminate. The ECM will default to the limp home mode.

Note: The following test procedure may create other diagnostic codes. Ignore these created diagnostic codes and clear these diagnostic codes when the original diagnostic code has been corrected. Ensure that the diagnostic code of CID 2142 FMI 03 is active before performing this procedure. Test Step 1. CHECK THE SIGNAL CIRCUIT OF THE SENSOR FOR A SHORT TO THE +BATTERY CIRCUIT A.

A. Turn the key start switch and the disconnect switch to the OFF position. B. Disconnect the machine harness connector from the sensor. Disconnect the machine harness connectors J-1 and J2 from the ECM. C. At the machine harness ECM connector J1, measure the resistance from signal contact J1-61 (wire T993-BR) to all ECM connector contacts that are connected to +battery. These contacts are: J1-58, J2-1, J2-23, J2-47, J2-57 and J2-70. Expected Result: Each resistance measurement is greater than 5000 ohms. Results: OK - Each resistance measurement is greater than 5000 ohms. The machine harness is correct. Proceed to Test Step 2. NOT OK - Each resistance measurement is not greater than 5000 ohms. There is a short in the machine harness. The short is between J1-62 (wire T993-BR) and the circuit that has a low resistance measurement. Repair: Repair the machine harness or replace the machine harness. Stop. Test Step 2. CHECK IF THE DIAGNOSTIC CODE IS STILL ACTIVE A. Inspect the contacts of the harness connectors that are used in the solenoid circuit. Ensure that the contacts are secure. Clean all of the contacts in the harness connectors. B. Reconnect all harness connectors. C. Turn the disconnect switch and the key start switch to the ON position. D. Operate the machine. E. Determine if the CID 2142 FMI 03 is active. Expected Result: The CID 2142 FMI 03 is active. Results: YES - The CID 2142 FMI 03 is active. Repair: Replace the travel pedal position sensor. After sensor replacement, repeat this Test Step again. If the diagnostic code is still active, the ECM may be faulty. It is unlikely that the ECM has failed. Exit this procedure and perform this procedure again. If the cause of the diagnostic code is not found, replace the ECM. See Testing and Adjusting, "Electronic Control Module (ECM) - Replace". Stop. NO - The CID 2142 FMI 03 is not active. The problem does not exist at this time. Repair: The initial diagnostic code was probably caused by a poor electrical connection or a short at one of the harness connectors that was disconnected and reconnected. Resume normal machine operation. Stop.

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MID 039 - CID 2142 - FMI 04 SMCS - 5574-038-P9 Conditions Which Generate This Code:

Illustration 1

g01145839

Schematic of the Travel Pedal Position Sensor

This diagnostic code is associated with the travel pedal position sensor. The FMI 04 means that the ECM has determined that the voltage of the signal voltage from the position sensor is below .25 VDC. The possible causes of this diagnostic code are listed below: The signal circuit for the sensor is shorted to ground. The sensor has failed. The ECM has failed. This is unlikely.

System Response: When the CID 2142 FMI 04 diagnostic code is active, the machine response will be: The warning indicator on the Monitor will illuminate. The ECM will default to the limp home mode.

Note: The following test procedure may create other diagnostic codes. Ignore these created diagnostic codes and clear these diagnostic codes when the original diagnostic code has been corrected. Ensure that the diagnostic code of CID 2142 FMI 04 is active before performing this procedure. Test Step 1. CHECK THE SENSOR A.

A. Turn the disconnect switch and the key start switch to the ON position. B. Observe the status of the diagnostic code. Disconnect the sensor from the machine harness. Expected Result: The CID 2142 FMI 04 remains active. The FMI 04 code has not changed and is still active. Results: OK - The diagnostic code remains active. The sensor is correct. Proceed to Test Step 2. NOT OK - The diagnostic code is no longer active. The sensor has failed. Repair: Replace the auxiliary pedal position sensor. Stop. Test Step 2. CHECK THE WIRING HARNESS OF THE SENSOR FOR A SHORT TO GROUND. A. Turn the key start switch and the disconnect switch to the OFF position. B. Disconnect the machine harness from the sensor. C. Disconnect the machine harness connectors from the ECM. D. At the machine harness connector for the ECM, measure the resistance from the signal contact J1-61 (wire T993-BR) to all other ECM connector ground contacts. The ground contacts on connector J2 are J2-2, J2-12, J2-13, J2-22, J2-36, J2-37, J2-46, J2-49, J2-52, J2-56, J2-59 and J2-69. The ground contact on connector J1 is J1-9. Expected Result: Each resistance measurement is greater than 5000 ohms. Results: OK - Each resistance measurement is greater than 5000 ohms. The machine harness is correct. Proceed to Test Step 3. NOT OK - One or more resistance measurements is not correct. There is a short in the machine harness. Repair: The short is between signal contact J1-61 (wire T993-BR) and the circuit with the low resistance measurement. Repair the machine harness or replace the machine harness. Stop. Test Step 3. CHECK IF THE DIAGNOSTIC CODE REMAINS. A. Inspect the contacts of the harness connectors and clean the contacts. B. Reconnect all harness connectors. C. Turn the disconnect switch and the key start switch to the ON position. D. Operate the machine. E. Check the status of the CID 2142 FMI 04. Expected Result: The CID 2142 FMI 04 is active. Results: YES - The CID 2142 FMI 04 is active. The diagnostic code has not been corrected. The ECM may have failed. Repair: It is unlikely that the ECM has failed. Exit this procedure and perform this procedure again. If the cause of the

diagnostic code is not found, replace the ECM. See Testing and Adjusting, "Electronic Control Module (ECM) - Replace". Stop. NO - The CID 2142 FMI 04 is not active. The diagnostic code does not exist at this time. Repair: The initial diagnostic code was probably caused by a poor electrical connection or a short at one of the harness connectors that was disconnected and reconnected. Resume normal machine operation. Stop.

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MID 039 - CID 2149 - FMI 03 SMCS - 5479-038 Conditions Which Generate This Code:

Illustration 1

g01145817

Schematic of the Travel Pilot Pressure Solenoid

This diagnostic code is associated with the travel pilot pressure solenoid. The FMI 03 means that the ECM has determined that the voltage of the solenoid circuit is above normal. Some possible causes of the diagnostic code are listed: The solenoid has failed. The energize circuit of the solenoid is shorted to the +battery circuit. The ECM has failed. This is unlikely.

System Response: When the CID 2149 FMI 03 diagnostic code is active, the machine response will be: The warning indicator on the Monitor will illuminate. The ECM will default to the limp home mode.

Note: The following test procedure may create other diagnostic codes. Ignore these created diagnostic codes and clear these diagnostic codes when the original diagnostic code has been corrected. Ensure that the diagnostic code of CID 2149 FMI 03 is active before performing this procedure. Test Step 1. CHECK THE ENERGIZE CIRCUIT OF THE SOLENOID FOR A SHORT TO THE +BATTERY

CIRCUIT A. Turn the key start switch and the disconnect switch to the OFF position. B. Disconnect the machine harness connector from the solenoid. Disconnect the machine harness connectors J-1 and J-2 from the ECM. C. At the machine harness ECM connector J2, measure the resistance from contact J2-50 (wire A881-YL) to all J-1 and J2 contacts that are connected to +battery. The J-1 contact is J1-58. The J2 contacts are: J2-1, J2-23, J2-47, J2-57 and J270. Expected Result: Each resistance measurement is greater than 5000 ohms. Results: OK - Each resistance measurement is greater than 5000 ohms. The machine harness is correct. Proceed to Test Step 2. NOT OK - Each resistance measurement is not greater than 5000 ohms. There is a short in the machine harness. The short is between J2-50 (wire A881-YL) and the circuit that has a low resistance measurement. Repair: Repair the machine harness or replace the machine harness. Stop. Test Step 2. CHECK IF THE DIAGNOSTIC CODE IS STILL ACTIVE A. Inspect the contacts of the harness connectors that are used in the solenoid circuit. Ensure that the contacts are secure. Clean all of the contacts in the harness connectors. B. Reconnect all harness connectors. C. Turn the disconnect switch and the key start switch to the ON position. D. Operate the machine. E. Determine if the CID 2149 FMI 03 is active. Expected Result: The CID 2149 FMI 03 is active. Results: YES - The CID 2149 FMI 03 is active. Repair: Replace the travel pilot pressure solenoid. After solenoid replacement, repeat this Test Step again. If the diagnostic code is still active, the ECM may be faulty. It is unlikely that the ECM has failed. Exit this procedure and perform this procedure again. If the cause of the diagnostic code is not found, replace the ECM. See Testing and Adjusting, "Electronic Control Module (ECM) - Replace". Stop. NO - The CID 2149 FMI 03 is not active. The problem does not exist at this time. Repair: The initial diagnostic code was probably caused by a poor electrical connection or a short at one of the harness connectors that was disconnected and reconnected. Resume normal machine operation. Stop.

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MID 039 - CID 2149 - FMI 05 SMCS - 5479-038 Conditions Which Generate This Code:

Illustration 1

g01145817

Schematic of the Travel Pilot Pressure Solenoid

This diagnostic code is associated with the travel pilot pressure solenoid. The FMI 05 means that the ECM has determined that the current for the solenoid is below normal. An open may exist in the circuit for the solenoid. Some possible causes of this diagnostic code are listed below: The energize circuit of the solenoid is open. The return circuit of the solenoid is open. The solenoid has failed. The ECM has failed. This is unlikely.

System Response: When the CID 2149 FMI 05 diagnostic code is active, the machine response will be: The warning indicator on the Monitor will illuminate. The ECM will default to the limp home mode.

Note: The following test procedure may create other diagnostic codes. Ignore these created diagnostic codes and clear these diagnostic codes when the original diagnostic code has been corrected. Ensure that the diagnostic code of CID 2149 FMI

05 is active before performing this procedure. Test Step 1. CHECK THE SOLENOID A. Disconnect the solenoid with the active diagnostic code from the machine harness. B. At the machine harness connector for the solenoid, place a jumper wire from contact 1 (wire A881-YL) to contact 2 (wire H802-GY). C. Turn the disconnect switch and the key start switch to the ON position. Do not start the engine. D. Observe the status of the CID 2149 FMI 05 diagnostic code. Expected Result: The CID 2149 FMI 05 diagnostic code remains active. Results: YES - The diagnostic code remains active. The jumper wire does not affect the diagnostic code. Proceed to Test Step 2. NO - The diagnostic is no longer active. The solenoid has failed. Repair: The solenoid has failed. Repeat this Test Step "CHECK THE SOLENOID" in order to verify the solenoid failure. Replace the solenoid. Verify that the new solenoid corrects the problem. Stop. Test Step 2. CHECK THE HARNESS FOR AN OPEN A. Turn the key start switch and the disconnect switch to the OFF position. B. Disconnect the machine harness ECM connector J2 from the ECM. C. The jumper wire that was installed in the previous Test Step remains in place. D. At the machine harness connector J2 for the ECM, measure the resistance from contact J2-50 (wire A881-YL) to contact J2-59 (wire H802-GY). Expected Result: The resistance is less than 5 ohms. Results: OK - The resistance is less than 5 ohms. The machine harness is correct. Proceed to Test Step 3. NOT OK - The resistance is greater than 5000 ohms. The resistance measurement is not correct. There is an open circuit in the machine harness. A resistance measurement that is much greater than 5 ohms but less than 5000 ohms could indicate that one of the connection points in the circuit is not open, but is not a good connection. Repair: The open or possible bad connection is in wire A881-YL or in wire H802-GY of the machine harness. Repair the machine harness or replace the machine harness. Stop. Test Step 3. CHECK IF THE DIAGNOSTIC CODE REMAINS A. Inspect the contacts of the harness connectors that are used in the solenoid circuit. Ensure that the contacts are secure. Clean all of the contacts in the harness connectors. B. Reconnect all harness connectors. C. Turn the disconnect switch and the key start switch to the ON position. D.

C. D. Operate the machine. E. Check the status of the CID 2149 FMI 05. Expected Result: The CID 2149 FMI 05 is active. Results: YES - The CID 2149 FMI 05 is active. The diagnostic code has not been corrected. The ECM may have failed. Repair: It is unlikely that the ECM has failed. Exit this procedure and perform this procedure again. If the cause of the diagnostic code is not found, replace the ECM. See Testing and Adjusting, "Electronic Control Module (ECM) - Replace". Stop. NO - The CID 2149 FMI 05 is not active. The diagnostic code does not exist at this time. Repair: The initial diagnostic code was probably caused by a poor electrical connection at one of the harness connectors that was disconnected, cleaned and reconnected. Resume normal machine operation. Stop.

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MID 039 - CID 2149 - FMI 06 SMCS - 5479-038 Conditions Which Generate This Code:

Illustration 1

g01145817

Schematic of the Travel Pilot Pressure Solenoid

This diagnostic code is associated with the travel pilot pressure solenoid. The FMI 06 means that the ECM has determined that the current for the solenoid is above normal. There may be a short to ground in the solenoid circuit. Some possible causes of this diagnostic code are listed: The energize circuit of the solenoid is shorted to ground. The solenoid has failed. The ECM has failed. This is unlikely.

System Response: When the CID 2149 FMI 06 diagnostic code is active, the machine response will be: The warning indicator on the Monitor will illuminate. The ECM will default to the limp home mode.

Note: The following test procedure may create other diagnostic codes. Ignore these created diagnostic codes and clear these diagnostic codes when the original diagnostic code has been corrected. Ensure that the diagnostic code of CID 2149 FMI 06 is active before performing this procedure. Test Step 1. CHECK THE SOLENOID A.

A. Turn the disconnect switch and the key start switch to the ON position. Do not start the engine. B. Observe the status of the diagnostic code. C. Disconnect the solenoid with the active diagnostic code from the machine harness. Expected Result: CID 2149 FMI 06 code changes to CID 2149 FMI 05 code when the solenoid is disconnected. Results: YES - CID 2149 FMI 06 code changes to CID 2149 FMI 05 code when the solenoid is disconnected. The circuit is correct. Repair: The solenoid has failed. Repeat this test "CHECK THE SOLENOID" in order to verify the solenoid failure. Replace the solenoid. Stop. NO - CID 2149 FMI 06 remains active. Proceed to Test Step 2. Test Step 2. CHECK THE ENERGIZE CIRCUIT OF THE SOLENOID FOR A SHORT TO GROUND A. Turn the key start switch and the disconnect switch to the OFF position. B. The solenoid remains disconnected from the machine harness. C. Disconnect the machine harness ECM connectors J1 and J2 from the ECM. D. At the machine harness ECM connectors, measure the resistance from the signal contact J2-50 (wire A881-YL) to all ground contacts on connectors J1 and J2. The ground contacts on connector J2 are J2-2, J2-12, J2-13, J2-22, J2-36, J237, J2-46, J2-49, J2-52, J2-56, J2-59 and J2-69. The ground contact on connector J1 is J1-9. Expected Result: Each resistance measurement is greater than 5000 ohms. Results: OK - Each resistance measurement is greater than 5000 ohms. The machine harness is correct. Proceed to Test Step 3. NOT OK - Each resistance measurement is not greater than 5000 ohms. There is a short in the machine harness. The short is between J2-50 (wire A881-YL) and the circuit with the low resistance measurement. Repair: Repair the machine harness or replace the machine harness. Stop. Test Step 3. CHECK IF THE DIAGNOSTIC CODE REMAINS A. Inspect the contacts of the harness connectors that are used in the solenoid circuit. Ensure that the contacts are secure. Clean all of the contacts in the harness connectors. B. Reconnect all harness connectors. C. Turn the disconnect switch and the key start switch to the ON position. D. Operate the machine. E. Check the status of the CID 2149 FMI 06. Expected Result: The CID 2149 FMI 06 is active.

Results: YES - The CID 2149 FMI 06 is active. The diagnostic code has not been corrected. The ECM may have failed. Repair: It is unlikely that the ECM has failed. Exit this procedure and perform this procedure again. If the cause of the diagnostic code is not found, replace the ECM. See Testing and Adjusting, "Electronic Control Module (ECM) - Replace". Stop. NO - The CID 2149 FMI 06 is not active. The diagnostic code does not exist at this time. Repair: The initial diagnostic code was probably caused by a poor electrical connection or a short at one of the harness connectors that was disconnected and reconnected. Resume normal machine operation. Stop.

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MID 039 - CID 2184 - FMI 03 SMCS - 5479-038-PX Conditions Which Generate This Code:

Illustration 1

g01146166

Schematic of the Medium Pressure Solenoid 1

This diagnostic code is associated with the medium pressure solenoid 1. The FMI 03 means that the ECM has determined that the voltage of the solenoid circuit is above normal. Some possible causes of the diagnostic code are listed: The solenoid has failed. The energize circuit of the solenoid is shorted to the +battery circuit. The ECM has failed. This is unlikely.

System Response: When the CID 2184 FMI 03 diagnostic code is active, the machine response will be: The warning indicator on the Monitor will illuminate. The medium pressure functions that are controlled by the right hand joystick thumbwheel will be disabled.

Note: The following test procedure may create other diagnostic codes. Ignore these created diagnostic codes and clear these diagnostic codes when the original diagnostic code has been corrected. Ensure that the diagnostic code of CID 2184 FMI 03 is active before performing this procedure. Test Step 1. CHECK THE ENERGIZE CIRCUIT OF THE SOLENOID FOR A SHORT TO THE +BATTERY

CIRCUIT A. Turn the key start switch and the disconnect switch to the OFF position. B. Disconnect the machine harness connector from the solenoid. Disconnect the machine harness connectors J-1 and J-2 from the ECM. C. At the machine harness ECM connector J2, measure the resistance from contact J2-14 (wire P941-WH) to all J-1 and J2 contacts that are connected to +battery. The J-1 contact is J1-58. The J2 contacts are: J2-1, J2-23, J2-47, J2-57 and J270. Expected Result: Each resistance measurement is greater than 5000 ohms. Results: OK - Each resistance measurement is greater than 5000 ohms. The machine harness is correct. Proceed to Test Step 2. NOT OK - Each resistance measurement is not greater than 5000 ohms. There is a short in the machine harness. The short is between J2-14 (wire P941-WH) and the circuit that has a low resistance measurement. Repair: Repair the machine harness or replace the machine harness. Stop. Test Step 2. CHECK IF THE DIAGNOSTIC CODE IS STILL ACTIVE A. Inspect the contacts of the harness connectors that are used in the solenoid circuit. Ensure that the contacts are secure. Clean all of the contacts in the harness connectors. B. Reconnect all harness connectors. C. Turn the disconnect switch and the key start switch to the ON position. D. Operate the machine. E. Determine if the CID 2184 FMI 03 is active. Expected Result: The CID 2184 FMI 03 is active. Results: YES - The CID 2184 FMI 03 is active. Repair: Replace the medium pressure solenoid 1. After solenoid replacement, repeat this Test Step again. If the diagnostic code is still active, the ECM may be faulty. It is unlikely that the ECM has failed. Exit this procedure and perform this procedure again. If the cause of the diagnostic code is not found, replace the ECM. See Testing and Adjusting, "Electronic Control Module (ECM) - Replace". Stop. NO - The CID 2184 FMI 03 is not active. The problem does not exist at this time. Repair: The initial diagnostic code was probably caused by a poor electrical connection or a short at one of the harness connectors that was disconnected and reconnected. Resume normal machine operation. Stop.

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MID 039 - CID 2184 - FMI 05 SMCS - 5479-038-PX Conditions Which Generate This Code:

Illustration 1

g01146166

Schematic of the Medium Pressure Solenoid 1

This diagnostic code is associated with the medium pressure solenoid. The FMI 05 means that the ECM has determined that the current for the solenoid is below normal. An open may exist in the circuit for the solenoid. Some possible causes of this diagnostic code are listed below: The energize circuit of the solenoid is open. The return circuit of the solenoid is open. The solenoid has failed. The ECM has failed. This is unlikely.

System Response: When the CID 2184 FMI 05 diagnostic code is active, the machine response will be: The warning indicator on the Monitor will illuminate. The medium pressure functions that are controlled by the right hand joystick thumbwheel will be disabled.

Note: The following test procedure may create other diagnostic codes. Ignore these created diagnostic codes and clear these diagnostic codes when the original diagnostic code has been corrected. Ensure that the diagnostic code of CID 2184 FMI

05 is active before performing this procedure. Test Step 1. CHECK THE SOLENOID A. Disconnect the solenoid with the active diagnostic code from the machine harness. B. At the machine harness connector for the solenoid, place a jumper wire from contact 1 (wire P941-WH) to contact 2 (wire H804-GN). C. Turn the disconnect switch and the key start switch to the ON position. Do not start the engine. D. Observe the status of the CID 2184 FMI 05 diagnostic code. Expected Result: The CID 2184 FMI 05 diagnostic code remains active. Results: YES - The diagnostic code remains active. The jumper wire does not affect the diagnostic code. Proceed to Test Step 2. NO - The diagnostic is no longer active. The solenoid has failed. Repair: The solenoid has failed. Repeat this Test Step "CHECK THE SOLENOID" in order to verify the solenoid failure. Replace the solenoid. Verify that the new solenoid corrects the problem. Stop. Test Step 2. CHECK THE HARNESS FOR AN OPEN A. Turn the key start switch and the disconnect switch to the OFF position. B. Disconnect the machine harness ECM connector J2 from the ECM. C. The jumper wire that was installed in the previous Test Step remains in place. D. At the machine harness connector J2 for the ECM, measure the resistance from contact J2-14 (wire P941-WH) to contact J2-13 (wire H804-GN). Expected Result: The resistance is less than 5 ohms. Results: OK - The resistance is less than 5 ohms. The machine harness is correct. Proceed to Test Step 3. NOT OK - The resistance is greater than 5000 ohms. The resistance measurement is not correct. There is an open circuit in the machine harness. A resistance measurement that is much greater than 5 ohms but less than 5000 ohms could indicate that one of the connection points in the circuit is not open, but is not a good connection. Repair: The open or possible bad connection is in wire P941-WH or in wire H804-GN of the machine harness. Repair the machine harness or replace the machine harness. Stop. Test Step 3. CHECK IF THE DIAGNOSTIC CODE REMAINS A. Inspect the contacts of the harness connectors that are used in the solenoid circuit. Ensure that the contacts are secure. Clean all of the contacts in the harness connectors. B. Reconnect all harness connectors. C. Turn the disconnect switch and the key start switch to the ON position. D.

C. D. Operate the machine. E. Check the status of the CID 2184 FMI 05. Expected Result: The CID 2184 FMI 05 is active. Results: YES - The CID 2184 FMI 05 is active. The diagnostic code has not been corrected. The ECM may have failed. Repair: It is unlikely that the ECM has failed. Exit this procedure and perform this procedure again. If the cause of the diagnostic code is not found, replace the ECM. See Testing and Adjusting, "Electronic Control Module (ECM) - Replace". Stop. NO - The CID 2184 FMI 05 is not active. The diagnostic code does not exist at this time. Repair: The initial diagnostic code was probably caused by a poor electrical connection at one of the harness connectors that was disconnected, cleaned and reconnected. Resume normal machine operation. Stop.

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MID 039 - CID 2184 - FMI 06 SMCS - 5479-038-PX Conditions Which Generate This Code:

Illustration 1

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Schematic of the Medium Pressure Solenoid 1

This diagnostic code is associated with the medium pressure solenoid 1. The FMI 06 means that the ECM has determined that the current for the solenoid is above normal. There may be a short to ground in the solenoid circuit. Some possible causes of this diagnostic code are listed: The energize circuit of the solenoid is shorted to ground. The solenoid has failed. The ECM has failed. This is unlikely.

System Response: When the CID 2184 FMI 06 diagnostic code is active, the machine response will be: The warning indicator on the Monitor will illuminate. The medium pressure functions that are controlled by the right hand joystick thumbwheel will be disabled.

Note: The following test procedure may create other diagnostic codes. Ignore these created diagnostic codes and clear these diagnostic codes when the original diagnostic code has been corrected. Ensure that the diagnostic code of CID 2184 FMI 06 is active before performing this procedure. Test Step 1. CHECK THE SOLENOID A.

A. Turn the disconnect switch and the key start switch to the ON position. Do not start the engine. B. Observe the status of the diagnostic code. C. Disconnect the solenoid with the active diagnostic code from the machine harness. Expected Result: CID 2184 FMI 06 code changes to CID 2184 FMI 05 code when the solenoid is disconnected. Results: YES - CID 2184 FMI 06 code changes to CID 2184 FMI 05 code when the solenoid is disconnected. The circuit is correct. Repair: The solenoid has failed. Repeat this test "CHECK THE SOLENOID" in order to verify the solenoid failure. Replace the solenoid. Stop. NO - CID 2184 FMI 06 remains active. Proceed to Test Step 2. Test Step 2. CHECK THE ENERGIZE CIRCUIT OF THE SOLENOID FOR A SHORT TO GROUND A. Turn the key start switch and the disconnect switch to the OFF position. B. The solenoid remains disconnected from the machine harness. C. Disconnect the machine harness ECM connectors J1 and J2 from the ECM. D. At the machine harness ECM connectors, measure the resistance from the signal contact J2-14 (wire P941-WH) to all ground contacts on connectors J1 and J2. The ground contacts on connector J2 are J2-2, J2-12, J2-13, J2-22, J2-36, J237, J2-46, J2-49, J2-52, J2-56, J2-59 and J2-69. The ground contact on connector J1 is J1-9. Expected Result: Each resistance measurement is greater than 5000 ohms. Results: OK - Each resistance measurement is greater than 5000 ohms. The machine harness is correct. Proceed to Test Step 3. NOT OK - Each resistance measurement is not greater than 5000 ohms. There is a short in the machine harness. The short is between J2-14 (wire P941-WH) and the circuit with the low resistance measurement. Repair: Repair the machine harness or replace the machine harness. Stop. Test Step 3. CHECK IF THE DIAGNOSTIC CODE REMAINS A. Inspect the contacts of the harness connectors that are used in the solenoid circuit. Ensure that the contacts are secure. Clean all of the contacts in the harness connectors. B. Reconnect all harness connectors. C. Turn the disconnect switch and the key start switch to the ON position. D. Operate the machine. E. Check the status of the CID 2184 FMI 06. Expected Result: The CID 2184 FMI 06 is active.

Results: YES - The CID 2184 FMI 06 is active. The diagnostic code has not been corrected. The ECM may have failed. Repair: It is unlikely that the ECM has failed. Exit this procedure and perform this procedure again. If the cause of the diagnostic code is not found, replace the ECM. See Testing and Adjusting, "Electronic Control Module (ECM) - Replace". Stop. NO - The CID 2184 FMI 06 is not active. The diagnostic code does not exist at this time. Repair: The initial diagnostic code was probably caused by a poor electrical connection or a short at one of the harness connectors that was disconnected and reconnected. Resume normal machine operation. Stop.

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MID 039 - CID 2198 - FMI 02 SMCS - 7332-038 Conditions Which Generate This Code:

Illustration 1 Schematic of the Medium Pressure Switch 1, 2, and 3

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Illustration 2 Medium pressure switch contacts

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This diagnostic code is recorded when the ECM determines that the one or more of the switch to battery type inputs from medium pressure switch 1, medium pressure switch 2, or medium pressure switch 3 is erratic, intermittent or incorrect. Possible conditions that can cause this diagnostic code are listed: The medium pressure switch has failed. One of the inputs is shorted to ground. One of the inputs is shorted to +battery. The ECM has failed. This is unlikely.

System Response: When the CID 2198 FMI 02 diagnostic code is active. Machine response will be: The warning indicator on the Monitor will flash. The medium pressure functions may not operate correctly.

Note: The medium pressure switch receives the +battery supply from the implement lockout relay. When the switch is placed in the selected position and the expected result does not take place, the ECM will not activate this diagnostic code if no power is present at the switch. If this type of condition takes place, ensure that the implement lockout switch is in the correct position and ensure that + battery power is present at switch contact 2. Note: Ensure that the diagnostic code of CID 2198 FMI 02 is active before performing this procedure. The ECM will activate this diagnostic code when ANY ONE of the three inputs from the switch is not correct. Determine which medium pressure function is not working correctly. Use the provided schematic or the machine electrical schematic in order to determine which connections or wires to check. Test Step 1. CHECK SWITCH OPERATION A. Turn the key start switch and the disconnect switch (if equipped) to the OFF position. B. Access the medium pressure switch contacts located under the left console. C. Place the medium pressure switch at position "I". At the contacts for the switch, measure the resistance between switch contact 2 and switch contact 3. The measurement should be less than 5 ohms. Measure the resistance between

C. switch contact 5 and switch contact 6. The measurement should be less than 5 ohms. D. Place the medium pressure switch at position "II". At the contacts for the switch, measure the resistance between switch contact 1 and switch contact 2. The measurement should be less than 5 ohms. Measure the resistance between switch contact 5 and switch contact 6. The measurement should be less than 5 ohms. E. Place the medium pressure switch at position "III". At the contacts for the switch, measure the resistance between switch contact 1 and switch contact 2. The measurement should be less than 5 ohms. Measure the resistance between switch contact 4 and switch contact 5. The measurement should be less than 5 ohms. Expected Result: All of the resistance measurements are correct. Results: OK - All of the resistance measurements are correct. The switch is working correctly. Proceed to Test Step 2. NOT OK - One or more of the resistance measurements is greater than 5 ohms. The medium pressure switch is faulty. Repair: Replace the medium pressure switch. Stop. Test Step 2. CHECK THE SWITCH CIRCUIT FOR A SHORT TO GROUND The key start switch and the disconnect switch (if equipped) remain in the OFF position. A. Disconnect the machine harness connectors J1 and J2 from the ECM. B. At the machine harness connector J2 for the ECM, measure the resistance from the medium pressure switch 1 input at contact J1-31 (wire L998-OR) to all other ECM J1 and J2 connector ground contacts. The ground contacts on connector J2 are J2-2, J2-12, J2-13, J2-22, J2-36, J2-37, J2-46, J2-49, J2-52, J2-56, J2-59 and J2-69. The ground contact on connector J1 is J1-9. Repeat this step for medium pressure switch 2 input at contact J1-38 (wire F864-WH) and medium pressure switch 3 input at contact J1-30 (wire 327-PK). Expected Result: Each resistance measurement should be greater than 5000 ohms. Results: OK - Each resistance measurement should be greater than 5000 ohms. The machine harness is correct. Proceed to Test Step 3. NOT OK - One or more of the resistance measurements is less than 5000 ohms. The machine harness is shorted to a ground circuit. Repair: There is a short in the machine harness. The short is between the input that was being checked when the bad measurement was observed and the circuit with the low resistance. Repair the machine harness or replace the machine harness. Stop. Test Step 3. CHECK THE SWITCH CIRCUIT FOR A SHORT +BATTERY The key start switch and the disconnect switch (if equipped) remain in the OFF position. The machine harness connectors remain disconnected from the ECM. A. At the machine harness ECM connector J2, measure the resistance from the medium pressure switch 1 input at contact J131 (wire L998-OR) to all J1 and J2 contacts that are connected to +battery. The J1 contact is J1-58. The J2 contacts are: J2-1, J2-23, J2-47, J2-57 and J2-70. Repeat this step for medium pressure switch 2 input at contact J1-38 (wire F864-WH) and medium pressure switch 3

input at contact J1-30 (wire 327-PK). Expected Result: Each resistance measurement is greater than 5000 ohms. Results: OK - Each resistance measurement is greater than 5000 ohms. The machine harness is correct. Proceed to Test Step 4. NOT OK - One or more of the resistance measurements is less than 5000 ohms. The machine harness is shorted to a + battery circuit. Repair: There is a short in the machine harness. The short is between the input that was being checked when the bad measurement was observed and the circuit with the low resistance. Repair the machine harness or replace the machine harness. Stop. Test Step 4. CHECK TO SEE IF THE DIAGNOSTIC CODE IS STILL ACTIVE A. Inspect the contacts of the machine harness connectors that are used in the medium pressure circuit. Ensure that the contacts are secure. Clean all of the contacts in the harness connectors. B. Reconnect all harness connectors. C. Turn the disconnect switch and the key start switch to the ON position. D. Operate the machine. E. Determine if the CID 2198 FMI 02 is active. Expected Result: The CID 2198 FMI 02 is no longer active. Results: OK - The CID 2198 FMI 02 is not active at this time. Repair: The initial diagnostic code was probably caused by a poor electrical connection or a short at one of the harness connectors that was disconnected and reconnected. Resume normal machine operation. Stop. NOT OK - The CID 2198 FMI 02 is still active. Repair: It is unlikely that the ECM has failed. Exit this procedure and perform this procedure again. If the cause of the diagnostic code is not found, replace the ECM. See Testing and Adjusting, "Electronic Control Module (ECM) - Replace". Stop.

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MID 039 - CID 2256 - FMI 03 SMCS - 5479-038-NP Conditions Which Generate This Code:

Illustration 1

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Schematic of the Hydraulic Modulation Solenoid

This diagnostic code is associated with the hydraulic modulation solenoid. The FMI 03 means that the ECM has determined that the voltage of the solenoid circuit is above normal. Some possible causes of the diagnostic code are listed: The solenoid has failed. The energize circuit of the solenoid is shorted to the +battery circuit. The ECM has failed. This is unlikely.

System Response: When the CID 2256 FMI 03 diagnostic code is active, the machine response will be: The warning indicator on the Monitor will illuminate. The hydraulic modulation function will be disabled.

Note: The following test procedure may create other diagnostic codes. Ignore these created diagnostic codes and clear these diagnostic codes when the original diagnostic code has been corrected. Ensure that the diagnostic code of CID 2256 FMI 03 is active before performing this procedure. Test Step 1. CHECK THE ENERGIZE CIRCUIT OF THE SOLENOID FOR A SHORT TO THE +BATTERY

CIRCUIT A. Turn the key start switch and the disconnect switch to the OFF position. B. Disconnect the machine harness connector from the solenoid. Disconnect the machine harness connectors J-1 and J-2 from the ECM. C. At the machine harness ECM connector J2, measure the resistance from contact J2-25 (wire E711-OR) to all J-1 and J2 contacts that are connected to +battery. The J-1 contact is J1-58. The J2 contacts are: J2-1, J2-23, J2-47, J2-57 and J270. Expected Result: Each resistance measurement is greater than 5000 ohms. Results: OK - Each resistance measurement is greater than 5000 ohms. The machine harness is correct. Proceed to Test Step 2. NOT OK - Each resistance measurement is not greater than 5000 ohms. There is a short in the machine harness. The short is between J2-25 (wire E711-OR) and the circuit that has a low resistance measurement. Repair: Repair the machine harness or replace the machine harness. Stop. Test Step 2. CHECK IF THE DIAGNOSTIC CODE IS STILL ACTIVE A. Inspect the contacts of the harness connectors that are used in the solenoid circuit. Ensure that the contacts are secure. Clean all of the contacts in the harness connectors. B. Reconnect all harness connectors. C. Turn the disconnect switch and the key start switch to the ON position. D. Operate the machine. E. Determine if the CID 2256 FMI 03 is active. Expected Result: The CID 2256 FMI 03 is active. Results: YES - The CID 2256 FMI 03 is active. Repair: Replace the hydraulic modulation solenoid. After solenoid replacement, repeat this Test Step again. If the diagnostic code is still active, the ECM may be faulty. It is unlikely that the ECM has failed. Exit this procedure and perform this procedure again. If the cause of the diagnostic code is not found, replace the ECM. See Testing and Adjusting, "Electronic Control Module (ECM) - Replace". Stop. NO - The CID 2256 FMI 03 is not active. The problem does not exist at this time. Repair: The initial diagnostic code was probably caused by a poor electrical connection or a short at one of the harness connectors that was disconnected and reconnected. Resume normal machine operation. Stop.

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MID 039 - CID 2256 - FMI 05 SMCS - 5479-038-NP Conditions Which Generate This Code:

Illustration 1

g01146311

Schematic of the Hydraulic Modulation Solenoid

This diagnostic code is associated with the hydraulic modulation solenoid. The FMI 05 means that the ECM has determined that the current for the solenoid is below normal. An open may exist in the circuit for the solenoid. Some possible causes of this diagnostic code are listed below: The energize circuit of the solenoid is open. The return circuit of the solenoid is open. The solenoid has failed. The ECM has failed. This is unlikely.

System Response: When the CID 2256 FMI 05 diagnostic code is active, the machine response will be: The warning indicator on the Monitor will illuminate. The hydraulic modulation function will be disabled.

Note: The following test procedure may create other diagnostic codes. Ignore these created diagnostic codes and clear these diagnostic codes when the original diagnostic code has been corrected. Ensure that the diagnostic code of CID 2256 FMI

05 is active before performing this procedure. Test Step 1. CHECK THE SOLENOID A. Disconnect the solenoid with the active diagnostic code from the machine harness. B. At the machine harness connector for the solenoid, place a jumper wire from contact 1 (wire E711-OR) to contact 2 (wire H804-GN). C. Turn the disconnect switch and the key start switch to the ON position. Do not start the engine. D. Observe the status of the CID 2256 FMI 05 diagnostic code. Expected Result: The CID 2256 FMI 05 diagnostic code remains active. Results: YES - The diagnostic code remains active. The jumper wire does not affect the diagnostic code. Proceed to Test Step 2. NO - The diagnostic is no longer active. The solenoid has failed. Repair: The solenoid has failed. Repeat this Test Step "CHECK THE SOLENOID" in order to verify the solenoid failure. Replace the solenoid. Verify that the new solenoid corrects the problem. Stop. Test Step 2. CHECK THE HARNESS FOR AN OPEN A. Turn the key start switch and the disconnect switch to the OFF position. B. Disconnect the machine harness ECM connector J2 from the ECM. C. The jumper wire that was installed in the previous Test Step remains in place. D. At the machine harness connector J2 for the ECM, measure the resistance from contact J2-25 (wire E711-OR) to contact J2-13 (wire H804-GN). Expected Result: The resistance is less than 5 ohms. Results: OK - The resistance is less than 5 ohms. The machine harness is correct. Proceed to Test Step 3. NOT OK - The resistance is greater than 5000 ohms. The resistance measurement is not correct. There is an open circuit in the machine harness. A resistance measurement that is much greater than 5 ohms but less than 5000 ohms could indicate that one of the connection points in the circuit is not open, but is not a good connection. Repair: The open or possible bad connection is in wire E711-OR or in wire H804-GN of the machine harness. Repair the machine harness or replace the machine harness. Stop. Test Step 3. CHECK IF THE DIAGNOSTIC CODE REMAINS A. Inspect the contacts of the harness connectors that are used in the solenoid circuit. Ensure that the contacts are secure. Clean all of the contacts in the harness connectors. B. Reconnect all harness connectors. C. Turn the disconnect switch and the key start switch to the ON position. D.

C. D. Operate the machine. E. Check the status of the CID 2256 FMI 05. Expected Result: The CID 2256 FMI 05 is active. Results: YES - The CID 2256 FMI 05 is active. The diagnostic code has not been corrected. The ECM may have failed. Repair: It is unlikely that the ECM has failed. Exit this procedure and perform this procedure again. If the cause of the diagnostic code is not found, replace the ECM. See Testing and Adjusting, "Electronic Control Module (ECM) - Replace". Stop. NO - The CID 2256 FMI 05 is not active. The diagnostic code does not exist at this time. Repair: The initial diagnostic code was probably caused by a poor electrical connection at one of the harness connectors that was disconnected, cleaned and reconnected. Resume normal machine operation. Stop.

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MID 039 - CID 2256 - FMI 06 SMCS - 5479-038-NP Conditions Which Generate This Code:

Illustration 1

g01146311

Schematic of the Hydraulic Modulation Solenoid

This diagnostic code is associated with the hydraulic modulation solenoid The FMI 06 means that the ECM has determined that the current for the solenoid is above normal. There may be a short to ground in the solenoid circuit. Some possible causes of this diagnostic code are listed: The energize circuit of the solenoid is shorted to ground. The solenoid has failed. The ECM has failed. This is unlikely.

System Response: When the CID 2256 FMI 06 diagnostic code is active, the machine response will be: The warning indicator on the Monitor will illuminate. The hydraulic modulation function will be disabled.

Note: The following test procedure may create other diagnostic codes. Ignore these created diagnostic codes and clear these diagnostic codes when the original diagnostic code has been corrected. Ensure that the diagnostic code of CID 2256 FMI 06 is active before performing this procedure. Test Step 1. CHECK THE SOLENOID A.

A. Turn the disconnect switch and the key start switch to the ON position. Do not start the engine. B. Observe the status of the diagnostic code. C. Disconnect the solenoid with the active diagnostic code from the machine harness. Expected Result: CID 2256 FMI 06 code changes to CID 2256 FMI 05 code when the solenoid is disconnected. Results: YES - CID 2256 FMI 06 code changes to CID 2256 FMI 05 code when the solenoid is disconnected. The circuit is correct. Repair: The solenoid has failed. Repeat this test "CHECK THE SOLENOID" in order to verify the solenoid failure. Replace the solenoid. Stop. NO - CID 2256 FMI 06 remains active. Proceed to Test Step 2. Test Step 2. CHECK THE ENERGIZE CIRCUIT OF THE SOLENOID FOR A SHORT TO GROUND A. Turn the key start switch and the disconnect switch to the OFF position. B. The solenoid remains disconnected from the machine harness. C. Disconnect the machine harness ECM connectors J1 and J2 from the ECM. D. At the machine harness ECM connectors, measure the resistance from the signal contact J2-25 (wire E711-OR) to all ground contacts on connectors J1 and J2. The ground contacts on connector J2 are J2-2, J2-12, J2-13, J2-22, J2-36, J237, J2-46, J2-49, J2-52, J2-56, J2-59 and J2-69. The ground contact on connector J1 is J1-9. Expected Result: Each resistance measurement is greater than 5000 ohms. Results: OK - Each resistance measurement is greater than 5000 ohms. The machine harness is correct. Proceed to Test Step 3. NOT OK - Each resistance measurement is not greater than 5000 ohms. There is a short in the machine harness. The short is between J2-25 (wire E711-OR) and the circuit with the low resistance measurement. Repair: Repair the machine harness or replace the machine harness. Stop. Test Step 3. CHECK IF THE DIAGNOSTIC CODE REMAINS A. Inspect the contacts of the harness connectors that are used in the solenoid circuit. Ensure that the contacts are secure. Clean all of the contacts in the harness connectors. B. Reconnect all harness connectors. C. Turn the disconnect switch and the key start switch to the ON position. D. Operate the machine. E. Check the status of the CID 2256 FMI 06. Expected Result: The CID 2256 FMI 06 is active.

Results: YES - The CID 2256 FMI 06 is active. The diagnostic code has not been corrected. The ECM may have failed. Repair: It is unlikely that the ECM has failed. Exit this procedure and perform this procedure again. If the cause of the diagnostic code is not found, replace the ECM. See Testing and Adjusting, "Electronic Control Module (ECM) - Replace". Stop. NO - The CID 2256 FMI 06 is not active. The diagnostic code does not exist at this time. Repair: The initial diagnostic code was probably caused by a poor electrical connection or a short at one of the harness connectors that was disconnected and reconnected. Resume normal machine operation. Stop.

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MID 039 - CID 2447 - FMI 03 SMCS - 5479-038-MQ Conditions Which Generate This Code:

Illustration 1

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Schematic of the Travel Motor Bypass Solenoid

This diagnostic code is associated with the travel motor bypass solenoid. The FMI 03 means that the ECM has determined that the voltage of the solenoid circuit is above normal. Some possible causes of the diagnostic code are listed: The solenoid has failed. The energize circuit of the solenoid is shorted to the +battery circuit. The ECM has failed. This is unlikely.

System Response: When the CID 2447 FMI 03 diagnostic code is active, the machine response will be: The warning indicator on the Monitor will illuminate. Sudden, jolting movement may occur during machine acceleration.

Note: The following test procedure may create other diagnostic codes. Ignore these created diagnostic codes and clear these diagnostic codes when the original diagnostic code has been corrected. Ensure that the diagnostic code of CID 2447 FMI 03 is active before performing this procedure. Test Step 1. CHECK THE ENERGIZE CIRCUIT OF THE SOLENOID FOR A SHORT TO THE +BATTERY

CIRCUIT A. Turn the key start switch and the disconnect switch to the OFF position. B. Disconnect the machine harness connector from the solenoid. Disconnect the machine harness connectors J-1 and J-2 from the ECM. C. At the machine harness ECM connector J2, measure the resistance from contact J2-17 (wire J754-OR) to all J-1 and J2 contacts that are connected to +battery. The J-1 contact is J1-58. The J2 contacts are: J2-1, J2-23, J2-47, J2-57 and J270. Expected Result: Each resistance measurement is greater than 5000 ohms. Results: OK - Each resistance measurement is greater than 5000 ohms. The machine harness is correct. Proceed to Test Step 2. NOT OK - Each resistance measurement is not greater than 5000 ohms. There is a short in the machine harness. The short is between J2-17 (wire J754-OR) and the circuit that has a low resistance measurement. Repair: Repair the machine harness or replace the machine harness. Stop. Test Step 2. CHECK IF THE DIAGNOSTIC CODE IS STILL ACTIVE A. Inspect the contacts of the harness connectors that are used in the solenoid circuit. Ensure that the contacts are secure. Clean all of the contacts in the harness connectors. B. Reconnect all harness connectors. C. Turn the disconnect switch and the key start switch to the ON position. D. Operate the machine. E. Determine if the CID 2447 FMI 03 is active. Expected Result: The CID 2447 FMI 03 is active. Results: YES - The CID 2447 FMI 03 is active. Repair: Replace the hydraulic modulation solenoid. After solenoid replacement, repeat this Test Step again. If the diagnostic code is still active, the ECM may be faulty. It is unlikely that the ECM has failed. Exit this procedure and perform this procedure again. If the cause of the diagnostic code is not found, replace the ECM. See Testing and Adjusting, "Electronic Control Module (ECM) - Replace". Stop. NO - The CID 2447 FMI 03 is not active. The problem does not exist at this time. Repair: The initial diagnostic code was probably caused by a poor electrical connection or a short at one of the harness connectors that was disconnected and reconnected. Resume normal machine operation. Stop.

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MID 039 - CID 2447 - FMI 05 SMCS - 5479-038-MQ Conditions Which Generate This Code:

Illustration 1

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Schematic of the Travel Motor Bypass Solenoid

This diagnostic code is associated with the travel motor bypass solenoid. The FMI 05 means that the ECM has determined that the current for the solenoid is below normal. An open may exist in the circuit for the solenoid. Some possible causes of this diagnostic code are listed below: The energize circuit of the solenoid is open. The return circuit of the solenoid is open. The solenoid has failed. The ECM has failed. This is unlikely.

System Response: When the CID 2447 FMI 05 diagnostic code is active, the machine response will be: The warning indicator on the Monitor will illuminate. Sudden, jolting movement may occur during machine acceleration.

Note: The following test procedure may create other diagnostic codes. Ignore these created diagnostic codes and clear these diagnostic codes when the original diagnostic code has been corrected. Ensure that the diagnostic code of CID 2447 FMI

05 is active before performing this procedure. Test Step 1. CHECK THE SOLENOID A. Disconnect the solenoid with the active diagnostic code from the machine harness. B. At the machine harness connector for the solenoid, place a jumper wire from contact 1 (wire J754-OR) to contact 2 (wire H805-BR). C. Turn the disconnect switch and the key start switch to the ON position. Do not start the engine. D. Observe the status of the CID 2447 FMI 05 diagnostic code. Expected Result: The CID 2447 FMI 05 diagnostic code remains active. Results: YES - The diagnostic code remains active. The jumper wire does not affect the diagnostic code. Proceed to Test Step 2. NO - The diagnostic is no longer active. The solenoid has failed. Repair: The solenoid has failed. Repeat this Test Step "CHECK THE SOLENOID" in order to verify the solenoid failure. Replace the solenoid. Verify that the new solenoid corrects the problem. Stop. Test Step 2. CHECK THE HARNESS FOR AN OPEN A. Turn the key start switch and the disconnect switch to the OFF position. B. Disconnect the machine harness ECM connector J2 from the ECM. C. The jumper wire that was installed in the previous Test Step remains in place. D. At the machine harness connector J2 for the ECM, measure the resistance from contact J2-17 (wire J754-OR) to contact J2-12 (wire H805-BR). Expected Result: The resistance is less than 5 ohms. Results: OK - The resistance is less than 5 ohms. The machine harness is correct. Proceed to Test Step 3. NOT OK - The resistance is greater than 5000 ohms. The resistance measurement is not correct. There is an open circuit in the machine harness. A resistance measurement that is much greater than 5 ohms but less than 5000 ohms could indicate that one of the connection points in the circuit is not open, but is not a good connection. Repair: The open or possible bad connection is in wire J754-OR or in wire H805-BR of the machine harness. Repair the machine harness or replace the machine harness. Stop. Test Step 3. CHECK IF THE DIAGNOSTIC CODE REMAINS A. Inspect the contacts of the harness connectors that are used in the solenoid circuit. Ensure that the contacts are secure. Clean all of the contacts in the harness connectors. B. Reconnect all harness connectors. C. Turn the disconnect switch and the key start switch to the ON position. D.

C. D. Operate the machine. E. Check the status of the CID 2447 FMI 05. Expected Result: The CID 2447 FMI 05 is active. Results: YES - The CID 2447 FMI 05 is active. The diagnostic code has not been corrected. The ECM may have failed. Repair: It is unlikely that the ECM has failed. Exit this procedure and perform this procedure again. If the cause of the diagnostic code is not found, replace the ECM. See Testing and Adjusting, "Electronic Control Module (ECM) - Replace". Stop. NO - The CID 2447 FMI 05 is not active. The diagnostic code does not exist at this time. Repair: The initial diagnostic code was probably caused by a poor electrical connection at one of the harness connectors that was disconnected, cleaned and reconnected. Resume normal machine operation. Stop.

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MID 039 - CID 2447 - FMI 06 SMCS - 5479-038-MQ Conditions Which Generate This Code:

Illustration 1

g01146343

Schematic of the Travel Motor Bypass Solenoid

This diagnostic code is associated with the travel motor bypass solenoid The FMI 06 means that the ECM has determined that the current for the solenoid is above normal. There may be a short to ground in the solenoid circuit. Some possible causes of this diagnostic code are listed: The energize circuit of the solenoid is shorted to ground. The solenoid has failed. The ECM has failed. This is unlikely.

System Response: When the CID 2447 FMI 06 diagnostic code is active, the machine response will be: The warning indicator on the Monitor will illuminate. Sudden, jolting movement may occur during machine acceleration.

Note: The following test procedure may create other diagnostic codes. Ignore these created diagnostic codes and clear these diagnostic codes when the original diagnostic code has been corrected. Ensure that the diagnostic code of CID 2447 FMI 06 is active before performing this procedure. Test Step 1. CHECK THE SOLENOID A.

A. Turn the disconnect switch and the key start switch to the ON position. Do not start the engine. B. Observe the status of the diagnostic code. C. Disconnect the solenoid with the active diagnostic code from the machine harness. Expected Result: CID 2447 FMI 06 code changes to CID 2447 FMI 05 code when the solenoid is disconnected. Results: YES - CID 2447 FMI 06 code changes to CID 2447 FMI 05 code when the solenoid is disconnected. The circuit is correct. Repair: The solenoid has failed. Repeat this test "CHECK THE SOLENOID" in order to verify the solenoid failure. Replace the solenoid. Stop. NO - CID 2447 FMI 06 remains active. Proceed to Test Step 2. Test Step 2. CHECK THE ENERGIZE CIRCUIT OF THE SOLENOID FOR A SHORT TO GROUND A. Turn the key start switch and the disconnect switch to the OFF position. B. The solenoid remains disconnected from the machine harness. C. Disconnect the machine harness ECM connectors J1 and J2 from the ECM. D. At the machine harness ECM connectors, measure the resistance from the signal contact J2-17 (wire J754-OR) to all ground contacts on connectors J1 and J2. The ground contacts on connector J2 are J2-2, J2-12, J2-13, J2-22, J2-36, J237, J2-46, J2-49, J2-52, J2-56, J2-59 and J2-69. The ground contact on connector J1 is J1-9. Expected Result: Each resistance measurement is greater than 5000 ohms. Results: OK - Each resistance measurement is greater than 5000 ohms. The machine harness is correct. Proceed to Test Step 3. NOT OK - Each resistance measurement is not greater than 5000 ohms. There is a short in the machine harness. The short is between J2-17 (wire J754-OR) and the circuit with the low resistance measurement. Repair: Repair the machine harness or replace the machine harness. Stop. Test Step 3. CHECK IF THE DIAGNOSTIC CODE REMAINS A. Inspect the contacts of the harness connectors that are used in the solenoid circuit. Ensure that the contacts are secure. Clean all of the contacts in the harness connectors. B. Reconnect all harness connectors. C. Turn the disconnect switch and the key start switch to the ON position. D. Operate the machine. E. Check the status of the CID 2447 FMI 06. Expected Result: The CID 2447 FMI 06 is active.

Results: YES - The CID 2447 FMI 06 is active. The diagnostic code has not been corrected. The ECM may have failed. Repair: It is unlikely that the ECM has failed. Exit this procedure and perform this procedure again. If the cause of the diagnostic code is not found, replace the ECM. See Testing and Adjusting, "Electronic Control Module (ECM) - Replace". Stop. NO - The CID 2447 FMI 06 is not active. The diagnostic code does not exist at this time. Repair: The initial diagnostic code was probably caused by a poor electrical connection or a short at one of the harness connectors that was disconnected and reconnected. Resume normal machine operation. Stop.

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Engine Does Not Start SMCS - 7000-038-EK System Operation Description: This procedure directs the technician to the proper resource when the engine will not start and the machine meets one of the following conditions: The machine currently has a Machine Security System installed. The machine has just had a Machine Security System removed.

Test Step 1. Check if the machine has a Machine Security System installed. Also, check if the machine has just had a Machine Security System removed. Results: YES - The machine has a Machine Security System installed or the machine has just had a Machine Security System removed. Repair: Refer to Service Manual, RENR2462, "Machine Security System". Stop. NO - The machine does not have the Machine Security System installed or recently removed. Repair: Refer to Troubleshooting, RENR2417, "3054E and 3056E Industrial Engines and Engines for Caterpillar Built Machines". Stop.

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Engine Stalls SMCS - 7000-038-EK System Operation Description: This procedure is used when the engine stalls when placed under load. Test Step 1. CHECK FOR DIAGNOSTIC CODES. Check for a CID 0590 diagnostic code. Results: YES - A CID 0590 diagnostic code is present. Repair: A CID 0590 diagnostic code is a communications error with the Cat Data Link. The circuits of the Cat Data Link must be inspected and tested. If any problems are found, repair the wiring and check if the communication error still exists. Stop. NO - A CID 0590 diagnostic code is not present. Repair: If a CID 0590 diagnostic code is not present, it is unlikely that the machine ECM is causing the problem. Refer to Troubleshooting, RENR2417, "3054E and 3056E Industrial Engines and Engines For Caterpillar Built Machines". Stop.

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Automatic Engine Speed Control Never Activates SMCS - 1915-038; 7000-038-EK System Operation Description: This procedure is used when the function for automatic engine speed control never activates. Test Step 1. VERIFY THE OPERATION OF THE CAN DATA LINK. A. Check the monitor for the following error messages: "SOFT SWITCH PANEL COMMUNICATION ERROR" and "CAN MONITOR ERROR" Expected Result: There are no error messages that are present on the monitor. Results: YES - There are no error messages that are present on the monitor. Proceed to Test Step 2. NO - There are error messages that are present on the monitor. Repair: Troubleshoot the communication error by checking the wires of the CAN data link. Ensure that each component has power and ground. Stop. Test Step 2. CHECK THE STATUS OF THE AUTOMATIC ENGINE SPEED CONTROL SWITCH. A. Connect the Electronic Technician (ET) to the service tool connector of the machine. See Troubleshooting, "Diagnostic Capabilities" for more information. B. Select the Machine ECM from the list of available controls. C. Go to "Status Group 1" and view the status of the "AESC Enable Momentary Switch".

Illustration 1

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D. Press the switch for the automatic engine speed (4) on the soft switch panel.

Expected Result: The LED indicator above the switch should illuminate. On the Electronic Technician, the "AESC Enable Momentary Switch" should show "Depressed". Results: OK - The LED indicator above the switch illuminates. On the Electronic Technician, the "AESC Enable Momentary Switch" shows "Depressed". Proceed to Test Step 3. NOT OK - The LED indicator above the switch does not illuminate. On the Electronic Technician, the "AESC Enable Momentary Switch" does not show "Depressed". Repair: There is a problem with the soft switch panel. Check the other functions that are controlled by the soft switch panel. Replace the soft switch panel if the panel has failed. Stop. Test Step 3. CHECK THE PARAMETER FOR THE OPERATING THRESHOLD.

Illustration 2

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A. On the ET, select the button (1) for configuring. B. Note the value for the "Main Pump Swash Plate Angle Machine Operating Threshold". C. Go to "Status Group 3" on the ET. While the engine is running ensure that no implements are being used. When the hydraulics are at rest, note the value of the "Main Pump Swash Plate Angle". D. Compare the value for the operating threshold to the angle of the swashplate.

Expected Result: The value for the operating threshold is at least 0.8 above the angle of the swashplate. Results: OK - The value for the operating threshold is at least 0.8 above the angle of the swashplate. Exit this procedure and check the function again. Stop. NOT OK - The value for the operating threshold is less than the angle of the swashplate. Repair: Change the operating threshold to a value that is at least 0.8 above the angle of the swashplate. Stop.

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Engine Speed Does Not Change SMCS - 1915-038; 7000-038-EK System Operation Description: This procedure is used when the engine speed does not change in response to commands from the operator. Test Step 1. CHANGE THE SETTING OF THE THROTTLE. Change the setting of the throttle to 10. Expected Result: The reading on the monitor changes to 10. Results: OK - The reading on the monitor changes to 10. Proceed to Test Step 2. NOT OK - The reading on the monitor does not change. Proceed to Test Step 3. Test Step 2. CHECK FOR DIAGNOSTIC CODES. Check for a CID 0590 diagnostic code. Results: YES - A CID 0590 diagnostic code is present. Repair: A CID 0590 diagnostic code is a communications error with the Cat Data Link. The circuits of the Cat Data Link must be inspected and tested. If any problems are found, repair the wiring and check if the communication error still exists. Stop. NO - A CID 0590 diagnostic code is not present. Proceed to Test Step 6. Test Step 3. CHECK THE THROTTLE POSITION SWITCH (DIAL). Perform the following procedure: Troubleshooting, RENR2417, "3054E and 3056E Industrial Engines and Engines for Caterpillar Built Machines", "Throttle Switch Circuit - Test". Expected Result: The procedure has corrected the problem. Results: YES - The procedure has corrected the problem. Stop. NO - The procedure has not corrected the problem. Repair: Perform the following procedure: Troubleshooting, RENR2417, "3054E and 3056E Industrial Engines and Engines for Caterpillar Built Machines", "Low Power/Poor or No Response to Throttle". Stop. Test Step 4. CHECK THE STATUS OF AUTOMATIC ENGINE SPEED CONTROL. With the throttle postion at 10, move the joystick for the boom. Connect the Electronic Technician to the machine and check the status of the automatic engine speed control. Expected Result: The automatic engine speed control is OFF. Results: YES - The automatic engine speed control is OFF.

Repair: Perform the following procedure: Troubleshooting, RENR2417, "3054E and 3056E Industrial Engines and Engines for Caterpillar Built Machines", "Low Power/Poor or No Response to Throttle". Stop. NO - The automatic engine speed control is ON Proceed to Test Step 5. Test Step 5. CHECK FOR A DIAGNOSTIC CODE. Check the monitor for a CID 0736 diagnostic code. Expected Result: There is a CID 0736 diagnostic code. Results: YES - There is a CID 0736 diagnostic code. Repair: Perform the appropriate CID 0736 diagnostic code procedure. Stop. NO - There is NO CID 0736 diagnostic code. Proceed to Test Step 6. Test Step 6. CHECK THE WIRING HARNESS. Check the wire H783-GN from contact J2-32 at the machine ECM to contact 30 of the engine ECM. Expected Result: The wiring harness is normal. Results: OK - The wiring harness is normal. Repair: There may be a problem with the engine ECM or the machine ECM. Contact the dealership's Technical Communicator for possible consultation with Caterpillar. This consultation may greatly reduce repair time. Stop. NOT OK - The wiring harness is damaged. Repair: Repair the wiring harness or replace the wiring harness. Stop.

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Engine Speed Increase Is Delayed During Hydraulic Demand SMCS - 1915-038; 7000-038-EK System Operation Description: When the function for automatic engine speed control is active, the engine is at low idle when the hydraulics are inactive. When the operator moves a control lever, the idle should quickly rise to the setting of the engine speed dial. This procedure is used when the rise in the engine speed does not occur quickly. Test Step 1. CHECK THE ANGLE OF THE MAIN PUMP SWASHPLATE. A. Connect the Electronic Technician (ET) to the service tool connector of the machine. See Troubleshooting, "Diagnostic Capabilities" for more information. B. Select the Machine ECM from the list of available controls. C. Go to "Status Group 3" on the ET. While the engine is running ensure that no implements are being used. When the hydraulics are at rest, note the value of the "Main Pump Swash Plate Angle".

Illustration 1

D. On the ET, select the button (1) for configuring. E. Note the value for the "Main Pump Swash Plate Angle Machine Operating Threshold". F.

g00991370

E. F. Compare the value for the operating threshold to the angle of the swashplate when the machine is at rest. Expected Result: The value for the operating threshold is less than 0.8 above the swashplate angle. Results: OK - The value for the operating threshold is less than 0.8 above the swashplate angle. Repair: The values are correct. The problem may be related to the engine. See the service manual for the engine. Stop. NOT OK - The value for the operating threshold is over 0.8 above the swashplate angle. Repair: Change the value for the operating threshold. See Testing and Adjusting, "Machine Operating Threshold Parameter - Adjust". Stop.

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Hydraulic Response Is Poor SMCS - 7000-038-EK System Operation Description: This procedure is used when the hydraulic response of the machine is poor. Test Step 1. CHECK FOR DIAGNOSTIC CODES. Check for a CID 0590 diagnostic code. Results: YES - A CID 0590 diagnostic code is present. Repair: A CID 0590 diagnostic code is a communications error with the Cat Data Link. The circuits of the Cat Data Link must be inspected and tested. If any problems are found, repair the wiring and check if the communication error still exists. Stop. NO - A CID 0590 diagnostic code is not present. Proceed to Test Step 2. Test Step 2. SELECT THE POWER MODE.

Illustration 1

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Press the power mode switch (5) until the second indicator light turns on. Expected Result: The machine enters the power mode and the second indicator light is ON. Results: OK - The machine enters the power mode and the second indicator light is ON. Proceed to Test Step 3. NOT OK - The machine does not enter the power mode. The first indicator light is on and the second indicator light is flashing. Repair: Refer to Troubleshooting, "Machine Only Operates in Economy Mode". Stop. Test Step 3. CHECK THE HYDRAULIC RESPONSE. Check the hydraulic response of the machine. Expected Result:

The hydraulic response of the machine is acceptable. Results: YES - The hydraulic response of the machine is acceptable. Stop. NO - The hydraulic response of the machine still poor. Proceed to Test Step 4. Test Step 4. ACTIVATE THE TRAVEL MODE. Press the travel pedal in order to activate the travel mode. Expected Result: The machine enters the travel mode and the hydraulic response is acceptable. Results: YES - The machine enters the travel mode and the hydraulic response is acceptable. Stop. MODE DOES NOT CHANGE - The machine does not enter the travel mode. Repair: The machine is not changing modes properly. Proceed to Troubleshooting, "Machine Only Operates in Power Mode". Stop. TRAVEL MODE ENTERED, RESPONSE STILL POOR - The machine enters the travel mode but the hydraulic response in still poor. Repair: The problem is not related to the power modes of the machine. The problem is related to the hydraulics. Refer to the proper manual: Testing and Adjusting, RENR5567, "M316C Excavators Hyraulic System" Testing and Adjusting, RENR5565, "M318C Excavators Hyraulic System" Testing and Adjusting, RENR7014, "M322C Excavators Hyraulic System" Stop.

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Machine Only Operates in Economy Mode SMCS - 7000-038-EK System Operation Description: This procedure is used when the machine is stuck in the economy mode, or the machine unexpectedly reverts to the economy mode. Test Step 1. ATTEMPT TO ENGAGE THE POWER MODE.

Illustration 1

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Press the power mode switch (5) until the second indicator light turns on. Expected Result: The LED for the power mode turns on and does not flash. Results: OK - The LED for the power mode turns on and does not flash. Proceed to Test Step 2. NOT OK - The LED for the power mode flashes and the LED for the ecomony mode is ON. Proceed to Test Step 4. Test Step 2. CHECK THAT THE POWER MODE IS ACTIVE. Check if the machine has full power. Results: YES - The machine has full power. The problem is not present. Resume normal operation. Stop. NO - The machine does not have full power. Proceed to Test Step 3. Test Step 3. CHECK FOR DIAGNOSTIC CODES. Check for a CID 1629 FMI 05 or CID 1629 FMI 06 diagnostic code. Results: YES - A CID 1629 FMI 05 or CID 1629 FMI 06 diagnostic code is present. Repair: A CID 1629 FMI 05 or CID 1629 FMI 06 diagnostic code is a short to +battery on the powershift pressure solenoid for the main pump. Proceed to Troubleshooting, "CID1629 FMI 05" or proceed to Troubleshooting, "CID1629 FMI 06". Stop.

NO - A CID 1629 FMI 05 or CID 1629 FMI 06 diagnostic code is not present. Repair: The machine ECM is not causing the problem. Refer to Troubleshooting, RENR2417, "3054E and 3056E Industrial Engines and Engines For Caterpillar Built Machines". Stop. Test Step 4. CHECK MACHINE CONDITIONS. Connect the Electronic Technician to the machine. Excessive values from certain sensors will cause the machine to stay in the economy mode. Check the following items: The coolant temperature must not be above 107 °C (224 °F). This will record an event. The hydraulic temperature must not be too high. This will record an event. The hydraulic temperature must not be too low. This will not record an event. The air filter must not be restricted. This will record an event.

Expected Result: There are no adverse machine conditions present. Results: OK - There are no adverse machine conditions present. Repair: The ECM may have failed. This is unlikely. Exit this procedure and perform the entire procedure again. If the problem remains, contact the dealership's Technical Communicator for possible consultation with Caterpillar. This consultaton may greatly reduce repair time. Stop. NOT OK - Adverse machine conditions are present. Repair: Correct the condition that is causing the machine to default to the economy mode. Stop.

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Machine Only Operates in Power Mode SMCS - 7000-038-EK System Operation Description: This procedure is used when the machine only operates in the power mode. Test Step 1. CHECK FOR COMMUNICATIONS ERRORS. Check the monitor for a communication error. Communications errors include the following items: Machine Controller Communication Error Engine Controller Communication Error Soft Switch Panel Communication Error Monitor Error CAN Monitor Error

Expected Result: There are no communications errors present. Results: OK - There are no communication errors present. Proceed to Test Step 2 NOT OK - A communication error is showing on the monitor. Repair: All communications errors require inspection of the circuits of the CAN data link. If any problems are found, repair the wiring and check if the communication error still exists. Stop. Test Step 2. CHECK FOR DIAGNOSTIC CODES. Check for a CID 0590 diagnostic code. Results: YES - A CID 0590 diagnostic code is present. Repair: A CID 0590 diagnostic code is a communications error with the Cat Data Link. The circuits of the Cat Data Link must be inspected and tested. If any problems are found, repair the wiring and check if the communication error still exists. Stop. NO - A CID 0590 diagnostic code is not present. Proceed to Test Step 3 Test Step 3. CHECK FOR DIAGNOSTIC CODES. Check for a CID 1629 FMI 03 diagnostic code. Results: YES - A CID 1629 FMI 03 diagnostic code is present. Repair: A CID 1629 FMI 03 diagnostic code is a short to +battery on the powershift pressure solenoid for the main pump. Proceed to Troubleshooting, "CID1629 FMI 03". Stop.

NO - A CID 1629 FMI 03 diagnostic code is not present. Proceed to Test Step 4. Test Step 4. ATTEMPT TO ENGAGE THE ECONOMY MODE.

Illustration 1

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Press the power mode switch (5) until the first indicator light turns on. Expected Result: The LED for the economy mode turns on and does not flash. Results: OK - The LED for the economy mode turns on and does not flash. Repair: The power modes may be programmed incorrectly. Refer to the following manuals in order to check the programming of the power modes: Testing and Adjusting, RENR5567, "M316C Excavators Hyraulic System" Testing and Adjusting, RENR5565, "M318C Excavators Hyraulic System" Testing and Adjusting, RENR7014, "M322C Excavators Hyraulic System" Stop. NOT OK - The LED for the economy mode flashes. Repair: The ECM may have failed. This is unlikely. Exit this procedure and perform the entire procedure again. If the problem remains, contact the dealership's Technical Communicator for possible consultation with Caterpillar. This consultaton may greatly reduce repair time. Stop.

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Machine Only Operates in Travel Mode SMCS - 7000-038-EK System Operation Description: This procedure is used when the machine is stuck in the travel mode, or the machine unexpectedly reverts to the travel mode. Test Step 1. ATTEMPT TO ENGAGE THE ECONOMY MODE.

Illustration 1

g00914074

Press the power mode switch (5) until the first indicator light turns on. Expected Result: The LED for the economy mode turns on and does not flash. Results: OK - The LED for the economy mode turns on and does not flash. Proceed to Test Step 2. NOT OK - The LED for the economy mode flashes and the LED for the travel mode is ON. Proceed to Test Step 3. Test Step 2. VERIFY THE OPERATION OF THE CAN DATA LINK. A. Check the monitor for the following error messages: "SOFT SWITCH PANEL COMMUNICATION ERROR" and "CAN MONITOR ERROR". Expected Result: There are no error messages that are present on the monitor. Results: YES - There are no error messages that are present on the monitor. Repair: The ECM may have failed. This is unlikely. Exit this procedure and perform the entire procedure again. If the problem remains, contact the dealership's Technical Communicator for possible consultation with Caterpillar. This consultaton may greatly reduce repair time. Stop. NO - There are error messages that are present on the monitor. Repair: Troubleshoot the communication error by checking the wires of the CAN data link for all possible failures. Ensure that each component has power and ground.

Stop. Test Step 3. CHECK THE TRAVEL PEDAL SWITCH. A. Connect the Electronic Technician to the machine. B. Do NOT press the travel pedal, and check the status of the forward travel pedal switch and check the status of the reverse trave pedal switch. Expected Result: When the travel pedal is not pressed, the status of both switches is OFF. Results: OK - When the travel pedal is not pressed, the status of both switches is OFF. Proceed to Test Step 4. NOT OK - When the travel pedal is not pressed, the status of one of the switches is ON. Repair: There is a problem with one of the travel pedal switches. Troubleshoot the switch and replace the switch if necessary. Stop. Test Step 4. CHECK FOR INSTALLATION OF A GENERATOR. Check if the machine has a generator installed. When an optional generator is ON, the machine automatically enters the travel mode. The generator must be installed, and configured as the active tool. Expected Result: A generator is installed and is ON. Results: YES - A generator is installed and is ON. The normal operation of the machine will activate the travel mode. Stop. NO - A generator is NOT installed. Repair: The ECM may have failed. This is unlikely. Exit this procedure and perform the entire procedure again. If the problem remains, contact the dealership's Technical Communicator for possible consultation with Caterpillar. This consultaton may greatly reduce repair time. Stop.