sera2020 ‘960F Wel Loader 87.100001-UP (MACHINE) POWERED BY 3116 Engine{SEBP2249- $3) - Documentation Finning. G Service Information System Previous Screen « Product: WHEEL LOADER Model: 960F WHEEL LOADER 92100166 Configuration: 960 Wnes! Loader 92100001-UP (MACHINE) POWERED BY 3116 Engine Testing and Adjusting ELECTRONIC TRANSMISSION CONTROL SYSTEM Media Number =SENRS922-02 Publication Date -03/10/1994 Testing And Adjusting Introduction TROUBLESHOOTING QUICK REFERENCE Go to the section Faults Detected By The Control for faults related to: Electrical System Voltage - CID 168 Procedure _ Engine Speed Sensor - CIO 190 Procedure CAT Data Link CID 248 Proseawe Ride Control Solenoid - CID 362 Procedure Auto/Manual Transmission Switch - CIO 368 Procedure Ar Inlet Heater Relay - CID 617 Procedure Downshift Switch - CIO 621 Procedure Park Brake Switch - GID 627 Procedure Solenoid 1 (Reverse) - GID 621 Procedure Solenoid 2 (Forwarch- CiD 692 Procedure Solenoid 3 (Gear 4) - CID 633 Procedure Solenoid 4 (Gear 3)- CID 634 Procedure Solenoid 5 (Gear 2)- CID 635 Provedure Solenoid 6 (Gear 1)- CID 636 Provecure Harnoss Gade | - CiD 650 Procedure 1 Shift Hande And Neutralizer Switch - CID 668 Procedure 10 671 Procedure Ride Contral Switch CID 689 Procedure Service Identification Code - CID 685 Procedure Options Identification Gode - CID 687 Procedure Dual Horsepower Solencid - CID 86 Procedure Go to the section Faults Not Detected By The Control for faults related Biank Control Display Area No Automatic Shifting, no faults shown ‘Harness cade and machine code are similar terms used to describe the particuar machine that the contral is instabed on Harness code is the status o! the three harness code inputs. htps127.00.tisiswebisisuebtechdcctechdoc_print page jsp?returu Date Updated -11/02/2009 'SENR59220002 -Isiswebsisuebimediascarchimediaheaderiniokameset|spScallecpage=isiswe.... 129‘12000 280 Wel Loader 92J00001-UP (MACHINE) POWERED BY 3116 Engine(SEBP2049- 58) -Docureriaton ‘Troubleshooting the electronic transmission control system requires additional information fom the machine Service ‘Manual, The Electronic System Schematic and the Operation & Maintenance Manual are required support materia. Asa guide, a simplified electronic transmission control schematic is at the end of this manual. For a complete schemutic, see the Electrical System Schematic in the machine Service Manual If wire insulation is punctured during troubleshooting, repair after probing. Seal the punctures with 81-0065 Adhesive. Cover the adhesive with two layers of 1P-0810 Tape. Remove the harness connector ftom the control using the single screw in the center of the connector. When the troubleshooting procedure instructs to REPAIR THE HARNESS, use the Electrical System Schematic in the machine Service Manual to trace the circuit. Perform continuity checks at connectors to locate harness failures. At component connectors, always check the ground circuit. Less than five ohms of resistance is required between the connector ground contacts and frame ground. Excessive ground resistance, greater than five ohms, can cause incorrect diagnosing of problems. During troubleshooting, inspect all component and hamess connections before any component is replaced. If these connections are not clean and tight they can cause electrical problems, either permanent or intermittent (come and g0). Make sure the connections are tight before other tests are made. GRAPHIC NOT AVAILABLE Caterpillar Digital Multimeter Use the 6V-7070 Digital Multimeter or equivalent for making continuity checks, resistance measurements or voltage ‘measurements, The optional 81-3224 Needle Tip Group for the 6V-7070, is useful during troubleshooting. For instruction on use of the 6V-7070, see Special Instruction SEHS7734. NOTE: Except for harness tests, continuity testers (such as 8T-0500), or voltage testers (such as SP-7277) are not recommended for use on present-day Caterpillar electrical circuits. Troubleshooting Using The Display On The Control (If Equipped) The service connector provides access to the service and clear inputs. Connector contact 1 is the service input and contact 2 is the clear input. The service connector is part of the cab harness and is located near the control. For a more exact service connector location and connector requirements, see the Ekctrical System Schematic in the ‘machine Service Manual, Various diagnostic functions require the grounding and/or opening of the service and clear contacts at the service connector. During troubleshooting, it is necessary for the service person to make the proper electrical connections hp:127.00.tsiswesiswebtechocechtor, print page jepeturur=iisuebsiuebnediasearctvneisheadernofanesetpScalecpage=siswe... 2291792000 S60F Wea! Loner 82 J0001-UP (MACHINE) POWERED BY 3116 Ergin SEBP2249- 3) - Oocumertaten between the contacts of the service code connector. These electrical connections may be made with two jumpers. Also see the topic Service Box in the Testing And Adjusting section. Changing Modes ACTIVATION OF DISPLAY OPERATIONS {Quick Reference) _Display Operation | Service Contact "| Clear Contact * Ground i Ground Open Open Service Made (Mode 1): To Scroll Ground Open To Hold Open? Open To Clear 3 1 Of the service connector. 2 Open when the desired information is shown during scrolling. 34 fautt is cleared only while it is onhold. A fault that is currently present cannot be cleared Ground fo) ‘C487 22P3 1 Control Display Aree (1) Readout. The control has three display modes. The different modes are identified by the mode number which is shown on readout (1). The three display modes and the corresponding mode numbers are: Normal Mode - "- 0 -." is shown on mode readout (1). Service Mode - "- 1 -."is shown on mode readout (1). Test Mode - "- " js shown on mode readout (1). Procedure htps127.00.tisiswebisisuebtechdcctechdoc_print page jsp?returu jeweblsionebtmediasearchimedisheaderinfokameset/spBcalledpagesisswe... 929sera2020 ‘960F Wel Loader 87.100001-UP (MACHINE) POWERED BY 3116 Engine{SEBP2249- $3) - Documentation 1, Tum key switch ON. Wait for the Self Test to finish; approximately seven seconds. 2. At the same time, ground the service and clear contacts of'the service connector or actuate the mode switch on ‘the service box. This causes the mode numbers ("- 0 -." through "- 2 -.") to scroll on mode readout (1). NOTE: Each time *- 0 -."is shown, the scrolling stops. The service and clear contacts must be opened fiom ground, then closed to ground, to scroll the modes again 3. When the desired mode number is shown on mode readout (1), remove ground from (open) the service and clear contacts. Service Tool ie 3 ete “~~ Lg ol i ear D250 91-6665 Service Tool (1) Adapter cable, (2) Mode select switch. (3) Clear switehs, (4) Seroll switeh, The 9U-6665 Service Tool is helpfil for the service person to make the proper electrical connections at the service connector during troubleshooting, The service tool and wiring adapter is shown in the Service Tool illstration. Adapter cable (1) has two connectors that are wited in parallel so that the service tool is usable on the different types of machine hamesses. Actuating mode switch (2) scrolls through the three display modes, Actuating scroll switch (4) scrolls the display with the control in the service or test mode. Actuating clear switch (3) clears the fault being continuously displayed in the service mode. To use the service tool, refer to the Tool Operating Manual, Form No. NEHS0586, Troubleshooting Using The Electronic Control Analyzer Programmer (ECAP) htps127.00.tisiswebisisuebtechdcctechdoc_print page jsp?returu jenebisinebtmediasearchinedisheaderintokameset/spBcalledpagesisiswe.. 429sera2020 ‘960F Wel Loader 87.100001-UP (MACHINE) POWERED BY 3116 Engine{SEBP2249- $3) - Documentation TRANSMISSION © ——> CONTROL 2 3 03465 ECAP Connections (1) Service connector. (2) 7X-1570 Cable, (3) 7%-1700 Communication Adapter (with NEXG#S23 Communication Adapter Software installed) (4): TX-1851 Cable for 8T-8697-A ECAP later or 7X-1420 Cable for 8T-8697 ECAP catlir, (5): S7-8697-A ECAP later (with NEXG4521 Machine Functions Dual SPM installed) or 81-8697 BCAP eatlier (with NEXG4521 Machine Functions Dual SPM installed), Optional (not shown): 8C-9995 Mounting Bracket and 7X-1703 Plate Group. The ECAP service tool is not needed to determine or clear system fauits, but it makes the tasks easier and faster. The ECAP can also display the status of certain system parameters. This feature along with the ability to display system faut history information, make the ECAP a usefil troubleshooting tool The ECAP connects to the service connector (if equipped) located next to the hanes code comector in the cab. To use the ECAP service tool, see SEHS9343 Tool Operating Manual. The Tool Operating Manual contains all the instructions and information needed to use the ECAP to troubleshoot the electronic transmission control system. ‘Afler determining the system fauits with the ECAP, see the topic Faults Detected By The Control in the Testing And Adjusting section. Troubleshooting Using The Caterpillar Monitoring System Or The Computerized Monitoring System (CMS) Transmission control diagnostic information can be shown on the monitoring system display. When using the monitoring system for troubleshooting, all faults associated with the transmission control have a MID of 81. For more information about use of the Caterpillar Monitoring System, see service manual SENR6717. For more information about use of the Computerized Monitoring System (CMS), see service manual SENRS247. htps127 00. Isisuebysisuebtechdcctechdoe_print page jsp?returur=isiswebisiswebymediasearchinecisheaderinfaameset/spBcalledpagesisiswe... 92sera2020 ‘960F Wel Loader 87.100001-UP (MACHINE) POWERED BY 3116 Engine{SEBP2249- $3) - Documentation Faults Detected By The Control CID No. / FMI No. DETECTED FAULTS For troubloshooting, see the procedure with the same Clb And CID 168 - Electrical System: FM FOS, System voltage above normal Mi Fos ‘System vollage below normal CID 190 - Engine Speed Sensor: Fi FOB T ee ‘Signal not corect. iD 362 - Ride Control Solenoid: Fai FOS Short to +battery. Fal FOS ‘Oper orc FFs Ton ogond L Fea 12 Internat matfunction GO 368 - Avo]Menel Sach ial Fo? [ Signal not corect CIO 617 - Air Inlet Heater Relay: Short to sbatiery. Fal FOS ‘Open cireut FMI FOS ‘Short to ground, FMIFI2 Internal malfunction. CID 627 - Park Brake Switch: Signal net conect, ‘Signal not correct htps127.00.tisisuebisiswebtechdoctechoe_pi Feat FOZ C1 631- Solenoid 1 (eoverse FMI FOS Short to-rbatery FM) FOS Open arcut FM £06 Short to ground | FMF Internal matfuretion = Isisuebisiswebimediasearchimecisheaderinforareset spcallecpage=isisne. int_page sp?returur assera2020 ‘960F Wel Loader 87.100001-UP (MACHINE) POWERED BY 3116 Engine{SEBP2249- $3) - Documentation ~OETECTED FAULTS 7 For woublehaating sete proves wth he sere ‘ib and Fan. 22 - Soleneld 7 (ora 7 F053 Opn ores 7 Fur) ena mation 0 6m - SuediaT apeed H Fu 8 rg seater Fanos ‘Ope sro i 5 Shot gourd FWLeTe ners malt GID EB Soon a FUG hero tatery Taras (sen eat FA FO8 ‘Shon te HONE BO 6B Sona ara 1 he itera ation {io eat -suenoid (apeed 1 | FFD Gaara Farros ‘pe out wo Shon gov | -ranommion Seed tos aro: ‘spranat eniet i bo - ee Cones Sen (00645 - Sevie ienvirabon Gade {20 627 - Options Henvizabon ose: PEC! Pi Fos ‘Sra “earn gpa eto: FOE ‘Son ralareet When the control detects a fault while in normal mode, the fault is shown on the display, ifequipped, or the operator monitor. Service mode shows the fault and is used to clear the fauit fom the control memory. For detailed information, see Service Mode (Mode 1) under the topic Diagnostic Operation located in the Systems Operation section. htps127.00. isisuebisiswebtechdcctechdoc_print page sp?returur Isisuebisiswebimediasearchimecisheaderinforareset spBcallecpage=isisne. 728167072020 ‘960F Whe Loader §7.100001-UP (MACHINE) POWERED BY 3116 Engine{SEBP2249- 53) - Documentation [73 [pa ake Sw p80) | Opera rat | 1} ran re SW Or Serena bout | Taerinen Some Sere not Spears out | [BE [oso cono Lome nr ‘pues rt eases wh en ey Initial Troubleshooting Procedure For A Control With A Display 3 cagr22P2 htps127.00.tisisuebysisuebtechdcctechdoc_print page jsp?returur=isiswebisiswebymediasearchimecisheaderinfaameset/spBcalledpagesisiswe.. 829sera2020 ‘960F Wel Loader 87.100001-UP (MACHINE) POWERED BY 3116 Engine{SEBP2249- $3) - Documentation Control Display Area (1) Power indicator. 2) Readout (component identifier and failure more identifier). (3) Service mode indicator (4) Fault present indicator, Use the following procedure when a fault is detected, When a fault is detected, the readout will show the faut 1, Enter service mode (mode 1) 2. A single fault is shown and is on-hold at this time. When no fault has occurred, the display shows " 3. To see all detected faults, scroll the faults. To do so, ground the service contact of the service connector. 4, Place the desired fault on-hold (stop the scrolling). To do so, remove ground fiom the service contact of the service connector when the desired fault is shown. 5. Observe fault present indicator (4): + If fault present indicator (4) is ON, the fault shown is currently present. * If fait present indicator (4) is OFF, the fault shown is not present at ths time. The fault has occurred and then went away, sometime in the past (intermittent) 6. To troubleshoot the fault, go to the procedure with that CID and FMI. 7. After a fault is corrected, clear the fault. To do so, momentarily ground the clear contact of the service connector ‘while the fault is on-hold. After clearing, the display advances to the next fault if there is one. 8. Repeat Steps 2 through 8 for any remaining fiults. Return to normal mode when finished Initial Troubleshooting Procedure For A Control Without A Display Ifthe machine is equipped with the Caterpillar Monitoring System or the Computerized Monitoring System (CMS) a detected transmission control fait will be displayed in the readout area. Use the following procedure when a fault is detected. When a faul is detected, the service code indicator shows "SERV CODE" while in normal mode. NOTE: For more information about use of the Caterpillar Monitoring System, see service manual SENR6717. For more information about use of the Computerized Monitoring System (CMS), see service manual SENRS247. 1. Enter service mode. NOTE: Diagnostic Scrolling Mode may be entered to see the detected faults, but The faults can be more easily diagnosed using Service Mode. Service Mode allows faults to be placed on-hold for fither investigation and to be cleared when the problem has been fixed. 2. A single fault is shown and is on-hold at this time. The display toggles between the MID, the CID, and the FMI. ‘When no faut is available; the MID shows "---", The display does not toggle to show the CID, FMI information, 3. To see all detected faults, scroll the faults. To do so, ground the service contact of the service connector, The display momentarily shows the MID then CID and FMI for each fault. The MID shows "End" after the last fault has been shown. 4, Place the desired fault on-hold (stop the scrolling). To do so, remove ground from the service contact of the service connector when the desired fault is shown, 5, Make sure that the MID is "81", 6. Observe the fault present indicator: htps127.00.tisiswebisisuebtechdcctechdoc_print page jsp?returu jeweblsionebtmedasearchinediaheaderinfokamesetspBcalledpagesisiswe... 92‘12000 280 Wel Loader 92J00001-UP (MACHINE) POWERED BY 3116 Engine(SEBP2049- 58) -Docureriaton * Ifthe fauit present indicator shows "SERV CODE, then the fault shown is currently present. * Ifthe faut present indicator is OFF, then the fault shown is not present at ths time, The fut has occurred and then went away, sometime in the past (intermittent) 7. To troubleshoot the fault, go to the procedure with the same CID and FMI. 8. Affer a fault is comected or itis no longer needed, clear the fault. To do so, momentarily ground the clear contact of the service connector while the fault is on-hold. After clearing, the display advances to the next available fault. 9. Repeat Steps 2 through 8 for the remaining fuults. Retumn to normal mode when finished, Troubleshooting Procedures: Go to the procedure which corresponds to the CID and FMI shown on the control display. Use the operator monitor to show the CID and FMI if the control has no display. NOTE: Repair wiring after probing. Seal the punctures with 8T-0065 Adhesive. Cover the adhesive with two layers of 1P-0810 Tape. CID 168 Procedure (Electrical System Voltage) The diagnostic circuit in the control identifies a system voltage that is either below 21.3 DCV or above 32.5 DCV. Ensure that the fault is being displayed. FMI F03 This fault should only be displayed with the fault present indicator ON and the engine running. If this occurs, the charging system is charging at an excessive voltage. Check the charging system, See Starting And Charging System module, SENR2947 in the machine Service Manual. Ifthis fault is displayed, with the fault present indicator ON, the engine stopped and no battery charger connected, replace the control, See the topic Control Replacement in the Testing And Adjusting section. FMLF04 1. CHECK BATTERY VOLTAGE - Start the engine and run at high idle for several minutes. Measure the battery voltage at the battery posts. * Voltage is at or above 21.3 DCYV; battery voltage is correct. Go to Step 2. * Voltage is below 21.3 DCV; the charging system is not correct. Check the charging system. See Starting, ‘And Charging System module, SENR2947 in the machine Service Manual. 2. CHECK SYSTEM VOLTAGE AT CONTROL - Using sharp meter test leads, puncture the wire insulation near the control connector. Measure the system voltage between wires 164-WH and 202-BK at contacts 1 and 2 of the hhamess connector, The engine must be running at high idle, * Voltage is below 21.3 DCV; hamess is not correct. Repair or replace the hamess. * Voltage is at or above 21.3 DCV; system voltage is correct. Check to make sure CID 168 and FMI F04 are still displayed and that the fault present indicator is ON. Disconnect the control hamess connector and inspect contacts 1 and 2. Connect hamess connector to the control. If faut still exists, with the fault present indicator ON, replace the control. See the topic Control Replacement in the Testing And Adjusting section. htps127.00.tisiswebisisuebtechdcctechdoc_print page jsp?returu jenebisionebimedasearchimedisheaderinfokamese/spBcalledpagesisisw... 1023sera2020 ‘960F Wel Loader 87.100001-UP (MACHINE) POWERED BY 3116 Engine{SEBP2249- $3) - Documentation CID 190 Procedure (Engine Speed Sensor) Service Notes: Ensure that fault being analyzed is on-hold. Ensure that the fault present indicator is ON. The engine RPM input is a fiequency type sensor input. The engine speed signal is at contact 6 of the control connector, FMI F08 1. CHECK SENSOR RESISTANCE - Disconnect the machine hamess from the sensor. At the sensor connector, measure the resistance between the two contacts, * Resistance is NOT between 100 and 500 Ohms; the speed sensor is faulty, Replace the sensor. Adjust the speed sensor properly when installing it. See Speed Sensor Adjustment, Clear the fault code. * Resistance is between 100 and 500 Ohms; the speed sensor resistance is correct. Go to Step 2. 2. CHECK SENSOR VOLTAGE - Reconnect the sensor to the machine harness. Disconnect the machine harness from the control Start the engine and run at low idle. At the machine harness connector, for the control, measure the voltage (ACV) between contact 2 (ground) and contact 6. * Voltage is greater than 3.0 ACV; the speed sensor voltage is correct. Replace the control; see Control Replacement. * Vollage is less than 3.0 ACV; the speed sensor voltage is NOT correct. Go to Step 3. 3. CHECK SENSOR - Remove the sensor and check for foreign material on sensor tip. Install the speed sensor and adjust correctly, see the topic Speed Sensor Adjustment in the Testing And Adjusting section. Check the sensor ‘voltage in the same manner as in Step 2. * Voltage remains less than 3.0 ACV; there is a defect. Go to Step 4. * Voltage is now greater than 3.0 ACV. Problem is NOT present; adjustment of the speed sensor corrected. the problem. Clear the fault code. 4, CHECK HARNESS - Connect the sensor to the machine hamess. The control remains disconnected from the machine hamess. At the machine hamess connector, for the control, measure the resistance between contact 2 (ground) and contact 6 * Resistance is between 100 and 500 Olms; the machine hamess resistance is correct. Replace the sensor. Adjust the speed sensor properly when instaling it. See the topic Speed Sensor Adjustment in the Testing ‘And Adjusting section. Clear the fault code. * Resistance is NOT between 100 and 500 Ohms; the machine hamess is shorted or open. Repair or replace the harness. Clear the fault code, CID 248 Procedure (Data Link) FMI F02 This fault is recorded when the control does not receive expected information from the data link (wire 944-OR or 945-BR). Service Notes: Ensure that the CID 248/FMI FO2 fault is on-hold and that the fault present indicator is ON. 1. INSPECT HARNESS CONNECTORS - Inspect the machine hamess comnections related to the data link. Make sure that connectors are clean and tight. Ifnecessary, repair or replace the machine hamess. Check to see if htps127.00.tisiswebisisuebtechdcctechdoc_print page jsp?returu jenebisionebtmedasearchinedisheaderintokameset/spBcalledpagesisiswe.... 129sera2020 ‘960F Wel Loader 87.100001-UP (MACHINE) POWERED BY 3116 Engine{SEBP2249- $3) - Documentation the fault present indicator remains ON for the CID 248/FMI FO2 fault. * Fault present indicator is OFF; a machine hamess connection was faulty. The fault is not present now. Possibly an intermittent connection exists in the data link circuits of the machine harness. Watch for a recurrence of this fault, * Fault present indicator is ON; the fault remains present. Go to Step 2. 2. CHECK FOR SHORTED HARNESS - Disconnect the machine hamess from the transmission control and CMS. At the machine hamess connector for the transmission control, measure the resistance between contacts 8 and 9, * Resistance is less than 5000 Ohms (continuity); the machine hamess is faulty. There is a short between frame gyound and the data lik circuit in the machine hamess. Repair or replace the machine hare * Resistance is greater than 5000 Obms (no continuity); hamess circuit resistance is corre Go to Step 3 3. CHECK FOR OPEN HARNESS - The transmission control and CMS remain disconnected from the machine hamess, Check the continuity of the data link citcuit in the machine hamess. Place a jumper between contacts 23 and 24 of the machine harness connector for CMS. Check for continuity between contacts 8 and 9 of the machine hamess connector for the transmission control. * There is NO continuity; the machine harness is faulty, The data link circuit (wire 944-OR or 945-BR) is ‘open in the machine hamess. Repair or replace the machine hamess. * There is continuity; this circuit is not the cause of the fait. Go to Step 4, 4, CHECK FOR OPEN HARNESS - The transmission control and CMS remain disconnected from the machine hamess, Remove the jumper of the previous Step, Check the continuity of the data link circuit in the machine hamess, Place a jumper between contacts 8 and 9 of the machine harness connector for the transmission control Check for continity between contacts 23 and 24 of the machine hamess comnector for CMS. * There is NO continuity; the machine harness is faulty, The data link circuit (wire 944-OR or 945-BR) is open in the machine harness. Repair or replace the machine harness. * There is continuity; the data link circuit in the machine hamess is correct. It is unlikely that an electronic contol is faulty. Perform the previous Steps again. Ifthe cause is not found, replace the controls one at a time to determine which control is the cause of the fault. See the subject Control Replacement. CID 368 Procedure (Auto/Manual Transmission Switch), CID 627 Procedure (Park Brake Switch), CID 621 Procedure (Downshift Switch) Service Notes: Ensure that fault being analyzed is on-hold, Ensure thatthe fauit present indicator is ON. FMIF02 These faults are recorded when the control reads improper signals ffom the auto/manual transmission switeh, the downshift switch or the park brake switch, The control detects the status of the switch circuits, The status is correct, when one circuit is open and one is grounded, The status is wrong, when both circuits are open or grounded at the same time. Comnector contacts 20 and 21 are for the auto/manual switch. Connector contacts 22 and 23 are for the downshift switch. Connector contacts 3 and 4 are for the park brake switch 1. CHECK CIRCUIT FOR PROPER OPERATION - Disconnect the hamess connector from the control, At the hamess comnector, check for contimity from contact 2 (ground) to the switch input circuits with the faults. One input htps127.00.tisiswebisisuebtechdcctechdoc_print page jsp?returu jeweblsionebimedasearchimedisheaderintokameset/spBcalledpagesisiw... 1229sn2000 960 Whee! Loader 97J00001-UP (MACHINE) POWERED BY 3116 Ergine(SEBP7249 - 53) - Decurersation for the circuit should have continuity and one should not, Place the switch in the other position and the status of each input should change. * Operation is correct; switch and switch hamess circuitry is correct. Inspect hamess connector contacts. Connect harness connector to control and check control for the same fault, wit the fault present indicator ON. Ifpresent, the control is faulty. Replace the control, see the topic Control Replacement in the Testing, And Adjusting section. * Operation is not correct; switch or switch hamess circuitry is not correct. Go to Step 2. 2, CHECK SWITCH - At the switch, check for the same operation as in Step * Operation is not correct; switch is faulty, Repair or replace the switch. * Operation is correct; hamess is faulty. Repair or replace the harness. CID 362 (Ride Control Solenoid), CID 631 Procedure (Solenoid 1 - Reverse), CID 632 Procedure (Solenoid 2 - Forward), CID 633 Procedure (Solenoid 3 - Gear 4), CID 634 Procedure (Solenoid 4 - Gear 3), CID 635 Procedure (Solen: 5 - Gear 2), CID CS0988P3 ‘Transmission Solenoid Location (1) Solenoid I -Reverse, (2) Solenoid 2 - Forward, (3) Solenoid 3 - Gear 4, (4) Solenoid 4 - Gear 3. (5) Solenoid 5 - Gear 2. (6) Solenoid 6 Gear | Service Notes: Fnsure that the fault being analyzed is on-hold, Ensure that the fault present indicator is ON. The aulo/manual switch should be in the manual position while troubleshooting solenoid circuit problems. The following chart shows which transmission solenoids are energized in each position of the shift handle. An easy check of the solenoids ean be done by placing a steel washer next to the solenoid that should be energized. When htps127.00.tisiswebisisuebtechdcctechdoc_print page jsp?returu jewebssinebtmediasearchinedisheaderinfoamesct/spBcalledpagesisisw... 1929sn2000 960 Whee! Loader 97J00001-UP (MACHINE) POWERED BY 3116 Ergine(SEBP7249 - 53) - Decurersation the solenoid is energized it becomes magnetic. The washer should be attracted to the energized solenoid, The same check can be done on the ride control and dual horsepower solenoids. TRANSMISSION SOLENOID INFORMATION Shift Handle Position Solenoid Energized Neutral Solenoid 4 Forward 4 2and6 Forward 2 t Forward 3 Forward 4 Reverse 1 Reverse 2 Reverse 3 FMI F03 This fault is recorded when the control senses there is a short to +battery in the solenoid circuit, 1, CHECK FOR SHORT TO +BATTERY - Disconnect the machine hamess connector fom the control. Check for continuity ftom the faulty solenoid output circuit to +battery (contact 1). The connector contacts are: Reverse - 31, Forward - 32, Gear 4 - 33, Gear 3 - 34, Gear 2 - 35, Gear | - 36, Ride Control - 37 and Dual Horsepower - 38. Tum the various power circuits (headlights, heater etc.) OFF and ON during this test to check for short from these s to the solenoid output circuit * There is NOT continuity; solenoid hamess is not shorted to +battery. Go to Step 2 * There is continuity; the solenoid harness is shorted to +battery. Repair or replace hamness, 2. CHECK FOR SHORT TO OTHER SOLENOID OUTPUTS - Check for contimity from the faulty solenoid output to the other solenoid outputs, The connector contacts are: Reverse - 31, Forward - 32, Gear 4 - 33, Gear 3 - 34, Gear 2 - 35, Gear 1 - 36, Ride Control - 37 and Dual Horsepower - 38. * There is NOT continuity; solenoid hamess circuitry is correct. Inspect hamess connector contacts. Connect harness connector to control and check control for the same fault, with the fault present indicator ON, If present, the control is fauity. Replace the control, see Control Replacement. * There is continuity; the solenoid hamess is shorted. Repair or replace harness. FMLFOS This fault is recorded when the control senses there is not a complete electrical circuit for this solenoid. CHECK FOR OPEN HARNESS - Disconnect the machine hamess connector from the control. Measure the resistance fiom the faulty solenoid output circuit to solenoid return (contact 39). The connector contacts are: Reverse - 31, Forward - 32, Gear 4 - 33, Gear 3 - 34, Gear 2 - 35, Gear I - 36, Ride Control - 37 and Dual Horsepower - 38, * Resistance is 8.15 +t .6 Ohms; solenoid circuitry resistance is correct. Inspect hamess connector contacts. Connect harness connector to control and check control for the same fault, with the fault present indicator htps127.00.tisisuebisiswebtechdcctechoe_print page jep?retrrut= swebsisuebimediasearchimediaheaderinfokamesct|spScallecpage=isisw.... 1429‘12000 280 Wel Loader 92J00001-UP (MACHINE) POWERED BY 3116 Engine(SEBP2049- 58) -Docureriaton ON. Ifpresent, the control is faulty, Replace the control, see the topic Control Replacement in the Testing And Adjusting section. * Resistance is NOT 8.15 = .6 Olnms; the solenoid or solenoid hamess circuitry is faulty, Repair or replace hamess and/or solenoid. EMIF06 This fault is recorded when the control senses there is a short to ground in the solenoid circuit, CHECK FOR SHORT TO GROUND - Disconnect the machine harness connector from the control Check for continuity from the fauty solenoid output circuit to ground (contact 2). The connector contacts are: Reverse - 31, Forward - 32, Gear 4 - 33, Gear 3 - 34, Gear 2 - 35, Gear 1 - 36, Ride Control - 37 and Dual Horsepower - 38. * There is NOT continuity; solenoid hamess circuitry is correct. Inspect harness connector contacts. Connect hamess connector to control and check control for the same faut. Ifpresent, the control is faulty. Replace the control, see the topic Control Replacement in the Testing And Adjusting section. * There is continuity; the solenoid or solenoid hamess is shorted to ground. Repair or replace hames: solenoid. indior EMIFI2 This fault is recorded when the control senses an internal fault. If this fault is present, replace the control. See the topic Control Replacement in the Testing And Adjusting section. CID 617 (Air Inlet Heater Relay) Service Not : Ensure that the fault being analyzed is on-hold. Ensure that the fault pr FMI F03 This fault is recorded when the control senses there is a short to +battery in the relay cicuit. 1. CHECK FOR SHORT TO +BATTERY - Disconnect the machine hamess connector from the control. Check for continuity from connector contact 10 to contact | (+battery). Tum the various power circuits (headlights, heater ete.) OFF and ON during this test to check for short from these circuits to the output circuit, * There is NOT contimity, relay hamess is not shorted to +battery. Go to Step 2. * There is continuity; the relay hamess is shorted to Hbattery. Repair or replace hamess, 2, CHECK FOR SHORT TO OTHER SOLENOID OUTPUTS - Check for continuity from connector contact 10 to the other solenoid outputs. The connector contacts are: Reverse - 31, Forward - 32, Gear 4 - 33, Gear 3 - 34, Gear 2 - 35, Gear 1 - 36, Ride Control - 37 and Dual Horsepower - 38. * There is NOT contimity; relay hamess circuitry is correct. Inspect hamess connector contacts. Comnect hamess connector to control and check control for the same faut, with the fault present indicator ON. If present, the control is faulty. Replace the control, see Control Replacement * There is continuity; the relay hamess is shorted. Repair or replace harness, EMI FOS: This fault is recorded when the control senses there is not a complete electrical circuit for this relay. htps127.00.tisiswebisisuebtechdcctechdoc_print page jsp?returu jswebssiowebimediasearchinedisheaderintokameset/spBcalledpagesisisw... 192‘12000 280 Wel Loader 92J00001-UP (MACHINE) POWERED BY 3116 Engine(SEBP2049- 58) -Docureriaton CHECK FOR OPEN HARNESS - Disconnect the machine harness connector fom the control, Measure the resistance from connector contact 10 to contact 39 (solenoid return). * Resistance is 15 to 65 Ohms; relay circuitry resistance is correct. Inspect hamess connector contacts. Connect harness connector to control and check control for the samme fault, with the fault present indicator ON. Ifpresent, the control is faulty. Replace the control, see the topic Control Replacement in the Testing, And Adjusting section. * Resistance is NOT 15 to 65 Ohms; the relay or relay hamess circuitry is faulty. Repair or replace hamess and/or relay. EMILEOG This fault is recorded when the control senses there is a short to ground in the solenoid circuit CHECK FOR SHORT TO GROUND - Disconnect the machine hamess connector from the control. Check for continuity from connector contaet 10 to contact 2 (ground). * There is NOT continuity; relay hamess circuitry is correct. Inspect hamess connector contacts. Connect hamess connector to control and check control for the same fauik. Ifpresent, the control is faulty. Replace the control, see the topic Control Replacement in the ‘Testing And Adjusting section. * There is continuity; the relay or relay hamess is shorted to ground. Repair or replace hamess and/or relay. FMIFI2 This faut is recorded when the control senses an internal fault, Ifthis fault is present, replace the control, See the topic Control Replacement in the Testing And Adjusting section. CID 650 Procedure (Harness Code) NOTE: Check to see if data link faut (CID 248/FMI F02) exists. Ifa data link fault is present, correct it prior to performing these procedures. Service Notes: Finsure that the fault being analyzed is on-hold, Ensure that the faut is present EMLFO2 This fault is recorded when the control does not recognize the harness code received fiom CMS on the data link (wires 944-OR and 945-BR). 1. CHECK CMS - The transmission control receives hamess code information ftom CMS. Check CMS for a related CMS fault. See service manual SENRS5247 Computerized Monitoring System (CMS) With VED Circular Gauges. * CMS has a related fault; correct the related fault per the CMS service manual. Then go to Step 2. * CMS does not have a related fault; check the data link. Perform the troubleshooting procedure for a data link fault (CID 248/FMI F02). 2, RECHECK FOR FAULT - Check the transmission control to see if the fault present indicator remains ON for this fault (CID 650/FMI FO2). * Fault present indicator is ON; check the data link, Perform the troubleshooting procedure for a data link fault (CID 248/FMI F02). * Fault present indicator is OFF; the fault is corrected. Clear the fault. Watch for a recurrence of this fault htps127.00.tisiswebisisuebtechdcctechdoc_print page jsp?returu jewebssionebimedasearchimediaheaderintokamesct/spBcalledpagesisisw... 1629sera2020 ‘960F Wel Loader 87.100001-UP (MACHINE) POWERED BY 3116 Engine{SEBP2249- $3) - Documentation CID 668 Procedure (Shift Handle) (Control Without a Display) Disconnect the shift handle hamess connectors. At the 9 contact machine hamess connector check for battery voltage between contact 2 (ground) and contact 1. Neutralizer switch must NOT be activated. Ifnot correct, repair or replace harness or switch. If correct tum the disconnect switch to OFF position. Use the machine Electrical System Schematic to check the wiring harness ffom the shift handle to the control. Check for shorts and continuity of the hamess circuits * Hames is NOT correct; repair or replace the hamess. * Hames is correct; check all connector contacts. Check for shift handle fault codes. Ifstill present replace the shift handle. Ifthe problem is still present replace the transmission control Service Notes: Ensure that the fault being analyzed is on-hold NOTE: The procedure that follows is used with 105-0154 and 106-4804 Shift Handle Control Group. Use the previous procedure "CID 668 Procedure (Shift Handle) (Control Without a Display)" to test the 107-6219 Shift Handle Control Group. Use test mode (mode 2) to find the area of the shift handle or shift handle hamess with the fault. In test mode the control detects faults that occur in the shift handle switches and related hamess circuits, NOTE: rhe neutralizer switch must NOT be activated during this test 1. Put control into test mode (mode 2). 2. Move the shift handle through neutral and all gear and direction positions, pausing for one second in each position, ‘After moving the shift handle through all positions the display shows "---." ifno faults exist. fa fault does exist, the display shows the control connector contact number(s) that corresponds to the faulty shift handle circuits. * Display shows number(s) "18" and/or "19"; shift handle and/or neutralizer switch circuits are not correct. Go to Step 4. * Display shows number(s) "12" through "17"; shift handle switch and/or ground circuits not correct. Go to Step 3. * Display shows "---."; shift handle circuit faut no longer exists. Check hamess and hamess connections for damage and poor connections. Clear the fault. Move the shift handle through each position several times. Wiggle the shift handle To find intermittent problems in the handle. Check the control for the same faut (CID 668). Ifthe control detected the fault, replace the shift handle. 3. CHECK SHIFT HANDLE GROUND CIRCUIT - Tum the disconnect switch to OFF position, Disconnect the 9 and 10 contact shift handle comeectors. AAt the 9 contact machine hamess connector for the shit handle, check for continuity from ground to contact 2 * There is continuity; the shift handle ground circuit is correct. Go to Step 5. * There is NO contimity; the shift handle ground circuit in the hamess has a fault. Repair or replace the hamess. 4, CHECK SHIFT HANDLE POWER CIRCUITS - Disconnect the 9 and 10 contact shift handle connectors. At the 9 contact machine hamess comector for the shift handle, check for battery voltage between contact 2 (ground) and contacts 1 and 9. Neutralizer switch must NOT be activated. * Battery voltage measured; the shift handle power circuits are comrect, Go to Step 5. htps127.00.tisiswebisisuebtechdcctechdoc_print page jsp?returu jewebssioneblmedasearchimediaheaderintoameset/spBcalledpagesisisw... 17723‘12000 280 Wel Loader 92J00001-UP (MACHINE) POWERED BY 3116 Engine(SEBP2049- 58) -Docureriaton * Battery voltage is NOT measured; the power circuit hamess or neutralizer switch is not correct. Repair or replace the hamess and/or switch. 5. CHECK SHIFT HANDLE - See the topic Shift Handle Test in the Testing And Adjusting section. * Shift handle is correct; hamess or hamess connector problem. Go to Step 6 * Shift handle NOT correct; there isa fault in the shift handle. Replace the shift handle. 6. CHECK HARNESS FROM SHIFT HANDLE TO CONTROL - Use the machine Eletrical System Schematic to check for shorts and continuity of the hamess circuits that correspond to the connector contacts shown on the control display. * Hamess is NOT correct; repair or replace the hares * Hames is correct; Check all connector contacts. Change the control to test mode and check shift handle again, [fnumbers are still shown, replace the control. See the topic Control Replacement in the Testing And Adjusting section. CID 671 Procedure (Transmission Speed Sensor) Service Notes: Ensure that fault being analyzed is on-hold. The transmission RPM input is a ffequency type sensor input, The transmission speed signal is at contact S of the control connector. FMLF08 1. CHECK SENSOR - Remove the sensor and check for foreign material on sensor tip. Install the speed sensor and adjust correctly, sce the topic Speed Sensor Adjustment in the Testing And Adjusting section. Clear the fault and test machine operation, Check the control for the same fault (CID 671). * Fault is shown; the speed sensor or harness is not correct. Go to Step 2. * Fault is NOT shown; adjustment of the speed sensor or cleaning speed sensor tip corrected the problem. Clear the fault code. 2, CHECK HARN - Connect the sensor to the machine harness. The control remains disconnected from the ‘machine hamess. At the machine hamess connector, for the control, measure the resistance between contact 2 (ground) and contact 5 * Resistance is between 1000 and 1200 Ohms; the machine harness resistance is correct. Replace the sensor. Adjust the speed sensor properly when installing it. See the topic Speed Sensor Adjustment in the Testing And Adjusting section. Clear the fault code. * Resistance is NOT between 1000 and 1200 Ohms; the machine harness is shorted or open. Repair or replace the hamess. Clear the fault code. CID 680 Procedure (Ride Control Switch) Service Notes: Ensure that fault being analyzed is on-hold, Ensure that the fault present indicator is ON. EMI F02 (Machines With Air Over Hydraulic Brakes) These faults are recorded when the control reads improper signals from the ride control switch, htps127.00.tisiswebisisuebtechdcctechdoc_print page jsp?returu jswebssionebimedasearchinedisheaderinfokameset/spBcalledpagesisisw... 18231792000 The control detects the status of the ride control switch circuits, The status is correct, when the ride switch control inputs are as specified in one of the following charts. Ifthe status is wrong a fault is recorded. 960 Whee! Loader 97J00001-UP (MACHINE) POWERED BY 3116 Ergine(SEBP7249 - 53) - Decurersation 1, CHECK CIRCUIT FOR PROPER OPERATION - Disconnect the harness connector from the control. At the hamess connector, check for continuity from contact 2 (ground) to the auto (contact 26) switch input circuit and fiom contact 1 (+battery) to the N/C (contact 11) and N/O (contact 10) switch input circuits, Use the following chart to check the status of each input for all tree switch positions. RIDE CONTROL SWITCH STATUS (Machines With Air Over Hydraulic Brakes) ‘Switch D744-WH D743-GN i E701-PK | Position | Circuit (Input 2) | Circuit (Input 1) | Circuit (Input 3) jon Closed Open Open OFF Open | Closed? Open AUTO Open Closed" Closed? 1 Closed to +battery. 2 Closed to ground, * Operation is correct; switch and switch hamess circuitry is correct. Inspect hamess connector contacts, Connect hamess connector to control and check control for the same fault, with the fault present indicator ON. Ifppresent, the control is faulty. Replace the control, see the topic Control Replacement in the Testing ‘And Adjusting section, * Operation is not correct; switch or switch harness circuitry is not correct. Go to Step 2. 2. CHECK SWITCH - At the switch, check for the same operation as in Step 1 * Operation is not correct; switch is faulty. Repair or replace the switch. * Operation is comect; hamess is fuity, Repair or replace the hamess. FMI F02 (Machines With Hydraulic Over Hydraulic Brakes) These faults are recorded when the control reads improper signals from the ride control switch, The control detects the status of the ride control switch circuits. The status is correct, when the ride switch control inputs are as specified in one of the following charts. I the status is wrong a fault is recorded, 1. CHECK CIRCUIT FOR PROPER OPERATION - Disconnect the hamess comnector fiom the control. At the hamess connector, check for contimity from contact 2 (ground) to the ride control switch inputs (contacts 24 and 26). Use the following chart to check the status of each input for all three switch positions. ~~ "RIDE CONTROL SWITCH STATUS (Machines With Hydraulic Over Hydraulic Brakes) D743-GN D744-WH Mode cuit (Input 2) | Circuit (Input 3) ON ‘Open Closed OFF Closed ~ [| Closed | AUTO Closed i Open 1 htps127.00.tisiswebisisuebtechdcctechdoc_print page jsp?returu jswebsiwebtmediasearchimed aheaderinframeset|spScallecpage=sisw. 1929‘12000 280 Wel Loader 92J00001-UP (MACHINE) POWERED BY 3116 Engine(SEBP2049- 58) -Docureriaton * Operation is correct; switch and switch hamess circuitry is correct, Inspect hamess connector contacts Connect hamess comnector to control and check control for the same fault, wit the fault present indicator ON. Ifpresent, the control is faulty. Replace the control, see the topic Control Replacement in the Testing ‘And Adjusting section. * Operation is not correct; switch or switch hamess circuitry is not comect. Go to Step 2. 2, CHECK SWITCH - At the switch, check for the same operation as in Step 1. * Operation is not correct; switch is faulty. Repair or replace the switch * Operation is comect; hamess is fully, Repair or replace the harness. e Ident CID 685 Procedure (Ser ation Code) Service Notes: It may be impossible to change modes or clear faults if this fault is present. Ifthis faut is present, fauit codes may not be displayed properly. FMI F02 CHECK HARNESS - Turn the disconnect switch to the OFF position. Disconnect the machine harness from the control, Check the hamess between the control connector and the service connector. Check for short to ground, short between service inputs and open circuits. * Hamess is correct; the control has a fault. Inspect the contacts on the machine harness connector and connect to the control. Check for presence of fault code 685. If faut is stil present, replace the control, See the topic Control Replacement in the Testing And Adjusting section, * Hamess is NOT correct; the harness has a fault. Repair or replace the hamess. CID 687 (Option Identification Code) Service Notes: Ensure that the fault being analyzed is on-hold, Ensure that the fault is ACTIVE, FMI F02 When turned ON, the control looks at the option code contacts, ifthe contacts do not represent a valid option code, this faults recorded. See the Options Code Configuration chart on the Electrical System Schematic for the machine being serviced. CHECK OPTION CODE - Disconnect the machine harness from the control, At the machine harness connector for the control, check for proper option code. The proper option code can be found in the Options Code Configuration chart on the Electrical System Schematic * Option code is correct; option code circuitry is correct. Inspect hamess connector contacts. Connect hamess to control. Clear the fauit. Tum the key switch OFF then back ON to recheck the control Ifthe same faults active, replace the control. See the topic Control Replacement in the Testing And Adjusting section. * Option code is NOT comrect; option code circuitry is faulty. Repair the option code circuits or replace the hamess. Clear the fault Faults Not Detected By The Control Transmission Does Not Shift Automatically htps127.00.tisiswebisisuebtechdcctechdoc_print page jsp?returu jenebisionebtmedasearchimedisheaderintokameset/spScalledpagesisisw... 20723‘e200 ‘9850 Wheel Loader 97100001-UP (MACHINE) POWERED BY 2116 Engine(SEBP7249 53) - Docureration CHECK AUTO/MANUAL SWITCH INPUT - Ifthe transmission does not shift automatically while in AUTO mode and there is no fit code displayed, verify that the control is getting the proper signals from the AUTO/MANUAL switch. See machine Electrical System Schematic for proper operation of switch. * Ifthe control has the proper signals for automatic operation, follow the procedure for fault codes CID 190 and CID 671 * If the control does not have the proper signals follow the procedure for fault codes CID 368 and CID 621 Control Display Area Is Blank (For Machines Equipped With A Control That Has A Display) 1, CHECK FOR BATTERY VOLTAGE AT THE CONTROL - Battery voltage is the voltage measured at the battery posts. Voltage at the control must not vary more than .5 volt from battery voltage. Using sharp meter test Jeads, puncture the wire insulation and measure the system voltage between contacts 1 and 2 of the control at the hamess connector. Key switch must be in the ON position. * Vollage measured does NOT vary from battery voltage more than .5 DCV; system voltage is correct. Disconnect connector and inspect connector contacts. Comnect harness connector to control. Ifthe display is still blank, the control is fully. Replace the control, see the topic Control Replacement in the Testing And Adjusting section. * Voltage measured does vary fiom battery voltage more than .5 DCV; system voltage is incorrect. Go to Step 2. 2. CHECK FOR OPEN TRANSMISSION CONTROL FUSE - Check machine fase panel for an open ‘transmission control fuse. * Fuse is open; fise is faulty. Go to Step 3. * Fuse is NOT open; the hamess is fiuty. There is an open circuit in the battery and/or ground circuits or the connector contacts are dirty. Inspect connector contacts. Repair or replace hamess, 3. CHECK FOR SHORTED HARNESS - Disconnect the machine harness connector from the control, Measure the resistance from connector contacts | and 2 on the hamess connector. * There is NO continuity; the hamess circuit resistance is correct. Go to Step 4. * There is continuity; the hamess is not correct, There is a short between the +battery and ffame ground or between wires in the hamess. Repair or replace the hamess. 4, CHECK CONTROL - Measure the resistance fiom harness connector contacts | and 2 on the control, * Resistance is less than 100 Ohms; the control is not correct. Replace the control, see the topic Control Replacement in the Testing And Adjusting section. * Resistance is greater than 100 Ohms; the harness is not correct. There is an intermittent short between ++battery and frame ground, Repair or replace the hamess. Speed Sensor Adjustment htps127.00.tisiswebisisuebtechdcctechdoc_print page jsp?returu jenebisionebimedasearchinedisheaderintokameset/spBcalledpagesisisw... 2120sn2000 960 Whee! Loader 97J00001-UP (MACHINE) POWERED BY 3116 Ergine(SEBP7249 - 53) - Decurersation 623303P1 Speed Sensor (1) Air gap. @) Locknut. 1, Remove the speed sensor. Align a gear tooth directly in the center of the threaded sensor opening 2. By hand, screw the sensor into the hole until the end of the sensor just makes contact with the gear tooth. 3. Tum the sensor back out 1/2 tur (180° in the counterclockwise direction). This sets air gap (1) to 0.89 mm (.035 in) 4, Tighten locknut (2) to 25 + 5 N-m(18 +4 bb fd. NO 10 not allow the sensor to tun as locknut (2) is tightened. Shift Handle Test Test For The 105-0154 And The 106-4804 Control Groups Use the charts below to check the shift handle switches. Use a 6V-7070 Digital Multimeter on the diode scale for these tests. The polarity of the meter leads is important for these tests. Ifthe shift handle switches operate according to the charts, the shift handle is good. htps1!127.00. Isisuebsisuebtechdcctechdoe_print page jsp?returrur=isiswebisiswebymediasearchinecisheaderinfarameset/spBcalledpagesisisw... 2223sn2000 960 Whee! Loader 97J00001-UP (MACHINE) POWERED BY 3116 Ergine(SEBP7249 - 53) - Decurersation SHIFT HANDLE TEST {Red Meter Lead On Contact 12) Shift Handle Position . {Contact | 1F ' 2F | 3F " aF | N | 1A: 2R | 3R | 4A 1 [oO ofojolo|[x]x|[x|x 2 x,x{x][xfelofloloioe 7 oO o Oo o:0/0 oO a oO 1 These contacts are in the 10 contact shift handle connector. 2 This contact is in the 9 contact shift handle connector. ONo voltage measured (OL). X Less than 1 DCV measured. NOTES: There should be no continuity in any shift handle position from contact 1 of the 9 contact connector. ta any shift handle connector contacts not tisted in the chart SHIFT HANDLE TEST (Black Meter Lead On Contact 22) ShiftHandle Position Contact 1F | 2F | aF | 4F ON 3 ixf[x}x[xio 4 ofolololo 5 o ofxlola — 6 fo ofo]x |x oi xlofole ofolfolof[e 6 ofolo|lo[x e [x]lofolofo 2 These contacts are in the 9 contact shift handle connector. ONo voltage measured {OL}. X Less than 1 DCV measured. NOTES: There should be no continuity in any shift handle position from contact 2 of the 9 contact connector, to any shift handle connector contacts not listed in the chart. hitps127.00. isisuebysiswebtechdcctechdoe_print page jsp?retirr jswebsiwebtmediasearchimed aheaderinframeset|spScallecpage=sisw. 238sn2000 960 Whee! Loader 97J00001-UP (MACHINE) POWERED BY 3116 Ergine(SEBP7249 - 53) - Decurersation GRAPHIC NOT AVAILABLE Use a 6V-7070 Digital Multimeter on the 200 Ohms scale for the following chart, Ifthe shift handle switch operates according to the chart, the shift handle is good. SHIFT HANDLE TEST (Meter Lead On Contact 32) __ Shift Handle Position Contact | 1F | oF | 3F | 4F | N | 1R | 2A | 3R | 4R a Oo oO/O/0;x/ Oo o,.0 Oo 2 These contacts are in the 9 contact shift handle connector. Q Open (no continuity) X Closed (continuity). NOTES: There should be no continuity in any shift handle position from contact 3 of the 9 contact connector, to any shift handle connector contacts not listed in the chart. Test For The 107-6219 Control Group The 107-6219 Control Group contains electronic circuitry and cannot be tested using the 6V-7070 Digital Multimeter: Ifthe electronic transmission control indicates a shift circuit fil, check the associated wiring hamess, before replacing the 107-6219 Control Group. Self Test (For Controls With A Display hitps127.00. isisuebysiswebtechdcctechdoe_print page jsp?retirr jenebisioneblmedasearchinedisheaderintoameset/spScalledpagesisisw... 2423sera2020 ‘960F Wel Loader 87.100001-UP (MACHINE) POWERED BY 3116 Engine{SEBP2249- $3) - Documentation 5 Les SS 3 4 C48722P2 Control Display Area (1) Power indicator. (2) Readout (component identifier and failure mode identifier). (3) Service mode indicator. (4) Fault present indicator. The self test verifies that the control is operating properly. The control performs an automatic self test each time the key switch is tumed ffom the OFF to the ON position. The internal circuits and the display are automatically checked. The operator must observe the display to determine whether or not the control is operating properly. During the self test, the tests follow this sequence: 1. Allthree indicators are ON and the digital display shows "888.", The dot in the upper left comer is shown for one half second and "888." is shown for two seconds. 2. The red and yellow indicators turn OFF. The digital display shows the one digit options identification code and the two digi machine identification code for two seconds. The lefl most digi is the options identification code and the right two digits are the machine code. The machine code is a two digit representation of the hamess code received from CMS via the data link. For the machine code of the machine being serviced, see the Operation And Maintenance Manual for that machine. 3. The digital display shows the software version. This number identifies the software which is used within the control. 4, The digital display shows "-0-." for two seconds. This indicates that the control is in normal mode (mode 0). 5. The green indicator remains ON and the digital display shows "---." ifthere are no fats. Ifa fault has occured the display will show the component identiier (CID) and the failure mode identifier (FMI) codes. Ifthe fault is present, the fault present indicator willbe ON. Ifthe fault is not present, the fault present indicator will be OFF. * Ifthe control operates as described; the control is operating properly * Ifthe control does not operate as described; there is a hamess code problem or the control is faulty, Check the hamess code, follow the troubleshooting procedure for the hamess code fault CID 650. Ifthe fault present indicator flashes and the display is blank, the control is faulty, Replace the control, see the topic Control Replacement in the Testing And Adjusting section. Control Replacement htps127.00.tisiswebisisuebtechdcctechdoc_print page jsp?returu jeneblsionebimedasearchimediaheaderinfokameset/spBcalledpagesisisw... 2523‘12000 280 Wel Loader 92J00001-UP (MACHINE) POWERED BY 3116 Engine(SEBP2049- 58) -Docureriaton Prior to replacement of the control, ensure that replacement is absolutely necessary. Rarely is the control the cause of a fault, Always check that power is available to the control; battery voltage is required between control comector contacts 1 and 2 of the machine hamess. Procedure 1. Tum the key switch to the OFF position. Discomnect the machine hamess ffom the control 2. Remove the control. 3. Make sure the replacement control has the correct part number. Connect the machine harness to the control, 5. Install the replacement control, 6. Tum the disconnect and key switches to the ON position. Make sure the control successflly completes the self test; see Self Test. Glossary Battery + Battery refers to any of the hamess wiring which is part of the circuit that connects to the positive batterypost. 4V +V is a constant voltage that is supplied to a component to provide electrical power for its operation, +V is provided by an electronic control module or the battery. Abnormal Abnormal refers to a machine condition or signal that is not normal. The presence of an abnormal condition or signal means a problem exists and warning operation is activated which notifies the operator. CID (Component Identifier) ‘The CID is a diagnostic code that tells which component or system is fiuity. For example; auto/manual switch, speed sensor, or shift handle, The CID is a three digit code that is located in the digital readout area when in normal or service mode. Clear Clear refers to removing diagnostic information ffom the memory of the control, Before clearing information, it is necessary that the information is on-hold and that the control sin service mode. Connector Contact A comnector contact is the component ofa harness connector that actually makes the electrical connection. Connector contacts are either pins or sockets ected Fault A detected fait is a fault that has been found by the control. The faut is recorded and diagnostic information is available when in service mode. Diagnostic Diagnostic refers to the showing, monitoring and/or recording of information other than normal, Diagnostic information is available from service, test or normal mode. Disphy Display refers to the indicators or digital readouts within the control display area. Fault A fuult isa failure of component of the system, For example; open or shorted hamess, faulty switch, sensor or control, FMI (Failure Mode Identifier) htps127.00.tisiswebisisuebtechdcctechdoc_print page jsp?returu -Isiswebsisuebimediascarchimediaheaderiniokameset|spScallecpage=isisw.... 2829‘12000 280 Wel Loader 92J00001-UP (MACHINE) POWERED BY 3116 Engine(SEBP2049- 58) -Docureriaton ‘The FMI is a diagnostic code that tells what type of failure has occurred. For example; voltage above normal, current below normal or abnormal frequency. The FMI is a two digit code preceded by the letter "F", This code is located in the digital readout area when in service mode. Hard Wired Hard wired refers to electrical connections made within the harness that are permanent. These soldered or crimped connections are not meant to be altered. Hold or On-Hold Hold or On-hold refers to holding (or locking) a set of diagnostic information that is shown in the digital display area when in service mode. It is necessary to hold the set of diagnostic information before troubleshooting or clearing. Jumper A jumper is a piece of wire used to make an electrical connection during troubleshooting. Option Code Option code refers to the grounded or open condition of the two option code inputs (connector contacts 25, 27 and 30). The option code tells the control what options are installed on the machine. Seroll Scrolling is the process of showing (within the digital display area) all available sets of diagnostic information, one set ata time. A set of diagnostic information is shown briefly and then the display automatically advances to the next set. After all sets are shown the sets are repeated. Show ‘Show refers to information within the control display area that is viewed by the operator or service person. Signal Wire ‘The signal wire is the hamess wire which connects the sensor or switch to the control. Switch Input A switch input is any input of the control which is expecting only an open (floating) or grounded signal. System Voltage System voltage is the ac voltage is also referred to Undetected Fault An undetected fault is a fault that exists and is not found by the control but is found by the operator or service person. Machine Code ‘The machine code is a two digit mumber that has been assigned to a particular hamess code for a particular machine. The machine code is shown on the control display during the Self Test. Each sales model has a specific harness code and therefore also a specific machine code. al voltage that exists between the positive battery post and frame ground. System battery voltage. Electronic Transmission Control System Schematics NOTE: ‘The simplified system schematics that follow are for controls with a display. These schematics are electrically correct, but do not show all the possible hamess connectors. For a complete electrical system schematic, always see the Electrical System Schematic module in the machine Service Manual. Machines With Air Over Hydraulic Brakes htps127.00.tisiswebisisuebtechdcctechdoc_print page jsp?returu jenebisionebtmedasearchinedisheaderintokameset/spBcalledpagesisisw... 27723‘02000, 960F Whee! Loader 97J00001-UP (MACHINE) POWERED BY 3116 Ergine(SEBP7249 - 53) - Decurersation Machines With Hydraulic Over Hydraulic Brakes hitps127.00. isisuebysiswebtechdcctechdoe_print page jsp?retirr jenebisionebtmedasearchimedisheaderinfokamesct/spBcalledpagesisisw... 2829sm2000 960F Whee! Loader 97J00001-UP (MACHINE) POWERED BY 3116 Ergine(SEBP7249 - 53) - Decurersation ae reer ols —— Copyright 1993 - 2020 Caterpillar Ine All Rights Reserved Private Network For SIS Licensees. Wed Sep 16 2020 15:19:46 GMT-0500 (nora de verano central) htps1127 00. Isisuebysisuebtechdcctechdoc_print page jsp?returur=isiswebisiswebymediasearchimecisheaderinfaameset/spBcalledpagesisisw... 2829