Renr9004-07-01-All-Power Train Electronic

RENR9004-07
September 2010
Systems Operation
Troubleshooting
Testing and Adjusting
120M, 12M, 140M, 14M, 160M
and 16M Motor Graders
Power Train Electronic Control System
B9C1-Up (Machine)
B9D1-Up (Machine)
B9E1-Up (Machine)
B9F1-Up (Machine)
B9G1-Up (Machine)
D9G1-Up (Machine)
B9H1-Up (Machine)
R9H1-Up (Machine)
B9J1-Up (Machine)
R9J1-Up (Machine)
B9L1-Up (Machine)
B9M1-Up (Machine)
B9N1-Up (Machine)
B9R1-Up (Machine)
B9T1-Up (Machine)
D9T1-Up (Machine)
B9W1-Up (Machine)
D9W1-Up (Machine)
SAFETY.CAT.COM
i03991620
Important Safety Information

Most accidents that involve product operation, maintenance and repair are caused by failure to observe
basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous
situations before an accident occurs. A person must be alert to potential hazards. This person should also
have the necessary training, skills and tools to perform these functions properly.
Improper operation, lubrication, maintenance or repair of this product can be dangerous and
could result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have
read and understood the operation, lubrication, maintenance and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings
are not heeded, bodily injury or death could occur to you or to other persons.
The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as
“DANGER”, “WARNING” or “CAUTION”. The Safety Alert “WARNING” label is shown below.
The meaning of this safety alert symbol is as follows:

Attention! Become Alert! Your Safety is Involved.
The message that appears under the warning explains the hazard and can be either written or pictorially
presented.
A non-exhaustive list of operations that may cause product damage are identified by “NOTICE” labels
on the product and in this publication.
Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard.
The warnings in this publication and on the product are, therefore, not all inclusive. You must
not use this product in any manner different from that considered by this manual without first
satisfying yourself that you have considered all safety rules and precautions applicable to the
operation of the product in the location of use, including site-specific rules and precautions
applicable to the worksite. If a tool, procedure, work method or operating technique that is not
specifically recommended by Caterpillar is used, you must satisfy yourself that it is safe for you
and for others. You should also ensure that the product will not be damaged or become unsafe by
the operation, lubrication, maintenance or repair procedures that you intend to use.
The information, specifications, and illustrations in this publication are on the basis of information that
was available at the time that the publication was written. The specifications, torques, pressures,
measurements, adjustments, illustrations, and other items can change at any time. These changes can
affect the service that is given to the product. Obtain the complete and most current information before you
start any job. Cat dealers have the most current information available.
When replacement parts are required for this

product Caterpillar recommends using Cat re-
placement parts or parts with equivalent speci-
fications including, but not limited to, physical
dimensions, type, strength and material.
Failure to heed this warning can lead to prema-

ture failures, product damage, personal injury or
death.
In the United States, the maintenance, replacement, or repair of the emission control devices and
systems may be performed by any repair establishment or individual of the owner's choosing.
RENR9004-07 3
Table of Contents
Table of Contents MID 027 - CID 0262 - FMI 04

MID 027 - CID 0368 - FMI 03
.............................
.............................
156
158
MID 027 - CID 0368 - FMI 04 ............................. 161
MID 027 - CID 0420 - FMI 03 ............................. 163
Systems Operation Section MID 027 - CID 0420 - FMI 05 ............................. 165
MID 027 - CID 0420 - FMI 06 ............................. 167
General Information ................................................ 5
MID 027 - CID 0444 - FMI 03 ............................. 169
Features .................................................................. 8
MID 027 - CID 0444 - FMI 05 ............................. 171
Location of Electrical Components ....................... 25
MID 027 - CID 0444 - FMI 06 ............................. 174
Electrical Input Components ................................. 27
MID 027 - CID 0573 - FMI 03 ............................. 177
Electronic Control Module ..................................... 41
MID 027 - CID 0573 - FMI 04 ............................. 180
Electrical Output Components .............................. 45
MID 027 - CID 0573 - FMI 08 ............................. 182
Data Link .............................................................. 52
MID 027 - CID 0585 - FMI 02 ............................. 185
MID 027 - CID 0588 - FMI 09 ............................. 189
Troubleshooting Section MID 027 - CID 0588 - FMI 14 ............................. 191
MID 027 - CID 0590 - FMI 09 ............................. 192
Introduction MID 027 - CID 0590 - FMI 14 ............................. 195
General Information .............................................. 54 MID 027 - CID 0596 - FMI 09 ............................. 197
Service Tools ........................................................ 56 MID 027 - CID 0596 - FMI 12 ............................. 201
Connector Locations ............................................. 57 MID 027 - CID 0596 - FMI 14 ............................. 204
Diagnostic Capabilities ......................................... 58 MID 027 - CID 0615 - FMI 02 ............................. 205
MID 027 - CID 0615 - FMI 03 ............................. 209
Symptom Troubleshooting MID 027 - CID 0615 - FMI 04 ............................. 214
Symptom Troubleshooting .................................... 65 MID 027 - CID 0615 - FMI 08 ............................. 217
Emerging Symptom Information ........................... 65 MID 027 - CID 0615 - FMI 13 ............................. 221
Indicator Lamp Does Not Illuminate ...................... 66 MID 027 - CID 0615 - FMI 14 ............................. 222
Indicator Lamp Is On Continuously ....................... 68 MID 027 - CID 0621 - FMI 03 ............................. 224
Parking Brake System .......................................... 69 MID 027 - CID 0621 - FMI 04 ............................. 228
Steering Direction Is Opposite of Expected MID 027 - CID 0622 - FMI 03 ............................. 230
Direction .............................................................. 82 MID 027 - CID 0622 - FMI 04 ............................. 234
Steering Does Not Function .................................. 86 MID 027 - CID 0623 - FMI 03 ............................. 236
Steering Movement Without Request ................... 89 MID 027 - CID 0623 - FMI 04 ............................. 240
Event Code List .................................................... 91 MID 027 - CID 0627 - FMI 03 ............................. 243
MID 027 - CID 0627 - FMI 04 ............................. 246
Diagnostic Code Procedures MID 027 - CID 0669 - FMI 02 ............................. 248
Diagnostic Code List ........................................... 100 MID 027 - CID 0673 - FMI 02 ............................. 251
Using Messenger to Determine Diagnostic MID 027 - CID 0674 - FMI 02 ............................. 254
Codes ................................................................ 106 MID 027 - CID 0675 - FMI 02 ............................. 257
Using Caterpillar Electronic Technician to Determine MID 027 - CID 0681 - FMI 03 ............................. 261
Diagnostic Codes .............................................. 107 MID 027 - CID 0681 - FMI 05 ............................. 263
MID 027 - CID 0041 - FMI 03 ............................. 109 MID 027 - CID 0681 - FMI 06 ............................. 266
MID 027 - CID 0041 - FMI 04 .............................. 111 MID 027 - CID 0967 - FMI 02 ............................. 268
4 RENR9004-07
Table of Contents
MID 027 - CID 1471 - FMI 03 ............................. 336 MID 027 - CID 3210 - FMI 05 .............................. 511
MID 027 - CID 1472 - FMI 03 ............................. 353
MID 027 - CID 1472 - FMI 04 ............................. 358 Diagnostic System Procedures
MID 027 - CID 1472 - FMI 08 ............................. 361 Power Supply Circuit of Electronic Control
MID 027 - CID 1472 - FMI 14 ............................. 364 Module .............................................................. 522
MID 027 - CID 1473 - FMI 02 ............................. 367 Pulse Width Modulated Sensor .......................... 525
MID 027 - CID 1473 - FMI 03 ............................. 372 Starting System .................................................. 526
MID 027 - CID 1473 - FMI 04 ............................. 376 Switch Circuits .................................................... 529
MID 027 - CID 1473 - FMI 08 ............................. 379
MID 027 - CID 1473 - FMI 14 ............................. 383 Testing and Adjusting Section
MID 027 - CID 1482 - FMI 03 ............................. 386
MID 027 - CID 1482 - FMI 04 ............................. 388 Testing and Adjusting
MID 027 - CID 1484 - FMI 03 ............................. 391 Calibration ........................................................... 532
MID 027 - CID 1484 - FMI 04 ............................. 393 Electrical Connector - Inspect ............................. 533
MID 027 - CID 1674 - FMI 03 ............................. 396 Wiring Harness (Open Circuit) - Test .................. 537
MID 027 - CID 1674 - FMI 04 ............................. 398 Wiring Harness (Short Circuit) - Test .................. 538
MID 027 - CID 1674 - FMI 05 ............................. 399 Electronic Control Module (ECM) - Flash
MID 027 - CID 1960 - FMI 09 ............................. 402 Program ............................................................ 539
MID 027 - CID 1961 - FMI 03 ............................. 404 Electronic Control Module (ECM) - Configure .... 539
MID 027 - CID 1961 - FMI 04 ............................. 407 Electronic Control Module (ECM) - Replace ....... 540
MID 027 - CID 2113 - FMI 03 .............................. 409 System Schematic .............................................. 543
MID 027 - CID 2113 - FMI 04 .............................. 412
MID 027 - CID 2175 - FMI 03 ............................. 414 Index Section
MID 027 - CID 2175 - FMI 05 ............................. 416
MID 027 - CID 2175 - FMI 06 ............................. 418 Index ................................................................... 549
MID 027 - CID 2176 - FMI 03 ............................. 420
MID 027 - CID 2176 - FMI 05 ............................. 422
MID 027 - CID 2176 - FMI 06 ............................. 425
MID 027 - CID 2199 - FMI 03 ............................. 427
MID 027 - CID 2199 - FMI 04 ............................. 430
MID 027 - CID 2199 - FMI 08 ............................. 432
MID 027 - CID 2200 - FMI 00 ............................. 435
MID 027 - CID 2200 - FMI 01 ............................. 437
MID 027 - CID 2200 - FMI 02 ............................. 440
MID 027 - CID 2200 - FMI 03 ............................. 444
MID 027 - CID 2200 - FMI 04 ............................. 448
MID 027 - CID 2200 - FMI 08 ............................. 450
MID 027 - CID 2200 - FMI 13 ............................. 453
MID 027 - CID 2200 - FMI 14 ............................. 454
MID 027 - CID 2201 - FMI 00 ............................. 457
MID 027 - CID 2201 - FMI 01 ............................. 459
MID 027 - CID 2201 - FMI 02 ............................. 462
MID 027 - CID 2201 - FMI 03 ............................. 466
MID 027 - CID 2201 - FMI 04 ............................. 469
MID 027 - CID 2201 - FMI 08 ............................. 472
RENR9004-07 5
Systems Operation Section

i03630830
General Information
SMCS Code: 1400; 4000; 4800
g01315518
Illustration 1
M Series Motor Grader
6 RENR9004-07
g01947667
Illustration 2
Block diagram of the Transmission/Chassis ECM power train control system
RENR9004-07 7
The M Series Motor Graders are equipped with a

Transmission/Chassis electronic control module
(ECM) that will enable full electronic control of the
transmission clutch valves. The ECM allows the
operator to manually shift the transmission, based
on the status of the shift controls that are located
on the left joystick. A software enabled attachment
“Autoshift” function is available that will enable
the ECM to automatically control the operation
of the transmission. The electronic control of the
transmission by the Transmission/Chassis ECM
allows the technician to program specific operating
gear ranges to be configured using the Caterpillar
Electronic Technician (Cat ET) service tool. The ECM
monitors the status of the other machine systems
and the operation of the transmission at all times.
In addition to controlling the transmission, the

Transmission/Chassis ECM controls the following
machine systems:
• The engine starting system that is based on Illustration 3

g01324430
machine conditions and input from the key start Transmission/Chassis ECM located on the rear end of the
switch transmission (arrow)
• The secondary steering system that is based on During machine operation, the Transmission/Chassis
machine conditions and communication with the ECM receives input data from a variety of
Implement ECM components in the power train system. The ECM
makes decisions that are based upon the state of
• Operation of the parking brake that is based on these inputs and the operating parameters that are
machine conditions and the parking brake switch stored in the ECM memory. Input devices in the
implement control system include:
• Operation of the inching pedal that is based on
position sensor and switch inputs • Components in the left joystick
• Operation of the air conditioning system that is • Other control modules on the machine via the Cat
based on the air conditioning switch input Data Link and the SAE J1939 Data Link
• Differential lock function that is based on selector • Various “hard wired” switches that include operator
switch input control switches and machine system pressure
switches
• Back up alarm operation that is based on machine
conditions • Various “hard wired” sensors of the machine
system that include position sensors, pressure
sensors and temperature sensors
• The Cat ET service tool through the service tool

connector
The Transmission/Chassis ECM will activate outputs

to energize or de-energize solenoids and relays in
order to control the transmission and other machine
functions for the power train control system.
8 RENR9004-07
i03841033
Features
SMCS Code: 1400; 4000; 4800
Air Conditioning System
g02089155
Illustration 4
Air conditioning control circuit connections
The attachment air conditioning system is controlled Power for the air conditioning control components is
by the transmission/chassis ECM. supplied through the 15 amp HVAC fuse. The power
circuit is connected to the HVAC “ON/OFF/FAN”
selector switch in the HVAC operator panel.
RENR9004-07 9
Power for the high speed blower (not shown) is The contacts for the low pressure switch will close the
supplied to the blower motor through a 20 amp circuit system pressure increases to 118 kPa (17.1 psi). The
breaker and is switched to the blower motor by the switch contacts will be held closed until the system
high speed relay. Refer to the full machine Electrical pressure decreases to 27.5 kPa (4.0 psi).
Schematic for blower motor control connections.
The switch contacts for the HI/LO pressure switch are
When the selector switch is switched to the ON closed when the system pressure system pressure
position, the system power is directed to the internal is in the range 275 kPa (39.9 psi) to 1750 kPa
AC relay coil in the operator panel which will cause (253.8 psi).
the relay contacts to close. Power is then passed to
the AC operator switch through the closed contacts. If the system pressure is not correct and the contacts
of one or both of the pressure switches are open, the
When the AC operator switch is moved to the AC ON system power will not reach the thermostat.
position, the system power will be directed through
the switch contacts to a transmission/chassis ECM A pull-down resistor is connected to the thermostat
switch to +battery type input contact. input circuit in order to hold the input circuit low. When
the system power is passed through the contacts of
During normal operation, the ECM internal pull down both of the pressure switches and the thermostat
voltage will hold the AC operator switch input circuit contacts are closed, the system power will pull the
low until the system power is passed through the circuit high. The ECM will detect the high signal in the
switch contacts and pulls the input circuit signal high. thermostat circuit and will then activate the sinking
When the ECM detects the high +battery signal in driver output for the AC clutch relay.
the circuit, the ECM will determines that the switch
contacts are in the AC ON position. Once the ECM turns on the sinking driver for the
relay, system power from the HVAC fuse is provided
a path to ground through the sinking circuit. This
energizes the relay coil which will cause the relay
contacts to changes states. A path to ground is then
provided through the relay contacts for the system
power from the fuse to pass through the AC clutch
solenoid. The energized clutch solenoid will then
engage the AC compressor in order to activate the
system.
The transmission/chassis ECM does not monitor the

component circuits in the air conditioning system for
diagnostics.
Backup Alarm Operation

The backup alarm alerts the surrounding
personnel that the machine is backing up. The
transmission/chassis ECM activates the back up
alarm by use of the backup alarm relay. The relay is
controlled by the ECM through an ON/OFF output
g01331971
Illustration 5 driver.
Typical M Series Motor Grader AC Compressor located on the left
side of the engine Whenever the transmission is shifted to the
(21) AC compressor REVERSE direction, the ECM will turn on the output
(22) AC low pressure switch driver for the relay in order to activate the backup
(23) AC HI/LO pressure switch alarm.
Once the ECM has received the signal to activate

the AC system from the operator switch, the ECM Limp Home Mode
will monitor the switch to +battery type input circuit
that is connected to the thermostat. Power from the A “Limp Home” mode is available in order to provide
fuse must pass through two series connected system an override to a transmission disabling diagnostic
pressure switches in order to be present at one side event. The limp home mode will be activated by the
of the thermostat contact. One is a low pressure transmission/chassis ECM when a diagnostic code
switch and the other is the HI/LO pressure switch. is activated for any of the transmission solenoids.
When the limp home mode is activated, the ECM will
allow the transmission to shift to gears that are not
affected by the active diagnostic code.
10 RENR9004-07
Parasitic Load Reduction
g01948549
Illustration 6
Schematic of the parasitic load reduction circuit
The cold engine parasitic load reduction feature 1. Place the transmission in the NEUTRAL position.
removes non-essential loads during cold weather
starts. This feature achieves parasitic load reduction 2. Place the parking brake switch in the ENGAGED
via transmission and fan/brake bypass. This feature position.
is an optional attachment available only on the
following models: 3. Start the engine.
• 12M 4. Depress the inching pedal.
• 120M The gears 1F and 1R will be displayed on the

instrument cluster.
• 140M
5. Manually upshift the transmission four consecutive
• 160M times within two seconds.
This feature looks at the transmission oil temperature The instrument cluster will display the gear 5F as
and hydraulic oil temperature. If either of these the active gear. No reverse gear can be selected.
temperatures is equal to or less than 0° C (32° F),
the cold engine parasitic load reduction feature will 6. Depress the throttle pedal and release the inching
activate. pedal.
When the cold engine parasitic load reduction feature Result: For correct operation of the parking brake,
is activated, the fan/brake pump and transmission depressing the throttle pedal and releasing the
pump will bypass to tank, reducing the load on inching pedal should force the engine to stall. If the
the engine. Once the engine rpm has stabilized, machine moves forward, the parking brake operation
the transmission pump bypass solenoid will be is not correct. Investigate the cause of the failed
deactivated first followed by the fan/brake bypass test of the parking brake. Repair the problem before
solenoid, increasing the load on the engine. operating the machine.
Parking Brake Test Parking Brake Emergency Drive

In order to check for the correct operation of the
Through Function
parking brake, the transmission/chassis ECM will
In the event that the parking brake will not disengage
allow a parking brake test to be performed when the
and the machine must be moved for emergency
transmission in gear 5F. The following procedure purposes, the machine can be made to “drive
should be performed in order to check the operation
through” the engaged park brake.
of the parking brake.
RENR9004-07 11
WARNING:
THE FOLLOWING PROCEDURE SHOULD
ONLY BE PERFORMED IN AN EMERGENCY
SITUATION IN ORDER TO AVOID DANGER TO
THE OPERATOR OR TO THE MACHINE. THIS
PROCEDURE MAY CAUSE DAMAGE TO THE
PARKING BRAKE COMPONENTS.
1. With the transmission in the NEUTRAL position

and the parking brake switch in the ENGAGED
position, start the engine.
2. Move the parking brake switch to the

DISENGAGED position.
3. Depress the inching pedal. The gears 1F and 1R

will be displayed on the instrument cluster.
4. Do not upshift or downshift. The active gear must

be either gear 1F or 1R.
5. Select a direction and release the inching pedal.
6. Depress the throttle pedal in order to “drive

through” the engaged parking brake.
Result: Releasing the inching pedal while depressing

the throttle pedal will result in the machine moving
in the selected direction and “driving through” the
engaged parking brake. Move the machine for the
shortest possible distance in order to minimize
damage to the parking brake components.
Secondary Steer System
g01326393
Illustration 7
Secondary Steer Control System
12 RENR9004-07
g01326014
Illustration 8
Secondary Steer System connections
The Series M Series motor graders are equipped with The transmission/chassis ECM and the implement
a secondary steering system that serves as a backup ECM monitor the position sensor input signals from
steering system in the event of a failure of the primary the following steering system sensors:
steering system. The transmission/chassis ECM is
the main control for the secondary steering system. • The Left joystick steer sensors 1, 2, and 3.
Note: When activated, the secondary steering • The left and the right steer cylinder position
system is designed to be used for a short period of sensors.
time in order to move the machine to a safe area
for shutdown. The steering system loads will cause • The machine articulation position sensors 1 and 2.
the secondary steer pump motor to overheat when
operated for more than a short period of time.
RENR9004-07 13
The implement ECM monitors the steering system

sensor signals in order to control the primary steering
system. The transmission/chassis ECM monitors
the same steering system sensor signals in order
to be able to activate and control the secondary
steering system at any time during the operation of
the machine.
When the implement ECM detects a problem in the

primary steering system, the implement ECM will
send a pulse width modulated (PWM) signal to the
transmission/chassis ECM on the “Secondary Steer
Request” circuit that is connected between the two
controls.
The implement ECM will send a request signal to the

transmission/chassis ECM in order to activate the
secondary steering system when any of the following
machine system conditions are detected:
• An active CID 2202 FMI 12 (Steering Valve Control

Module Error) diagnostic code. Illustration 9
g01326509
Secondary Steer Solenoids located in front of the cab behind the

• A failure of the main hydraulic pump. rear valve stack.
(17) Secondary steer right solenoid
• Steering motion is detected when no primary (18) Secondary steer left solenoid
steering command is present.
• Steering motion is not detected when a primary

steering command is present.
• Steering motion is detected in the wrong direction.

• A manual secondary steer test has been requested.
• An automatic secondary steering pump test is
being performed at initial engine start-up.
The transmission/chassis ECM will activate the

secondary steering system without receiving a
request signal from the implement ECM when the
following condition is present:
• An active CID 2199 (Secondary Steering Request

Signal from the implement ECM) diagnostic code.
g01326526
Illustration 10
Secondary Steer Motor Relay and Pump Motor (View: Underneath
the machine on the rear side of the articulation hitch.)
(19) Secondary steer motor relay
(20) Secondary steering pump motor
14 RENR9004-07
When the implement ECM sends a PWM secondary When an 80 percent duty cycle request is received by
steer request signal to the transmission/chassis the transmission/chassis ECM, the ECM will energize
ECM, the duty cycle of the PWM signal will determine the secondary steer relay in order to energize the
which specific secondary steer system components secondary steering pump motor. The ECM will
will be activated. During normal operation, the also activate the proportional secondary steer pilot
implement ECM maintains a 20 percent duty cycle solenoids.
on the request circuit. When a secondary steer
test is requested or when the implement ECM has In order to control the secondary steer system, the
detected a problem in the primary steering system, transmission/chassis ECM will use a “closed loop”
the secondary steer request signal will be one of the command and feedback system similar to the system
following duty cycle signals: that the implement ECM uses to control the primary
steering system.
20 percent PWM duty cycle – Normal operation, no
request to activate. The transmission/chassis ECM outputs the PWM
output signal to the appropriate solenoid based on
40 percent PWM duty cycle – Request to activate the steer sensor input signal from the left joystick.
the secondary steering pump motor only. Then, the ECM monitors the position of the steer
cylinders in order to adjust the electrical current to
60 percent PWM duty cycle – Request to activate the solenoid accordingly. As the steering cylinders
the secondary steer pilot solenoid valves only. approach and reach the commanded position, the
ECM will decrease the output current to the solenoid
80 percent PWM duty cycle – Request to activate until movement of the cylinders is stopped. The cycle
the secondary steering pump and the secondary repeats as steering input from the joystick changes.
steer pilot solenoid valves.
If one of the steer cylinder position sensor signals
When a 40 percent duty cycle request is received is not available, the transmission/chassis ECM will
by the transmission/chassis ECM, the ECM will use the signal from the other cylinder position sensor
energize the secondary steer relay. This will allow to determine the position of the front wheels. If both
power to pass through the relay contacts which will of the steer cylinder position sensor signals are not
energize the secondary steer motor relay. Power available, the transmission/chassis ECM will use the
from the power control box will then be supplied to last known cylinder position sensor data and the
the secondary steering pump motor which turns the commanded hydraulic oil flow in order to estimate
secondary steering pump. When a pump request only the position the steer cylinders and the front wheels.
is received, the secondary steering pump will supply This condition will result in limited steering motion
hydraulic oil flow to the primary steering system. over time.
Note: When the secondary steering pump motor is Once the transmission/chassis ECM has activated
activated in order to supply hydraulic oil flow to the the secondary steering system, the system will
primary steering system or the secondary steering remain active until the machine is turned OFF. If the
system, the secondary steering pump motor will condition that caused the activation of the secondary
overheat if operated for more than a short period of steering system is no longer present, the primary
time. steering system will be active when the machine is
restarted.
When a 60 percent duty cycle request is received by
the transmission/chassis ECM, the ECM will activate
the proportional secondary steer pilot solenoid valves
Secondary Steer System Test
in order to control the hydraulic oil flow to the steer The implement ECM and the transmission/chassis
cylinders. The ECM will use a PWM output signal in
ECM perform an automatic test or a manual test in
order to energize the secondary steer solenoids. The
order to check the system for proper operation.
transmission/chassis ECM will vary the amount of
electrical current that is sent to the solenoids in order
to control the angle of the front wheels. Automatic Secondary Steering Test
When the secondary steer solenoids are energized, The automatic secondary pump test is performed
pilot oil is directed to the same main hydraulic once each time that the engine is started. If the
valve that is used for the primary steering system. system does not perform as expected, the implement
The steering valve control module that is used for ECM will activate a level 3 EID 0560 (Secondary
operation of the primary steering system is not used Steering Pump No Response) event in order to alert
when the secondary steer solenoids are active. the operator that the system has failed the test.
RENR9004-07 15
During the automatic test, the engine must be If the implement ECM detects that the secondary
operating and the machine speed must be zero. pump pressure is greater than 10,000 kPa
During an automatic secondary steering test, all (1450.4 psi) within the specified time limit, the
implement and primary steering functions are implement ECM will send an 80 percent PWM duty
disabled by the implement ECM for the ten second cycle signal to the transmission/chassis ECM over
duration of the test. the secondary steering request circuit. An 80 percent
duty cycle indicates that the transmission/chassis
Note: If the automatic secondary steer test or ECM should activate the secondary steering pump
the manual test results in an active level 3 EID motor and the secondary steer pilot solenoid valves.
0560 (Secondary Steering Pump No Response)
event being activated by the implement ECM, When the operator sees that no EID 0560 event code
the machine must be immediately shutdown in a has been activated on the Messenger, the operator
safe manner. The problem in the secondary steer should immediately move the left joystick to the steer
system must be investigated and repaired before left and the steer right positions. If the front wheels
operating the machine. follow the steer commands, the secondary steer
system is performing correctly.
Manual Secondary Steering Test
After the operator holds the momentary secondary
The manual test for the secondary steer system steer test switch in the test position for ten seconds,
should be performed every 100 hours of machine the implement ECM will deactivate the test mode.
operation or every two weeks.
Note: If the manual secondary steer test results
During a manual secondary steering test, all in no active EID 0560 (Secondary Steering Pump
implement and primary steering functions are No Response) event code, however, the front
disabled by the implement ECM for the ten second wheels do not respond correctly to the steering
duration of the test. commands within the ten second time limit, the
machine must be immediately shutdown in a safe
In order to perform the manual secondary steering manner. There is a problem in the secondary
test, the engine must be running and the machine steer system that must be investigated and
speed must be zero. repaired before operating the machine.
To begin the test, the operator holds the momentary

secondary steering test switch in the test position for
a period of ten seconds.
When the implement ECM detects that the switch

input circuit has been grounded through the switch,
the implement ECM will initiate the manual test for
the system.
First, the implement ECM disables the primary

steering system and the implement system. Then,
the implement ECM sends a 40 percent PWM duty
cycle signal to the transmission/chassis ECM over
the secondary steering request circuit. A 40 percent
duty cycle indicates that the transmission/chassis
ECM should activate the secondary steering pump
motor only.
While the transmission/chassis ECM energizes

the secondary steer relay in order to turn ON the
secondary steering pump motor, the implement ECM
monitors the main hydraulic discharge pressure
sensor. Two check valves are used in the hydraulic
system to enable the main pressure sensor to detect
the secondary pump pressure.
If the implement ECM does not detect that the

secondary pump pressure is greater than 10,000 kPa
(1450.4 psi) in a specified short period of time, the
implement ECM will activate an EID 0560 (Secondary
Steering Pump No Response) event code.
16 RENR9004-07
Transmission Electronic Clutch The ECM will output a pulse width modulated (PWM)
signal in order to vary the current to the solenoid.
Pressure Control (ECPC) The current to the solenoid determines the amount
of pilot oil pressure that is applied to the hydraulic
valve spool. The travel of the spool is proportional to
the electrical current that is supplied to the solenoid.
The position of the valve spool controls the amount
of hydraulic oil pressure that is applied to the clutch
which determines the amount of clutch engagement.
An increase in electrical current will cause an
increase in the engagement pressure from the clutch.
The following two modes are available for operation

of the transmission:
• The standard mode of operation is the manual

mode.
• The attachment autoshift mode.

When in the manual mode, the transmission/chassis
ECM selects the transmission clutches that must be
engaged according to the inputs from the operator
controls on the left joystick. When the machine is in
g01324626
Illustration 11 the attachment autoshift mode, the ECM controls
Transmission clutch solenoids that are located on the left side the shifting pattern according to machine operating
of the transmission conditions and the transmission output speed (TOS).
(1) Transmission clutch solenoid 1 (forward high)
(2) Transmission clutch solenoid 2 (forward low) Note: When the transmission oil is changed and
(3) Transmission clutch solenoid 3 (reverse) the viscosity of the new oil is not the same as the
(4) Transmission clutch solenoid 4 (2nd speed) viscosity of the old oil, the new oil viscosity must be
(5) Transmission clutch solenoid 5 (3rd speed)
(6) Transmission clutch solenoid 6 (1st speed) configured for the machine. The parameter for the
(7) Transmission clutch solenoid 7 (low range) viscosity of the new oil can be changed by use of the
(8) Transmission clutch solenoid 8 (high range) Messenger or by use of the Cat ET service tool in the
configuration screen. Once the new oil viscosity is
The transmission/chassis ECM on the configured, the Transmission Clutch Fill Calibration
Series M Series Motor Graders enables the MUST be performed. The transmission/chassis ECM
operation of Electronic Clutch Pressure Control will adjust the operation of the transmission according
(ECPC) valves for control of the transmission. to the viscosity of the new transmission oil. Refer to
The ECM controls the eight proportional solenoid the Testing and Adjusting, “Machine Control Module
valves of the transmission clutch in order to shift (ECM) - Configure” section of this manual for more
the transmission. The transmission solenoid valves information.
control the hydraulic circuits that engage the
transmission clutch pressures. The ECM supplies
electrical current to the appropriate transmission
solenoid valves in order to move the machine in one
of the two available speed ranges that enable eight
speeds in the forward direction and 6 speeds in the
reverse direction.
On an ECPC controlled transmission, the clutch

pressure is modulated electronically. The ECM
controls the modulation of clutch pressure by
sending a variable output current to the appropriate
proportional clutch solenoids. In order to determine
the correct output current to send to the clutch
solenoids, the ECM monitors the following data:
• Engine torque data from the Engine ECM

• Input data from the transmission speed sensors
• Temperature data from the transmission sensor
RENR9004-07 17
g01324764
Illustration 12
Note: Illustration 12 shows the internal push buttons • The upshift switch
and ground assignments for the transmission
controls in the left joystick. The left joystick for the • The downshift switch
implement and steering components that provide
inputs to the implement ECM are not shown here. • The FORWARD/NEUTRAL/REVERSE (FNR)
The components that are in the left joystick are switch
not serviceable. If a component in the joystick has
failed, the complete assembly must be replaced. Each switch is internally connected to two of the four
The illustration is displayed in order to aid in the ECM return (ground) circuits that are supplied to the
component and the troubleshooting of the circuit for left joystick. One of the return circuits of the ECM for
the transmission controls. For a complete connection the switches is supplied by the transmission/chassis
diagram for all of the joystick to ECM connections, ECM and the other return circuit of the ECM for the
refer to the System Schematics in the back of this switches is supplied by the implement ECM. Both
manual. ground connections must fail either internally or
externally in order to interrupt the operation of the
The following switches provide a switch to ground switch due to loss of ground connections.
input to the transmission/chassis ECM in order to
indicate the commands of the operator for gear
selection:
18 RENR9004-07
The ECM has an internal “pull up” voltage that is The transmission on the M Series Motor Graders
connected to each of the switch input connections. is equipped with five transmission speed sensors.
The pull up voltage holds the circuit high until Each speed sensor supplies a frequency input to the
the switch grounds the circuit through the switch transmission/chassis ECM.
contacts. The ECM expects one of the switch inputs
to be grounded at all times. If all of the switch inputs The input speed sensor is mounted at a location
are grounded or if none of the switch inputs are that will monitor a gear on the input shaft of the
grounded, the ECM will activate a diagnostic code transmission. The two intermediate speed sensors
for the switch. are mounted at a location in order to monitor a large
intermediate gear in the transmission. The two output
The ECM monitors the state of the three inputs of the speed sensors are mounted at a location in order to
switch for the FNR trigger selector switch. The switch monitor a gear that is mounted on the output shaft
input that is grounded through the switch contacts of the transmission.
will determine the directional mode that the ECM will
activate for the transmission. Each of the speed sensors is attached to the
transmission with a fixed mount. No adjustment of
The ECM monitors the state of the two switch inputs the mount for the speed sensor is necessary.
for the upshift switch and the down shift switch. When
the ECM detects the transition from the normally The speed sensors produce a signal that varies in
closed input being grounded through the switch frequency (Hz) as the tooth of the gear is passed in
contacts to the normally open input being grounded front of the sensor. As each tooth of the gear passes
through the switch contacts, the ECM will activate the sensor one cycle or hertz is detected by the
the solenoid outputs for the next higher or lower gear speed sensor. The ECM detects the frequency of
in the selected forward or reverse direction. If the the signal. The ECM then determines the speed and
upshift switch or the down shift switch is depressed the direction of the shaft that is associated with that
numerous times, the ECM will detect the number of gear. Each speed sensor has two input connections
switch input transitions and activate the solenoids for to the ECM (“+” and “-”). The following applies to all
the requested higher or lower gear provided that the speed sensors:
requested shift will not cause damage to transmission
components. • Connector contact 2 is the signal (+)
Operation of the Transmission Speed • Connector contact 1 is the return line (-)
Sensor When the speed of the transmission output shaft is
greater than 150 rpm, the transmission/chassis ECM
monitors the two output speed sensors in order to
determine the transmission output speed (TOS) and
the direction of travel. If no TOS or direction signals
are coming from the two output speed sensors, the
ECM will use the signals from intermediate speed
sensors in order to calculate the TOS and in order
to determine the direction. This enables the ECM to
maintain control of the transmission if a failure of the
two output speed sensor circuits should occur.
When the speed of the transmission output shaft

is less than 150 rpm, the ECM will use the signals
from the two intermediate speed sensors to calculate
the TOS and the direction of travel. At the lower
TOS, the slower speed of the output gear results in
a poor signal from the output speed sensors. The
larger intermediate gear is rotating faster at the lower
output shaft speed which results in a more reliable
intermediate speed sensor signal.
g01330023
Illustration 13 Note: In the event that both of the intermediate speed
Transmission speed sensors that are located on the top side and sensors fail, the speed of the transmission output
the right side of the transmission shaft will not be able to be determined at a speed of
(9) Transmission input speed sensor less than 150 rpm.
(10) Transmission intermediate speed sensor 2
(12) Transmission output speed sensor 2
RENR9004-07 19
The ECM uses the TOS and direction data in order

to control the shifting of the transmission when
operating in the autoshift mode. The ECM uses the
TOS and direction information in order to control the
operation of the transmission and to prevent unsafe
operating conditions that could be dangerous to the
operator or cause damage to the machine.
During normal operation of the transmission, the

transmission/chassis ECM is using the signal from
the input speed sensor to determine the speed of the
engine. In addition, the ECM is receiving data about
engine speed from the Engine ECM over the J1939
Data Link. The ECM is comparing the speed data
for the engine against the frequency from the input
speed sensor. The ECM is continuously comparing
the signals that are supplied by the two output speed
sensors to each other and the ECM is continuously
comparing the signals that are supplied by the two
intermediate speed sensors to each other.
If the ECM detects that the two output speed sensor

signals differ by more than 50 rpm, the ECM will use
the signals from the intermediate speed sensors
to determine which output speed sensor signal is
correct. In the unlikely event that the signals from the
two intermediate speed sensors differ by more than
50 rpm, the ECM will use the input speed sensor
signal and calculate which output speed sensor
signal is the correct signal and which intermediate
speed sensor signal is the correct signal. The ECM
will then activate a diagnostic code for the speed
sensor circuits that are determined to be producing
the faulty signal.
If the ECM determines that the signals of the two

intermediate speed sensors differ by more than 50
rpm, the ECM will use the input speed sensor signal
and calculate which intermediate speed sensor signal
is the correct signal. The ECM will then activate a
diagnostic code for the intermediate speed sensor
circuit that is producing the faulty signal.
Operation of Transmission Shifting

In order to control the shifting of the transmission,
the transmission/chassis ECM will energize two
clutch solenoids when the machine is in PARK
or NEUTRAL. The ECM will energize different
combinations of three clutch solenoids when the
machine is in one of the available gears in the
forward or the reverse direction. Table 1 indicates
which solenoids are energized in order to activate the
corresponding gear arrangement.
Note: During machine operation, the selected gear

and direction are displayed on the LCD screen of the
instrument cluster. When in NEUTRAL, the selected
gear for FORWARD and for REVERSE are displayed.
20 RENR9004-07
Table 1
Transmission Gear and Solenoid Valve Logic
Solenoid Solenoid Solenoid Solenoid Solenoid Solenoid Solenoid
Solenoid 3
1 (forward 2 (forward 4 (second 5 (third 6 (first 7 (low 8 (high
(reverse)
high) low) speed) speed) speed) range) range)
Park X X
Neutral X X
First Speed
X X X
Forward
Second Speed
X X X
Forward
Third Speed
X X X
Forward
Fourth Speed
X X X
Forward
Fifth Speed
X X X
Forward
Sixth Speed
X X X
Forward
Seventh Speed
X X X
Forward
Eighth Speed
X X X
Forward
First Speed
X X X
Reverse
Second Speed
X X X
Reverse
Third Speed
X X X
Reverse
Fourth Speed
X X X
Reverse
Fifth Speed
X X X
Reverse
Sixth Speed
X X X
Reverse
RENR9004-07 21
Operation of Manual Mode
g01324667
Illustration 14
Transmission Shift Controls on the left joystick
(14) Upshift switch (15) Downshift switch (16) FNR trigger selector switch
The standard mode of transmission operation is the The initial gear that is configured in the Cat ET
manual mode. The manual mode is active when the service tool or in Messenger will be the first gear that
engine is started. If the machine is equipped with the ECM will shift to when the machine is shifted to
the autoshift attachment, the manual mode is active the FORWARD position or to the REVERSE position.
anytime the autoshift function is in the OFF position. For example, the factory default for the Initial gear
When in manual mode, the operator uses the push is set to gear 3F and gear 3R. At start-up of the
button switch controls on the left joystick to send shift machine with the transmission in NEUTRAL, both
commands to the transmission/chassis ECM. the gear 3F and the gear 3R will be displayed on the
instrument cluster. When the transmission is shifted
Two gear presets can be configured for use in the into the FORWARD position and no upshift or no
standard manual mode or for use in the attachment downshift has been requested by the operator, the
autoshift mode if it is installed on the machine. The active gear will be gear 3F. Gear 3R would be active if
presets are the “Initial” gear and the “Maximum” gear. the machine were shifted to the REVERSE position.
Initial Gear Upshifts or downshifts can be requested while the

transmission is in the NEUTRAL position. Upshifts
The transmission/chassis ECM allows an “Initial or downshifts can also be requested during travel to
Gear” to be configured for the FORWARD and activate a gear other than the defined initial gear.
REVERSE direction by use of the Cat ET service tool
or the Messenger. The configuring of the initial gear The defined Initial gear is effective at all times during
must be done when the transmission is in NEUTRAL the machine operation. When the “Autoshift” mode
and the transmission output speed is zero (no travel). is active, the initial gear may be ignored under
The configured Initial gear will be recognized in the certain operating conditions that are covered in the
Manual Mode and the Initial gear will be recognized “Autoshift” section below.
under some conditions in the Autoshift Mode.
The ECM will accept gears in the following gear
ranges as the configured initial gear. In the
FORWARD direction, gear 1F to gear 5F. In the
REVERSE direction, gear 1R to gear 4R. The factory
defaults for the Initial gears are gear 3F and gear 3R.
22 RENR9004-07
Maximum Gear • When (TOS) is greater than 150 rpm: When

shifting to NEUTRAL from either the FORWARD
The transmission/chassis ECM allows a “Maximum” or the REVERSE direction, the gear that is active
gear to be configured for the FORWARD and when the shift to NEUTRAL takes place will
REVERSE directions by use of the Cat ET service remain the same. Example: Active gear is 2F.
tool only. The configuring of the Maximum Gear must The transmission is shifted to NEUTRAL from 2F.
be done when the transmission is in NEUTRAL and Gear 2F will be active if the transmission is shifted
the transmission output speed is zero (no travel). The back to FORWARD. Gear 2R will be active if the
configured Maximum gear will be used at all times transmission is shifted to REVERSE. If the active
during machine operation in either the manual mode gear is set greater than 3F or 3R then the opposite
or the autoshift mode. direction is set to 3F or 3R.
The configured maximum gear that is configured • When (TOS) is less than 150 rpm: Shifting to
in the Cat ET service tool will be the highest gear the NEUTRAL position from a gear that is lower
that the ECM will activate when the machine is in than the configured initial gear will result in the
operation in the FORWARD direction or the machine same gear being available for the next request of
is in operation in the REVERSE direction. The a directional shift. Example: The Initial gear is 3F
maximum FORWARD gear can be configured as low and 3R. The transmission is shifted to NEUTRAL
as 3F and up to 8F and the maximum REVERSE gear from active gear 2F. Gear 2F will be active when a
can be configured starting at 3R and up to 6R. For shift to FORWARD is requested. Gear 2R will be
example, the factory default for the Maximum gear active if a shift to REVERSE is requested.
is set to gear 8F and gear 6R. The maximum gear
setting allows for the normal operation of all of the • When (TOS) is less than 150 rpm: Shifting to
available gears for the operation of the transmission. the NEUTRAL position from a gear that is higher
If the operator wants to limit transmission operation than the configured initial gear will result in the
to no higher than gear 4F in the FORWARD direction configured initial gear being active the next time a
and 3R in the REVERSE direction, the technician directional shift is requested. Example: The Initial
can configure the maximum gears to gear 4F and gear is 3F and 3R. The transmission is shifted to
gear 3R by use of the Cat ET service tool. When this NEUTRAL from active gear 5F. Initial gear 3F will
is done, the ECM will not allow a shift to a gear that be active when a shift to FORWARD is requested.
is higher than gear 4F or gear 3R at any time during Gear 3R will be active if a shift to REVERSE is
machine operation in either transmission mode. requested.
The ECM will retain the configured maximum gear
parameter in both directions until the parameters are • If the transmission is operating in an overspeed
changed using the Cat ET service tool. condition for the active gear, the active gear display
on the instrument cluster will flash ON and OFF
Transmission/Chassis ECM Shifting Logic In until the overspeed condition is no longer occurring.
Manual Mode
Directional Shifting
The transmission/chassis ECM monitors the input
signals from the transmission speed sensors in order The ECM will allow directional shifting in gear 1, gear
to determine the transmission output speed (TOS) 2, gear 3, or gear 4 when the machine is in gear and
and direction of travel. The ECM will use “speed traveling. The following directional shifts are allowed:
inhibit logic” to prevent hazardous transmission
operation. The ECM will allow directional shifts while • From FORWARD to REVERSE: 1F to 1R, 2F to
traveling if the requested change in operation will not 2R, 3F to 3R and 4F to 3R.
result in damage to the machine or in danger to the
operator. If a requested gear shift is determined to • From REVERSE to FORWARD: 1R to 1F, 2R to
be improper at a given machine speed, the ECM will 2F, 3R to 3F.
shift to a gear that is close to the requested gear in
order to allow for safe operation. The following logic is used by the ECM for directional
shifting operation of the transmission and to prevent
The following logic is used by the ECM for normal hazardous transmission operation:
operation of the transmission and to prevent
hazardous transmission operation: • For a directional shift, the FNR switch must pass
through NEUTRAL in less than 0.1 seconds.
• All shifts must be performed as the engine is
running, the operator is in the seat and the parking • Directional shifts may be performed with or without
brake is disengaged. the operation of the inching pedal. If the inching
pedal is depressed, during a directional shift
• If an active gear is not selected after the machine request, and is then released, the ECM will shift to
start-up, the default or configured initial gear will be the appropriate gear for the current machine speed
the active gear in both directions. and execute the requested directional shift.
RENR9004-07 23
• A directional shift from gear 4F to gear 3R will not • The “FNR” switch is moved out of the NEUTRAL
be allowed if the TOS is above a defined speed. position.
The ECM will initiate a down shift to gear 3F before
shifting to gear 3R. • The inching pedal is depressed.
• When a directional shift is initiated from a gear • The transmission output speed is greater than 95
higher than gear 3, the ECM will downshift the rpm.
transmission to gear 3 and will execute the
requested directional shift. • A signal is not received from the transmission
output speed sensor.
Note: If, for example, the directional shift was
initiated in 7F and the inching pedal was depressed • The engine is turned OFF.
and the machine was allowed to slow to a 5F
speed, releasing the inching pedal would engage 5F The ECM will also deactivate the priming of the clutch
and continue to down shift to 3F and execute the when a diagnostic code is activated for any of the
directional shift to 3R. following components.
Cold Transmission Oil Mode - Direction • Any of the transmission clutch solenoids
Clutch Priming
• The FNR switch
In order to avoid harsh shifting that can be caused by
cold transmission oil, the transmission/chassis ECM • Any of the electrical components of the parking
brake system
will perform an automatic procedure for priming the
direction clutch. The ECM will activate the direction
clutch priming cycle when the engine is started and • The position sensor of the inching pedal
the following machine conditions are present.
Transmission Over Speed Protection
• The temperature of the transmission oil is equal to Strategy
or less than 15 °C (59.0 °F).
Overspeed protection is a feature that utilizes
• The starting sequence of the machine is complete. transmission shifts to help protect the engine from
The engine is running and the speed sensors are running at an overspeed condition. In addition,
active. overspeed protection ensures that the transmission
will never be shifted into a gear that would cause an
• The parking brake is engaged. overspeed condition.
• The FNR switch is in the NEUTRAL position. Overspeed Upshift
• The inching pedal is not depressed. The control will upshift the transmission by one gear
when the transmission output speed reaches the
During the priming cycle of the clutch, the ECM will overspeed up shift point for the current gear. The
inhibit the calculated transmission output speed. The control does not limit the number of overspeed up
ECM will change the minimum transmission output shifts. If the transmission output speed continues to
speed from 150 rpm to 95 rpm in order to detect any increase, the control will upshift, based on overspeed
machine movement. upshift points, until the transmission reaches the top
gear.
During the priming of the clutch, the ECM will send
a pulse of electrical current to the outputs for the Overspeed Downshift
transmission clutch solenoid valves. This procedure
fills the clutch valves with oil in order to avoid harsh The control will downshift the transmission by one
transmission shifts. gear when the actual gear is higher than the selected
gear and the transmission output speed decreases
The ECM performs the automatic direction clutch below the overspeed downshift point.
priming cycle in less than 10 seconds.
The ECM will deactivate the priming of the clutch

when the automatic cycle is completed or if the
following machine conditions occur.
• The parking brake is disengaged.

24 RENR9004-07
Engine Controlled Downshift The autoshift function is an attachment function that

is software enabled. A factory password is required
The shift control logic contains downshift inhibit to enable this function.
points. These “inhibit” points were established in
order to prevent abusive operation of the power The operator turns on the function with the autoshift
train. The “inhibit” points also protect the operator switch on the right console. When the autoshift mode
from possible adverse operation of the machine. The is active, the ECM will illuminate the autoshift LED
Transmission ECM will downshift the transmission that is located below the instrument cluster on the
by one gear when the actual gear is higher than the dash. The LED will flash “ON” and “OFF” when the
desired gear and the transmission output speed is machine is operated in a gear that is lower than
below the overspeed downshift rpm point. The current the configured minimum autoshift gear or when the
downshift inhibit strategy is good for protecting transmission is in NEUTRAL position.
the transmission and protecting the engine from
damage caused by overspeed. The downshift inhibit The ECM uses the transmission output speed (TOS)
strategy does not allow the requested shift to take data from the transmission output speed sensors
place as quickly as possible. The engine controlled to determine the shift points at which the autoshift
downshift feature will try to resolve this issue. If the function is active. If the output speed sensor signals
transmission/chassis ECM requests a downshift are determined to be faulty, the ECM will use the
and the transmission output speed is above the speed and direction signals from the intermediate
overspeed downshift point, the transmission/chassis speed sensors to determine the autoshift shift points.
ECM will command the minimum engine speed
among the gears between the current gear and the In order to set up the operating gear range of the
minimum downshift gear. autoshift, the ECM will recognize a configured
autoshift minimum gear and a configured autoshift
In an example of this process, suppose that the maximum gear. These operating gear limits are
actual gear is 6F. The operator request downshifts configured for the FORWARD and REVERSE
to 3F. If the transmission output speed is above the direction by use of the Cat ET service tool or
overspeed downshift transmission output speed for Messenger. The configuring of the autoshift minimum
5F, the transmission/chassis ECM will command the gear and autoshift maximum gear must be done
minimum engine speed between 6F to 5F, 5F to 4F when the transmission is in NEUTRAL and the
and 4F to 3F. transmission output speed is zero (no travel).
Note: The downshift function for engine control will Note: The autoshift maximum gear that can be set
be deactivated if the parking brake is engaged. The up using the Cat ET service tool or the Messenger
downshift function for engine control will also be should not be confused with the maximum gear
deactivated if the inching pedal or the switch for the that is set up in the Cat ET service tool only. The
inching pedal is depressed. autoshift maximum gear set up using the Cat ET
service tool and the maximum gear that is set up in
Transmission Gear Limiting the Messenger are two different parameters. The
autoshift maximum gear is only active when the
The Transmission Output Speed Steering Limit autoshift function is enabled. The maximum gear
(TOSSL) is evaluated against the transmission speed is active at all times in any mode of transmission
limiting tables to determine the highest gear that operation.
would not exceed TOSSL. All gears above this gear
will be inhibited. If the actual gear is an inhibited gear, The ECM will accept certain gear ranges for the
the gear limiting feature will check to see if shifting autoshift maximum gear and the autoshift minimum
to the highest gear would cause an overspeed gear. The following table displays the selectable
condition. If no overspeed condition is predicted, the gears that the ECM will accept for each parameter.
transmission will command a shift to this gear. If an The table also displays the factory default settings
overspeed condition is predicted, a shift command for the gears.
will be prohibited.
Table 2
Autoshift Operation Selectable Range Of Autoshift Gears

Direction Allowable Allowable Factory
The autoshift function allows the operator to “Autoshift “Autoshift Default
set or configure the range of gears that the Minimum” Maximum” Settings
transmission/chassis ECM will use for automatic Gears Gears (Minimum to
shifting of the transmission in the FORWARD Maximum)
direction or the REVERSE direction. Forward 1F to 5F 3F to 8F 3F to 8F
Reverse 1R to 4R 3R to 6R 3R to 6R
RENR9004-07 25
The following logic is used by the ECM for operation i02912116

of the transmission in the autoshift mode.
Location of Electrical
• In order for the ECM to enable the autoshift Components
function, there can be no active diagnostic codes
for the transmission solenoids, the FNR switch, the SMCS Code: 1400; 4000
Autoshift switch or the parking brake components.
If the ECM detects an abnormal condition the ECM
may active a diagnostic code for any of these
components. The autoshift function will be turned
OFF.
• If the ECM can not determine the TOS speed

signal or the direction signal from the output speed
sensors or from the intermediate speed sensors,
the autoshift mode will not be enabled. If these
signals are lost during autoshift operation, the ECM
will turn OFF the Autoshift mode.
• When the autoshift mode is active and a shift from

NEUTRAL in either direction is performed, the
configured initial gear will be ignored if it is within
the set autoshift gear range. If the Initial gear is
not within the set autoshift range, then the ECM
will shift to the Initial gear. A manual shift into the
autoshift range is then required to operate in the
Autoshift mode.
g01322755
Illustration 15
• A manual shift will be required when operating
outside the configured range of the autoshift. Once Transmission/Chassis ECM location on the rear of the transmission
a manual shift to a gear within the autoshift range
takes place, the ECM will continue the automatic The Transmission/Chassis ECM is mounted on the
transmission operation in the autoshift gear range. rear of the transmission. Many of the components,
that make up the electronic control system of the
• When operating the machine in the autoshift range, Power Train, are located at the transmission or near
if the ECM detects an operator requested upshift the transmission. For the locations of many of these
or downshift from the push button switches on components, refer to the Systems Operation, “Inputs”
the left joystick, the ECM will change the autoshift and Systems Operation, “Outputs” sections of this
maximum gear to the operator requested gear. manual.
This temporary change of the autoshift maximum
gear will be in effect until the key switch is turned The Electrical System Schematic of the machine that
to the OFF position. When the engine is started is in the Service Manual will illustrate locations for all
again, the ECM will return to the original configured of the electrical components and harness connectors
maximum gear of the autoshift. Example: The that are installed on the machine.
ECM is automatically shifting in the configured
autoshift range of gear 3F to gear 6F in the Cab Relay Locations
FORWARD direction and gear 2R to gear 4R in
the REVERSE direction. While in gear 6F, the Note: The following relay locations for cab mounted
operator depresses the downshift switch once in relays are correct at the time of publication of
order to manually downshift into gear 5F. The ECM this manual. The location of the relays on some
executes the downshift and this action changes early model machines may be slightly different.
the autoshift maximum gear to gear 5F until the When servicing a particular relay, always refer to
next key start cycle. The same process will occur the complete Electrical System Schematic of the
in the REVERSE direction if a manual upshift or machine in order to verify the wire numbers of the
downshift is requested. relay that is being serviced.
26 RENR9004-07
g01379724
Illustration 16
Relays that are located behind the cover on the right side headliner
(1) Power air cleaner relay
(2) Cab floodlights relay
(3) Backlight relay
(4) Mounting location of attachment heated mirror relay when
installed
(5) Blade flood relay
(6) Condenser fan relay 2
(7) Condenser fan relay
g01379730
Illustration 17
Relays that are located on the rear wall of the cab behind the right
hand console
(8) Horn relay
(9) L. H. position relay
(10) Diff lock relay
(11) Headlamp relay
(13) Enable relay
(14) R.H. position relay
(15) Dimmer relay
(16) Rear flood relay
(17) Fast speed relay
RENR9004-07 27
i03630956
Electrical Input Components

SMCS Code: 1400; 4000
g01947755
Illustration 18
Block diagram of the Transmission/Chassis ECM power train input components
The electronic control system of the power train Switches provide signals to the switch inputs of the
utilizes a variety of different types of devices that ECM. The possible outputs of a switch are an open
provide input data to the Transmission/Chassis signal, a grounded signal or a voltage signal.
ECM. The ECM receives data about the status of
the machine from the input devices. The ECM will Sensors provide an electrical signal to the ECM that
use the machine status information to determine the constantly changes. The sensor input to the ECM can
correct output action that is needed in order to control be one of several different types of electrical signals
the power train functions of the machine based on such as the following: pulse width modulated (PWM)
memory and software parameters. All of the power signals, active analog (voltage) input signals, passive
train system components that supply inputs to the analog (resistance) input signals, and frequency
ECM fall into one of the following groups: switch-type input signals.
inputs and sensor type inputs.
28 RENR9004-07
The Transmission/Chassis ECM monitors most of the

circuits of the input components for diagnostics. If the
ECM determines that an abnormal condition exists in
one of the circuits, the ECM will log a diagnostic code
for the involved component.
Sensors
Most input circuits of the sensors have an internal
ECM “pull up voltage” that is present at the contacts
of the ECM. An above normal voltage is internally
connected to the input circuit of the ECM through a
resistor. During normal operation, the sensor signal
will hold the circuit at a certain amplitude. Circuit
conditions such as a loss of power to the component,
a disconnection of the circuit or an open circuit will
allow the circuit to be pulled high by the pull up
voltage of the ECM. This will result in an above
normal voltage at the contact of the ECM. As a result,
the ECM will activate an FMI 03 (voltage above
normal) diagnostic code for the affected circuit.
The types of ECM input sensor circuits that have pull

up voltage present are listed below:
• Pulse Width Modulated (PWM) sensor input circuits

• Active analog (voltage) input signal circuits
• Passive analog (resistance) input signal circuits
Articulation Position Sensors
g01313624
Illustration 20
Articulation Position Sensors 1 and 2 Input circuits
The two machine articulation position sensors for the

M Series Motor Graders are mounted on the front
half of the machine in front of the articulation hinge.
Each position sensor will provide a PWM input to the
Implement ECM and to the Transmission/Chassis
ECM.
The position sensor for articulation angle (1) is

powered by the 8 volt sensor power supply of the
Implement ECM. The position sensor for articulation
angle (2) is powered by the 8 volt sensor power
supply of the Transmission/Chassis ECM.
The Transmission/Chassis ECM monitors the signals

from the sensors in order to instantly be ready to
activate and control the secondary steer system.
g01327588
Illustration 19
The angle position sensors for machine articulation of the M Series
Motor Graders are located on the front half of the machine. The
sensors are located in front of the articulation hitch. (View: Looking
from the left side of the machine)
(1) Articulation angle sensor 2
RENR9004-07 29
The Transmission/Chassis ECM monitors the PWM Inching Pedal Position Sensor
duty cycle from the articulation position sensors
in order to determine the articulation angle of the
machine. The sensor operates at a frequency of
approximately 500 hertz. When the articulation angle
of the machine is in the neutral position, the duty cycle
from the position sensor to the ECM is approximately
55%. When the machine is articulated to the full
left position, the duty cycle will be approximately
33%. When the machine is articulated to the full right
position, the duty cycle will be approximately 74%.
When an abnormal condition is detected in one or

both of the machine articulation position sensor
circuits, the ECM will activate a diagnostic code for
the affected circuit.
Fuel Level Sender
g01329249
Illustration 22
Inching Pedal Position sensor location (arrow)
g01287755
Illustration 21
Input circuit of the “Fuel Level Sender”
The fuel level sender is mounted on the top of the

fuel tank under the left side of the cab.
The Transmission/Chassis ECM monitors the

resistance of the fuel level sender input signal. The
ECM associates the resistance value of the sender
signal of the circuit with a specific level of fuel in the
fuel tank. The ECM sends this information to the
Messenger over the data link.
g01288530
When the fuel tank is nearly empty, the resistance Illustration 23
in the sender circuit is approximately 248 ± 8 ohms. Inching Pedal Position sensor input circuits
When the fuel tank is nearly full, the resistance in the
sender circuit is approximately 27 ± 2 ohms. The position of the inching pedal is monitored by
the Transmission/Chassis ECM. A position sensor is
mounted on the shaft of the pedal. The PWM duty
cycle from the sensor is converted by the ECM into
a pedal position that represents the position of the
inching pedal.
30 RENR9004-07
The inching pedal position sensor operates in a Service Brake Accumulator Pressure
frequency range of 200 hertz to 600 hertz. The Sensor
optimal operating frequency is approximately 500
hertz. The Transmission/Chassis ECM will recognize
a duty cycle of 4 percent to 96 percent as valid. If
the ECM detects a duty cycle that is greater than 96
percent or less than 4 percent, the ECM will activate
a diagnostic code for the circuit of the position sensor.
During machine operation, every time the

inching pedal is depressed and released, the
Transmission/Chassis ECM performs an auto
calibration sequence for the position sensor. The
ECM defaults to a 30 percent duty cycle when the
pedal is not depressed. The ECM defaults to a 70
percent duty cycle when the pedal is fully depressed.
During the auto calibration procedure, the ECM will
adjust the acceptable pedal position limits from a
possible 4 percent duty cycle when the pedal is not
depressed to a possible 96 percent duty cycle when
the pedal is fully depressed. Duty cycles beyond
these limits are not considered acceptable by the
ECM.
g01328784
Illustration 24
Pulse Width Modulated (PWM) Position Service Brake Accumulator Pressure Sensor (arrow) located on
Sensor Operation the brake manifold on the left rear side of the engine compartment
When powered up, the position sensors continuously

send a Pulse Width Modulated (PWM) square wave
signal to the ECM. Any movement on a specific axis is
detected by the position sensor for that axis. The duty
cycle signal of the PWM sensor changes depending
on the direction and the amount of movement on the
axis. The duty cycle is the percentage of time that the
signal is high as compared to the period of the cycle.
The longer the time that the duty cycle is high, the
greater the percentage of the duty cycle will be.
The percentage of duty cycle signal from a typical

position sensor that the ECM will recognize as valid
is 10 ± 5 percent to 90 ± 5 percent at the extreme
g01305473
ends of the axis movement. Illustration 25
Input circuit of the pressure sensor for the Service Brake
Accumulator
The position sensor for the service brake accumulator

is an active analog sensor that sends a 0 to 4.5 volt
signal to the Transmission/Chassis ECM in order to
indicate the hydraulic pressure that is in the service
brake accumulator.
When the ECM detects that the hydraulic pressure

for the service brake accumulator is less than
8101.3 kPa (1175.0 psi) for more than one second,
the ECM will activate an EID 0284 warning level
3 event code and illuminate the brake subsystem
indicator on the Instrument Cluster. The ECM will
deactivate the event code, turn OFF the indicator,
when the brake accumulator pressure is greater than
9825.0 kPa (1425.0 psi) for one second.
RENR9004-07 31
The ECM will not log the level 3 event for ten The position sensors for the steering cylinders are
seconds after the engine is started in order to mounted on the head end of the front steering
give the accumulator pressure time to reach the cylinders. The position sensors provide a PWM
operating pressure. Ten seconds after the machine is input signal to the Implement ECM and to the
started, if the pressure is not greater than8101.3 kPa Transmission/Chassis ECM.
(1175.0 psi), the EID 0284 event code will be logged.
The position sensor of the left steering cylinder is
Steer Cylinder Position Sensors powered by the 8 volt sensor power supply of the
Implement ECM. The position sensor of the right
steering cylinder is powered by the 10 volt sensor
power supply of the Transmission/Chassis ECM.
The sensor is a PWM sensor that operates at a

frequency of approximately 500 hertz. When the
length of the extension of the steering cylinder
changes, the duty cycle of the PWM sensor changes.
The duty cycle of the PWM signal that is supplied
to the ECM is measured in very small increments.
This makes the measurement of the changes of the
duty cycle difficult.
The Transmission/Chassis ECM monitors the signals

from the articulation sensors in order to be able to
Illustration 26
g01313639 activate the secondary steering system at any time
Steer Cylinder Position Sensor
during machine operation. The Transmission/Chassis
ECM will use the signals from the position sensors
when the secondary steering system is active in
order to control the angle of the front wheels. The
Transmission/Chassis ECM activates the outputs to
the secondary steering solenoids based on the left
joystick steering axis position. The ECM monitors
the signals from the position sensors of the steering
cylinder in order to adjust the output current to the
solenoids accordingly.
The Implement ECM will use the signals from the

position sensors to control the primary steering
system.
g01313665
Illustration 27
Steer Cylinder Position sensor input circuits
32 RENR9004-07
Transmission Oil Temperature Sensor If the ECM detects that the resistance of the sensor
circuit is 60.6 ohms this is equal to 104 °C (219.2 °F)
oil temperature, the ECM will activate an EID 0877
event code for high oil temperature. When the circuit
resistance of the sensor is 68.0 ohms, which equals
100 °C (212.0 °F) oil temperature, the ECM will
deactivate the event code.
When the resistance of the sensor circuit is

above 33650 ohms or below 18.6 ohms, the
Transmission/Chassis ECM will activate a diagnostic
code for the circuit.
Transmission Pump Pressure Sensor
g01321613
Illustration 28
Transmission Oil Temperature sensor location on the left side of
the transmission (arrow)
g01948597
Illustration 30
Transmission pump pressure sensor circuit
The transmission pump pressure sensor allows

the Transmission/Chassis ECM to determine the
transmission pump oil pressure. The ECM reads the
pulse width modulated (PWM) signal from the sensor
and computes a main hydraulic pump discharge
pressure.
g01287815
Illustration 29
Input circuit of the Transmission Oil Temperature sensor
The transmission oil temperature sensor allows

the Transmission/Chassis ECM to monitor the
temperature of the transmission oil. The sensor
provides a passive analog (resistance) input signal
to the ECM.
The ECM associates the resistance value of the

sensor signal with a specific temperature of the
transmission oil.
The resistance range of the sensor that the ECM will

consider valid is 33650 ohms at −40 °C (−40.0 °F) to
18.6 ohms at 150 °C (302.0 °F).
RENR9004-07 33
Transmission Speed Sensors
g01327859
Illustration 31
Transmission speed sensors located on the top side and the right
side of the transmission.
(3) Transmission input speed sensor
g01375824
Illustration 32
Input circuits of the Transmission speed sensors
The transmission on the M Series Motor Graders The input speed sensor is mounted at a location
is equipped with five speed sensors. Each that will monitor a gear on the input shaft of the
speed sensor supplies a frequency input to the transmission. The two intermediate speed sensors
Transmission/Chassis ECM. are mounted at a location in order to monitor a large
intermediate gear in the transmission. The two output
speed sensors are mounted at a location in order to
monitor a gear that is mounted on the output shaft
of the transmission.
34 RENR9004-07
Each of the speed sensors is attached to the Secondary Steer Request Signal
transmission with a fixed mount. No adjustment of
the mount for the speed sensor is necessary.
The speed sensors produce a signal that varies in

frequency (Hz) as the tooth of the gear is passed
in front of the sensor. Each tooth that passes the
gear will produce one cycle or hertz of the frequency
signal. The ECM detects the frequency of the
signal. The ECM then determines the speed and
the direction of the gear and the shaft that the gear
is mounted on. Each speed sensor has two input
connections to the ECM (“+” and “-”). On all of the
speed sensors, connector contact 2 is the signal (+).
Connector contact 1 is the return line (-).
g01305868
When the speed of the transmission output shaft Illustration 33
is greater than 150 rpm, the Transmission/Chassis Input circuit connections of the “Secondary Steer Request”
ECM monitors the two output speed sensors in
order to determine the transmission output speed The secondary steer request circuit is a hard wired
(TOS) and the direction of travel. If no TOS or circuit that is connected between the Implement
direction signals are coming from the two output ECM and the Transmission/Chassis ECM. When the
speed sensors, the ECM will use the signals from Implement ECM detects a problem in the primary
intermediate speed sensors in order to calculate the steering circuit, the Implement ECM will send a PWM
TOS and to determine the direction. As a result, the signal to the Transmission/Chassis ECM through the
ECM will maintain control of the transmission if a circuit requesting activation of specific components
failure of the two output speed sensor circuits occur. in the secondary steer system or requesting that the
complete secondary steer system be activated.
When the speed of the transmission output shaft
is less than 150 rpm, the ECM will use the signals The Implement ECM will send a signal to the
from the two intermediate speed sensors to calculate Transmission/Chassis ECM in order to activate the
the TOS and the direction of travel. At the lower secondary steering system when any of the following
TOS, the slower speed of the output gear results in conditions of the machine system are detected:
a poor signal from the output speed sensors. The
larger intermediate gear is rotating faster at the lower • An active CID 2202 FMI 12 (Steering Valve Control
output shaft speed which results in a more reliable Module Error) diagnostic code.
intermediate speed sensor signal.
• A failure of the main hydraulic pump.
The ECM uses the TOS and direction data in order
to control the shifting of the transmission when • Steering motion is detected when no primary
operating in the “Autoshift” mode. The ECM will use steering command is present.
the TOS and direction information in order to control
the operation of the transmission and to prevent • Steering motion is not detected when a primary
unsafe operating conditions that could be dangerous steering command is present.
to the operator or cause damage to the machine.
• Steering motion is detected in the wrong direction.
Both of the intermediate speed sensors are monitoring
one intermediate gear in the transmission. Both of the • A manual secondary steer test has been requested.
output speed sensors are monitoring an output gear
in the transmission. The Transmission/Chassis ECM • An automatic test of the secondary steering pump
expects approximately the same signal to be coming is being performed at initial engine start-up.
from each the pairs of speed sensors. If the signals
differ more than 50 Hz, the ECM will determine the The Transmission/Chassis ECM will activate the
correct signal based on the input signals from the secondary steering system without receiving a
other speed sensors on the transmission. Then, the request signal from the Implement ECM when the
ECM will activate a diagnostic code for the speed following condition is present:
sensor circuit that has the abnormal condition.
• An active CID 2199 (Secondary Steering Request
Signal from the Implement ECM) diagnostic code.
RENR9004-07 35
When the Implement ECM sends a PWM secondary Switches

steer request signal to the Transmission/Chassis
ECM, the duty cycle of the PWM signal will determine Switches will provide one of the following types of
which specific secondary steer system components input signals to the ECM:
will be activated. During normal operation, the
Implement ECM maintains a 20 percent duty cycle • An Open signal
on the request circuit. When a secondary steer
test is requested or when the Implement ECM has • A Ground signal
detected a problem in the primary steering system,
the secondary steer request signal will be one of the • A +battery or voltage signal
following duty cycle signals:
The contacts of a switch have two states of contact.
20 percent PWM duty cycle – Normal operation, no The switch contacts are open or the switch contacts
request to activate. are closed.
40 percent PWM duty cycle – Request to activate • When switch contacts are open, no signal is
the secondary steering pump motor only. provided to the corresponding input of the ECM.
This “no signal” condition is also referred to as
60 percent PWM duty cycle – Request to activate floating.
the secondary steering pilot solenoid valves only.
• When switch contacts are closed, either a ground
80 percent PWM duty cycle – Request to activate signal or the +battery signal is passed through the
the secondary steering pump and the secondary contacts of the switch and to the corresponding
steering pilot solenoid valves. input of the ECM.
When a 40 percent duty cycle request is received Switch to ground type input circuits have an internal
by the Transmission/Chassis ECM, the ECM will ECM pull-up voltage that is present at the contacts
energize the secondary steer relay. This will allow of the ECM. An above normal voltage is internally
system power to pass through the relay contacts connected to the input circuit of the ECM through a
and will energize the secondary steer motor relay. resistor. This allows the ECM to detect a problem
System power from the power control box will then be in the switch circuit. During normal operation, the
supplied to the secondary steering pump motor which switch signal will hold the circuit low, however, circuit
turns the secondary steering pump. When a pump conditions such as a disconnection or an open circuit
request only is received, the secondary steering will allow the circuit to be pulled high by the ECM
pump will supply hydraulic pressure and flow to the pull-up voltage. This will result in an above normal
primary steering system. Under these circumstances, voltage at the contact of the ECM. If this occurs when
the secondary steering pump motor will overheat if the ECM is expecting the circuit to be low, the ECM
operated for more than a short period of time. will activate a diagnostic code for the circuit.
When a 60 percent duty cycle request is received by Switch to +battery type input circuits have an internal
the Transmission/Chassis ECM, the ECM will activate ECM pull-down voltage that is present at the ECM
the proportional secondary steer pilot solenoid valves contacts. A below normal voltage is internally
in order to control the hydraulic oil flow to the steer connected to the input circuit of the ECM through a
cylinders. The ECM will use a PWM output signal in resistor. This allows the ECM to detect a problem in
order to energize the secondary steer solenoids. The the switch circuit. The circuit will be held high when
Transmission/Chassis ECM will vary the amount of the switch contacts are closed to a +battery source. If
electrical current that is sent to the solenoids in order the circuit is open or has a bad connection, the pull
to control the angle of the front wheels. down voltage will pull the circuit low. If this occurs
when the ECM is expecting the circuit to be high, the
When the secondary steer solenoids are energized, ECM will activate a diagnostic code for the circuit.
pilot hydraulic oil pressure is directed to the same
main hydraulic valve that is used for the primary The ECM monitors the switch input circuits for most
steering system. The steering valve control module of the following switches unless otherwise noted.
that is used for operation of the primary steering The ECM will activate a diagnostic code for the input
system is not used when the secondary steer circuits of the switch when an abnormal condition is
solenoids are active. detected.
When an 80 percent duty cycle request is received

by the Transmission/Chassis ECM, the ECM will
energize the secondary steer relay in order to
energize the secondary steer pump motor. The ECM
will also activate the proportional secondary steer
pilot solenoids.
36 RENR9004-07
“Key Start” Switch Inputs Left Joystick Transmission Control

Inputs
g01329042
Illustration 34
Input circuits of the “Key Start” switch g01329215
Illustration 35
Left Joystick Transmission Controls
The Transmission/Chassis ECM monitors the status (8) Upshift push button switch
of the “key start” switch. When the “key start” switch (9) Upshift push button switch
is in the ON position or in the START position, a (10) Forward/neutral/reverse trigger switch
voltage input is supplied to the ECM through the
contacts of the “key start” switch.
When the “key start” switch is in the OFF position, the

ECM is in a “sleep” mode. In the sleep mode, system
power is still supplied to the ECM, however, the ECM
is not functioning. When the “key start” switch is
moved to the ON position, the Transmission/Chassis
ECM will detect the system voltage at the key ON
input. When this occurs, the ECM will activate an
internal start-up initialization procedure in order to
activate the operation mode.
When the Transmission/Chassis ECM detects

the system voltage at the START input, the ECM
will activate the start relay in order to initiate the
engine start process provided the following machine
conditions are present:
• The parking brake is engaged.

• The transmission is in NEUTRAL.
• The operator is in the seat.
RENR9004-07 37
g01329216
Illustration 36
Input circuits of the “Left Joystick Transmission Control”
The illustration above shows the internal push The upshift switch, the downshift switch and
button and ground assignments for the transmission the FORWARD/NEUTRAL/REVERSE “(FNR)”
controls in the left joystick. The components that are switch provide switch to ground inputs to the
in the left joystick are not serviceable. If a component Transmission/Chassis ECM in order to indicate
in the joystick is found to have failed, the complete operator commands for gear selection. Each switch
joystick assembly must be replaced. The illustration is internally connected to two of the four ECM return
is displayed in order to aid in component and circuit (ground) circuits that are supplied to the left joystick.
troubleshooting for the transmission controls. For a One of the ECM return circuits for the switches is
complete connection diagram for all of the joystick to supplied by the Transmission/Chassis ECM and the
ECM connections, refer to the System Schematics in other ECM return circuit for the switches is supplied
the back of this manual. by the Implement ECM. Both ground connections
must fail either internally or externally in order to
interrupt switch operation due to loss of ground
connections.
38 RENR9004-07
The ECM expects one of the switch inputs to be

grounded at all times. If all of the switch inputs
are grounded or if none of the switch inputs are
grounded, the ECM will activate a diagnostic code
for the switch.
Autoshift Switch, Park Brake Switch,

Compression Brake Switch
g01376002
Illustration 38
Input circuits of the “Autoshift” switch, “Parking Brake” switch and
g01376046 “Compression Brake” switch (16M)
Illustration 37
Rocker Switch Contacts
The autoshift switch, the parking brake switch and the
compression brake switch each provide two switch to
ground inputs to the Transmission/Chassis ECM. The
switches are two-pole, double-throw rocker switches.
The switches are located on the right hand console
in the cab.
One pole on each of the switches is used to provide

the two inputs to the ECM in order to indicate the
switch status. During normal operation, one of the
inputs is open and the other input is closed to ground.
The other switch pole is either not used or is used for
switch backlighting.
If the ECM detects that both of the switch inputs

are grounded at the same time or both of the switch
inputs are open at the same time, the ECM will
activate a diagnostic code for the involved switch.
RENR9004-07 39
For the operation of the autoshift switch, when the The operator present switch supplies two switch to
ECM detects a ground condition in the “ON” switch ground type inputs to the Implement ECM and to the
input circuit, the ECM will activate the autoshift Transmission/Chassis ECM. The switch is located
transmission mode when the required machine under the operator seat.
conditions are correct. When the ECM detects a
ground condition in the “OFF” switch input circuit, the The Transmission/Chassis ECM will not allow a
ECM will deactivate the autoshift transmission mode. shift out of NEUTRAL, will not allow the parking
brake to be disengaged, or will not permit the engine
For the operation of the parking brake switch, when start sequence to be enabled unless the switch is
the ECM detects a ground condition in the “ON” input indicating that an operator is present in the seat.
circuit of the switch, the ECM will deactivate the
parking brake solenoid in order to engage the parking Inching Pedal Switch, Brake Pedal Switch
brake. When the ECM detects a ground condition
in the “OFF” input circuit of the switch, the ECM
will energize the parking brake solenoid in order to
disengage the parking brake.
The compression brake is only equipped on the 16M

motor graders.
For the operation of the compression brake switch,

when the Transmission/Chassis ECM detects a
ground condition in the “ON” input circuit of the
switch, the ECM will send this information to the
Engine ECM on the J1939 data link. The Engine
ECM will activate the output for the appropriate
compression brake solenoid if the machine conditions
are correct. When the Transmission/Chassis ECM
detects a ground condition in the “OFF” input circuit
of the switch, the Transmission/Chassis ECM will
send this information to the Engine ECM on the
J1939 data link. The Engine ECM will turn OFF the
output for the “compression brake” solenoid.
g01329157
Illustration 40
Operator Present Switch
“Inching pedal” switch and “Brake pedal” switch locations
(11) Brake pedal switch
(12) Inching pedal switch
(13) Brake light switch
g01314204
Illustration 39
Input circuits for the “Operator Present” switch
40 RENR9004-07
Park Brake Pressure Switch
g01329253
Illustration 42
Park Brake pressure switch location on the output shaft side of
g01329178
Illustration 41
Input circuits of the “Inching pedal” switch and “Brake pedal” switch
The inching pedal limit switch and the brake pedal

limit switch each provide switch to ground inputs to
the Transmission/Chassis ECM. The inching pedal
switch provides two inputs to the ECM. The brake
pedal switch provides one input to the ECM.
The ECM monitors the inputs from the inching pedal

switch in order to determine when the inching pedal
is depressed. This function is used as a backup in
the event that the inching pedal position sensor fails. Illustration 43
g01375676
Park Brake pressure switch connections

For the inching pedal switch operation, the ECM
expects one of the input circuits to be grounded The pressure switch for the park brake supplies two
and the other input circuit to be open at all times. switch to ground inputs to the Transmission/Chassis
If the ECM detects that both of the switch inputs ECM. The switch allows the ECM to detect if the
are grounded at the same time or both of the switch parking brake is engaged or if the parking brake is
inputs are open at the same time, the ECM will disengaged.
activate a diagnostic code for the switch circuits.
The ECM expects the two switch inputs to be
The ECM monitors the input from the switch of the connected through the switch contacts when the
brake pedal in order to detect if the brake pedal is parking brake is engaged. The ECM expects the
depressed or is not depressed. normally open (N/O.) contact to be grounded when
the park brake is disengaged. When the ECM detects
that the switch inputs are not connected and the
N/O. contact is not grounded, the ECM will activate a
diagnostic code for the switch circuit.
RENR9004-07 41
i03631710 Note: The ECM is not serviceable. If the ECM is

damaged, the ECM must be replaced. The rate of
Electronic Control Module failure for the ECM is very low. If a failure of an ECM
is suspected, contact the technical communicator
SMCS Code: 7610-DTN at your dealership for possible consultation with
Caterpillar before replacing the ECM. Replace the
ECM only after all of the other possible causes of a
particular problem have been investigated.
ECM Pull Up Voltage

In order to aid in diagnostics of certain types of
electrical circuits that are controlled by the ECM, an
internal “pull up voltage” is connected to the switch
and sensor signal input contacts of the ECM. An
above normal voltage is internally connected to the
signal input of the ECM through a resistor.
During normal operation, the switch or sensor

signal will hold the circuit low or at a certain signal
amplitude, however, circuit conditions such as a loss
of power to the component, a disconnection or an
open circuit will allow the circuit to be pulled high by
the ECM pull up voltage. This will result in an above
normal voltage reading at the contact of the ECM. As
a result, the ECM will activate an FMI 03 (voltage
above normal) diagnostic code for the affected circuit.
The types of input circuits of the ECM that have a pull


• Switch to ground switch input circuits
ECM Pull Down Voltage

In order to aid in diagnostics of electrical circuits that
are controlled by the ECM, an internal “pull down
voltage” is connected to ECM switch to battery type
input circuits.
g01309473
Illustration 44
ECM connectors and contacts During normal operation, the switch contacts that are
allowing the connection to a voltage source will hold
The Transmission/Chassis ECM of the Series M the circuit high. When circuit conditions such as a
Series of Motor Grader is mounted on the rear of the loss of power to the supply voltage of the switch, a
transmission. disconnection in the switch circuit or an open circuit
will allow the circuit to be pulled low by the ECM pull
The ECM will make decisions that are based on down voltage. This will result in below normal voltage
input data information and programming parameters at the contact of the ECM. As a result, the ECM will
that have been flashed to the ECM memory. After activate an FMI 04 (voltage below normal) diagnostic
the ECM receives the input information, the ECM code for the affected circuit.
determines the correct response. The ECM will
send an output signal to the appropriate device. The
internal input circuits and the internal output circuits
of the ECM are connected to the machine wiring
harness by two 70 contact connectors (J1 and J2).
42 RENR9004-07
Inputs Communication between the Transmission/Chassis

ECM and between the other control modules on the
The machine has several different types of input machine are conducted over the SAE J1939 data link
devices. The ECM receives status information about circuit that is connected to each control module. The
the machine from the input devices. The ECM then ECM uses the Cat Data Link to send and to receive
determines the correct output action that is needed information from the Caterpillar Electronic Technician
in order to control machine operations. The output (ET).
action is based on memory and software parameters.
The machine utilizes the following types of inputs: A module identifier (MID) is assigned to the
switch type and sensor type. Transmission/Chassis ECM. The MID for the
Transmission/Chassis ECM is:
Switches provide signals to the switch inputs of the
ECM. The possible outputs of a switch are listed: an Transmission/Chassis ECM – MID 027
open signal, a grounded signal, and + battery signal.
Note: The following tables list the circuit connections
Sensors provide an electrical signal to the ECM that for the Transmission/Chassis ECM.
constantly changes. The sensor input to the ECM
can be one of several different types of electrical Table 3
signals such as the following: pulse width modulated Transmission/Chassis ECM Connector J1
(PWM) signals, voltage signals, and frequency Contact Descriptions(1)
input signals. Each possible input to each of the
Transmission/Chassis ECM is listed in the tables for No. Function Type
the 70-pin connectors. 1 Key Switch Run Input
Transmission Input Speed
Outputs 2
Sensor (+)
Speed Sensor
The ECM sends electrical signals through the Transmission Input Speed
3 Speed Sensor
Sensor (-)
outputs. The outputs can create an action or the
outputs can provide information to the ECM. The Transmission
ECM can send output signals to system components 4 Intermediate Speed Speed Sensor
in one of the following types of electrical signals: Sensor 1 (+)
driver outputs, sinking driver outputs, sensor power Transmission
supply outputs, and data link outputs. The possible 5 Intermediate Speed Speed Sensor
outputs for each of the transmission/chassis ECM Sensor 1 (-)
are listed in the tables for the 70-pin connectors.
Transmission
6 Intermediate Speed Speed Sensor
Input/Output Sensor 2(+)
Transmission
Communication between the Transmission/Chassis 7 Intermediate Speed Speed Sensor
ECM and between the other ECM modules on the Sensor 2 (-)
machine are conducted over the data link circuits.
The data link circuits allow the sharing of information 10 Cat Data Link (+) Input/Output
with other electronic control modules. The data link 11 +5 Volt Supply Power Supply
circuits are bidirectional. The data link circuit allows
the ECM to send information and the data link allows 13 Unswitched Battery 1 (-) System Ground
the ECM to receive information. Transmission Output
15 Speed Sensor
Speed Sensor 1 (+)
The ECM supports two types of data link systems.
Transmission Output Speed Sensor
16
Speed Sensor 1 (-)
• Cat Data Link
Transmission Output Speed Sensor
17
• SAE J1939 (CAN) Data Link Speed Sensor 2(+)
The two types of data links are the main structure for Transmission Output
18 Speed Sensor
Speed Sensor 2 (-)
communication between all of the control modules on
the machine. More than one CAN data link system 20 Cat Data Link (-) Input/Output
can be present on a machine. Dedicated CAN data
21 5 Volt Return ECM Ground
link circuits can be used for communication between
specific controls on the machine. Transmission Oil Active Analog
22
Temperature Sensor Input
(continued)
RENR9004-07 43
(Table 3, contd) (Table 3, contd)

Transmission/Chassis ECM Connector J1 Transmission/Chassis ECM Connector J1
Contact Descriptions(1) Contact Descriptions(1)
No. Function Type No. Function Type
23 Unswitched Battery 2 (-) System Ground 57 Unswitched Battery 3 (-) System Ground
Switch to PWM Driver
24 Cab AC Switch 58 Transmission Solenoid 5
Battery Output
26 ECM Location 0 (Ground) Ground 59 Transmission Solenoid 6 PWM Output
27 ECM Location 1 (Open) Open Solenoid
60 PWM Driver Return
Return
28 ECM Location 2 (Open) Open
PWM Driver
Active Analog 61 Transmission Solenoid 1
29 Fuel Level Sensor Output
Input
PWM Driver
31 Unswitched Battery 1 (-) System Ground 62 Transmission Solenoid 8
Output
ECM Location Enable Operator in Seat Switch
32 Ground 63 STG Input
(Ground) (Normally Closed)
Transmission Filter Operator in Seat Switch
33 STG(3) Input 64 STG Input
Bypass Switch (Normally Open)
Differential Lock (Normally Transmission Pump PWM Driver
34 STG Input 65
Open) Bypass Solenoid Output
Parking Brake Pressure PWM Driver
35 STG Input 66 Fan/Brake Solenoid
Switch (Normally Open) Output
Service Brake Accum Active Analog Secondary Steer Left PWM Driver
36 67
Pressure Sensor Input Solenoid Output
Active Analog Secondary Steer Right PWM Driver
37 Steering Valve Signal 68
Input Solenoid Output
38 Unswitched Battery 4 (+) System Power 69 +10 Volt Supply Power Supply
39 Unswitched Battery 2 (+) System Power 70 Unswitched Battery 4 (-) System Ground
Parking Brake Pressure (1) Contacts that are not listed are not used.
40 STG Input
Switch (Normally Closed) (3) Switch to ground.
44 + 8 Volt Supply Power Supply
Table 2
45 8 Volt Return ECM Ground Transmission/Chassis ECM Connector J2
46 Unswitched Battery 5 (+) System Power Contact Descriptions(1)
47 Unswitched Battery 3 (+) System Power No. Function Type
PWM Driver 1 Key Switch - Start STB(2) Input

48 Transmission Solenoid 7
Output Secondary Steering
2 On/Off Output
PWM Driver Relay
Output 3 Differential Lock Relay On/Off Output
Solenoid 4 On/Off Driver Return ECM Ground
50 PWM Driver Return
Return
5 Backup Alarm Relay On/Off Output
PWM Driver
Output 6 Parking Brake Solenoid On/Off Output
PWM Driver 7 Starter Motor Relay On/Off Output
Output
8 On/Off Driver Return ECM Ground
Solenoid
54 Solenoid Return 1 9 MSS Status LED Sinking Output
Return
Solenoid Autoshift Enabled
55 Driver Return 11 Sinking Output
Return Indicator
56 Unswitched Battery 5 (-) System Ground 14 R - Terminal R - Terminal

(continued) (continued)
44 RENR9004-07

Transmission/Chassis ECM Connector J2 Transmission/Chassis ECM Connector J2
Contact Descriptions(1) Contact Descriptions(1)
No. Function Type No. Function Type
Left Steer Cylinder Steer Control Position
15 PWM Input 48 PWM Input
Position Sensor Sensor 2
Right Steer Cylinder Transmission
16 PWM Input
Position Sensor 52 Auto/Manual Switch STG Input
(Normally Closed)
Machine Articulation
17 PWM Input
Angle Sensor 2 Compression Brake
61 Switch (Normally STG Input
Steer Control Position Open)
18 PWM Input
Sensor 1
Compression Brake
20 AC Clutch Relay Sinking Output 62 Switch (Normally STG Input
Direction Switch Closed)
23 STG(3) Input
(Forward) 67 J1939 High Input/Output
Secondary Steer 68 J1939 Low Input/Output
25 PWM Input
Request Signal
69 J1939 Shield Input/Output
Transmission Pump
26 PWM Input (1) Contacts that are not listed are not used.
Pressure Sensor
(2) Switch to + battery.
Direction Switch (3) Switch to ground.
28 STG Input
(Neutral)
Direction Switch
29 STG Input
(Reverse)
Upshift Switch
30 STG Input
(Normally Open)
Upshift Switch
31 STG Input
(Normally Closed)
Steer Control Position
34 PWM Input
Sensor 3
Downshift Switch
36 STG Input
(Normally Open)
Downshift Switch
37 STG Input
(Normally Closed)
Parking Brake Switch
38 STG Input
(Off)
Parking Brake Switch
39 STG Input
(On)
Machine Articulation
41 PWM Input
Angle Sensor
Inching Pedal Position
43 PWM Input
Sensor
Service Brake Pedal
44 STG Input
Switch
Inching Pedal Switch
45 STG Input
(Normally Closed)
Inching Pedal Switch
46 STG Input
(Normally Open)
Transmission
47 Auto/Manual Switch STG Input
(Normally Open)
(continued)
RENR9004-07 45
i03631740
Electrical Output Components

SMCS Code: 1400; 4000
Outputs
g01948197
Illustration 45
Block diagram of the output components
The Transmission/Chassis ECM will use output • Sinking driver

circuits to send electrical control signals to the output
components. The output signals can create an action • Sensor power supply
or the output signals can provide information to the
ECM. The ECM will use different types of output • Data link
signals to control the system components. Following
are the types output signals: The ECM monitors the circuits of the output
components. If the ECM determines that an abnormal
• PWM proportional driver condition exists in one of the circuits, the ECM will
log a diagnostic code for the involved component.
• ON/OFF driver
46 RENR9004-07
Back Up Alarm Relay The differential lock relay is controlled by the

Transmission/Chassis ECM through an ON/OFF
output driver. The ECM will activate or deactivate
the output when the differential lock operator switch
in the cab changes states. This will result in the
differential axle being mechanically locked.
When the differential lock switch is pressed by the

operator, the ECM will turn ON the ON/OFF output
driver for the relay. This allows system power to
be directed to the differential lock solenoid through
the relay contacts. When the operator presses the
differential lock switch again, the ECM will turn off
the output for the relay in order to deactivate the
differential lock function.
ECPC Transmission Proportional

Solenoid Valves
g01287438
Illustration 46
Back up alarm relay output connections
The back up alarm relay is controlled by the

output driver.
The backup alarm alerts the surrounding personnel

that the machine is backing up. Whenever the
transmission is shifted to the reverse direction, the
ECM will turn on the output driver for the relay in
order to activate the backup alarm.
Differential Lock Relay
g01324626
Illustration 48
Transmission clutch solenoid valves are located on the left side of
the transmission.
(1) Transmission clutch solenoid valve 1 (forward high)
(2) Transmission clutch solenoid valve 2 (forward low)
(3) Transmission clutch solenoid valve 3 (reverse)
(4) Transmission clutch solenoid valve 4 (2nd speed)
(5) Transmission clutch solenoid valve 5 (3rd speed)
(6) Transmission clutch solenoid valve 6 (1st speed)
(7) Transmission clutch solenoid valve 7 (low range)
(8) Transmission clutch solenoid valve 8 (high range)
g01322415
Illustration 47
Differential lock relay output connections
RENR9004-07 47
g01329409
Illustration 49
Transmission solenoid output connections
The Transmission/Chassis ECM controls the The ECM will output a pulse width modulated (PWM)
operation of the “Electronic Clutch Pressure signal in order to vary the current to the solenoid.
Control” (ECPC) solenoid valves for control of the The current to the solenoid determines the amount
transmission. The ECM uses eight transmission of pilot oil pressure that is applied to the hydraulic
clutch proportional solenoid valves in order to valve spool. The travel of the spool is proportional
shift the transmission. The transmission solenoid to the electrical current that is supplied to the
valves control the hydraulic circuits that engage the solenoid. The position of the valve spool controls the
transmission clutch pressures. The ECM supplies amount of hydraulic oil pressure that is applied to
electrical current to the appropriate transmission the clutch which will determine the amount of clutch
solenoid valves in order to move the machine in one engagement. An increase in the electrical output
of the two available speed ranges that enable eight current of the ECM will result in an increase of the
gears in the forward direction and 6 gears in the engagement pressure of the clutch.
reverse direction.
In order to control the shifting of the transmission,
On an ECPC controlled transmission, the clutch the Transmission/Chassis ECM will energize two
pressure is modulated electronically. The ECM clutch solenoids when the machine is in PARK
controls the modulation of clutch pressure by or NEUTRAL. The ECM will energize different
sending a variable output current to the appropriate combinations of three clutch solenoids when the
proportional clutch solenoids. The ECM uses machine is in one of the available gears in the forward
input information from the operator controls, the or the reverse direction. The table below indicates
transmission speed sensors and the transmission the solenoids that are energized in order to activate
temperature sensor in order to determine the correct each gear arrangement.
output current to the solenoid valves.
48 RENR9004-07
Table 3
Transmission Gear and Solenoid Valve Logic
Solenoid Solenoid Solenoid Solenoid Solenoid Solenoid Solenoid
Solenoid 3
1 (forward 2 (forward 4 (second 5 (third 6 (first 7 (low 8 (high
(reverse)
high) low) speed) speed) speed) range) range)
Park X X
Neutral X X
First Speed
X X X
Forward
Second Speed
X X X
Forward
Third Speed
X X X
Forward
Fourth Speed
X X X
Forward
Fifth Speed
X X X
Forward
Sixth Speed
X X X
Forward
Seventh Speed
X X X
Forward
Eighth Speed
X X X
Forward
First Speed
X X X
Reverse
Second Speed
X X X
Reverse
Third Speed
X X X
Reverse
Fourth Speed
X X X
Reverse
Fifth Speed
X X X
Reverse
Sixth Speed
X X X
Reverse
Fan/Brake Bypass Solenoid The fan/brake pump load sense bypass solenoid
allows the Transmission/Chassis ECM to bypass the
fan/brake pump load signal straight to the tank.
g01948555
Illustration 50
Fan/brake bypass solenoid circuit
RENR9004-07 49
Park Brake Solenoid Secondary Steer Proportional

Solenoid Valves
g01329544
Illustration 51
g01329510
Illustration 53
Secondary steer solenoids are located in front of the cab behind
the rear valve stack.
(9) Secondary steer right solenoid
(10) Secondary steer left solenoid
g01301698
Illustration 52
Park brake solenoid connections
The park brake solenoid is controlled by the

output driver.
The parking brake on the motor graders is spring

applied and hydraulically released. When the park
brake solenoid is not activated, the parking brake is
engaged.
g01329463
When the Transmission/Chassis ECM receives a Illustration 54
disengage input from the park brake switch, the Secondary steer solenoid output connections
ECM will turn on the ON/OFF output driver in order
to energize the park brake solenoid. This will allow
hydraulic oil pressure to disengage the parking brake.
The ECM will not disengage the parking brake unless

the following conditions are satisfied:
• The transmission is in the NEUTRAL position.

50 RENR9004-07
When the Transmission/Chassis ECM has activated Secondary Steer Relay

the secondary steering system and the secondary
steering pump is supplying the hydraulic pressure
to the system, the Transmission/Chassis ECM will
use the proportional secondary steer solenoids
to send hydraulic pressure to the steer cylinders.
The ECM will output a PWM output signal in order
to energize the secondary steer solenoids. The
Transmission/Chassis ECM will vary the amount of
electrical current that is sent to the solenoids in order
to control the angle of the front wheels.
When the secondary steer solenoids are energized,

pilot hydraulic oil pressure is directed to the same
main hydraulic valve that is used for the primary
steering system.
The Transmission/Chassis ECM outputs the PWM

output signal to the appropriate solenoid based on
the steer sensor input signal from the left joystick.
Then, the ECM monitors the position of the front
steer cylinders in order to adjust the electrical current
to the solenoid accordingly. As the steering cylinders
approach and reach the commanded position, the
ECM will decrease the output current to the solenoid
until movement of the cylinders is stopped. The cycle
repeats as steering input from the joystick changes.
g01329477
Illustration 55
Secondary steer relay output connections
When the Transmission/Chassis ECM receives a

secondary steer request from the Implement ECM,
the Transmission/Chassis ECM will immediately
energize the secondary steer relay. This will allow
system power to pass through the relay contacts
which will energize the secondary steer motor relay.
System power from the power control box will then
be supplied to the secondary steering pump motor
which turns the secondary steering hydraulic pump.
The pump will supply hydraulic pressure and flow to
the secondary steering system.
RENR9004-07 51
Starter Motor Relay When the Transmission/Chassis ECM receives a

START input from the key start switch, the ECM
will turn ON the ON/OFF output driver in order to
activate the starter motor relay provided the following
machine conditions are present:

When the ECM activates the starter motor relay,
system power is directed to the starter motor through
the relay contacts.
Transmission Pump Bypass

Solenoid
g01329531
Illustration 56
The circuit breaker box is located on left side of machine behind
the cab.
(11) Start Relay
g01948590
Illustration 58
Transmission pump bypass solenoid circuit
The transmission pump bypass solenoid allows the

ECM to bypass the transmission pump straight to
the tank.
g01288379
Illustration 57
Starter motor relay output connections
The starter motor relay is controlled by the

output driver.
52 RENR9004-07
i02913081
Data Link
SMCS Code: 7610-DTN
g01315688
Illustration 59
Series M Series Data Link Communication System
The Transmission/Chassis ECM will use two data The Transmission/Chassis ECM communicates over
link systems for communication between the other the two data link communication systems that are
electronic control modules that are on the machine. present on the machine. The two types of systems
The data link systems also allows communication are listed below.
with service tools.
Cat Data Link – The Cat Data Link is used to send
The data link is bidirectional. The Transmission/ system status information between control modules
Chassis ECM can send information and the and the Caterpillar Electronic Technician (ET). All
Transmission/Chassis ECM can receive information. implement system diagnostic codes are activated
The data link is not a visible component. The data link using the Cat Data Link.
consists of internal ECM circuits, the related harness
wiring, and the harness connectors.
RENR9004-07 53
SAE J1939 Data Link – The SAE J1939 Data

Link is a high speed data link system. The J1939
Data Link is used for high speed system operation
communication between the controls of the ECM and
the control modules of other machine systems.
In the event of a failure of the SAE J1939 Data

Link system, the Cat Data Link is used as a backup
system for operational communication.
Data Link Diagnostics

Both of the data link systems on the machine are
monitored by the Transmission/Chassis ECM for
abnormal internal or external circuit conditions. The
ECM will activate diagnostic codes for a specific
control module and the data link circuit when an
abnormal condition is detected.
When the Transmission/Chassis ECM detects an

abnormal condition in a data link circuit, the ECM will
activate a “companion” diagnostic code along with
the diagnostic code for the involved control module in
order to alert the technician to which data link system
is involved. The companion diagnostic codes for the
implement system are listed below:
CID 0247 - FMI 09 or FMI 14 – SAE J1939 Data Link
CID 0248 - FMI 09 or FMI 14 – Cat Data Link
An example of how the companion diagnostic codes

are used by the Transmission/Chassis ECM for the
data link circuits:
The Transmission/Chassis ECM is communicating

with the Implement ECM over the SAE J1939 Data
Link circuit, however, some expected data is not
being communicated. The Transmission/Chassis
ECM will activate the CID 0596 FMI 14 diagnostic
code (Special Instruction - not receiving expected
information) for the Implement ECM. The
Transmission/Chassis ECM will also activate the CID
0247 - FMI 14 companion diagnostic code (SAE
J1939 Data Link) in order to indicate the data link
circuit that is involved. The companion diagnostic
code will clear after the primary diagnostic code is
cleared.
A CID 0247 or a CID 0248 companion diagnostic

code will always be activated when any of the
following module communication codes is activated
by the Transmission/Chassis ECM.
CID 0588 FMI 09 – Monitoring System
CID 0596 FMI 09 – Implement ECM
CID 0590 – Engine ECM

54 RENR9004-07
Troubleshooting Section
Troubleshooting Section When the troubleshooting procedure instructs you

to “REPAIR THE HARNESS OR REPLACE THE
HARNESS”, use the Electrical System Schematic
in the Service Manual of the machine to trace the
Introduction circuit. Perform resistance checks at the harness
connectors in order to locate harness failures. Always
check the ground circuit at the machine harness
i02913110 connector for the components. Less than five ohms
General Information of resistance is required between the ground contacts
of the connector and the frame ground. Excessive
ground resistance that is greater than five ohms can
SMCS Code: 4800
cause an incorrect diagnosis of the system.
The diagnostics for the Transmission/Chassis
During troubleshooting, inspect all harness
ECM Electronic Power Train Control System can
connections before any component is replaced. If
be accessed through the Messenger or through
these connections are not clean and tight, permanent
the Caterpillar Electronic Technician (Cat ET).
electrical problems or intermittent electrical problems
Troubleshooting the system requires additional
can result. Check that the wires are pushed into
information from the Service Manual for the machine.
the connectors completely. Make sure that the
The following list of references should be used to
connections are tight before other tests are made.
troubleshoot the systems of the machine:
Table 4 Failure of an electrical component can cause the

failure of other components. Always attempt to
Related Service Manuals correct the cause of an electrical system failure
Title Form Number before you replace a component. If wire insulation
is punctured during troubleshooting, repair the
Series M Series Motor Grader Service RENR9030 damage. Seal the damaged wires with 8T-0065
Manual RTV Silicone Sealant. Cover the sealant with two
14M Implement Electronic Control RENR9013 layers of 1P-0810 Electrical Tape
System
14M Implement and Steering Hydraulic RENR8484 ECM Pull Up Voltage
System
In order to aid in the diagnostics of certain types of
Motor Graders Monitoring System RENR9034
electrical circuits, that are controlled by the ECM, an
Additional References internal “pullup voltage” is connected to the switch of
the ECM and the sensor signal input contacts. An
14M Electrical System Schematic RENR9023
above normal voltage is internally connected to the
14M Hydraulic System Schematic RENR9028 signal input of the ECM through a resistor.
Accugrade GPS System For Motor SEBU8003
Graders
During normal operation, the switch or sensor
signal will hold the circuit low or at a certain signal
Accugrade Laser System For Motor SEBU8276 amplitude, however, circuit conditions such as a loss
Graders of power to the component, a disconnection or an
open circuit will allow the circuit to be pulled high by
As a reference, a simplified Transmission/Chassis the ECM pull up voltage. This will result in an above
ECM electrical system schematic is included at the normal voltage reading at the contact of the ECM. As
end of this manual. For a complete representation a result, the ECM will activate an FMI 03 (voltage
of the machine that is being diagnosed, refer to the above normal) diagnostic code for the affected circuit.
Electrical System Schematic in the Service Manual
of the machine. The types of input circuits of the ECM that have a pull

• Switch to ground switch input circuits
RENR9004-07 55
The ECM pull up voltage should always be

considered when troubleshooting one of the circuit
types that are listed.
ECM Pull Down Voltage

In order to aid in the diagnostics of electrical circuits
that are controlled by the ECM, an internal “pull down
voltage” is connected to the ECM switch-to-battery
type input circuits.
During normal operation, the switch contacts that

are allowing the connection to a voltage source will
hold the circuit high. The circuit will be pulled low by
the pull down voltage of the ECM when there is a
loss of power to the supply voltage of the switch, a
disconnection in the switch circuit or an open circuit.
This will result in a below normal voltage reading at
the contact of the ECM. As a result, the ECM will
activate an FMI 04 (voltage below normal) diagnostic
code for the affected circuit. g01379724
Illustration 60
The pull down voltage of the ECM should always be Relays that are located behind the cover on the right side headliner
considered when troubleshooting a switch-to-battery (1) Power air cleaner relay
type of input circuit. (2) Cab floodlights relay
(3) Backlight relay
(4) Mounting location of attachment heated mirror relay when
Cab Relay Locations installed
(6) Condenser fan relay 2
Note: The following relay locations for cab mounted (7) Condenser fan relay
relays are correct at the time of publication of
this manual. The location of the relays on some
early model machines may be slightly different.
When servicing a particular relay, always refer to
the complete Electrical System Schematic of the
machine in order to verify the wire numbers of the
relay that is being serviced.
g01379730
Illustration 61
Relays that are located on the rear wall of the cab behind the right
hand console
(8) Horn relay
(9) L. H. position relay
(10) Diff lock relay
(11) Headlamp relay
(13) Enable relay
(14) R.H. position relay
(15) Dimmer relay
(16) Rear flood relay
(17) Fast speed relay
56 RENR9004-07
i03120840 Note: Caterpillar Electronic Technician (ET) is a

software program that can be used on an IBM
Service Tools compatible personal computer.
SMCS Code: 0785 In order to use the Cat ET, order the following
materials: Special Publication, JERD2124, “ET
The following service tools can be used to aid in Single Use Program License”, Special Publication,
troubleshooting the electrical system. JEHP1026, “Information and Requirements Sheet”,
7X-1425 Data Link Cable and the Data Subscription,
Table 5
and Special Publication, JERD2142, “Data
Service Tools Subscription”. The Special Publication, JEHP1026,
“Information and Requirements Sheet” lists the
Part Number Part
required hardware and the features of the Cat ET.
Caterpillar Electronic Technician (Cat
ET) The Cat ET is not required in order to determine the
6V-7070 Digital Multimeter diagnostic codes and the Cat ET is not required in
9U-7330 order to clear the diagnostic codes. However, the
process of determining the diagnostic codes is easier
8T-3224 Needle Tip Group and faster by using the Cat ET. The Cat ET can also
7X-1710 Multimeter Probe Group display information on the history of a diagnostic
code and the parameter status of diagnostic codes.
8T-8726 Adapter Cable Assembly These features allow the Cat ET to be a useful tool
151-6320 Removal Tool for troubleshooting.
9U-7246 Connector Repair Kit The Cat ET is used to communicate to the electronic
DT control module over the data link by connecting
4C-3406 Connector Repair Kit to the machine diagnostic connector. For more
information and the locations of the connectors,
see Troubleshooting, “Electrical Components and
Connector Locations” and the Electrical System
Schematic in your machine's Service Manual.
For instructions on servicing Sure Seal connectors,

see Special Instruction, SMHS7531. For instructions
on servicing Deutsch connectors, see Special
Instruction, SEHS9615.
Use the digital multimeter for measuring resistance

or for measuring voltage. For instructions about the
use of the 6V-7070 Digital Multimeter, see Special
Instruction, SEHS7734. The 7X-1710 Multimeter
Probes are used to measure the voltage at the
connectors without disconnecting the connectors.
The probe ends are pushed into the back of the
connector along the wire. The 151-6320 Removal
Tool is used in order to remove a wire terminal or a
pin from the connector body. The 8T-8726 Adapter
Cable has a breakout with 3 pins. The adapter cable
is used for measurements in the sensor circuits.
g00774942
Illustration 62
Connections for the Communication Adapter II and the Caterpillar Note: Except for harness tests, using continuity
Electronic Technician (ET) testers such as the 8T-0500 Continuity Tester or
The components that are needed in order to use the voltage testers such as the 5P-7277 Voltage Tester
Communication Adapter II and the Caterpillar Electronic Technician is not recommended for today's Caterpillar electrical
( ET) in order to determine diagnostic codes are listed: circuits.
(6) Cable
(7) 171-4400 Communication Adapter II
(8) Service diagnostic cable.
(9) Current version of Cat ET software and an IBM-COMPATIBLE
personal computer
Reference: See Special Publication, NEHS0758,

“Communications Adapter II User's Manual Contains
Software”.
RENR9004-07 57
i02913154 When a procedure requires that the machine's

electrical system should be turned OFF, move the
Connector Locations key start keyswitch to the OFF position and move the
electrical disconnect switch to the OFF position.
SMCS Code: 7553-546-WW
In order to locate machine wiring harness connectors
on the machine, the Electrical System Schematic,
Parts Manual and Operation and Maintenance
Manual for the machine that is being serviced should
be used.
The following information is a guide to reading the

tables for the component location on the back of the
Electrical System Schematic.
• The “Component Location” table uses white circles

or light gray circles in order to mark the locations
in the profile of the machine and in the area views.
Alphabetical letters in the “Machine Location”
column indicate a general area of the machine.
Refer to the corresponding footnote at the end of
the table for a description of the location.
• The “Harness Connector Location” table uses

white circles or light gray circles in order to mark
the locations in the general view and in the
g01324226
Illustration 63 area views. Alphabetical letters in the “Machine
Transmission/Chassis ECM located on the rear of the transmission Location” column indicate a general area of the
(1) Transmission/Chassis ECM
machine. Refer to the corresponding footnote at
(2) J1 Connector the end of the table for a description of the location.
(3) J2 Connector
g01317147
Illustration 64
Fuse Panels and Service Connector on the left side of the operator
seat
(4) Fuse panels
(5) Service Connector
The Transmission/Chassis ECM is mounted on

the rear of the transmission. The machine service
connector for the Cat ET connection is located in the
cab on the left side of the operators seat.
58 RENR9004-07
ECM Connector Contact Numbers
g01309473
Illustration 65
ECM Connectors and Contacts
The J1 and the J2 connectors on the ECM are 70

pin connectors. The two connectors contacts are
numbered identically.
i03895348
Diagnostic Capabilities
SMCS Code: 4800
The diagnostic information for the Power Train

Electronic Control System can be accessed by the
technician using the Caterpillar Electronic Technician
Service Tool or by using the Messenger display.
RENR9004-07 59
The Caterpillar Electronic

Technician (Cat ET)
g01277712
Illustration 66
Connections for the Caterpillar Electronic Technician (Cat ET)
The Caterpillar Electronic Technician (Cat ET) is • Program the ECM (Flash). This is done with the
a software program that is used to access, view, “WINflash” program. See Testing and Adjusting,
monitor and sometimes change the data that a “Electronic Control Module (ECM) - Flash
particular ECM is using to control a machine system. Program”.
The service technician can use the Cat ET in order
to perform maintenance on the machine. Some of • Print reports.
the options that are available with the Caterpillar
Electronic Technician are listed below: The following list contains some of the diagnostic
functions and programming functions that are
• View the active diagnostic codes and logged performed by the service tools.
diagnostic codes. See Troubleshooting, “Using
the Caterpillar Electronic Technician to Determine • The failures of the ECM system are displayed.
Diagnostic Codes”.
• The status of most of the inputs and the outputs
• Viewing the active event codes and logged event are displayed.
codes
• The settings for the ECM are displayed.
• View the status of parameters.
• Display the status of the input and output
• Clear active diagnostic codes and clear logged parameters in real time.
diagnostic codes
• Display the clock hour of the internal diagnostic
• Perform calibrations of machine systems. clock.
60 RENR9004-07
• The number of occurrences and the clock hour

of the first occurrence and the last occurrence is
displayed for each logged diagnostic code.
• The definition for each logged diagnostic code and

each event is displayed.
• Load new FLASH software.

See Troubleshooting, “Diagnostic Code List” for the
list of diagnostic codes for the ECM.
• Active diagnostic codes

• Logged diagnostic codes
Event Codes
Logged Event Codes
g02138889
Illustration 67
Typical ET screen for logged events
RENR9004-07 61
g01308956
Illustration 68
An indicator for logged events is provided. The

indicator allows the service technician to keep track
of event codes that are intermittent. The data for the
logged event will include the following information:
• An event identifier (EID)

• A text description of the problem
• The number of occurrences of the problem
• A time stamp will display the first occurrence of the
problem.
• A time stamp will display the last occurrence of the

problem.
Status Groups For The Electronic

Technician
The Status groups are lists of machine parameters.
The status of the parameters are shown in real time.
62 RENR9004-07
g02138890
Illustration 69
RENR9004-07 63
g01308958
Illustration 70
Typical ET Status Screen
Messenger • View Logged Events and Diagnostic Codes.

• View Active Events and Diagnostic Codes.
• View the status of system components.
• View the system parameters.
Some warnings will generate a detailed message that
will appear on the Messenger display.
Accessing Diagnostic Codes With The

Messenger
Perform the following steps in order to view the active
g01116427 diagnostic codes and the logged diagnostic codes:
Illustration 71
Messenger Display Module
The Messenger display is located on the right console

of the cab. The Messenger monitors the operation
of the machine.
The Messenger allows the technician to access the

following diagnostic information:
64 RENR9004-07
SRC – Source
CODE – MID, CID, FMI, EID, and WCI
OCC – The number of occurrences of the codes
ACT – The fact that the code is active
Pressing “OK” on any of these codes will display

the Diagnostic/Event screen.
Note: If the code is Active, there will be an “A” in the

“ACT” column.
g01299082
Illustration 72
Messenger Main Menu
1. From the Messenger Main Menu page, scroll to

“Service” menu and press the “OK” button.
g01299332
Illustration 75
The Messenger Diagnostic/Event Detail screen
The Messenger Diagnostic/Event Detail screen will

display the following:
g01299096
• Source of the failure
Illustration 73
Messenger Service Menu • Code CID, FMI, EID, and WCI
2. From the Messenger Service Menu page, • Text description of failed component
the first option in the service menu will be
“Diagnostics/Events”. Press “OK” in order to view • Text description of the type of failure
the list of Active codes and Logged codes.
g01299326
Illustration 74
The Messenger Diagnostics/Events List screen
3. The Messenger Diagnostics/Events List screen

shows the following:
RENR9004-07 65
Symptom Troubleshooting Determine if the ECM has detected any faults. A

diagnostic code is used to specify each detected
fault.
i04040172
Symptom Troubleshooting Determine Possible Causes

SMCS Code: 3000-035; 7000-035 Use the information from the operator and your
inspection. Attempt to identify a common cause if
Use the following guidelines as you troubleshoot a there is more than one symptom.
symptom:
If you troubleshoot diagnostic codes and the problem
is not resolved, continue troubleshooting using the
Know the Machine “Symptom Troubleshooting” section of this manual.
Identify the component that is the most probable
Understand the operation of the machine. Know if the cause of the symptom.
symptom is a characteristic of normal operation or if
the symptom is a failure.
Test and Repair the System
Read the systems operation information to
understand the systems of the machine. Understand Use the tests and procedures in this manual to verify
the interaction of the machine systems. the cause of the symptom. Once the cause has been
identified, repair the failure. Then, test the system
again to verify that the symptom is resolved.
Understand the Symptom
Speak with the operator about the symptom. Acquire Provide Feedback to Caterpillar
the following Information:
Share your troubleshooting information. Use the form
in “SIS” or “CBT” feedback to write a brief description
• The performance of the machine prior to the failure about the symptom, testing, and repair. Include
your phone number or e-mail address so that you
• First occurrence of the symptom can be contacted. This feedback information helps
Caterpillar improve service information.
• The operating conditions at the time of the failure
• The sequence of events prior to the failure (order i03699320
of the occurrences)
Emerging Symptom
• The troubleshooting steps that have been taken Information
• The history of repairs of the machine SMCS Code: 3000-035; 7000-035
• The preventive maintenance of the machine This space is for new symptom information for this
product.
• Related service information about current problems
that affect the serial number of the machine
Note: Use the Service Information System on the
web in order to find the most up-to-date information.
• Inspect the Machine. Look for problems. Notice any
unusual odors in the air. Listen for unusual noises.
Share your troubleshooting knowledge of symptoms.
Perform the “Visual Inspection” steps. Refer Please use the feedback form in “SIS” or “CBT” to
to Troubleshooting, “Machine Preparation for write a brief description about the symptom, testing
Troubleshooting”. and repair of the machine. Your feedback information
will help Caterpillar improve the symptom information
for this product.
Verify the Symptom
When possible, attempt to duplicate the symptom.
Operate the machine and repeat the conditions that
caused the failure. Check the gauges inside the
cab. Notice any unusual odors in the air. Listen for
unusual noises.
66 RENR9004-07
i02651913 Test Step 1. CHECK THE POWER

BREAKER CIRCUIT FOR AN OPEN
Indicator Lamp Does Not
Illuminate Note: Verify that the transmission control breaker is
not open, however, it is unlikely that the transmission
SMCS Code: 7400-035-IND control breaker would be open. If the transmission
control breaker is open, the Transmission Chassis
System Operation Description: ECM will not function. The transmission control
breaker also supplies system power to the Implement
ECM.
A. Turn the disconnect switch and the key start

switch to the ON position.
B. Check the transmission control breaker at the

power box. If the breaker is open, reset the
breaker. If the breaker is not open, proceed to the
next step.
C. At the machine harness connector for the LED,

measure the voltage between contact 1 (wire
126-RD) and a good frame ground contact.
Illustration 76
g01331347 Expected Result:
Autoshift Enabled LED Indicator connections
The voltage measurement is between 18.0 VDC and
The autoshift enabled LED indicator is controlled by 32.0 VDC.
the Transmission Chassis ECM. The LED circuit is
not monitored by the ECM for diagnostics. Results:
System power for the LED is supplied by the 15 amp • OK – The voltage measurement is between 18.0
transmission control breaker. The indicator circuit is VDC and 32.0 VDC. The voltage at the LED is
connected to an ECM sinking output. When the ECM correct. Proceed to Test Step 2.
activates the transmission autoshift mode, the ECM
will turn ON the sinking output. This allows a path to • NOT OK – The voltage measurement is less than
ground for the power circuit through the LED which 18.0 VDC. The voltage measurement indicates
will cause the LED to illuminate. that there is an open or a bad connection in the
power circuit in the machine harness.
Conditions that could cause an LED indicator to be
OFF when the autoshift mode is activated are listed: Repair: There is an open or a bad connection
in the LED power supply circuit in the machine
harness.
• The transmission control breaker is open.
Refer to the complete machine Electrical System
• The power supply circuit is open or has a poor Schematic. Check all of the connectors that are in
connection
power supply circuit. Ensure that all connections
are clean, secure and in good condition. Repair the
• The sinking LED circuit is open or has a poor machine harness or replace the machine harness.
connection
STOP.
• The LED has failed.
• The ECM has failed. This is not likely Test Step 2. CHECK THE LED, THE ECM
AND THE CIRCUIT
When the transmission autoshift mode is active
and the LED indicator is OFF, perform the following Turn the disconnect switch and the key start switch
troubleshooting procedure. to the OFF position.
Note: Verify that the autoshift mode is active and the A. At the machine harness connector J2 for the
LED should be ON before performing this procedure. ECM, use a 151-6320 Removal Tool to remove
the autoshift enabled LED indicator circuit (wire
M998-OR) and socket at contact J2-11 from
the ECM connector. The J2 connector remains
connected to the ECM.
RENR9004-07 67
B. Connect one end of a jumper wire to the E. At the machine harness connector J2 for the ECM,
disconnected LED circuit wire M998-OR. Connect measure the resistance between contact J2-11
the other end of the jumper wire to a good frame (wire M998-OR) and a good frame ground contact.
ground contact.
Expected Result:
C. Turn the disconnect switch and the key start
switch to the ON position. The resistance measurement is less than 5.0 ohms.
Expected Result: Results:
The LED indicator is illuminated when the jumper • OK – The resistance measurement is less than
wire was connected to frame ground. 5.0 ohms. The resistance measurement does not
indicate an open or a bad connection in the LED
Results: circuit in the machine harness.
• YES – The LED indicator is illuminated when the Repair: The LED may have failed.
jumper wire was connected to frame ground. The
LED and the circuit wire are operating correctly. Exit this procedure and perform this procedure
The ECM could be causing the problem. again. If the indication is that the LED has failed,
replace the autoshift enabled LED indicator.
Repair: Verify that the LED indicator is supposed
to be ON. Ensure that the autoshift mode switch STOP.
is in the ON position and that the autoshift mode
is active. • NOT OK – The resistance measurement is greater
than 5.0 ohms. The resistance measurement does
Exit this procedure and perform this procedure indicate an open or a bad connection in the LED
again. If the indication is that the ECM is causing circuit in the machine harness.
the problem, contact your dealership's Technical
Communicator for possible consultation with Repair: There is an open or a bad connection
Caterpillar. This consultation may greatly reduce in the LED circuit in the machine harness. A
repair time. resistance measurement that is greater than 5
ohms but less than 5000 ohms could indicate that
If the ECM must be replaced, refer to Testing and one of the connection points in the circuit is not
Adjusting, “Electronic Control Module (ECM) - open but is not a good connection.
Replace”.
STOP. Schematic. Check all of the connectors that are in
LED circuit. Ensure that all connections are clean,
• NO – The LED indicator is still not illuminated secure and in good condition. Repair the machine
when the jumper wire was connected to frame harness or replace the machine harness.
ground. The ECM is not causing the problem.
STOP.
Reinstall the LED circuit wire and socket that was
removed from the ECM J2 connector.
Proceed to Test Step 3
Test Step 3. CHECK THE CIRCUIT FOR

AN OPEN
switch to the OFF position.
B. Disconnect the machine harness connector from

the autoshift enabled LED indicator.
C. At the machine harness connector for the LED,

connect a jumper wire between contact 2 (wire
M998-OR) and a good frame ground contact.
D. Disconnect the machine harness connector J2

from the Transmission Chassis ECM.
68 RENR9004-07
i02443772 C. Disconnect the machine harness ECM connectors

J1 and J2 from the Transmission Chassis ECM.
Indicator Lamp Is On
Continuously D. At the machine harness ECM connectors,
measure the resistance from the LED circuit
SMCS Code: 7400-035-IND contact J2-11 (wire M998-OR) to frame ground.
Measure the resistance from the contact J2-11
System Operation Description: (wire M998-OR) to all of the other contacts that
are used in the J1 and J2 ECM connectors.
Expected Result:
Each resistance measurement is greater than 5000

ohms.
Results:
• OK – Each resistance measurement is greater

than 5000 ohms. The resistance measurement
does not indicate a short to frame ground or to
another circuit in the machine harness. Proceed
to Test Step 2.
Illustration 77
g01331347 • NOT OK – One or more of the resistance
Autoshift Enabled LED Indicator connections
measurements is less than 5000 ohms. There is a
short to frame ground or to another ground circuit
The autoshift enabled LED indicator is controlled by in the machine harness.
the Transmission Chassis ECM. The LED circuit is
not monitored by the ECM for diagnostics. Repair: Refer to the complete machine Electrical
System Schematic. Check all of the connectors
System power for the LED is supplied by the 15 amp that are in the autoshift enabled LED indicator
transmission control breaker. The indicator circuit is circuit. Ensure that all connections are clean,
connected to an ECM sinking output. When the ECM secure and in good condition. Check the machine
activates the transmission autoshift mode, the ECM harness for areas where the there is contact with
will turn ON the sinking output. This allows a path to the machine frame. Look for worn or missing
ground for the power circuit through the LED which insulation on the wire. Repair the machine harness
will cause the LED to illuminate. or replace the machine harness.
Conditions that could cause an LED indicator to be Refer to Testing and Adjusting, “Wiring Harness
ON when the autoshift mode is not activated are (Short Circuit) - Test” for more information on
listed: finding and correcting a short circuit.
STOP.
• The LED sinking output circuit is shorted to a
ground source in the machine harness.
Test Step 2. CHECK THE ECM
• The ECM has failed. This is not likely OPERATION
When the transmission autoshift mode is not active A. Reconnect the ECM connectors to the ECM and
and the LED indicator is ON, perform the following reconnect the harness connector to the autoshift
troubleshooting procedure. enabled LED indicator.
Note: Verify that the autoshift mode switch is in the B. Turn the disconnect switch and the key start
OFF position and the LED should be OFF before switch to the ON position.
performing this procedure.
C. With the autoshift enabled LED indicator ON, use
Test Step 1. CHECK THE CIRCUIT FOR A a 151-6320 Removal Tool to remove the autoshift
SHORT TO GROUND enabled LED indicator circuit (wire M998-OR) and
socket at contact J2-11 from the ECM connector.
A. Turn the disconnect switch and the key start The J2 connector remains connected to the ECM.
Expected Result:
the autoshift enabled LED indicator. The LED indicator is still illuminated.
RENR9004-07 69
Results: • The parking brake does not engage when the

parking brake switch is set to the ON position.
• YES – The LED indicator is still illuminated.
Disconnecting the circuit wire from the ECM • The parking brake slowly engages when the
connector did not cause the LED to turn OFF. The parking brake switch is set to the ON position.
ECM is not causing the problem.
• The parking brake intermittently engages when
Repair: The LED circuit wire is grounded to the parking brake switch is set to the ON position.
another source in the machine harness or to frame
ground. • The parking brake intermittently disengages when
the parking brake switch is set to the OFF position.
Schematic. Check all of the connectors that are • The parking brake does not release when the
in the autoshift enabled LED indicator circuit. parking brake switch is set to the OFF position.
Ensure that all connections are clean, secure and
in good condition. Check the machine harness for • Event code “E627 - Parking Brake Abused” occurs.
areas where the there is contact with the machine
frame. Look for worn or missing insulation on the
wire. Repair the machine harness or replace the
Recommended Actions
machine harness. Use the procedures in this section in order to identify
the parking brake symptoms. After the symptom(s) is
Refer to Testing and Adjusting, “Wiring Harness
identified, follow the troubleshooting that is directed
(Short Circuit) - Test” for more information on for the parking brake system.
finding and correcting a short circuit. Repair the
machine harness or replace the machine harness.
Machine Safety
STOP.
Ensure that all safety information, warnings, and
• NO – The LED indicator is no longer illuminated instructions are read and understood before any
when the circuit wire is disconnected from the ECM operation or any procedures are performed. Perform
connector. Disconnecting the circuit wire from the the following safety measures before you begin
ECM connector caused the LED to turn OFF. The troubleshooting the machine:
ECM is could be causing the problem.
1. Stop the machine on a surface that is hard and
Repair: Verify that the autoshift enabled LED level.
indicator should not be ON.
2. Lower all of the implements to the ground.
Exit this procedure and perform this procedure
again. If the indication is that the ECM is causing 3. Toggle the parking brake switch to the ON position.
the problem, contact your dealership's Technical This action engages the parking brake.
Communicator for possible consultation with
Caterpillar. This consultation may greatly reduce 4. Place chocks in front of the wheels and behind
repair time. the wheels.
If the ECM must be replaced, refer to Testing and 5. Shut off the engine.
Adjusting, “Electronic Control Module (ECM) -
Replace”. Diagnostic Code Retrieval
STOP. Several of the parking brake symptoms list CID
diagnostic codes. These CID codes can be viewed
by using either of the following methods:
i03911570
Parking Brake System • Caterpillar Electronic Technician (Cat ET) service

tool
SMCS Code: 4267-035
• Operator display on the machine
Parking Brake Symptoms
A malfunction in the parking brake system could
result in the following symptoms:
70 RENR9004-07
Symptoms that occur when the parking d. The left joystick is aligned with the front wheels.
brake switch is set to the ON position: Refer to the “Safety Section” of the Operation
and Maintenance Manual , “Operation” for your
Parking Brake Does Not Engage specific machine.
Parking Brake Slowly Engages
Parking Brake Intermittently Engages 3. Use Cat ET to verify the input/output states.
Troubleshoot the state if any of the conditions
1. Check for active diagnostic codes that are related cannot be met.
to the parking brake system. Troubleshoot any of
the following active CID diagnostic codes: a. Select “Trans/Chassis” for your machine.
CID 70 – “Parking Brake Operator Switch” b. Select “Operator Present”.
CID 627 – “Parking Brake Pressure Switch”
CID 681 – “Parking Brake Solenoid”
Reference: Refer to the CID diagnostic code

procedures in this manual.
2. If all of the listed diagnostic codes are resolved,

proceed to “Troubleshooting the Parking Brake
System”.
Symptoms that occur when the parking

brake switch is set to the OFF position:
Parking Brake Does Not Disengage
Parking Brake Intermittently Does Not
Disengage
1. Check for active diagnostic codes that are related
to the parking brake system. Troubleshoot any of
the following active CID diagnostic codes:
CID 70 – “Parking Brake Operator Switch”
CID 623 – “Transmission Control Switch”
CID 627 – “Parking Brake Pressure Switch”
CID 681 – “Parking Brake Solenoid”
CID 2113 – “Operator Present Switch”
Reference: Refer to the CID diagnostic code

procedures in this manual.
2. The following conditions must be met in order for

the parking brake to release when the parking
brake switch is toggled to the OFF position:
a. The parking brake switch must be in the ON

position.
b. The operator is present in the seat.
c. The transmission control switch “(Direction

Switch)” is in the NEUTRAL position.
RENR9004-07 71
g01978334
Illustration 78
c. Verify that the “Value” of the “Operator Present

Status” indicates “Present”.
d. Select “Transmission - Shifting”.
g01978573
Illustration 79
“Transmission - Shifting” values
72 RENR9004-07
e. Verify that the “Value” of the “Direction Switch

Position” indicates “Neutral”.
f. Start the engine.
g. Align the left joystick with the front wheels.
4. Toggle the parking brake switch to the OFF

position. If the parking brake does not disengage,
proceed to “Troubleshooting the Parking Brake
System”.
Note: Event code “EID 562 - Steering lever has

not been aligned to wheel steering angle” will be
active if the left joystick is not properly aligned with
the front wheels.
Event code E627 - Parking Brake Abused

occurs
Reference: Refer to the “Event Code List” in this
manual.
E627 will occur if both of the following conditions

are true:
• The machine is traveling at a speed that is greater

than 8 km/h (5.0 mph).
• The parking brake switch is toggled to the ON

position.
This event is logged in order to identify parking brake

abuse. The parking brake should be engaged only
after the machine has come to a complete stop. The
use of the parking brake as a service brake in regular
operation will cause severe damage to the parking
brake.
No repair is required if this event occurs. Perform the

“Parking Brake - Test” in order to confirm that the
parking brake is functional.
Refer to Testing and Adjusting, “Parking Brake -

Test”. Refer to Table 6 in order to determine the
manual for your specific machine.
Table 6
Manuals for the “Parking Brake - Test”
Machine
Reference
Model
12M
120M Systems Operation, Testing and Adjusting, RENR8454 , “120M,
140M 12M, 140M and 160M Motor Graders Power Train”
160M
14M Systems Operation, Testing and Adjusting, RENR8482 ,

16M “14M and 16M Motor Graders Power Train”
RENR9004-07 73
Troubleshooting the Parking Brake

System
When testing and adjusting the transmission and

power train, move the machine to an area clear of
obstructions, with safe exhaust ventilation for the
exhausts. Sudden movement of the machine or re-
lease of oil under pressure can cause injury to per-
sons on or near the machine. To prevent possible
injury, do the procedure that follows before testing
and adjusting the transmission and power train.
Personal injury can result from spring force re-

leased when removing cap screws.
Internal spring force will be released when cylin-

der assembly cap screws are removed causing in-
jury.
Always restrain cover as cap screws are loosened.
Follow the established procedure in the Service

Manual to service these parts.
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting, and repair of the machine. Be prepared
to collect the fluid with suitable containers before
opening any compartment or disassembling any com-
ponent containing fluids.
Dispose of all fluids according to local regulations and

mandates.
1. Verify the main relief valve setting for the

transmission. Refer to Testing and Adjusting,
“Power Train Charge System Pressure - Test and
Adjust”.
Refer to the information in Table 7 for the correct

setting for your machine.
74 RENR9004-07
Table 7
Manuals for the “ Power Train Charge System Pressure - Test and Adjust”
Machine
Reference
Model
12M
120M Systems Operation, Testing and Adjusting, RENR8454 , “120M,
140M 12M, 140M and 160M Motor Graders Power Train”(1)
160M
14M Systems Operation, Testing and Adjusting, RENR8482 , “14M

16M and 16M Motor Graders Power Train”(1)
(1) Use this manual to test and adjust the pressure of the main relief valve.
2. Use Cat ET to verify the electrical components of

the parking brake system.
a. Select “Trans/Chassis” for your machine.
b. Select “Braking”.
g01978664
Illustration 80
“Braking” values
c. Verify the parking brake switch. The value changes when the switch is toggled.
Toggle the parking brake switch and observe Results:

the value of the “Parking Brake Switch” on Cat
ET. • YES - The value changes when the switch is
toggled. The switch is functional. Proceed
Expected Results: to Step 2.d.
RENR9004-07 75
• NO - The value does not change when the Expected Results:

switch is toggled.
The values correlate.
Repair: Check the continuity of the wiring. If
no fault is found in the wiring, then replace the Results:
parking brake switch.
• YES - The values correlate. The parking
d. Verify the parking brake command. brake indicator on the dashboard changes.
The switch and the parking brake indicator
Toggle the parking brake switch. Verify that the are functional.
“Value” of the “Parking Brake Switch” correlates
to the following command to the “Parking Brake • NO - The values do not correlate or the
Solenoid”. parking brake indicator does not change.
“On” – “Not Energized” Repair: If the state of the parking brake

pressure switch changes and the parking brake
“Off” – “Energized” indicator does not change on the dashboard,
perform the following actions: Check for a
Expected Results: CDL communication problem between the
Trans/Chassis ECM, the monitor, and the
The value changes to the correct state when cluster in the dash.
the parking brake switch is toggled.
If the state of the parking brake pressure switch
Results: does not change, proceed to “Troubleshooting
the Parking Brake Solenoid”.
• YES - The value changes to the correct state
when the switch is toggled. The parking Troubleshooting the Parking Brake
brake command is functional. Proceed to
Step 2.e.
Solenoid
Cat ET can be used to test the parking brake system.
• NO - The value does not change. By using Cat ET, a technician can override the
Refer to “Symptoms that occur when the parking brake solenoid. The technician can energize
or de-energize the solenoid, as required.
parking brake switch is set to the OFF position:
Parking Brake Does Not Disengage
Parking Brake Intermittently Does Not Specific voltage and pressure values are recorded.
The values are then compared with the expected
Disengage”.
values. This comparison is used in order to determine
e. Verify the parking brake pressure switch. if either the solenoid or the pressure switch for the
parking brake should be replaced.
Toggle the parking brake switch. Verify that
the “Value” of the “Parking Brake Solenoid” Required Tools
correlates to the following state of the“ Parking
Brake Pressure Switch”. Table 8 lists the tools that are required for Motor
Graders with the following range of transmission
View the parking brake indicator on the serial numbers:
dashboard and verify the following:
• (S/N: CZM1-03319)
• The parking brake indicator is on when the
parking brake pressure switch is low.
• The parking brake indicator is off when the

parking brake pressure switch is high.
“Not Energized” – “LOW - Indicator ON”
“Energized” – “HIGH - Indicator Off”
Note: The parking brake pressure switch only

indicates whether the parking brake is Engaged or
Disengaged. This switch does not control the parking
brake.
76 RENR9004-07
Table 8 Overriding the Parking Brake Solenoid

Required Tools For Troubleshooting
The following steps provide general instructions for
Tooling Part Number Description Qty using Cat ET in order to override the parking brake
Digital Pressure solenoid:
A 198-4240 2
Indicator Gp
Parking Brake
B
Adapter
B1 6V-3965 Fitting 1
B2 3J-1907 O-Ring Seal 1
B3 1U-3176 Connector
B4 3K-0360 O-Ring Seal
C Digital Voltage Meter 1
Table 9 lists the tools that are required for Motor

Graders with the following range of transmission
serial numbers:
• (S/N: DZM1-Up)
• (S/N: CZM03320-Up)
Table 9
Required Tools For Troubleshooting
Tooling Part Number Description Qty
Digital Pressure
A 198-4240 2
Indicator Gp
Parking Brake
B
Adapter
B1 6V-3965 Fitting 1
B2 3J-1907 O-Ring Seal 1
C Digital Voltage Meter 1
Test Procedures
Preliminary Steps
1. Operate the machine until the transmission oil

is at an operating temperature of 80° ± 10°C
(176° ± 18°F).
2. Stop the machine on a surface that is hard and

level.
3. Move the transmission control lever to the Neutral

position.
4. Lower all of the implements to the ground.
5. Toggle the parking brake switch to the ON position.
6. Shut down the engine.
7. Place chocks in front of the wheels and behind

the wheels.
RENR9004-07 77
g01978596
Illustration 81
Selecting the “Trans/Chassis” ECM
1. Connect Cat ET to the data link connector and

select the “Trans/Chassis” ECM for your machine.
g01978613
Illustration 82
Selecting “Override Parameters” from “Diagnostic Tools”
78 RENR9004-07
2. Select “Diagnostic Tools”.
3. Select “Override Parameters”.
g01978637
Illustration 83
“Change Parameter Value” screen
4. Select “Parking Brake Solenoid Override”. The

“Change Parameter Value” screen opens. The
“Current Value:” is shown.
5. By using the drop-down arrow in the “New Value:”

field, select the desired state for the solenoid.
6. Select the “OK” button.
Running the Test
Refer to the “Required Tools” section for the tooling

for your machine.
Record all of the values that are requested in Table

10 below. These values will be used in order to
troubleshoot the parking brake system.
Table 10
Recorded Values for Troubleshooting

Main Relief Hydraulic Solenoid
Override State
Valve Circuit Voltage
Off(1) P1 = ____ V1 = ____
On(2) P2 = ____ P3 = ____ V2 = ____
(1) The parking brake solenoid is de-energized.
(2) The parking brake solenoid is energized.
RENR9004-07 79
1. Connect Tooling (C) across the parking brake

solenoid.
g01935458
Illustration 84
Main Relief Valve (MRV)
(1) Dust Cap
(2) Main Relief Valve Fitting
g01944242
Illustration 86
2. Remove the dust cap (1).
253-8427 Parking Brake Gp
3. Attach Tooling (A) to the main relief valve fitting (3) Parking brake hydraulic circuit port
(2) of the parking brake housing.
4. Remove the plug assembly from the parking brake
hydraulic circuit port (3).
5. Attach Tooling (B) between Tooling (A) and the

parking brake hydraulic circuit port.
6. Ensure that the transmission control lever is in the

NEUTRAL position.
7. Start the engine and run the engine at high idle.
8. By using Cat ET, change the “Parking Brake

Solenoid Override” to “Off”. This action
de-energizes the solenoid.
9. Observe the pressure of the “Parking Brake

Hydraulic Circuit Pressure”. Record this value as
“P1”.
10. Measure the voltage across the parking brake

solenoid. Record this value as “V1”.
g01935459
Illustration 85 11. Use Cat ET to change the “Parking Brake
253-8424 Parking Brake Gp Solenoid Override” to “On”. This action energizes
(3) Parking brake hydraulic circuit port the solenoid.
12. Observe the pressure of the “Main Relief Valve”.

Record this value as “P2”.
13. Observe the pressure of the “Parking Brake

Hydraulic Circuit Pressure”. Record this value as
“P3”.
14. Measure the voltage across the parking brake

solenoid. Record this value as “V2”.
80 RENR9004-07
15. Exit the “Override” mode by performing one of the

following actions:
• Close Cat ET.

• Select a different screen on Cat ET.
16. Turn off the engine.
17. Refer to Table 11 in order to determine the

problem with the system. If the Parking Brake
Solenoid is replaced, repeat Step 6 through Step
16 in order to verify that the solenoid was the
problem. If the pressures do not improve, check
for hydraulic contamination or for a parking brake
piston that is leaking.
18. Remove Tooling (A) from the main relief valve

fitting.
19. Remove Tooling (B) from the parking brake

hydraulic circuit port.
20. Attach the plug assembly onto the parking brake

hydraulic circuit port.
21. Install the dust cap.
Expected Values
Refer to Table 11 and the values that were recorded

in Table 10 in order to troubleshoot the parking brake
system.
RENR9004-07 81
Table 11
Expected Values for Troubleshooting
Step Value Recorded Action
0 VDC ± 0.5 OK. Proceed to Step 2.
1 V1 Troubleshoot for CID 681 in
> 0.5 VDC
RENR9004.
0 PSI(1) OK. Proceed to Step 3.
2 P1
Replace the parking brake
> 1 PSI
solenoid.(2)
24 VDC ± 3 VDC OK. Proceed to Step 4.

3 V2 Troubleshoot for CID 681 in
< 21 VDC
RENR9004.

P3 = P2 ± 10 PSI(3)
pressure switch.
4 P3

P3 < P2 - 10 PSI
solenoid.(2)
(1) This is the “Hydraulic Circuit Pressure” when the parking brake solenoid is de-energized.
(2) Refer to “Removing and Installing the Parking Brake Solenoid”.. Verify that the pressure
has improved. If the pressure does not improve, check for hydraulic contamination or
for a parking brake piston that is leaking.
(3) The “Parking Brake Hydraulic Circuit Pressure” and the “Main Relief Valve Pressure” vary
by no more than 10 PSI of each other when the parking brake solenoid is de-energized.
Removing and Installing the Parking

Brake Solenoid
Use the correct removal and installation procedures
for the parking brake solenoid and other associated
components.
Reference: Refer to Table 12 in order to determine

the Disassembly and Assembly manual for your
specific machine.
82 RENR9004-07
Table 12
Manuals for Removal and Installation of the Parking Brake
Machine
Reference
Model
12M Disassembly and Assembly KENR6419 “120M and 12M

120M Motor Graders Power Train”
Disassembly and Assembly RENR8639 “14M Motor

14M
Grader Power Train”
Disassembly and Assembly KENR6425 “140M Motor
140M
Disassembly and Assembly KENR6019 “16M Motor
16M
Disassembly and Assembly , RENR9726, “160M
160M
Motor Grader Power Train”
i03877193 • Hydraulic steering valve is malfunctioning

Steering Direction Is Opposite
of Expected Direction
SMCS Code: 4300-035
S/N: B9C1-Up
S/N: B9D1-Up
S/N: B9E1-Up
S/N: B9F1-Up
S/N: B9G1-Up
S/N: D9G1-Up
S/N: B9H1-Up
S/N: R9H1-Up
S/N: B9J1-Up
S/N: R9J1-Up
S/N: B9L1-Up
S/N: B9M1-Up
S/N: B9N1-Up
S/N: B9R1-Up
S/N: B9T1-Up
S/N: B9W1-Up
This event code is associated with the machine

steering cylinders moving in the opposition direction
from the commanded flow. Possible causes are the
following:
• Hydraulic hose connections are reversed

• Secondary solenoids electrical connections are
reversed
RENR9004-07 83
g02231034
Illustration 87
84 RENR9004-07
g02231040
Illustration 88
RENR9004-07 85
g02231042
Illustration 89
86 RENR9004-07
i03880184
Steering Does Not Function

SMCS Code: 4300-035
Immediate safe shutdown required
Potential causes of the E258 Event Code are as

follows:
• Secondary steering test results in insufficient pump

pressure
• Electrical problem in the secondary steering pump

motor circuit
• Mechanical problem with the secondary steering

pump
• Machine wheels are locked into a position due to

external forces/obstruction
Use the following flowchart to troubleshoot this event:

RENR9004-07 87
g02231413
Illustration 90
88 RENR9004-07
g02231414
Illustration 91
RENR9004-07 89
g02231415
Illustration 92
i03878710 Use the following flowcharts to troubleshoot this

event:
Steering Movement Without
Request
SMCS Code: 4300-035
Immediate safe shutdown required.
This event code is associated with the machine

steering cylinders moving when there is no command
given by the operator.
90 RENR9004-07
g02230634
Illustration 93
RENR9004-07 91
g02230653
Illustration 94
i04044155 When the transmission/chassis ECM activates an

event code, the operator or the technician will be
Event Code List alerted by the Messenger. Most active events will be
logged by the ECM, however some events are active
SMCS Code: 7569 only and active only events are not logged. Event
codes are referred to by an event identifier number
Event codes identify significant events that occur (EID). The events that are active and the events
to machine systems. electronic control modules that are logged can be viewed with the following
(ECMs) store the data from the events. This function equipment:
allows tracking of the machine history and is an aid
in troubleshooting. • Messenger
• Cat® Electronic Technician (Cat® ET) service tool
92 RENR9004-07
Warning Levels
The ECM will assign a warning level to an active
event code. Event codes are one of three levels,
according to the severity of the abnormal condition.
Each warning level requires a specific response
from the operator. The warning levels and required
operator response are listed below.
Warning Level 1
Warning level 1 alerts the operator that a system
requires attention. The operator should check the
involved system or perform maintenance on the
involved system at the earliest possible time.
Warning Level 2
Warning level 2 requires changing the operation of
the machine or performing a maintenance procedure.
Failure to correct a level 2 warning may result in
component damage.
Warning Level 2S
Warning level 2S requires an immediate change in
machine operation to avoid possible system damage.
Warning Level 3
Warning level 3 requires an immediate safe machine
shutdown to avoid damage to the machine or injury
to personnel around the machine. The problem that
caused the event must be corrected before machine
operation can resume.
Indications and System Response

Messenger
Messenger alerts the operator when an event code
is active.
RENR9004-07 93
g01318378
Illustration 95
Indicators that are on the Instrument Cluster
(1) Blade left float (7) Throttle lock (engaged) (13) Secondary steering system
(2) Charging system (8) Action Lamp (14) Braking system
(3) Air inlet heater (active) (9) Park brake (engaged) (15) Operator not present
(4) Engine system (10) Differential lock (16) Blade right float
(5) Implement system (11) Transmission system
(6) Primary steering system (12) High beam
The warning indicators for the subsystem on the

Instrument Cluster will illuminate when a EID is
activated for a particular subsystem. When level
1 events are active, the warning indicator for the
subsystem will be the only type of indicator that will
illuminate.
The action Indicator will flash red when a level 2

warning or level 3 warning is active. If communication
between Messenger and the Instrument Cluster fails,
the action lamp will flash yellow.
The action alarm is driven as an output directly from

the Instrument Cluster. If a level 3 warning is active,
the action alarm will sound a tone that is pulsing.
The action alarm will sound these tones to alert the
operator that immediate action is required.
If two warnings of a different level are active at

the same time, the highest level warning will be
displayed.
Table 13 shows the Messenger response to these

warning levels.
94 RENR9004-07
Table 13
WARNING OPERATION
Warning Indications
Warning Action Sounds Of The Action That Is Required Possible Result
Warning Level Indicators Indicator Action Alarm By The Operator (1)
1 ON OFF OFF No immediate action is No harmful effects

required. The system or damaging
needs attention soon. effects
2 ON Flash ON and OFF Change machine Damage
OFF. operation or perform to system
maintenance to the components
system.
2S ON ON ON Immediately change the Severe damage
machine operation. to system
components
3 ON Flash ON and Pulse ON and OFF Immediately perform a Injury to operator
OFF safe engine shutdown. or severe damage
to components
(1) Possible result if no action is taken by the operator.
Cat® Electronic Technician (Cat® ET) Note: Always clear logged event codes after
Service Tool investigating and correcting the problem which
generated the code.
When a power train abnormal operating condition
occurs, the status screen on Cat ET indicates that Troubleshooting
there is an active event.
Perform the following steps to troubleshoot an event.
Event codes are displayed on Cat ET in the following
format: 1. Obtain the following information from the operator:
EXXXX Description of the code • The event

The “E” means that the code is an event code. The • Time the event occurred
“XXXX” is a numeric identifier. The numeric identifier
is followed by a description of the code. • Engine operating conditions at the time of the
event.
Active event codes are listed in ascending numerical
order, the lowest number is listed first. Active event • Any systems that were installed by the dealer or
codes are removed from the list when the condition is customer that could cause the event
no longer present.
2. Verify that the event is not due to normal machine
Logged Event Codes operation or operator error.
Some event codes are logged in the ECM memory. 3. Check all fluid levels.
Some event codes are active only. The logged event
codes are listed in chronological order, the most 4. Troubleshoot and repair any active diagnostic
recent code is listed first. codes.
A logged code is cleared from memory when one of

the following occurs: List of Event Codes For the
Transmission/Chassis ECM
• The technician clears the code.
Table 14 lists the event codes that apply to the
• The code does not reoccur for 1000 hours. power train control system and the recommended
responses. Use Cat ET to determine the event codes
• A new code is logged and there are already ten that are active or logged.
logged codes in memory. In this case, the oldest
logged code is cleared.
RENR9004-07 95
Table 14
List of Event Codes (EID) For the Transmission/Chassis ECM
EID Level Description Possible Cause and Recommended Response

0077 2 Differential filter plugged Replace the differential oil filter.
0179 2 Alternator not charging Charging system voltage is less than 18.0 VDC.
Check drive belt tension.

Check alternator connections.
To troubleshoot the charging system, refer
to “REHS0354”.
0192 3 Steering system malfunction Immediate safe shutdown is required.
The following active diagnostic codes will

cause this EID to activate:
CID 0262, 0597, 1471, 1472, 1473, 2175, 2176,
1674, 2200, 2201, 2202, 2650
Repair the cause of the active diagnostic code.
0233 1 Low engine pre-lube pressure The prelube relay is de-energized due to the
prelube pressure target not being achieved within
15 seconds of the cycle start.
Check lube oil level.

Check for an active secondary steering pump EID. If
present, problem could be related to the motor or relay.
Check the prelube pump or the pressure sensor.
Check for a kinked prelube line or blockage
in a prelube line.
0256 3 Steering output detected in the Immediate safe shutdown is required.
wrong direction
Usually occurs after servicing.
Possible causes are the following:

Hydraulic hose connections are reversed.
Electrical connections of the secondary
solenoid are reversed.
The hydraulic steering valve is malfunctioning.
Refer to Troubleshooting, “Steering Direction
is Opposite of Expected Direction” for
additional troubleshooting.
0257 3 Steering output detected with Immediate safe shutdown is required.
no command
Front wheels are moving without a command.

Operating the machine in rough terrain is forcing
unexpected movement of the front wheels.
Problem with the hydraulic control valve
A short circuit in the circuit of the steering
control signal.
Refer to Troubleshooting, “Steering Movement
Without Request” for additional troubleshooting.
0258 1 No Steering detected with Travel speed is less than 9 km/h (5.6 mph) and no
command given movement of the front wheel is detected.

The front wheels are physically blocked and the
front wheels do not respond to a command.
The mechanical steering linkage is physically blocked.
Mechanical problem in the steering control valve
Refer to Troubleshooting, “Steering Does Not
Function” for additional troubleshooting.
(continued)
96 RENR9004-07
(Table 14, contd)


0258 3 No steering detected with Immediate safe shutdown is required.
command given
Travel speed is greater than 9 km/h (5.6 mph) and
no movement of the front wheel is detected.

Mechanical problem in the steering control valve
The mechanical steering linkage is physically blocked.
The front wheels are physically blocked and the
front wheels will not respond to a command.
Refer to Troubleshooting, “Steering Does Not
Function” for additional troubleshooting.
0284 3 Low brake pressure Immediate safe shutdown is required. The event
will be logged if the EID is active for more than 10
seconds after the start of the machine.
The event is active when brake accumulator pressure

is less than 8101.3 kPa (1175.0 psi). The event
deactivates when brake accumulator pressure
reaches 9825.0 kPa (1425.0 psi).
If the machine is logging this event, perform the

following steps:
1. Verify that the service brake accumulator pressure
sensor is reading accurately. Compare the pressure
sensor reading to a hydraulic pressure gage hooked
to same hydraulic circuit.
2. If the pressure sensor is reading accurately, do
not replace the pressure sensor. Troubleshoot the
hydraulic system. Look for hydraulic leaks.
3. Verify that the brake accumulators hold charge per
their specifications.
0329 2 Transmission filter plugged Replace the transmission oil filter.
0334 2 Low autolube pressure Activated during the autolube cycle (configured
Autolube duration) when the pressure does not
reach the minimum configured Autolube pressure
target. Stays active until pressure is reached
during a cycle. This event is logged.
In Cat® ET, check the following configured

parameters:
Cycle duration. The default is 240 seconds. Low time
setting may not allow time for pressure to be reached.
Minimum pressure. Default is 18615.9 kPa
(2700.0 psi).
High setting may not allow pressure to be reached
in the configured duration time.
Check for leaks, kinked or plugged lines, fuse or pump.
0490 2 Parking brake ON Disengage the parking brake before shifting
out of neutral.
0521 2 Autolube malfunction Activated when the autolube pressure does not
decrease below 7584.2 kPa (1100.0 psi)within the
configured interval time. Stays active until pressure
decreases during interval. This event is logged.
Check for kinked or plugged lines that will prevent

the decrease in system pressure.
(continued)
RENR9004-07 97
(Table 14, contd)


0560 3 Secondary steering pump pressure Immediate safe shutdown is required.
not responding to command
Secondary steering test indicates insufficient
pump pressure.
Check for an active MID 027 - CID 420 -

FMI 03 diagnostic code.
If the code is active, refer to the Diagnostic

Code Procedures, “MID 027 - CID 420 - FMI
03” Story in this manual for details.
If the MID 027 - CID 420 - FMI 03 diagnostic code is

not active, refer to the System Operation, “Secondary
Steering System” Section of this manual and use
good troubleshooting to diagnose the problem.
0562 1 Steering lever has not been aligned Left joystick must be “swept” fully left and right
to wheel steering angle (Active to align the front wheel angle with the correct
only - Not logged) joystick position for that angle.
Must be aligned when the machine is started.
If machine is parked and the operator leaves the seat.
Possible causes for not aligning are the following:

Operator present switch is indicating no operator
in the seat. Operator must be seated.
Left Joystick is being swept too fast. Sweep slower
Wheels are out of the accepted angle (extreme angle).
Manually move the wheels into the accepted range.
0627 3 Parking brake abuse Immediate safe shutdown is required.
Caused by driving the machine with the
parking brake ON.
E627 will occur if the machine is traveling at a speed
that is greater than 8 km/h (5.0 mph) and the parking
brake switch is toggled to the ON position.
Disengage the parking brake before shifting
out of neutral.
644 3 Transmission oil pressure Activated when the transmission oil pressure
is low for five seconds.
Shutdown the machine.
Check for transmission problems.
0737 2 Inching pedal disabled due to Active when both the inching pedal sensor and
system fault the inching pedal switch are faulted.
0792 1 A/C clutch cycle rate Activated when the AC clutch is cycling ON
and OFF more than is expected.
Decrease the temperature setting to allow the

system compressor to stay ON longer.
Check for problems in the AC clutch relay
and solenoid circuits.
(continued)
98 RENR9004-07
(Table 14, contd)


0794 3 Steering not synchronized Immediate safe shutdown is required.
One ECM (Implement or Transmission/Chassis)

has lost steer alignment between joystick and steer
cylinders and the other ECM is still aligned.
Can be caused by rapid key ON/OFF/ON cycle.

Shut down machine, restart and align steering
(see EID 0562 above).
Check for Data Link communication faults (CIDs

0247, 0590, 0596, 0296).
Clear the active fault and align steering.
Could be caused by activation of any of the following

CIDs: 1471, 1472, 1473, 2200, 2201.
Clear the active fault and align steering.
0795 3 Machine speed excessive for Immediate safe shutdown is required.
machine articulation angle (Active
only - Not logged) Machine articulation angle is greater than 5.5°.
Machine will not operate in high gears.
Decrease the articulation angle to operate

in the high gears.
0861 1 Clock manual alignment required The ECM internal clock is too far out of alignment
with the other control module clocks on the machine.
Use the Cat ET service tool to manually align the

clock with the other control modules.
0877 1 High transmission oil temperature Activation/De-activation points are speed dependant.
If machine speed is less than 20 km/h (12.4 mph):

Activated when transmission oil temperature reaches
101 °C (213.8 °F) for 60 seconds. Resets when oil
temperature decreases to less than 99 °C (210.2 °F).
If machine speed is greater than 20 km/h (12.4 mph):

temperature decreases to less than104 °C (219.2 °F).
Check transmission oil level.

Modify machine operation to reduce system load.
0877 2 High transmission oil temperature Activation/De-activation points are speed dependant.
If machine speed is less than 20 km/h (12.4 mph):

If machine speed is greater than 20 km/h (12.4 mph):

Activated when transmission oil temperature
reaches 109 °C (228.2 °F) for 600 seconds OR
Check transmission oil level.

Modify machine operation to reduce system load.
(continued)
RENR9004-07 99
(Table 14, contd)


1256 3 Key input off while machine in operation May occur if the key is turned off while the
machine is operating. If this condition occurs
while the keyswitch is in the ON position, check
the keyswitch circuit for a failure.
100 RENR9004-07
Diagnostic Code (Table 16, contd)

FMI 03 Voltage above normal
Procedures FMI 04 Voltage below normal
CID 0070 - Parking Brake Switch
i03617320
Diagnostic Code List
FMI 04 Voltage below normal
SMCS Code: 7569 CID 0096 - Fuel Level Sensor
Use the Messenger or the Caterpillar Electronic FMI 03 Voltage above normal
Technician (Cat ET) service tool in order to view the FMI 04 Voltage below normal
active diagnostic codes for the transmission/chassis
ECM. Perform the procedure that corresponds to the CID 0127 - Transmission Oil Pressure Sensor
Module Identifier (MID), the Component Identifier FMI 03 Voltage above normal
(CID) and the Failure Mode Identifier (FMI) of the
diagnostic code. CID 0127 - Transmission Oil Pressure Sensor
Module Identifier (MID) CID 0144 - Backup Alarm Relay
The module identifier (MID) identifies the electronic FMI 03 Voltage above normal
control module that activated the diagnostic code. FMI 05 Current below normal
Each electronic control module on the machine
has a unique MID. Use the following chart in order FMI 06 Current above normal
to match the MID for each diagnostic code to a CID 0168 - Electrical System Voltage
specific electronic control module. The chart for the
Module Identifier (MID) is located on the electrical FMI 00 Data is valid, but above normal operational
schematic for your machine. See the chart if the range
MID is not shown on the display of your machine. FMI 01 Voltage below normal
After the operator determines the electronic control
module that has detected the failure, see the service FMI 02 Incorrect, intermittent, erratic data
manual module for that particular ECM for more CID 0177 - Transmission Oil Temperature Sensor
troubleshooting information. The service manual for
each ECM is part of the machine's Service Manual. FMI 03 Voltage above normal
Table 15
Module Identifiers CID 0247 - SAE J1939 Data Link
MID Description FMI 09 Abnormal update
027 Transmission/Chassis ECM FMI 14 Special instruction
082 Implement ECM CID 0248 - Cat Data Link
145 Implement ECM 2 FMI 09 Abnormal update

FMI 14 Special Instruction
Component Identifier (CID) CID 0262 - 5 Volt Sensor DC Power Supply

Each component has a component identifier (CID).
The ECM will activate the CID diagnostic code for a FMI 04 Voltage below normal
particular component when a problem in the circuit CID 0368 - Transmission Auto/Manual Switch
is detected.
All the CID codes that can be activated by the FMI 04 Voltage below normal
transmission/chassis ECM are shown in Table 16.
CID 0420 - Secondary Steering Relay
Table 16
Diagnostic Code List of the Transmission/
FMI 05 Current below normal
Chassis ECM
(MID 027)(1) FMI 06 Current above normal
CID 0041 - 8 Volt DC Sensor Power Supply CID 0444 Starter Motor Relay
(continued) (continued)
RENR9004-07 101

FMI 03 Voltage above normal CID 0673 - Transmission Output Speed Sensor 2
FMI 05 Current below normal FMI 02 Incorrect, intermittent, erratic data
FMI 06 Current above normal CID 0674 - Transmission Intermediate Speed Sensor
1
CID 0573 - Inching Pedal Position Sensor
FMI 02 Incorrect, intermittent, erratic data
CID 0675 - Transmission Intermediate Speed Sensor
FMI 04 Voltage below normal 2
FMI 08 Abnormal frequency, pulse width, or period FMI 02 Incorrect, intermittent, erratic data
CID 0585 - Transmission Output Speed Sensor 1 CID 0681 - Parking Brake Solenoid Valve
FMI 02 Incorrect, intermittent, erratic data FMI 03 Voltage above normal
CID 0588 - Monitoring System Display FMI 05 Current below normal
FMI 09 Abnormal update FMI 06 Current above normal
FMI 14 Special instruction CID 0967 - Machine Application
CID 0590 - Engine ECM FMI 02 Incorrect, intermittent, erratic data
FMI 09 Abnormal update FMI 09 Abnormal update
FMI 14 Special instruction CID 1326 - Location Code
CID 0596 - Implement ECM FMI 02 Incorrect, intermittent, erratic data
FMI 09 Abnormal update CID 1401 - Transmission Clutch Solenoid 1
FMI 12 Bad device or component FMI 03 Voltage above normal
FMI 14 Special instruction FMI 05 Current below normal
CID 0615 - Machine Articulation Angle Position FMI 06 Current above normal
Sensor
FMI 13 Out of calibration
CID 1402 - Transmission Clutch Solenoid 2
FMI 08 Abnormal frequency, pulse width, or period
FMI 06 Current above normal
FMI 14 Special instruction
CID 0621 - Downshift Switch
CID 0622 - Upshift Switch
CID 0623 - Directional Switch
CID 0627 - Park Brake Pressure Switch
CID 0669 - Transmission Input Speed Sensor
(continued)
(continued)
102 RENR9004-07

FMI 13 Out of calibration CID 1674 - Solenoid Return 1
CID 1406 - Transmission Clutch Solenoid 6 FMI 03 Voltage above normal
FMI 03 Voltage above normal FMI 04 Voltage below normal
FMI 05 Current below normal FMI 05 Current below normal
FMI 06 Current above normal CID 1960 - Ignition Key Reader
FMI 13 Out of calibration FMI 09 Abnormal update
CID 1407 - Transmission Clutch Solenoid 7 CID 1961 - Service Brake Accumulator Pressure
Sensor
CID 2113 - Operator Present Switch
CID 2175 - Secondary Steer Left Solenoid
CID 1471 - Steering Control Position Sensor 1
CID 2176 - Secondary Steer Right Solenoid
CID 2199 - Secondary Steering Request Signal Line
CID 2200 - Left Steering Cylinder Position Sensor
FMI 00 Data valid but above normal operational range
CID 2201 - Right Steering Cylinder Position Sensor
CID 1482 - 10 Volt Sensor DC Power Supply
FMI 00 Data valid but above normal operational range
CID 1484 Inching Pedal Switch
(continued)
(continued)
RENR9004-07 103
(Table 16, contd) Table 17

FMI 13 Out of calibration Failure Mode Identifier and Message Center Displays
FMI 14 Special instruction FMI Description of Failure
CID 2252 - Machine Articulation Angle Sensor 2 00 “Data valid but above normal operating
range”
01 “Data valid but below normal operating
range”
02 “Incorrect, intermittent, erratic data”
03 “Voltage above normal”
04 “Voltage below normal”
05 “Current below normal”
CID 2304 - Differential Lock Relay
06 “Current above normal”
07 “Mechanical system not responding
FMI 05 Current below normal properly”
FMI 06 Current above normal 08 “Abnormal frequency, pulse width, or

period”
CID 2734 - Compression Brake Switch
09 “Abnormal update”
10 “Abnormal rate of change”
11 “Failure mode not identifiable”
CID 3210 - Transmission Pump Bypass Solenoid
12 “Bad device or component”
13 “Out of calibration”
14 “Special Instruction”
CID 3382 - Fan/Brake Pump Load Sense Bypass
Solenoid
Detailed FMI Explanation
FMI 03 Voltage above normal 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.
FMI 06 Current above normal The high limit includes over range signals. This could
(1) This table is only for MID 027 diagnostic codes that can be be a high temperature. A sensor that is still operating
activated by the transmission/chassis ECM. but sending a signal above the expected limit will
cause a FMI 00 to be activated.
Failure Mode Identifier Some of the conditions that can cause the FMI 00
diagnostic code to be activated are listed below:
The codes for the Failure Mode Identifier are defined
by the SAE standards. The following list contains a
CAT version of definitions.
• The medium or the component that is being
monitored is above the normal range.
• The signal is shorted to another voltage source.

• The sensor needs to be calibrated.
• An ECM has failed. This is unlikely.
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.
104 RENR9004-07
Some of the conditions that can cause the FMI 01 • The circuit is shorted to a ground source.
• The circuit is an open circuit or the circuit has a
• The medium or the component that is being poor connection.
monitored is above the normal range.
• The ground circuit has failed.
• There are poor connections in the circuit.
• A component has failed.
• The sensor has failed.
FMI 05 Current Below Normal – The current
FMI 02 Data erratic, intermittent or incorrect – through the component or the system is lower than
The signal from a component is present. The control the limit. FMI 05 is most often related to a driver
that reads the diagnostic information can not read circuit.
the signal properly. The signal appears to be gone,
unstable or invalid. The data can be correct or Conditions that could cause a FMI 05 diagnostic
incorrect intermittently. Also, this condition relates to code are listed below.
communication between controls. This is an example
of communication between controls. When the • There is an open circuit or a poor harness
monitoring system is looking for the engine speed connection.
from the Engine ECM over the CAT Data Link.
• The component has failed or the component has
Some of the conditions that can cause the FMI 02 an open internally.
• There is a poor connection in the circuit.
FMI 06 Current Above Normal – The current
• The signal is intermittent or erratic. through the circuit of the component is higher than
the limit. FMI 06 is most often related to a driver
• The software has been changed. circuit for a solenoid. This diagnostic code is similar
to an FMI 04 diagnostic code.
• The signal is receiving interference from another
circuit. Conditions that could cause a FMI 06 diagnostic
code are listed below.
• The signal is out of the range.
• The component has failed.
• There is a short circuit to a ground source in the
FMI 03 Voltage Above Normal – The component or machine harness.
system voltage is higher than the limit. An FMI 03
most often relates to a signal circuit. • An ECM has failed. This is unlikely.
Some of the conditions that could cause a FMI 03 FMI 07 Mechanical System Not Responding
diagnostic code to be activated are listed below. Properly – The control detects a signal that is sent
to a mechanical system and the response is not
• Loss of power supply correct.
• A open circuit or a bad connection Conditions that could cause a FMI 07 diagnostic
• A short to another voltage source
• The component responds improperly.
• The sensor or the switch has failed.
• The component is mechanically stuck in a position.
• The mechanical component has failed.
FMI 04 Voltage Below Normal – The component
or system voltage is lower than the limit. An FMI 04 • The engine is shut down.
diagnostic code most often relates to a power supply
circuit. • The machine is being used improperly.
Conditions that could cause a FMI 04 diagnostic
RENR9004-07 105
FMI 08 Abnormal Frequency, Pulse Width or • There is damage to multiple circuits.

Period – This occurs when the signal is not in the
expected range. FMI 08 can also relate to a faulty • An ECM has failed. This is unlikely.
sensor.
FMI 12 Bad Device or Component – The electronic
Conditions that could cause a FMI 08 diagnostic control sends a signal and the electronic control
code are listed below. expects a response. The control receives no
response or the response is incorrect.
• The harness connections are intermittent or poor.
• The signal is noisy due to nearby interference. code are listed below.
• There are loose mechanical devices. • The component has failed.

• The component has failed. • There is a failure on the data link.
• An ECM has failed. This is unlikely. • There are one or more controls with mismatched
software.
FMI 09 Abnormal Update – This relates to
communications on the data link. FMI 09 occurs • An ECM has failed. This is unlikely.
when a control is not able to get information from
another control. FMI 13 Out of Calibration – The electrical signal is
not within limits for a specific mechanical condition.
code are listed below. Conditions that could cause a FMI 13 diagnostic
• The control module is not communicating on the
data link correctly. • Calibration is required.
• The rate of data transmission is abnormal. • The component has failed.
• The data link circuit has failed. • The data is out of the range.
• There is a mismatch of software. • An ECM has failed. This is unlikely.
• An ECM has failed. This is unlikely. FMI 14 Parameter Failures – This diagnostic code
is set up for special circumstances for a particular
FMI 10 Abnormal Rate of Change – This code component. The FMI 14 troubleshooting procedure
relates to a signal that has a rate of change that is for the component will list the possible conditions that
too fast or too slow. The rate of change is outside of can cause this code.
the expected limit.

• The component has failed.

• Poor connections in the circuit
• The medium or the component that is being
monitored has failed.

FMI 11 Failure Mode Not Identifiable – The control
identifies more than one FMI as being responsible
for a single failure.
Conditions that could cause a FMI 11 diagnostic code

are listed below.
• There is a mechanical failure.

106 RENR9004-07
i02626144 2. From the Messenger Service Menu page,

the first option in the service menu will be
Using Messenger to Determine “Diagnostics/Events”. Press “OK” in order to view
Diagnostic Codes the list of Active codes and Logged codes.
SMCS Code: 7490; 7569

S/N: B9C1-Up
S/N: B9D1-Up
S/N: B9F1-Up
S/N: B9H1-Up
S/N: R9H1-Up
S/N: B9J1-Up
S/N: R9J1-Up
g01299326
S/N: B9R1-Up Illustration 98
The Messenger Diagnostics/Events List screen
Active and logged diagnostic codes can be viewed
and cleared using the Messenger. 3. The Messenger Diagnostics/Events List screen
shows the following:
Perform the following steps in order to view the active
and logged diagnostic codes: SRC – Source
CODE – MID, CID, FMI, EID, and WCI
OCC – The number of occurrences of the codes
ACT – The fact that the code is active
Pressing “OK” on any of these codes will display

the Diagnostic/Event screen.
Note: If the code is Active, there will be an “A” in the

“ACT” column.
g01299082
Illustration 96
Messenger Main Menu
1. From the Messenger Main Menu page, scroll to

“Service” menu and press the “OK” button.
g01299332
Illustration 99
The Messenger Diagnostic/Event Detail screen
The Messenger Diagnostic/Event Detail screen will

display the following:
• Source of the failure

Illustration 97
g01299096
• Code CID, FMI, EID, and WCI
Messenger Service Menu
RENR9004-07 107
• Text description of failed component

• Text description of the type of failure
i02765103
Using Caterpillar Electronic

Technician to Determine
Diagnostic Codes
SMCS Code: 0785-UE; 7569
Connect the Cat ET to the machine. Turn the Key

switch to the RUN position. Start the Cat ET. The Cat
ET will initiate communications with the Electronic
Control Modules (ECMs) on the machine. After
communication has been established, the ET will list
the ECMs on the machine. Choose the desired ECM.
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
g00859671
Illustration 100
Typical Cat ET screen for active diagnostic codes
108 RENR9004-07
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 Cat 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
g00859762
Illustration 101
Typical Cat ET screen for logged diagnostic codes
RENR9004-07 109
A screen is provided in Cat ET for logged diagnostic Note: The 8.0 volt power supply for the
codes. The screen will display diagnostic codes that “Transmission/Chassis ECM” is one of two power
are logged. The Cat ET will log diagnostic codes that supplies that are used for the left hand joystick.
are intermittent. The logged diagnostic data shall The other power source for the left hand joystick is
include a component identifier (CID), a failure mode supplied by the Implement ECM.
identifier (FMI), and a text description of the problem.
Also, the logged diagnostic data shall include the The CID 0041 FMI 03 diagnostic code is activated
number of occurrences of the problem and two time when the ECM detects that the voltage of the 8.0 volt
stamps. The time stamp displays the first occurrence power supply circuit is above normal.
of the problem and the time stamp displays the most
recent occurrence of the problem. The following conditions could cause this diagnostic
code:
Diagnostics are logged in non-volatile memory. On
powerup, the ECM will clear any diagnostic codes • The power supply circuit is shorted to a higher
that have not been detected or active within the last voltage source.
150 hours of machine operation.
• The ECM has failed. This is unlikely.
i03794625
Note: Before performing this procedure, inspect
MID 027 - CID 0041 - FMI 03 the harness connectors that are involved in the
circuit. Poor connections can often be the cause
SMCS Code: 1439-038 of a problem in an electrical circuit. Verify that
all connections in the circuit are clean, that all
Conditions Which Generate This Code: connections are secure and that all connections
are in good condition. If a problem with a
connection is found, correct the problem and
verify that this diagnostic code is active before
Note: The following test procedure may cause

other diagnostic codes to be activated. Ignore these
created diagnostic codes and clear the diagnostic
codes when the problem has been corrected.
Test Step 1. CHECK THE VOLTAGE AT

A COMPONENT

the inching pedal position sensor.
C. At the machine harness connector for the sensor,

measure the voltage from the contact of the
supply A (wire T998-BR) to return contact B (wire
X800-OR).
Expected Result:
The voltage measurement is 8.0 ± 0.3 VDC.
Illustration 102
g02101074 Results:
8.0 VDC Power Supply connections for the ECM
• OK – The voltage measurement is 8.0 ± 0.3 VDC.
This diagnostic code is associated with the 8.0 volt The voltage is correct. Proceed to Test Step 4.
power supply of the “Transmission/Chassis ECM”.
The 8.0 volt power supply provides power for the left • NOT OK – The voltage measurement is greater
joystick, the inching pedal position sensor and the than 8.0 ± 0.3 VDC. The measurement is not
machine articulation angle sensor 2. correct. Proceed to Test Step 2.
110 RENR9004-07
Test Step 2. CHECK THE POWER SUPPLY C. Disconnect the machine harness connectors J1
AT THE ECM and J2 from the “Transmission/Chassis ECM”.
A. Turn the disconnect switch and the key start D. At the harness connector J1 for the
switch to the OFF position. “Transmission/Chassis ECM”, check the
resistance from contact J1-44 (wire T998-BR)
B. At the connector of the “Transmission/Chassis to all of the other ECM +battery (wire 126-RD)
ECM” J1, use a 151-6320 Removal Tool to contacts that are connected to the ECM. The
remove the supply wire and the socket at contact contacts are J1-31, J1-38, J1-39, J1-46 and J1-47.
J1-44 (wire T998-BR) and remove the return wire
and the socket at contact J1-45 (wire X800-OR) E. At the harness connector J1 for the
from the connector. The machine harness “Transmission/Chassis ECM”, check the
connector J1 remains connected to the ECM. resistance from contact J1-44 (wire T998-BR) to
all of the other contacts that are used in connectors
C. Turn the disconnect switch and the key start J1 and J2 for the “Transmission/Chassis ECM”.
Expected Result:
D. Use the multimeter probes in order to make
contact on the connector pins of the ECM. Each resistance measurement is greater than 5000
Measure the voltage at the ECM pins between the ohms.
contact of the power supply J1-44 and the return
contact J1-45. Results:
Expected Result: • OK – Each resistance measurement is greater

than 5000 ohms. The supply circuit is not shorted
The voltage measurement is 8.0 ± 0.3 VDC. to another circuit in the machine harness. Proceed
to Test Step 4.
Results:
• NOT OK – One or more of the resistance
• OK – The voltage measurement is 8.0 ± 0.3 VDC. measurements is less than 5000 ohms. There is a
The voltage is correct. The ECM power supply is short in the machine harness.
correct. Install the wires and sockets that were
removed from the J1 connector back into the Repair: The power supply circuit is shorted to
original locations. Proceed to Test Step 3. another circuit in the machine harness. Refer to
the complete Electrical System Schematic of the
• NOT OK – The voltage measurement is greater machine. Examine the supply circuit in order to
than 8.0 ± 0.3 VDC. The ECM power supply is not determine the location of the problem.
correct. The ECM has failed.
For information on testing for short circuits and
Repair: Prior to replacing an ECM, always finding short circuits, refer to Testing and Adjusting,
contact your dealership's Technical Communicator “Wiring Harness (Short Circuit) - Test”. Repair the
for possible consultation with Caterpillar. This machine harness or replace the machine harness.
consultation may greatly reduce repair time. If
the ECM requires replacement, refer to Testing STOP.
and Adjusting, “Electronic Control Module (ECM)
- Replace”. Test Step 4. CHECK THE STATUS OF THE
DIAGNOSTIC CODE
STOP.
A. Inspect the harness connectors. Clean the
Test Step 3. CHECK FOR A SHORT contacts of the harness connectors. Check the
CIRCUIT IN THE MACHINE HARNESS wires for damage to the insulation that is caused
by excessive heat, battery acid, or chafing.
The machine harness connector remains
disconnected from the inching pedal position sensor. B. Perform a 45 N (10 lb) pull test on each of the
wires that are associated with the sensor circuit.
switch to the OFF position. C. Reconnect all harness connectors. Make sure that
the connectors are fully seated. Observe that the
B. Disconnect the machine harness connector J3 clips for each connector are completely fastened.
from the connector of the left joystick. Disconnect
the machine harness connector from the “machine D. Turn the disconnect switch and the key start
articulation sensor 2”. switch to the ON position.
RENR9004-07 111
E. Operate the machine. i03794637
F. Determine if the CID 0041 FMI 03 diagnostic code MID 027 - CID 0041 - FMI 04
is active.
SMCS Code: 1439-038
Expected Result:
Conditions Which Generate This Code:
The CID 0041 FMI 03 diagnostic code is no longer
active.
Results:
• YES – The CID 0041 FMI 03 diagnostic code 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.
• NO – The CID 0041 FMI 03 diagnostic code is

active. The problem has not been corrected.
Repair: Check the circuit again. Use the Caterpillar

Electronic Technician (ET) service tool, if available,
in order to perform a wiggle test on the machine
wiring harness. The wiggle test can detect
momentary or intermittent shorts or opens in the
machine wiring harness.
If the cause of the problem is not found, the ECM

may be activating the diagnostic code incorrectly. g02101074
Illustration 103
The ECM may have failed.
8.0 VDC Power Supply connections of the ECM
Prior to replacing an ECM, always contact your
dealership's Technical Communicator for possible This diagnostic code is associated the 8.0 volt power
consultation with Caterpillar. This consultation may supply of the “Transmission/Chassis ECM”. The 8.0
greatly reduce repair time. If the ECM requires volt power supply provides power for the left joystick,
replacement, refer to Testing and Adjusting, the inching pedal position sensor and the machine
“Electronic Control Module (ECM) - Replace”. articulation angle sensor 2.
STOP. The 8.0 volt power supply for the “Transmission/

Chassis ECM” is one of two power supplies that
are used for the left hand joystick. The other power
source for the left hand joystick is supplied by the
Implement ECM.
The CID 0041 FMI 04 diagnostic code is recorded

when the ECM detects that the voltage of the 8.0 volt
power supply circuit is below normal.
The following conditions could cause this diagnostic

code:
• A sensor has failed.

• The sensor supply circuit is shorted to a ground
source.

112 RENR9004-07
Note: Before performing this procedure, inspect B. At the connector of the Transmission/Chassis
the harness connectors that are involved in the ECM, J1, use a 151-6320 Removal Tool to
circuit. Poor connections can often be the cause remove the supply wire and the socket at contact
of a problem in an electrical circuit. Verify that J1-44 (wire T998-BR) and the return wire and the
all connections in the circuit are clean, that all socket at contact J1-45 (wire X800-OR) from the
connections are secure and that all connections connector. The machine harness connector J1
are in good condition. If a problem with a remains connected to the ECM.
verify that this diagnostic code is active before C. Turn the disconnect switch and the key start
performing this procedure. switch to the ON position.
Note: The following test procedure may cause D. Use the multimeter probes in order to make
other diagnostic codes to be activated. Ignore these contact on the connector pins of the ECM.
created diagnostic codes and clear the diagnostic Measure the voltage at the ECM pins between
codes when the problem has been corrected. the power supply, contact J1-44, and the return
contact J1-45.
Test Step 1. CHECK THE SENSORS
Expected Result:
A. Turn the key start switch and the disconnect
switch to the ON position. The voltage measurement is 8.0 ± 0.3 VDC.
B. Observe the status of the diagnostic code, as Results:

each component is disconnected. Disconnect the
connector of the left joystick (J3), the “machine • OK – The voltage measurement is 8.0 ± 0.3 VDC.
articulation” sensor 2 and the “inching pedal The voltage is correct. The ECM power supply is
position” sensor from the machine harness. correct. Install the wires and sockets that were
removed from the J1 connector back into the
Expected Result: original locations. Proceed to Test Step 3.
The CID 0041 FMI 04 diagnostic code is no longer • NOT OK – The voltage measurement is less than
active when one of the components in the supply 8.0 ± 0.3 VDC. The ECM power supply is not
circuit is disconnected. correct. The ECM has failed.
Results: Repair: Prior to replacing an ECM, always

contact your dealership's Technical Communicator
• YES – The diagnostic code is not active when for possible consultation with Caterpillar. This
one of the components in the supply circuit is consultation may greatly reduce repair time. If
disconnected. The power supply circuit is correct. the ECM requires replacement, refer to Testing
The sensor that was disconnected, when the and Adjusting, “Electronic Control Module (ECM)
diagnostic code was cleared, has failed. - Replace”.
Repair: Repeat this test step in order to verify the STOP.

component that is causing the problem. Replace
the component that is causing the problem. Test Step 3. CHECK FOR A SHORT TO
GROUND
STOP.
The components that are powered by the 8.0 volt
• NO – The diagnostic code is still active. power supply remain disconnected from the machine
Disconnecting the components in the circuit did not harness.
affect the status of the diagnostic code. Proceed
to Test Step 2. A. Turn the key start switch and the disconnect
Test Step 2. CHECK THE POWER SUPPLY
AT THE ECM B. Disconnect the machine harness connectors J1
and J2 from the “Transmission/Chassis ECM”.
switch to the OFF position. C. At the harness connector for the ECM, measure
the resistance between the supply voltage, contact
J1-44 (wire T998-BR), and the frame ground.
Measure the resistance between supply voltage,
contact J1-44 (wire T998-BR), and all of the other
contacts that are used in the J1 and J2 connectors
for the ECM.
RENR9004-07 113
Expected Result: Repair: The initial diagnostic code was probably

Each resistance measurement is greater than 5000 short at one of the harness connectors that was
ohms. disconnected and reconnected. Resume normal
machine operation.
Results:
STOP.
than 5000 ohms. The harness circuit resistance is • NO – The CID 0041 FMI 04 diagnostic code is
correct. Proceed to Test Step 4. active. The problem has not been corrected.
• NOT OK – One or more of the resistance Repair: Check the circuit again. Use the Caterpillar
measurements is less than 5000 ohms. The circuit Electronic Technician (ET) service tool, if available,
is shorted in the machine harness. in order to perform a wiggle test on the machine
Repair: The power supply wire T998-BR is shorted momentary or intermittent shorts or opens in the
to ground in the machine harness. Refer to the machine wiring harness.
complete Electrical System Schematic for your
machine. Check all harness connectors that If the cause of the problem is not found, the ECM
are in the power supply circuit. Ensure that the may be activating the diagnostic code incorrectly.
connectors are clean and secure. The ECM may have failed.
For information on testing for short circuits and Prior to replacing an ECM, always contact your
finding short circuits, refer to Testing and Adjusting, dealership's Technical Communicator for possible
“Wiring Harness (Short Circuit) - Test”. Repair the consultation with Caterpillar. This consultation may
machine harness or replace the machine harness. greatly reduce repair time. If the ECM requires
replacement, refer to Testing and Adjusting,
STOP. “Electronic Control Module (ECM) - Replace”.
Test Step 4. CHECK THE STATUS OF THE STOP.

DIAGNOSTIC CODE
i03794642
contacts of the harness connectors. Check the
wires for damage to the insulation that is caused
MID 027 - CID 0070 - FMI 03
by excessive heat, battery acid, or chafing. SMCS Code: 7332-038-BRK
B. Perform a 45 N (10 lb) pull test on each of the Conditions Which Generate This Code:
C. Reconnect all harness connectors. Make sure that

clips for each connector are completely fastened.
D. Turn the disconnect switch and the key start

E. Operate the machine.
F. Determine if the CID 0041 FMI 04 diagnostic code

is active.
Expected Result:

active.
Results:
• YES – The CID 0041 FMI 04 diagnostic code is g02101113

not active. The problem does not exist at this time. Illustration 104
“Parking Brake Operator” Switch connections
114 RENR9004-07
The “parking brake operator” switch is a two-pole, B. Disconnect the machine harness connector from
double-throw switch. One pole is used to provide the switch.
two switch-to-ground inputs to the ECM in order to
indicate the status of the switch. The other pole of the C. With the switch in the ON position, measure the
switch is not used for operation of the ECM. resistance from the common contact of the switch
2 to the input contact of the switch 1. Compare the
During normal operation, one of the inputs is not measurement to the table above.
connected to ground and the other input is connected
to ground through the contacts of the switch. An D. With the switch in the ON position, measure the
internal pull up voltage is present at the ECM switch resistance from the common contact of the switch
inputs. When the input is grounded through the 2 to the input contact of the switch 3. Compare the
switch, the ECM detects the ground signal. measurement to the table above.
The FMI 03 diagnostic code is activated by the ECM E. Move the switch to the OFF position and repeat
when neither of the inputs is showing a ground signal. Steps “C” and “D”.
The conditions that could cause the ECM to activate Expected Result:
this diagnostic code are listed below:
The resistance measurements for each position of
• The switch has failed. the switch are correct according to the table at the
beginning of this test step.
• The common ground circuit is an open connection
or the circuit has a bad connection. Results:
• There is an open or a bad connection in one or • YES – All of the resistance checks for the switch
both of the switch input circuits. are correct in each switch position according to
the table above. The switch is working correctly.
• The ECM has failed. This is unlikely. Proceed to Test Step 2.
Note: Before performing this procedure, inspect • NO – The states of the switch are not correct
the harness connectors that are involved in the according to the table above. The switch has failed.
of a problem in an electrical circuit. Verify that Repair: Replace the operator switch for the parking
all connections in the circuit are clean, that all brake. After the switch is replaced, verify that the
connections are secure and that all connections switch operation is correct before operating the
are in good condition. If a problem with a machine.
verify that this diagnostic code is active before STOP.
Test Step 2. CHECK COMMON GROUND
Note: The following test procedure may cause OF THE SWITCH FOR AN OPEN
created diagnostic codes and clear the diagnostic The key start switch and the disconnect switch
codes when the problem has been corrected. remain in the OFF position. The machine harness
remains disconnected from the switch.
Test Step 1. CHECK THE SWITCH
A. At the machine harness connector for the switch,
Table 18 measure the resistance from the common ground
Contact states of the “Parking Brake Operator Switch” of the switch, contact 2 (wire A202-BK), and frame
ground.
Switch Position OFF Input J2-38 ON) Input J2-39
(wire U734-GN) (wire U735-GY B. Use a multimeter in order to observe the resistance
Parking Brake Open(2) Closed(1) measurement and wiggle the connector of the
ON machine harness for the switch. Gently pull on the
wires and move the wires in a circular motion.
Parking Brake Closed Open
OFF
Expected Result:
(2) Open to ground circuit A202-BK.
(1) Closed to ground circuit A202-BK. The resistance measurement is less than 5 ohms at
all times during the manipulation of the harness.
RENR9004-07 115
Results: Results:
• OK – The resistance measurement is less than 5 • OK – The resistance measurement is less than 5
ohms. The common ground circuit of the switch is ohms. The input circuits of the switch are not open
correct. Proceed to Test Step 3. in the machine harness. Proceed to Test Step 4.
• NOT OK – The resistance measurement is greater • NOT OK – The resistance measurement is greater
than 5 ohms. There is an open or a bad connection than 5 ohms. There is a problem with one or both
in the common ground circuit of the switch (wire of the switch input circuits in the machine harness.
A202-BK).
Repair: Refer to the connection diagram at the
Repair: A resistance measurement that is greater beginning of this procedure.
than 5000 ohms could indicate that a wire is either
not connected or that a wire is open. A resistance Connect one end of the jumper wire to the common
measurement that is greater than 5 ohms but less ground of the harness connector of the switch
than 5000 ohms could indicate that one of the contact 2 (wire A202-BK).
connection points or splices in the ground circuit is
not an open connection but not a good connection. One at a time, connect the other end of the jumper
wire to each switch input. Check the resistance
Refer to the complete Electrical System Schematic at the harness connector of the ECM J1 from the
of the machine. Check all of the connectors that appropriate input contact to one of the ground
are in the ground circuit. Start the check of the contacts (wire A202-BK) that are used on the J1
connectors at the switch. Work back to the ground connector. This will identify the input circuit that is
terminal that is located at the rear of the cab. open or has the bad connection.
Ensure that all connections are clean, that all
connectors are secure and that all connectors are A resistance measurement that is greater than
in good condition. Repair the machine harness or 5000 ohms could indicate that a wire is either not
replace the machine harness. connected or a wire that is open. A resistance
measurement that is greater 5 ohms but less
STOP. than 5000 ohms could indicate that one of the
connection points in the circuit is not open but is
Test Step 3. CHECK THE INPUT not a good connection.
CIRCUITS OF THE SWITCH FOR AN
OPEN CONNECTION Refer to the complete Electrical System Schematic
of the machine. Check all of the connectors
The key start switch and the disconnect switch that are in the faulty input circuit. Ensure that
remain in the OFF position. The machine harness all connections are clean, that all connectors
remains disconnected from the switch. are secure and that all connectors are in good
condition. Repair the machine harness or replace
A. At the machine harness connector for the switch, the machine harness.
place a jumper wire between input contact 1 (wire
U734-GN) and input contact 3 (wire U735-GY). STOP.
B. Disconnect the machine harness connectors J1 Test Step 4. CHECK THE STATUS OF THE
and J2 from the ECM. DIAGNOSTIC CODE
C. At the machine harness connector of the ECM, J2, A. Inspect the harness connectors. Clean the
measure the resistance from switch input contact contacts of the harness connectors. Check the
J2-38 (wire U734-GN) to the input of the switch, wires for damage to the insulation that is caused
contact J2-39 (wire U735-GY). by excessive heat, battery acid, or chafing.
D. Observe the resistance measurement of the B. Perform a 45 N (10 lb) pull test on each of the
multimeter and wiggle the connector of the wires that are associated with the sensor circuit.
machine harness for the switch. Gently pull on the
wires and move the wires in a circular motion. Do C. Reconnect all harness connectors. Make sure that
not disconnect the jumper wire. the connectors are fully seated. Observe that the
Expected Result:
The resistance measurement is less than 5 ohms at switch to the ON position.
116 RENR9004-07
F. Check the status of the CID 0070 FMI 03 i03795149

diagnostic code.
MID 027 - CID 0070 - FMI 04
Expected Result:
SMCS Code: 7332-038-BRK
active. Conditions Which Generate This Code:
Results:
• YES – The CID 0070 FMI 03 is not active. The

diagnostic code does not exist at this time.

machine operation.
STOP.
• NO – The CID 0070 FMI 03 diagnostic code

is active. The diagnostic code has not been
corrected.
Repair: Check the input circuits of the switch

again. Use the Caterpillar Electronic Technician
(ET) service tool, if available, in order to perform
g02101113
a wiggle test on the machine wiring harness. The Illustration 105
wiggle test can detect momentary or intermittent Connections for the “Parking Brake Operator” Switch
shorts or opens in the machine wiring harness.
The “parking brake operator” switch is a two-pole,
If the cause can not be found, the ECM may double-throw switch. One pole is used to provide
have failed. Verify that all possible causes of the two switch to ground inputs to the ECM in order to
diagnostic code have been investigated before indicate the status of the switch. The other pole of the
replacement of the ECM. switch is not used for the operation of the ECM.
Prior to replacing an ECM, always contact your During normal operation, one of the inputs is not
dealership's Technical Communicator for possible connected to ground and the other input is connected
consultation with Caterpillar. This consultation to ground through the switch contacts. An internal
may greatly reduce repair time. If the cause of the pull-up voltage is present at the ECM switch inputs.
diagnostic code is not found, replace the ECM. When the input is grounded through the switch, the
Refer to Testing and Adjusting, “Electronic Control ECM detects the ground signal.
Module (ECM) - Replace”.
The FMI 04 diagnostic code is activated by the ECM
STOP. when both of the inputs are showing a ground signal
at the same time.
The conditions that could cause the ECM to activate

• The switch has failed.

• There is a short to a ground source in one or both
of the switch input circuits.

RENR9004-07 117
Note: Before performing this procedure, inspect • NO – The states of the switch are not correct
the harness connectors that are involved in the according to the table of the switch contact. The
circuit. Poor connections can often be the cause switch has failed.
of a problem in an electrical circuit. Verify that
all connections in the circuit are clean, that all Repair: Replace the operator switch for the parking
connections are secure and that all connections brake. After the switch is replaced verify that the
are in good condition. If a problem with a operation of the switch is correct before operating
connection is found, correct the problem and the machine.
performing this procedure. STOP.
Note: The following test procedure may cause Test Step 2. CHECK THE SWITCH INPUT
other diagnostic codes to be activated. Ignore these CIRCUITS FOR A SHORT
codes when the problem has been corrected. The key start switch and the disconnect switch
remain in the OFF position. The machine harness
Test Step 1. CHECK THE SWITCH remains disconnected from the switch.
Table 19 A. Disconnect the machine harness connectors J1
Contact States for the “Parking Brake Operator” Switch and J2 from the ECM.
Switch Position OFF Input J2-38 ON Input J2-39 B. At the machine harness connector J2 for the
(wire U734-GN) (wire U735-GY) ECM, measure the resistance between the switch
Parking Brake Open(2) Closed(1) input, contact J2-38 (wire U734-GN), and the
ON frame ground. Measure the resistance between
the switch input, contact J2-38 (wire U734-GN),
Parking Brake Closed Open
OFF
and all of the other contacts that are used in the
J1 and J2 harness connectors for the ECM.
(2) Open to ground circuit A202-BK.
(1) Closed to ground circuit A202-BK. C. At the machine harness connector J2 for the ECM,
measure the resistance between the switch input,
A. Turn the key start switch and the disconnect contact J2-39 (wire U735-GY), and the frame
switch to the OFF position. ground. Measure the resistance between the
switch input, contact J2-39 (wire U735-GY), and
B. Disconnect the machine harness connector from all of the other contacts that are used in the J1
the switch. and J2 harness connectors for the ECM.
C. With the switch in the ON position, measure the Expected Result:
resistance from common contact of the switch,
2, to the switch input contact 1. Compare the Each resistance measurement is greater than 5000
measurement to the table for the switch contacts. ohms.
D. With the switch in the ON position, measure the Results:
resistance from the common contact of the switch
2, to the contact of the switch input 3. Compare the • OK – Each resistance measurement is greater
measurement to the table for the switch contacts. than 5000 ohms. The input circuits of the switch
are not shorted to ground or to another circuit in
E. Move the switch to the OFF position and repeat the machine harness. Proceed to Test Step 3.
Steps “C” and “D”.
Expected Result: measurements is less than 5000 ohms. There is a
short to ground or to another circuit in the machine
The resistance measurements for each of the switch harness.
positions agree with the table for the contact of the
switch found at the beginning of this test step. Repair: The input circuit that checks the low
resistance to frame ground or to another circuit is
Results: the cause of the problem.
• YES – All of the resistance checks for the switch

are correct in each of the switch positions,
according to the contact status table. The switch is
working correctly. Proceed to Test Step 2.
118 RENR9004-07
Refer to the complete Electrical System Schematic Repair: Check the input circuits of the switch
of the machine. Check all of the connectors again. Use the Caterpillar Electronic Technician
that are in the faulty input circuit. Ensure that (ET) service tool, if available, in order to perform
all connections are clean, that all connectors a wiggle test on the machine wiring harness. The
are secure and that all connectors are in good wiggle test can detect momentary or intermittent
condition. shorts or opens in the machine wiring harness.
For information on testing for short circuits and If the cause can not be found, the ECM may
finding short circuits, refer to Testing and Adjusting, have failed. Verify that all possible causes of the
“Wiring Harness (Short Circuit) - Test”. Repair the diagnostic code have been investigated before
machine harness or replace the machine harness. replacement of the ECM.
STOP. Prior to replacing an ECM, always contact your

dealership's Technical Communicator for possible
Test Step 3. CHECK THE STATUS OF THE consultation with Caterpillar. This consultation
DIAGNOSTIC CODE may greatly reduce repair time. If the cause of the
diagnostic code is not found, replace the ECM.
A. Inspect the harness connectors. Clean the Refer to Testing and Adjusting, “Electronic Control
contacts of the harness connectors. Check the Module (ECM) - Replace”.
by excessive heat, battery acid, or chafing. STOP.
B. Perform a 45 N (10 lb) pull test on each of the

i03795170

MID 027 - CID 0096 - FMI 03
the connectors are fully seated and that the clips SMCS Code: 1439-038
for each connector are completely fastened.
F. Check the status of the CID 0070 FMI 04

diagnostic code.
Expected Result:

active.
Results:
• YES – The CID 0070 FMI 04 is not active. The Illustration 106
g02101793
diagnostic code does not exist at this time. Connections of the “Fuel Level Sender”
Repair: The initial diagnostic code was probably This diagnostic code is associated with the “Fuel
caused by a poor electrical connection or a Level Sender”. The FMI 03 diagnostic code means
short at one of the harness connectors that was that the “Transmission/Chassis ECM” has detected
disconnected and reconnected. Resume normal that the voltage of the for the circuit of the “Fuel Level
machine operation. Sender” is above 4.5 VDC.
STOP. In addition to monitoring the voltage of the sender
signal, the ECM monitors the resistance of the sender
• NO – The CID 0070 FMI 04 diagnostic code signal. The ECM associates the resistance value of
is active. The diagnostic code has not been the sender circuit with a specific amount of fuel in
corrected. the fuel tank. The ECM sends this information to the
Messenger over the data link.
RENR9004-07 119
When the fuel tank is nearly empty, the resistance B. At the machine harness connector for the sender,
in the circuit of the sender is approximately 248 ± 8 measure the resistance between contact 2 (wire
ohms. When the fuel tank is nearly full, the resistance A202-BK) and frame ground.
in the circuit of the sender is approximately 27 ± 2
ohms. Expected Result:
Conditions that can cause this diagnostic code to be The resistance measurement is less than 5 ohms.
activated are listed below:
Results:
• The sender has failed.
• OK – The resistance measurement is less than
• The ground circuit for the sender is open in the 5.0 ohms. The ground circuit is correct. Proceed
machine harness. to Test Step 3.
• The signal circuit in the machine harness is open • NOT OK – The resistance measurement is greater
or the sender is disconnected. than 5.0 ohms. There is an open circuit or a bad
connection in the ground circuit for the sender.
Repair: A resistance measurement that is greater
Test Step 1. CHECK THE RESISTANCE than 5000 ohms could indicate that a wire is either
OF THE SENDER not connected or that a wire is open. A resistance
measurement that is greater than 5 ohms but less
A. Turn the disconnect switch and the key start than 5000 ohms could indicate that one of the
switch to the OFF position. connection points or a splice in the circuit is not an
open connection but not a good connection.
the “Fuel Level Sender”. Refer to the complete Electrical System Schematic
of the machine. Ensure that all connections and
C. At the connector for the sender, measure the splices in the ground circuit for the sender are
resistance between the contact 1 and the contact clean, that all connections are secure and that all
2. connections are in good condition.
Expected Result: Start at the component connector for the faulty

circuit. When checking the wire for an open point
The resistance measurement should be around or a bad connection point, work your way through
247 ohms when the tank is empty. The resistance the circuit in order to isolate the location of the
measurement should be around 27 ohms when the problem. Repair the machine harness or replace
tank is full. the machine harness.
Results: STOP.
• OK – The resistance measurement is in the correct Test Step 3. CHECK THE SIGNAL
range. The sender is OK. Proceed to Test Step 3. CIRCUIT OF THE HARNESS
• NOT OK – The resistance measurement is not in The sender remains disconnected from the machine
the correct range. The fuel level sender has failed. harness. The disconnect switch and the key start
switch remain in the OFF position.
Repair: Replace the fuel level sender. Ensure that
the new sender corrects the problem. A. The ECM machine harness connector J1 is
disconnected from the ECM. Disconnect the J2
STOP. machine harness connector from the ECM.
Test Step 2. CHECK THE GROUND B. At the machine harness connector J1, measure
CIRCUIT OF THE HARNESS the resistance between the signal circuit at contact
J1-29 (wire U723-PU) and all of the other contacts
The sender remains disconnected from the machine that are used for the J1 and J2 contacts for the
harness. The disconnect switch and the key start ECM.
Expected Result:
A. Disconnect the J1 machine harness connector
from the ECM. Each resistance measurement is greater than 5000
ohms.
120 RENR9004-07
Results: • NOT OK – The CID 0096 FMI 03 diagnostic

code is active. The diagnostic code has not been
• OK – Each resistance measurement is greater corrected. The ECM may have failed.
than 5000 ohms. The circuit is not shorted in the
machine harness. Proceed to Test Step 4. Repair: Check the circuit for the sender again. Use
the Caterpillar Electronic Technician (ET) service
• NOT OK – One or more of the resistance tool, if available, in order to perform a wiggle test
measurements is less than 5000 ohms. The signal on the machine wiring harness. The wiggle test can
circuit for the sender is shorted to another circuit detect momentary or intermittent shorts or opens
in the machine harness. in the machine wiring harness.
Repair: The short is between signal wire If the cause can not be found, the ECM may have
U723-PU and the circuit with the low resistance failed.
measurement.
Refer to the complete Electrical System Schematic dealership's Technical Communicator for possible
of the machine. Ensure that all connections in consultation with Caterpillar. This consultation
the signal circuit for the sender are clean, that all may greatly reduce repair time. If the cause of the
connections are secure and that all connections diagnostic code is not found, replace the Machine
are in good condition. ECM. Refer to Testing and Adjusting, “Electronic
Control Module (ECM) - Replace”.
finding short circuits, refer to Testing and Adjusting, STOP.
“Wiring Harness (Short Circuit) - Test”. Repair the
i03795294
STOP. MID 027 - CID 0096 - FMI 04

Test Step 4. CHECK THE STATUS OF THE SMCS Code: 1439-038
DIAGNOSTIC CODE



E. Operate the machine. g02101793

Illustration 107
Connections of the “Fuel Level Sender”
diagnostic code. This diagnostic code is associated with the “Fuel
Level Sender”. The FMI 04 diagnostic code means
Expected Result: that the “Transmission/Chassis ECM” has detected
that the voltage of the fuel level sender circuit is
The CID 0096 FMI 03 diagnostic code is not active. below 0.1 VDC.
Results: In addition to monitoring the voltage of the sender
signal, the ECM monitors the resistance of the sender
• OK – The CID 0096 FMI 03 diagnostic code is signal. The ECM associates the resistance value of
not active. The diagnostic code does not exist at the sender with the amount of fuel in the fuel tank.
this time. The initial diagnostic code was probably The ECM sends this information to the Messenger
caused by a poor connection or a short at one over the data link.
of the connectors that was disconnected and
reconnected. Resume normal operation. STOP.
RENR9004-07 121
When the fuel tank is nearly empty, the resistance B. At the machine harness connector J1, measure
in the circuit of the sender is around 248 ± 8 ohms. the resistance from the signal circuit, contact J1-29
When the fuel tank is nearly full, the resistance in the (wire U723-PU), and frame ground. Measure the
circuit of the sender is around 27 ± 2 ohms. resistance from the signal circuit, contact J1-29
(wire U723-PU), and all of the other contacts that
Conditions that can cause this diagnostic code to be are used in the J1 and J2 connectors for the ECM.
Expected Result:
• The sender has failed.
• The signal circuit in the machine harness is shorted ohms.
to a ground source.
Results:
Test Step 1. CHECK THE RESISTANCE than 5000 ohms. The circuit is not shorted in the
OF THE SENDER machine harness. Proceed to Test Step 3.
A. Turn the disconnect switch and the key start • NOT OK – One or more of the resistance
switch to the OFF position. measurements is less than 5000 ohms. The signal
circuit for the sender is shorted to another circuit or
B. Disconnect the machine harness connector from to frame ground in the machine harness.
the “Fuel Level Sender”.
Repair: The short is between signal wire
C. At the connector for the sender, measure the U723-PU and the circuit with the low resistance
resistance between the contact 1 and the contact measurement.
2.
Refer to the complete Electrical System Schematic
Expected Result: of the machine. Ensure that all connections in
the signal circuit for the sender are clean, that all
The resistance measurement should be connections are secure and that all connections
approximately 247 ohms when the tank is empty. The are in good condition.
resistance measurement should be approximately 27
ohms when the tank is full. For information on testing for short circuits and
finding short circuits, refer to Testing and Adjusting,
Results: “Wiring Harness (Short Circuit) - Test”. Repair the
• OK – The resistance measurement is in the correct
range. The sender is OK. Proceed to Test Step 2. STOP.
• NOT OK – The resistance measurement is not in Test Step 3. CHECK THE STATUS OF THE
the correct range. The “Fuel Level Sender” has DIAGNOSTIC CODE
failed.
Repair: Replace the “Fuel Level Sender”. Ensure contacts of the harness connectors. Check the
that the new sender corrects the problem. wires for damage to the insulation that is caused
STOP.
Test Step 2. CHECK THE SIGNAL wires that are associated with the sensor circuit.
CIRCUIT OF THE HARNESS
The sender remains disconnected from the machine the connectors are fully seated. Observe that the
harness. The disconnect switch and the key start clips for each connector are completely fastened.
A. Disconnect the J1 and J2 machine harness switch to the ON position.
connectors from the ECM.

diagnostic code.
122 RENR9004-07
Expected Result: This diagnostic code is associated with the

transmission pump pressure sensor. The FMI 03
The CID 0096 FMI 04 diagnostic code is not active. means that the transmission/chassis electronic
control module (ECM) has determined that the
Results: voltage of the circuit for the sensor is above normal.
• OK – The CID 0096 FMI 04 diagnostic code is The output of the sensor is an analog signal from
not active. The diagnostic code does not exist at 0.2 DCV to 4.95 DCV. The voltage changes as the
this time. The initial diagnostic code was probably pressure changes. The ECM recognizes a voltage in
caused by a poor connection or a short at one the range of 0.2 DCV to 4.95 DCV as valid input from
of the connectors that was disconnected and the sensor. If the voltage is below 0.2 DCV for more
reconnected. Resume normal operation. STOP. than 2 seconds, the ECM determines that the sensor
is shorted to ground. If the voltage is above 4.95 DCV
• NOT OK – The CID 0096 FMI 04 diagnostic for more than 2 seconds, the ECM determines that
code is active. The diagnostic code has not been the sensor is shorted to the + battery.
corrected. The ECM may have failed.
The possible causes of this diagnostic code are listed
Repair: Check the circuit of the sender again. Use below:
tool, if available, in order to perform a wiggle test • The signal circuit for the sensor is open.
on the machine wiring harness. The wiggle test can
detect momentary or intermittent shorts or opens • The signal circuit for the sensor is shorted to the
in the machine wiring harness. +battery circuit.
If the cause can not be found, the ECM may have • The sensor has failed.
failed.
• The power circuit or the ground circuit has failed.
dealership's Technical Communicator for possible • The ECM has failed. ECM failure is unlikely.
consultation with Caterpillar. This consultation
may greatly reduce repair time. If the cause of the Note: The following test procedure may create other
diagnostic code is not found, replace the Machine diagnostic codes. Ignore these created diagnostic
ECM. Refer to Testing and Adjusting, “Electronic codes and clear the diagnostic codes when the
Control Module (ECM) - Replace”. original diagnostic code has been corrected. Ensure
that the diagnostic code of CID 0127 FMI 03 is
STOP. active before performing this procedure.
Note: Use a calibrated 146-4080 Digital Multimeter

i03966149
for the measurements in this procedure.
MID 027 - CID 0127 - FMI 03 Test Step 1. CHECK FOR POWER AT THE
SMCS Code: 1439-038-T3; 3080-038-PXS SENSOR.
Conditions Which Generate This Code: A. Do not disconnect the harness connector from the
sensor.
B. Turn the keyswitch to the ON position.
C. Turn the disconnect switch to the ON position.
D. At the back of the harness connector for the

sensor, insert a 7X-1710 Multimeter Probe along
the voltage supply wire (contact A).
E. Measure the voltage from contact A to frame

ground.
Expected Result:
g02161515 The voltage is +24 DCV.
Illustration 108
Transmission pump pressure sensor circuit
RENR9004-07 123
Results: Expected Result:
• OK – The voltage is +24 DCV. Proceed to Test The resistance is less than 5 ohms.
Step 2.
Results:
• NOT OK – The voltage is not +24 DCV. The +
battery circuit in the harness has failed. • OK – The resistance is less than 5 ohms. The
circuit is correct. Proceed to Test Step 4.
Repair: Replace or repair the harness.
• NOT OK – The resistance is greater than 5 ohms.
STOP. The circuit is not correct. There is an open circuit in
the wiring harness.
Test Step 2. CHECK FOR PROPER
GROUND AT THE SENSOR. Repair: There is an open circuit in the wiring
harness. Repair or replace the wiring harness.
Note: The harness remains connected to the sensor.
STOP.
A. Turn the keyswitch and the disconnect switch to
the OFF position. Test Step 4. CHECK THE WIRING
HARNESS OF THE SENSOR FOR A
B. Remove the 7X-1710 Multimeter Probe from the SHORT TO THE +BATTERY CIRCUIT.
voltage supply wire (contact A).
Note: The keyswitch and the disconnect switch
C. At the back of the harness connector for the remain in the OFF position. The harness remains
sensor, insert a 7X-1710 Multimeter Probe along disconnected from the sensor. The harness
the ground wire (contact B). connectors remain disconnected from the ECM.
D. Measure the resistance from contact B to frame A. Remove the jumper wire that was installed in the
ground. previous step.
Expected Result: B. At the harness connector for the ECM, measure

the resistance from the signal contact J2-26 (wire
The resistance is less than 5 ohms. C458-BR) of the harness to all contacts that are
used in the harness connectors for the ECM.
Results:
Expected Result:
• OK – The resistance is less than 5 ohms. The
ground circuit is correct. Proceed to Test Step 3. Each resistance is greater than 5000 ohms.
• NOT OK – The resistance is greater than 5 ohms. Results:

The ground circuit in the harness has failed.
• OK – Each resistance is greater than 5000 ohms.
Repair: Replace or repair the harness. The harness is correct. Proceed to Test Step 5.
STOP. • NOT OK – A resistance is not correct. There is

a short in the harness.
Test Step 3. CHECK THE WIRING
HARNESS OF THE SENSOR FOR AN Repair: The short is between the contact for (wire
OPEN CIRCUIT. C458-BR) and the circuit with the low resistance.
Repair or replace the harness.
Note: The keyswitch and the disconnect switch
remain in the OFF position. STOP.
A. Disconnect the harness from the sensor. Test Step 5. CHECK THE OUTPUT OF
THE SENSOR.
B. At the harness connector for the sensor, connect
a jumper wire between contact B and contact C. A. Reconnect the harness connectors to the ECM.
C. Disconnect the harness connectors from the ECM. B. Reconnect the harness connector to the sensor.
D. At the harness connector for the ECM, measure C. At the back of the harness connector for the
the resistance between the contact for (wire sensor, insert a 7X-1710 Multimeter Probe along
200-BK) and the contact for (wire C458-BR). the signal wire (contact C).
124 RENR9004-07
D. At the back of the harness connector for the Repair: Verify that all possible causes of the
sensor, insert a 7X-1710 Multimeter Probe along diagnostic code have been investigated. If
the ground wire (contact B). the cause of the failure is not found, contact
technical communicator at your dealer for possible
E. Turn the disconnect switch to the ON position. consultation with Caterpillar. This consultation
may greatly reduce repair time. If the cause of
F. Turn the keyswitch to the ON position. the diagnostic code is not found, replace the
transmission/chassis ECM. If the ECM must
G. Measure the signal of the sensor. The proper be replaced, refer to the Testing and Adjusting,
signal is described at the beginning of this “Electronic Control Module (ECM) - Replace”
procedure. section of this manual.
Expected Result: STOP.
The signal from the sensor is valid. • NO – The CID 0127 FMI 03 is not active. The
Results:
Repair: The diagnostic code was probably
• OK – The signal from the sensor is valid. Proceed caused by a poor connection or a short at one
to Test Step 6. of the connectors that was disconnected and
reconnected. Resume normal machine operation.
• NOT OK – The signal from the sensor is not valid.
STOP.
Repair: The sensor has failed. Replace the sensor.
i03966191
STOP.
Test Step 6. CHECK IF THE DIAGNOSTIC

MID 027 - CID 0127 - FMI 04
CODE REMAINS. SMCS Code: 1439-038-T3; 3080-038-PXS
A. Inspect and clean the contacts of the harness Conditions Which Generate This Code:
connectors.
B. Reconnect all harness connectors.
D. Turn the keyswitch to the ON position.
F. Check the status of the CID 0127 FMI 03.
Expected Result:
The CID 0127 FMI 03 is active.

g01943324
Illustration 109
Results: Transmission pump pressure sensor circuit
• YES – The CID 0127 FMI 03 is active. The This diagnostic code is associated with the
diagnostic code has not been corrected. The ECM transmission pump pressure sensor. The FMI 04
may have failed, however, ECM failure is unlikely. means that the ECM has determined that the voltage
of the circuit for the position sensor is below normal.

below:
• The signal circuit for the sensor is shorted to

ground.

• The ECM has failed. ECM failure is unlikely.
RENR9004-07 125
Note: The following test procedure may create other • NOT OK – A resistance is not correct. There is
diagnostic codes. Ignore these created diagnostic a short in the harness.
codes and clear the diagnostic codes when the
original diagnostic code has been corrected. Ensure Repair: The short is between signal contact
that the diagnostic code of CID 0127 FMI 04 is J2-26 (wire C458-BR) and the circuit with the low
active before performing this procedure. resistance. Repair or replace the harness.
Note: Use a calibrated 146-4080 Digital Multimeter STOP.

for the measurements in this procedure.
Test Step 1. CHECK THE SENSOR. CODE REMAINS.
A. Turn the disconnect switch to the ON position. A. Inspect and clean the contacts of the harness
connectors.
B. Turn the keyswitch to the ON position.
C. Ensure that the diagnostic code is active.
D. Observe the status of the diagnostic code.
Disconnect the sensor from the harness. D. Turn the keyswitch to the ON position.
Expected Result: E. Operate the machine.
The CID 0127 FMI 04 remains active. FMI 04 is still F. Check the status of the CID 0127 FMI 04.
active.
Expected Result:
Results:
• OK – The diagnostic code remains active. The
sensor is correct. Proceed to Test Step 2. Results:
• NOT OK – The diagnostic code is no longer active. • YES – The CID 0127 FMI 04 is active. The
The sensor has failed. diagnostic code has not been corrected. The ECM
may have failed, however, ECM failure is unlikely.
Repair: Replace the sensor.
Repair: Verify that all possible causes of the
STOP. diagnostic code have been investigated. If
the cause of the failure is not found, contact
Test Step 2. CHECK THE WIRING technical communicator at your dealer for possible
HARNESS OF THE SENSOR FOR A consultation with Caterpillar. This consultation
SHORT TO GROUND. may greatly reduce repair time. If the ECM must
be replaced, refer to the Testing and Adjusting,
A. Turn the keyswitch and the disconnect switch to “Electronic Control Module (ECM) - Replace”
the OFF position. section of this manual.
B. Disconnect the harness from the sensor. STOP.
C. Disconnect the harness connectors from the ECM. • NO – The CID 0127 FMI 04 is not active. The
D. At the harness connector for the ECM, measure
the resistance from the signal contact J2-26 (wire Repair: The diagnostic code was probably
C458-BR) of the harness to all possible sources caused by a poor connection or a short at one
of ground. Measure the resistance to all contacts of the connectors that was disconnected and
of the harness connectors for the ECM. reconnected. Resume normal machine operation.
Expected Result: STOP.
Each resistance is greater than 5000 ohms.
Results:
• OK – Each resistance is greater than 5000 ohms.

The harness is correct. Proceed to Test Step 3.
126 RENR9004-07
i02839788 Test Step 1. CHECK THE RELAY

MID 027 - CID 0144 - FMI 03 A. Turn the key start switch and the disconnect
SMCS Code: 4493-038-UB
B. While observing the status of the active CID 0144
Conditions Which Generate This Code: FMI 03 diagnostic code, disconnect the backup
alarm relay from the machine harness.
C. At the relay, measure the resistance of the coil

between contact 85 and contact 86. Measure the
resistance between power contact 30 and all of
the other relay contacts.
Expected Result:
When the relay is disconnected from the harness,

the status of the active CID 0144 FMI 03 diagnostic
code does not change.
The resistance of the relay coil is in the range of 288

to 396 ohms at 25 °C (77 °F).
The resistance measurement between power

contact 30 and contact 87a is less than 5 ohms. The
resistance measurement between power contact 30
and all the other relay contacts is greater then 5000
ohms.
g01287438
Illustration 110
Back Up Alarm Relay connections Results:
This diagnostic code is associated with the back up • YES – All of the checks for the relay are correct.
alarm relay. The back up alarm relay is controlled The relay is not causing the problem. The CID
by the ECM through an ON/OFF output driver. The 0144 FMI 03 diagnostic code is still active. Proceed
FMI 03 means that the ECM has determined that the to Test Step 2.
voltage is present in the relay circuit when the output
driver is OFF. • NO – The active CID 0144 FMI 03 diagnostic code
became inactive when the relay was disconnected.
The conditions that could cause this diagnostic code The resistance checks are not correct according to
to activate are listed: the expected results listed above. The relay has
failed.
• The relay has failed.
Repair: Verify that the relay has failed by
• The energize circuit of the relay is shorted to substituting a known good relay that is the same
another voltage source. part number for the defective relay. The cab
flood lights relay can be substituted. Replace the
• The ECM has failed. This is unlikely. defective relay.
Note: Before performing this procedure, inspect STOP.

the harness connectors that are involved in the
circuit. Poor connections can often be the cause Test Step 2. CHECK THE ENERGIZE
of a problem in an electrical circuit. Verify that all CIRCUIT OF THE RELAY FOR A SHORT
connections in the circuit are clean, secure and
in good condition. If a problem with a connection The relay remains disconnected from the machine
is found, correct the problem and verify that this harness.
diagnostic code is active before performing this
procedure. A. Turn the key start switch and the disconnect
other diagnostic codes to be activated. Ignore these B. Disconnect the machine harness connectors J1
created diagnostic codes and clear the diagnostic and J2 from the Transmission/Chassis ECM.
RENR9004-07 127
C. At the machine harness connector J2 for the ECM, Results:

measure the resistance from contact J2-5 (wire
F916-GN) to all of the other contacts that are used • YES – The CID 0144 FMI 03 diagnostic code is
in the machine harness connectors J1 and J2 for active. The problem has not been corrected.
the ECM.
Repair: Check the relay circuit again. Use the
Expected Result: Caterpillar Electronic Technician (ET) service tool,
if available, in order to perform a "Wiggle Test" on
Each resistance measurement is greater than 5000 the machine wiring harness. The wiggle test can
ohms. detect momentary or intermittent shorts or opens
in the machine wiring harness.
Results:
• OK – Each resistance measurement is greater may have failed.
than 5000 ohms. The energize circuit is not shorted
to another circuit in the machine harness. Proceed Prior to replacing an ECM, always contact your
to Test Step 3. dealership's Technical Communicator for possible
• NOT OK – Each resistance measurement is not may greatly reduce repair time. If the ECM must
greater than 5000 ohms. There is a short in the be replaced, refer to Troubleshooting, “Electronic
machine harness. The short is between J2-5 (wire Control Module (ECM) - Replace”.
F916-GN) and the circuit that has a low resistance
measurement. STOP.
Repair: Refer to the complete machine Electrical • NO – The CID 0144 FMI 03 diagnostic code is not
System Schematic. Check all of the connectors that active. The problem does not exist at this time.
are in the relay circuit. Ensure that all connections
are clean, secure and in good condition. Repair: The initial diagnostic code was probably
caused by a poor electrical connection or a short at
For information on testing for short circuits and one of the harness connectors or at the relay base
finding short circuits, refer to Testing and Adjusting, that was disconnected and reconnected. Resume
“Wiring Harness (Short Circuit) - Test”. Repair the normal machine operation.
machine harness or replace machine harness.
STOP.
STOP.
Test Step 3. CHECK THE STATUS OF THE

DIAGNOSTIC CODE
A. Inspect the harness connectors and clean the
contacts of the harness connectors and check the

wires that are associated with the circuit.
C. Reconnect all harness connectors making sure

that the connectors are fully seated and the clips


is active.
Expected Result:
The CID 0144 FMI 03 diagnostic code is active.

128 RENR9004-07

Conditions Which Generate This Code: the relay.
C. At the harness connector for the relay, connect a

jumper wire between contact 5 (wire F916-GN)
and contact 2 (wire J765-BU).

E. Observe the status of the active CID 0144 FMI

05 diagnostic code.
Expected Result:
The active CID 0144 FMI 05 diagnostic code is no

longer active when the key start switch is turned ON.
A CID 0144 FMI 06 diagnostic code is now active.
Results:

no longer active, a CID 0144 FMI 06 diagnostic
g01287438
Illustration 111 code becomes active when the key start switch is
Back Up Alarm Relay connections turned ON.
This diagnostic code is associated with the back up Repair: The relay is causing the problem. Verify
alarm relay. The back up alarm relay is controlled by that the relay has failed by substituting a known
the ECM through an ON/OFF output driver. The FMI good relay that is the same part number as the
05 means that the ECM has energized the output defective relay. The cab flood lights relay can be
for the relay and the current for the relay circuit is substituted. Replace the defective relay.
below normal.
STOP.
The conditions that could cause this diagnostic code
to activate are listed: • NO – The jumper wire does not affect the status
of the active CID 0144 FMI 05 diagnostic code
• The relay has failed. when the key switch is turned ON. The relay is not
causing the problem. Proceed to Test Step 2.
• The energize circuit of the relay is open or has a
bad connection in the machine harness. Test Step 2. CHECK THE RELAY CIRCUIT
FOR AN OPEN
The relay remains disconnected from machine
Note: Before performing this procedure, inspect harness. The jumper wire remains connected
the harness connectors that are involved in the between contact 5 and contact 2.
of a problem in an electrical circuit. Verify that all A. Turn the key start switch and the disconnect
connections in the circuit are clean, secure and switch to the OFF position.
in good condition. If a problem with a connection
is found, correct the problem and verify that this B. Disconnect the machine harness connectors J1
diagnostic code is active before performing this and J2 from the Transmission Chassis ECM.
procedure.
C. At the machine harness connector J2 for the ECM,
Note: The following test procedure may cause measure the resistance between contact J2-5
other diagnostic codes to be activated. Ignore these (wire F916-GN) and contact J2-4 (wire J765-GN).
RENR9004-07 129
D. At the machine harness connector J2 for the ECM, Test Step 3. CHECK THE STATUS OF THE
measure the resistance between contact J2-5 DIAGNOSTIC CODE
(wire F916-GN) and contact J2-8 (wire J765-GN).
Expected Result: contacts of the harness connectors and check the
Both resistance measurements are less than 5 ohms. by excessive heat, battery acid, or chafing.
Results: B. Perform a 45 N (10 lb) pull test on each of the

• OK – The resistance measurements are less than
5 ohms. The energize circuit and the return circuit C. Reconnect all harness connectors making sure
are not open in the machine harness. Proceed to that the connectors are fully seated and the clips
Test Step 3. for each connector are completely fastened.
• NOT OK – One or both of the resistance D. Turn the disconnect switch and the key start
measurements is greater than 5 ohms. There is an switch to the ON position.
open or a bad connection in either the return circuit
or the energize circuit. E. Operate the machine.
Repair: A resistance measurement that is greater F. Determine if the CID 0144 FMI 05 diagnostic code
than 5000 ohms could indicate that a wire is is active.
either not connected or is open. A resistance
measurement that is greater than 5 ohms but less Expected Result:
than 5000 ohms could indicate that one of the
connection points or a splice connection in the The CID 0144 FMI 05 diagnostic code is active.
circuit is not open but is not a good connection.
Results:
If one of the resistance measurements is greater
than 5 ohms and the other measurement is less • YES – The CID 0144 FMI 05 diagnostic code is
than 5 ohms, one of the return circuits is not active. The problem has not been corrected.
correct. This will not cause the diagnostic code
to activate as the other return circuit is working Repair: Check the relay circuit again. Use the
correctly, however, this is a problem that needs to Caterpillar Electronic Technician (ET) service tool,
be investigated and corrected. if available, in order to perform a "Wiggle Test" on
the machine wiring harness. The wiggle test can
If both measurements are greater than 5 ohms, detect momentary or intermittent shorts or opens
determine whether the energize circuit or the return in the machine wiring harness.
circuit is causing the problem. Disconnect the
jumper wire. Use a spare length of wire in order to If the cause of the problem is not found, the ECM
check the resistance of the energize circuit and the may have failed.
return circuit individually.
Refer to the complete machine Electrical System dealership's Technical Communicator for possible
Schematic. Check all of the connectors that are in consultation with Caterpillar. This consultation
the circuit. Ensure that all connections are clean, may greatly reduce repair time. If the ECM must
secure and in good condition. be replaced, refer to Troubleshooting, “Electronic
Start at either the ECM connector or the component
connector for the defective circuit. While checking STOP.
the wire for an open or a bad connection point,
work your way through the circuit in order to isolate • NO – The CID 0144 FMI 05 diagnostic code is not
where the problem is. Repair the machine harness active. The problem does not exist at this time.
or replace the machine harness.
STOP. caused by a poor electrical connection or a short at
one of the harness connectors or at the relay base
that was disconnected and reconnected. Resume
normal machine operation.
STOP.
130 RENR9004-07

B. While observing the status of the active CID 0144
Conditions Which Generate This Code: FMI 06 diagnostic code, disconnect the machine
harness connector from the relay.
Expected Result:
When the relay is disconnected from the harness, the

CID 0144 FMI 06 diagnostic code is no longer active.
A CID 0144 FMI 05 is now active.
Results:
• YES – When the relay is disconnected from the

harness, the CID 0144 FMI 06 diagnostic code is
no longer active. A CID 0144 FMI 05 diagnostic
code becomes active. The relay is causing the
problem.

substituting a known good relay that is the same
part number as the defective relay. The cab
flood lights relay can be substituted. Replace the
defective relay.
g01287438
Illustration 112
Back Up Alarm Relay connections STOP.
This diagnostic code is associated with the back up • NO – The status of the active CID 0144 FMI 06
alarm relay. The back up alarm relay is controlled by diagnostic code did not change when the relay is
the ECM through an ON/OFF output driver. The FMI disconnected from the machine harness. The relay
06 means that the ECM has energized the output is not causing the problem. Proceed to Test Step 2.
for the relay and the current for the relay circuit is
above normal. Test Step 2. CHECK THE ENERGIZE
CIRCUIT OF THE RELAY FOR A SHORT
to activate are listed: The relay remains disconnected from the machine
harness.
• The energize circuit of the relay is shorted to a switch to the OFF position.
ground source.
B. Disconnect the machine harness connectors J1
• The ECM has failed. This is unlikely. and J2 from the Transmission Chassis ECM.
Note: Before performing this procedure, inspect C. At the machine harness connector J2 for the
the harness connectors that are involved in the ECM, measure the resistance from contact J2-5
circuit. Poor connections can often be the cause (wire F916-GN) to frame ground. Measure the
of a problem in an electrical circuit. Verify that all resistance from contact J2-5 (wire F916-GN) to all
connections in the circuit are clean, secure and of the other contacts that are used in the machine
in good condition. If a problem with a connection harness connectors J1 and J2 for the ECM.
is found, correct the problem and verify that this
diagnostic code is active before performing this Expected Result:
procedure.
Note: The following test procedure may cause ohms.
RENR9004-07 131
Results: If the cause of the problem is not found, the ECM

may have failed.
than 5000 ohms. The energize circuit is not shorted Prior to replacing an ECM, always contact your
to another circuit in the machine harness. Proceed dealership's Technical Communicator for possible
to Test Step 3. consultation with Caterpillar. This consultation
may greatly reduce repair time. If the ECM must
• NOT OK – Each resistance measurement is not be replaced, refer to Troubleshooting, “Electronic
greater than 5000 ohms. There is a short in the Control Module (ECM) - Replace”.
machine harness. The short is between J2-5 (wire
F916-GN) and the circuit that has a low resistance STOP.
measurement.
• NO – The CID 0144 FMI 06 diagnostic code is not
Repair: Refer to the complete machine Electrical active. The problem does not exist at this time.
System Schematic. Check all of the connectors that
are in the relay circuit. Ensure that all connections Repair: The initial diagnostic code was probably
are clean, secure and in good condition. caused by a poor electrical connection or a short at
one of the harness connectors or at the relay base
For information on testing for short circuits and that was disconnected and reconnected. Resume
finding short circuits, refer to Testing and Adjusting, normal machine operation.
machine harness or replace machine harness. STOP.
STOP.
i02914253
Test Step 3. CHECK THE STATUS OF THE MID 027 - CID 0168 - FMI 00
DIAGNOSTIC CODE
SMCS Code: 1406-038
contacts of the harness connectors and check the Conditions Which Generate This Code:

C. Reconnect all harness connectors making sure

that the connectors are fully seated and the clips


is active.
Expected Result:

g01323933
Results: Illustration 113
Power Breaker Box located on left side of machine behind the Cab
• YES – The CID 0144 FMI 06 diagnostic code is (1) Accugrade Breaker (20 Amp)
active. The problem has not been corrected. (2) Transmission Control Breaker (15 Amp)
(3) Key Switch Breaker (15 Amp)
(4) Engine Control Breaker (20 Amp)
Repair: Check the relay circuit again. Use the (5) Alternator Breaker (150 Amp)
Caterpillar Electronic Technician (ET) service tool, (6) Load Breaker (80 Amp)
if available, in order to perform a "Wiggle Test" on (7) Main Breaker (80 Amp)
the machine wiring harness. The wiggle test can
detect momentary or intermittent shorts or opens
132 RENR9004-07
B. At the J1 harness connector for the

Transmission/Chassis ECM, insert a7X-1710
Multimeter Probe along the supply connection for
the system power J1-31 (wire 126-RD). Use the
other multimeter probe to make contact to frame
ground.
D. Start the engine and run the engine at half throttle.
E. Measure the voltage between contact J1-31 (wire

126-RD) and frame ground.
F. At the J1 harness connector for the ECM, insert

the 7X-1710 Multimeter Probe that was used for
the frame ground contact along the system power
supply -battery contact J1-13 (wire A202-BK).
G. Measure the voltage between contact J1-31 (wire

126-RD) and contact J1-13 (wire A202-BK).
Expected Result:
Both voltage measurements are approximately in the

range of 18.0 VDC to 32.0 VDC.
Results:
g01287806
Illustration 114
Transmission/Chassis ECM System Voltage connections • OK – Both voltage measurements are
approximately in the range of 18.0 VDC to 32.0
This diagnostic code is associated with the system VDC. The system voltage is correct. Proceed to
voltage of the machine that is supplied to the Test Step 5.
Transmission/Chassis ECM. The FMI 00 means that
the ECM has detected that the system voltage is • NOT OK – Each voltage measurement is
above normal. The ECM activates this diagnostic approximately greater than 32.0 VDC. The system
code when the system voltage is above 32.0 VDC. voltage is above normal. Proceed to Test Step 3.
The possible causes of this diagnostic code are listed • NOT OK – The measurement from the +battery
below: contact to frame ground is in the range of 18.0 VDC
to 32.0 VDC, however, the measurement between
• A charging system component has failed. the ECM +battery contact and the ECM -battery
contact is not in the correct range. The ground
• The harness wiring has failed. circuit may have failed. Proceed to Test Step 2.
• The ECM has failed. This is unlikely. Test Step 2. CHECK THE GROUND
CIRCUITS
the harness connectors that are involved in the A. Turn the key start switch and the disconnect
circuit. Poor connections can often be the cause switch to the OFF position.
all connections in the circuit are clean, that all B. Disconnect the machine harness J1 connector
connections are secure and that all connections from the ECM.
connection is found, correct the problem and C. At the J1 harness connector for the ECM,
verify that this diagnostic code is active before measure the resistance between each of the 5
performing this procedure. -battery contacts and frame ground. The contacts
for the -battery connections are illustrated in
Test Step 1. CHECK THE SYSTEM the connection diagram at the beginning of this
VOLTAGE AT THE ECM procedure.

RENR9004-07 133
Expected Result: Expected Result:
Each resistance measurement is less than 5.0 ohms. The output current of the alternator at half throttle
is approximately 40 amps, half of the alternator full
Results: current output rating (80 Amps).
• OK – Each resistance measurement is less than Results:

5.0 ohms. The ground circuit is correct. Reconnect
the J1 machine harness connector to the ECM • YES – The output current of the alternator at half
before proceeding to the next test step. Proceed throttle is approximately 40 amps. Proceed to Test
to Test Step 3. Step 4.
• NOT OK – One or more of the resistance • NO – The output current of the alternator at half
measurements is greater than 5.0 ohms. There is throttle is not approximately 40 amps. The current
an open circuit or a poor connection in the ground output of the alternator is not correct.
circuit.
Repair: Refer to Service Manual, SENR4130 for
Repair: The open circuit or the possible poor brushless alternators for further testing and repair
connection is in the ground circuit wire of the procedures for the alternator.
ECM A202-BK in the machine harness. Refer to
the complete Electrical System Schematic of the STOP.
machine. Check the ground connection at the
rear frame by locating wire A202-BK. Ensure that Test Step 4. CHECK THE ALTERNATOR
the ground connection is clean, that the ground VOLTAGE OUTPUT
connection is tight and that the ground connection
is in good condition. Check all of the connectors The multimeter and the ammeter are still connected
and splice points that are in the ground circuit. as in the last test step. The engine is running.
Ensure that all connections are clean, that all
connections are secure and that all connections A. Run the engine for approximately 10 minutes at
are in good condition. Repair the machine harness half throttle.
B. Check the voltage at the alternator output “B”
STOP. terminal.
Test Step 3. CHECK THE ALTERNATOR Expected Result:

CURRENT OUTPUT
The voltage measurement is 28.0 ± 1.0 VDC.
A. Before performing this test step, partially discharge
the batteries. This can be done by cranking the Results:
engine for approximately 30 seconds without
starting the engine. This can also be done by • YES – The voltage measurement is 28.0 ± 1.0
turning on the lights for about 10 minutes without VDC. The voltage output of the alternator is correct.
running the engine. Proceed to Test Step 5.
B. Turn the disconnect switch and the key start • NO – The voltage is greater than 32.0 VDC.
Repair: Refer to the complete Electrical System
C. At the alternator, connect multimeter probes Schematic for your machine. Check all connections
between the alternator “B” terminal (wire 109-RD) that are in the charging circuit. Ensure that all
and the alternator case (frame ground). ground connections are clean, that all connections
are tight and that all connections are in good
D. Connect a clamp on 8T-0900 AC/DC Clamp-on condition.
Ammeter or an equivalent ammeter around the
output wire 109-RD. If a problem is not found in the machine harness
or connection points, refer to Service Manual,
E. Turn the disconnect switch to the ON position. SENR4130 for brushless alternators for further
testing and repair procedures for the alternator.
F. Start the engine.
STOP.
G. Run the engine at approximately half throttle.
H. Immediately check the output current of the

alternator.
134 RENR9004-07
Test Step 5. CHECK THE STATUS OF THE i02914286

DIAGNOSTIC CODE
MID 027 - CID 0168 - FMI 01
switch to the OFF position. SMCS Code: 1406-038
B. Reconnect any harness connectors that were Conditions Which Generate This Code:
disconnected and checked.

D. Operate the machine.
E. Determine if the CID 0168 FMI 00 diagnostic code

is active.
Expected Result:
The CID CID 0168 FMI 00 diagnostic code is active.
Results:

active.
Repair: Perform this procedure again. Verify

that the measurements of the alternator are
g01323933
correct. Verify that the circuit connections for the Illustration 115
system voltage are in good condition and that the Power Breaker Box located on left side of machine behind the Cab
connections are tight. (1) Accugrade Breaker (20 Amp)
(2) Transmission Control Breaker (15 Amp)
If the problem remains and no cause can be found, (3) Key Switch Breaker (15 Amp)
the ECM may have failed. faulty. (4) Engine Control Breaker (20 Amp)
(5) Alternator Breaker (150 Amp)
(6) Load Breaker (80 Amp)
It is unlikely that the ECM has failed. Verify that (7) Main Breaker (80 Amp)
all possible causes of the diagnostic code have
been investigated. Exit this procedure and perform
this procedure again. If the cause of the diagnostic
code is not found, replace the ECM. See Testing
- Replace”.
STOP.
• NO – The CID 0168 FMI 00 code is not active. The

problem does not exist at this time.

machine operation.
STOP.
RENR9004-07 135
Test Step 1. CHECK THE SYSTEM

VOLTAGE AT THE ECM
B. At the J1 harness connector for the ECM, insert

a7X-1710 Multimeter Probe along the system
power supply, contact J1-31 (wire 126-RD). Use
the other multimeter probe to make contact to
frame ground.
D. Start the engine and run the engine at half throttle.
E. Measure the voltage between contact J1-31 (wire

126-RD) and frame ground.
F. At the J1 harness connector for the Implement

ECM, insert the 7X-1710 Multimeter Probe that
was used for the frame ground contact along the
system power supply -battery contact J1-13 (wire
A202-BK).

g01287806
Illustration 116 Expected Result:
Transmission/Chassis ECM System Voltage connections
Both voltage measurements are approximately in the
This diagnostic code is associated with the system range of 18.0 VDC to 32.0 VDC.
voltage of the machine that is supplied to the
Transmission/Chassis ECM. The FMI 01 means that Results:
the ECM has detected that the system voltage is
below normal. The ECM activates this diagnostic • OK – Each voltage measurement is approximately
code when the system voltage is below 18.0 VDC. in the range of 18.0 VDC to 32.0 VDC. The system
voltage is correct. Proceed to Test Step 6.
below: • NOT OK – Each voltage measurement
is approximately the same, however, the
• An open circuit or a poor system ground circuit measurements are less than 18.0 VDC. The
connection. system voltage is below normal. Proceed to Test
Step 4.
• An open circuit or poor connection in the system
voltage supply circuit. • NOT OK – The measurement from the +battery
contact to frame ground is in the range of 18.0 VDC
• A charging system component has failed. to 32.0 VDC, however, the measurement between
the ECM +battery contact and the ECM -battery
• The ECM has failed. This is unlikely. contact is not in the correct range. The ground
circuit may have failed. Proceed to Test Step 2.
Note: Before performing this procedure, verify
that all circuit breakers and fuses in the charging Test Step 2. CHECK THE GROUND
circuit and the supply circuit of the ECM are CIRCUIT
closed. If a problem with a circuit breaker or a
fuse is found, correct the problem and verify that A. Turn the key start switch and the disconnect
this diagnostic code is active before performing switch to the OFF position.
this procedure.
B. Disconnect the machine harness J1 connector
from the ECM.
136 RENR9004-07
C. At the J1 harness connector for the ECM, Results:

measure the resistance between each of the 5
-battery contacts and frame ground. The contacts • OK – Each resistance measurement is less than
for the -battery connections are illustrated in 5.0 ohms. The supply circuit is correct. Reconnect
the connection diagram at the beginning of this the J1 machine harness connector to the ECM
procedure. before proceeding to the next test step. Proceed
to Test Step 4.
Expected Result:
Each resistance measurement is less than 5.0 ohms. measurements is greater than 5.0 ohms. There is
an open circuit or a poor connection in the supply
Results: circuit.
• OK – Each resistance measurement is less than Repair: The open or the possible poor connection
5.0 ohms. The ground circuit is correct. Proceed is in the supply circuit for the system voltage of the
to Test Step 3. ECM (wire 126-RD) in the machine harness. Verify
that there are no open circuit breakers or fuses in
• NOT OK – One or more of the resistance the circuit.
measurements is greater than 5.0 ohms. There is
an open circuit or a poor connection in the ground Refer to the complete Electrical System Schematic
circuit. of the machine. Check all of the connectors and
splice points that are in the supply circuit. Ensure
Repair: The open or the possible poor connection that all connections are clean, that all connections
is in the ground circuit of the ECM (wire A202-BK) are secure and that all connections are in good
in the machine harness. Refer to the complete condition. Repair the machine harness or replace
Electrical System Schematic of the machine. the machine harness.
Check the ground connection point of the rear
frame by locating wire A202-BK. Ensure that STOP.
the ground connection is clean, that the ground
connection is tight and that the ground connection Test Step 4. CHECK THE ALTERNATOR
is in good condition. Check all of the connectors CURRENT OUTPUT
and splice points that are in the ground circuit.
Ensure that all connections are clean, that all A. Before performing this test step, partially discharge
connections are secure and that all connections the batteries. This can be done by cranking the
are in good condition. Repair the machine harness engine for approximately 30 seconds without
or replace the machine harness. starting the engine. This can also be done by
turning on the lights for about 10 minutes without
STOP. running the engine.
Test Step 3. CHECK THE SUPPLY B. Turn the disconnect switch and the key start
CIRCUITS switch to the OFF position.
The key start switch and the disconnect switch C. At the alternator, connect multimeter probes
remain in the OFF position. The machine harness J1 between the alternator “B” terminal (wire 109-RD)
connector remains disconnected from the ECM. and the alternator case (frame ground).
A. At the J1 harness connector for the ECM, using D. Connect a clamp on 8T-0900 AC/DC Clamp-on
a length of spare wire, measure the resistance Ammeter or equivalent ammeter around the output
between the alternator “B” terminal (wire 109-RD) wire 109-RD.
to each of the 5 +battery contacts that are
connected to the J1 harness connector. The E. Turn the disconnect switch to the ON position.
contacts for the 5 +battery connections are
illustrated in the connection diagram at the F. Start the engine.
beginning of this procedure.
Expected Result:
H. Immediately check the output current of the
Each resistance measurement is less than 5.0 ohms. alternator.
RENR9004-07 137
Expected Result: Test Step 6. CHECK THE STATUS OF THE

DIAGNOSTIC CODE
The output current of the alternator at half throttle is
approximately 40 amps, half the alternator full current A. Turn the disconnect switch and the key start
output rating (80 Amps). switch to the OFF position.
Results: B. Reconnect any harness connectors that were

• YES – The output current of the alternator at half
throttle is approximately 40 amps. Proceed to Test C. Turn the disconnect switch and the key start
Step 5. switch to the ON position.
• NO – The output current of the alternator at half D. Operate the machine.

throttle is not approximately 40 amps. The current
output of the alternator is not correct. E. Determine if the CID 0168 FMI 01 diagnostic code
is active.
brushless alternators for further testing and repair Expected Result:
procedures for the alternator.
STOP.
Results:
Test Step 5. CHECK THE ALTERNATOR
VOLTAGE OUTPUT • YES – The CID 0168 FMI 01 diagnostic code is
active.
The multimeter and the ammeter are still connected
from the last test step. The engine is running. Repair: Perform this procedure again. Verify
that the measurements of the alternator are
A. Run the engine for approximately 10 minutes at correct. Verify that the circuit connections for the
half throttle. system voltage are in good condition and that the
connections for system voltage are tight.
B. Check the voltage at the alternator output “B ”
terminal. If the problem remains and no cause can be found,
the ECM may have failed. faulty.
Expected Result:
It is unlikely that the ECM has failed. Verify that
The voltage measurement is 28.0 ± 1.0 VDC. all possible causes of the diagnostic code have
Results: this procedure again. If the cause of the diagnostic
• YES – The voltage measurement is 28.0 ± 1.0 and Adjusting, “Electronic Control Module (ECM)
VDC. The voltage output of the alternator is correct. - Replace”.
Proceed to Test Step 6.
STOP.
• NO – The voltage is less than 18.0 VDC.
Repair: Refer to the complete Electrical System problem does not exist at this time.
Schematic for your machine. Check all connections
that are in the charging circuit. Ensure that all Repair: The initial diagnostic code was probably
ground connections are clean, that all connections caused by a poor electrical connection or a
are tight and that all connections are in good short at one of the harness connectors that was
condition. disconnected and reconnected. Resume normal
machine operation.
If a problem is not found in the machine harness
or connection points, refer to Service Manual, STOP.
SENR4130 for brushless alternators for further
testing and repair procedures for the alternator.
STOP.
138 RENR9004-07
i02914568
MID 027 - CID 0168 - FMI 02

SMCS Code: 1406-038
g01323933 g01287806
Illustration 117 Illustration 118
Power Breaker Box located on the left side of the machine behind Transmission/Chassis ECM System Voltage connections
the Cab
(1) Accugrade Breaker (20 Amp) This diagnostic code is associated with the system
(2) Transmission Control Breaker (15 Amp) voltage of the machine that is supplied to the
(3) Key Switch Breaker (15 Amp) Transmission/Chassis ECM. The FMI 02 means that
(4) Engine Control Breaker (20 Amp) the ECM has detected that the system voltage is
(6) Load Breaker (80 Amp) erratic or that the system voltage is intermittent. The
(7) Main Breaker (80 Amp) ECM activates this diagnostic code when the system
voltage is not in the range of 18.0 VDC to 32.0 VDC
for more than a few seconds.

below:
• A poor circuit connection to the system ground

• A poor circuit connection to system voltage
• A charging system component has failed.
Note: Before performing this procedure, verify
that all circuit breakers and fuses in the charging
circuit and the system supply circuit of the ECM
are closed. If a problem with a circuit breaker or
the fuse is found, correct the problem. Verify that
this diagnostic code is active before performing
this procedure.
RENR9004-07 139
Test Step 1. CHECK THE SYSTEM • NOT OK – The measurement from the +battery
VOLTAGE AT THE ECM contact to frame ground is stable and is in the
range of 18.0 VDC to 32.0 VDC, however, the
A. Turn the disconnect switch and the key start measurement between the ECM +battery contact
switch to the OFF position. and the ECM -battery contact is not stable in the
correct range at all times. Proceed to Test Step 2.
B. At the J1 harness connector for the Implement
ECM, insert a 7X-1710 Multimeter Probe along Test Step 2. CHECK THE GROUND
the supply circuit for the system power J1-31 (wire CIRCUITS
126-RD). Use the other multimeter probe to make
contact to frame ground. A. Turn the key start switch and the disconnect
B. Disconnect the machine harness J1 connector
D. Start the engine and run the engine at half throttle. from the ECM.
E. Measure the voltage between contact J1-31 (wire C. At the J1 harness connector for the ECM,
126-RD) and frame ground. measure the resistance between each of the 5
-battery contacts and frame ground. The contacts
F. Observe the resistance measurement of the for the -battery connections are illustrated in
multimeter and wiggle the machine harness the connection diagram at the beginning of this
connectors for the ECM. Gently pull on the wires procedure.
and move the wires around.
Expected Result:
G. At the J1 harness connector for the ECM, insert
the 7X-1710 Multimeter Probe that was used for Each resistance measurement is less than 5.0 ohms.
the frame ground contact along the system power
supply -battery contact J1-13(wire A202-BK). Results:
H. Measure the voltage between contact J1-31 (wire • OK – Each resistance measurement is less than
126-RD) and contact J1-13 (wire A202-BK). 5.0 ohms. The ground circuit is correct. Reconnect
the J1 machine harness connector to the ECM
I. Observe the resistance measurement of the before proceeding to the next test step. Proceed
multimeter and wiggle the machine harness to Test Step 3.
connectors for the ECM. Gently pull on the wires
and wiggle the wires. • NOT OK – One or more of the resistance
measurements is greater than 5.0 ohms. There is
Expected Result: an open circuit or a poor connection in the ground
circuit.
Both voltage measurements are approximately the
same and are in the range of 18.0 VDC to 32.0 VDC Repair: The open or the possible poor connection
at all times during the manipulation of the harness is in the ground circuit of the ECM (wire A202-BK)
and the connectors. in the machine harness. Refer to the complete
Electrical System Schematic of the machine.
Results: Check the ground connection located on the rear
frame (wire A202-BK). Ensure that the ground
• OK – Each voltage measurement is approximately connection is clean, that the ground connection
the same and is in the range of 18.0 VDC to is tight and that the ground connection is in good
32.0 VDC. The system voltage is correct at all condition. Check all of the connectors and splice
times during the manipulation of the harness and points that are in the ground circuit. Ensure that
connectors. Proceed to Test Step 6. all connections are clean, that all connectors
are secure and that all connectors are in good
• NOT OK – Each voltage measurement condition. Repair the machine harness or replace
is approximately the same, however, the the machine harness.
measurements are not stable. The voltage
measurements are showing a large amount of STOP.
variation. The manipulation of the machine harness
and connectors does not affect the measurement. Test Step 3. CHECK THE SUPPLY
Proceed to Test Step 4. CIRCUITS
The key start switch and the disconnect switch
remain in the OFF position. The machine harness J1
connector remains disconnected from the ECM.
140 RENR9004-07
A. At the J1 harness connector for the ECM, using F. Start the engine.
a length of spare wire, measure the resistance
between the alternator “B” terminal (wire 109-RD) G. Run the engine at approximately half throttle.
and each of the five +battery contacts that are
connected to the J1 harness connector. The H. Immediately check the output current of the
contacts for the 5 +battery connections are alternator.
illustrated in the connection diagram at the
beginning of this procedure. Expected Result:
Expected Result: The output current of the alternator at half throttle is

approximately 40 amps, half the alternator full current
Each resistance measurement is less than 5.0 ohms. output rating (80 Amps). The current measurement
is stable.
Results:
Results:
• OK – Each resistance measurement is less than
5.0 ohms. The supply circuit is correct. Reconnect • YES – The output current of the alternator at half
the J1 machine harness connector to the ECM throttle is approximately 40 amps and is stable.
before proceeding to the next test step. Proceed Proceed to Test Step 5.
to Test Step 4.
• NO – The output current of the alternator at half
• NOT OK – One or more of the resistance throttle is not stable. The measurement is showing
measurements is greater than 5.0 ohms. There is a large variation of current values. The current
an open circuit or a poor connection in the supply output of the alternator is not correct.
circuit.
Repair: The open or the possible poor connection brushless alternators for further testing and repair
is in the voltage supply circuit of the ECM (wire procedures for the alternator.
126-RD) in the machine harness. Verify that there
are no open circuit breakers or fuses in the circuit. STOP.
Refer to the complete Electrical System Schematic Test Step 5. CHECK THE ALTERNATOR
of the machine. Check all of the connectors and VOLTAGE OUTPUT
splice points that are in the supply circuit. Ensure
that all connections are clean, that all connections The multimeter and the ammeter are still connected
are secure and that all connections are in good as used in the last test step. The engine is running.
the machine harness. A. Run the engine for approximately 10 minutes at
half throttle.
STOP.
B. Check the voltage at the alternator output terminal
Test Step 4. CHECK THE ALTERNATOR (“B”).
CURRENT OUTPUT
Expected Result:
A. Before performing this test step, partially discharge
the batteries. This can be done by cranking the The voltage measurement is 28.0 ± 1.0 VDC.
engine for approximately 30 seconds without There is little variation or no variation in the voltage
starting the engine. This can also be done by measurement.
turning on the lights for about 10 minutes without
running the engine. Results:
B. Turn the disconnect switch and the key start • YES – The voltage measurement is 28.0 ± 1.0
switch to the OFF position. VDC. The voltage is stable. The voltage output of
the alternator is correct. Proceed to Test Step 6.
C. At the alternator, connect multimeter probes
between the alternator “B” terminal (wire 109-RD) • NO – The voltage is not stable. There is a large
and the alternator case (frame ground). variation in the measured voltage. The voltage
output is not correct.
D. Connect a clamp on 8T-0900 AC/DC Clamp-on
output wire 109-RD.
E. Turn the disconnect switch to the ON position.

RENR9004-07 141
Repair: Refer to Service Manual, SENR4130 for i04040109

brushless alternators for further testing and repair
procedures for the alternator. MID 027 - CID 0168 - FMI 03
STOP. SMCS Code: 1406-038
Test Step 6. CHECK THE STATUS OF THE Conditions Which Generate This Code:
DIAGNOSTIC CODE
B. Reconnect any harness connectors that were



is active.
Expected Result:
Results:
g01405586
Illustration 119
• YES – The CID 0168 FMI 02 diagnostic code is Circuit breaker box located in the engine compartment behind
active. the right rear wheel
(1) Alternator circuit breaker (150 amp)
Repair: Perform this procedure again. Verify that (2) Battery circuit breaker (150 amp)
the measurements at the alternator are correct. (3) Main breaker (80 amp)
Confirm that the circuit connections for the system (4) Load circuit breaker (80 amp)
voltage are in good condition and that the circuit
connections are tight.
If the problem remains and no cause can be found,

the ECM may have failed.
It is unlikely that the ECM has failed. Verify that

all possible causes of the diagnostic code have
this procedure again. If the cause of the diagnostic
- Replace”.
STOP.


short at one of the harness connectors that was Illustration 120
g01323933
machine operation.
STOP.
142 RENR9004-07
B. At the J1 harness connector for the

transmission/chassis ECM, insert a7X-1710
Multimeter Probe along the +battery contact,
J1-31 (wire 126-RD). Use the other multimeter
probe to contact the frame ground.
C. Turn on the disconnect switch.
D. Start the engine and run at half throttle.
E. Measure the voltage between contact J1-31, (wire

126-RD) and the frame ground.
F. At the J1 harness connector for the ECM, insert

the 7X-1710 Multimeter Probe along the -battery
contact J1-13 (wire A202-BK).

Expected Result:
Both voltages are approximately the same and are

18 to 32 VDC.
Results:
g01379576
• OK – Voltages are approximately the same and
Illustration 121 are 18 to 32 VDC. Proceed to Test Step 5.
Transmission/chassis ECM system voltage connections
• NOT OK – Voltages are approximately the same,
This diagnostic code is associated with the supply but are greater than 32 VDC. Proceed to Test Step
voltage of the Transmission/Chassis ECM. The ECM 3.
activates this diagnostic code when the system
voltage is above 32.0 VDC. • NOT OK – The voltage from the +battery contact
to frame (ground) is 18 to 32 VDC. However, the
The possible causes of this diagnostic code are listed voltage between the ECM +battery contact and the
below: ECM -battery contact is not 18 to 32 VDC. The
ground circuit may have failed. Proceed to Test
• Charging system component failure. Step 2.
• Harness failure. Test Step 2. CHECK THE GROUND

CIRCUITS
• The ECM failure. ECM failure is unlikely.
A. Turn the keyswitch and the disconnect switch off.
the harness connectors that are involved in B. Disconnect the harness J1 connector from the
the circuit. Poor connections can be the cause ECM.
of an electrical circuit problem. Verify that all
connections in the circuit are clean, secure, and C. At the J1 harness connector for the ECM, measure
in good condition. If a connection problem is the resistance between each -battery contact and
found, correct the problem and verify that this ground. The contacts for the -battery connections
diagnostic code is active before performing this are shown in Illustration 121.
procedure.
Expected Result:
Test Step 1. CHECK SYSTEM VOLTAGE
AT THE TRANSMISSION/CHASSIS ECM Each resistance is less than 5.0 ohms.
A. Turn off the disconnect switch and the keyswitch.

RENR9004-07 143
Results: Test Step 4. CHECK THE ALTERNATOR

VOLTAGE OUTPUT
• OK – Each resistance is less than 5.0 ohms.
Reconnect the J1 harness connector to the ECM The multimeter and the ammeter are still connected
before proceeding to the next test step. Proceed as in the last test step. The engine is running.
to Test Step 3.
A. Run the engine for approximately 10 minutes at
• NOT OK – A resistance is greater than 5.0 ohms. half throttle.
There is an open or possible poor connection in
ground wire A202-BK of the ECM circuit. B. Check the voltage at the alternator “B” terminal.
Repair: Check the ground A202-BK connection at Expected Result:

the rear frame. Ensure that the ground connection
is clean, tight, and in good condition. Check all of The voltage is 28 ± 1.0 VDC.
the ground circuit connectors and splice points.
Ensure that all connections are clean, tight, and in Results:
good condition. Repair or replace the harness.
• YES – The voltage is 28 ± 1.0 VDC. Proceed to
STOP. Test Step 5.
Test Step 3. CHECK THE ALTERNATOR • NO – The voltage is greater than 32 VDC.
CURRENT OUTPUT
Repair: See the machine Electrical Schematic.
A. Before performing this test step, partially discharge Check all charging circuit connections. Ensure
the batteries. Crank the engine for approximately that all ground connections are clean, tight, and
30 seconds without starting the engine or turn on in good condition.
the lights for about 10 minutes without the running
the engine. If a problem is not found in the harness or
connections, see Service Manual, SENR4130.
B. Turn off the disconnect switch and keyswitch.
STOP.
C. Connect multimeter probes at the alternator
between the alternator “B” terminal (wire 109-RD) Test Step 5. CHECK THE STATUS OF THE
and the alternator case (frame ground). DIAGNOSTIC CODE
D. Connect a clamp on 8T-0900 AC/DC Clamp-on A. Turn off the keyswitch and disconnect switch.
output wire 109-RD. B. Reconnect any harness connectors that were
disconnected.
E. Turn on the disconnect switch.
C. Turn on the disconnect switch and keyswitch.
F. Start the engine.
E. Determine if CID 0168 FMI 03 is active.
H. Immediately check the alternator output current.
Expected Result:
Expected Result:
CID 0168 FMI 03 is active.
The alternator output current at half throttle is
approximately 40 amps. Results:
Results: • YES – CID 0168 FMI 03 is active.

• YES – The alternator output current at half throttle Repair: Perform this procedure again. Verify
is approximately 40 amps. Proceed to Test Step 4. that the alternator voltage is correct and the
connections are in good condition.
• NO – The alternator output current at half throttle
is not approximately 40 amps. If the problem remains and no cause can be found,
the ECM may have failed. However, ECM failure
Repair: See Service Manual, SENR4130. is unlikely.
STOP.
144 RENR9004-07
If the cause of the diagnostic code is not found,

contact your Cat® dealer. If ECM replacement is
required, see Testing and Adjusting, “Electronic
STOP.
• NO – CID 0168 FMI 03 is not active.

caused by a poor connection or short. Resume
STOP.
i04040461
MID 027 - CID 0168 - FMI 04

SMCS Code: 1406-038
g01379576
Illustration 123
Transmission/Chassis ECM voltage connections
This diagnostic code is associated with the

Transmission/Chassis ECM supply voltage. FMI 04
means that the ECM has detected the voltage is
below 19.0 VDC.

below:
• An open or poor ground circuit connection

• An open or poor voltage supply connection
g01405586 • Charging system component failure

Illustration 122
Power circuit breaker box located in the engine compartment • ECM failure (ECM failure is unlikely)
behind the right rear wheel
(1) Alternator circuit breaker (150 amp) Note: Before performing this procedure, verify
(2) Battery circuit breaker (80 amp) that all circuit breakers and fuses in the charging
(3) Main breaker (80 amp)
(4) Load circuit breaker (80 amp) circuit and ECM supply circuit are closed. If a
problem with a circuit breaker or fuse is found,
correct the problem. Verify that this diagnostic
code is active before performing this procedure.
Test Step 1. CHECK SYSTEM VOLTAGE

AT THE TRANSMISSION/CHASSIS ECM
A. Turn off the keyswitch and disconnect switch.
B. At the J1 harness connector for the ECM, insert

a 7X-1710 Multimeter Probe along the +battery
contact, J1-31 (wire 126-RD). Use the other
multimeter probe to contact to frame ground.
RENR9004-07 145
C. Turn on the disconnect switch. Repair: Check ground wire A202-BK at the rear
frame. Ensure that the ground connection is clean,
D. Start the engine and run at half throttle. tight, and in good condition. Check all of the ground
circuit connectors and splice points. Ensure that
E. Measure the voltage between contact J1-31 (wire all connections are clean, secure, and in good
126-RD) and frame ground. condition. Repair or replace the harness.
F. At the J1 harness connector for the ECM, insert STOP.

the 7X-1710 Multimeter Probe along -battery
contact J1-13, (wire A202-BK). Test Step 3. CHECK THE SUPPLY
CIRCUITS
126-RD) and contact J1-13 (wire A202-BK). The keyswitch and disconnect switch remain off. The
harness J1 connector remains disconnected from the
Expected Result: ECM.
Both voltages are approximately the same and are A. At the J1 harness connector for the ECM, using
19 to 32 VDC. a jumper wire, measure the resistance between
the alternator “B” terminal (wire 109-RD) and each
Results: +battery contacts that are connected to the J1
harness connector. The contacts for the +battery
• OK – Voltages are approximately the same and connections are shown in Illustration 123.
are 19 to 32 VDC. Proceed to Test Step 6.
Expected Result:
• NOT OK – Voltages are approximately the same,
but are less than 19 VDC. Proceed to Test Step 4. Each resistance is less than 5.0 ohms.
• NOT OK – The voltage from the +battery contact Results:

to frame ground is 8 to 32 VDC. However, the
measurement between the ECM +battery contact • OK – Each resistance is less than 5.0 ohms.
and the ECM -battery contact is not in 8 to 32 VDC. Reconnect the J1 harness connector to the ECM
The ground circuit may have failed. Proceed to before proceeding to the next test step. Proceed
Test Step 2. to Test Step 4.
Test Step 2. CHECK THE GROUND • NOT OK – A resistance is greater than 5.0 ohms.
CIRCUIT There is an open or a poor connection at (wire
126-RD).
A. Turn off the keyswitch and disconnect switch.
Repair: Verify that there are no open circuit
B. Disconnect the harness J1 connector from the breakers or fuses in the circuit.
ECM.
See the machine Electrical Schematic. Check all
C. At the J1 harness connector for the ECM, measure of the supply circuit connectors and splice points.
the resistance between each -battery contacts Ensure that all connections are clean, secure, and
and frame ground. The contacts for the -battery in good condition. Repair or replace the harness.
connections are shown in Illustration 123.
STOP.
Expected Result:
Each resistance is less than 5.0 ohms. CURRENT OUTPUT
Results: A. Before performing this test step, partially discharge
the batteries. Crank the engine for approximately
• OK – Each resistance is less than 5.0 ohms. 30 seconds without starting the engine or turn on
Proceed to Test Step 3. the lights for about 10 minutes without running the
engine.
• NOT OK – A resistance is greater than 5.0 ohms.
There is an open or poor connection in the ECM B. Turn off the keyswitch and disconnect switch.
ground circuit (wire A202-BK).
C. Connect multimeter probes between the alternator
“B” terminal (wire 109-RD) and the alternator case.
146 RENR9004-07
D. Connect a clamp on 8T-0900 AC/DC Clamp-on Test Step 6. CHECK THE STATUS OF THE
Ammeter around output wire 109-RD. DIAGNOSTIC CODE
E. Turn on the disconnect switch. A. Turn off the keyswitch and disconnect switch.
F. Start the engine. B. Reconnect any disconnected connectors.
G. Run the engine at approximately half throttle. C. Turn on the disconnect switch and keyswitch.
H. Immediately check the alternator output current. D. Operate the machine.
Expected Result: E. Determine if CID 0168 FMI 04 is active.
The alternator output current at half throttle is Expected Result:

approximately 40 amps.
CID 0168 FMI 04 is active.
Results:
Results:
• YES – The alternator output current at half throttle
is approximately 40 amps. Proceed to Test Step 5. • YES – CID 0168 FMI 04 is active. The ECM may
have failed. However, ECM failure is unlikely.
• NO – The alternator output current at half throttle
is not approximately 40 amp. Repair: Perform this procedure again.
Repair: See Service Manual, SENR4130. If the cause of the diagnostic code is not found,
contact your Cat® dealer. If ECM replacement is
STOP. required, see Testing and Adjusting, “Electronic
VOLTAGE OUTPUT STOP.
The multimeter and ammeter are still connected. • NO – CID 0168 FMI 04 is not active.
A. Run the engine for approximately 10 minutes at Repair: The initial diagnostic code was probably
half throttle. caused by a poor connection or short. Resume
B. Check the voltage at alternator terminal “B”.
STOP.
Expected Result:
The voltage is 28 ± 1.0 VDC.
Results:
• YES – The voltage is 28 ± 1.0 VDC. Proceed to

Test Step 6.
• NO – The voltage is less than 19.0 VDC.

Repair: See the machine Electrical Schematic.
Check all charging circuit connections. Ensure
that all ground connections are clean, tight, and
in good condition.
If a problem is not found in the harness or

connection points, see the machine Service
Manual.
STOP.
RENR9004-07 147
i04022704 The resistance range of the sensor that the ECM will
MID 027 - CID 0177 - FMI 03 18.6 ohms at 150 °C (302.0 °F).
SMCS Code: 3194-038-OC Conditions that can cause this diagnostic code to be
• The ground circuit for the sensor is open in the
machine harness.
• The signal circuit in the machine harness is open

or the sensor is disconnected.

• The oil temperature is below −40 °C (−40.0 °F).
Test Step 1. CHECK THE RESISTANCE
OF THE SENSOR

the sensor.
g01321613
Illustration 124 C. At the connector for the sensor, measure the
Transmission Oil Temperature Sensor location on the left side of resistance between contact 1 and contact 2.
Expected Result:
The resistance measurement is less than 33650

ohms.
Results:

33650 ohms. The resistance of the sensor is
correct. Proceed to Test Step 3.
• NOT OK – The resistance measurement is

greater than 33650 ohms. The transmission oil
temperature sensor has failed.
g01287815
Illustration 125 Repair: Replace the transmission oil temperature
Transmission Oil Temperature sensor connections sensor. Ensure that the new sensor corrects the
problem.
transmission oil temperature sensor. The FMI 03 STOP.
means that the Transmission/Chassis ECM has
detected that the voltage of the sensor circuit is Test Step 2. CHECK THE GROUND
above 4.9 VDC and the resistance of the sensor is CIRCUIT OF THE HARNESS
more than 33650 ohms.
The sensor remains disconnected from the machine
In addition to monitoring the voltage of the sensor harness. The disconnect switch and the key start
signal, the ECM monitors the resistance of the sensor switch remain in the OFF position.
signal. The ECM associates the resistance value of
the sensor circuit with a specific temperature of the A. Disconnect the J1 machine harness connector
transmission oil. from the ECM.
148 RENR9004-07
B. At the machine harness connector for the sensor, Results:

measure the resistance between contact 2 (wire
A202-BK) to frame ground. • OK – Each resistance measurement is greater
than 5000 ohms. The circuit is not shorted in the
Expected Result: machine harness. Proceed to Test Step 4.
The resistance measurement is less than 5 ohms. • NOT OK – One or more of the resistance
measurements is less than 5000 ohms. The signal
Results: circuit for the sensor is shorted to another circuit
in the machine harness.
5.0 ohms. The ground circuit is correct. Proceed Repair: The short is between signal wire
to Test Step 3. R818-YL and the circuit with the low resistance
measurement.
• NOT OK – The resistance measurement is greater
than 5.0 ohms. There is an open circuit or a bad Refer to the complete Electrical System Schematic
connection in the ground circuit for the sensor. of the machine. Ensure that all connections in
the signal circuit for the sensor are clean, that all
Repair: A resistance measurement that is greater connections are secure and that all connections
than 5000 ohms could indicate that a wire is either are in good condition.
not connected or a wire is open. A resistance
measurement that is greater than 5 ohms but less For information on testing for short circuits and
than 5000 ohms could indicate that one of the finding short circuits, refer to Testing and Adjusting,
connection points or a splice connection in the “Wiring Harness (Short Circuit) - Test”. Repair the
circuit is not open but is not a good connection. machine harness or replace the machine harness.
Refer to the complete Electrical System Schematic STOP.

of the machine. Ensure that all connections and
splices in the ground circuit for the sensor are Test Step 4. CHECK THE STATUS OF THE
clean, secure and in good condition. DIAGNOSTIC CODE
Start at the component connector for the defective A. Inspect the harness connectors. Clean the
circuit. While checking the wire for an open or a contacts of the harness connectors. Check the
bad connection point, work your way through the wires for damage to the insulation that is caused
circuit in order to isolate the problem. Repair the by excessive heat, battery acid, or chafing.
STOP. wires that are associated with the sensor circuit.
Test Step 3. CHECK THE SIGNAL C. Reconnect all harness connectors. Make sure that
CIRCUIT OF THE HARNESS the connectors are fully seated and that the clips
harness. The disconnect switch and the key start D. Turn the disconnect switch and the key start
switch remain in the OFF position. switch to the ON position.
A. The ECM machine harness connector J1 is E. Operate the machine.

disconnected from the ECM. Disconnect the J2
machine harness connector from the ECM. F. Check the status of the CID 0177 FMI 03
diagnostic code.
B. At the machine harness connector J1, measure
the resistance between the signal circuit at contact Expected Result:
J1-22 (wire R818-YL) and all of the other contacts
that are used in the J1 and J2 contacts for the The CID 0177 FMI 03 diagnostic code is not active.
ECM.
Results:
Expected Result:
• OK – The CID 0177 FMI 03 diagnostic code is
Each resistance measurement is greater than 5000 not active. The diagnostic code does not exist at
ohms. this time. The initial diagnostic code was probably
caused by a poor connection or a short at one
RENR9004-07 149
• NOT OK – The CID 0177 FMI 03 diagnostic

Repair: Check the sensor circuit again. Use the

Caterpillar Electronic Technician (ET) service tool,
if available, in order to perform a wiggle test on the
machine wiring harness. The wiggle test can detect
If the cause can not be found, the ECM may have

failed.
Prior to replacing an ECM, always contact your g01287815

dealership's Technical Communicator for possible Illustration 127
consultation with Caterpillar. This consultation Transmission Oil Temperature sensor connections
may greatly reduce repair time. If the cause of the
diagnostic code is not found, replace the Machine This diagnostic code is associated with the
ECM. Refer to Testing and Adjusting, “Electronic transmission oil temperature sensor. The FMI 04
Control Module (ECM) - Replace”. means that the Transmission/Chassis ECM has
detected that the voltage of the sensor circuit is
STOP. below 0.18 VDC and the resistance of the sensor is
less than 18.6 ohms.
i02906333 In addition to monitoring the voltage of the sensor
signal, the ECM monitors the resistance of the sensor
MID 027 - CID 0177 - FMI 04 signal. The ECM associates the resistance value of
the sensor circuit with a specific temperature of the
SMCS Code: 3194-038-OC
transmission oil.
The resistance range of the sensor that the ECM will
18.6 ohms at 150 °C (302.0 °F).
Conditions that can cause this diagnostic code to be


• The signal circuit in the machine harness is shorted
to a ground source.

Test Step 1. CHECK THE RESISTANCE
OF THE SENSOR

g01321613
the sensor.
Illustration 126
Transmission Oil Temperature sensor location is on the left side of C. At the connector for the sensor, measure the
the transmission (arrow). resistance between contact 1 and contact 2.
Expected Result:
The resistance measurement is greater than 18.6

ohms.
150 RENR9004-07
Results: For information on testing for short circuits and

• OK – The resistance measurement is greater than “Wiring Harness (Short Circuit) - Test”. Repair the
18.6 ohms. The resistance of the sensor is correct. machine harness or replace the machine harness.
STOP.
• NOT OK – The resistance measurement is less
than 18.6 ohms. The sensor has failed. Test Step 3. CHECK THE STATUS OF THE
DIAGNOSTIC CODE
Repair: Replace the transmission oil temperature
sensor. Ensure that the new sensor corrects the A. Inspect the harness connectors. Clean the
problem. contacts of the harness connectors. Check the
STOP. by excessive heat, battery acid, or chafing.
Test Step 2. CHECK THE SIGNAL B. Perform a 45 N (10 lb) pull test on each of the
CIRCUIT OF THE HARNESS wires that are associated with the sensor circuit.
The sensor remains disconnected from the machine C. Reconnect all harness connectors. Make sure that
harness. The disconnect switch and the key start the connectors are fully seated. Observe that the
switch remain in the OFF position. clips for each connector are completely fastened.
A. Disconnect the J1 and J2 machine harness D. Turn the disconnect switch and the key start
connectors from the ECM. switch to the ON position.
B. At the machine harness connector J1, measure E. Operate the machine.

the resistance from the signal circuit at contact
J1-22 (wire R818-YL) to frame ground. Measure F. Check the status of the CID 0177 FMI 04
the resistance from the signal circuit at contact diagnostic code.
J1-22 (wire R818-YL) to all of the other contacts
that are used in the J1 and J2 connectors for the Expected Result:
ECM.
The CID 0177 FMI 04 diagnostic code is not active.
Expected Result:
Results:
ohms. • OK – The CID 0177 FMI 04 diagnostic code is
not active. The diagnostic code does not exist at
Results: this time. The initial diagnostic code was probably
• OK – Each resistance measurement is greater of the connectors that was disconnected and
than 5000 ohms. The circuit is not shorted in the reconnected. Resume normal operation. STOP.
machine harness. Proceed to Test Step 3.
• NOT OK – One or more of the resistance code is active. The diagnostic code has not been
measurements is less than 5000 ohms. The signal corrected. The ECM may have failed.
circuit for the sensor is shorted to another circuit or
to frame ground in the machine harness. Repair: Check the sensor circuit again. Use the
Repair: The short is between signal wire if available, in order to perform a wiggle test on the
R818-YL and the circuit with the low resistance machine wiring harness. The wiggle test can detect
measurement. momentary or intermittent shorts or opens in the
of the machine. Ensure that all connections in If the cause can not be found, the ECM may have
the signal circuit for the sensor are clean, that all failed.
connections are secure and that all connections
are in good condition.
RENR9004-07 151
Prior to replacing an ECM, always contact your Perform the following procedure when the CID 0247
dealership's Technical Communicator for possible FMI 09 diagnostic code is activated. Verify that the
consultation with Caterpillar. This consultation CID 0247 FMI 09 diagnostic code is active before
may greatly reduce repair time. If the cause of the performing this procedure.
diagnostic code is not found, replace the Machine
ECM. Refer to Testing and Adjusting, “Electronic A. The CID 0247 FMI 09 diagnostic code for the
Control Module (ECM) - Replace”. SAE J1939 Data Link is active. Look for one of
the active control module diagnostic codes that is
STOP. listed at the beginning of this procedure.
Expected Result:
i02914601
MID 027 - CID 0247 - FMI 09 One of the control module diagnostic codes that is
listed at the beginning of this procedure is active.
SMCS Code: 7610-038-DTN
Results:
• YES – One of the control module diagnostic codes
SAE J1939 Data Link that is listed at the beginning of this procedure is
active.
The CID 0247 FMI 09 diagnostic code is used by the
Transmission/Chassis ECM as a “companion code” Repair: Go to the troubleshooting procedure for
that is activated simultaneously with a diagnostic the active control module CID FMI diagnostic code.
code from another control module in order to indicate Perform the troubleshooting procedure for the SAE
that the SAE J1939 data link has an abnormal J1939 Data Link circuit that is detailed for the
condition. control module in order to isolate the problem.
The FMI 09 code will match the FMI 09 code STOP.

that is activated for the diagnostic code of
the control module. The FMI 09 means that i02914658
the Transmission/Chassis ECM has lost all
communication with the other control module. MID 027 - CID 0247 - FMI 14
The CID 0247 FMI 09 diagnostic code will SMCS Code: 7610-038-DTN
never be activated by the Transmission/Chassis
ECM as a stand-alone diagnostic code. The Conditions Which Generate This Code:
Transmission/Chassis ECM will only activate the CID
0247 FMI 09 diagnostic code along with one of the SAE J1939 DATA LINK
following module communication codes.
The CID 0247 FMI 14 diagnostic code is used by the
CID 0590 FMI 09 – Engine ECM Transmission/Chassis ECM as a “companion code”
that is activated simultaneously with a diagnostic
CID 0596 FMI 09 – Implement ECM code from another control module in order to indicate
that the SAE J1939 Data Link has an abnormal
For example, if the Transmission/Chassis ECM condition.
detects that no communication is being received from
the Implement ECM over the SAE J1939 Data Link, The FMI 14 will match the FMI 14 that is activated
the Transmission/Chassis ECM will simultaneously for the control module diagnostic code. The FMI
activate a CID0596 FMI 09 (Implement ECM) 14 means that the Transmission/Chassis ECM
diagnostic code and a CID0247 FMI 09 (SAE J1939 is communicating with the other control module,
Data Link) diagnostic code. however, the Transmission/Chassis ECM is not
receiving all of the expected information.
If the Transmission/Chassis ECM did not activate the
companion diagnostic code CID 0247 FMI 09 along The CID 0247 FMI 14 diagnostic code will
with the control module code, the technician would never be activated by the Transmission/Chassis
not know which data link circuit (Cat Data Link or ECM as a stand-alone diagnostic code. The
J1939 Data Link) is involved. Transmission/Chassis ECM will only activate the CID
0247 FMI 14 diagnostic code along with one of the
When the CID 0247 FMI 09 diagnostic code is following module communication codes.
activated by the Transmission/Chassis ECM, always
look for one of the control module diagnostic codes CID 0596 FMI 14 – Implement ECM
that are listed above in order to troubleshoot the
problem. CID 0590 FMI 14 – Engine ECM
152 RENR9004-07
For example, if the Transmission/Chassis ECM The CID 0248 FMI 09 diagnostic code is used by
detects that some expected operating parameter the Transmission/Chassis ECM as a companion
information is not being received from the Implement diagnostic code that is activated simultaneously with
ECM over the SAE J1939 Data Link, the Implement another control module diagnostic code in order to
ECM will simultaneously activate a CID 0596 FMI 14 indicate that the Cat Data Link has an abnormal
(Implement ECM) diagnostic code and a CID 0247 condition.
FMI 14 (SAE J1939 Data Link) diagnostic code.
The FMI 09 will match the FMI 09 that is activated
If the Transmission/Chassis ECM did not activate the for the control module diagnostic code. The FMI 09
companion diagnostic code CID 0247 FMI 14 along means that the Transmission/Chassis ECM has lost
with the control module code, the technician would all communication with the other control module.
not know which data link circuit (Cat Data Link or
J1939 Data Link) is involved. The CID 0248 FMI 09 diagnostic code will
When the CID 0247 FMI 14 diagnostic code is ECM as a stand-alone diagnostic code. The
activated by the Transmission/Chassis ECM, always Transmission/Chassis ECM will only activate the CID
look for one of the control module diagnostic codes 0248 FMI 09 diagnostic code along with one of the
that are listed above in order to troubleshoot the following module communication codes.
problem.
Perform the following procedure when the CID 0247
FMI 14 diagnostic code is activated. Verify that the CID 0596 FMI 09 – Implement ECM
CID 0247 FMI 14 diagnostic code is active before
performing this procedure. CID 0590 FMI 09 – Engine ECM
A. The CID 0247 FMI 14 diagnostic code for the For example, if the Transmission/Chassis ECM
SAE J1939 Data Link is active. Look for one of detects that no communication is being received
the active control module diagnostic codes that is from the Implement ECM over the Cat Data Link, the
listed at the beginning of this procedure. Implement ECM will simultaneously activate a CID
0596 FMI 09 (Implement ECM) diagnostic code and
Expected Result: a CID 0248 FMI 09 (Cat Data Link) diagnostic code.
One of the control module diagnostic codes that is If the Transmission/Chassis ECM did not activate the
listed at the beginning of this procedure is active. companion diagnostic code CID 0248 FMI 09 along
with the control module code, the technician would
Results: not know which data link circuit (Cat Data Link or
J1939 Data Link) is involved.
• YES – One of the control module diagnostic codes
that is listed at the beginning of this procedure is When the CID 0248 FMI 09 diagnostic code is
active. activated by the Transmission/Chassis ECM, always
look for one of the control module diagnostic codes
Repair: Go to the troubleshooting procedure for that are listed above in order to troubleshoot the
the active control module CID FMI diagnostic code. problem.
Perform the troubleshooting procedure for the SAE
J1939 Data Link circuit that is detailed for the Perform the following procedure when the CID 0248
control module in order to isolate the problem. FMI 09 diagnostic code is activated. Verify that the
STOP. performing this procedure.
A. The CID 0248 FMI 09 diagnostic code for the Cat

i02914790
Data Link is active. Look for one of the active
MID 027 - CID 0248 - FMI 09 control module diagnostic codes that is listed at
the beginning of this procedure.
Expected Result:
One of the control module diagnostic codes that is
CAT DATA LINK listed at the beginning of this procedure is active.
RENR9004-07 153
Results: If the Transmission/Chassis ECM did not activate the

companion diagnostic code CID 0248 FMI 14 along
• YES – One of the control module diagnostic codes with the control module code, the technician would
that is listed at the beginning of this procedure is not know which data link circuit (Cat Data Link or
active. J1939 Data Link) is involved.
Repair: Go to the troubleshooting procedure for When the CID 0248 FMI 14 diagnostic code is
the active control module CID FMI diagnostic code. activated by the Transmission/Chassis ECM, always
Perform the troubleshooting procedure for the Cat look for one of the control module diagnostic codes
Data Link circuit that is detailed for the control that are listed above in order to troubleshoot the
module in order to isolate the problem. problem.
STOP. Perform the following procedure when the CID 0248

FMI 14 diagnostic code is activated. Verify that the
i03820799
MID 027 - CID 0248 - FMI 14 A. The CID 0248 FMI 14 diagnostic code for the Cat
SMCS Code: 7610-038-DTN Data Link is active. Look for one of the active
diagnostic codes that is listed at the beginning of
Conditions Which Generate This Code: this procedure.
Cat Data Link Expected Result:
The CID 0248 FMI 14 diagnostic code is used by One of the diagnostic codes that is listed at the
the Transmission/Chassis ECM as a companion beginning of this procedure is active.
diagnostic code that is activated simultaneously
with a diagnostic code from another control module Results:
in order to indicate that the Cat Data Link has an
abnormal condition. • YES – One of the diagnostic codes that is listed at
the beginning of this procedure is active.
The FMI 14 will match the FMI 14 that is activated
by the control module. The FMI 14 diagnostic Repair: Go to the troubleshooting procedure
code means that the Transmission/Chassis ECM for the CID-FMI diagnostic code. Perform the
is communicating with another control module, troubleshooting procedure for the Cat Data Link
however, the Transmission/Chassis ECM is not circuit that is detailed for the control module in
receiving all of the expected information. order to isolate the problem.
The CID 0248 FMI 14 diagnostic code will STOP.

ECM as a stand-alone diagnostic code. The
Transmission/Chassis ECM will only activate the CID
0248 FMI 14 diagnostic code along with one of the
following module communication codes:
CID 0590 FMI 14 – Engine ECM
CID 0596 FMI 14 – Implement ECM
For example, if the Transmission/Chassis ECM

detects that some expected operating parameter
information is not being received from the
Implement ECM over the Cat Data Link, the
Transmission/Chassis ECM will simultaneously
activate a CID 0596 FMI 14 (Implement ECM)
diagnostic code and a CID 0248 FMI 14 (Cat Data
Link) diagnostic code.
154 RENR9004-07
i02839878 Note: The following test procedure may create other

diagnostic codes. Ignore these created diagnostic
MID 027 - CID 0262 - FMI 03 codes and clear the diagnostic codes when the
problem has been corrected.
SMCS Code: 1439-038
Conditions Which Generate This Code: THE SENSOR
B. Disconnect the connector of the machine harness

from the accumulator pressure sensor of the
service brake.
C. At the connector of the machine harness for the

sensor, measure the voltage from supply contact
A (wire L730-OR) to the return contact B (wire
L731-BR).
Expected Result:
The voltage measurement is 5.0 ± 0.5 DCV.
Results:
• OK – The voltage measurement is 5.0 ± 0.5 DCV.

The voltage is correct. Proceed to Test Step 4.
g01287820
Illustration 128
5 VDC Power Supply Connections • NOT OK – The voltage measurement is greater
than 5.0 ± 0.5 DCV. The measurement is not
This diagnostic code is associated with the ECM 5 correct. Proceed to Test Step 2.
volt power supply. The 5 volt power supply provides
power for the accumulator pressure sensor of the Test Step 2. CHECK THE POWER SUPPLY
service brake. The return circuit of the power supply AT THE ECM
is also used by the left joystick.
The CID 0262 FMI 03 diagnostic code is active when switch to the OFF position.
the ECM detects that the voltage of the 5 volt power
supply circuit is higher than normal. B. At ECM connector J1, use a 151-6320 Removal
Tool to remove the supply wire and the socket at
The following conditions could cause this diagnostic contact J1-11 (wire L730-OR) and the return wire
code to be active: and the socket at contact J1-21 (wire L731-BR)
from the connector. The machine harness
• The power supply circuit is shorted to a higher connector J1 remains connected to the ECM.
voltage source.
• The ECM has failed. This is unlikely. switch to the ON position.
Note: Before performing this procedure, inspect D. Use the multimeter probes in order to make
the harness connectors that are involved in the contact at the connector pins of the ECM. Measure
circuit. Poor connections can often be the cause the voltage at the ECM pins between the contact
of a problem in an electrical circuit. Verify that of the power supply J1-11 and the return contact
all connections in the circuit are clean, that all J1-21.
are in good condition. If a problem with a Expected Result:
verify that this diagnostic code is active before The voltage measurement is 5.0 ± 0.5 DCV.
RENR9004-07 155
Results: Repair: The power supply circuit is shorted to

another circuit in the machine harness. Refer to
• OK – The voltage measurement is 5.0 ± 0.5 DCV. the complete Electrical System Schematic of the
The voltage is correct. The ECM power supply is machine. Examine the supply circuit in order to
correct. Install the wires and sockets that were determine the possible location for the problem.
removed from the J1 connector in the original
locations. Proceed to Test Step 3. For information on testing for short circuits and
• NOT OK – The voltage measurement is greater “Wiring Harness (Short Circuit) - Test”. Repair the
than 5.0 ± 0.5 DCV. The ECM power supply is not machine harness or replace the machine harness.
correct.
STOP.
Repair: Prior to replacing an ECM, always
contact your dealership's Technical Communicator Test Step 4. CHECK THE STATUS OF THE
for possible consultation with Caterpillar. This DIAGNOSTIC CODE
the ECM requires replacement, refer to Testing A. Inspect the harness connectors. Clean the
and Adjusting, “Electronic Control Module (ECM) contacts of the harness connectors. Check the
- Replace”. wires for damage to the insulation that is caused
STOP.
Test Step 3. CHECK FOR A SHORT wires that are associated with the sensor circuit.
CIRCUIT IN THE MACHINE HARNESS
The machine harness connector remains the connectors are fully seated. Observe that the
disconnected from the sensor. clips for each connector are completely fastened.
A. Turn the disconnect switch and the key start D. Turn the disconnect switch and the key start
switch to the OFF position. switch to the ON position.
B. Disconnect the machine harness connectors J1 E. Operate the machine.

and J2 from the ECM.
C. At the harness connector J1, check the resistance is active.
from contact J1-11 (wire L730-OR) to all of the
other ECM +battery (wire 126-RD) contacts that Expected Result:
are connected to the ECM. The contacts are
J1-31, J1-38, J1-39, J1-46 and J1-47. The CID 0262 FMI 03 diagnostic code is active.
D. At the harness connector J1, check the resistance Results:

from contact J1-11 (wire L730-OR) to all of the
other contacts that are used in connectors J1 and • YES – The CID 0262 FMI 03 diagnostic code is
J2. active. The problem has not been corrected.
Expected Result: Repair: Check the circuit again. Use the Caterpillar
Each resistance measurement is greater than 5000 in order to perform a wiggle test on the machine
ohms. wiring harness. The wiggle test can detect
Results: machine wiring harness.
• OK – Each resistance measurement is greater If the cause of the problem is not found, replace
than 5000 ohms. The supply circuit is not shorted the pressure sensor. After the sensor is replaced,
to another circuit in the machine harness. Proceed perform this test step again.
to Test Step 4.

short in the machine harness.
156 RENR9004-07
If the problem is still present after the sensor The following conditions could cause this diagnostic
has been replaced, the ECM may have failed. code to be active:
dealership's Technical Communicator for possible • A sensor has failed.
consultation with Caterpillar. This consultation may
greatly reduce repair time. If the ECM requires • The sensor supply circuit is shorted to a ground
replacement, refer to Testing and Adjusting, source.
“Electronic Control Module (ECM) - Replace”.
STOP.
• NO – The CID 0262 FMI 03 diagnostic code is not the harness connectors that are involved in the
active. The problem does not exist at this time. circuit. Poor connections can often be the cause
Repair: The initial diagnostic code was probably all connections in the circuit are clean, that all
caused by a poor electrical connection or a connections are secure and that all connections
short at one of the harness connectors that was are in good condition. If a problem with a
disconnected and reconnected. Resume normal connection is found, correct the problem and
machine operation. verify that this diagnostic code is active before
STOP.
Note: The following test procedure may create other
i02839871
MID 027 - CID 0262 - FMI 04 problem has been corrected.
SMCS Code: 1439-038 Test Step 1. CHECK THE SENSOR
Conditions Which Generate This Code: A. Turn the key start switch and the disconnect
B. Disconnect the accumulator pressure sensor of

the service brake from the machine harness.
C. After disconnecting the sensor, check the status

of the CID 262 FMI 04 diagnostic code.
Expected Result:

active.
Results:
• OK – The diagnostic code is not active. The

harness circuit is correct. The sensor that was just
disconnected has failed.
Repair: Replace the sensor. Verify that the new

sensor corrected the problem before operating the
g01287820
machine.
Illustration 129
5 VDC Power Supply Connections STOP.
This diagnostic code is associated with the ECM 5 • NOT OK – The diagnostic code is still active. The
volt power supply. The 5 volt power supply provides sensor is not causing the problem. Proceed to Test
power for the accumulator pressure sensor of the Step 2.
service brake. The return circuit of the power supply
is also used by the left joystick. Test Step 2. CHECK THE POWER SUPPLY
AT THE ECM
The CID 0262 FMI 04 diagnostic code is active when
the ECM detects that the voltage of the power supply A. Turn the disconnect switch and the key start
circuit is below normal. switch to the OFF position.
RENR9004-07 157
B. At ECM connector J1, use a 151-6320 Removal Results:

Tool to remove the supply wire and the socket at
contact J1-11 (wire L730-OR) and the return wire • OK – Each resistance measurement is greater
and the socket at contact J1-21 (wire L731-BR) than 5000 ohms. The harness circuit resistance is
from the connector. The machine harness correct. Proceed to Test Step 4.
connector J1 remains connected to the ECM.
C. Turn the disconnect switch and the key start measurements is less than 5000 ohms. The circuit
switch to the ON position. is shorted in the machine harness.
D. Use the multimeter probes in order to make Repair: The power supply wire L730-OR is
contact on the connector pins of the ECM. shorted to ground in the machine harness. Refer
Measure the voltage at the ECM pins between the to the complete Electrical System Schematic for
contact of the power supply J1-11 and the return your machine. Check all harness connectors that
contact J1-21. are in the power supply circuit. Ensure that the
connectors are clean and secure.
Expected Result:
The voltage measurement is 5.0 ± 0.5 DCV. finding short circuits, refer to Testing and Adjusting,
Results: machine harness or replace the machine harness.
• OK – The voltage measurement is 5.0 ± 0.5 DCV. STOP.

The voltage is correct. The ECM power supply
is correct. Install the wires and the sockets that Test Step 4. CHECK THE STATUS OF THE
were removed from the J1 connector in the original DIAGNOSTIC CODE
locations. Proceed to Test Step 3.
• NOT OK – The voltage measurement is less than contacts of the harness connectors. Check the
5.0 ± 0.5 DCV. The ECM power supply is not wires for damage to the insulation that is caused
correct. by excessive heat, battery acid, or chafing.
Repair: Prior to replacing an ECM, always B. Perform a 45 N (10 lb) pull test on each of the
contact your dealership's Technical Communicator wires that are associated with the sensor circuit.
for possible consultation with Caterpillar. This
consultation may greatly reduce repair time. If C. Reconnect all harness connectors. Make sure that
the ECM requires replacement, refer to Testing the connectors are fully seated. Observe that the
and Adjusting, “Electronic Control Module (ECM) clips for each connector are completely fastened.
- Replace”.
STOP. switch to the ON position.
Test Step 3. CHECK FOR A SHORT TO E. Operate the machine.

GROUND
A. Turn the key start switch and the disconnect is active.
Expected Result:
and J2 from the ECM. The CID 0262 FMI 04 diagnostic code is active.
C. At the harness connector for the ECM, measure Results:

the resistance between contact of the supply J1-11
(wire L730-OR) and frame ground. Measure the • YES – The CID 0262 FMI 04 diagnostic code is
resistance between contact of the supply J1-11 active. The problem has not been corrected.
J1 and J2 connectors for the ECM. Repair: Check the circuit again. Use the Caterpillar
Expected Result: in order to perform a wiggle test on the machine
Each resistance measurement is greater than 5000 momentary or intermittent shorts or opens in the
ohms. machine wiring harness.
158 RENR9004-07
If the cause of the problem is not found, the ECM During normal operation, one of the inputs is not
may be activating the diagnostic code incorrectly. connected to ground and the other input is connected
The ECM may have failed. to ground through the switch contacts. An internal
pull-up voltage is present at the ECM switch inputs.
Prior to replacing an ECM, always contact your When the input is grounded through the switch, the
dealership's Technical Communicator for possible ECM detects the ground signal.
greatly reduce repair time. If the ECM requires The FMI 03 diagnostic code is activated by the ECM
replacement, refer to Testing and Adjusting, when neither of the inputs is showing a ground signal.
STOP. this diagnostic code are listed below:
• NO – The CID 0262 FMI 04 diagnostic code is not • The switch has failed.
active. The problem does not exist at this time.
• The common ground circuit has an open or a bad
Repair: The initial diagnostic code was probably connection.
short at one of the harness connectors that was • There is an open or a bad connection in one or
disconnected and reconnected. Resume normal both of the switch input circuits.
machine operation.
STOP.
i02915156
MID 027 - CID 0368 - FMI 03 of a problem in an electrical circuit. Verify that
SMCS Code: 7332-038-T3 connections are secure and that all connections
Conditions Which Generate This Code: connection is found, correct the problem and


Table 20
States of Contact for the Transmission
Auto/Manual Switch
Switch Position “N/O” Input J2-47 “N/C” Input J2-52
(wire U726-GY) (wire U725-GN)
Autoshift OFF Open(2) Closed(1)
Autoshift ON Closed Open
(2) Open to ground (wire A202-BK).
(1) Closed to ground (wire A202-BK)
g01376083
Illustration 130 A. Turn the key start switch and the disconnect
Connections of the Transmission Auto/Manual Switch switch to the OFF position.
The auto/manual switch of the transmission is a B. Disconnect the machine harness connector from
two pole, double-throw switch. One pole is used to the switch.
provide two switch to ground inputs to the ECM in
order to indicate the status of the switch. The other
pole of the switch is not used for operations of the
ECM.
RENR9004-07 159
C. With the switch in the ON position, measure the Results:

resistance from common contact of the switch (2)
to input contact of the switch (1). Compare the • OK – The resistance measurement is less than 5
measurement of the status of the switch to the ohms. The common ground circuit of the switch is
table above. correct. Proceed to Test Step 3.
D. With the switch in the ON position, measure the • NOT OK – The resistance measurement is greater
resistance from common contact of the switch (2) than 5 ohms. There is an open or a bad connection
to the input contact of the switch (3). Compare the in the common ground circuit of the switch (wire
measurement of the status of the switch to the A202-BK).
table above.
E. Move the switch to the OFF position and repeat than 5000 ohms could indicate that a wire is not
Steps “C” and “D”. connected. A resistance measurement of greater
than 5000 ohms could also indicate that a wire has
Expected Result: an open connection. A resistance measurement
that is greater than 5 ohms but less than 5000
The resistance measurements in each position of ohms could indicate that one of the connection
the switch are correct according to the table at the points or splice connection in the ground circuit
beginning of this test step. does not have an open connection but does not
have a good connection.
Results:
• YES – All of the resistance checks for the switch of the machine. Check all of the connectors that are
are correct in each switch position according to the in the ground circuit. Start from the switch. Work
table. The switch is working correctly. Proceed to your way back to the connections for the ground
Test Step 2. terminal, located at the rear of the cab. Ensure
that all connections are clean, that all connections
• NO – The states of the switch are not correct are secure and that all connections are in good
according to the table. The switch has failed. condition. Repair the machine harness or replace
the machine harness.
Repair: Replace the transmission auto/manual
switch. After the switch is replaced, verify that the STOP.
switch operation is correct before operating the
machine. Test Step 3. CHECK THE INPUT CIRCUITS
OF THE SWITCH FOR AN OPEN
STOP.
Test Step 2. CHECK THE SWITCH OF remain in the OFF position. The machine harness
THE COMMON GROUND CIRCUIT FOR remains disconnected from the switch.
AN OPEN
The key start switch and the disconnect switch place a jumper wire between input contact 1 (wire
remain in the OFF position. The machine harness U725-GN) and input contact 3 (wire U726-GY).
remains disconnected from the switch.
A. At the machine harness connector for the switch, and J2 from the ECM.
measure the resistance from common ground
contact of the switch 2 (wire A202-BK) to frame C. At the machine harness connector for the ECM
ground. J2, measure the resistance between the input
contact of the switch J2-52 (wire U725-GN) and
B. Observe the resistance measurement of the input contact of the switch J2-47 (wire U726-GY).
multimeter as you wiggle the machine harness
connector for the switch. Gently pull on the wires D. Observe the resistance measurement of the
and wiggle the wires. multimeter and wiggle the machine harness
Expected Result: and wiggle the wires.
The resistance measurement is less than 5 ohms at E. Observe the resistance measurement of the
all times during the manipulation of the harness. multimeter and wiggle the machine harness
connector for the switch. Gently pull on the wires
and wiggle the wires. Do not disconnect the
jumper wire.
160 RENR9004-07
Expected Result: D. Turn the disconnect switch and the key start
The resistance measurement is less than 5 ohms at
all times during the manipulation of the harness. E. Operate the machine.
Results: F. Check the status of the CID 0368 FMI 03

diagnostic code.
• OK – The resistance measurement is less than 5
ohms. The inputs circuits of the switch are not open Expected Result:
in the machine harness. Proceed to Test Step 4.
than 5 ohms. There is a problem with one or both Results:
of the switch input circuits in the machine harness.
• YES – The CID 0368 FMI 03 diagnostic code
Repair: Refer to the illustration of the connection is active. The diagnostic code has not been
diagram at the beginning of this procedure. corrected.
Connect one end of the jumper wire to the harness Repair: Check the input circuits of the switch
connector of the switch, common ground contact 2 again. Use the Caterpillar Electronic Technician
(wire A202-BK. (ET) service tool, if available, in order to perform
a wiggle test on the wiring harness of the
One at a time, connect the other end of the jumper machine. The wiggle test can detect momentary or
wire to each switch input and check the resistance intermittent shorts or opens in the machine wiring
at the harness connector for the ECM J1 from the harness.
appropriate input contact to one of the ground
contacts (wire A202-BK) that are used on the J1 If the cause can not be found, the ECM may
connector. This will identify the input circuit that have failed. Verify that all possible causes of the
has an open or a bad connection. diagnostic code have been investigated before
replacement of the ECM.
A resistance measurement that is greater than
5000 ohms could indicate a wire that is not Prior to replacing an ECM, always contact your
connected or a wire that is open. A resistance dealership's Technical Communicator for possible
measurement that is greater 5 ohms but less consultation with Caterpillar. This consultation
than 5000 ohms could indicate that one of the may greatly reduce repair time. If the cause of the
connection points in the circuit has an open or a diagnostic code is not found, replace the ECM.
poor connection. Refer to Testing and Adjusting, “Electronic Control
of the machine. Check all of the connectors STOP.
that are in the faulty input circuit. Ensure that
all connections are clean, that all connectors • NO – The CID 0368 FMI 03 is not active. The
are secure and that all connectors are in good diagnostic code does not exist at this time.
the machine harness. Repair: The initial diagnostic code was probably
STOP. short at one of the harness connectors that was
Test Step 4. CHECK THE STATUS OF THE machine operation.
DIAGNOSTIC CODE
STOP.


RENR9004-07 161
i02915216 Note: Before performing this procedure, inspect

MID 027 - CID 0368 - FMI 04 circuit. Poor connections can often be the cause
SMCS Code: 7332-038-T3 all connections in the circuit are clean, that all
Conditions Which Generate This Code: are in good condition. If a problem with a


Table 21
States of Contact for the Transmission
Auto/Manual Switch
Switch Position N/O Input J2-47 N/C Input J2-52
(wire U726-GY) (wire U725-GN)
Autoshift OFF Open(2) Closed(1)
Autoshift ON Closed Open
(2) Open to ground (wire A202-BK).
g01376083 (1) Closed to ground (wire A202-BK).
Illustration 131
“Transmission Auto/Manual” switch connections
The “transmission auto/manual” switch is a two pole, switch to the OFF position.
double-throw switch. One pole is used to provide
two switch to ground inputs to the ECM in order to B. Disconnect the machine harness connector from
indicate the status of the switch. The other pole of the the switch.
switch is not used for operations of the ECM.
C. With the switch in the ON position, measure the
During normal operation, one of the inputs is not resistance from the common contact of the switch
connected to ground and the other input is connected (2) to the input contact of the switch (1). Compare
to ground through the switch contacts. An internal the measurement of the switch to the table above.
pull-up voltage is present at the ECM switch inputs.
When the input is grounded through the switch, the D. With the switch in the ON position, measure the
ECM detects the ground signal. resistance from the common contact of the switch
(2) to the input contact of the switch (3). Compare
The FMI 04 diagnostic code is activated by the ECM the status of the switch to the table above.
when both of the inputs are showing a ground signal
at the same time. E. Move the switch to the OFF position and repeat
this diagnostic code are listed below: Expected Result:
The measurements of resistance for each of the

• The switch has failed. positions of the switch agree with the status shown in
the table at the beginning of this test step.
Results:
• YES – All of the resistance checks for the switch
are correct in each switch position according to
the table above. The switch is working correctly.
162 RENR9004-07
• NO – The states of the switch are not correct For information on testing for short circuits and
according to the table. The switch has failed. finding short circuits, refer to Testing and Adjusting,
Repair: Replace the “Transmission Auto/Manual” machine harness or replace the machine harness.
switch. After the switch is replaced, verify that the
switch operation is correct before operating the STOP.
machine.
STOP. DIAGNOSTIC CODE
Test Step 2. CHECK THE INPUT CIRCUITS A. Inspect the harness connectors. Clean the
OF THE SWITCH FOR A SHORT contacts of the harness connectors. Check the
The key start switch and the disconnect switch by excessive heat, battery acid, or chafing.
remains disconnected from the switch. B. Perform a 45 N (10 lb) pull test on each of the
A. Disconnect the machine harness connectors J1
and J2 from the ECM. C. Reconnect all harness connectors. Make sure that
B. At the machine harness connector J2 for the ECM, clips for each connector are completely fastened.
measure the resistance between input contact of
the switch J2-52 (wire U725-GN) and the frame D. Turn the disconnect switch and the key start
ground. Measure the resistance between input switch to the ON position.
contact of the switch J2-52 (wire U725-GN) and all
of the other contacts that are used in the J1 and E. Operate the machine.
J2 harness connectors for the ECM.
C. At the machine harness connector J2 for the ECM, diagnostic code.
measure the resistance between input contact of
the switch J2-47 (wire U726-GY) and the frame Expected Result:
ground. Measure the resistance between input
contact of the switch J2-47 (wire U726-GY) and all The CID 0368 FMI 04 diagnostic code is active.
of the other contacts that are used in the J1 and
J2 harness connectors for the ECM. Results:
Expected Result: • YES – The CID 0368 FMI 04 diagnostic code

Each resistance measurement is greater than 5000 corrected.
ohms.
Results: again. Use the Caterpillar Electronic Technician
• OK – Each resistance measurement is greater a wiggle test on the machine wiring harness. The
than 5000 ohms. The input circuits of the switch wiggle test can detect momentary or intermittent
are not shorted to ground or to another circuit in shorts or opens in the machine wiring harness.
the machine harness. Proceed to Test Step 3.
If the cause can not be found, the ECM may
• NOT OK – One or more of the resistance have failed. Verify that all possible causes of the
measurements is less than 5000 ohms. There is a diagnostic code have been investigated before
short to ground or to another circuit in the machine replacement of the ECM.
harness.
Repair: The input circuit that checks the low dealership's Technical Communicator for possible
resistance to frame ground or to another circuit is consultation with Caterpillar. This consultation
causing the problem. may greatly reduce repair time. If the cause of the
Refer to the complete Electrical System Schematic Refer to Testing and Adjusting, “Electronic Control
of the machine. Check all of the connectors Module (ECM) - Replace”.
all connections are clean, that all connections STOP.
are secure and that all connections are in good
condition.
RENR9004-07 163
• NO – The CID 0368 FMI 04 is not active. The The conditions that could cause this diagnostic code
diagnostic code does not exist at this time. to activate are listed:
Repair: The initial diagnostic code was probably • The relay has failed.
short at one of the harness connectors that was • The energize circuit of the relay is shorted to
disconnected and reconnected. Resume normal another voltage source.
machine operation.
STOP.
i02915576
MID 027 - CID 0420 - FMI 03 of a problem in an electrical circuit. Verify that
SMCS Code: 4493-038-ZH connections are secure and that all connections
Conditions Which Generate This Code: connection is found, correct the problem and

Test Step 1. CHECK THE RELAY

B. Observe the status of the active CID 0420 FMI

03 diagnostic code and disconnect the relay for
secondary steer from the machine harness.

Expected Result:


to 396 ohms at 25 °C (77 °F).
The resistance measurement between the power

contact 87 and all the other relay contacts is greater
then 5000 ohms.
g01288273
Illustration 132 Results:
Relay Connections for Secondary Steer
• YES – All of the checks for the relay are correct.
This diagnostic code is associated with the relay The relay is not causing the problem. The CID
for secondary steer. The relay is controlled by the 0420 FMI 03 diagnostic code is still active. Proceed
ECM through an “ON/OFF” output driver. The FMI 03 to Test Step 2.
means that the ECM has determined that the voltage
is present in the relay circuit when the output driver is
OFF.
164 RENR9004-07
• NO – The active CID 0420 FMI 03 diagnostic code Test Step 3. CHECK THE STATUS OF THE
became inactive when the relay was disconnected. DIAGNOSTIC CODE
The resistance checks are not correct compared
to the expected results listed above. The relay has A. Inspect the harness connectors. Clean the
failed. contacts of the harness connectors. Check the
Repair: Verify that the relay has failed by by excessive heat, battery acid, or chafing.
part number for the faulty relay. The relay for the B. Perform a 45 N (10 lb) pull test on each of the
flood lights of the cab can be substituted. Replace wires that are associated with the circuit.
the faulty relay.
C. Reconnect all harness connectors in order to
STOP. make sure that the connectors are fully seated.
Observe that the clips for each connector are
Test Step 2. CHECK THE ENERGIZE completely fastened.
The relay remains disconnected from the machine switch to the ON position.
harness.
switch to the OFF position. F. Determine if the CID 0420 FMI 03 diagnostic code
is active.
and J2 from the Transmission/Chassis ECM. Expected Result:
C. At the machine harness connector J2 for the ECM, The CID 0420 FMI 03 diagnostic code is active.
T969-YL) to all of the other contacts that are used Results:
in the machine harness connectors J1 and J2 for
the ECM. • YES – The CID 0420 FMI 03 diagnostic code is
Expected Result:
Each resistance measurement is greater than 5000 Caterpillar Electronic Technician (ET) service tool,
ohms. if available, in order to perform a wiggle test on the
Results: momentary or intermittent shorts or opens in the
than 5000 ohms. The energize circuit is not shorted If the cause of the problem is not found, the ECM
to another circuit in the machine harness. Proceed may have failed.
to Test Step 3.
• NOT OK – Each resistance measurement is not dealership's Technical Communicator for possible
greater than 5000 ohms. There is a short in the consultation with Caterpillar. This consultation
machine harness. The short is between wire may greatly reduce repair time. If the cause of the
T969-YL and the circuit that has a low resistance diagnostic code is not found, replace the Machine
measurement. ECM. Refer to Troubleshooting, “Electronic Control
Schematic of the machine. Check all of the STOP.
connectors that are in the relay circuit. Ensure
that all connections are clean, that all connections • NO – The CID 0420 FMI 03 diagnostic code is not
are secure and that all connections are in good active. The problem does not exist at this time.
condition.
For information on testing for short circuits and caused by a poor electrical connection or a short
finding short circuits, refer to Testing and Adjusting, at one of the harness connectors or a short at
“Wiring Harness (Short Circuit) - Test”. Repair the the base of the relay that was disconnected and
machine harness or replace the machine harness. reconnected. Resume normal machine operation.
STOP. STOP.
RENR9004-07 165
i02915696 Note: Before performing this procedure, inspect

SMCS Code: 4493-038-ZH all connections in the circuit are clean, that all



the relay.
C. At the harness connector for the relay, connect

a jumper wire between contact 5 (wire T969-YL)
and contact 2 (wire J765-BU).


05 diagnostic code.
Expected Result:
The active CID 0420 FMI 05 diagnostic code is no

longer active when the key start switch is turned ON.
A CID 0420 FMI 06 diagnostic code is now active.
Results:
g01288273
Illustration 133
Relay Connections for Secondary Steer • YES – The CID 0420 FMI 05 diagnostic code is
This diagnostic code is associated with the relay code becomes active when the key start switch is
for secondary steer. The relay is controlled by the turned ON.
ECM through an “ON/OFF” output driver. The FMI
05 means that the ECM has energized the output Repair: The relay is causing the problem. Verify
for the relay and the current for the relay circuit is that the relay has failed by substituting a known
below normal. good relay that is the same part number as the
faulty relay. The relay for the flood lights of the cab
The conditions that could cause this diagnostic code can be substituted for the suspect relay. Replace
to activate are listed below: the faulty relay.
STOP.
• The energize circuit of the relay has an open or a • NO – The jumper wire does not affect the status of
bad connection in the machine harness. the active CID 0420 FMI 05 diagnostic code when
the key start switch is turned ON. The relay is not
166 RENR9004-07
Test Step 2. CHECK THE CIRCUIT OF Refer to the complete Electrical System Schematic
THE RELAY FOR AN OPEN of the machine. Check all of the connectors that
are in the circuit. Ensure that all connections are
The relay remains disconnected from the machine clean, that all connections are secure and that all
harness. The jumper wire remains connected connections are in good condition.
between contact 5 and contact 2.
A. Turn the key start switch and the disconnect connector for the faulty circuit. Check the wire for
switch to the OFF position. an open or a bad connection point by working
your way through the circuit in order to isolate the
B. Disconnect the machine harness connectors J1 location of the suspect wire or connection. Repair
and J2 from the Transmission/Chassis ECM. the machine harness or replace the machine
harness.
measure the resistance between contact J2-2 STOP.
(wire T969-YL) and contact J2-4 (wire J765-GN).
D. At the machine harness connector J2 for the ECM, DIAGNOSTIC CODE
measure the resistance between contact J2-2
(wire T969-YL) and contact J2-8 (wire J765-GN). A. Inspect the harness connectors. Clean the
Expected Result: wires for damage to the insulation that is caused
Both resistance measurements are less than 5 ohms.
Results: wires that are associated with the circuit.
• OK – The resistance measurements are less than C. Reconnect all the harness connectors and make
5 ohms. The energize circuit and the return circuit sure that the connectors are fully seated. Observe
are not open in the machine harness. Proceed to that the clips for each connector are completely
Test Step 3. fastened.
• NOT OK – One or both of the resistance D. Turn the disconnect switch and the key start
measurements is greater than 5 ohms. There is an switch to the ON position.
open or a bad connection in the machine harness.
than 5000 ohms could indicate that a wire is not F. Determine if the CID 0420 FMI 05 diagnostic code
connected or that a wire is open. A resistance is active.
than 5000 ohms could indicate that one of the Expected Result:
connection points or a splice connection in the
circuit is not open but is not a good connection. The CID 0420 FMI 05 diagnostic code is active.
If one of the resistance measurements is greater Results:

than 5 ohms and the other measurement is less
than 5 ohms, one of the return circuits is not • YES – The CID 0420 FMI 05 diagnostic code is
correct. This will not cause the diagnostic code active. The problem has not been corrected.
to activate as the other return circuit is working
correctly, however, this is a problem that needs to Repair: Check the relay circuit again. Use the
be investigated and corrected. Caterpillar Electronic Technician (ET) service tool,
If both measurements are greater than 5 ohms, wiring harness of the machine. The wiggle test can
determine whether the energize circuit or the return detect momentary or intermittent shorts or opens
circuit is causing the problem. Disconnect the in the machine wiring harness.
jumper wire. Use a spare length of wire in order to
check the resistance of the energize circuit and the If the cause of the problem is not found, the ECM
return circuit individually. may have failed.
RENR9004-07 167
Prior to replacing an ECM, always contact your i02915968

consultation with Caterpillar. This consultation MID 027 - CID 0420 - FMI 06
diagnostic code is not found, replace the Machine SMCS Code: 4493-038-ZH
ECM. Refer to Troubleshooting, “Electronic Control
Module (ECM) - Replace”. Conditions Which Generate This Code:
STOP.


caused by a poor electrical connection or a short
at one of the harness connectors or at the base of
the relay that was disconnected and reconnected.
Resume normal machine operation.
STOP.
g01288273
Illustration 134
Relay Connections for Secondary Steer
This diagnostic code is associated with the relay for

the secondary steer. The relay is controlled by the
ECM through an “ON/OFF” output driver. The FMI
06 means that the ECM has energized the output
for the relay and the current for the relay circuit is
above normal.

to activate are listed:

• The energize circuit of the relay is shorted to a
ground source.

168 RENR9004-07
Note: Before performing this procedure, inspect C. At the machine harness connector J2 for the
the harness connectors that are involved in the ECM, measure the resistance from contact J2-2
circuit. Poor connections can often be the cause (wire T969-YL) to frame ground. Measure the
of a problem in an electrical circuit. Verify that resistance from contact J2-2 (wire T969-YL) to all
all connections in the circuit are clean, that all of the other contacts that are used in the machine
connections are secure and that all connections harness connectors J1 and J2 for the ECM.
connection is found, correct the problem and Expected Result:
performing this procedure. Each resistance measurement is greater than 5000
ohms.
other diagnostic codes to be activated. Ignore these Results:
codes when the problem has been corrected. • OK – Each resistance measurement is greater
than 5000 ohms. The energize circuit is not shorted
Test Step 1. CHECK THE RELAY to another circuit in the machine harness. Proceed
to Test Step 3.
switch to the ON position. • NOT OK – Each resistance measurement is not
greater than 5000 ohms. There is a short in the
B. Observe the status of the active CID 0420 FMI machine harness. The short is between wire
06 diagnostic code and disconnect the machine T969-YL and the circuit that has a low resistance
harness connector from the relay. measurement.
Expected Result: Repair: Refer to the complete Electrical System

Schematic of the machine. Check all of the
When the relay is disconnected from the harness, the connectors that are in the relay circuit. Ensure
CID 0420 FMI 06 diagnostic code is no longer active. that all connections are clean, that all connections
A CID 0420 FMI 06 is now active. are secure and that all connections are in good
condition.
Results:
• YES – When the relay is disconnected from the finding short circuits, refer to Testing and Adjusting,
harness, the CID 0420 FMI 06 diagnostic code is “Wiring Harness (Short Circuit) - Test”. Repair the
no longer active. A CID 0420 FMI 05 diagnostic machine harness or replace the machine harness.
code becomes active. The relay is causing the
problem. STOP.
Repair: Verify that the relay has failed by Test Step 3. CHECK THE STATUS OF THE
substituting a known good relay that is the same DIAGNOSTIC CODE
part number as the faulty relay. The relay used for
the flood lights of the cab can be substituted for the A. Inspect the harness connectors. Clean the
suspect relay. Replace the faulty relay. contacts of the harness connectors. Check the
STOP. by excessive heat, battery acid, or chafing.
• NO – The status of the active CID 0420 FMI 06 B. Perform a 45 N (10 lb) pull test on each of the
diagnostic code did not change when the relay was wires that are associated with the circuit.
disconnected from the machine harness. The relay
is not causing the problem. Proceed to Test Step 2. C. Reconnect all harness connectors in order to
make sure that the connectors are fully seated.
Test Step 2. CHECK THE ENERGIZE Observe that the clips for each connector are
CIRCUIT OF THE RELAY FOR A SHORT completely fastened.
The relay remains disconnected from the machine D. Turn the disconnect switch and the key start
harness. switch to the ON position.
A. Turn the key start switch and the disconnect E. Operate the machine.
B. Disconnect the machine harness connectors J1 is active.
and J2 from the Transmission/Chassis ECM.
RENR9004-07 169
Expected Result: i02916173
The CID 0420 FMI 06 diagnostic code is active. MID 027 - CID 0444 - FMI 03
Results: SMCS Code: 1426-038
• YES – The CID 0420 FMI 06 diagnostic code is Conditions Which Generate This Code:


may have failed.

diagnostic code is not found, replace the Machine
ECM. Refer to Troubleshooting, “Electronic Control
STOP.
g01324002
Illustration 135
• NO – The CID 0420 FMI 06 diagnostic code is not Power Breaker Box located on left side of machine behind the Cab
active. The problem does not exist at this time. (1) Accugrade Breaker (20 Amp)
Repair: The initial diagnostic code was probably (3) Key Switch Breaker (15 Amp)
caused by a poor electrical connection or a short (4) Engine Control Breaker (20 Amp)
at one of the harness connectors or at the base of (5) Alternator Breaker (150 Amp)
the relay that was disconnected and reconnected. (7) Main Breaker (80 Amp)
Resume normal machine operation. (8) Start Relay
(9) Main Power Relay
STOP.
170 RENR9004-07


the relay for the starter motor.
C. At the connector for the relay, measure the

resistance of the coil between contact 1 and
contact 2.
Expected Result:
The resistance of the relay coil should measure

approximately 27.5 ± 3 ohms at 20 °C (68.0 °F).
Results:
• OK – The resistance measurement of the relay

coil is within the acceptable range. Proceed to Test
Step 2.
• NOT OK – The resistance measurement of the

relay coil is NOT within the acceptable range.
Repair: The relay coil is not correct. Replace the

relay for the starter motor. After the relay has been
g01288379
Illustration 136 replaced, verify that the new relay corrected the
Starter Motor Relay connections problem before operating the machine.
This diagnostic code is associated with the starter STOP.

motor relay. The FMI 03 means that the ECM has
determined that voltage is present in the relay circuit Test Step 2. CHECK THE ENERGIZE
when the output driver is OFF. CIRCUIT OF THE RELAY FOR A SHORT
The possible causes of the diagnostic code are listed The key start switch and the disconnect switch
below: remain in the OFF position. The machine harness
connector remains disconnected from the relay.
A. Disconnect the harness connectors J1 and J2
• The power circuit of the relay is shorted to another from the ECM.
voltage source.
• The ECM has failed. This is unlikely. the diode for the arc suppressor.
Note: Before performing this procedure, inspect C. At the machine harness connector for the ECM,
the harness connectors that are involved in the measure the resistance from contact J2-7 (wire
circuit. Poor connections can often be the cause 306-GN) to all of the contacts that are used in the
of a problem in an electrical circuit. Verify that machine harness connectors for the ECM.
connections are secure and that all connections Expected Result:
connection is found, correct the problem and Each resistance measurement is greater than 5000
verify that this diagnostic code is active before ohms.
Results:
Note: The following test procedure may cause other
diagnostic codes to activate. Ignore these created • OK – Each resistance measurement is greater
diagnostic codes and clear these diagnostic codes than 5000 ohms. The machine harness is correct.
when the original problem has been corrected. Proceed to Test Step 3.
RENR9004-07 171
• NOT OK – Each resistance measurement is not If the cause can not be found, the ECM may
greater than 5000 ohms. There is a short in the have failed. Prior to replacing an ECM, always
machine harness. The short is between wire contact your dealership's Technical Communicator
306-GN and the circuit that has a low resistance for possible consultation with Caterpillar. This
measurement. consultation may greatly reduce repair time. If the
cause of the diagnostic code is not found, replace
Repair: Refer to the complete Electrical System the ECM that activated the diagnostic code. Refer
Schematic of the machine. Examine all of the to Testing and Adjusting, “Electronic Control
connectors in circuits for points in the machine Module (ECM) - Replace”.
harness where the circuits could be shorted.
For information on testing for short circuits and STOP.
“Wiring Harness (Short Circuit) - Test”. Repair the • NO – The CID 0444 FMI 03 diagnostic code is not
machine harness or replace the machine harness. active. The problem does not exist at this time.
STOP. Repair: The initial diagnostic code was probably

Test Step 3. CHECK THE STATUS OF THE short at one of the harness connectors that was
DIAGNOSTIC CODE disconnected and reconnected. Resume normal
machine operation.
contacts of the harness connectors. Check the STOP.
i02916178

MID 027 - CID 0444 - FMI 05
SMCS Code: 1426-038
the connectors are fully seated. Observe that the Conditions Which Generate This Code:


is active.
Expected Result:
Results:

Repair: Check the starter relay circuit again. Use

tool, if available, in order to perform a wiggle test g01324002
on the machine wiring harness. The wiggle test can Illustration 137
detect momentary or intermittent shorts or opens Power Breaker Box located on left side of machine behind the Cab
in the machine wiring harness. (1) Accugrade Breaker (20 Amp)
(3) Key Switch Breaker (15 Amp)
(7) Main Breaker (80 Amp)
(8) Start Relay
172 RENR9004-07

Note: The coil resistance of the start relay should

measure 27.5 ± 3 ohms at 20 °C (68.0 °F).

B. Disconnect the relay for the starter motor from the

machine harness.
C. At the machine harness connector for the relay,

place a jumper wire from contact 1 (wire 306-GN)
to contact 2 (wire J765-BU).

switch to the START position for a few seconds.
E. Observe the status of the CID 0444 FMI 05

diagnostic code.
Expected Result:
g01288379
Illustration 138 The CID 0444 FMI 05 diagnostic code is no longer
Starter Motor Relay connections active. A CID 0444 FMI 06 diagnostic code has been
activated when the jumper wire is installed.
This diagnostic code is associated with the relay for
the starter motor. The FMI 05 means that the ECM Results:
has determined that the current of the relay circuit is
below normal. • YES – The CID 0444 FMI 05 diagnostic is no
longer active. A CID 0444 FMI 06 becomes active
Conditions that can cause this diagnostic code are when the jumper wire is installed. The relay is
listed below: causing the problem.
• The relay has failed. Repair: The relay has failed. Repeat this Test Step
“CHECK THE RELAY” in order to verify the failure
• The energize circuit of the relay is an open of the relay.
connection or the circuit has a bad connection.
Check the resistance of the relay coil. Measure
• The return circuit of the relay is an open connection the resistance from contact 1 to contact 2 on the
or the circuit has a bad connection. relay connector. The resistance of a good relay coil
should be 27.5 ± 3 ohms at 20 °C (68.0 °F). The
• The ECM has failed. This is unlikely. likely cause of this problem is a greater resistance
of the relay coil.
the harness connectors that are involved in the Replace the relay. Verify that the new relay corrects
circuit. Poor connections can often be the cause the problem.
all connections in the circuit are clean, that all STOP.
are in good condition. If a problem with a • NO – The CID 0444 FMI 05 diagnostic remains
connection is found, correct the problem and active after the jumper wire has been installed. The
verify that this diagnostic code is active before jumper wire did not affect the status of the active
performing this procedure. diagnostic code. Proceed to Test Step 2.
RENR9004-07 173
Test Step 2. CHECK THE RELAY CIRCUIT A resistance measurement greater than 5000
FOR AN OPEN ohms could indicate a wire that is not connected or
a wire that is open. A resistance measurement that
The relay for the starter motor remains disconnected is greater 5 ohms but less than 5000 ohms could
from the machine harness. The jumper wire that was indicate that one of the connection points in the
installed in the previous test step remains in place. circuit is not an open connection but a connection
point that is not a good connection.
switch to the OFF position. If both measurements are greater than 5 ohms,
determine whether the energize circuit or the return
B. Disconnect the machine harness connector J2 circuit is causing the problem. Disconnect the
from the ECM. jumper wire. Use a spare length of wire in order to
check the resistance of the energize circuit and the
C. At the machine harness connector J2, measure return circuit individually.
the resistance from signal contact J2-7 (wire
306-GN) to contact J2-4 (wire J765-BU). Once the faulty circuit is identified, a poor
connection could be causing the problem. A
D. Observe the resistance measurement of the connector may be loose, dirty or corroded. Inspect
multimeter as you wiggle the machine harness the connectors that are in the circuit. Ensure that
connectors for the ECM. Observe the resistance all connectors are clean, that all connections are
measurement of the multimeter and wiggle the tight and that all connections are in good condition.
machine harness connector for the relay. Gently
pull on the wires and wiggle the wires. Repair the machine harness or replace the
machine harness.
E. At the machine harness connector J2, measure
the resistance from signal contact J2-7 (wire STOP.
306-GN) to contact J2-8 (wire J765-BU).
F. Observe the resistance measurement of the DIAGNOSTIC CODE
multimeter and wiggle the machine harness
connectors for the ECM. Observe the resistance A. Inspect the harness connectors. Clean the
measurement of the multimeter and wiggle the contacts of the harness connectors. Check the
machine harness connector for the relay. Gently wires for damage to the insulation that is caused
pull on the wires and wiggle the wires. by excessive heat, battery acid, or chafing.
Expected Result: B. Perform a 45 N (10 lb) pull test on each of the

The resistance measurement is less than 5 ohms at
all times during the manipulation of the harness and C. Reconnect all harness connectors and make sure
connectors. that the connectors are fully seated. Observe
that the clips for each connector are completely
Results: fastened.
• OK – The resistance is less than 5.0 ohms. The D. Turn the disconnect switch and the key start
machine harness is correct. Proceed to Test Step switch to the ON position.
3.
• NOT OK – The resistance is greater than 5 ohms.
The resistance measurement is not correct. There F. Check the status of the CID 0444 FMI 05
could be an open connection or a poor connection diagnostic code.
in the harness circuit of the machine.
Expected Result:
Repair: If one of the resistance measurements is
greater than 5 ohms and the other measurement The CID 0444 FMI 05 diagnostic code is active.
is less than 5 ohms, one of the return circuits is
not correct. This will not cause the diagnostic code Results:
to activate as the other return circuit is working
correctly. However, this is a problem that needs • YES – The CID 0444 FMI 05 diagnostic code
to be investigated. is active. The diagnostic code has not been
corrected.
174 RENR9004-07
Repair: Check the relay circuit again. Use the i02916190

if available, in order to perform a wiggle test on the MID 027 - CID 0444 - FMI 06
momentary or intermittent shorts or opens in the SMCS Code: 1426-038
have failed. Prior to replacing an ECM, always
consultation may greatly reduce repair time. If the
the ECM that activated the diagnostic code. Refer
to Testing and Adjusting, “Electronic Control
STOP.
• NO – The CID 0444 FMI 05 is not active. The


machine operation.
g01324002
STOP. Illustration 139
Power Breaker Box located on left side of machine behind the Cab
(1) Accugrade Breaker (20 Amp)
(3) Keyswitch Breaker (15 Amp)
(5) Alternator Circuit Breaker (150 Amp)
(7) Main Breaker (80 Amp)
(8) Start Relay
RENR9004-07 175
Note: The coil resistance of the start relay should

measure 27.5 ± 3 ohms at 20 °C (68.0 °F).
Test Step 1. CHECK THE DIODE FOR THE

ARC SUPPRESSOR
A. Turn the disconnect switch and the starter
keyswitch to the OFF position.
B. Disconnect the diode for the arc suppressor from

C. Check the resistance of the diode for the arc

suppressor between contact 1 and contact 2.
D. Check the resistance of the diode again. For this

check, reverse the placement of the multimeter
probes to the opposite contacts of the diode that
were checked in the previous step.
Expected Result:
The resistance measurement of the diode is less than

5 ohms when checked one way and the resistance
measurement is greater than 5000 ohms when the
multimeter probes are reversed.
g01288379
Results:
Illustration 140
Starter Motor Relay connections • YES – The resistance measurement of the diode
is less than 5 ohms when the diode is checked one
This diagnostic code is associated with the relay for way and the resistance measurement is greater
the starter motor. The FMI 06 means that the ECM than 5000 ohms when the multimeter probes are
has determined that the current of the relay circuit is reversed. The diode for the arc suppressor is not
above normal. shorted. Proceed to Test Step 2.
Conditions that can cause this diagnostic code are • NO – The resistance measurement of the diode is
listed below: less than 5 ohms when checked in one direction
and is still less than 5 ohms when the multimeter
• The diode for the arc suppressor has failed. probes are reversed. The diode is faulty.
• The relay has failed. Repair: Replace the diode of the arc suppressor.
After replacement of the diode, verify that the
• The energize circuit of the relay is shorted to a problem has been corrected before operating the
ground source. machine.
• The ECM has failed. This is unlikely. NOTE: If the resistance checks on the diode
indicate greater than 5000 ohms one way and
Note: Before performing this procedure, inspect greater than 5000 ohms when the multimeter
the harness connectors that are involved in the probes are reversed, the diode for the arc
circuit. Poor connections can often be the cause suppressor should be replaced. This condition
of a problem in an electrical circuit. Verify that would not cause this code to activate, however,
all connections in the circuit are clean, that all this condition needs to be corrected.
are in good condition. If a problem with a STOP.
verify that this diagnostic code is active before Test Step 2. CHECK THE RELAY
The diode for the arc suppressor remains
Note: The following test procedure may cause disconnected from the machine harness.
created diagnostic codes and clear the diagnostic A. Turn the disconnect switch and the key start
codes when the problem has been corrected. switch to the OFF position.
176 RENR9004-07
B. Disconnect the starter relay from the machine Expected Result:

harness.
C. Observe the status of the diagnostic code. Turn ohms.
the disconnect switch to the ON position and turn
the starter keyswitch to the START position for a Results:
few seconds.
Expected Result: than 5000 ohms. The machine harness is correct.
The active CID 0444 FMI 06 diagnostic code changes
to an active CID 0444 FMI 05 diagnostic code when • NOT OK – Each resistance measurement is not
the relay is disconnected. greater than 5000 ohms. There is a short in the
machine harness. The short is between wire
Results: 306-GN and the circuit with the low resistance
measurement.
• YES – The active CID 0444 FMI 06 diagnostic
code changes to an active CID 0444 FMI 05 Repair: Refer to the complete Electrical System
diagnostic code when the relay is disconnected. Schematic of the machine. Examine all of the
The circuit is correct. connectors in circuits for points in the machine
harness where the circuits could be shorted.
Repair: The relay has failed. Repeat this test For information on testing for short circuits and
“CHECK THE RELAY” in order to verify the failure finding short circuits, refer to Testing and Adjusting,
of the relay. “Wiring Harness (Short Circuit) - Test”. Repair the
Check the resistance of the relay coil. Measure
the resistance from contact 1 to contact 2 on the STOP.
relay connector. The resistance of a good relay coil
should be 27.5 ± 3 ohms at 20 °C (68.0 °F). To Test Step 4. CHECK THE STATUS OF THE
cause this problem, the resistance of the relay coil DIAGNOSTIC CODE
is most likely much less.
Replace the relay. Verify that the new relay corrects contacts of the harness connectors. Check the
the problem. wires for damage to the insulation that is caused
STOP.
• NO – The CID 0444 FMI 06 diagnostic code wires that are associated with the circuit.
remains active. Disconnecting the relay did not
change the status of the diagnostic code. Proceed C. Reconnect all connectors of the wiring harness.
to Test Step 3. Make sure that the connectors are fully seated.
Test Step 3. CHECK THE ENERGIZE completely fastened.
TO GROUND D. Turn the disconnect switch and the starter
keyswitch to the ON position.
The relay remains disconnected from the machine
harness. The diode for the arc suppressor remains E. Operate the machine.
disconnected from the machine harness.
A. Turn the starter keyswitch and the disconnect diagnostic code.
Expected Result:
and J2 from the ECM. The CID 0444 FMI 06 diagnostic code is active.
C. At the machine harness connectors for the ECM, Results:

measure the resistance from the signal contact
J2-7 (wire 306-GN) to frame ground. Measure • YES – The CID 0444 FMI 06 diagnostic code
the resistance from the signal contact J2-7 (wire is active. The diagnostic code has not been
306-GN) to all of the other contacts that are used corrected. The ECM may have failed.
in the machine harness connectors for the ECM.
RENR9004-07 177
Repair: Check the starter relay circuit again. Use

tool, if available, in order to perform a wiggle test
If the diagnostic code is still active and the cause

can not be found, the ECM may have failed.
Refer to Testing and Adjusting, “Electronic Control
Module (ECM) - Replace”
STOP.

g01288530
Illustration 142
Repair: The initial diagnostic code was probably Inching Pedal position sensor connections
short at one of the harness connectors that was This diagnostic code is associated with the inching
disconnected and reconnected. Resume normal pedal position sensor. The FMI 03 diagnostic code
machine operation. means that the Transmission/Chassis ECM has
detected that the voltage of the signal circuit for the
STOP. position sensor is above normal.
i02906526 The position sensor is a PWM sensor that operates in

a frequency range of between 200 hertz to 600 hertz.
MID 027 - CID 0573 - FMI 03 The optimal operating frequency is approximately
500 hertz. The position sensor sends a PWM input
SMCS Code: 1439-038-P9 signal to the Transmission/Chassis ECM. The ECM
will recognize a duty cycle of 4% to 96% as valid.
Conditions Which Generate This Code: If the ECM detects a duty cycle that is greater than
96%, the FMI 03 diagnostic code is activated.
For inching pedal operation, the Transmission/

Chassis ECM is constantly running an auto calibration
when the inching pedal is being used. The ECM
defaults to a 30 percent duty cycle when the pedal is
not depressed. The ECM defaults to a 70 percent
duty cycle when the pedal is fully depressed. Using
the auto calibration procedure, the ECM will adjust
the acceptable pedal position limits from a possible 4
percent duty cycle when the pedal is not depressed
to a possible 96 percent duty cycle when the pedal
is fully depressed. Duty cycles beyond these limits
will cause the ECM to activate a diagnostic code for
the position sensor.

below:
• There is a problem with the sensor power supply.

Illustration 141
g01324021 • The signal circuit for the sensor has an open or
Inching Pedal position sensor location
a bad connection.
(1) Inching pedal position sensor
(2) Inching pedal Switch • The signal circuit for the sensor is shorted to a
voltage source.
178 RENR9004-07
• The sensor has failed. Refer to the CID 0041 diagnostic code procedures
in this manual for troubleshooting the 8 VDC power
• The ECM has failed. This is unlikely. supply. Correct the ECM power supply. After the
power supply is correct, verify that this diagnostic
Note: Before performing this procedure, inspect code is still active before proceeding with this
the harness connectors that are involved in the procedure.
of a problem in an electrical circuit. Verify that STOP.
connections are secure and that all connections Test Step 2. CHECK FOR AN OPEN IN
are in good condition. If a problem with a THE SENSOR CIRCUIT
verify that this diagnostic code is active before A. Turn the key start switch and the disconnect
performing this procedure. switch to the OFF position.
Note: The following test procedure may create other B. Disconnect the machine harness connector from
diagnostic codes. Ignore these created diagnostic the position sensor.
original diagnostic code has been corrected. C. At the machine harness connector for the sensor,
place a jumper wire between the contact of the
Test Step 1. CHECK THE SENSOR sensor return B (wire X800-OR) and the contact
POWER SUPPLY of the signal C (wire F843-YL) .
A. Turn the key start switch and the disconnect D. Disconnect machine harness connectors J1 and
switch to the ON position. J2 from the ECM.
B. At the machine harness connector for the sensor, E. At the harness connectors for the ECM, measure
insert 7X-1710 Multimeter Probes along the the resistance from return contact J1-45 (wire
contact of the power supply A (wire T998-BR) and X800-OR) to signal contact J2-43 (wire F843-YL).
along ground contact B (wire X800-OR).
Expected Result:
C. Measure the DC voltage of the sensor power
supply. The resistance measurement is less than 5 ohms.
The voltage measurement is 8.0 ± 0.3 VDC. • OK – The resistance measurement is less than 5
ohms. The sensor circuit is not open. Proceed to
Results: Test Step 3.
• OK – The voltage measurement is approximately • NOT OK – The resistance measurement is greater

8.0 ± 0.3 VDC. The power supply for the sensor is than 5 ohms. There is an open or a bad connection
correct. Proceed to Test Step 2. in the signal circuit.
• NOT OK – The voltage measurement is less than Repair: A resistance measurement that is greater
8.0 ± 0.3 VDC. The power supply for the sensor than 5000 ohms could indicate that a wire is either
is not correct. not connected or that a wire is open. A resistance
Repair: Either the wire of the return circuit than 5000 ohms could indicate that one of the
X800-OR or the wire of the supply circuit T998-BR connection points in the circuit is not open but is
has a bad connection or an open in the machine not a good connection.
harness. Examine all of the connectors that are
in the circuit. Ensure that the connections are Refer to the complete Electrical System Schematic
clean, that the connections are secure and that the of the machine. Check all of the connectors
connections are in good condition. that are in the sensor signal circuit. Ensure that
all connections are clean, that all connections
STOP.
RENR9004-07 179
Test Step 3. CHECK THE SIGNAL B. At the machine harness for the sensor connector,
CIRCUIT OF THE SENSOR FOR A SHORT use a 151-6320 Removal Tool to remove the
signal wire F843-YL and the socket at contact C
The sensor remains disconnected from the machine from the harness connector. The machine harness
harness. The disconnect switch and the key start connector remains connected to the connector of
switch remain in the OFF position. The machine the inching pedal sensor.
harness connectors remain disconnected from the
ECM. C. At the back of the sensor connector, insert
7X-1710 Multimeter Probes along the sensor
A. Remove the jumper wire that was used in the last signal contact C and the return contact at B.
test step.
B. At the harness connector J2 for the ECM, switch to the ON position.
measure the resistance from signal contact J2-43
(wire F843-YL) to all of the other contacts that E. Measure the duty cycle of the sensor at the sensor
are used for the J1 and J2 connectors on the contacts C and B. Move the inching pedal through
Transmission/Chassis ECM. the full range of movement.
Each resistance measurement is greater than 5000 For inching pedal operation, the position sensor duty
ohms. cycle is in the range of 4 percent when the pedal is
not depressed to 96 percent when the inching pedal
Results: is fully depressed. The duty cycle of the sensor is
never above 96%.
than 5000 ohms. The signal circuit is not shorted Results:
to another circuit in the machine harness. Proceed
to Test Step 4. • OK – The duty cycle of the sensor is correct. The
sensor is not the problem. Proceed to Test Step 5.
• NOT OK – One or more resistance of the
resistance measurements is less than 5000 ohms. • NOT OK – The duty cycle of the sensor is NOT
There is a short in the machine harness. correct according to the description above. The
sensor has failed.
Repair: The wire of the sensor signal circuit
F843-YL is shorted to the circuit with the low Repair: The operation of the inching pedal position
resistance measurement in the machine harness. sensor is not correct. Replace the inching pedal
position sensor. After replacement of the sensor,
Refer to the complete Electrical System Schematic verify that the operation of the new sensor is
of the machine. Examine all of the connectors correct before operating the machine.
in the circuits for points in the machine harness
where a short could occur. STOP.
For information on testing for short circuits and Test Step 5. CHECK THE STATUS OF THE
finding short circuits, refer to Testing and Adjusting, DIAGNOSTIC CODE
machine harness or replace the machine harness. A. Inspect the harness connectors. Clean the
STOP. wires for damage to the insulation that is caused
Test Step 4. CHECK THE SIGNAL AT THE
SENSOR B. Perform a 45 N (10 lb) pull test on each of the
remain in the OFF position. C. Reconnect all harness connectors. Make sure that
A. Reconnect the machine harness connectors to the clips for each connector are completely fastened.
sensor and to the ECM.

180 RENR9004-07
F. Determine if the CID 0573 FMI 03 diagnostic code i02906561

is active.
MID 027 - CID 0573 - FMI 04
Expected Result:
SMCS Code: 1439-038-P9
Results:
• OK – The CID 0573 FMI 03 diagnostic code is not

active. The problem has been corrected.

cause by a poor electrical connection or a short
at one of the harness connectors that was
machine operation.
STOP.
• NOT OK – The CID 0573 FMI 03 diagnostic code

is still active. The problem has not been corrected.
Repair: Perform this test step again. If the problem

has not been corrected, use the Caterpillar
in order to perform a wiggle test on the sensor
circuit in the machine wiring harness. The wiggle
g01324021
test can detect momentary or intermittent shorts or Illustration 143
opens in the machine wiring harness. Inching Pedal position sensor location
(1) Inching pedal position sensor
If a problem is not found in the machine harness, (2) Inching pedal Switch
the ECM may have failed.

may greatly reduce repair time. If the cause of
the diagnostic code is not found, replace the
Implement ECM. Refer to Testing and Adjusting,
STOP.
g01288530
Illustration 144
Inching Pedal position sensor connections
This diagnostic code is associated with the inching

pedal position sensor. The FMI 04 means that the
Transmission/Chassis ECM has detected that the
duty cycle and the voltage of the position sensor
signal circuit are below normal.
RENR9004-07 181
The position sensor is a PWM sensor that operates in Expected Result:

a frequency range of between 200 hertz to 600 hertz.
The optimal operating frequency is approximately The FMI 04 diagnostic code will remain active if
500 hertz. The position sensor sends a PWM input the sensor is not the cause of the problem. The
signal to the Transmission/Chassis ECM. The ECM sensor is internally shorted if the FMI 04 diagnostic
will recognize a duty cycle of 4% to 96% as valid. If code changes to an active FMI 03 diagnostic code
the ECM detects a duty cycle that is less than 4%, when the sensor is disconnected from the machine
the FMI 04 diagnostic code is activated. harness.
For inching pedal operation, the Transmission/ Results:

Chassis ECM is constantly running an auto calibration
when the inching pedal is being used. The ECM • OK – The FMI 04 diagnostic code remains active.
defaults to a 30 percent duty cycle when the pedal is The sensor has not failed. Proceed to Test Step 2.
not depressed. The ECM defaults to a 70 percent
duty cycle when the pedal is fully depressed. Using • NOT OK – The FMI 04 diagnostic code changes
the auto calibration procedure, the ECM will adjust to an FMI 03 diagnostic code when the sensor is
the acceptable pedal position limits from a possible 4 disconnected. The machine harness and the ECM
percent duty cycle when the pedal is not depressed are operating correctly.
to a possible 96 percent duty cycle when the pedal
is fully depressed. Duty cycles beyond these limits Repair: The inching pedal position sensor has
will cause the ECM to activate a diagnostic code for failed. Replace the sensor. After replacement of
the position sensor. the sensor, verify that the operation of the new
sensor is correct before operating the machine.
The possible conditions that can cause this diagnostic
code to activate are listed below: STOP.
• The sensor has failed. Test Step 2. CHECK THE SENSOR

CIRCUIT FOR A SHORT
• The signal circuit for the sensor is shorted to a
ground source. The position sensor remains disconnected from the
machine harness.
Note: Before performing this procedure, inspect switch to the OFF position.
circuit. Poor connections can often be the cause B. Disconnect the machine harness connector J1
of a problem in an electrical circuit. Verify that and J2 from the ECM.
connections are secure and that all connections C. At the machine harness connector J2 for the ECM,
are in good condition. If a problem with a measure the resistance from the signal contact
connection is found, correct the problem and J2-43 (wire F743-YL) to frame ground. Measure
verify that this diagnostic code is active before the resistance from the signal contact J2-43 (wire
performing this procedure. F743-YL) to all of the contacts that are used in the
machine harness connectors for the ECM.
Note: This procedure can cause new diagnostic
codes to be activated. Ignore these created Expected Result:
diagnostic codes. When the problem has been
corrected, clear the created diagnostic codes. Each resistance measurement is greater than 5000
ohms.
Test Step 1. CHECK THE SENSOR
Results:
switch to the ON position. • OK – Each resistance measurement is greater
than 5000 ohms. The machine harness is correct.
B. While observing the status of the diagnostic code, Proceed to Test Step 3.
disconnect the machine harness connector from
the position sensor of the inching pedal. • NOT OK – One or more resistance measurements
is not correct. There is a short in the machine
harness.
Repair: The short is between the signal wire

F743-YL and the circuit with the low resistance
measurement or frame ground.
182 RENR9004-07
Refer to the complete Electrical System Schematic Prior to replacing an ECM, always contact your
of the machine. Examine all of the connectors in dealership's Technical Communicator for possible
circuits for points in the machine harness where a consultation with Caterpillar. This consultation
short circuit could occur. may greatly reduce repair time. If the cause of the
diagnostic code is not found, replace the ECM that
For information on testing for short circuits and activated the diagnostic code. Refer to Testing
finding short circuits, refer to Testing and Adjusting, and Adjusting, “Electronic Control Module (ECM)
“Wiring Harness (Short Circuit) - Test”. Repair the - Replace”.
STOP.
STOP.
Test Step 3. CHECK THE STATUS OF THE active. The problem does not exist at this time.
DIAGNOSTIC CODE
A. Inspect the harness connectors. Clean the caused by a poor electrical connection or a
contacts of the harness connectors. Check the short at one of the harness connectors that was
wires for damage to the insulation that is caused disconnected and reconnected. Resume normal
by excessive heat, battery acid, or chafing. machine operation.
B. Perform a 45 N (10 lb) pull test on each of the STOP.

i02906061
MID 027 - CID 0573 - FMI 08
switch to the ON position. Conditions Which Generate This Code:

diagnostic code.
Expected Result:
Results:

Repair: Perform this procedure again. If the

problem has not been corrected, Use the
sensor circuit in the machine wiring harness. The
wiggle test can detect momentary or intermittent g01324021
shorts or opens in the machine wiring harness. Illustration 145
Inching Pedal Position sensor location
If the cause of the problem is not found, the ECM (1) Inching pedal position sensor
may have failed. (2) Inching pedal Switch
RENR9004-07 183



SENSOR
Turn the key start switch and the disconnect switch
to the OFF position.
g01288530
Illustration 146
Inching Pedal position sensor connections
A. At the machine harness for the sensor connector,
use a 151-6320 Removal Tool to remove the
This diagnostic code is associated with the inching signal wire F843-YL and the socket at contact C
pedal position sensor. The FMI 08 means that the from the harness connector. The machine harness
ECM has determined that the signal frequency or the connector remains connected to the connector of
signal pulse width is not within the expected range. the inching pedal sensor.
The position sensor is a PWM sensor that operates in B. At the back of the sensor connector, insert
a frequency range of between 200 hertz to 600 hertz. 7X-1710 Multimeter Probes along the sensor
The optimal operating frequency is approximately signal contact C and the return contact at B.
500 hertz. The position sensor sends a PWM input
signal to the Transmission/Chassis ECM. The ECM C. Turn the disconnect switch and the key start
will recognize a duty cycle of 4% to 96% as valid. switch to the ON position.
If the ECM detects a duty cycle that is greater than
96%, the FMI 03 diagnostic code is activated. D. Measure the frequency of the sensor signal.
Measure the duty cycle of the sensor at the
For inching pedal operation, the Transmission/ contacts of the sensor connector C and B.
Chassis ECM is constantly running an auto calibration Move the inching pedal through the full range of
when the inching pedal is being used. The ECM movement.
defaults to a 20 percent duty cycle when the pedal is
not depressed. The ECM defaults to a 70 percent E. While measuring the frequency and the duty cycle
duty cycle when the pedal is fully depressed. Using of the sensor, wiggle the sensor connector.
the auto calibration procedure, the ECM will adjust
the acceptable pedal position limits from a possible 4 Expected Result:
percent duty cycle when the pedal is not depressed
to a possible 96 percent duty cycle when the pedal The frequency and the duty cycle of the inching
is fully depressed. Duty cycles beyond these limits pedal position sensor are correct according to the
will cause the ECM to activate a diagnostic code for description at the beginning of this procedure at all
the position sensor. times during manipulation of the connector.
The possible causes of this diagnostic code are listed Results:

below:
• OK – The frequency and the duty cycle of
the inching pedal position sensor are correct.
• The sensor has failed. The sensor is not the problem. Reinstall the
disconnected wire and the socket in the machine
• Intermittent connections or poor connections in the harness connector for the sensor before
sensor signal circuit.
proceeding to the next test step. Proceed to Test
Step 2.
Note:
184 RENR9004-07
• NOT OK – The duty cycle of the sensor is Repair: A resistance measurement that is greater
NOT correct according to the description at the than 5000 ohms could indicate that a wire is
beginning of this procedure. The sensor has failed. either not connected or is open. A resistance
A circuit connection of the sensor signal has failed. measurement that is greater than 5 ohms but less
Repair: Investigate the cause of the incorrect connection points in the circuit is not open but is
measurement. Check the wiring and connections not a good connection.
of the sensor. If the sensor is faulty, replace the
sensor. After replacement of the sensor, verify that Refer to the complete Electrical System Schematic
the operation of the inching pedal is correct before of the machine. Check all of the connectors
operating the machine. that are in the sensor signal circuit. Ensure that
STOP. are secure and that all connections are in good
Test Step 2. CHECK FOR AN OPEN IN the machine harness.
THE SENSOR CIRCUIT
STOP.
switch to the OFF position. Test Step 3. CHECK THE SIGNAL
CIRCUIT OF THE SENSOR FOR A SHORT
the position sensor. The sensor remains disconnected from the machine
harness. The disconnect switch and the key start
C. At the machine harness connector for the sensor, switch remain in the OFF position. The machine
place a jumper wire between the sensor return harness connectors remain disconnected from the
contact B (wire X800-OR) and the signal contact ECM.
C (wire F843-YL) .
A. Remove the jumper wire that was used in the last
D. Disconnect machine harness connectors J1 and test step.
J2 from the ECM.
B. At the harness connector J2 for the ECM,
E. At the harness connectors for the ECM, measure measure the resistance from signal contact J2-43
the resistance from return contact J1-45 (wire (wire F843-YL) to all of the other contacts that
X800-OR) to signal contact J2-43 (wire F843-YL). are used for the J1 and J2 connectors on the
Transmission/Chassis ECM.
F. While observing the resistance measurement,
wiggle the machine harness at the ECM connector C. While observing the resistance measurements,
and wiggle the machine wiring harness at the wiggle the machine harness at the ECM connector
sensor connector. Do not disconnect the jumper and wiggle the machine wiring harness at the
wire. sensor connector.
The resistance measurement is less than 5 ohms Each resistance measurement is greater than 5000
at all times during the manipulation of the machine ohms at all times during the manipulation of the
harness. machine harness.
Results: Results:
• OK – The resistance measurement is less than 5 • OK – Each resistance measurement is greater

ohms. The sensor circuit is not open. Proceed to than 5000 ohms. The signal circuit is not shorted
Test Step 3. to another circuit in the machine harness. Proceed
to Test Step 4.
than 5 ohms. There is an open or a bad connection • NOT OK – One or more resistance of the
in the signal circuit. resistance measurements is less than 5000 ohms.
There is a short in the machine harness.
Repair: The circuit wire for the signal of the sensor

F843-YL is shorted to the circuit with the low
resistance measurement in the machine harness.
RENR9004-07 185
Refer to the complete Electrical System Schematic It is unlikely that the ECM has failed. Exit this
of the machine. Examine all of the connectors procedure and perform this procedure again. If the
in the circuits for points in the machine harness cause of the failure is not found, replace the ECM.
where a short could occur. Prior to replacing an ECM, always contact your
For information on testing for short circuits and consultation with Caterpillar. This consultation
finding short circuits, refer to Testing and Adjusting, may greatly reduce repair time. If the cause of the
“Wiring Harness (Short Circuit) - Test”. Repair the diagnostic code is not found, replace the ECM that
machine harness or replace the machine harness. activated the diagnostic code. Refer to Testing
STOP. - Replace”.

DIAGNOSTIC CODE
i02916221
MID 027 - CID 0585 - FMI 02
by excessive heat, battery acid, or chafing. SMCS Code: 3175-038-OJ
C. Reconnect all harness connectors and make sure

that the connectors are fully seated. Observe
fastened.

Expected Result:
The CID 0573 FMI 08 is not active.
Results:
• OK – The CID 0573 FMI 08 is not active. The

diagnostic code does not exist at this time. The g01323251
initial diagnostic code was probably caused by a Illustration 147
poor connection or a short at one of the connectors Transmission Output Speed Sensors are located on the right side
that was disconnected and reconnected. Resume rear of the transmission.
normal operation. STOP. (1) Transmission output speed sensor 2
• NOT OK – The CID 0573 FMI 08 is active. The

diagnostic code has not been corrected.

If the cause of the diagnostic code is not found, the

ECM may have failed.
186 RENR9004-07
Expected Result:
The correct range of resistance for the sensor is 600

ohms at −40 °C (−40.0 °F) to 1800 ohms at 120 °C
(248.0 °F). The resistance will be approximately 1055
ohms at 25 °C (77.0 °F).
Results:
• YES – The resistance of the speed sensor is

within the correct resistance range. The sensor is
• NO – The resistance of the speed sensor is not

g01289188
within the correct resistance range. The speed
Illustration 148 sensor has failed.
Transmission Output Speed Sensor 1 connections
Repair: Verify that the speed sensor is causing
This diagnostic code is associated with the the problem. Mark the harness connector for the
transmission output speed sensor 1. The transmission output speed sensor 1. Connect
transmission output speed sensor 1 is located toward the marked machine harness connector for
the rear of the transmission on the right hand side. transmission output speed sensor 1 to the
transmission output speed sensor 2. Connect
The ECM monitors the signals from the transmission the machine harness connector for transmission
output speed sensor 1 and the transmission output output speed sensor 2 to the transmission output
speed sensor 2. When the ECM detects that the speed sensor 1. Turn the disconnect switch and
signal of the speed sensor 1 is not within the the key start switch to the ON position.
accepted limits and that the speed sensor 2 signal is
within the accepted limits, the ECM will activate the If the transmission output speed sensor 1 has
FMI 02 diagnostic code. failed, the CID 0585 FMI 02 diagnostic code will no
longer be active. A CID 0673 FMI 02 diagnostic
The following conditions could cause the ECM to code for the transmission output speed sensor 2
activate this diagnostic code: will become active.
• The speed sensor has failed. Replace the transmission output speed sensor 1.
Verify that the new sensor corrects the problem
• There is an intermittent short or an open in the before operating the machine.
speed sensor circuit.
STOP.
• The speed sensor is not mounted securely.
Test Step 2. SWITCH THE SENSORS
Note: Before performing this procedure, verify that remain in the OFF position. The transmission output
the speed sensor is mounted securely. A loose mount speed sensor 1 remains disconnected from the
could cause this diagnostic code to be activated. machine harness.
Ensure that this diagnostic code is active before
performing this procedure. A. Mark the transmission output speed sensor 1
harness connector in order to keep track of the
Test Step 1. CHECK THE SENSOR connector that is used for each sensor.
A. Turn the key start switch and the disconnect B. Disconnect the transmission output speed sensor
switch to the OFF position. 2 from the machine harness.
B. Disconnect the machine harness from the speed C. Switch the speed sensor harness connectors.
sensor. Connect the marked machine harness connector
for transmission output speed sensor 1 to the
C. At the connector for the speed sensor, measure transmission output speed sensor 2. Connect
the resistance from contact 2 to contact 1. the machine harness connector for transmission
output speed sensor 2 to the transmission output
speed sensor 1.
RENR9004-07 187
D. Turn the key start switch and the disconnect G. Observe the resistance measurement and wiggle
switch to the ON position. the speed sensor connector. Gently pull on the
wires and wiggle the wires. Do not disconnect the
E. Observe the status of the active diagnostic code. jumper wire.
The CID 0585 FMI 02 diagnostic code is no longer The resistance measurement is less than 5 ohms all
active. A CID 0673 FMI 02 diagnostic code for the times during the manipulation of the wires and the
transmission output speed sensor 2 is active after connectors.
the switch.
Results:
Results:
• YES – The resistance measurement is less than 5
• YES – The CID 0585 FMI 02 diagnostic code is no ohms. The speed sensor circuit is not open in the
longer active after the sensors are switched. A CID machine harness. Proceed to Test Step 4.
0673 FMI 02 diagnostic code for the transmission
output speed sensor 2 is now active. • NO – The resistance measurement is greater than
5 ohms for all of the time or for part of the time
Repair: The transmission output speed sensor 1 that the resistance is being measured. There is an
has failed. Replace the speed sensor. Verify that open connection or a bad connection in the one
the new speed sensor corrects the problem before of the wires for the circuit of the speed sensor.
operating the machine. Check each wire individually in order to determine
whether the problem is in the signal circuit or the
STOP. ground circuit.
• NO – The CID 0585 FMI 02 diagnostic code is still Repair: A resistance measurement that is greater
active. Switching the speed sensors did not affect than 5000 ohms could indicate that a wire is either
the status of the CID 0585 FMI 02 diagnostic code. not connected or that a wire is open. A resistance
The sensor is not causing the problem. measurement that is greater than 5 ohms but less
Reconnect the machine harness connectors to the than 5000 ohms could indicate that one of the
correct transmission output speed sensor before connection points or a splice connection in the
proceeding to the next test step. circuit is not open but is not a good connection.
Test Step 3. CHECK THE SENSOR 5 ohms at some time during the manipulation of
CIRCUIT FOR AN OPEN the machine harness indicates that there is an
intermittent open or a loose connection in the
A. Turn the disconnect switch and the key start machine harness.
B. Disconnect the machine harness connector from of the machine. Check all of the connectors that are
the sensor. in the circuit. Ensure that all of the contacts for the
circuit are in good condition, that all the contacts
C. Disconnect the machine harness connectors J1 are clean, and that all the contacts are securely
from the ECM. fastened in each of the harness connectors. Repair
the machine harness or replace the machine
D. At the machine harness connector for the sensor, harness.
E906-OR) and contact 2 (wire E907-GY). STOP.
E. At the machine harness connector J1 for the Test Step 4. CHECK THE SIGNAL
ECM, measure the resistance between contact CIRCUIT FOR A SHORT
J1-17 (wire E907-GY) and contact J1-18 (wire
E906-OR). The disconnect switch and the key start switch
F. Observe the resistance measurement and wiggle connectors remain disconnected from the sensor
the ECM connector. Gently pull on the wires and and the ECM.
wiggle the wires.
A. Disconnect the jumper wire that was used in the
last test step.
188 RENR9004-07
B. Disconnect the machine harness connectors J2 Test Step 5. CHECK THE STATUS OF THE
from the ECM. DIAGNOSTIC CODE
C. At the machine harness connector J1 for the ECM, A. Inspect the harness connectors. Clean the
measure the resistance between contact J1-17 contacts of the harness connectors. Check the
(wire E907-GY) and frame ground. Measure the wires for damage to the insulation that is caused
resistance between contact J1-17 (wire E907-GY) by excessive heat, battery acid, or chafing.
J1 and J2 connectors for the ECM. B. Perform a 45 N (10 lb) pull test on each of the
D. Observe the resistance measurements and
wiggle the ECM connectors and the speed sensor C. Reconnect all harness connectors in order to
connector. Gently pull on the wires and wiggle the make sure that the connectors are fully seated.
wires. Observe that the clips for each connector are
completely fastened.
E. At the machine harness connector J1 for the ECM,
measure the resistance between contact J1-18 D. Turn the disconnect switch and the key start
(wire E906-OR) and frame ground. Measure the switch to the ON position.
resistance between contact J1-18 (wire E906-OR)
and all of the other contacts that are used in the E. Operate the machine.
J1 and J2 connectors for the ECM.
F. Determine if the CID 0585 FMI 02diagnostic code
F. Observe the resistance measurements and is active.
wiggle the ECM connectors and the speed sensor
connector. Gently pull on the wires and wiggle the Expected Result:
wires.
Expected Result:
Results:
ohms at all times during the manipulation of the • YES – The CID 0585 FMI 02 diagnostic code is
machine harness. active. The problem has not been corrected.
Results: Repair: Check the relay circuit again. Use the

• YES – Each resistance measurement is greater if available, in order to perform a wiggle test on the
than 5000 ohms. The measurements do not machine wiring harness. The wiggle test can detect
indicate a short circuit. Proceed to Test Step 5. momentary or intermittent shorts or opens in the
• NO – One or more of the resistance measurements
is less than 5000 ohms. There is a short in the If the cause of the problem is not found, the ECM
machine harness. may have failed.
Repair: The short is between the circuit for the Prior to replacing an ECM, always contact your
speed sensor that was being checked and the dealership's Technical Communicator for possible
circuit with the low resistance measurement. consultation with Caterpillar. This consultation may
greatly reduce repair time. If the ECM must be
Refer to the complete Electrical System Schematic replaced, refer to Testing and Adjusting, “Electronic
of the machine. Check all of the connectors that Control Module (ECM) - Replace”.
are in the faulty speed sensor circuit. Ensure
that all connections are clean, that all connectors STOP.
are secure and that all connectors are in good
condition. • NO – The CID 0585 FMI 02 diagnostic code is not
finding short circuits, refer to Testing and Adjusting, Repair: The initial diagnostic code was probably
“Wiring Harness (Short Circuit) - Test”. Repair the caused by a poor electrical connection or a
machine harness or replace the machine harness. short at one of the harness connectors that was
STOP. machine operation.
STOP.
RENR9004-07 189
i03850449
MID 027 - CID 0588 - FMI 09

SMCS Code: 7490-038
g02072336
Illustration 149
Cat Data Link connections
The CID 0590 FMI 09 diagnostic code is • The “Transmission/Chassis ECM” has failed. This
associated with the communication between the is unlikely.
“Transmission/Chassis ECM” and the Monitoring
System (Messenger) that is conducted on the Cat Note: A loss of power to the Monitoring System
Data Link circuit. can cause the “Transmission/Chassis ECM”
to activate this diagnostic code. Ensure that
The FMI 09 means that the “Transmission/Chassis the Monitoring System is powered up before
ECM” is not receiving any communication from the proceeding with this procedure.
Monitoring System over the Cat Data Link circuit.
Note: Ensure that the CID 0588 FMI 09 diagnostic
The possible causes of the CID 0588 FMI 09 code is active before performing this procedure.
diagnostic code are listed below:
Test Step 1. CHECK THE CAT DATA LINK
• An open or a poor connection in the Cat Data Link CIRCUIT FOR AN OPEN
circuit
• The “Messenger” Module has failed. This is switch to the OFF position.
unlikely.
190 RENR9004-07
B. Disconnect the machine harness connector B. Reconnect all harness connectors. Make sure that
J1 from the “Transmission/Chassis ECM”. the connectors are fully seated. Observe that the
Disconnect the machine harness connector from clips for each connector are completely fastened.
the Messenger.
C. Inspect the harness connectors and clean all of switch to the ON position.
the contacts of the harness connectors. Refer to
the illustration above in order to check the Cat D. Operate the machine.
Data Link connection on each of the connectors
for the machine harness. Ensure that the wires E. Check the status of the CID 0588 FMI 09
are secured in the connector, that the contacts are diagnostic code.
clean and that the contacts are in good condition.
Expected Result:
D. At the disconnected harness connector for
the Monitoring System, connect a jumper wire The CID 0588 FMI 09 diagnostic code is not active.
between contact 6 (wire 893-GN) and contact 5
(wire 892-BR). Results:
E. At the disconnected harness connector J1 for • OK – The CID 0588 FMI 09 diagnostic code is
the “Transmission/Chassis ECM”, measure the not active. The diagnostic code does not exist at
resistance between contact J1-10 (wire 893-GN) this time. The initial diagnostic code was probably
and contact J1-20 (wire 892-BR). caused by a poor connection or a short at one
Expected Result: reconnected. Resume normal operation. STOP.
The resistance measurement is less than 5 ohms. • NOT OK – The CID 0588 FMI 09 diagnostic
Results: corrected.
• OK – The resistance measurement is less than Repair: Check the circuit again. Use the Caterpillar
5 ohms. The Cat Data Link circuit in the machine Electronic Technician (ET) service tool, if available,
harness is not open. Proceed to Test Step 2. in order to perform a wiggle test on the machine
• NOT OK – The resistance measurement is greater momentary or intermittent shorts or opens in the
than 5 ohms. There is an open or a bad connection machine wiring harness.
in the Cat Data Link circuit in the machine harness.
If the cause of the problem is not found, one of
Repair: A resistance measurement that is greater the ECM modules may have failed. The ECM that
than 5 ohms but less than 5000 ohms could activated the diagnostic code may have failed.
indicate that one of the wires or one of the
connection points in the circuit is not an open Prior to replacing an ECM, always contact your
connection but not a good connection. dealership's Technical Communicator for possible
Refer to the complete Electrical System Schematic may greatly reduce repair time. If the cause of the
of the machine. Locate all the connectors and diagnostic code is not found, replace the ECM that
examine all of the connectors of the machine activated the diagnostic code. Refer to Testing
harness that are involved in the data link circuit. and Adjusting, “Electronic Control Module (ECM)
Check each wire section from each end of the - Replace”.
connectors for an open or a bad connection.
Ensure that all connections are clean, that all STOP.
connectors are secure and that all connectors are
in good condition. Repair the machine harness or
replace the machine harness.
STOP.

DIAGNOSTIC CODE
A. Perform a 45 N (10 lb) pull test on each of the
wires that are associated with the data link circuit.
RENR9004-07 191
i02916304 • The software that is installed on the

Transmission/Chassis ECM is incorrect.
MID 027 - CID 0588 - FMI 14
• A new ECM has been installed but the ECM is not
SMCS Code: 7490-038 the correct part.
Conditions Which Generate This Code: Note: Ensure that the CID 0588 FMI 14 diagnostic
Test Step 1. VERIFY THE HARDWARE

AND THE SOFTWARE PART NUMBERS
A. Verify that the following information is correct:
• The part number of the installed software for

the Transmission/Chassis ECM

the Messenger
• The part number of the Transmission/Chassis

ECM
• The part number of the Messenger

Note: Contact your dealership's Technical
Communicator for the correct part numbers of the
hardware and the correct part numbers for the
configuration software for your machine.
Expected Result:
All hardware and software part numbers are correct.
Results:
• OK – All hardware and software part numbers are

• NOT OK – All hardware and software part

numbers are NOT correct.
g01332252
Illustration 150
Cat Data Link connections Repair: Replace the hardware or software that
is incorrect with the correct version. For flashing
This CID 0588 FMI 14 diagnostic code is software, refer to Testing and Adjusting, “Electronic
associated with the communication between the Control Module (ECM) - Flash Program”. For
Transmission/Chassis ECM and the Monitoring replacing ECM modules, refer to Testing and
System (Messenger) that is conducted on the circuit Adjusting, “Electronic Control Module (ECM) -
for the Cat Data Link. Replace”
The FMI 14 means that the Transmission/Chassis STOP.

ECM is not receiving the expected operating
parameter information from the Messenger. The Test Step 2. CHECK THE STATUS OF THE
Messenger and the Transmission/Chassis ECM are DIAGNOSTIC CODE
still communicating over the CAT data link.
The possible causes of the CID 0588 FMI 14 switch to the ON position.
B. Operate the machine.
• The software that is installed on the Messenger
is incorrect. C. Check the status of the CID 0588 FMI 14
diagnostic code.
192 RENR9004-07
Expected Result: CID 0248 FMI 09 – Cat Data Link
The CID 0588 FMI 14 diagnostic code is not active. Determine the companion diagnostic codes that are
active, along with the CID 0590 FMI 09 diagnostic
Results: code, to indicate the data link system that is involved.
• OK – The CID 0588 FMI 14 diagnostic code is not When the CID 0590 FMI 09 diagnostic code is
active. The diagnostic code does not exist at this cleared, the data link companion diagnostic code
time. The initial diagnostic code could have been will also clear.
caused by a problem at start-up with one of the
controls of the ECM. Resume normal operation. The possible causes of the CID 0590 FMI 09
STOP. diagnostic code are listed below:
• NOT OK – The CID 0588 FMI 14 diagnostic • An open connection or a poor connection in the
code is active. The diagnostic code has not been data link circuit
corrected.
• The Engine ECM has failed. This is unlikely.
Repair: Repeat this procedure again and verify
that the information is correct. • The Transmission/Chassis ECM has failed. This
is unlikely.
that has activated the diagnostic code may have Note: A loss of power to the Engine ECM can
failed. cause the Transmission/Chassis ECM to activate
this diagnostic code. Ensure that the Engine
Prior to replacing an ECM, always contact your ECM is powered up before proceeding with this
dealership's Technical Communicator for possible procedure.
may greatly reduce repair time. If the cause of the Note: Ensure that the CID 0590 FMI 09 diagnostic
diagnostic code is not found, replace the ECM that code is active before performing this procedure.
has activated the diagnostic code. Refer to Testing
and Adjusting, “Electronic Control Module (ECM) Test Step 1. DETERMINE THE
- Replace”. COMPANION DIAGNOSTIC CODE
OF THE DATA LINK THAT IS ACTIVE
STOP.
A. Check the list of active diagnostic codes in order
to determine which of the following companion
i02916317
diagnostic codes is active:
MID 027 - CID 0590 - FMI 09 CID 0247 FMI 09 - SAE J1939 Data Link
CID 0248 FMI 09 - Cat Data Link
SMCS Code: 1901-038
Results:
The CID 0590 FMI 09 diagnostic code is active indicating that the problem is in the Cat
associated with the communication between the Data Link. In order to perform the troubleshooting
Transmission/Chassis ECM and the Engine ECM procedure for the Cat Data Link, proceed to Test
that is conducted on the Cat Data Link or the Step 2.
communication that is conducted over the SAE J1939
Data Link. • OK – The CID 0247 FMI 09 diagnostic code
is active indicating that the problem is in the
The FMI 09 means that the Transmission/Chassis SAE J1939 Data Link. In order to perform the
ECM is not receiving any communication from the troubleshooting procedure for the SAE J1939 Data
Engine ECM on the involved data link circuit. Link, proceed to Test Step 4.
When this diagnostic code is activated by the

Transmission/Chassis ECM, a “companion”
diagnostic code is activated in order to indicate the
data link that is involved. The companion diagnostic
code that has been activated will be either of the
following:
CID 0247 FMI 09 – SAE J1939 Data Link

RENR9004-07 193
Test Step 2. CHECK THE CAT DATA LINK E. At the disconnected harness connector J1 for
CIRCUIT FOR AN OPEN the Transmission/Chassis ECM, measure the
resistance between contact J1-10 (wire 893-GN)
and contact J1-20 (wire 892-BR).
Expected Result:
The resistance measurement is less than 5 ohms.
Results:

5 ohms. The Cat Data Link circuit in the machine
harness is not open. Proceed to Test Step 3.

than 5 ohms. There is an open or a bad connection

than 5 ohms but less than 5000 ohms could
connection points in the circuit is not an open
connection but not a good connection.

of the machine. Examine all of the connectors
for the machine harness that are involved in the
data link circuit. Check each section from one wire
connector to the other wire connector for an open
or a bad connection. Ensure that all connections
are clean, that all connections are secure and that
all connections are in good condition. Repair the
STOP.
g01321267
Illustration 151
DIAGNOSTIC CODE
A. Turn the key start switch and the disconnect A. Perform a 45 N (10 lb) pull test on each of the
switch to the OFF position. wires that are associated with the data link circuit.
B. Disconnect the machine harness connector J1 B. Reconnect all harness connectors. Make sure that
from the Transmission/Chassis ECM. Disconnect the connectors are fully seated. Observe that the
the machine harness connector J1 from the clips for each connector are completely fastened.
Engine ECM.
C. Inspect the harness connectors and clean all of the switch to the ON position.
contacts of the harness connectors. Refer to the
illustration above in order to check the connection D. Operate the machine.
of the Cat Data Link on each of the machine
harness connectors. Ensure that the wires are E. Check the status of the CID 0590 FMI 09
secured in the connector, that the contacts are diagnostic code.
Expected Result:
D. At the disconnected harness connector J1 for
the Engine ECM, connect a jumper wire between The CID 0590 FMI 09 diagnostic code is not active.
contact J1-8 (wire 893-GN) and contact J1-9 (wire
892-BR).
194 RENR9004-07
Results: Test Step 4. CHECK THE SAE J1939

DATA LINK CIRCUIT FOR AN OPEN
this time. The initial diagnostic code was probably

corrected.


the ECM modules may have failed. The ECM that
activated the diagnostic code may have failed.

activated the diagnostic code. Refer to Testing
- Replace”.
STOP.
g01321279
Illustration 152
SAE J1939 Data Link Circuit connections

B. Disconnect the machine harness connector J2

from the Transmission/Chassis ECM. Disconnect
the machine harness connector J1 from the
Engine ECM.
C. Inspect the harness connectors and clean all of the

illustration above in order to check the SAE J1939
Data Link connection on each of the machine
harness connectors. Ensure that the wires are
secured in the connector, that the contacts are
D. At the disconnected harness connector J1 for

the Engine ECM, connect a jumper wire between
contact J1-50 (wire K900-YL) and contact J1-34
(wire K990-GN).
RENR9004-07 195
E. At the disconnected harness connector J2 for Results:

the Transmission/Chassis ECM, measure the
resistance between contact J2-67 (wire K900-YL) • OK – The CID 0590 FMI 09 diagnostic code is
and contact J2-68 (wire K990-GN). not active. The diagnostic code does not exist at
Expected Result: caused by a poor connection or a short at one
The resistance measurement is less than 5 ohms. reconnected. Resume normal operation. STOP.

• OK – The resistance measurement is less than corrected.
5 ohms. The SAE J1939 Data Link circuit in the
machine harness is not open. Proceed to Test Step Repair: Check the circuit again. Use the Caterpillar
3. Electronic Technician (ET) service tool, if available,
• NOT OK – The resistance measurement is greater wiring harness. The wiggle test can detect
than 5 ohms. There is an open or a bad connection momentary or intermittent shorts or opens in the
in the SAE J1939 Data Link circuit in the machine machine wiring harness.
harness.
Repair: Refer to the complete Electrical System the ECM modules may have failed. The ECM that
Schematic of the machine. Examine all of the activated the diagnostic code may have failed.
harness connections of the machine that are
involved in the data link circuit. Check each wire Prior to replacing an ECM, always contact your
section from one connector to the other connector dealership's Technical Communicator for possible
for an open or a bad connection. Ensure that consultation with Caterpillar. This consultation
all connections are clean, that all connections may greatly reduce repair time. If the cause of the
are secure and that all connections are in good diagnostic code is not found, replace the ECM that
condition. Repair the machine harness or replace activated the diagnostic code. Refer to Testing
the machine harness. and Adjusting, “Electronic Control Module (ECM)
- Replace”.
STOP.
STOP.
DIAGNOSTIC CODE
i02916351

MID 027 - CID 0590 - FMI 14
SMCS Code: 1901-038
B. Reconnect all harness connectors. Make sure that
This CID 0590 FMI 14 diagnostic code is
C. Turn the disconnect switch and the key start associated with the communication between the
switch to the ON position. Transmission/Chassis ECM and the Engine ECM
that is conducted on the Cat Data Link or the
D. Operate the machine. communication that is conducted over the SAE J1939
Data Link.
E. Check the status of the CID 0590 FMI 09
diagnostic code. The FMI 14 means that the Transmission/Chassis
ECM is not receiving expected operating parameter
Expected Result: information from the Engine ECM. However, the
Transmission/Chassis ECM and the Engine ECM are
The CID 0590 FMI 09 diagnostic code is not active. communicating.
When the CID 0590 FMI 14 diagnostic code is

activated by the Transmission/Chassis ECM, a
“companion” diagnostic code will be activated in
order to indicate the data link that is involved. The
companion diagnostic code that has been activated
will be either of the following diagnostic codes:
196 RENR9004-07
CID 0247 FMI 14 – SAE J1939 Data Link • The part number of the installed software for
the Transmission/Chassis ECM
CID 0248 FMI 14 – Cat Data Link
Determine the companion diagnostic codes that the Engine ECM
have been activated along with the CID 0590 FMI
14 diagnostic code in order to indicate the data link • The part number of the Transmission/Chassis
that is involved. ECM
Note: When the CID 0590 FMI 14 diagnostic code is • The part number of the Engine ECM
cleared, the companion diagnostic code for the data
link will also clear. Note: Contact your dealership's Technical
Communicator for the correct part numbers of the
The possible causes of the CID 0590 FMI 14 hardware and the correct part numbers for the
diagnostic code are listed below: configuration software for your machine.
• The software that is installed on the Engine ECM Expected Result:

is incorrect.
All hardware and software part numbers are correct.
• The software that is installed on the
Transmission/Chassis ECM is incorrect. Results:
• A new ECM has been installed and the ECM is not • OK – All hardware and software part numbers are
the correct part. correct. Proceed to Test Step 3.
Note: Ensure that the CID 0590 FMI 14 diagnostic • NOT OK – All hardware and software part
code is active before performing this procedure. numbers are NOT correct.
Test Step 1. DETERMINE THE Repair: Replace the hardware or software that
COMPANION DIAGNOSTIC CODE is incorrect with the correct version. For flashing
FOR THE DATA LINK THAT IS ACTIVE software, refer to Testing and Adjusting, “Electronic
Control Module (ECM) - Flash Program”. For
Note: If the incorrect software or an incorrect replacing ECM modules, refer to Testing and
control module is causing the problem, both of the Adjusting, “Electronic Control Module (ECM) -
companion diagnostic codes for the data link may Replace”
be active.
STOP.
to determine which of the following companion Test Step 3. CHECK THE STATUS OF THE
diagnostic codes is active: DIAGNOSTIC CODE
CID 0247 FMI 14 - SAE J1939 Data Link
CID 0248 FMI 14 - Cat Data Link A. Turn the disconnect switch and the key start
Results:
active indicating that the problem is in the Cat C. Check the status of the CID 0590 FMI 14
Data Link. In order to perform the troubleshooting diagnostic code.
procedure for the Cat Data Link, proceed to Test
Step 2. Expected Result:
• OK – The CID 0247 FMI 09 diagnostic code The CID 0590 FMI 14 diagnostic code is not active.
SAE J1939 Data Link. In order to perform the Results:
troubleshooting procedure for the SAE J1939 Data
Link, proceed to Test Step 2. • OK – The CID 0590 FMI 14 diagnostic code is not
active. The diagnostic code does not exist at this
Test Step 2. VERIFY THE HARDWARE time. The initial diagnostic code could have been
AND THE SOFTWARE PART NUMBERS caused by a problem during start-up with one of the
ECM modules. Resume normal operation. STOP.
A. Verify that the following information is correct:
RENR9004-07 197
• NOT OK – The CID 0590 FMI 14 diagnostic • An open connection or a poor connection in the
code is active. The diagnostic code has not been data link circuit
corrected.
• The Implement ECM has failed. This is unlikely.
that the information is correct. • The Transmission/Chassis ECM has failed. This
is unlikely.
that has activated the diagnostic code may have Note: A loss of power to the Implement ECM can
failed. cause the Transmission/Chassis ECM to activate
this diagnostic code. Ensure that the Implement
Prior to replacing an ECM, always contact your ECM is powered up before proceeding with this
dealership's Technical Communicator for possible procedure.
may greatly reduce repair time. If the cause of the Note: Ensure that the CID 0596 FMI 09 diagnostic
diagnostic code is not found, replace the ECM that code is active before performing this procedure.
and Adjusting, “Electronic Control Module (ECM) Test Step 1. DETERMINE THE
- Replace”. COMPANION DIAGNOSTIC CODE
STOP.
to determine which of the following companion
i02916378
diagnostic codes is active:
MID 027 - CID 0596 - FMI 09 CID 0247 FMI 09 - SAE J1939 Data Link
SMCS Code: 7610-038-II
Results:
The CID 0596 FMI 09 diagnostic code is active indicating that the problem is in the Cat
associated with the communication between the Data Link. In order to perform the troubleshooting
Transmission/Chassis ECM and the Implement procedure for the Cat Data Link, proceed to Test
ECM that is conducted on the Cat Data Link or Step 2.
the communication that is conducted over the SAE
J1939 Data Link. • OK – The CID 0247 FMI 09 diagnostic code
The FMI 09 means that the Transmission/Chassis SAE J1939 Data Link. In order to perform the
ECM is not receiving any communication from the troubleshooting procedure for the SAE J1939 Data
Implement ECM on the involved data link circuit. Link, proceed to Test Step 4.
When this diagnostic code is activated by the

Transmission/Chassis ECM, a “companion”
diagnostic code will be activated in order to indicate
the data link that is involved. The companion
diagnostic code that has been activated will be either
of the following:
CID 0247 FMI 09 – SAE J1939 Data Link
CID 0248 FMI 09 – Cat Data Link
Determine the companion diagnostic codes that have

been activated in conjunction with the CID 0596 FMI
09 diagnostic code in order to indicate the data link
that is involved.

cleared, the companion diagnostic code of the data
link will also clear.
The possible causes of the CID 0596 FMI 09

198 RENR9004-07
Test Step 2. CHECK THE CAT DATA LINK E. At the disconnected harness connector J1 for
CIRCUIT FOR AN OPEN the Transmission/Chassis ECM, measure the
resistance between contact J1-10 (wire 893-GN)
and contact J1-20 (wire 892-BR).
Expected Result:
Results:

5 ohms. The Cat Data Link circuit in the machine
harness is not open. Proceed to Test Step 3.



of the machine. Examine all of the harness
connections for the machine that are involved in
the data link. Check each wire section from one
connector to another connector for an open or a
bad connection. Ensure that all connections are
clean, that all connections are secure and that
STOP.
g01321267
Illustration 153
DIAGNOSTIC CODE
A. Turn the key start switch and the disconnect A. Perform a 45 N (10 lb) pull test on each of the
switch to the OFF position. wires that are associated with the data link circuit.
B. Disconnect the machine harness connector J1 B. Reconnect all harness connectors. Make sure that
from the Transmission/Chassis ECM. Disconnect the connectors are fully seated. Observe that the
the machine harness connector J1 from the clips for each connector are completely fastened.
Implement ECM.
C. Inspect the harness connectors and clean all of switch to the ON position.
the contacts of the harness connectors. Refer to
the illustration above in order to check the Cat D. Operate the machine.
harness connectors. Ensure that the wires are E. Check the status of the CID 0596 FMI 09
secured in the connector, that the contacts are diagnostic code.
Expected Result:
D. At the disconnected harness connector J1 for the
Implement ECM, connect a jumper wire between The CID 0596 FMI 09 diagnostic code is not active.
contact J1-10 (wire 893-GN) and contact J1-20
(wire 892-BR).
RENR9004-07 199
Results: Test Step 4. CHECK THE SAE J1939

DATA LINK CIRCUIT FOR AN OPEN

corrected.


the ECM modules may have failed. The ECM that
activated the diagnostic code may have failed.

- Replace”.
STOP.
g01321279
Illustration 154
SAE J1939 Data Link Circuit connections


from the Transmission/Chassis ECM. Disconnect
the machine harness connector J2 from the
Implement ECM.
C. Inspect the harness connectors and clean all of the

illustration above in order to check the SAE J1939
harness connectors. Ensure that the wires are
secured in the connector, that the contacts are
D. At the disconnected harness connector J2 for the

Implement ECM, connect a jumper wire between
(wire K990-GN).
200 RENR9004-07
E. At the disconnected harness connector J2 for Results:

the Transmission/Chassis ECM, measure the
and contact J2-68 (wire K990-GN). not active. The diagnostic code does not exist at
Expected Result: caused by a poor connection or a short at one
The resistance measurement is less than 5 ohms. reconnected. Resume normal operation. STOP.

• OK – The resistance measurement is less than corrected.
5 ohms. The SAE J1939 Data Link circuit in the
machine harness is not open. Proceed to Test Step Repair: Check the circuit again. Use the Caterpillar
3. Electronic Technician (ET) service tool, if available,
• NOT OK – The resistance measurement is greater wiring harness. The wiggle test can detect
than 5 ohms. There is an open connection or a bad momentary or intermittent shorts or opens in the
connection in the SAE J1939 Data Link circuit in machine wiring harness.
Repair: Refer to the complete Electrical System the ECM modules may have failed. The ECM that
Schematic of the machine. Examine all of the activated the diagnostic code may have failed.
harness connections of the machine that are
involved in the data link circuit. Check each wire Prior to replacing an ECM, always contact your
section from one connector to another connector dealership's Technical Communicator for possible
for an open or a bad connection. Ensure that consultation with Caterpillar. This consultation
all connections are clean, that all connections may greatly reduce repair time. If the cause of the
are secure and that all connections are in good diagnostic code is not found, replace the ECM that
condition. Repair the machine harness or replace activated the diagnostic code. Refer to Testing
the machine harness. and Adjusting, “Electronic Control Module (ECM)
- Replace”.
STOP.
STOP.
DIAGNOSTIC CODE



diagnostic code.
Expected Result:

RENR9004-07 201
i03850559 This diagnostic code is associated with the

communication between the “Transmission/Chassis
MID 027 - CID 0596 - FMI 12 ECM” and the “Implement ECM” that is conducted on
the Cat Data Link and the J1939 CAN Data Link.
The FMI 12 means that the “Transmission/Chassis
Conditions Which Generate This Code: ECM” is not receiving expected communication
from the “Implement ECM” on the J1939 CAN data
Link and on the CAT Data Link circuit. However, the
“Transmission/Chassis ECM” is receiving expected
data from the other control modules on the machine.
Specifically, the “Transmission/Chassis ECM” is NOT

receiving ANY of the following information from the
“Implement ECM”.
• The steering lever to alignment status information

for the angle of the wheel over the CAT Data Link.
• The hydraulic system pressure over the SAE

J1939 Data Link
In addition to the loss of the information above, an

active diagnostic code of the secondary steering
request circuit (CID 2199) is present.
The possible causes of the active CID 0596 FMI 12

• The “Implement ECM” is not powered up.

• The key start switch ON input for the “Implement
ECM” is an open connection or is a poor connection
Illustration 155
g01375418 • An open connection or a poor connection in both of
the data link circuits at the “Implement ECM”
Key Start Switch ON and Power Connections of the Implement
ECM
• The Implement ECM has failed.
Test Step 1. CHECK THE INPUT OF THE

KEY START SWITCH AND THE ECM
POWER SUPPLY
B. At the connector for the “Implement ECM” J1,

insert a 7X-1710 Multimeter Probes along the
contact for ground J1-13 (wire A295-BK) and
along the contact of the key start switch ON J1-1
(wire 308-YL). Measure the voltage.
C. At the connector for the Implement ECM J1,

remove the multimeter probe from the key start
switch “ON” contact J1-1 (wire 308-YL) and
insert the probe along the +battery contact J1-31
g01375409
Illustration 156 (wire 180-RD). The other multimeter probe that
Connections of the System Data Link is inserted along ground contact J1-13 (wire
A295-BK) remains in place. Measure the voltage.
202 RENR9004-07
D. Repeat the last test step and measure the voltage Refer to the complete Electrical Schematic for your
between each of the +battery connections and machine. Examine the +battery circuit connections
the ground connections that are illustrated in the and the ground at each connector starting at the
diagram at the beginning of this procedure. “Implement ECM” J1 connector and working your
way back through the harness connectors. Verify
Expected Result: that each circuit connection in each connector is
clean, that the circuit connection is secure and that
All of the voltage measurements are at the level of the circuit connection is in good condition. Fix the
the battery voltage. machine harness or replace the machine harness.
Results: STOP.
• OK – All of the voltage measurements are at the Test Step 2. CHECK THE CAT DATA LINK
level of the battery voltage. The key start switch CIRCUIT FOR AN OPEN
“ON” input voltage and the ECM supply voltages
are correct. Proceed to Test Step 2. A. Turn the key start switch and the disconnect
• NOT OK – One or more of the voltage
measurements are NOT at the level of the battery B. Disconnect the machine harness connector J1
voltage. There is a problem with either the input from the Implement ECM.
voltage of the key start switch “ON” or the supply
voltage of the ECM. C. Inspect the harness connector and clean all of the
contacts of the harness connector. Refer to the
Repair: If the input voltage of the key start switch illustration above in order to check the Cat Data
“ON” did not measure the level of the battery Link connections on the harness connector of the
voltage, there is an open or a poor connection in ECM. Ensure that the wires are secured in the
the input circuit between a connection point or a connector, that the contacts are clean and that the
splice and the “Implement ECM”. contacts are in good condition.
Turn the disconnect switch and the key start switch D. At the disconnected harness connector J1 for the
to the OFF position. Implement ECM, connect a jumper wire between
contact J1-10 (wire 893-GN) and contact J1-20
Refer to the complete Electrical Schematic for (wire 892-BR).
your machine. Examine the circuit connections
at each connector. Start at the connector of the E. Disconnect the harness connector J1 from
“Implement ECM” J1 and work your way back the Transmission/Chassis ECM. Measure the
through the harness connectors. Verify that each resistance between contact J1-10 (wire 893-GN)
circuit connection in each connector is clean, that and contact J1-20 (wire 892-BR) on the connector
each connector is secure and that each connector of the Transmission/Chassis ECM.
is in good condition.
Expected Result:
Less likely than a failure of the harness connection,
a splice point in the harness of the machine may The resistance measurement is less than 5 ohms.
have failed. If no other cause can be found, locate
the splice connections and examine the splice Results:
connections for failures. Fix the machine harness
or replace the machine harness. • OK – The resistance measurement is less than
5 ohms. The Cat Data Link circuit between the
A failure in one or two of the Implement ECM “Transmission/Chassis ECM” and the Implement
supply circuits or ground circuits would most likely ECM is not open. Proceed to Test Step 3.
not cause the ECM to lose all power. However, the
cause of a loss of power for any one of the supply • NOT OK – The resistance measurement is greater
circuits or the ground circuits must be investigated than 5 ohms. There is an open or a bad connection
and the problem must be fixed in order for the ECM in the Cat Data Link circuit in the machine harness
to operate correctly. between the “Transmission/Chassis ECM” and the
Implement ECM.
If none of the ECM supply contacts measured the
same as the battery voltage, check the Implement Repair: A resistance measurement that is greater
Control Master Circuit Breaker for an open. Check than 5 ohms but less than 5000 ohms could
the ground circuits for continuity to frame ground. indicate that one of the wires or one of the
RENR9004-07 203
Refer to the complete Electrical System Schematic Repair: A resistance measurement that is greater
of the machine. Starting at the “Implement ECM”, than 5 ohms but less than 5000 ohms could
locate and examine all of the machine harness indicate that one of the wires or one of the
connections that are involved in the data link circuit. connection points in the circuit is not an open
Check each wire section from one connector to connection but not a good connection.
another connector for an open or a bad connection.
Ensure that all connections are clean, that all Refer to the complete Electrical System Schematic
connections are secure and that all connections of the machine. Start at the “Implement ECM” and
are in good condition. Repair the machine harness examine all of the connections of the machine
or replace the machine harness. harness that are involved in the circuit of the
data link. Check each wire section from one
STOP. connector to another connector for an open or a
bad connection. Ensure that all connections are
Test Step 3. CHECK THE J1939 CIRCUIT clean, that all connections are secure and that
OF THE CAN DATA LINK FOR AN OPEN all connections are in good condition. Repair the
remain in the OFF position. STOP.
A. Disconnect the connector of the “Implement ECM” Test Step 4. CHECK THE STATUS OF THE
J2 from the machine harness. DIAGNOSTIC CODE
B. At the connector of the “Implement ECM” J2, A. Reconnect all harness connectors. Make sure that
clean all of the contacts of the harness connector. the connectors are fully seated. Observe that the
Refer to the illustration above in order to check clips for each connector are completely fastened.
the J1939 connections of the CAN Data Link on
the harness connector of the ECM. Ensure that B. Turn the disconnect switch and the key start
the wires are secured in the connector, that the switch to the ON position.
contacts are clean and that the contacts are in
good condition. C. Check the status of the CID 0596 FMI 12
diagnostic code.
C. At the disconnected harness connector J2 for the
Implement ECM, connect a jumper wire between Expected Result:
(wire K990-GN). The CID 0596 FMI 12 diagnostic code is not active.
D. Disconnect the harness connector J2 from Results:

the Transmission/Chassis ECM. Measure the
and contact J2-68 (wire K990-GN) on the not active. The diagnostic code does not exist at
connector of the Transmission/Chassis ECM. this time. The initial diagnostic code was probably
Expected Result: of the connectors that was disconnected and
Results: is still active. The diagnostic code has not been
corrected.
5 ohms. The J1939 CAN Data Link between the Repair: Check the data link circuits again. Use the
“Transmission/Chassis ECM” and the “Implement Caterpillar Electronic Technician (ET) service tool,
ECM” is not open. Proceed to Test Step 4. if available, in order to perform a wiggle test on the
• NOT OK – The resistance measurement is greater momentary or intermittent shorts or opens in the
than 5 ohms. There is an open or a bad connection machine wiring harness.
in the J1939 CAN Data Link in the machine
harness between the “Transmission/Chassis ECM” If the cause of the problem is not found, the
and the “Implement ECM”. Implement ECM may have failed.
204 RENR9004-07
Prior to replacing an ECM, always contact your • A new ECM has been installed and the ECM is not
dealership's Technical Communicator for possible the correct part.
may greatly reduce repair time. If the cause of Note: Ensure that the CID 0596 FMI 14 diagnostic
the diagnostic code is not found, replace the code is active before performing this procedure.
“Implement ECM”. Refer to Testing and Adjusting,
RENR 9004, “Electronic Control Module (ECM) - Test Step 1. DETERMINE THE
Replace”. COMPANION DIAGNOSTIC CODE
STOP.
Note: If incorrect software or an incorrect control
module is causing the problem, both of the companion
i02916571
diagnostic codes of the data link may be active.
MID 027 - CID 0596 - FMI 14 A. Check the list of active diagnostic codes in order
SMCS Code: 7610-038-II to determine the companion diagnostic codes that
are active:
Conditions Which Generate This Code: CID 0247 FMI 14 - SAE J1939 Data Link
This CID 0596 FMI 14 diagnostic code is
associated with the communication between the Results:
Transmission/Chassis ECM and the Implement
ECM that is conducted on the Cat Data Link or • OK – The CID 0248 FMI 09 diagnostic code is
the communication that is conducted over the SAE active indicating that the problem is in the Cat
J1939 Data Link. Data Link. In order to perform the troubleshooting
procedure for the Cat Data Link, proceed to Test
The FMI 14 means that the Transmission/Chassis Step 2.
ECM is communicating with the Implement
ECM on the involved data link. However, the • OK – The CID 0247 FMI 09 diagnostic code
Transmission/Chassis ECM is not receiving expected is active indicating that the problem is in the
operating parameter information from the Implement SAE J1939 Data Link. In order to perform the
ECM. troubleshooting procedure for the SAE J1939 Data
Link, proceed to Test Step 2.
activated by the Transmission/Chassis ECM, a Test Step 2. VERIFY THE HARDWARE
companion diagnostic code will be activated in AND THE SOFTWARE PART NUMBERS
order to indicate the data link that is involved. The
companion diagnostic code that has been activated A. Verify that the following information is correct:
will be either of the following diagnostic codes:
CID 0247 FMI 14 – SAE J1939 Data Link the Transmission/Chassis ECM
CID 0248 FMI 14 – Cat Data Link • The part number of the installed software for
the Implement ECM
Determine the companion diagnostic codes that
have been activated along with the CID 0596 FMI • The part number of the Transmission/Chassis
14 diagnostic code in order to indicate the data link ECM
system that is involved.
• The part number of the Implement ECM
Note: After the CID 0596 FMI 14 diagnostic code has
been cleared, the data link companion diagnostic Note: Contact your dealership's Technical
code will also clear. Communicator for the correct part numbers of the
hardware and the correct part numbers for the
The possible causes of the CID 0596 FMI 14 configuration software for your machine.
Expected Result:
• The software that is installed on the Implement
ECM is incorrect. All hardware and software part numbers are correct.
• The software that is installed on the Results:

Transmission/Chassis ECM is incorrect.
• OK – All hardware and software part numbers are
RENR9004-07 205
• NOT OK – All hardware and software part i02916591

numbers are NOT correct.
MID 027 - CID 0615 - FMI 02
Repair: Replace the hardware or software that
is incorrect with the correct version. For flashing SMCS Code: 4806-038
software, refer to Testing and Adjusting, “Electronic
Control Module (ECM) - Flash Program”. For Conditions Which Generate This Code:
replacing ECM modules, refer to Testing and
Replace”
STOP.

DIAGNOSTIC CODE
C. Check the status of the CID 0596 FMI 14

diagnostic code.
Expected Result:

g01242576
Results: Illustration 157
Connections of the Machine Articulation Angle Sensor 1.
this time. The initial diagnostic code could have
been caused by a problem during start-up with
one of the controls of the ECM. Resume normal
operation. STOP.

corrected.

that the information is correct.

that has activated the diagnostic code may have
failed.

may greatly reduce repair time. If the cause of the g01252009
diagnostic code is not found, replace the ECM that Illustration 158
has activated the diagnostic code. Refer to Testing Locations of Articulation Angle Sensors
and Adjusting, “Electronic Control Module (ECM) (1) Articulation angle sensor 1
- Replace”. (2) Articulation angle sensor 2
(3) Mechanical linkage
STOP.
Two articulation angle sensors are required for
correct operation of the articulation of the machine.
Each sensor will provide a PWM input to the
Transmission/Chassis ECM and the Implement ECM.
206 RENR9004-07
This diagnostic code is associated with the Note: The following test procedure may create other
articulation angle sensor 1 of the machine. The diagnostic codes. Ignore these created diagnostic
FMI 02 means that the ECM has determined codes and clear the diagnostic codes when the
that the input data from the sensor is erratic, original diagnostic code has been corrected.
intermittent, or incorrect. The Implement ECM, the
Transmission/Chassis ECM or both of the ECM Test Step 1. CHECK THE MECHANICAL
modules can activate this diagnostic code. LINKAGE
The sensor is a PWM sensor that operates at a A. Turn the key start switch and the disconnect
frequency of approximately 500 hertz. When the switch to the OFF position.
machine is in the neutral position, the duty cycle of
the sensor to the ECM is approximately 55%. When B. Remove any guards or shielding for the articulation
the machine is articulated to the full left position, sensors.
the duty cycle will be approximately 33%. When the
machine is articulated to the full right position, the C. Check the mounting bolts for the articulation
duty cycle will be approximately 74%. sensors. Ensure that the sensors are securely
mounted.
below: D. Visually inspect the mechanical linkage for the
articulation sensors. Verify that all mechanical
• Mechanical devices are loose or mechanical components are tight and that all components are
devices are not adjusted correctly. in good condition. Verify that the adjustment of the
linkage is correct.
• There is an Intermittent connection or a poor
connection in the circuit. Expected Result:
• The sensor has failed. All mechanical linkage and adjustment components
for the articulation sensors are in good condition and
• The ECM has failed. This is unlikely. no mechanical connections are loose.
Note: The Transmission/Chassis ECM (MID 027) Results:

and the Implement ECM (MID 082) receive an input
signal from the articulation sensor 1. Both ECM • OK – All mechanical linkage and adjustment for
modules can activate a CID 0615 FMI 02 diagnostic the articulation sensors is correct. Proceed to Test
code when an erratic signal or an intermittent signal Step 2.
is detected.
If one ECM has activated a CID 0615 FMI 02 • NOT OK – All mechanical linkage and adjustment
diagnostic code and the other ECM has not, it is for the articulation sensors is not correct.
likely that the sensor is operating correctly. When this
occurs, a poor connection in the machine harness Repair: Perform the maintenance that is required
would be suspected. in order to correct the problem with the mechanical
When both of the ECM modules have activated connections for the articulation sensors. After
the diagnostic code, either the sensor or a harness the problem has been corrected, verify that this
problem could be the cause. diagnostic code is still active before proceeding
If both ECM modules have activated the diagnostic with this procedure.
code, it is very unlikely that either ECM is causing the
problem. STOP.
For either condition, proceed with this procedure in Test Step 2. CHECK FOR POWER AT THE
order to verify the cause of the problem. SENSOR
Note: Before performing this procedure, inspect A. Turn the key start switch and the disconnect
the harness connectors that are involved in the switch to the OFF position.
of a problem in an electrical circuit. Verify that B. Do not disconnect the harness connector from the
all connections in the circuit are clean, that all sensor.
are in good condition. If a problem with a C. At the back of the harness connector for the
connection is found, correct the problem and sensor, insert 7X-1710 Multimeter Probes along
verify that this diagnostic code is active before the contact for the power circuit A (wire R800-OR)
performing this procedure. and along the contact for the return circuit B (wire
P967-PU).
RENR9004-07 207
D. Turn the key start switch and the disconnect Results:

• OK – The sensor's signal responds correctly. The
E. Measure the voltage from contact A to contact B. sensor is operating correctly. Proceed to Test Step
4.
Expected Result:
• NOT OK – The sensor's signal does not respond
The voltage measurement is 8.0 ± 0.5 DCV. correctly. The sensor is NOT operating correctly.
Results: Repair: Replace the articulation angle 1 sensor.

After replacement of the sensor, the sensor must
• OK – The voltage measurement is 8.0 ± 0.5 DCV. be calibrated. Refer to Testing and Adjusting,
The power supply circuit is correct. Proceed to “Calibration” section of this manual for the correct
Test Step 3. calibration procedure.
• NOT OK – The voltage measurement is not 8.0 ± STOP.

0.5 DCV. The power supply circuit is not correct.
Test Step 4. CHECK FOR AN OPEN IN
Repair: There is a problem with the 8 VDC power THE SIGNAL CIRCUIT
supply circuit of the Implement ECM for the sensor.
Refer to the complete Electrical System Schematic The key start switch and the disconnect switch
of the machine. Check all of the connections that remain in the OFF position.
are in the power supply circuit and the return
circuit. Ensure that all connections are clean, that A. Disconnect the machine harness connector from
all connections are secure and that all connections the sensor.
are in good condition. Repair the machine harness
or replace the machine harness. B. Disconnect the machine harness connector J2
from the Transmission/Chassis ECM.
STOP.
Test Step 3. CHECK THE SIGNAL OF THE connect the jumper wire between a good contact
SENSOR of the frame ground and signal contact C (wire
E929-GY).
switch to the OFF position. D. At the machine harness connectors for
the Transmission/Chassis ECM, measure
B. At the back of the harness connector for the the resistance from a good contact of the
sensor, remove the multimeter probe from contact frame ground to the connector contact for
A (wire R800-OR) and insert the probe along the the Transmission/Chassis ECM J2-41 (wire
signal contact C (wire E929-GY). E929-GY).
C. The multimeter probe along return contact B (wire E. Observe the resistance measurement and wiggle
P967-PU) remains in place. the ECM connector and the sensor connector.
Gently pull on the wires and wiggle the wires for
D. Turn the disconnect switch and the key start both connectors.
Expected Result:
E. Monitor the signal of the sensor with a digital
multimeter. The resistance measurement is less than 5 ohms
at all times during the manipulation of the wiring
F. Without disconnecting the sensor or the hardware harness.
that is associated with the sensor from the
machine, take the sensor through the full Results:
operating range of the sensor.
Note: 5 ohms. The resistance measurement is not
indicating an open in the circuit. Proceed to Test
Expected Result: Step6.
The sensor's signal responds in the manner that is • NOT OK – The resistance measurement is greater
described at the beginning of this procedure. than 5 ohms. There is an open connection or a bad
connection in the signal circuit.
208 RENR9004-07
Repair: If both of the ECM modules have activated Results:

this diagnostic code, there is most likely an open
connection or a bad connection on the sensor side • YES – The CID 0615 FMI 02 diagnostic code is no
of the splice connection of the machine harness longer active. A CID 0615 FMI 03 diagnostic code
for the signal wire. has been activated after the wire for the sensor
signal was disconnected. The ECM has responded
If only the Transmission/Chassis ECM has correctly to the open circuit condition in the sensor
activated this diagnostic code, then there is most circuit.
likely an open connection or a bad connection
on the ECM side of the splice connection of the Reinstall the disconnected sensor signal wire back
machine harness for the signal wire. into the correct spot in the connector of the ECM
before proceeding to the next test step.
In either case, refer to the complete Electrical
System Schematic for the machine. Check all of Proceed to Test Step 6.
the connectors that are in the suspected section
of the signal circuit for the sensor. Ensure that • NO – The CID 0615 FMI 03 diagnostic code
all connections are clean, that all connectors remains active. The status of the active diagnostic
are secure and that all connectors are in good code does not change as the sensor signal wire is
condition. Repair the machine harness or replace disconnected from the ECM.
Repair: The ECM has not responded correctly
STOP. to the open condition in the sensor circuit. The
operation of the ECM is not correct.
Test Step 5. CHECK THE OPERATION OF
THE ECM Prior to replacing an ECM, always contact your
The key start switch and the disconnect switch consultation with Caterpillar. This consultation may
remain in the OFF position. The machine harness greatly reduce repair time. If the ECM must be
connectors for the sensor and both the Implement replaced, refer to Testing and Adjusting, “Electronic
ECM and the Transmission/Chassis ECM remain Control Module (ECM) - Replace”.
disconnected.
STOP.
Note: This check should be performed on the ECM
that has activated the diagnostic code. If both of the Test Step 6. CHECK THE STATUS OF THE
ECM modules have activated the diagnostic code, DIAGNOSTIC CODE
perform this check on both of the ECM modules.
A. At the machine harness connector J2 for the contacts of the harness connectors. Check the
ECM, use a 151-6320 Removal Tool to remove wires for damage to the insulation that is caused
the sensor signal wire E929-GY and the socket at by excessive heat, battery acid, or chafing.
contact J2-41 from the harness connector.
B. Reconnect the machine harness J1 and J2 wires that are associated with the sensor circuit.
connectors to the ECM.
C. Turn the key start switch and the disconnect the connectors are fully seated. Observe that the
switch to the ON position. clips for each connector are completely fastened.
D. Observe the status of the active CID 0615 FMI D. Turn the disconnect switch and the key start
02 diagnostic code. switch to the ON position.
Expected Result: E. Operate the machine.
The CID 0615 FMI 02 diagnostic code is no longer F. Check the status of the CID 0615 FMI 02
active. A CID 0615 FMI 03 diagnostic code is now diagnostic code.
active.
Expected Result:

RENR9004-07 209
Results: i02916763
• OK – The CID 0615 FMI 02 diagnostic code is MID 027 - CID 0615 - FMI 03
this time. The initial diagnostic code was probably SMCS Code: 4806-038
of the connectors that was disconnected and Conditions Which Generate This Code:

corrected.

If the cause of the active diagnostic code is not

found, replace the sensor. After replacement of the
sensor, the sensor must be calibrated. Refer to the
Testing and Adjusting, “Calibration” section of this
manual for the correct calibration procedure.
If the problem is still present after replacement

of the sensor, the ECM may have failed. This is
g01242576
unlikely as the ECM responded correctly to the Illustration 159
condition change in the previous test step. Connections of the Machine Articulation Angle Sensor 1.

again. If the cause of the failure is not found,
replace the ECM that activated the diagnostic
code.

diagnostic code is not found, and the ECM must be
replaced, refer to Testing and Adjusting, “Electronic
STOP.
g01252009
Illustration 160
Locations of the Articulation Angle Sensors

Implement ECM and the Transmission/Chassis ECM.
210 RENR9004-07
The FMI 03 diagnostic code is activated when the Note: Before performing this procedure, inspect
ECM reads the input signal from the articulation the harness connectors that are involved in the
angle sensor of the machine 1 and the voltage of the circuit. Poor connections can often be the cause
signal is above normal. The Implement ECM, the of a problem in an electrical circuit. Verify that
Transmission/Chassis ECM or both ECM modules all connections in the circuit are clean, that all
can activate this diagnostic code. connections are secure and that all connections
The sensor is a PWM sensor that operates at a connection is found, correct the problem and
frequency of approximately 500 hertz. When the verify that this diagnostic code is active before
machine is in the neutral position, the duty cycle of performing this procedure.
the sensor to the ECM is approximately 55%. When
the machine is articulated to the full left position, Note: The following test procedure may create other
the duty cycle will be approximately 33%. When the diagnostic codes. Ignore these created diagnostic
machine is articulated to the full right position, the codes and clear the diagnostic codes when the
duty cycle will be approximately 74%. original diagnostic code has been corrected.
The possible causes of this diagnostic code are listed Test Step 1. CHECK THE MECHANICAL
below: LINKAGE
• The circuit of the sensor power supply is open. A. Turn the key start switch and the disconnect
• The return circuit is open.
B. Remove any guards or shielding for the articulation
• The signal circuit is open or the sensor is sensors.
disconnected.
C. Check the mounting bolts for the articulation
• The signal circuit is shorted to the sensor power sensors. Ensure that the sensors are securely
supply. mounted.
• The sensor has failed. D. Visually inspect the mechanical linkage for the
• The ECM has failed. This is unlikely. components are tight and that all components are
in good condition. Verify that the adjustment of the
Note: Before performing this procedure, check for an linkage is correct.
active CID 0041 diagnostic code for the 8 volt sensor
power supply of the ECM. Correct any problem Expected Result:
with the 8 volt power supply before performing this
procedure. All mechanical linkage and components for adjusting
the articulation sensors are in good condition and no
Note: The Transmission/Chassis ECM (MID 027) and mechanical connections are loose.
the Implement ECM (MID 082) receive an input signal
from the articulation sensor 1. Both ECM modules Results:
can activate a CID 0615 FMI 03 diagnostic code
when an above normal voltage signal is detected. • OK – All mechanical linkage and adjustment for
If one ECM has activated a CID 0615 FMI 03 the articulation sensors is correct. Proceed to Test
diagnostic code and the other ECM has not, it is Step 2.
occurs, a poor connection in the machine harness • NOT OK – All mechanical linkage and adjustment
would be suspected. for the articulation sensors is not correct.
When both ECM modules have activated the
diagnostic code, either the sensor or a harness Repair: Perform the maintenance that is required
problem could be the cause. in order to correct the problem with the mechanical
If both ECM modules have activated the diagnostic connections for the articulation sensors. After
code, it is very unlikely that either ECM is causing the the problem has been corrected, verify that this
problem. diagnostic code is still active before proceeding
For either condition, proceed with this procedure in with this procedure.
order to verify the cause of the problem.
STOP.
RENR9004-07 211
Test Step 2. CHECK THE SUPPLY D. At the machine harness connector for the
VOLTAGE AT THE SENSOR Transmission/Chassis ECM, measure the
resistance from a good contact for the frame
A. Turn the key start switch and the disconnect ground and the connector contact for the
switch to the OFF position. Transmission/Chassis ECMJ2-41 (wire E929-GY).
B. Do not disconnect the harness connector from the E. Observe the resistance measurement and wiggle
sensor. the ECM connector and the sensor connector.
C. At the back of the harness connector for the both connectors.
sensor, insert 7X-1710 Multimeter Probes along
contact for the supply A (wire R800-OR). Insert Expected Result:
a multimeter probe along return contact B (wire
P967-PU). The resistance measurement is less than 5 ohms
D. Turn the key start switch and the disconnect harness.
Results:
E. Measure the voltage from contact A to contact B.
Expected Result: 5 ohms. The resistance measurement is not
indicating an open in the circuit. Proceed to Test
The voltage measurement is 8.0 ± 0.5 DCV. Step4.
Results: • NOT OK – The resistance measurement is greater

• OK – The voltage measurement is 8.0 ± 0.5 DCV. in the signal circuit.
The power supply circuit is correct. Proceed to
Test Step 3. Repair: If both of the ECM modules have activated
this diagnostic code, there is most likely an open
• NOT OK – The voltage measurement is not 8.0 ± connection or a bad connection on the sensor side
0.5 DCV. The power supply circuit is not correct. of the splice connection for the machine harness
of the signal wire.
Repair: There is a problem with the power supply
(8 VDC) of the Implement ECM for the sensor. If only the Transmission/Chassis ECM has
Refer to the complete Electrical System Schematic activated this diagnostic code, there is most likely
of the machine. Check all of the connections that an open or a bad connection on the ECM side
are in the power supply circuit and the return of the machine harness splice connection for the
circuit. Ensure that all connections are clean, that signal wire.
all connections are secure and that all connections
are in good condition. Repair the machine harness In either case, refer to the complete Electrical
or replace the machine harness. System Schematic of the machine. Check all of
the connectors in the faulty section the signal
STOP. circuit of the sensor. Ensure that all connections
Test Step 3. CHECK FOR AN OPEN IN all connections are in good condition. Repair the
THE SIGNAL CIRCUIT machine harness or replace the machine harness.
The key start switch and the disconnect switch STOP.

remain in the OFF position.
Test Step 4. CHECK THE SIGNAL
A. Disconnect the machine harness connector from CIRCUIT FOR A SHORT
the sensor.
The key start switch and the disconnect switch remain
B. At the machine harness connector for the sensor, in the OFF position. The harness connectors of the
connect the jumper wire between a good contact Transmission/Chassis ECM remain disconnected
for the frame ground and the signal contact C from the machine harness.
(wire E929-GY).
A. Remove the jumper wire that was installed in the
C. Disconnect the machine harness connectors J1 last step.
and J2 from the Implement ECM.
212 RENR9004-07
C. At the J1 and J2 machine harness connectors D. Monitor the signal of the sensor with a digital
for the Transmission/Chassis ECM, measure multimeter.
the resistance from the sensor signal contact
J2-41 (wire E929-GY) to all of the other E. Without disconnecting the sensor or the hardware
J1 and J2 contacts that are used for the that is associated with the sensor from the
Transmission/Chassis ECM. machine, take the sensor through the full
D. At the J1 and J2 machine harness connectors for
the Implement ECM, measure the resistance from Expected Result:
the sensor signal contact J2-41 (wire E929-GY) to
all of the other J1 and J2 contacts that are used The sensor's signal responds in the manner that is
for the Implement ECM. described at the beginning of this procedure.
Each resistance measurement is greater than 5000 • OK – The sensor's signal responds correctly. The
ohms. sensor is operating correctly. Proceed to Test Step
6.
Results:
• OK – Each resistance measurement is greater correctly. The sensor is NOT operating correctly.
than 5000 ohms. The signal circuit is not shorted.
Proceed to Test Step 5. Repair: Replace the articulation angle 1 sensor.
• NOT OK – A resistance measurement is less than be calibrated. Refer to Testing and Adjusting,
5000 ohms. “Calibration” section of this manual for the correct
calibration procedure.
Repair: There is a short in the machine harness.
The short is between the signal circuit and the STOP.
circuit with the low resistance measurement.
Refer to the complete Electrical System Schematic THE ECM
of the machine. Check all of the connectors that are
in the sensor circuit. Ensure that all connections Note: This check should be performed on the ECM
are clean, that all connectors are secure and that that has activated the diagnostic code. If both of the
all connectors are in good condition. ECM modules have activated the diagnostic code,
finding short circuits, refer to Testing and Adjusting, A. Turn the disconnect switch and the key start
“Wiring Harness (Short Circuit) - Test”. Repair the switch to the OFF position.
B. At the machine harness connector J2 for the
STOP. ECM, use a 151-6320 Removal Tool to remove
the sensor signal wire E929-GY and the socket at
Test Step 5. CHECK THE SIGNAL OF THE contact J2-41 from the harness connector. The
SENSOR connector J2 remains connected to the ECM.
The key start switch and the disconnect switch C. Turn the key start switch and the disconnect
remain in the OFF position. switch to the ON position.
A. Reconnect the harness connectors to the sensor D. Use a 7X-1710 Multimeter Probe that is not
and reconnect the J1 and J2 connectors to the connected to a multimeter or a similar device to
Implement ECM and to the Transmission/Chassis make contact with the ECM pin at J2-41 through
ECM. the empty space in the J2 connector.
B. At the back of the harness connector for the E. Observe the status of the active CID 0615 FMI 03
sensor, insert the multimeter probe along contact diagnostic code and ground the other end of the
B (wire P967-GY) and insert the probe along the 7X-1710 Multimeter Probe to frame ground.
signal contact C (wire E929-GY).

RENR9004-07 213
The CID 0615 FMI 03 diagnostic code is no longer The CID 0615 FMI 03 diagnostic code is not active.
active. A CID 0615 FMI 04 diagnostic code becomes
active when the ECM pin at J2-41 is grounded. Results:
Results: • OK – The CID 0615 FMI 03 diagnostic code is

• YES – The CID 0615 FMI 03 diagnostic code is no this time. The initial diagnostic code was probably
longer active. A CID 0615 FMI 04 diagnostic code caused by a poor connection or a short at one
has been activated after the ECM pin is grounded. of the connectors that was disconnected and
The ECM has responded correctly to the grounded reconnected. Resume normal operation. STOP.
circuit condition in the solenoid circuit. The the
problem is probably not caused by the ECM. • NOT OK – The CID 0615 FMI 03 diagnostic
Reinstall the disconnected sensor signal wire back corrected.
into the correct spot in the ECM connector before
proceeding to the next test step. Repair: Check the circuit again. Use the Caterpillar
Proceed to Test Step 7. in order to perform a wiggle test on the machine
• NO – The CID 0615 FMI 03 diagnostic code momentary or intermittent shorts or opens in the
remains active. The status of the active diagnostic machine wiring harness.
code does not change when the ECM pin for the
sensor signal is grounded. If the cause of the active diagnostic code is not
found, replace the sensor. After replacement of the
Repair: The ECM has not responded correctly to sensor, the sensor must be calibrated. Refer to the
the grounded condition in the sensor circuit. The Testing and Adjusting, “Calibration” section of this
operation of the ECM is not correct. manual for the correct calibration procedure.
Prior to replacing an ECM, always contact your If the problem is still present after replacement
dealership's Technical Communicator for possible of the sensor, the ECM may have failed. This is
consultation with Caterpillar. This consultation may unlikely as the ECM responded correctly to the
greatly reduce repair time. If the ECM must be condition change in the previous test step.
Control Module (ECM) - Replace”. Prior to replacing an ECM, always contact your
STOP. consultation with Caterpillar. This consultation
Test Step 7. CHECK THE STATUS OF THE diagnostic code is not found, and the ECM must be
DIAGNOSTIC CODE replaced, refer to Testing and Adjusting, “Electronic




is active.
214 RENR9004-07

articulation angle sensor 1 of the machine. The FMI
MID 027 - CID 0615 - FMI 04 04 code means that the ECM has detected that the
voltage of the sensor signal is below normal. Either
SMCS Code: 4806-038 the Implement ECM or the Transmission/Chassis
ECM or both ECM's can activate this diagnostic code.
machine is in the neutral position, the duty cycle
of the sensor input to the ECM is approximately
The possible causes of this diagnostic code are

listed:
• The signal circuit is shorted to ground.

Note: The Transmission/Chassis ECM (MID 027)
signal from the articulation sensor 1. Both ECM's can
g01407303
Illustration 161 activate a CID 0615 FMI 04 diagnostic code when a
Machine Articulation Angle Sensor 1 connections below normal voltage signal is detected.
If one ECM has an active CID 0615 FMI 04 diagnostic
code and the other ECM does not, it is probable that
the sensor is operating correctly. When this occurs,
a poor connection in the machine harness would be
suspected.
When both ECM's have an active diagnostic code,
either the sensor OR a harness problem could be the
cause.
If both ECM's have activated the diagnostic code, it is
very unlikely that either ECM is causing the problem.
For either condition, proceed with this procedure in

g01397991 verify that this diagnostic code is active before
Illustration 162 performing this procedure.
Locations of Articulation Angle Sensors
Two articulation angle sensors are required for diagnostic codes. Ignore these created diagnostic
correct operation of the articulation control of the codes and clear the diagnostic codes when the
machine. Each sensor will provide a PWM input to the original diagnostic code has been corrected.
RENR9004-07 215
Test Step 1. CHECK THE MECHANICAL Results:

LINKAGE
• YES – The CID 0615 FMI 04 diagnostic code is no
A. Turn the key start switch and the disconnect longer active. A CID 0615 FMI 03 diagnostic code
switch to the OFF position. is now active. The ECM and the circuit are correct.
The position sensor is causing the problem.
B. Remove any guards or shielding for the articulation
sensors. Repair: The sensor has failed. Replace the
articulation angle 1 sensor. After replacement of
C. Check the mounting bolts for the articulation the sensor, the sensor must be calibrated. Refer to
sensors. Ensure that the sensors are securely the Testing and Adjusting, “Calibration” section of
mounted. this manual for the correct calibration procedure.
D. Visually inspect the mechanical linkage for the STOP.

components are tight. Verify that all mechanical • NO – The CID 0615 FMI 04 diagnostic code
components are in good condition. Verify that the remains active. Disconnecting the sensor did not
adjustment of the linkage is correct. affect the status of the active diagnostic code.
The position sensor is not causing the problem.
Expected Result: Proceed to Test Step 3.
All mechanical linkage and adjustment components Test Step 3. CHECK THE SIGNAL
for the articulation sensors are in good condition and CIRCUIT FOR A SHORT TO GROUND
no mechanical connections are loose.
A. The sensor remains disconnected from the
Results: machine harness.
• OK – All mechanical linkage and adjustment for B. Turn the key start switch and the disconnect
the articulation sensors is correct. Proceed to Test switch to the OFF position.
Step 2.
C. Disconnect the J1 and J2 machine harness
• NOT OK – All mechanical linkage and adjustment connectors from the Implement ECM and the
for the articulation sensors is not correct. Transmission/Chassis ECM.
Repair: Perform the maintenance that is required D. At machine harness connector J2 for the
in order to correct the problem with the mechanical Transmission/Chassis ECM, measure the
connections for the articulation sensors. After resistance from contact J2-41 (wire E929-GY) to
the problem has been corrected, verify that this frame ground. Measure the resistance between
diagnostic code is still active before proceeding contact J2-41 (wire E929-GY) and all of the other
with this procedure. contacts that are used in the connectors of the
machine harness for the Transmission/Chassis
STOP. ECM.
Test Step 2. CHECK THE SENSOR E. At machine harness connector J2 for the
Implement ECM, measure the resistance from
A. Turn the disconnect switch and the key start contact J2-41 (wire E929-GY) to frame ground.
switch to the ON position. Measure the resistance from contact J2-41 (wire
E929-GY) to all of the other contacts that are
B. Ensure that the diagnostic code is active. used in the machine harness connectors for the
Implement ECM.
C. Observe the status of the diagnostic code while
disconnecting the sensor from the machine Expected Result:
harness.
Expected Result: ohms.
The CID 0615 FMI 04 diagnostic code is no longer Results:

active. A CID 0615 FMI 03 diagnostic code is now
active. • OK – Each resistance measurement is greater
216 RENR9004-07
• NOT OK – One or more of the resistance Results:

measurements is NOT correct. The machine
harness has failed. • YES – The CID 0615 FMI 04 diagnostic code is
Repair: There is a short in the machine harness code is active after the sensor signal wire is
between the signal circuit and the circuit with the disconnected. The ECM has responded correctly
low resistance measurement. to the open circuit condition in the sensor circuit.
Refer to the complete Electrical System Schematic Reinstall the disconnected sensor signal wire back
of the machine. Check all of the connectors that are into the correct spot in the ECM connector before
in the sensor circuit. Ensure that all connections proceeding to the next test step.
are clean, that all connectors are secure and that
all connectors are in good condition. Proceed to Test Step 5.
For information on testing for short circuits and • NO – The CID 0615 FMI 04 diagnostic code
finding short circuits, refer to Testing and Adjusting, remains active. The status of the active diagnostic
“Wiring Harness (Short Circuit) - Test”. Repair the code does not change when the sensor signal wire
machine harness or replace the machine harness. is disconnected from the ECM.
STOP. Repair: The ECM has not responded correctly

to the open condition in the sensor circuit. The
Test Step 4. CHECK THE OPERATION OF operation of the ECM is not correct.
THE ECM
The key start switch and the disconnect switch dealership's Technical Communicator for possible
remain in the OFF position. The machine harness consultation with Caterpillar. This consultation may
connectors for the sensor and both the Implement greatly reduce repair time. If the ECM must be
ECM and the Transmission/Chassis ECM remain replaced, refer to Testing and Adjusting, “Electronic
disconnected. Control Module (ECM) - Replace”.
Note: This check should be performed on the ECM STOP.

that has activated the diagnostic code. If both of the
ECM's have activated the diagnostic code, perform Test Step 5. CHECK THE STATUS OF THE
this check on both of the ECM's. DIAGNOSTIC CODE
A. At the machine harness connector J2 for the A. Inspect the harness connectors. Clean the
ECM, use a 151-6320 Removal Tool to remove contacts of the harness connectors. Check the
the sensor signal wire E929-GY and the socket at wires for damage to the insulation that is caused
contact J2-41 from the harness connector. by excessive heat, battery acid, or chafing.
B. Reconnect the machine harness J1 and J2 B. Perform a 45 N (10 lb) pull test on each of the
connectors to the ECM. wires that are associated with the sensor circuit.
C. Turn the key start switch and the disconnect C. Reconnect all harness connectors. Make sure that
switch to the ON position. the connectors are fully seated. Observe that the
D. Observe the status of the active CID 0615 FMI
04 diagnostic code. D. Turn the disconnect switch and the key start
Expected Result:
active. A CID 0615 FMI 03 diagnostic code is now F. Determine if the CID 0615 FMI 04 diagnostic code
active. is active.
Expected Result:

RENR9004-07 217
Results: i02917085
this time. The initial diagnostic code was probably SMCS Code: 4806-038

corrected.

If the problem is still present the ECM may have

failed. This is not likely as the ECM responded
correctly to the condition change in the previous
test step.

g01242576
may greatly reduce repair time. If the cause of the Illustration 163
diagnostic code is not found, and the ECM must be Connections of the Machine Articulation Angle Sensor 1.
STOP.
g01252009
Illustration 164
Location of the Articulation Angle Sensors

218 RENR9004-07
This diagnostic code is associated with the Note: The following test procedure may create other
articulation angle sensor 1 of the machine. The FMI diagnostic codes. Ignore these created diagnostic
08 means that the ECM has determined that the codes and clear the diagnostic codes when the
signal frequency or the signal pulse width is not original diagnostic code has been corrected.
within the expected range. The Implement ECM, the
Transmission/Chassis ECM or both ECM modules Test Step 1. CHECK THE MECHANICAL
can activate this diagnostic code. LINKAGE
machine is in the neutral position, the input of the
duty cycle to the ECM is approximately 55%. When B. Remove any guards or shielding for the articulation
the machine is articulated to the full left position, sensors.
machine is articulated to the full right position, the C. Check the mounting bolts for the articulation
duty cycle will be approximately 74%. sensors. Ensure that the sensors are securely
mounted.
• The sensor has failed. components are tight and that all mechanical
components are in good condition. Verify that the
• Intermittent connections or poor connections adjustment of the linkage is correct.
• Mechanical devices are loose. Expected Result:
• The ECM has failed. This is unlikely. All mechanical linkage and components for
adjustment of the articulation sensors are in good
Before performing this procedure, check for an active condition and no mechanical connections are loose.
CID 0041 diagnostic code for the 8 volt sensor power
supply of the ECM. Correct any problem with the 8 Results:
volt power supply before performing this procedure.
• OK – All mechanical linkage and adjustment for
Note: The Transmission/Chassis ECM (MID 027) the articulation sensors is correct. Proceed to Test
and the Implement ECM (MID 082) receive an input Step 2.
signal from the articulation sensor 1. Both ECM
modules can activate a CID 0615 FMI 08 diagnostic • NOT OK – All mechanical linkage and adjustment
code when the signal frequency or the signal pulse for the articulation sensors is not correct.
width is not within the expected range.
If one ECM has activated a CID 0615 FMI 08 Repair: Perform the maintenance that is required
diagnostic code and the other ECM has not activated in order to correct the problem with the mechanical
the code, it is possible that the sensor is operating connections for the articulation sensors. After
correctly. When this occurs, a poor connection in the the problem has been corrected, verify that this
machine harness would be suspected. diagnostic code is still active before proceeding
When both ECM modules have activated the with this procedure.
diagnostic code, either the sensor or a harness
problem could be the cause. STOP.
If both ECM modules have activated the diagnostic
code, it is very unlikely that either ECM is causing the Test Step 2. CHECK THE SIGNAL OF THE
problem. SENSOR
order to verify the cause of the problem. A. Turn the key start switch and the disconnect
the harness connectors that are involved in the B. At the back of the harness connector for the
circuit. Poor connections can often be the cause sensor, insert 7X-1710 Multimeter Probes along
of a problem in an electrical circuit. Verify that return contact B (wire P967-PU) and insert a
all connections in the circuit are clean, that all probe along the signal contact C (wire E929-GY).
are in good condition. If a problem with a C. Turn the disconnect switch and the key start
connection is found, correct the problem and switch to the ON position.
RENR9004-07 219
D. Monitor the signal of the sensor with a digital Results:

multimeter.
E. Without disconnecting the sensor or the hardware 5 ohms. The resistance measurement is not
that is associated with the sensor from the indicating an open in the circuit. Proceed to Test
machine, take the sensor through the full Step4.
• NOT OK – One or both of the resistance
Expected Result: measurements is greater than 5 ohms. There is an
open connection or a bad connection in the signal
The sensor's signal responds in the manner that is circuit.
described at the beginning of this procedure.
Repair: If both of the ECM modules have activated
Results: this diagnostic code, there is most likely an open
connection or a bad connection on the sensor side
• OK – The sensor's signal responds correctly. The of the machine harness splice connection for the
sensor is operating correctly. Proceed to Test Step signal wire.
3.
If only the Transmission/Chassis ECM has
• NOT OK – The sensor's signal does not respond activated this diagnostic code, there is most likely
correctly. The sensor is not operating correctly. an open or a bad connection on the ECM side
of the machine harness splice connection for the
Repair: Replace the articulation angle 1 sensor. signal wire.
be calibrated. Refer to Testing and Adjusting, In either case, refer to the complete Electrical
“Calibration” section of this manual for the correct System Schematic of the machine. Check all of the
calibration procedure. connectors that are in the suspected section of the
sensor signal circuit. Ensure that all connections
STOP. are clean, that all connections are secure and that
Test Step 3. CHECK FOR AN OPEN IN machine harness or replace the machine harness.
THE SIGNAL CIRCUIT
STOP.
switch to the OFF position. Test Step 4. CHECK THE OPERATION OF
THE ECM
the sensor. The key start switch and the disconnect switch
C. At the machine harness connector for the sensor, connector for the sensor and the J2 connector for the
connect the jumper wire between a good ground Transmission/Chassis ECM remain disconnected.
contact of the frame and the signal contact C (wire
E929-GY). Note: This check should be performed on the ECM
that has activated the diagnostic code. If both of the
D. Disconnect the machine harness connector J2 ECM modules have activated the diagnostic code,
from the Transmission/Chassis ECM. perform this check on both of the ECM modules.
E. At the machine harness connectors for the A. At the machine harness connector J2 for the
Transmission/Chassis ECM, measure the ECM, use a 151-6320 Removal Tool to remove
resistance from the frame ground to the connector the sensor signal wire E929-GY and the socket at
contact of the Transmission/Chassis ECM J2-41 contact J2-41 from the harness connector.
(wire E929-GY).
B. Reconnect the machine harness J1 and J2
F. Observe the resistance measurement and wiggle connectors to the ECM.
the ECM connector and the sensor connector.
Gently pull on the wires and wiggle the wires for C. Turn the key start switch and the disconnect
both connectors. switch to the ON position.
Expected Result: D. Observe the status of the active CID 0615 FMI
08 diagnostic code.
The resistance measurement is less than 5 ohms
harness.
220 RENR9004-07
The CID 0615 FMI 08 diagnostic code is no longer • OK – The CID 0615 FMI 08 is not active. The
active. A CID 0615 FMI 03 diagnostic code is now diagnostic code does not exist at this time. The
active. initial diagnostic code was probably caused by a
poor connection or a short at one of the connectors
Results: that was disconnected and reconnected. Resume
normal operation. STOP.
longer active. A CID 0615 FMI 03 diagnostic code • NOT OK – The CID 0615 FMI 08 is active. The
has been activated after the sensor signal wire was diagnostic code has not been corrected.
disconnected. The ECM has responded correctly
to the open circuit condition in the sensor circuit. Repair: Check the circuit again. Use the Caterpillar
Reinstall the disconnected sensor signal wire back in order to perform a wiggle test on the machine
into the correct spot in the ECM connector before wiring harness. The wiggle test can detect
proceeding to the next test step. momentary or intermittent shorts or opens in the
• NO – The CID 0615 FMI 08 diagnostic code found, replace the sensor. After replacement of the
remains active. The status of the active diagnostic sensor, verify that the new sensor corrected the
code does not change when the sensor signal wire problem. If the problem is still present after the
is disconnected from the ECM. replacement of the sensor, the ECM may have
failed. This is unlikely as the ECM responded
Repair: The ECM has not responded correctly correctly to the condition in the previous test step.
operation of the ECM is not correct. Prior to replacing an ECM, always contact your
Prior to replacing an ECM, always contact your consultation with Caterpillar. This consultation
dealership's Technical Communicator for possible may greatly reduce repair time. If the cause of the
consultation with Caterpillar. This consultation may diagnostic code is not found, and the ECM must be
greatly reduce repair time. If the ECM must be replaced, refer to Testing and Adjusting, “Electronic
replaced, refer to Testing and Adjusting, “Electronic Control Module (ECM) - Replace”.
STOP.
STOP.

DIAGNOSTIC CODE



Expected Result:

RENR9004-07 221
i02917093 CALIBRATION
MID 027 - CID 0615 - FMI 13 A. Perform the calibration procedure for the sensor.
Refer to Testing and Adjusting, “Calibration”
SMCS Code: 4806-038 section of this manual for the correct calibration
procedure.
Expected Result:
The calibration procedure was performed

successfully.
Results:
• YES – The calibration procedure was performed

successfully. Resume normal machine operation.
STOP.
• NO – The calibration was not successful.

Repair: Repeat the calibration procedure for the
sensor.
If the second calibration procedure is not

successful, replace the position sensor. Refer to
the Testing and Adjusting, “Calibration” section of
this manual for the correct calibration procedure. If
the problem is still present after replacement and
g01252009
Illustration 165 calibration of the new sensor, the ECM may be
Locations of the Articulation Angle Sensors faulty.
(2) Articulation angle sensor 2 Prior to replacing an ECM, always contact your
(3) Mechanical linkage dealership's Technical Communicator for possible
Two articulation angle sensors are required for may greatly reduce repair time. If the cause of the
correct operation of the articulation of the machine. diagnostic code is not found, replace the ECM that
Each sensor will provide a PWM input to the activated the diagnostic code. Refer to Testing
Implement ECM and the Transmission/Chassis ECM. and Adjusting, “Electronic Control Module (ECM)
- Replace”.
The CID 0615 FMI 13 diagnostic code is recorded
when the ECM detects that the angle sensor 1 STOP.
is out of calibration. The Implement ECM and
the Transmission/Chassis ECM can activate this
diagnostic code.

machine is in the neutral position, the duty cycle to
the ECM is approximately 55%. When the machine
is articulated to the full left position, the duty cycle
will be approximately 33%. When the machine is
articulated to the full right position, the duty cycle will
be approximately 74%.
Note: The sensor supply of the ECM provides power

to the sensor. The sensor does not connect directly to
the frame ground. The sensor connects to the return
circuit of the ECM. The ECM internally connects the
return wire to frame ground. In order to correct this
diagnostic code, calibrate the sensor.
222 RENR9004-07

articulation angle sensor 1 of the machine. The
MID 027 - CID 0615 - FMI 14 FMI 14 diagnostic code is recorded when the
ECM determines that the signal from the sensor is
SMCS Code: 4806-038 incorrect.
Conditions Which Generate This Code: The sensor is a PWM sensor that operates at a
machine is in the neutral position, the duty cycle of
the sensor to the ECM is approximately 55%. When
the machine is articulated to the full left position,
machine is articulated to the full right position, the
duty cycle will be approximately 74%.

below:
• The mechanical linkage for the position sensor is

not functioning correctly.

Note: Before performing this procedure, ensure that
g01242576
Illustration 166 there are no active CID 0041 diagnostic codes for the
Connections for the Machine Articulation Angle Position Sensor 1. power supply (8 VDC) of the sensor. Ensure that the
power supply for the angular sensor is correct.


original diagnostic code has been corrected.
Test Step 1. CHECK THE MECHANICAL

LINKAGE
g01252009 A. Turn the key start switch and the disconnect

Illustration 167 switch to the OFF position.
Locations for the Machine Articulation Angle Sensors.
(1) Articulation angle sensor 1 B. Remove any guards or shielding for the articulation
(2) Articulation angle sensor 2 sensors.
Two articulation angle sensors are required for sensors. Ensure that the sensors are securely
correct operation of the articulation of the machine. mounted.
RENR9004-07 223
D. Visually inspect the mechanical linkage for the • NOT OK – The calibration procedure has been
articulation sensors. Verify that all mechanical performed for the articulation sensor 1 of the
components are tight and that all mechanical machine. However, the FMI 14 diagnostic code is
components are in good condition. Verify that the still active. The problem has not been corrected.
adjustment of the linkage is correct. Proceed to Test Step 3.
Expected Result: Test Step 3. CHECK THE SIGNAL

CIRCUIT OF THE SENSOR
All mechanical linkage and components for
adjustment of the articulation sensors are in good A. The key start switch and the disconnect switch
condition and no mechanical connections are loose. remain in the OFF position.
Results: B. Do not disconnect the harness connector from the

sensor.
the articulation sensors is correct. Proceed to Test C. At the back of the harness connector for the
Step 2. sensor, insert 7X-1710 Multimeter Probes along
the return contact B (wire P967-PU) and insert a
• NOT OK – All mechanical linkage and adjustment multimeter probe along the contact of the signal
for the articulation sensors is not correct. wire C (wire E929-GY).
Repair: Perform the maintenance that is required D. Turn the disconnect switch and the key start
in order to correct the problem with the mechanical switch to the ON position.
connections for the articulation sensors. After
the problem has been corrected, verify that this E. Monitor the signal of the sensor with a digital
diagnostic code is still active before proceeding multimeter.
with this procedure.
F. Without disconnecting the sensor or the hardware
STOP. that is associated with the sensor from the
machine, articulate the machine through the full
Test Step 2. CALIBRATE THE POSITION range of operation.
SENSOR
Expected Result:
A. Verify that the linkage for the sensor is correct.
Use the Caterpillar Electronic Technician (ET) The sensor's signal responds in the manner that is
service tool in order to perform the calibration described at the beginning of this procedure.
procedure for the articulation angle sensor 1.
Refer to Testing and Adjusting, “Calibrations” Results:
for information on the process to access the
articulation sensor calibration procedure. • OK – The sensor's signal responds correctly. The
sensor is operating correctly. Proceed to Test Step
Expected Result: 4.
The calibration procedure has been performed for • NOT OK – The sensor's signal does not respond
the articulation sensor 1 of the machine and the FMI correctly. The sensor is not operating correctly.
14 diagnostic code is no longer active.
Repair: Replace the articulation angle 1 sensor.
Results: After replacement of the sensor, the sensor must
be calibrated. Refer to the Testing and Adjusting,
• OK – The calibration procedure has been “Calibration” section of this manual for the correct
performed for the articulation sensor 1 of the calibration procedure.
machine and the FMI 14 diagnostic code is no
longer active. STOP.
NOTE: If the position sensor has been calibrated Test Step 4. CHECK THE STATUS OF THE
recently and the FMI 14 diagnostic code becomes DIAGNOSTIC CODE
active after a short time, the linkage for the
articulation position sensor is most likely causing A. Turn the disconnect switch and the key start
the problem. Repair the linkage or replace the switch to the ON position.
linkage for the sensor. STOP.
224 RENR9004-07
C. Check the status of the CID 0615 FMI 12 i02917131

diagnostic code.
MID 027 - CID 0621 - FMI 03
Expected Result:
SMCS Code: 3171-038; 7332-038-Q9
Results:


corrected.
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, replace
the ECM that activated the diagnostic code. See
Testing and Adjusting, “Electronic Control Module
(ECM) - Replace”.
STOP.
g01301129
Illustration 168
Connections of the Downshift Switch
RENR9004-07 225
This diagnostic code is associated with the downshift D. Disconnect the machine harness connectors J1
switch that is located on the left joystick handle. The and J2 from the Transmission/Chassis ECM.
switch supplies two switch to ground inputs to the
Transmission/Chassis ECM. The ECM expects one E. At the ECM machine harness connector J2,
of the two switch inputs to be grounded at all times. measure the resistance between N/O contact
When the ECM detects that neither of the switch J2-36 (wire F781-BR) and N/C contact J2-37 (wire
inputs is grounded, the ECM will activate an FMI 03 F784-YL).
diagnostic code to indicate a voltage above normal
condition. Expected Result:
The downshift switch is connected to ground at the The resistance measurement is less than 5 ohms.
Transmission/Chassis ECM 5 volt sensor return
(ECM ground) and the Implement ECM 5 volt sensor Results:
return (ECM ground). The switch must lose both
grounds in order to disrupt the switch operation. The • OK – The resistance measurement is less than 5
illustration above indicates the power and ground ohms. The input circuits of the switch are not open
connections for the switch. in the machine harness. Proceed to Test Step 2.
Possible conditions that can cause this diagnostic • NOT OK – The resistance measurement is greater
code are listed: than 5 ohms. One of the switch circuits is open in
• One or both of the switch circuits are open in the
machine harness. Repair: There is an open or a bad connection in
input wire of the switch F781-BR or switch input
• Both of the switch ground circuits are open in the wire F784-YL. Refer to the complete Electrical
machine harness. System Schematic of the machine. Check the
connectors that are in the switch circuits for a loose
• One or more of the switch inputs are shorted to connection or a corroded connection. Repair the
a voltage source. machine harness or replace the machine harness.
• The switch has failed. STOP.
• The ECM has failed. This is unlikely. Test Step 2. CHECK THE GROUND
CIRCUITS FOR AN OPEN
Before performing this procedure, inspect the
harness connectors that are involved in the The disconnect switch and the key start switch remain
circuit. Poor connections can often be the cause in the OFF position. The connector of the left joystick
of a problem in an electrical circuit. Verify that J2 remains disconnected from the machine harness.
all connections in the circuit are clean, that all The connectors of the Transmission/Chassis ECM
connections are secure and that all connections remain disconnected from the machine harness.
connection is found, correct the problem and A. Disconnect the connectors of the left joystick J1
verify that this diagnostic code is active before and J3 from the machine harness connector.
Note: The following test procedure may create other from the Implement ECM.
codes and clear the diagnostic codes when the C. At the joystick connectors J1 and J3, connect a
original diagnostic code has been corrected. jumper wire between the ground 3 contact J1-3
(wire L731-BR) and ground 4 contact J3-3 (wire
Test Step 1. CHECK THE SWITCH 998-BR).
CIRCUITS FOR AN OPEN
D. Obtain a spare length of wire that is long enough
A. Turn the disconnect switch and the key start to reach from the Transmission/Chassis ECM
switch to the OFF position. to the cab of the machine. Connect one end of
the spare wire to the Transmission/Chassis ECM
B. Disconnect the connector of the left joystick J2 return contact J1-21 (wire L731-BR).
from the machine harness connector.
C. At the joystick connector J2, connect a jumper

wire between the normally open (N/O) contact
J2-7 (wire F781-BR) and the normally closed
(N/C) contact J2-8 (wire F784-YL).
226 RENR9004-07
E. At the machine harness connector of the B. At the machine harness connector of the
Implement ECM J1, measure the resistance Transmission/Chassis ECM J2, measure the
between return contact J1-21 (wire 998-BR) and resistance between contact J2-36 (wire F781-BR)
the end of the spare wire that is connected to to all of the other contacts that are used in the J1
return contact of the Transmission/Chassis ECM and J2 connectors for the ECM.
J1-21 (wire L731-BR).
Expected Result:
Expected Result:
The resistance measurement is less than 5 ohms. ohms.
Results: Results:
• OK – The resistance measurement is less than • OK – Each resistance measurement is greater

5 ohms. The ground circuits are not open in the than 5000 ohms. The input circuits of the switch
machine harness. Proceed to Test Step 3. are not shorted in the machine harness. Proceed
to Test Step 4.
than 5 ohms. One or both of the switch ground • NOT OK – One or more of the resistance
circuits is an open connection or a bad connection measurements is less than 5000 ohms.
Repair: Verify that the connection of the spare The short is between one of the switch circuits and
wire at the connector of the Transmission/Chassis the circuit with the low resistance measurement.
ECM is a good connection. Check the ground
circuits again to verify that there is an open or a Check each input circuit of the switch for a short, in
bad connection present in the ground circuits. order to determine the circuit that is shorted to the
If the resistance measurement is still greater than
5 ohms, there is an open or a bad connection in Refer to the complete Electrical System Schematic
ground wire 998-BR or wire L731-BR. of the machine. Check all of the connectors that
are in the switch circuit. Ensure that all connections
NOTE: Both of the ground circuits must be are clean, that all connections are secure and that
open in order to cause this diagnostic code to all connections are in good condition.
activate. However, if one of the ground circuits
is faulty, the faulty circuit must be repaired For information on testing for short circuits and
before proceeding with this procedure. finding short circuits, refer to Testing and Adjusting,
Refer to the complete Electrical System Schematic machine harness or replace the machine harness.
of the machine. Check the connectors that are
in the ground circuits for a loose connection or a STOP.
corroded connection. Repair the machine harness
or replace the machine harness. Test Step 4. CHECK THE SWITCH
OPERATION
STOP.
The connectors of the left joystick remain
Test Step 3. CHECK THE HARNESS FOR disconnected from the machine harness. The
A SHORT disconnect switch and the key start switch remain
in the OFF position.
remain in the OFF position. A. At the joystick connectors, measure the resistance
(continuity) between ground 3 contact J1-3 and
The harness connectors for the joystick and the joystick N/O switch contact J2-7 when the
the harness connectors for the ECM remain switch is not depressed and when the switch is
disconnected. depressed.
A. Connect the jumper wire that was used in the last B. At the joystick connectors, measure the resistance
test step between the harness connector contact (continuity) between ground 3 contact J1-3 and
of the joystickJ2-7 (wire F781-BR) and contact the joystick N/C switch contact J2-8 when the
J2-8 (wire F784-YL). switch is not depressed and when the switch is
depressed.
RENR9004-07 227
Expected Result: • NOT OK – The CID 0621 FMI 03 diagnostic

When the switch is not depressed, the measurement corrected.
results are as listed below:
J1-3 (ground) to J2-7 (N/O) - No continuity (Open) Electronic Technician (ET) service tool, if available,
J1-3 (ground) to J2-8 (N/C) - Continuity (Closed) wiring harness. The wiggle test can detect
When the switch is depressed, the measurement machine wiring harness.
J1-3 (ground) to J2-7 (N/O) - Continuity (Closed) found, the ECM that has activated this diagnostic
code may have failed.
J1-3 (ground) to J2-8 (N/C) - No continuity (Open)
Results: again. If the cause of the failure is not found,
• OK – The continuity checks between ground for possible consultation with Caterpillar. This
contact J1-3 to the switch contacts are correct. consultation may greatly reduce repair time.
The switch is operating correctly. Proceed to Test
Step 5. If the ECM must be replaced, refer to Testing and
• NOT OK – The continuity checks between the Replace”.
ground contact J1-3 and the switch contacts are
not correct. The switch is not working correctly. STOP.
Repair: The downshift switch is not correct.

Replace the assembly of the left joystick. After
replacement of the assembly of the joystick, verify
that the operation of the new assembly of the
joystick is correct before operating the machine.
STOP.

DIAGNOSTIC CODE
A. Inspect the contacts. Clean the contacts of any
harness connectors that are disconnected.


is not active.
Expected Result:
Results:

228 RENR9004-07
i02839858 This diagnostic code is associated with the downshift

switch that is located on the left joystick handle. The
MID 027 - CID 0621 - FMI 04 switch supplies two switch-to-ground type inputs to
the Implement ECM. The ECM expects one of the
SMCS Code: 3171-038; 7332-038-Q9 two switch inputs to be grounded at all times. When
the ECM detects that both of the switch inputs are
Conditions Which Generate This Code: grounded at the same time, the ECM will activate an
FMI 04 diagnostic code indicating that the voltage is
below normal.
The downshift switch switch is connected to ground

at the Transmission/Chassis ECM 5 volt sensor
return (ECM ground) and the Implement ECM 5 volt
sensor return (ECM ground). The switch would have
to lose both grounds in order to disrupt the switch
operation. The illustration above indicates the power
and ground connections for the switch.
Possible conditions that can cause this diagnostic

code are listed:
• One or both of the switch inputs is shorted to a

ground source.

harness connectors that are involved in the


B. Ensure that the diagnostic code is active.
C. Observe the status of the diagnostic code while

disconnecting the left joystick J2 connector from
g01301129
Illustration 169
Expected Result:
Downshift Switch connections
The CID 0621 FMI 04 diagnostic code will remain

active if the switch is not the cause of the diagnostic
code. The switch is the cause of the diagnostic
code if the CID 0621 FMI 04 diagnostic code is NO
longer active and a CID 0621 FMI 03 diagnostic code
becomes active.
RENR9004-07 229
Results: Repair: The downshift switch is not correct.

Replace the left joystick assembly. After
• OK – The CID 0621 FMI 04diagnostic code replacement of the joystick assembly, verify that
remains active. The switch has not failed. Proceed the operation of the new joystick assembly is
to Test Step 3. correct before operating the machine.
• NOT OK – The CID 0621 FMI 04 diagnostic code STOP.

is NO longer active. A CID 0621 FMI 03 diagnostic
code becomes active when the J2 connector is Test Step 3. CHECK THE SIGNAL
disconnected. The machine harness and the ECM CIRCUIT FOR A SHORT TO GROUND
are operating correctly. The switch may have failed.
Verify that the switch is not operating correctly. The connector of the left joystick J2 remains
Proceed to Test Step 2. disconnected from the machine harness. The
disconnect switch and the key start switch remain
Test Step 2. CHECK THE SWITCH in the OFF position.
OPERATION
A. Disconnect the J1 and J2 machine harness
The connector of the left joystick J2 remains connectors from the Transmission/Chassis ECM.
disconnected from the machine harness. The
disconnect switch and the key start switch remain B. At machine harness connector J2 for the ECM,
in the OFF position. measure the resistance from contact J2-36
(wire F781-BR) to frame ground. Measure the
A. Disconnect the joystick J1 connector from the resistance to all of the contacts that are used in
machine harness. the J1 and J2 connectors for the ECM.
B. At the joystick connectors, measure the resistance C. At machine harness connector J2 for the ECM,
(continuity) between ground 3 contact J1-3 and measure the resistance from contact J2-37
the joystick N/O switch contact J2-7 when the (wire F784-YL) to frame ground. Measure the
switch is not depressed and when the switch is resistance to all of the contacts that are used in
depressed. the J1 and J2 connectors for the ECM.
C. At the joystick connectors, measure the resistance Expected Result:

the joystick N/C switch contact J2-8 when the Each resistance measurement is greater than 5000
switch is not depressed and when the switch is ohms.
depressed.
Results:
Expected Result:
When the switch is NOT depressed, the measurement than 5000 ohms. The switch circuits are not
results are as listed: shorted to another circuit in the machine harness.
J1-3 (ground) to J2-7 (N/O) - No continuity (Open)
J1-3 (ground) to J2-8 (N/C) - Continuity (Closed) measurements is NOT correct. The machine
harness has failed.
When the switch IS depressed, the measurement
results are as listed: Repair: There is a short in the machine harness.
The short is between the switch circuit and the
J1-3 (ground) to J2-7 (N/O) - Continuity (Closed) circuit with the low resistance measurement.
J1-3 (ground) to J2-8 (N/C) - No continuity (Open) Refer to the complete Electrical System Schematic
Results: in the sensor circuit. Ensure that all connections
• OK – The continuity checks between contact all connections are in good condition.
ground J1-3 to the switch contacts are correct. The
switch is operating correctly. Proceed to Test Step For information on testing for short circuits and
3. finding short circuits, refer to Testing and Adjusting,
• NOT OK – The continuity checks between the machine harness or replace the machine harness.
ground contact J1-3 to the switch contacts are not
correct. The switch is not working correctly. STOP.
230 RENR9004-07

DIAGNOSTIC CODE
MID 027 - CID 0622 - FMI 03
contacts of the harness connectors. Check the SMCS Code: 3171-038; 7332-038-Q9
by excessive heat, battery acid, or chafing. Conditions Which Generate This Code:

wires that are associated with the switch circuit.



is active.
Expected Result:
Results:


corrected.


found, the ECM that has activated this diagnostic

for possible consultation with Caterpillar. This Illustration 170
g01301319
consultation may greatly reduce repair time.
Connections of the Upshift Switch
If the ECM must be replaced, refer to Testing and

Replace”.
STOP.
RENR9004-07 231
This diagnostic code is associated with the upshift D. Disconnect the machine harness connectors J1
switch that is located on the left joystick handle. The and J2 from the Transmission/Chassis ECM.
switch supplies two switch to ground inputs to the
Transmission/Chassis ECM. The ECM expects one E. At the ECM machine harness connector J2,
of the two switch inputs to be grounded at all times. measure the resistance between N/O contact
When the ECM detects that neither of the switch J2-30 (wire F785-WH) and N/C contact J2-31
inputs is grounded, the ECM will activate an FMI 03 (wire F783-GN).
diagnostic code for “voltage above normal”.
Expected Result:
The upshift switch is connected to ground at the
Transmission Chassis ECM 5 volt sensor return The resistance measurement is less than 5 ohms.
(ECM ground) and the Implement ECM 5 volt sensor
return (ECM ground). The switch must lose both Results:
grounds in order to disrupt the switch operation. The
illustration above indicates the power and ground • OK – The resistance measurement is less than 5
connections for the switch. ohms. The input circuits of the switch are not open
code are listed: • NOT OK – The resistance measurement is greater
than 5 ohms. One of the switch circuits is open in
• One or both of the switch circuits are open in the the machine harness.
machine harness.
Repair: There is an open or a bad connection in
• Both of the switch ground circuits are open in the input wire of the switch F785-WH or switch input
machine harness. wire F783-GN. Refer to the complete Electrical
System Schematic of the machine. Check the
• One or more of the switch inputs are shorted to connectors that are in the switch circuits for a loose
a voltage source. connection or a corroded connection. Repair the
STOP.
Test Step 2. CHECK THE GROUND
Before performing this procedure, inspect the CIRCUITS FOR AN OPEN
circuit. Poor connections can often be the cause The disconnect switch and the key start switch remain
of a problem in an electrical circuit. Verify that in the OFF position. The connector of the left joystick
all connections in the circuit are clean, that all J2 remains disconnected from the machine harness.
connections are secure and that all connections The connectors of the Transmission/Chassis ECM
are in good condition. If a problem with a remain disconnected from the machine harness.
verify that this diagnostic code is active before A. Disconnect the connectors of the left joystick J1
performing this procedure. and J3 from the machine harness connector.
Note: The following test procedure may create other B. Disconnect the machine harness connectors J1
diagnostic codes. Ignore these created diagnostic from the Implement ECM.
original diagnostic code has been corrected. C. At the connectors of the joystick J1 and J3,
connect a jumper wire between the ground 3
Test Step 1. CHECK THE SWITCH contact J1-3 (wire L731-BR) and ground 4 contact
CIRCUITS FOR AN OPEN J3-3 (wire 998-BR).
A. Turn the disconnect switch and the key start D. Obtain a spare length of wire that is long enough
switch to the OFF position. to reach from the Transmission Chassis ECM
to the cab of the machine. Connect an end
B. Disconnect the left connector of the joystick J2 of the spare wire to the return contact of the
from the machine harness connector. Transmission/Chassis ECM J1-21 (wire L731-BR).
C. At the joystick connector J2, connect a jumper

wire between the normally open (N/O) contact
J2-5 (wire F785-WH) and the normally closed
(N/C) contact J2-6 (wire F783-GN).
232 RENR9004-07
E. At the machine harness connector of the B. At the machine harness connector of the
Implement ECM J1, measure the resistance Transmission/Chassis ECM J2, measure the
between return contact J1-21 (wire 998-BR) and resistance between contact J2-30 (wire F785-WH)
the end of the spare wire that is connected to to all of the other contacts that are used in the J1
return contact of the Transmission/Chassis ECM and J2 connectors for the ECM.
J1-21 (wire L731-BR).
Expected Result:
Expected Result:
The resistance measurement is less than 5 ohms. ohms.
Results: Results:
• OK – The resistance measurement is less than • OK – Each resistance measurement is greater

5 ohms. The ground circuits are not open in the than 5000 ohms. The input circuits of the switch
machine harness. Proceed to Test Step 3. are not shorted in the machine harness. Proceed
to Test Step 4.
than 5 ohms. One or both of the switch ground • NOT OK – One or more of the resistance
circuits is an open connection or a bad connection measurements is less than 5000 ohms.
Repair: Verify that the connection of the spare wire The short is between one of the switch circuits and
at the connector of the Transmission/Chassis ECM the circuit with the low resistance measurement.
is a good connection. Check the ground circuits to
verify that there is an open connection or a bad Check each input circuit of the switch individually
connection present in the ground circuits. for a short in order to determine the circuit that
is shorted to the circuit with the low resistance
If the resistance measurement is still greater than measurement.
5 ohms, there is an open or a bad connection in
ground wire 998-BR or wire L731-BR. Refer to the complete Electrical System Schematic
of the machine. Check all of the connectors that
NOTE: Both of the ground circuits must be are in the switch circuit. Ensure that all connections
open in order to cause this diagnostic code to are clean, that all connections are secure and that
activate. However, if one of the ground circuits all connections are in good condition.
is faulty, the faulty circuit must be repaired
before proceeding with this procedure. For information on testing for short circuits and
Refer to the complete Electrical System Schematic “Wiring Harness (Short Circuit) - Test”. Repair the
of the machine. Check the connectors that are machine harness or replace the machine harness.
in the ground circuits for a loose connection or a
corroded connection. Repair the machine harness STOP.
STOP. OPERATION
Test Step 3. CHECK THE HARNESS FOR The connectors of the left joystick remain
A SHORT disconnected from the machine harness. The
The key start switch and the disconnect switch in the OFF position.
A. At the joystick connectors, measure the resistance
The harness connectors for the joystick and the (continuity) between ground 3 contact J1-3 and
harness connectors of the ECM remain disconnected. the joystick N/O switch contact J2-5 when the
switch is not depressed and when the switch is
A. Connect the jumper wire that was used in the depressed.
last test step between the contact of the joystick
harness, connector J2-5 (wire F785-WH), and B. At the joystick connectors, measure the resistance
contact J2-6 (wire F783-GN). (continuity) between ground 3 contact J1-3 and
the joystick N/C switch contact J2-6 when the
switch is not depressed and when the switch is
depressed.
RENR9004-07 233
Expected Result: • NOT OK – The CID 0622 FMI 03 diagnostic

When the switch is not depressed, the measurement corrected.
J1-3 (ground) to J2-5 (N/O) - No continuity (Open) Electronic Technician (ET) service tool, if available,
J1-3 (ground) to J2-6 (N/C) - Continuity (Closed) wiring harness. The wiggle test can detect
When the switch is depressed, the measurement machine wiring harness.
J1-3 (ground) to J2-5 (N/O) - Continuity (Closed) found, the ECM that has activated this diagnostic
J1-3 (ground) to J2-6 (N/C) - No continuity (Open)
Results: again. If the cause of the failure is not found,
• OK – The continuity checks between ground for possible consultation with Caterpillar. This
contact J1-3 and the switch contacts are correct. consultation may greatly reduce repair time.
The switch is operating correctly. Proceed to Test
Step 5. If the ECM must be replaced, refer to Testing and
• NOT OK – The continuity checks between the Replace”.
Repair: The upshift switch is not correct. Replace

the assembly of the left joystick. After replacement
of the assembly of the joystick, verify that the
operation of the assembly of the new joystick is
correct before operating the machine.
STOP.

DIAGNOSTIC CODE
A. Inspect the contacts. Clean the contacts of any


is not active.
Expected Result:
Results:

234 RENR9004-07
i02917401 This diagnostic code is associated with the upshift

switch. The upshift switch is located on the handle
MID 027 - CID 0622 - FMI 04 of the left joystick. The upshift switch supplies two
switch to ground inputs to the Transmission/Chassis
SMCS Code: 3171-038; 7332-038-Q9 ECM. The ECM expects one of the two switch
inputs to be grounded at all times. When the ECM
Conditions Which Generate This Code: detects that both of the switch inputs are grounded
at the same time, the ECM will activate an FMI 04
diagnostic code to indicate “voltage below normal”.
The upshift switch is connected to ground at the

(ECM ground) and the Implement ECM 5 volt sensor
illustration above indicates the power and ground
connections for the switch.

code are listed below:

ground source.



B. Ensure that the diagnostic code is active.
C. Observe the status of the diagnostic code and

disconnect the connector of the left joystick J2
from the machine harness.
g01301319
Illustration 171
Expected Result:
Connections of the Upshift Switch

active if the switch is not the cause of the diagnostic
code if the CID 0622 FMI 04 diagnostic code is no
longer active and a CID 0622 FMI 03 diagnostic code
becomes active.
RENR9004-07 235
Results: Repair: The upshift switch is not correct. Replace

the assembly of the left joystick . After replacement
• OK – The CID 0622 FMI 04diagnostic code of the assembly of the joystick, verify that the
remains active. The switch has not failed. Proceed operation of the assembly for the new joystick is
to Test Step 3. correct before operating the machine.
• NOT OK – The CID 0622 FMI 04 diagnostic code STOP.

is NO longer active. A CID 0622 FMI 03 diagnostic
code becomes active when the J2 connector is Test Step 3. CHECK THE SIGNAL
disconnected. The machine harness and the ECM CIRCUIT FOR A SHORT TO GROUND
are operating correctly. The switch may have failed.
Verify that the switch is not operating correctly. The connector of the left joystick J2 remains
Proceed to Test Step 2. disconnected from the machine harness. The
Test Step 2. CHECK THE SWITCH in the OFF position.
OPERATION
A. Disconnect the J1 and J2 machine harness
The connector of the left joystick J2 remains connectors from the Transmission/Chassis ECM.
disconnect switch and the key start switch remain B. At machine harness connector J2 for the ECM,
in the OFF position. measure the resistance from contact J2-30
(wire F785-WH) to frame ground. Measure the
A. Disconnect the joystick J1 connector from the resistance to all of the contacts that are used in
machine harness. the J1 and J2 connectors for the ECM.
B. At the joystick connectors, measure the resistance C. At machine harness connector J2 for the ECM,
(continuity) between ground 3 contact J1-3 and measure the resistance from contact J2-31
the joystick N/O switch contact J2-5 when the (wire F783-GN) to frame ground. Measure the
switch is not depressed and when the switch is resistance to all of the contacts that are used in
depressed. the J1 and J2 connectors for the ECM.
C. At the joystick connectors, measure the resistance Expected Result:

the joystick N/C switch contact J2-6 when the Each resistance measurement is greater than 5000
switch is not depressed and when the switch is ohms.
depressed.
Results:
Expected Result:
When the switch is not depressed, the measurement than 5000 ohms. The switch circuits are not
results are as listed below: shorted to another circuit in the machine harness.
J1-3 (ground) to J2-6 (N/O) - No continuity (Open)
J1-3 (ground) to J2-6 (N/C) - Continuity (Closed) measurements is not correct. The machine
harness has failed.
When the switch is depressed, the measurement
results are as listed below: Repair: There is a short in the machine harness.
The short is between the switch circuit and the
J1-3 (ground) to J2-5 (N/O) - Continuity (Closed) circuit with the low resistance measurement.
J1-3 (ground) to J2-6 (N/C) - No continuity (Open) Refer to the complete Electrical System Schematic
Results: in the sensor circuit. Ensure that all connections
• OK – The continuity checks between ground all connectors are in good condition.
contact J1-3 and the switch contacts are correct.
The switch is operating correctly. Proceed to Test For information on testing for short circuits and
Step 3. finding short circuits, refer to Testing and Adjusting,
• NOT OK – The continuity checks between the machine harness or replace the machine harness.
236 RENR9004-07

DIAGNOSTIC CODE
MID 027 - CID 0623 - FMI 03
contacts of the harness connectors. Check the SMCS Code: 3171-038; 7332-038-Q9




is active.
Expected Result:
Results:


corrected.

momentary shorts, intermittent shorts or open
connections in the machine wiring harness.


g01301397
Directional Switch connections

Replace”.
STOP.
RENR9004-07 237
This diagnostic code is associated with the directional D. Disconnect the connectors of the machine harness
switch that is located on the left joystick handle. The J1 and J2 from the Transmission/Chassis ECM.
switch supplies three switch to ground type of inputs
to the Transmission/Chassis ECM. The ECM expects E. At the ECM machine harness connector J2,
one of the three switch inputs to be grounded at all measure the resistance between forward contact
times. When the ECM detects that none of the switch J2-23 (wire G750-BU) and neutral contact J2-28
inputs is grounded, the ECM will activate an FMI 03 (wire G763-PU).
diagnostic code for voltage above normal.
F. At the connector of the joystick J2, leave one
The directional switch is connected to ground at end of the jumper wire connected to the forward
the Transmission/Chassis ECM 5 volt sensor return contact J2-9 (wire G750-BU) and connect the
(ECM ground) and the Implement ECM 5 volt sensor other end of the jumper wire to the reverse contact
return (ECM ground). The switch must lose both J2-11 (wire G755-GY).
illustration above indicates the ground connections G. At the ECM machine harness connector J2,
and the input connections for the switch. measure the resistance between forward contact
J2-23 (wire G750-BU) and reverse contact J2-29
Possible conditions that can cause this diagnostic (wire G755-GY).
code are listed:
Expected Result:
• One or more of the switch circuits are open in the
machine harness. Both of the resistance measurements are less than
5 ohms.
• Both of the switch ground circuits are open in the
machine harness. Results:
• One or more of the switch inputs are shorted to • OK – Both of the resistance measurements are
a voltage source. less than 5 ohms. The input circuits of the switch
are not open in the machine harness. Proceed to
• The switch has failed. Test Step 2.
• The ECM has failed. This is unlikely. • NOT OK – One or both of the resistance
measurements is greater than 5 ohms. One or
Before performing this procedure, inspect the both of the switch circuits is open in the machine
harness connectors that are involved in the harness.
of a problem in an electrical circuit. Verify that Repair: There is an open or a bad connection in at
all connections in the circuit are clean, that all least one of the switch input circuits. Check each
connections are secure and that all connections circuit individually in order to determine the circuits
are in good condition. If a problem with a that have an open connection or a bad connection.
verify that this diagnostic code is active before A resistance measurement that is more than 5
performing this procedure. ohms but less than 5000 ohms could indicate that
the circuit is not open but has a poor or corroded
Note: The following test procedure may create other connection.
codes and clear the diagnostic codes when the Refer to the complete Electrical System Schematic
original diagnostic code has been corrected. of the machine. Check the connectors in the switch
circuits for a loose or a corroded connection.
Test Step 1. CHECK THE SWITCH Repair the machine harness or replace the
CIRCUITS FOR AN OPEN machine harness.
A. Turn the disconnect switch and the key start STOP.

Test Step 2. CHECK THE GROUND
B. Disconnect the connector of the left joystick J2 CIRCUITS FOR AN OPEN
from the connector of the machine harness.
The disconnect switch and the key start switch remain
C. At the connector of the joystick J2, connect a in the OFF position. The connector of the left joystick
jumper wire between the forward contact J2-9 J2 remains disconnected from the machine harness.
(wire G750-BU) and the neutral contact J2-10 The connectors of the Transmission/Chassis ECM
(wire G763-PU). remain disconnected from the machine harness.
238 RENR9004-07
A. Disconnect the connectors of the left joystick J1 Test Step 3. CHECK THE HARNESS FOR
and J3 from the connector of the machine harness. A SHORT
B. Disconnect the machine harness connectors J1 The key start switch and the disconnect switch
from the Implement ECM. remain in the OFF position.
C. At the connectors of the joystick J1 and J3, The harness connectors for the joystick and
connect a jumper wire between the ground 3 the harness connectors for the ECM remain
contact J1-3 (wire L731-BR) and ground 4 contact disconnected.
J3-3 (wire 998-BR).
A. Connect the jumper wire that was used in the
D. Obtain a spare length of wire that is long enough last test step between the harness connector
to reach from the Transmission/Chassis ECM of the joystick at the forward contact J2-9 (wire
to the cab of the machine. Connect one end of G750-BU) and the neutral contact J2-10 (wire
the spare wire to the Transmission/Chassis ECM G763-PU).
return contact J1-21 (wire L731-BR).
B. At the machine harness connector of the
E. At the machine harness connector of the Transmission/Chassis ECM J2, measure the
Implement ECM J1, measure the resistance resistance between contact J2-23 (wire G750-BU)
between return contact J1-21 (wire 998-BR) and and all of the other contacts that are used in the
the end of the spare wire that is connected to J1 and J2 connectors for the ECM.
return contact of the Transmission/Chassis ECM
J1-21 (wire L731-BR). C. At the connector of the joystick J2, leave one
end of the jumper wire connected to the forward
Expected Result: contact J2-9 (wire G750-BU) and connect the
other end of the jumper wire to the reverse contact
The resistance measurement is less than 5 ohms. J2-29 (wire G755-GY).
Results: D. At the machine harness connector of the

Transmission/Chassis ECM J2, measure the
• OK – The resistance measurement is less than resistance between contact J2-29 (wire G755-GY)
5 ohms. The ground circuits are not open in the to all of the other contacts that are used in the J1
machine harness. Proceed to Test Step 3. and J2 connectors for the ECM.
• NOT OK – The resistance measurement is greater Expected Result:

than 5 ohms. One or both of the switch ground
circuits is open or has a bad connection in the Each resistance measurement is greater than 5000
machine harness. ohms.
Repair: Verify that the connection of the spare Results:

wire at the connector of the Transmission/Chassis
ECM is a good connection. Check the ground • OK – Each resistance measurement is greater
circuits again to verify that there is an open or bad than 5000 ohms. The input circuits of the switch
connection present in the ground circuits. are not shorted in the machine harness. Proceed
to Test Step 4.
If the resistance measurement is still greater than
5 ohms, there is an open or a bad connection in • NOT OK – One or more of the resistance
ground wire 998-BR or wire L731-BR. measurements is less than 5000 ohms.
NOTE: Both of the ground circuits must be Repair: There is a short in the machine harness.
open in order to cause this diagnostic code to The short is between one of the switch circuits and
be active, however, if one of the ground circuits the circuit with the low resistance measurement.
is faulty, the faulty circuit must be repaired
before attempting this procedure. Check each switch of the input circuit individually
for a short in order to determine the circuit that
Refer to the complete Electrical System Schematic is shorted to the circuit with the low resistance
of the machine. Check the connectors that are measurement.
in the ground circuits for loose or corroded
connections. Repair the machine harness or Refer to the complete Electrical System Schematic
replace the machine harness. of the machine. Check all of the connectors that
are in the switch circuit. Ensure that all connections
STOP. are clean, that all connections are secure and that
all connections are in good condition.
RENR9004-07 239
For information on testing for short circuits and J1-3 (ground) to forward contact J2-9 - No continuity
finding short circuits, refer to Testing and Adjusting, (Open)
machine harness or replace the machine harness. J1-3 (ground) to neutral contact J2-10 - No continuity
(Open)
STOP.
J1-3 (ground) to reverse contact J2-11 - Continuity
Test Step 4. CHECK THE SWITCH (Closed)
OPERATION
Results:
The connectors of the left joystick remain
disconnected from the machine harness. The • OK – The continuity checks between ground
disconnect switch and the key start switch remain contact J1-3 to the contacts of the switch are
in the OFF position. correct in all switch positions. The switch is
operating correctly. Proceed to Test Step 5.
A. At the connectors of the joystick, measure the
resistance (continuity) between ground 3 contact • NOT OK – The continuity checks between the
J1-3 and the forward switch contact J2-9 when ground contact J1-3 to the contacts of the switch
the switch is in the FORWARD, NEUTRAL, and are not correct. The switch is not working correctly.
REVERSE position.
Repair: The directional switch is not correct.
B. At the connectors of the joystick, measure the Replace the left joystick assembly. After
resistance (continuity) between ground 3 contact replacement of the joystick assembly, verify that
J1-3 and the neutral switch contact J2-10 when the operation of the new joystick assembly is
the switch is in the FORWARD, NEUTRAL, and correct before operating the machine.
REVERSE position.
STOP.
C. At the connectors of the joystick, measure the
resistance (continuity) between ground 3 contact Test Step 5. CHECK THE STATUS OF THE
J1-3 and the reverse switch contact J2-11 when DIAGNOSTIC CODE
the switch is in the FORWARD, NEUTRAL, and
REVERSE position. A. Inspect the contacts and clean the contacts of any
Expected Result:
When the switch is in the FORWARD position, the
results of the measurement are listed below: C. Turn the disconnect switch and the key start
J1-3 (ground) to forward contact J2-9 - Continuity
(Closed) D. Operate the machine.
J1-3 (ground) to neutral contact J2-10 - No continuity E. Determine if the CID 0623 FMI 03 diagnostic code
(Open) is not active.
J1-3 (ground) to reverse contact J2-11 - No continuity Expected Result:

(Open)
When the switch is in the NEUTRAL position, the
results of the measurement are as listed below: Results:
J1-3 (ground) to forward contact J2-9 - No continuity • OK – The CID 0623 FMI 03 diagnostic code is
(Open) not active. The diagnostic code does not exist at
J1-3 (ground) to neutral contact J2-10 - Continuity caused by a poor connection or a short at one
(Closed) of the connectors that was disconnected and
J1-3 (ground) to reverse contact J2-11 - No continuity
(Open) • NOT OK – The CID 0623 FMI 03 diagnostic
When the switch is in the REVERSE position, the corrected.
measurement results are as listed:
240 RENR9004-07
Repair: Check the circuit again. Use the Caterpillar i02839851

in order to perform a wiggle test on the machine MID 027 - CID 0623 - FMI 04
momentary or intermittent shorts or opens in the SMCS Code: 3171-038; 7332-038-Q9


Replace”.
STOP.
g01301397
Illustration 173
Directional Switch connections
RENR9004-07 241
This diagnostic code is associated with the directional Results:

switch that is located on the left joystick handle. The
switch supplies three switch to ground types of inputs • OK – The CID 0623 FMI 04diagnostic code
to the Transmission/Chassis ECM. The ECM expects remains active. The switch has not failed. Proceed
one of the three switch inputs to be grounded at all to Test Step 3.
times. When the ECM detects that more than one of
the inputs to the switch is grounded at the same time, • NOT OK – The CID 0623 FMI 04 diagnostic code
the ECM will activate an FMI 04 diagnostic code for is NO longer active. A CID 0623 FMI 03 diagnostic
“voltage below normal”. code becomes active when the J2 connector is
disconnected. The machine harness and the ECM
The directional switch is connected to ground at are operating correctly. The switch may have failed.
the Transmission/Chassis ECM 5 volt sensor return Verify that the switch is not operating correctly.
(ECM ground) and the Implement ECM 5 volt sensor Proceed to Test Step 2.
grounds in order to disrupt the switch operation. The Test Step 2. CHECK THE SWITCH
illustration above indicates the power and ground OPERATION
connections for the switch.
The connector of the left joystick J2 remains
Possible conditions that can cause this diagnostic disconnected from the machine harness. The
code are listed: disconnect switch and the key start switch remain
in the OFF position.
• One or more of the switch inputs is shorted to a
ground source. A. Disconnect the joystick J1 connector from the
machine harness.
B. At the connectors of the joystick, measure the
• The ECM has failed. This is unlikely. resistance (continuity) between ground 3 contact
J1-3 and the forward switch contact J2-9 when
Before performing this procedure, inspect the the switch is in the FORWARD, NEUTRAL, and
harness connectors that are involved in the REVERSE position.
of a problem in an electrical circuit. Verify that C. At the connectors of the joystick, measure the
all connections in the circuit are clean, that all resistance (continuity) between ground 3 contact
connections are secure and that all connections J1-3 and the neutral switch contact J2-10 when
are in good condition. If a problem with a the switch is in the FORWARD, NEUTRAL, and
connection is found, correct the problem and REVERSE position.
performing this procedure. D. At the connectors of the joystick, measure the
resistance (continuity) between ground 3 contact
Note: The following test procedure may create other J1-3 and the reverse switch contact J2-11 when
diagnostic codes. Ignore these created diagnostic the switch is in the FORWARD, NEUTRAL, and
codes and clear the diagnostic codes when the REVERSE position.
Expected Result:
When the switch is in the FORWARD position, the
A. Turn the disconnect switch and the key start measurement results are as follows:
J1-3 (ground) to forward contact J2-9 - Continuity
B. Ensure that the diagnostic code is active. (Closed)
C. Observe the status of the diagnostic code after J1-3 (ground) to neutral contact J2-10 - No continuity
disconnecting the connector of the left joystick J2 (Open)
J1-3 (ground) to reverse contact J2-11 - No continuity
Expected Result: (Open)
The CID 0623 FMI 04 diagnostic code will remain When the switch is in the NEUTRAL position, the
active if the switch is not the cause of the diagnostic measurement results are as follows:
code if the CID 0623 FMI 04 diagnostic code is NO J1-3 (ground) to forward contact J2-9 - No continuity
longer active and a CID 0623 FMI 03 diagnostic code (Open)
becomes active.
242 RENR9004-07
J1-3 (ground) to neutral contact J2-10 - Continuity D. At machine harness connector J2 for the ECM,
(Closed) measure the resistance from contact J2-29
(wire G755-GY) to frame ground. Measure the
J1-3 (ground) to reverse contact J2-11 - No continuity resistance to all of the contacts that are used in
(Open) the J1 and J2 connectors for the ECM.
When the switch is in the REVERSE position, the Expected Result:

measurement results are as follows:
J1-3 (ground) to forward contact J2-9 - No continuity ohms.
(Open)
Results:
J1-3 (ground) to neutral contact J2-10 - No continuity
(Open) • OK – Each resistance measurement is greater
than 5000 ohms. The switch circuits are not
J1-3 (ground) to reverse contact J2-11 - Continuity shorted to another circuit in the machine harness.
(Closed) Proceed to Test Step 4.
Results: • NOT OK – One or more of the resistance

measurements is NOT correct. The machine
• OK – The continuity checks between ground harness has failed.
contact J1-3 to the contacts of the switch are
correct in all switch positions. The switch is Repair: There is a short in the machine harness.
operating correctly. Proceed to Test Step 3. The short is between the switch circuit and the
• NOT OK – The continuity checks between the
ground contact J1-3 to the contacts of the switch Refer to the complete Electrical System Schematic
are not correct. The switch is not working correctly. of the machine. Check all of the connectors that are
in the sensor circuit. Ensure that all connections
Repair: The directional switch is not correct. are clean, that all connections are secure and that
Replace the left joystick assembly. After all connections are in good condition.
replacement of the joystick assembly, verify that
the operation of the new joystick assembly is For information on testing for short circuits and
correct before operating the machine. finding short circuits, refer to Testing and Adjusting,
STOP. machine harness or replace the machine harness.
Test Step 3. CHECK THE SIGNAL STOP.

CIRCUIT FOR A SHORT TO GROUND
The connectors of the left joystick J1 and J2 remain DIAGNOSTIC CODE
disconnect switch and the key start switch remain A. Inspect the harness connectors. Clean the
in the OFF position. contacts of the harness connectors. Check the
A. Disconnect the J1 and J2 machine harness by excessive heat, battery acid, or chafing.
connectors from the Transmission/Chassis ECM.
B. At machine harness connector J2 for the ECM, wires that are associated with the switch circuit.
measure the resistance from contact J2-23
(wire G750-BU) to frame ground. Measure the C. Reconnect all harness connectors. Make sure that
resistance to all of the contacts that are used in the connectors are fully seated. Observe that the
the J1 and J2 connectors for the ECM. clips for each connector are completely fastened.
C. At machine harness connector J2 for the ECM, D. Turn the disconnect switch and the key start
measure the resistance from contact J2-28 switch to the ON position.
(wire G763-PU) to frame ground. Measure the
resistance to all of the contacts that are used in E. Operate the machine.
the J1 and J2 connectors for the ECM.
is active.
RENR9004-07 243
The CID 0623 FMI 04 diagnostic code is not active. MID 027 - CID 0627 - FMI 03
Results: SMCS Code: 1435-038-BRK
• OK – The CID 0623 FMI 04 diagnostic code is Conditions Which Generate This Code:

corrected.

in order to perform a “wiggle” test on the machine
wiring harness. The “wiggle” test can detect

g01323394
Exit this procedure and perform this procedure Illustration 174
again. If the cause of the failure is not found, Park Brake Pressure Switch located on the park brake housing on
contact your dealership's Technical Communicator the engine side of the transmission
for possible consultation with Caterpillar. This (1) Park Brake Pressure Switch

Replace”.
STOP.
g01375676
Illustration 175
Park Brake Pressure Switch connections
This diagnostic code is associated with the park

brake pressure switch. The switch supplies two
inputs to the Transmission/Chassis ECM. The switch
allows the ECM to detect whether the parking brake
is applied or is not applied.
244 RENR9004-07
The ECM expects the two switch inputs to be D. Disconnect the machine harness connector J1
connected through the switch contacts when the park from the Transmission/Chassis ECM.
brake is applied. The ECM expects the normally open
(N/O) contact to be grounded when the park brake is E. At the Transmission/Chassis ECM machine
not applied. When the ECM detects that the switch harness connector J1, measure the resistance
inputs are not connected and the N/O contact is not between N/C contact J1-40 (wire C491-PU) and
grounded, the ECM will activate an FMI 03 diagnostic N/O contact J1-64 (wire R736-PK).
code for voltage above normal.
Expected Result:
code are listed: The resistance measurement is less than 5 ohms.
• One or both of the switch circuits is open in the Results:

machine harness.
• The ground circuit is open in the machine harness. ohms. The input circuits of the switch are not open
• The ECM has failed. This is unlikely. than 5 ohms. One of the input circuits of the switch
is an open connection or a poor connection in the
Note: Before performing this procedure, inspect machine harness.
circuit. Poor connections can often be the cause Repair: There is an open or a poor connection in
of a problem in an electrical circuit. Verify that input wire of the switch C491-PU or switch input
all connections in the circuit are clean, that all wire R736-PK. Check each input circuit of the
connections are secure and that all connections switch in order to determine the circuit that has the
are in good condition. If a problem with a problem.
verify that this diagnostic code is active before Refer to the complete Electrical System Schematic
performing this procedure. of the machine. Verify that all connection points in
the suspected part of the circuits are clean, secure
Table 22 and in good condition. Repair the machine harness
Contact States of the Park Brake Pressure Switch or replace the machine harness.
Park Brake N/O Input J1-35 N/C Input J1-40 STOP.
Status (wire R736-PK) (wire C491-PU)
Applied Connected to Connected to Test Step 2. CHECK THE SWITCH
J1-40 J1-35 GROUND CIRCUIT FOR AN OPEN
Not Applied Grounded(1) Open
The disconnect switch and the key start switch
(1) Connected to frame ground - switch contact B (wire A202-BK). remain in the OFF position. The machine
harness connector J1 remains disconnected from the
Note: The following test procedure may create other Transmission/Chassis ECM and the machine harness
diagnostic codes. Ignore these created diagnostic connector for the switch remains disconnected.
original diagnostic code has been corrected. A. At the machine harness connector for the switch,
connect the jumper wire that was used in the last
Test Step 1. CHECK THE INPUT CIRCUITS test step between the common ground contact A
OF THE SWITCH FOR AN OPEN (wire A202-BK) and the normally closed (N/O)
contact B (wire R736-PK).
A. Turn the disconnect switch and the key START
switch to the OFF position. B. At the machine harness connector of the
B. Disconnect the machine harness connector from resistance between ground contact J1-13 (wire
the switch. A202-BK) and N/O contact J1-35 (wire R736-PK).
C. At the machine harness connector for the switch, Expected Result:

connect a jumper wire between the normally open
(N/O) contact B (wire R736-PK) and the normally The resistance measurement is less than 5 ohms.
closed (N/C) contact C (wire C491-PU).
RENR9004-07 245
Results: Repair: The pressure switch of the park brake has

failed. Replace the switch. After replacement of the
• OK – The resistance measurement is less than switch, verify that the operation of the new switch
5 ohms. The ground circuit is not open in the is correct before operating the machine.
STOP.
than 5 ohms. The ground circuit is an open Test Step 4. CHECK THE STATUS OF THE
connection or a poor connection in the machine DIAGNOSTIC CODE
harness.
Repair: There is an open or a poor connection in contacts of the harness connectors. Check the
switch ground wire A202-BK. Refer to the complete wires for damage to the insulation that is caused
Electrical System Schematic of the machine. Check by excessive heat, battery acid, or chafing.
all of the connectors that are in the ground circuit.
Verify that all connection points for the circuit are B. Perform a 45 N (10 lb) pull test on each of the
clean, that all connections are secure and that wires that are associated with the sensor circuit.
machine harness or replace the machine harness. C. Reconnect all harness connectors. Make sure that
STOP. clips for each connector are completely fastened.
Test Step 3. CHECK THE SWITCH D. Turn the disconnect switch and the key start
OPERATION switch to the ON position.
The switch remains disconnected from the machine E. Operate the machine.
harness. The disconnect switch and the key start
switch remain in the OFF position. F. Determine if the CID 0627 FMI 03 diagnostic code
is active.
A. At the connector for the switch, measure the
resistance (continuity) between N/O contact B and Expected Result:
the switch N/C contact C when the park brake is
applied and when the park brake is not applied. The CID 0627 FMI 03 diagnostic code is active.
B. At the connector for the switch, measure the Results:

resistance (continuity) between the common
ground contact A and the switch N/O contact B • YES – The CID 0627 FMI 03 diagnostic code is
when the park brake is applied and when the park active. The problem has not been corrected.
brake is not applied.
Repair: Repeat this procedure. Use the Caterpillar
C. At the connector for the switch, measure the Electronic Technician (ET) service tool, if available,
resistance (continuity) between the common in order to perform a wiggle test on the switch
ground contact A and the switch N/C contact C circuits in the machine wiring harness. The wiggle
when the park brake is applied and when the park test can detect momentary or intermittent shorts or
brake is not applied. opens in the machine wiring harness.
Expected Result: If the cause of the problem is not found, the ECM
may have failed. Prior to replacing an ECM, always
The continuity checks of the switch are correct contact your dealership's Technical Communicator
according to the table at the beginning of this for possible consultation with Caterpillar. This
procedure. consultation may greatly reduce repair time. If
the ECM must be replaced, refer to Testing and
Results: Adjusting, “Electronic Control Module (ECM) -
Replace”.
• OK – The continuity checks between the switch
contacts are correct according to the table at STOP.
the beginning of this procedure. The switch is
operating correctly. Proceed to Test Step 4. • NO – The CID 0627 FMI 03 diagnostic code is not
switch contacts are not correct. The switch is not
working correctly.
246 RENR9004-07
Repair: The initial diagnostic code was probably This diagnostic code is associated with the pressure
caused by a poor electrical connection or a switch of the park brake. The switch supplies two
short at one of the harness connectors that was inputs to the Transmission/Chassis ECM. The switch
disconnected and reconnected. Resume normal allows the ECM to detect if the parking brake is
machine operation. applied or if the parking brake is not applied.
STOP. The ECM expects the two switch inputs to be

connected through the switch contacts when the park
brake is applied. The ECM expects the normally open
i02917723
(N/O) contact to be grounded when the park brake
MID 027 - CID 0627 - FMI 04 is not applied. When the ECM detects that the both
of the switch input circuits are grounded, the ECM
SMCS Code: 1435-038-BRK will activate an FMI 04 diagnostic code for voltage
below normal.
code are listed:

ground source.

Table 23
g01323394
Illustration 176
Contact States of the Park Brake Pressure Switch
Park Brake Pressure Switch located on the park brake housing on
the engine side of the transmission Park Brake N/O Input J1-35 N/C Input J1-40
(1) Park Brake Pressure Switch Status (wire R736-PK) (wire C491-PU)
Applied Connected to Connected to
J1-40 J1-35
Not Applied Grounded(1) Open
(1) Connected to frame ground - switch contact B (wire A202-BK).


g01375676
Illustration 177
Connectors of the Park Brake Pressure Switch B. Ensure that the diagnostic code is active.
C. Observe the status of the diagnostic code and

disconnect the connector of the pressure switch
RENR9004-07 247
Expected Result: • NOT OK – One or more of the resistance

measurements is less than 5000 ohms.
active if the switch is not the cause of the diagnostic Repair: A input circuit of the switch is shorted to
code. The switch is the cause of the diagnostic the frame or to the circuit with the low resistance
code if the CID 0627 FMI 04 diagnostic code is NO measurement. Refer to the complete Electrical
longer active and a CID 0627 FMI 03 diagnostic code System Schematic of the machine. Check the
becomes active. connectors that are in the involved circuits.
Verify that all connection points for the circuit are
Results: clean, that all connections are secure and that
• OK – The CID 0627 FMI 04 diagnostic code machine harness or replace the machine harness.
remains active. The pressure switch has not failed.
Proceed to Test Step 2. STOP.
• NOT OK – The CID 0627 FMI 04 diagnostic code Test Step 3. CHECK THE STATUS OF THE
is NO longer active. A CID 0627 FMI 03 diagnostic DIAGNOSTIC CODE
code becomes active when the connector of the
switch is disconnected. The machine harness A. Inspect the harness connectors. Clean the
and the Transmission/Chassis ECM are operating contacts of the harness connectors. Check the
correctly. The pressure switch has failed. wires for damage to the insulation that is caused
Repair: Replace the pressure switch of the park
brake. After replacement of the switch, verify that B. Perform a 45 N (10 lb) pull test on each of the
the operation of the new switch is correct before wires that are associated with the switch circuit.
operating the machine.
STOP. the connectors are fully seated. Observe that the
Test Step 2. CHECK THE HARNESS FOR
A SHORT D. Turn the disconnect switch and the key start
The switch remains disconnected from the machine
harness. E. Operate the machine.
A. Disconnect the machine harness connectors J1 F. Determine if the CID 0627 FMI 04 diagnostic code
and J2 from the Transmission/Chassis ECM. is active.
B. At the ECM machine harness connector J1, Expected Result:

(wire R736-PK) and frame ground. Measure the The CID 0627 FMI 04 diagnostic code is not active.
resistance between contact J1-35 (wire R736-PK)
to all of the other contacts that are used in the J1 Results:
and J2 connectors for the ECM.
C. At the connector of the machine harness of not active. The diagnostic code does not exist at
the ECM J1, measure the resistance between this time. The initial diagnostic code was probably
contact J1-40 (wire C491-PU) and frame ground. caused by a poor connection or a short at one
Measure the resistance between contact J1-40 of the connectors that was disconnected and
(wire C491-PU) to all of the other contacts that are reconnected. Resume normal operation. STOP.
used in the J1 and J2 connectors for the ECM.
Expected Result: code is active. The diagnostic code has not been
corrected.
ohms. Repair: Check the circuit again. Use the Caterpillar
Results: in order to perform a wiggle test on the machine
• OK – Each resistance measurement is greater momentary or intermittent shorts or opens in the
than 5000 ohms. The input circuits of the switch machine wiring harness.
are not shorted in the machine harness. Proceed
to Test Step 3.
248 RENR9004-07
If the cause of the problem is not found, the ECM This diagnostic code is associated with the
may have failed. Prior to replacing an ECM, always transmission input speed sensor. The transmission
contact your dealership's Technical Communicator input speed sensor is located on the top of the
for possible consultation with Caterpillar. This transmission.
the ECM must be replaced, refer to Testing and The ECM monitors the signals from the input speed
Adjusting, “Electronic Control Module (ECM) - sensor of the transmission. The ECM compares
Replace”. the signal to other machine conditions such as the
selected gear or the sensor signals for the output
STOP. speed. When the ECM determines that the sensor
signal for the input speed is not within the accepted
limits, the ECM will activate the FMI 02 diagnostic
i02917813
code.
MID 027 - CID 0669 - FMI 02 The following conditions could cause the ECM to
SMCS Code: 3175-038-IV activate this diagnostic code:
Conditions Which Generate This Code: • The speed sensor has failed.
• There is an intermittent short or an open connection
in the speed sensor circuit.

Note: Before performing this procedure, verify that
the speed sensor is mounted securely. A loose mount
could cause this diagnostic code to be activated.

B. Disconnect the machine harness from the speed

sensor.
g01323388
Illustration 178 C. At the connector for the speed sensor, measure
Transmission Input Speed Sensor located on the top of the the resistance from contact 2 to contact 1.
transmission
Expected Result:

ohms at 25 °C (77.0 °F).
Results:


Illustration 179
g01321396 within the correct resistance range. The speed
sensor has failed.
Connections of the Transmission Input Speed Sensor
RENR9004-07 249
Repair: Replace the speed sensor for the A resistance measurement that is greater than
transmission input. Verify that the new sensor 5 ohms at some time during the manipulation of
corrects the problem before operating the machine. the machine harness indicates that there is an
STOP. machine harness.
Test Step 2. CHECK THE SENSOR Refer to the complete Electrical System Schematic
CIRCUIT FOR AN OPEN of the machine. Check all of the connectors that
are in the circuit. Ensure that all of the contacts for
The disconnect switch and the key start switch the circuit are in good condition, that all connectors
remain in the OFF position. The machine harness are clean, and that all connectors are securely
connector remains disconnected from the sensor. fastened in each of the harness connectors. Repair
the machine harness or replace the machine
A. At the machine harness connector for the sensor, harness.
E908-BR) and contact 2 (wire E909-WH). STOP.
B. Disconnect the machine harness connectors J1 Test Step 3. CHECK THE SIGNAL
from the ECM. CIRCUIT FOR A SHORT
C. At the machine harness connector J1 for the ECM, The disconnect switch and the key start switch
measure the resistance between contact J1-2 remain in the OFF position. The machine harness
(wire E908-BR) and contact J1-3 (wire E909-WH). connectors remain disconnected from the sensor
and the ECM.
D. Observe the resistance measurement and wiggle
the ECM connector. Gently pull on the wires and A. Disconnect the jumper wire that was used in the
wiggle the wires. last test step.
E. Observe the resistance measurement and wiggle B. Disconnect the machine harness connector J2
the speed sensor connector. Gently pull on the from the ECM.
jumper wire. C. At the machine harness connector J1 for the ECM,
Expected Result: (wire E909-WH) and frame ground. Measure the
resistance between contact J1-2 (wire E909-WH)
The resistance measurement is less than 5 ohms, all and all of the other contacts that are used in the
times, during the manipulation of the wires and the J1 and J2 connectors for the ECM.
connectors.
Results: wiggle the ECM connectors and the speed sensor
connector. Gently pull on the wires and wiggle the
• YES – The resistance measurement is less than 5 wires.
ohms. The speed sensor circuit is not open in the
machine harness. Proceed to Test Step 3. E. At the machine harness connector J1 for the ECM,
• NO – The resistance measurement is greater than (wire E908-BR) and frame ground. Measure the
5 ohms for all of the time or for part of the time resistance between contact J1-3 (wire E908-BR)
that the resistance is being measured. There is and all of the other contacts that are used in the
an open connection or a bad connection in one of J1 and J2 connectors for the ECM.
the wires in the speed sensor circuit. Check each
wire individually in order to determine whether the F. Observe the resistance measurements and
problem is in the signal circuit or the ground circuit. wiggle the ECM connectors and the speed sensor
Repair: A resistance measurement that is greater wires.
than 5000 ohms could indicate that a wire is not
connected or that a wire is open. A resistance Expected Result:
than 5000 ohms could indicate that one of the Each resistance measurement is greater than 5000
connection points or a splice in the circuit is not an ohms at all times during the manipulation of the
open connection but not a good connection. machine harness.
250 RENR9004-07
Results: Repair: Check the relay circuit again. Use the

• YES – Each resistance measurement is greater if available, in order to perform a wiggle test on the
than 5000 ohms. The measurements do not machine wiring harness. The wiggle test can detect
indicate a short circuit. Proceed to Test Step 4. momentary or intermittent shorts or opens in the
• NO – One or more of the resistance measurements
is less than 5000 ohms. There is a short in the If the cause of the problem is not found, the ECM
machine harness. may have failed.
Repair: The short is between the circuit for the Prior to replacing an ECM, always contact your
speed sensor that was being checked and the dealership's Technical Communicator for possible
circuit with the low resistance measurement. consultation with Caterpillar. This consultation may
Refer to the complete Electrical System Schematic replaced, refer to Testing and Adjusting, “Electronic
of the machine. Check all of the connectors that Control Module (ECM) - Replace”.
are in the faulty speed sensor circuit. Ensure that
all connections are clean, that all connections STOP.
condition. • NO – The CID 0669 FMI 02 diagnostic code is not
finding short circuits, refer to Testing and Adjusting, Repair: The initial diagnostic code was probably
“Wiring Harness (Short Circuit) - Test”. Repair the caused by a poor electrical connection or a
machine harness or replace the machine harness. short at one of the harness connectors that was
STOP. machine operation.

DIAGNOSTIC CODE




is active.
Expected Result:
Results:

RENR9004-07 251
i03740022 • The signal for speed sensor 2 is not within the

accepted limits.
MID 027 - CID 0673 - FMI 02
• The signal for speed sensor 1 is within the
SMCS Code: 3175-038-OJ accepted limits.
Conditions Which Generate This Code: The following conditions could cause the ECM to
activate this diagnostic code:
• The speed sensor has failed.

• There is an intermittent short or an open connection
in the speed sensor circuit.


g01323251
Illustration 180
Speed sensors for transmission output are located on the right B. Disconnect the machine harness from the speed
side rear of the transmission. sensor.
(2) Transmission output speed sensor 1 C. At the connector for the speed sensor, measure
the resistance from contact 2 to contact 1.
Expected Result:
The correct range of resistance for the sensor is

approximately 75 ohms at −40° C (−40° F) to 230
ohms at 120 °C (248 °F). The resistance will be
approximately 140 ohms at 25 °C (77 °F).
Results:

g02019556
Illustration 181 • NO – The resistance of the speed sensor is not
Connections of the transmission output speed sensor 2 within the correct resistance range. The speed
sensor may have failed.
transmission output speed sensor 2. The Repair: In order to verify that the speed sensor has
transmission output speed sensor 2 is located toward failed, switch the sensor connections and check
the rear of the transmission on the right hand side. the codes. Perform the following steps in order to
perform this verification:
The ECM monitors the signals from the transmission
output speed sensor 2 and the transmission output 1. Mark the harness connector for the transmission
speed sensor 1. The ECM will activate the FMI 02 output speed sensor 2.
diagnostic code when both of the following conditions
occur: 2. Connect the harness connector of the
transmission output speed sensor 2 to the
transmission output speed sensor 1.
252 RENR9004-07
3. Connect the harness connector of the F. Observe the resistance measurement and wiggle
transmission output speed sensor 1 to the the ECM connector. Gently pull on the wires and
transmission output speed sensor 2. wiggle the wires.
4. Turn the disconnect switch to the ON position. G. Observe the resistance measurement and wiggle
the speed sensor connector. Gently pull on the
5. Turn the key start switch to the ON position. wires and wiggle the wires. Do not disconnect the
jumper wire.
If the transmission output speed sensor 2 has
failed, both of the following will occur: Expected Result:
• The CID 0673 FMI 02 diagnostic code will no The resistance measurement is less than 5 ohms
longer be active. at all times during the manipulation of the wires and
connectors.
• A CID 0585 FMI 02 diagnostic code for the
transmission output speed sensor 1 will Results:
become active.
• YES – The resistance measurement is less than 5
If diagnostic code CID 0673 FMI 02 is active and ohms. The speed sensor circuit is not open in the
diagnostic code CID 0585 FMI 02 is not active, the machine harness. Proceed to Test Step 3.
sensor is operating properly. Perform the following
actions: • NO – The resistance is intermittently greater than
5 ohms or the resistance is continually greater than
1. Reconnect the machine harness connectors to 5 ohms. One of the wires for the speed sensor has
the correct transmission output speed sensor. an open or there is a bad connection in the speed
sensor wiring. Check each wire individually in order
2. Proceed to the next test step. to determine whether the problem is in the signal
circuit or the ground circuit.
If diagnostic code CID 0673 FMI 02 is not active
and diagnostic code CID 0585 FMI 02 is active, Repair: A resistance that is greater than 5000
perform the following actions: ohms could indicate one of the following conditions:
1. Replace the transmission output speed sensor • A wire is not connected.

2.
• A wire is an open.
2. Reconnect the machine harness connectors to
the correct transmission output speed sensor. A resistance measurement that is greater than 5
ohms, but less than 5000 ohms could indicate the
3. Verify that the new sensor corrects the problem following condition:
before operating the machine.
• One of the connection points or a splice in the
STOP. circuit is not a completely open connection, but
the connection is not good.
CIRCUIT FOR AN OPEN A resistance measurement that is greater than
5 ohms at some time during the manipulation of
A. Turn the disconnect switch and the key start the machine harness could indicate one of the
switch to the OFF position. following conditions:
B. Disconnect the machine harness connector from • There is an intermittent open in the machine
the sensor. harness.
C. Disconnect the machine harness connectors “J1” • There is a loose connection in the machine
from the ECM. harness.
D. At the machine harness connector for the sensor,

E906-OR) and contact 2 (wire E907-GY).
E. At the machine harness connector “J1” for the

ECM, measure the resistance between contact
“J1-17” (wire E907-GY) and contact “J1-18” (wire
E906-OR).
RENR9004-07 253
Refer to the Electrical Schematic of the machine. • NO – One or more of the resistance measurements
Check all of the connectors that are in the circuit. is less than 5000 ohms. There is a short in the
Ensure that all of the contacts for the circuit are in machine harness.
good condition, that all of the contacts are clean,
and that all of the contacts are securely fastened Repair: The short is between the circuit of the
in each of the harness connectors. Repair the speed sensor that was being checked and the
machine harness or replace the machine harness. circuit with the low resistance measurement.
STOP. Refer to the Electrical Schematic of the machine.

Check all of the connectors that are in the faulty
Test Step 3. CHECK THE SIGNAL speed sensor circuit. Ensure that all connections
CIRCUIT FOR A SHORT are clean, that all connectors are secure and that
all connectors are in good condition.
remain in the OFF position. The machine harness For information on testing for short circuits and
connectors remain disconnected from the sensor finding short circuits, refer to the Testing and
and the ECM. Adjusting, “Wiring Harness (Short Circuit) - Test”
Story in this manual. Repair the machine harness
A. Disconnect the jumper wire that was used in the or replace the machine harness.
last test step.
STOP.
B. Disconnect the machine harness connectors “J2”
from the ECM. Test Step 4. CHECK THE STATUS OF THE
DIAGNOSTIC CODE
C. At the machine harness connector “J1” for the
ECM, measure the resistance between contact A. Inspect the harness connectors. Clean the
“J1-17” (wire E907-GY) and frame ground. contacts of the harness connectors. Check the
Measure the resistance between contact “J1-17” wires for damage to the insulation that is caused
(wire E907-GY) and all of the other contacts that by excessive heat, battery acid, or chafing.
are used in the “J1” and “J2” connectors for the
ECM. B. Perform a 45 N (10 lb) pull test on each of the
wiggle the ECM connectors and the speed sensor C. Reconnect all harness connectors. Make sure that
connector. Gently pull on the wires and wiggle the the connectors are fully seated. Observe that the
wires. clips for each connector are completely fastened.
E. At the machine harness connector “J1” for the D. Turn the disconnect switch and the key start
ECM, measure the resistance between contact switch to the ON position.
“J1-18” (wire E906-OR) and frame ground.
Measure the resistance between contact “J1-18” E. Operate the machine.
(wire E906-OR) and all of the other contacts that
are used in the “J1” and “J2” connectors for the F. Determine if the CID 0673 FMI 02 diagnostic code
ECM. is active.
F. Observe the resistance measurements and Expected Result:

connector. Gently pull on the wires and wiggle the The CID 0673 FMI 02 diagnostic code is active.
wires.
Results:
Expected Result:
Each resistance measurement is greater than 5000 active. The problem has not been corrected.
ohms at all times during the manipulation of the
machine harness. Repair: Check the relay circuit again. Use the
Caterpillar Electronic Technician (Cat ET) service
Results: tool in order to perform a wiggle test on the
• YES – Each resistance measurement is greater intermittent shorts or opens in the machine wiring
than 5000 ohms. The measurements do not harness.
indicate a short circuit. Proceed to Test Step 4.
may have failed.
254 RENR9004-07
Prior to replacing an ECM, always contact

the technical communicator at your dealership
the ECM must be replaced, refer to the Testing
- Replace” Story in this manual.
STOP.


caused by a poor electrical connection or a g01321514
short at one of the harness connectors that was Illustration 183
disconnected and reconnected. Resume normal Connections of the “Transmission Intermediate Speed Sensor 1”
machine operation.
STOP. “transmission intermediate speed sensor 1”. The
“transmission intermediate speed sensor 1” is located
on the right hand side of the transmission.
i02917851
The ECM monitors the signals from the “transmission
MID 027 - CID 0674 - FMI 02 intermediate speed sensor 1” and the “transmission
intermediate speed sensor 2”. When the ECM detects
SMCS Code: 3175-038-IMD
that the signal of “speed sensor 1” is not within the
accepted limits and the signal of “speed sensor 2” is
within the accepted limits, the ECM will activate the
FMI 02 diagnostic code.
The following conditions could cause the ECM to

activate this diagnostic code:
• The speed sensor has failed.

• There is an intermittent short or an open in the
speed sensor circuit.

g01323376
Illustration 182
“Transmission Intermediate Speed Sensors” are located on the A. Turn the key start switch and the disconnect
right hand side of the transmission. switch to the OFF position.
(1) “Transmission intermediate speed sensor 2”
(2) “Transmission intermediate speed sensor 1” B. Disconnect the machine harness from the speed
sensor.
C. At the connector for the speed sensor, measure

the resistance from contact 2 to contact 1.
RENR9004-07 255
Expected Result: D. Turn the key start switch and the disconnect
ohms at −40 °C (−40.0 °F) to 1800 ohms at 120 °C E. Observe the status of the active diagnostic code.
ohms at 25 °C (77.0 °F). Expected Result:
Results: The CID 0674 FMI 02 diagnostic code is no longer

active. A CID 0675 FMI 02 diagnostic code for the
• YES – The resistance of the speed sensor is “transmission intermediate speed sensor 2” is active
within the correct resistance range. The sensor is after the switch.
Results:
within the correct resistance range. The speed • YES – The CID 0674 FMI 02 diagnostic code is no
sensor has failed. longer active after the sensors are switched. A CID
0675 FMI 02 diagnostic code for the “transmission
Repair: Verify that the speed sensor is causing intermediate speed sensor 2” is now active.
the problem. Mark the harness connector for
the “transmission intermediate speed sensor 1”. Repair: The “transmission intermediate speed
Connect the marked machine harness connector sensor 1” has failed. Replace the speed sensor.
for “transmission intermediate speed sensor 1” Verify that the new speed sensor corrects the
to the “transmission intermediate speed sensor problem before operating the machine.
2”. Connect the machine harness connector for
“transmission intermediate speed sensor 2” to the STOP.
“transmission intermediate speed sensor 1”. Turn
the disconnect switch and the key start switch to • NO – The CID 0674 FMI 02 diagnostic code is still
the ON position. active. Switching the speed sensors did not affect
the status of the CID 0674 FMI 02 diagnostic code.
If the “transmission intermediate speed sensor The sensor is not causing the problem.
1” has failed, the CID 0674 FMI 02 diagnostic Reconnect the machine harness connectors to the
code will no longer be active. A CID 0675 FMI 02 correct transmission intermediate speed sensor
diagnostic code for the “transmission intermediate before proceeding to the next test step.
speed sensor 2” will become active. Proceed to Test Step 3.
Replace the “transmission intermediate speed Test Step 3. CHECK THE SENSOR
sensor 1”. Verify that the new sensor corrects the CIRCUIT FOR AN OPEN
problem before operating the machine.
STOP. switch to the OFF position.
Test Step 2. SWITCH THE SENSORS B. Disconnect the machine harness connector from
the sensor.
remain in the OFF position. The “transmission C. Disconnect the machine harness connectors J1
intermediate speed sensor 1” remains disconnected from the ECM.
D. At the machine harness connector for the sensor,
A. Mark the harness connector of the “transmission connect a jumper wire between contact 1 (wire
intermediate speed sensor 1” in order to keep E902-PU) and contact 2 (wire E903-YL).
track of the connector that is used for each sensor.
B. Disconnect the “transmission intermediate speed measure the resistance between contact J1-4
sensor 2” from the machine harness. (wire E903-YL) and contact J1-5 (wire E902-PU).
C. Switch the speed sensor harness connectors. F. Observe the resistance measurement and wiggle
Connect the marked machine harness connector the ECM connector. Gently pull on the wires and
for “transmission intermediate speed sensor 1” wiggle the wires.
to the “transmission intermediate speed sensor
2”. Connect the machine harness connector for G. Observe the resistance measurement and wiggle
“transmission intermediate speed sensor 2” to the the speed sensor connector. Gently pull on the
“transmission intermediate speed sensor 1”. wires and wiggle the wires. Do not disconnect the
jumper wire.
256 RENR9004-07
Expected Result: C. At the machine harness connector J1 for the ECM,

The resistance measurement is less than 5 ohms all (wire E903-YL) and frame ground. Measure the
times during the manipulation of the wires and the resistance between contact J1-4 (wire E903-YL)
connectors. and all of the other contacts that are used in the
Results:
• YES – The resistance measurement is less than 5 wiggle the ECM connectors and the speed sensor
ohms. The speed sensor circuit is not open in the connector. Gently pull on the wires and wiggle the
machine harness. Proceed to Test Step 4. wires.
• NO – The resistance measurement is greater than E. At the machine harness connector J1 for the ECM,
5 ohms for all of the time or for part of the time measure the resistance between contact J1-5
that the resistance is being measured. There is an (wire E902-PU) and frame ground. Measure the
open connection or a bad connection in the one resistance between contact J1-5 (wire E902-PU)
of the wires of the circuit for the speed sensor. and all of the other contacts that are used in the
Check each wire individually in order to determine J1 and J2 connectors for the ECM.
whether the problem is in the signal circuit or the
ground circuit. F. Observe the resistance measurements and
Repair: A resistance measurement that is greater connector. Gently pull on the wires and wiggle the
than 5000 ohms could indicate that a wire is either wires.
not connected or that a wire is open. A resistance
measurement that is greater than 5 ohms but less Expected Result:
connection points or a splice in the circuit is not an Each resistance measurement is greater than 5000
open connection but not a good connection. ohms at all times during the manipulation of the
machine harness.
5 ohms at some time during the manipulation of Results:
the machine harness indicates that there is an
intermittent open or a loose connection in the • YES – Each resistance measurement is greater
machine harness. than 5000 ohms. The measurements do not
indicate a short circuit. Proceed to Test Step 5.
of the machine. Check all of the connectors that • NO – One or more of the resistance measurements
are in the circuit. Ensure that all of the contacts is less than 5000 ohms. There is a short in the
for the circuit are in good condition, that all of the machine harness.
contacts are clean, and that all of the contacts
are securely fastened in each of the harness Repair: The short is between the circuit of the
connectors. Repair the machine harness or replace speed sensor that was being checked and the
the machine harness. circuit with the low resistance measurement.
STOP. Refer to the complete Electrical System Schematic

Test Step 4. CHECK THE SIGNAL are in the faulty speed sensor circuit. Ensure that
CIRCUIT FOR A SHORT all connections are clean, that all connections
The disconnect switch and the key start switch condition.
connectors remain disconnected from the sensor For information on testing for short circuits and
and the ECM. finding short circuits, refer to Testing and Adjusting,
A. Disconnect the jumper wire that was used in the machine harness or replace the machine harness.
last test step.
STOP.
from the ECM.
RENR9004-07 257

DIAGNOSTIC CODE
MID 027 - CID 0675 - FMI 02
contacts of the harness connectors. Check the SMCS Code: 3175-038-IMD




is active.
Expected Result:
Results:
g01323376
Illustration 184
• YES – The CID 0674 FMI 02 diagnostic code is “Transmission Intermediate Speed Sensors” are located on the
active. The problem has not been corrected. right hand side of the transmission.
(1) “Transmission Intermediate Speed Sensor 2”
Repair: Check the relay circuit again. Use the (2) “Transmission Intermediate Speed Sensor 1”

may have failed.

g01321549
Illustration 185
STOP. Connections of the “Transmission Intermediate Speed Sensor 2”
• NO – The CID 0674 FMI 02 diagnostic code is not This diagnostic code is associated with the
active. The problem does not exist at this time. “transmission intermediate speed sensor 2”. The
“transmission intermediate speed sensor 2” is located
Repair: The initial diagnostic code was probably on the right hand side of the transmission.
short at one of the harness connectors that was The ECM monitors the signals from the “transmission
disconnected and reconnected. Resume normal intermediate speed sensor 2” and the “transmission
machine operation. intermediate speed sensor 1”. When the ECM
detects that the signal of the “speed sensor 2” is not
STOP. within the accepted limits and the signal of the “speed
sensor 1” is within the accepted limits, the ECM will
activate the FMI 02 diagnostic code.
258 RENR9004-07
The following conditions could cause the ECM to If a CID 0674 FMI 02 diagnostic code is active after
activate this diagnostic code: the sensors are switched, replace the “transmission
intermediate speed sensor 2”. Verify that the new
• The speed sensor has failed. sensor corrects the problem before operating the
machine.
• There is an intermittent short or an open in the
speed sensor circuit. STOP.
• The speed sensor is not mounted securely. Test Step 2. SWITCH THE SENSORS
• The ECM has failed. This is unlikely. The key start switch and the disconnect switch
remain in the OFF position. The “transmission
Note: Before performing this procedure, verify that intermediate speed sensor 2” remains disconnected
the speed sensor is mounted securely. A loose mount from the machine harness.
Ensure that this diagnostic code is active before A. Mark the harness connector of “transmission
performing this procedure. intermediate speed sensor 2” in order to keep
track of the connector that is used for each sensor.
B. Disconnect the “transmission intermediate speed
A. Turn the key start switch and the disconnect sensor 1” from the machine harness.
C. Switch the speed sensor connectors. Connect
B. Disconnect the machine harness from the speed the marked machine harness connector for
sensor. “transmission intermediate speed sensor 2” to
the “transmission intermediate speed sensor
C. At the connector for the speed sensor, measure 1”. Connect the machine harness connector for
the resistance from contact 2 to contact 1. “transmission intermediate speed sensor 1” to the
“transmission intermediate speed sensor 2”.
Expected Result:
D. Turn the key start switch and the disconnect
The correct range of resistance for the sensor is 600 switch to the ON position.
(248.0 °F). The resistance will be approximately 1055 E. Observe the status of the active diagnostic code.
ohms at 25 °C (77.0 °F).
Expected Result:
Results:
• YES – The resistance of the speed sensor is active. A CID 0674 FMI 02 diagnostic code for the
within the correct resistance range. The sensor is “transmission intermediate speed sensor 1” is active
correct. Proceed to Test Step 2. after the switch.
• NO – The resistance of the speed sensor is not Results:

within the correct resistance range. The speed
sensor has failed. • YES – The CID 0675 FMI 02 diagnostic code is no
longer active after the sensors are switched. A CID
Repair: Verify that the speed sensor is causing 0674 FMI 02 diagnostic code for the “transmission
the problem. Mark the harness connector for intermediate speed sensor 1” is now active.
the “transmission intermediate speed sensor
2”. Connect the “transmission intermediate Repair: The “transmission intermediate speed
speed sensor 2” harness connector to the sensor 2” has failed. Replace the speed sensor.
“transmission intermediate speed sensor 1” and Verify that the new speed sensor corrects the
connect the “transmission intermediate speed problem before operating the machine.
sensor 1” harness connector to the “transmission
intermediate speed sensor 2”. Turn the disconnect STOP.
switch and the key start switch to the ON position.
If the “transmission intermediate speed sensor

2” has failed, the CID 0675 FMI 02 diagnostic
code will no longer be active. A CID 0674 FMI 02
diagnostic code for the “transmission intermediate
speed sensor 1” will become active.
RENR9004-07 259
• NO – The CID 0675 FMI 02 diagnostic code is still Repair: A resistance measurement that is greater
active. Switching the speed sensors did not affect than 5000 ohms could indicate that a wire is either
the status of the CID 0675 FMI 02 diagnostic code. not connected or that a wire is open. A resistance
The sensor is not causing the problem. measurement that is greater than 5 ohms but less
Reconnect the machine harness connectors to the than 5000 ohms could indicate that one of the
correct transmission intermediate speed sensor connection points or a splice in the circuit is not an
before proceeding to the next test step. open connection but not a good connection.
Test Step 3. CHECK THE SENSOR 5 ohms at some time during the manipulation of
CIRCUIT FOR AN OPEN the machine harness indicates that there is an
A. Turn the disconnect switch and the key start machine harness.
B. Disconnect the machine harness connector from of the machine. Check all of the connectors that
the sensor. are in the circuit. Ensure that all of the contacts
for the circuit are in good condition, that all of the
C. Disconnect the machine harness connectors J1 contacts are clean, and that all of the contacts
from the ECM. are securely fastened in each of the harness
connectors. Repair the machine harness or replace
D. At the machine harness connector for the sensor, the machine harness.
E904-BR) and contact 2 (wire E905-GN). STOP.
E. At the machine harness connector J1 for the ECM, Test Step 4. CHECK THE SIGNAL
measure the resistance between contact J1-6 CIRCUIT FOR A SHORT
(wire E905-GN) and contact J1-7 (wire E904-BR).
F. Observe the resistance measurement and wiggle remain in the OFF position. The machine harness
the ECM connector. Gently pull on the wires and connectors remain disconnected from the sensor
wiggle the wires. and the ECM.
G. Observe the resistance measurement and wiggle A. Disconnect the jumper wire that was used in the
the speed sensor connector. Gently pull on the last test step.
jumper wire. B. Disconnect the machine harness connectors J2
from the ECM.
Expected Result:
The resistance measurement is less than 5 ohms measure the resistance between contact J1-6
at all times during the manipulation of the wires and (wire E905-BU) and frame ground. Measure the
connectors. resistance between contact J1-6 (wire E905-BU)
Results: J1 and J2 connectors for the ECM.
• YES – The resistance measurement is less than 5 D. Observe the resistance measurements and
ohms. The speed sensor circuit is not open in the wiggle the ECM connectors and the speed sensor
machine harness. Proceed to Test Step 4. connector. Gently pull on the wires and wiggle the
wires.
• NO – The resistance measurement is greater than
5 ohms for all of the time or part of the time that the E. At the machine harness connector J1 for the ECM,
resistance is being measured. There is an open measure the resistance between contact J1-7
connection or bad connection in the one of the (wire E904-BR) and frame ground. Measure the
wires of the circuit of the speed sensor. Check each resistance between contact J1-7 (wire E904-BR)
wire individually in order to determine whether the and all of the other contacts that are used in the
problem is in the signal circuit or the ground circuit. J1 and J2 connectors for the ECM.
F. Observe the resistance measurements and

wires.
260 RENR9004-07
Each resistance measurement is greater than 5000 • YES – The CID 0675 FMI 02 diagnostic code is
ohms at all times during the manipulation of the active. The problem has not been corrected.
machine harness.
Results: Caterpillar Electronic Technician (ET) service tool,
• YES – Each resistance measurement is greater machine wiring harness. The wiggle test can detect
than 5000 ohms. The measurements do not momentary or intermittent shorts or opens in the
indicate a short circuit. Proceed to Test Step 5. machine wiring harness.
• NO – One or more of the resistance measurements If the cause of the problem is not found, the ECM
is less than 5000 ohms. There is a short in the may have failed.
machine harness.
Repair: The short is between the circuit of the dealership's Technical Communicator for possible
speed sensor that was being checked and the consultation with Caterpillar. This consultation may
circuit with the low resistance measurement. greatly reduce repair time. If the ECM must be
Refer to the complete Electrical System Schematic Control Module (ECM) - Replace”.
are in the faulty speed sensor circuit. Ensure STOP.
that all connections are clean, that all connectors
are secure and that all connectors are in good • NO – The CID 0675 FMI 02 diagnostic code is not
condition. active. The problem does not exist at this time.
For information on testing for short circuits and Repair: The initial diagnostic code was probably
finding short circuits, refer to Testing and Adjusting, caused by a poor electrical connection or a
“Wiring Harness (Short Circuit) - Test”. Repair the short at one of the harness connectors that was
machine harness or replace the machine harness. disconnected and reconnected. Resume normal
machine operation.
STOP.
STOP.
DIAGNOSTIC CODE

C. Reconnect all the harness connectors. Make sure

that the connectors are fully seated. Observe
fastened.


is active.
Expected Result:

RENR9004-07 261
i02917913 • The ECM has failed. This is unlikely.

MID 027 - CID 0681 - FMI 03 Note: Before performing this procedure, inspect
SMCS Code: 5479-038-BRK circuit. Poor connections can often be the cause
Conditions Which Generate This Code: all connections in the circuit are clean, that all

codes and clear these diagnostic codes when the
Test Step 1. CHECK THE ENERGIZE

CIRCUIT OF THE SOLENOID FOR A
SHORT

the solenoid. Disconnect the machine harness
connectors J1 and J2 from the ECM.
g01323395
Illustration 186
The “Park Brake” solenoid is located on the housing of the park C. At the machine harness connectors for the ECM,
brake of the engine side of the transmission. measure the resistance from contact J2-6 (wire
(1) “Park Brake” solenoid G730-PK) to all of the other contacts that are used
in the J1 and J2 connectors for the ECM.
Expected Result:

ohms.
Results:
• YES – Each resistance measurement is greater

does not indicate a short in the machine harness.
Proceed to test step 2.
• NO – Each resistance measurement is not greater

g01301698 than 5000 ohms. There is a short in the machine
Illustration 187
Connections of the “Park Brake” solenoid harness.
This diagnostic code is associated with the parking Repair: The short is between wire G730-PK and
brake solenoid. The solenoid is connected to an the circuit that has a low resistance measurement.
“ON/OFF” output at the Transmission/Chassis ECM.
The FMI 03 diagnostic code means the ECM has For information on testing for short circuits and
detected that the voltage of the solenoid circuit is finding short circuits, refer to Testing and Adjusting,
above normal or that the ECM has detected voltage “Wiring Harness (Short Circuit) - Test”. Repair the
in the circuit when no voltage should be present. machine harness or replace the machine harness.
Conditions that could cause this diagnostic code to STOP.

be activated are:
• The energize circuit of the solenoid is shorted to

another voltage source.
262 RENR9004-07
Test Step 2. CHECK THE OPERATION OF Test Step 3. CHECK IF THE DIAGNOSTIC
THE ECM CODE REMAINS
The disconnect switch and the key start switch A. Inspect the harness connectors. Clean the
remain in the OFF position. The machine harness contacts of the harness connectors. Check the
connectors for the solenoid and the ECM remain wires for damage to the insulation that is caused
disconnected. by excessive heat, battery acid, or chafing.
A. At the machine harness connector J2 for the ECM, B. Perform a 45 N (10 lb) pull test on each of the
use a 151-6320 Removal Tool to remove the wires that are associated with the circuit.
energize wire of the solenoid G730-PK and the
socket at contact J2-6 from the harness connector. C. Reconnect all harness connectors. Make sure that
B. Reconnect the machine harness J1 and J2 clips for each connector are completely fastened.
C. Turn the disconnect switch and the key start switch to the ON position.
03 diagnostic code. F. Determine if the CID 0681 FMI 03 diagnostic code
is active.
Expected Result:
Expected Result:
active. A CID 0681 FMI 05 diagnostic code is now The CID CID 0681 FMI 03 diagnostic code is not
active. active.
Results: Results:
• YES – The CID 0681 FMI 03 diagnostic code is no • YES – The diagnostic code is not active at this
longer active. A CID 0681 FMI 05 diagnostic code time. The initial diagnostic code was probably
is active after the energize circuit of the solenoid is caused by a poor electrical connection or a
disconnected. The ECM has responded correctly short at one of the harness connectors that was
to the open circuit condition in the solenoid circuit. disconnected and reconnected. Resume normal
machine operation. STOP.
Reinstall the energize wire of the solenoid into
the correct space of the connector of the ECM. • NO – The CID 0681 FMI 03 diagnostic code
Proceed to the next test step. remains active. The problem has not been
corrected.
• NO – The CID 0681 FMI 03 diagnostic code Electronic Technician (ET) service tool, if available,
remains active. The status of the active diagnostic in order to perform a wiggle test on the machine
code did not change when the solenoid energize wiring harness. The wiggle test can detect
wire was disconnected from the ECM. momentary or intermittent shorts or opens in the
to the open condition in the solenoid circuit. The If the problem remains, the ECM may have failed.
operation of the ECM is not correct. This is unlikely because the ECM detected the
open circuit condition in the solenoid circuit and the
Prior to replacing an ECM, always contact your ECM activated the FMI 05 diagnostic code when
dealership's Technical Communicator for possible the solenoid energize wire was disconnected.
greatly reduce repair time. If the ECM must be Verify that all possible causes of the diagnostic
replaced, refer to Testing and Adjusting, “Electronic code have been investigated. Exit this procedure
Control Module (ECM) - Replace”. and perform this procedure again.
STOP.
RENR9004-07 263
Prior to replacing an ECM, always contact your This diagnostic code is associated with the “park
dealership's Technical Communicator for possible brake” solenoid. The solenoid is connected to an
consultation with Caterpillar. This consultation ON/OFF output at the Transmission/Chassis ECM.
may greatly reduce repair time. If the cause of the The FMI 05 diagnostic code means that the ECM has
diagnostic code is not found and the ECM must be detected that the current for the circuit of the solenoid
replaced, refer to Testing and Adjusting, “Electronic is below normal.
Conditions that could cause this diagnostic code to
STOP. be active are:
i02917935
• The energize circuit of the solenoid is open.
MID 027 - CID 0681 - FMI 05 • The return circuit of the solenoid is open.
SMCS Code: 5479-038-BRK • The solenoid has failed.
Conditions Which Generate This Code: • The ECM has failed. This is unlikely.

Test Step 1. CHECK THE SOLENOID

A. Disconnect the solenoid from the machine
harness.
g01323395
Illustration 188 B. At the machine harness connector for the
The “Park Brake” solenoid is located on the housing of the park solenoid, place a jumper wire from contact 1 (wire
brake on the engine side of the transmission. G730-PK) to contact 2 (wire J765-BU).
(1) “Park Brake” Solenoid
switch to the ON position. Do not start the engine.
D. Observe the status of the CID 0681 FMI 05

diagnostic code.
Expected Result:

active when the jumper wire is connected.
Results:
g01301698 • YES – The CID 0681 FMI 05 diagnostic code is

Illustration 189 no longer active. A CID 0681 FMI 06 diagnostic
“Park Brake” Solenoid code becomes active when the jumper wire is
connected. The solenoid has failed.
264 RENR9004-07
Repair: Repeat this Test Step “CHECK THE Repair: A resistance measurement that is greater
SOLENOID” in order to verify the solenoid failure. than 5000 ohms could indicate that a wire is
Replace the solenoid. Verify that the new solenoid not connected or that a connection is open. A
corrects the problem. resistance measurement that is greater than 5.0
ohms but less than 5000 ohms could indicate that
STOP. one of the connection points in the circuit is not an
open connection but not a good connection.
remains active. The jumper wire does not affect the The open or the possible bad connection is in
status of the active diagnostic code. The solenoid supply wire G730-PK or in return wire J765-BU
is not causing the problem. Proceed to Test Step 2. of the machine harness. Refer to the complete
Test Step 2. CHECK THE CIRCUIT FOR Check all of the connectors that are in the solenoid
AN OPEN circuit. Ensure that all connections are clean, that
all connections are secure and that all connections
The jumper wire that was installed in the previous are in good condition. Repair the machine harness
Test Step remains in place. or replace the machine harness.
A. Turn the disconnect switch and the key start STOP.

B. Disconnect the machine harness connector of the THE ECM
ECM J2 from the ECM.
C. At the machine harness connector J2 for the ECM, remain in the OFF position. The machine harness
measure the resistance from contact J2-4 (wire connector for the solenoid and the ECM J2 connector
J765-BU) to contact J2-8 (wire J765-BU). remain disconnected.
D. Observe the resistance measurement of A. Remove the jumper wire that was installed in the
the multimeter. Wiggle the machine harness last test step.
connectors for the ECM. Wiggle the machine
harness connector for the solenoid. Gently pull on B. At the machine harness connector J2 for the ECM,
the wires and wiggle the wires. use a 151-6320 Removal Tool to remove the
energize wire of the solenoid G730-PK and the
E. At the machine harness connector J2 for the ECM, socket at contact J2-6 from the harness connector.
J765-BU) to contact J2-6 (wire J730-PK). C. Reconnect the machine harness J2 connector to
the ECM.
F. Observe the resistance measurement of
the multimeter. Wiggle the machine harness D. Turn the disconnect switch and the key start
connectors for the ECM. Wiggle the machine switch to the ON position.
harness connector for the solenoid. Gently pull on
the wires and wiggle the wires. E. Use a 7X-1710 Multimeter Probe that is not
connected to a multimeter or a similar device to
Expected Result: make contact with the ECM pin at J2-6 through
the empty space in the J2 connector.
Each resistance measurement is less than 5.0 ohms
at all times during the manipulation of the harness F. Observe the status of the active CID 0681 FMI 05
and connectors. diagnostic code and ground the other end of the
7X-1710 Multimeter Probe to frame ground.
Results:
Expected Result:
5.0 ohms. The resistance measurements are not The CID 0681 FMI 05 diagnostic code is no longer
indicating an open or a bad connection in the active. A CID 0681 FMI 06 diagnostic code becomes
circuit. Proceed to Test Step 3. active when the ECM pin at J2-6 is grounded.

than 5.0 ohms. The resistance measurement is
indicating an open circuit or a bad connection in
RENR9004-07 265
Results: Results:
• YES – The CID 0681 FMI 05 diagnostic code is no • OK – The CID 0681 FMI 05 diagnostic code is not
longer active. A CID 0681 FMI 06 diagnostic code active. The diagnostic code does not exist at this
has been activated after the ECM pin is grounded. time.
The ECM has responded correctly to the grounded
circuit condition in the solenoid circuit. It is unlikely Repair: The initial diagnostic code was probably
that the ECM is causing the problem. caused by a poor electrical connection at one of
the harness connectors that was disconnected and
Reinstall the energize wire of the solenoid into the reconnected. Resume normal machine operation.
correct spot of the ECM connector. Proceed to the
next test step. STOP.
Proceed to Test Step 4. • NOT OK – The CID 0681 FMI 05 diagnostic

• NO – The CID 0681 FMI 05 diagnostic code corrected.
remains active. The status of the active diagnostic
code does not change when the ECM pin for the Repair: Check the circuit again. Use the Caterpillar
solenoid is grounded. Electronic Technician (ET) service tool, if available,
Repair: The ECM has not responded correctly to wiring harness. The wiggle test can detect
the grounded condition in the solenoid circuit. The momentary or intermittent shorts or opens in the
operation of the ECM is not correct. machine wiring harness.
Prior to replacing an ECM, always contact your If the cause of the problem is not found in the
dealership's Technical Communicator for possible machine harness, the ECM may have failed. This
consultation with Caterpillar. This consultation may is unlikely as the ECM responded correctly to the
greatly reduce repair time. If the ECM must be grounded condition in the previous test step.
Control Module (ECM) - Replace”. Verify that all possible causes of the diagnostic
code have been investigated. Exit this procedure
STOP. and perform this procedure again.
Test Step 4. CHECK THE STATUS OF THE Prior to replacing an ECM, always contact your
DIAGNOSTIC CODE dealership's Technical Communicator for possible
A. Inspect the harness connectors. Clean the greatly reduce repair time. If the cause of the active
contacts of the harness connectors. Check the diagnostic code is not found and the ECM must be
wires for damage to the insulation that is caused replaced, refer to Testing and Adjusting, “Electronic
by excessive heat, battery acid, or chafing. Control Module (ECM) - Replace”.




diagnostic code.
Expected Result:

266 RENR9004-07

SMCS Code: 5479-038-BRK circuit. Poor connections can often be the cause


B. Observe the status of the diagnostic code.
C. Disconnect the solenoid with the active diagnostic

code from the machine harness.
g01323395
Illustration 190 Expected Result:
The “Park Brake” solenoid is located on the housing of the park
brake on the engine side of the transmission. The active CID 0681 FMI 06 diagnostic code changes
(1) “Park Brake” Solenoid to a CID 0681 FMI 05 diagnostic code when the
solenoid is disconnected.
Results:

code changes to a CID 0681 FMI 05 diagnostic
code when the solenoid is disconnected. The
solenoid circuit in the machine harness is correct.
Repair: The solenoid has failed. Repeat this test

“CHECK THE SOLENOID” in order to verify the
solenoid failure. Replace the solenoid.
STOP.
Illustration 191
g01301698
Connections of “Park Brake” solenoid remains active. Disconnecting the solenoid did not
change the status of the active diagnostic code.
This diagnostic code is associated with the parking The solenoid is not causing the problem. Proceed
brake solenoid. The FMI 06 diagnostic code means to Test Step 2.
that the ECM has detected that the current for the
solenoid circuit is above normal. Test Step 2. CHECK THE ENERGIZE
Conditions that could cause this diagnostic code to SHORT TO GROUND
be activated are listed below:
The solenoid remains disconnected from the machine
• The energize circuit of the solenoid is shorted to a harness.
ground source.
• The solenoid has failed. switch to the OFF position.
RENR9004-07 267
B. Disconnect the machine harness connectors of F. Check the status of the CID 0681 FMI 06
the ECM J1 and J2 from the ECM. diagnostic code.
C. At the machine harness connectors for the ECM, Expected Result:

measure the resistance from the signal contact
J2-6 (wire G730-PK) to frame ground. Measure The CID 0681 FMI 06 diagnostic code not active.
the resistance from the signal contact J2-6 (wire
G730-PK) to all of the other contacts that are used Results:
in J1 and J2 ECM connectors.
D. Observe the resistance measurements of the diagnostic code does not exist at this time.
multimeter and wiggle the machine harness
connectors for the ECM and the solenoid. Gently Repair: The initial diagnostic code was probably
pull on the wires and wiggle the wires. caused by a poor electrical connection or a
Expected Result: disconnected and reconnected. Resume normal
machine operation.
ohms at all times during the manipulation of the STOP.
harness and connectors.
• NOT OK – The CID 0681 FMI 06diagnostic code
Results: is still active. The diagnostic code has not been
corrected.
than 5000 ohms. The machine harness is correct. Repair: Check the circuit again. Use the Caterpillar
Proceed to Test Step 3. Electronic Technician (ET) service tool, if available,
• NOT OK – One or more of the resistance wiring harness. The wiggle test can detect
measurements is less than 5000 ohms. The momentary or intermittent shorts or opens in the
resistance measurement is indicating that a short machine wiring harness.
is present in the machine harness. The short is
between wire G730-PK and the frame ground or Verify that all possible causes of the diagnostic
the circuit with the low resistance measurement. code have been investigated. Exit this procedure
and perform this procedure again. If the cause of
Repair: For information on testing for short the problem is not found, the ECM may have failed.
circuits and finding short circuits, refer to Testing
and Adjusting, “Wiring Harness (Short Circuit) - Prior to replacing an ECM, always contact your
Test”. Repair the machine harness or replace the dealership's Technical Communicator for possible
machine harness. consultation with Caterpillar. This consultation
STOP. diagnostic code is not found and the ECM must be
Test Step 3. CHECK THE STATUS OF THE Control Module (ECM) - Replace”.
DIAGNOSTIC CODE
STOP.




268 RENR9004-07
i02917974 Test Step 2. CHECK THE STATUS OF THE

DIAGNOSTIC CODE
MID 027 - CID 0967 - FMI 02
A. The disconnect switch and the key start switch
SMCS Code: 7610-038-DTN remain in the ON position.
Conditions Which Generate This Code: B. Operate the machine.
This diagnostic code is associated with the C. Determine if the CID 0967 FMI 02 diagnostic code
communication between the Transmission/Chassis is active.
ECM and the Messenger that is conducted over
the Cat Data Link. The machine serial number is Expected Result:
programmed into the Messenger. The serial number
is communicated to the Transmission/Chassis ECM The CID 0967 FMI 02 diagnostic code is not active.
and to the other ECM modules on the machine. The
Transmission/Chassis ECM activates the CID 0967 Results:
FMI 02 diagnostic code when the machine serial
number, received from the Messenger, is incorrect or • OK – The CID 0967 FMI 02 diagnostic code is not
the serial number has been changed. active. The diagnostic code does not exist at this
time. Resume normal operation. STOP.
code is active before performing this procedure. • NOT OK – The CID 0967 FMI 02 diagnostic
Test Step 1. Check The Serial Number corrected.
That Is Programmed
Repair: It is unlikely that the ECM has failed. Exit
A. Connect the Caterpillar Electronic Technician this procedure and perform this procedure again. If
(ET) service tool to the service connector of the the cause is not found, contact your dealership's
machine. Technical Communicator for possible consultation
with Caterpillar. This consultation may greatly
B. Turn the key start switch and the disconnect reduce repair time. If the cause of the diagnostic
switch to the ON position. code can not be found, replace the ECM. Refer
to Troubleshooting, “Electronic Control Module
C. Check the machine serial number that is (ECM) - Replace”.
programmed for the Messenger.
STOP.
Expected Result:
The machine serial number is not correct for this

machine.
Results:
• YES – The programmed machine serial number is

NOT the correct serial number for this machine.
Repair: Program the complete machine serial

number for this machine into the Messenger using
the ET service tool. After the correct serial number
has been programmed, turn the key start switch
to the OFF position. Wait a minute, then turn the
key start switch to the ON position. Verify that the
diagnostic code has been cleared.
STOP.
• NO – The machine serial number IS correct for

this machine. The complete serial number for
this machine is programmed correctly for the
Messenger. Proceed to Test Step 2.
RENR9004-07 269
i02839839 Note: If the Messenger is not operating correctly,

refer to Testing and Adjusting, RENR9034 for
MID 027 - CID 0967 - FMI 09 information on troubleshooting the Messenger.
Ensure that CID 0967 FMI 09 diagnostic code is
SMCS Code: 7610-038-DTN active before performing this procedure. Check the
Messenger for correct operation before performing
Conditions Which Generate This Code: this procedure.
Test Step 1. CHECK THE DATA LINK

CIRCUIT FOR AN OPEN
B. Disconnect the connector of the machine

harness J1 from the Transmission/Chassis ECM.
Disconnect the machine harness connector from
the Messenger.
C. Inspect the harness connectors and clean all of

the contacts of the harness connectors. Refer
to the illustration above in order to check the
connection of the Cat Data Link on each of the
machine harness connectors. Ensure that the
wires are secured in the connector and in good
condition.
D. At the disconnected harness connectors, measure

the resistance from the contact of ECM connector
J1-10 (wire 893-GN) to contact of the Messenger
6 (wire 893-GN).
E. At the disconnected harness connectors, measure

the resistance from ECM connector contact J1-20
(wire 892-BR) to Messenger contact 5 (wire
892-BR).
Expected Result:
Both of the resistance measurements are less than

5 ohms.
g01405233
Illustration 192
Results:
Connections of the Cat Data Link
• OK – Both of the resistance measurements are
less than 5 ohms. The Cat Data Link circuit in the
machine harness is not open. Proceed to Test Step
communication between the Transmission/Chassis
ECM and the Messenger that is conducted over the
Cat Data Link. The FMI 09 code means that the • NOT OK – At least one of the resistance
measurements is more than 5 ohms.
Transmission/Chassis ECM has lost communication
with the Messenger.

below:
• An open or a faulty connection in the Cat Data Link

circuit.
• The Messenger has failed. This is unlikely

270 RENR9004-07
Repair: There is an open or a bad connection in the i02917979

Cat Data Link circuit in the machine harness. Refer
to the complete Electrical System Schematic of the MID 027 - CID 1326 - FMI 02
machine. Locate all the connectors and examine all
of the connectors of the machine harness that are SMCS Code: 1408-038
involved in the data link circuit. Check each wire
section from connector to connector for an open Conditions Which Generate This Code:
or a bad connection. Ensure that all connections
STOP.

DIAGNOSTIC CODE

the connectors are fully seated. Observe that the g01301815
Illustration 193
This diagnostic code is recorded when the software
location code for the Implement ECM does not match
switch to the ON position. the hard wired location codes.
The probable cause of this diagnostic code is
software. The wrong software has been flashed into
E. Check the status of the CID 0967 FMI 09 the ECM. A short to a ground source in one of the
diagnostic code.
location code circuits in the machine harness could
also cause this diagnostic code to activate.
Expected Result:
Note: Do not change the hard wired location code
The CID 0967 FMI 09 diagnostic code is not active. if you have flashed the incorrect software into the
control.
Results:
Note: For help with verification of correct location
• OK – The CID 0967 FMI 09 diagnostic code is codes, in the Cat ET status screen, the “actual”
location code and the “desired” location code for
this time. The initial diagnostic code was probably each ECM on the machine can be displayed.
Test Step 1. VERIFY HARDWARE AND
SOFTWARE PART NUMBERS
• NOT OK – The CID 0967 FMI 09 diagnostic A. Verify whether the part number of the software for
the ECM is correct.
corrected.
Expected Result:
Contact the Business Unit that is producing the
in order to perform a “wiggle” test on the machine
product for the correct configuration for the machine.
wiring harness. The “wiggle” test can detect
Results:
It is unlikely that the ECM has failed. Exit this • OK – All part numbers are correct for the ECM.
procedure and perform this procedure again. If the
cause of the failure is not found, replace the ECM.
See the Testing and Adjusting, “Electronic Control • NOT OK – All part numbers are NOT correct.
The installed ECM has the wrong part number or
incorrect configuration software is installed.
STOP.
RENR9004-07 271
Repair: Replace the ECM with a module that Results:

has the correct part number or flash the correct
configuration software. See Troubleshooting, • OK – The machine harness connectors are tight
“Electronic Control Module - Flash Program”. and the machine harness connectors are free from
corrosion. Proceed to Test Step 4.
STOP.
• NOT OK – One or more of the machine harness
Test Step 2. VERIFY WHETHER THE connectors are in need of repair.
LOCATION CODE MATCHES THE ET
STATUS SCREEN Repair: Repair the connector and verify that all
connections are correct before reconnecting to the
A. Check the ET status screen in order to verify the mating connector. After the connector is repaired,
location code. The codes are listed below: verify that the problem has been corrected before
operating the machine.
TRansmission/Chassis ECM ....................... 1
STOP.
Expected Result:
Test Step 4. CHECK FOR SHORTS TO
The location codes in the ET are correct. GROUND
Results: A. The disconnect switch and the key start switch
• OK – The location codes in the ET are correct.
Proceed to Test Step 3. B. Disconnect the machine harness connector from
the ECM.
• NOT OK – The location codes are NOT correct.
C. At the machine harness for the ECM, measure
Repair: Repeat this test step in order to verify the resistance between the frame ground and the
that the software and hardware part numbers are J1 location codes.
correct.
Expected Result:
Proceed to Test Step 3 if the part numbers are
correct. The resistance that is measured is greater than 5
ohms at contacts J1-27 and J1-28. The resistance
Test Step 3. INSPECT HARNESS measures less than 5 ohms at contacts J1-26 and
CONNECTIONS J1-32.
A. Turn the key start switch and the disconnect Results:

• OK – The resistance measurements are correct.
B. Inspect the harness connections that are related to The harness circuit is correct. Proceed to Test Step
the location codes. Make sure that the connectors 5.
are clean. Make sure that the connectors are tight.
C. Check for the proper mating of the connector. measurements is NOT correct. The machine
harness has failed.
D. Check all wires at the connector.
Repair: Repair the machine harness or replace the
E. Check each wire for nicks. Check each wire for machine harness.
signs of abrasion in the insulation.
STOP.
F. Check for moisture at the connector.
Test Step 5. CHECK FOR AN OPEN
G. Check for dirty contacts or corroded contacts. HARNESS
H. Check each pin and check each socket. A. The disconnect switch and the key start switch
remain in the OFF position. The ECM remains
Expected Result: disconnected from the machine harness.
The machine harness connectors are tight and the B. At the machine harness for the ECM, measure the
machine harness connectors are free of corrosion. resistance between the frame ground and J1-27.
272 RENR9004-07
C. At the machine harness for the ECM, measure the i02917988

resistance between the frame ground and J1-32.
MID 027 - CID 1401 - FMI 03
Expected Result:
SMCS Code: 3139-038-T3
The resistance measurements are less than 5 ohms.
Results:

5 ohms. The location code circuit is correct. The
ECM may have failed.
Repair: Check the location code circuit again. Use

tool, if available, in order to perform a wiggle test
If the cause of the problem can not be found,

The ECM may have failed. Prior to replacing an
ECM, always contact your dealership's Technical
Caterpillar. This consultation may greatly reduce
repair time. If the cause of the diagnostic code is not
found, replace the ECM. Refer to Troubleshooting,
g01321566
Illustration 194
STOP. Transmission Solenoids located on the left side of the transmission
(1) “Transmission solenoid 1” (forward high)
• NOT OK – The resistance is greater than 5 ohms. (2) “Transmission solenoid 2” (forward low)
The machine harness has failed. (3) “Transmission solenoid 3 ” (reverse)
(4) “Transmission solenoid 4” (2nd speed)
Repair: Repair the machine harness or replace the (5) “Transmission solenoid 5” (3rd speed)
(6) “Transmission solenoid 6” (1st speed)
machine harness. (7) “Transmission solenoid 7” (low range)
(8) “Transmission solenoid 8” (high range)
STOP.
g01288780
Illustration 195
Connections for “Transmission Solenoid 1”

“transmission solenoid 1”. The FMI 03 means that
the Transmission/Chassis ECM has determined that
the voltage of the solenoid circuit is above normal.
Conditions that can cause this diagnostic code are

listed below:
RENR9004-07 273
• The energize circuit of the solenoid is shorted to Repair: For information on testing for short
another voltage source. circuits and finding short circuits, refer to Testing
and Adjusting, “Wiring Harness (Short Circuit) -
• The ECM has failed. This is unlikely. Test”. Repair the machine harness or replace the
machine harness.
harness connectors that are involved in the STOP.
of a problem in an electrical circuit. Verify that Test Step 2. CHECK THE OPERATION OF
all connections in the circuit are clean, that all THE ECM
are in good condition. If a problem with a The disconnect switch and the key start switch remain
connection is found, correct the problem and in the OFF position. The machine harness connectors
verify that this diagnostic code is active before for the solenoid and the Transmission/Chassis ECM
performing this procedure. remain disconnected.
Note: The following test procedure may create other A. At the machine harness connector J1 for the
diagnostic codes. Ignore these created diagnostic ECM, use a 151-6320 Removal Tool to remove
codes and clear these diagnostic codes when the the energize wire of the solenoid 754-BU and
original diagnostic code has been corrected. the socket at contact J1-60 from the harness
connector.
Note: The resistance of the solenoid coil should be
8.7 ± .4 ohms at 25 °C (77.0 °F). B. Reconnect the machine harness J1 and J2
CIRCUIT OF THE SOLENOID FOR A C. Turn the disconnect switch and the key start
SHORT switch to the ON position.
A. Turn the key start switch and the disconnect D. Observe the status of the active CID 1401 FMI
switch to the OFF position. 03 diagnostic code.
B. Disconnect the machine harness connector Expected Result:

from the solenoid. Disconnect the machine
harness connectors J1 and J2 from the The CID 1401 FMI 03 diagnostic code is no longer
Transmission/Chassis ECM. active. A CID 1401 FMI 05 diagnostic code is now
active.
C. At the machine harness connector of the ECM J1,
measure the resistance from contact J1-61 (wire Results:
754-BU) to all J1 and J2 contacts that are used on
the connectors of the Transmission/Chassis ECM. • YES – The CID 1401 FMI 03 diagnostic code is no
longer active. A CID 1401 FMI 05 diagnostic code
Expected Result: has been activated after the solenoid energize
circuit was disconnected. The ECM has responded
Each resistance measurement is greater than 5000 correctly to the open circuit condition in the
ohms. solenoid circuit.
Results: Reinstall the energize wire of the solenoid into

the correct space of the connector on the ECM.
• OK – Each resistance measurement is greater Proceed to the next test step.
Proceed to Test Step 2. Proceed to Test Step 3.
• NOT OK – Each resistance measurement is not • NO – The CID 1401 FMI 03 diagnostic code
greater than 5000 ohms. There is a short in the remains active. The status of the active diagnostic
machine harness. The short is between wire code did not change when the energize wire of the
754-BU and the circuit that has a low resistance solenoid was disconnected from the ECM.
measurement.
to the open condition in the solenoid circuit. The
274 RENR9004-07
Prior to replacing an ECM, always contact your It is unlikely that the ECM has failed. Verify that all
dealership's Technical Communicator for possible possible causes of the diagnostic code have been
consultation with Caterpillar. This consultation may investigated. If the cause of the failure is not found,
greatly reduce repair time. If the ECM must be contact your dealership's Technical Communicator
replaced, refer to Testing and Adjusting, “Electronic for possible consultation with Caterpillar. This
Control Module (ECM) - Replace”. consultation may greatly reduce repair time. If the
STOP. the Transmission/Chassis ECM. Refer to Testing
Test Step 3. CHECK THE STATUS OF THE - Replace”.
DIAGNOSTIC CODE
STOP.
contacts of the harness connectors. Check the • NO – The CID 1401 FMI 03 code is not active. The
wires for damage to the insulation that is caused problem does not exist at this time.
B. Perform a 45 N (10 lb) pull test on each of the caused by a poor electrical connection or a
wires that are associated with the sensor circuit. short at one of the harness connectors that was
C. Reconnect all harness connectors. Make sure that machine operation.
clips for each connector are completely fastened. STOP.

i02918023

MID 027 - CID 1401 - FMI 05
is active. Conditions Which Generate This Code:
Expected Result:
Results:

active.

If the problem remains, the ECM may have failed.

This is unlikely because the ECM detected the
open circuit condition in the solenoid circuit and
activated the FMI 05 diagnostic code when the
energize wire of the solenoid was disconnected. g01321566
Illustration 196
Transmission Solenoids located on the left side of the transmission
(2) “Transmission solenoid 2” (forward low)
(3) “Transmission solenoid 3” (reverse)
(5) “Transmission solenoid 5” (3rd speed)
(7) “Transmission solenoid 7” (low range)
RENR9004-07 275


diagnostic code.
Expected Result:
The active diagnostic code changes from an FMI

“05” to an FMI “06” diagnostic code when the jumper
wire is installed.
Results:
g01288780 • YES – The active diagnostic code changes from

Illustration 197 an FMI “05” to an FMI “06” diagnostic code when
Connections of “Transmission Solenoid 1” the jumper wire is installed. The solenoid has
failed.
transmission solenoid 1. The FMI 05 means that the Repair: The solenoid has failed. Repeat this Test
Transmission/Chassis ECM has determined that the Step “CHECK THE SOLENOID” in order to verify
current for the solenoid circuit is below normal. the solenoid failure. Replace the solenoid. Verify
that the new solenoid corrects the problem.
Some possible causes of this diagnostic code are
listed below: STOP.
• The energize circuit of the solenoid is open. • NO – The CID 1401 FMI 05 diagnostic code
remains active. The jumper wire does not affect the
• The return circuit of the solenoid is open. status of the diagnostic code. The solenoid is not
• The solenoid has failed.
• The ECM has failed. This is unlikely. AN OPEN
Before performing this procedure, inspect the A. Turn the key start switch and the disconnect
harness connectors that are involved in the switch to the OFF position.
of a problem in an electrical circuit. Verify that B. Disconnect the machine harness connector J1
all connections in the circuit are clean, that all from the Transmission/Chassis ECM.
are in good condition. If a problem with a C. The jumper wire that was installed in the previous
connection is found, correct the problem and Test Step remains in place.
performing this procedure. D. At the machine harness connector J1 for the
Transmission/Chassis ECM, measure the
Note: The following test procedure may create other resistance from the return contact J1-60 (wire
diagnostic codes. Ignore these created diagnostic 922-BR) to the energize contact J1-61 (wire
codes and clear these diagnostic codes when the 754-BU).
Expected Result:
8.7 ± .4 ohms at 25 °C (77.0 °F). The resistance measurement is less than 5 ohms.
Test Step 1. CHECK THE SOLENOID Results:
A. Disconnect the solenoid from the machine • OK – The measurement of the resistance is less
harness. than 5 ohms. The circuit is not open in the machine
harness. Proceed to Test Step 3.
B. At the machine harness connector for the
solenoid, place a jumper wire from contact 1 (wire
754-BU) to contact 2 (wire 922-BR).
276 RENR9004-07
• NOT OK – The resistance measurement is greater Results:

than 5000 ohms. The resistance measurement is
not correct. There is an open or a bad connection in • YES – The CID 1401 FMI 05 diagnostic code is no
the machine harness. A resistance measurement longer active. A CID 1401 FMI 06 diagnostic code
that is much greater than 5 ohms but less than 5000 has been activated after the ECM pin is grounded.
ohms could indicate that one of the connection The ECM has responded correctly to the grounded
points in the circuit is not an open connection but circuit condition in the solenoid circuit. The problem
not a good connection. is likely not being caused by the ECM.
Repair: The open or the possible poor connection Reinstall the energize wire of the solenoid into the
is in supply wire 754-BU or in return wire 922-BR correct spot of the connector on the ECM. Proceed
of the machine harness. Refer to the complete to the next test step.
Check all of the connectors that are in the solenoid Proceed to Test Step 4.
circuit. Ensure that all connections are clean, that
all connectors are secure and that all connectors • NO – The CID 1401 FMI 05 diagnostic code
are in good condition. Repair the machine harness remains active. The status of the active diagnostic
or replace the machine harness. code does not change when the ECM pin for the
solenoid is grounded.
STOP.
Repair: The ECM has not responded correctly to
Test Step 3. CHECK THE OPERATION OF the grounded condition in the solenoid circuit. The
THE ECM operation of the ECM is not correct.
The disconnect switch and the key start switch Prior to replacing an ECM, always contact your
remain in the OFF position. The machine harness dealership's Technical Communicator for possible
connector for the solenoid and the ECM J1 connector consultation with Caterpillar. This consultation may
remain disconnected. greatly reduce repair time. If the ECM must be
A. Remove the jumper wire that was installed in the Control Module (ECM) - Replace”.
last test step.
STOP.
ECM, use a 151-6320 Removal Tool to remove Test Step 4. CHECK THE STATUS OF THE
the energize wire of the solenoid 754-BU and DIAGNOSTIC CODE
the socket at contact J1-61 from the harness
connector. A. Inspect the harness connectors. Clean the
C. Reconnect the machine harness J1 connector to wires for damage to the insulation that is caused
the ECM. by excessive heat, battery acid, or chafing.
D. Turn the disconnect switch and the key start B. Perform a 45 N (10 lb) pull test on each of the
switch to the ON position. wires that are associated with the sensor circuit.
E. Use a 7X-1710 Multimeter Probe that is not C. Reconnect all harness connectors. Make sure that
connected to a multimeter or a similar device to the connectors are fully seated. Observe that the
make contact with the ECM pin at J1-61 through clips for each connector are completely fastened.
F. Observe the status of the active CID 1401 FMI 05 switch to the ON position.
diagnostic code and ground the other end of the
7X-1710 Multimeter Probe to frame ground. E. Operate the machine.
Expected Result: F. Check the status of the CID 1401 FMI 05

diagnostic code.
active. A CID 1401 FMI 06 diagnostic code becomes Expected Result:
active when the ECM pin at J1-61 is grounded.
RENR9004-07 277
Results: i02918078
• YES – The CID 1401 FMI 05 diagnostic code MID 027 - CID 1401 - FMI 06
corrected. The ECM may have failed. SMCS Code: 3139-038-T3
Repair: Check the circuit again. Use the Caterpillar Conditions Which Generate This Code:
If the cause of the problem is not found in the

machine harness, the ECM may have failed. This
is unlikely as the ECM responded correctly to the
grounded condition in the previous test step.
Verify that all possible causes of the diagnostic code

have been investigated. If the cause of the failure
is not found, contact your dealership's Technical
repair time. If the cause of the diagnostic code is
not found, replace the Transmission/Chassis ECM.
g01321566
Transmission Solenoids located on the left side of the transmission
• NO – The CID 1401 FMI 05 diagnostic code is not (1) “Transmission solenoid 1” (forward high)
active. The diagnostic code does not exist at this (2) “Transmission solenoid 2” (forward low)
time. (3) “Transmission solenoid 3” (reverse)
Repair: The initial diagnostic code was probably (5) “Transmission solenoid 5” (3rd speed)
caused by a poor electrical connection at one of (7) “Transmission solenoid 7” (low range)
the harness connectors that was disconnected and (8) “Transmission solenoid 8” (high range)
STOP.
g01288780
Illustration 199

the current of the solenoid circuit is above normal.

listed below:
278 RENR9004-07
• The energize circuit of the solenoid is shorted to Test Step 2. CHECK THE ENERGIZE
ground. CIRCUIT OF THE SOLENOID FOR A
SHORT TO GROUND
• The ECM has failed. This is unlikely. switch to the OFF position.
Before performing this procedure, inspect the B. The solenoid remains disconnected from the
harness connectors that are involved in the machine harness.
circuit. Poor connections can often be the
cause of a problem in an electrical circuit. Verify C. Disconnect the machine harness connectors J1
that all connections in the circuit are clean, and J2 from the Transmission/Chassis ECM.
that all connections are secure and that all the
connections are in good condition. If a problem D. At the machine harness connectors of the ECM,
with a connection is found, correct the problem measure the resistance from the contact J1-61
and verify that this diagnostic code is active (wire 754-BU) to frame ground. Measure the
before performing this procedure. resistance from the contact J1-61 (wire 754-BU) to
all of the other J1 and J2 contacts that are used in
Note: The following test procedure may create other the connectors of the Transmission/Chassis ECM.
codes and clear these diagnostic codes when the Expected Result:
Note: The resistance of the solenoid coil should be ohms.
8.7 ± .4 ohms at 25 °C (77.0 °F).
Results:
A. Turn the disconnect switch and the key start than 5000 ohms. The machine harness is correct.
switch to the ON position. Do not start the engine. Proceed to Test Step 3.
B. Observe the status of the diagnostic code. • NOT OK – One or more of the resistance
C. Disconnect the solenoid with the active diagnostic short in the machine harness. The short is between
code from the machine harness. wire 754-BU and the circuit with the low resistance
measurement.
Expected Result:
Repair: For information on testing for short
The active CID 1401 FMI 06 diagnostic code changes circuits and finding short circuits, refer to Testing
to a CID 1401 FMI 05 diagnostic code when the and Adjusting, “Wiring Harness (Short Circuit) -
solenoid is disconnected. Test”. Repair the machine harness or replace the
machine harness.
Results:
STOP.
code changes to a CID 1401 FMI 05 diagnostic Test Step 3. CHECK THE STATUS OF THE
code when the solenoid is disconnected. The DIAGNOSTIC CODE
circuit is correct.
Repair: The solenoid has failed. Repeat this test contacts of the harness connectors. Check the
“CHECK THE SOLENOID” in order to verify the wires for damage to the insulation that is caused
solenoid failure. Replace the solenoid. by excessive heat, battery acid, or chafing.
STOP. B. Perform a 45 N (10 lb) pull test on each of the

• NO – The CID 1401 FMI 06 remains active when
the solenoid is disconnected. The solenoid is not C. Reconnect all harness connectors. Make sure that
causing the problem. Proceed to Test Step 2. the connectors are fully seated. Observe that the

RENR9004-07 279
E. Operate the machine. Note: Before performing this procedure, verify that
no other active CID 1401 diagnostic codes exist
F. Check the status of the CID 1401 FMI 06 for the solenoid. If any other diagnostic codes are
diagnostic code. active for the solenoid, correct the problem before
Expected Result:
CALIBRATION
The CID 1401 FMI 06 diagnostic code is still active.
A. Perform the calibration procedure for the solenoid.
Results: Refer to Testing and Adjusting, “Calibration”
section of this manual for the correct calibration
• YES – The CID 1401 FMI 06diagnostic code is procedure.
still active. The diagnostic code has not been
corrected. Expected Result:
Repair: Check the circuit again. Use the Caterpillar The calibration procedure was performed
Electronic Technician (ET) service tool, if available, successfully.
wiring harness. The wiggle test can detect Results:
machine wiring harness. • YES – The calibration procedure was performed
If the cause of the problem is not found, the ECM STOP.
may have failed.
It is unlikely that the ECM has failed. Verify that all
possible causes of the diagnostic code have been Repair: Repeat the calibration procedure for the
investigated. If the cause of the failure is not found, solenoid.
for possible consultation with Caterpillar. This If the second calibration procedure is not
consultation may greatly reduce repair time. If the successful, replace the solenoid. After solenoid
cause of the diagnostic code is not found, replace replacement, refer to Testing and Adjusting,
the Transmission/Chassis ECM. Refer to Testing “Calibration” section of this manual for the correct
and Adjusting, “Electronic Control Module (ECM) calibration procedure. If the problem is still present
- Replace”. after replacement and calibration of the new
solenoid, the ECM may have failed.
STOP.
• NO – The CID 1401 FMI 06 is not active. The dealership's Technical Communicator for possible
diagnostic code does not exist at this time. consultation with Caterpillar. This consultation
Repair: The initial diagnostic code was probably diagnostic code is not found, replace the ECM.
caused by a poor electrical connection or a Refer to Testing and Adjusting, “Electronic Control
short at one of the harness connectors that was Module (ECM) - Replace”.
STOP.
i02572896
MID 027 - CID 1401 - FMI 13


transmission solenoid 1. The FMI 13 diagnostic code
is activated when the ECM detects that the solenoid
needs calibration.
280 RENR9004-07
i02918167 • The energize circuit of the solenoid is shorted to

MID 027 - CID 1402 - FMI 03
Conditions Which Generate This Code: harness connectors that are involved in the


8.7 ± .4 ohms at 25 °C (77.0 °F).

SHORT
g01321566
Connections of the “Transmission Solenoids” located on the left switch to the OFF position.
side of the transmission.
(1) “Transmission solenoid 1” (forward high) B. Disconnect the machine harness connector
(2) “Transmission solenoid 2” (forward low) from the solenoid. Disconnect the machine
(3) “Transmission solenoid 3” (reverse) harness connectors J1 and J2 from the
(4) “Transmission solenoid 4” (2nd speed) Transmission/Chassis ECM.
(7) “Transmission solenoid 7” (low range) C. At the machine harness connector of the ECM J1,
(8) “Transmission solenoid 8” (high range) measure the resistance from contact J1-49 (wire
752-YL) to all J1 and J2 contacts that are used on
the connectors of the Transmission/Chassis ECM.
Expected Result:

ohms.
Results:

g01288812
• NOT OK – Each resistance measurement is not
Illustration 201 greater than 5000 ohms. There is a short in the
Connections of “Transmission Solenoid 2” machine harness. The short is between wire
752-YL and the circuit that has a low resistance
This diagnostic code is associated with the measurement.

listed:
RENR9004-07 281
Repair: For information on testing for short Prior to replacing an ECM, always contact your
circuits and finding short circuits, refer to Testing dealership's Technical Communicator for possible
and Adjusting, “Wiring Harness (Short Circuit) - consultation with Caterpillar. This consultation may
Test”. Repair the machine harness or replace the greatly reduce repair time. If the ECM must be
machine harness. replaced, refer to Testing and Adjusting, “Electronic
STOP.
STOP.
THE ECM Test Step 3. CHECK THE STATUS OF THE
DIAGNOSTIC CODE
remain in the OFF position. The machine harness A. Inspect the harness connectors. Clean the
connectors for the solenoid and the ECM remain contacts of the harness connectors. Check the
disconnected. wires for damage to the insulation that is caused
A. At the machine harness connector J1 for the
ECM, use a 151-6320 Removal Tool to remove B. Perform a 45 N (10 lb) pull test on each of the
the energize wire of the solenoid 752-YL and wires that are associated with the sensor circuit.
connector. C. Reconnect all harness connectors. Make sure that
is active.
Expected Result:
Expected Result:
active. A CID 1402 FMI 05 diagnostic code is now The CID 1402 FMI 03 diagnostic code is active.
active.
Results:
Results:
• YES – The CID 1402 FMI 03 diagnostic code is no active.
has been activated after the solenoid energize Repair: Check the circuit again. Use the Caterpillar
circuit was disconnected. The ECM has responded Electronic Technician (ET) service tool, if available,
correctly to the open circuit condition in the in order to perform a wiggle test on the machine
solenoid circuit. wiring harness. The wiggle test can detect
Reinstall the energize wire of the solenoid in machine wiring harness.
the correct space of the connector of the ECM.
Proceed to the next test step. If the problem remains, the ECM may have failed.
Proceed to Test Step 3. open circuit condition in the solenoid circuit and
• NO – The CID 1402 FMI 03 diagnostic code solenoid energize wire was disconnected.
code did not change when the solenoid energize
wire was disconnected from the ECM.

282 RENR9004-07

STOP.

g01288812
Repair: The initial diagnostic code was probably Illustration 203
caused by a poor electrical connection or a Connections for “Transmission Solenoid 2”
disconnected and reconnected. Resume normal This diagnostic code is associated with the
machine operation. “transmission solenoid 2”. The FMI 05 means that
STOP. the current for the solenoid circuit is below normal.

i02918539 listed below:
MID 027 - CID 1402 - FMI 05 • The energize circuit of the solenoid is open.
• The return circuit of the solenoid is open.


g01321566
8.7 ± .4 ohms at 25 °C (77.0 °F).
Illustration 202
Transmission Solenoids located on the left side of the transmission Test Step 1. CHECK THE SOLENOID
(2) “Transmission solenoid 2” (forward low) A. Disconnect the solenoid from the machine
(3) “Transmission solenoid 3” (reverse) harness.
(6) “Transmission solenoid 6” (1st speed) B. At the machine harness connector for the
(7) “Transmission solenoid 7” (low range) solenoid, place a jumper wire from contact 1 (wire
(8) “Transmission solenoid 8” (high range) 752-YL) to contact 2 (wire 921-WH).
RENR9004-07 283
C. Turn the disconnect switch and the key start • NOT OK – The resistance measurement is greater
switch to the ON position. Do not start the engine. than 5000 ohms. The resistance measurement is
not correct. There is an open or a bad connection in
D. Observe the status of the CID 1402 FMI 05 the machine harness. A resistance measurement
diagnostic code. that is much greater than 5 ohms but less than 5000
ohms could indicate that one of the connection
Expected Result: points in the circuit is not an open connection but
not a good connection.
“05” to an FMI “06” diagnostic code when the jumper Repair: The open connection or a possible poor
wire is installed. connection is in supply wire 752-YL or in return
wire 921-WH of the machine harness. Refer to
Results: the complete Electrical System Schematic of the
machine. Check all of the connectors that are in
• YES – The active diagnostic code changes from the solenoid circuit. Ensure that all connections
an FMI “05” to an FMI “06” diagnostic code when are clean, that all connections are secure and that
the jumper wire is installed. The solenoid has all connections are in good condition. Repair the
failed. machine harness or replace the machine harness.
Repair: The solenoid has failed. Repeat this Test STOP.

Step “CHECK THE SOLENOID” in order to verify
the solenoid failure. Replace the solenoid. Verify Test Step 3. CHECK THE OPERATION OF
that the new solenoid corrects the problem. THE ECM
STOP. The disconnect switch and the key start switch
• NO – The CID 1402 FMI 05 diagnostic code connector for the solenoid and the ECM J1 connector
remains active. The jumper wire does not affect the remain disconnected.
status of the diagnostic code. The solenoid is not
causing the problem. Proceed to Test Step 2. A. Remove the jumper wire that was installed in the
last test step.
AN OPEN B. At the machine harness connector J1 for the
ECM, use a 151-6320 Removal Tool to remove
A. Turn the key start switch and the disconnect the energize wire of the solenoid 752-YL and
switch to the OFF position. the socket at contact J1-49 from the harness
connector.
from the Transmission/Chassis ECM. C. Reconnect the machine harness J1 connector to
the ECM.
C. The jumper wire that was installed in the previous
Test Step remains in place. D. Turn the disconnect switch and the key start
D. At the machine harness connector J1 for the
Transmission/Chassis ECM, measure the E. Use a 7X-1710 Multimeter Probe that is not
resistance from the return contact J1-50 (wire connected to a multimeter or a similar device to
921-WH) to the energize contact J1-49 (wire make contact with the ECM pin at J1-49 through
752-YL). the empty space in the J1 connector.
Expected Result: F. Observe the status of the active CID 1402 FMI 05
The resistance measurement is less than 5 ohms. 7X-1710 Multimeter Probe to frame ground.
• OK – The measurement of the resistance is less The CID 1402 FMI 05 diagnostic code is no longer
than 5 ohms. The circuit is not open in the machine active. A CID 1402 FMI 06 diagnostic code becomes
harness. Proceed to Test Step 3. active when the ECM pin at J1-49 is grounded.
284 RENR9004-07
Results: Results:
• YES – The CID 1402 FMI 05 diagnostic code is no • YES – The CID 1402 FMI 05 diagnostic code
longer active. A CID 1402 FMI 06 diagnostic code is active. The diagnostic code has not been
has been activated after the ECM pin is grounded. corrected. The ECM may have failed.
circuit condition in the solenoid circuit. The problem Repair: Check the circuit again. Use the Caterpillar
is likely not being caused by the ECM. Electronic Technician (ET) service tool, if available,
Reinstall the energize wire of the solenoid into the wiring harness. The wiggle test can detect
correct spot of the ECM. Proceed to the next test momentary or intermittent shorts or opens in the
step. machine wiring harness.
Proceed to Test Step 4. If the cause of the problem is not found in the
• NO – The CID 1402 FMI 05 diagnostic code is unlikely as the ECM responded correctly to the
remains active. The status of the active diagnostic grounded condition in the previous test step.
solenoid is grounded. Verify that all possible causes of the diagnostic code
Repair: The ECM has not responded correctly to is not found, contact your dealership's Technical
the grounded condition in the solenoid circuit. The Communicator for possible consultation with
operation of the ECM is not correct. Caterpillar. This consultation may greatly reduce
Prior to replacing an ECM, always contact your not found, replace the Transmission/Chassis ECM.
dealership's Technical Communicator for possible Refer to Testing and Adjusting, “Electronic Control
consultation with Caterpillar. This consultation may Module (ECM) - Replace”.
replaced, refer to Testing and Adjusting, “Electronic STOP.
STOP. active. The diagnostic code does not exist at this
time.
DIAGNOSTIC CODE Repair: The initial diagnostic code was probably
caused by a poor electrical connection at one of
A. Inspect the harness connectors. Clean the the harness connectors that was disconnected and
contacts of the harness connectors. Check the reconnected. Resume normal machine operation.




diagnostic code.
Expected Result:

RENR9004-07 285

ground.
MID 027 - CID 1402 - FMI 06


8.7 ± .4 ohms at 25 °C (77.0 °F).

g01321566
Illustration 204 A. Turn the disconnect switch and the key start
Transmission Solenoids that are located on the left side of the switch to the ON position. Do not start the engine.
transmission
(1) “Transmission solenoid 1” (forward high) B. Observe the status of the diagnostic code.
(3) “Transmission solenoid 3” (reverse) C. Disconnect the solenoid with the active diagnostic
(4) “Transmission solenoid 4” (2nd speed) code from the machine harness.
(7) “Transmission solenoid 7” (low range) Expected Result:
to a CID 1402 FMI 05 diagnostic code when the
Results:

circuit is correct.

in order to verify the solenoid failure. Replace the
solenoid.
g01288812
Illustration 205 STOP.
This diagnostic code is associated with the the solenoid is disconnected. The solenoid is not
“transmission solenoid 2”. The FMI 06 means that causing the problem. Proceed to Test Step 2.

listed below:
286 RENR9004-07
Test Step 2. CHECK THE ENERGIZE E. Operate the machine.

SHORT TO GROUND F. Check the status of the CID 1402 FMI 06
diagnostic code.
switch to the OFF position. Expected Result:
B. The solenoid remains disconnected from the The CID 1402 FMI 06 diagnostic code is still active.
machine harness.
Results:
C. Disconnect the machine harness connectors J1
and J2 from the Transmission/Chassis ECM. • YES – The CID 1402 FMI 06diagnostic code is
D. At the machine harness connectors for the ECM, corrected.
measure the resistance from the contact J1-49
(wire 752-YL) to frame ground. Measure the Repair: Check the circuit again. Use the Caterpillar
resistance from the contact J1-49 (wire 752-YL) to Electronic Technician (ET) service tool, if available,
all of the other J1 and J2 contacts that are used in in order to perform a wiggle test on the machine
the connectors of the Transmission/Chassis ECM. wiring harness. The wiggle test can detect
Expected Result: machine wiring harness.
Each resistance measurement is greater than 5000 If the cause of the problem is not found, the ECM
ohms. may have failed.
Results: It is unlikely that the ECM has failed. Verify that all
possible causes of the diagnostic code have been
• OK – Each resistance measurement is greater investigated. If the cause of the failure is not found,
than 5000 ohms. The machine harness is correct. contact your dealership's Technical Communicator
Proceed to Test Step 3. for possible consultation with Caterpillar. This
• NOT OK – One or more of the resistance cause of the diagnostic code is not found, replace
measurements is less than 5000 ohms. There is a the Transmission/Chassis ECM. Refer to Testing
short in the machine harness. The short is between and Adjusting, “Electronic Control Module (ECM)
wire 752-YL and the circuit with the low resistance - Replace”.
measurement.
STOP.
circuits and finding short circuits, refer to Testing • NO – The CID 1402 FMI 06 is not active. The
and Adjusting, “Wiring Harness (Short Circuit) - diagnostic code does not exist at this time.
Test”. Repair the machine harness or replace the
machine harness. Repair: The initial diagnostic code was probably
DIAGNOSTIC CODE
STOP.
i02572899
by excessive heat, battery acid, or chafing. MID 027 - CID 1402 - FMI 13
B. Perform a 45 N (10 lb) pull test on each of the SMCS Code: 3139-038-T3
the connectors are fully seated. Observe that the This diagnostic code is associated with the
clips for each connector are completely fastened. transmission solenoid 2. The FMI 13 diagnostic code
D. Turn the disconnect switch and the key start needs calibration.
RENR9004-07 287
Note: Before performing this procedure, verify that i02918709

for the solenoid. If any other diagnostic codes are MID 027 - CID 1403 - FMI 03
active for the solenoid, correct the problem before
performing this procedure. SMCS Code: 3139-038-T3
CALIBRATION Conditions Which Generate This Code:

procedure.
Expected Result:

successfully.
Results:

STOP.

solenoid.
g01321566
Illustration 206
If the second calibration procedure is not Transmission Solenoids are located on the left side of the
successful, replace the solenoid. After solenoid transmission.
replacement, refer to Testing and Adjusting, (1) “Transmission solenoid 1” (forward high)
“Calibration” section of this manual for the correct (2) “Transmission solenoid 2” (forward low)
calibration procedure. If the problem is still present (3) “Transmission solenoid 3” (reverse)
after replacement and calibration of the new (4) “Transmission solenoid 4” (2nd speed)
solenoid, the ECM may have failed. (6) “Transmission solenoid 6” (1st speed)
Prior to replacing an ECM, always contact your (8) “Transmission solenoid 8” (high range)
STOP.
g01288824
Illustration 207
Connection of “Transmission Solenoid 3”


listed below:
288 RENR9004-07
machine harness.
are in good condition. If a problem with a The disconnect switch and the key start switch
connection is found, correct the problem and remain in the OFF position. The machine harness
verify that this diagnostic code is active before connectors for the solenoid and the ECM remain
performing this procedure. disconnected.
codes and clear these diagnostic codes when the the energize wire of the solenoid 751-GN and
connector.

active.
C. At the machine harness connector of the ECM J1,
751-GN) to all J1 and J2 contacts that are used on
the Transmission/Chassis ECM. • YES – The CID 1403 FMI 03 diagnostic code is
Expected Result: code has been activated after the energize circuit
of the solenoid was disconnected. The ECM has
Each resistance measurement is greater than 5000 responded correctly to the open circuit condition in
ohms. the solenoid circuit.
Results: Reinstall the energize wire of the solenoid back into

the correct space in the ECM connector. Proceed
• OK – Each resistance measurement is greater to the next test step.
751-GN and the circuit that has a low resistance solenoid was disconnected from the ECM.
measurement.
RENR9004-07 289
Prior to replacing an ECM, always contact your Verify that all possible causes of the diagnostic code
dealership's Technical Communicator for possible have been investigated. If the cause of the failure
consultation with Caterpillar. This consultation may is not found, contact your dealership's Technical
greatly reduce repair time. If the ECM must be Communicator for possible consultation with
replaced, refer to Testing and Adjusting, “Electronic Caterpillar. This consultation may greatly reduce
Control Module (ECM) - Replace”. repair time. If the cause of the diagnostic code is
STOP. Refer to Testing and Adjusting, “Electronic Control
DIAGNOSTIC CODE STOP.
A. Inspect the harness connectors. Clean the • NO – The CID 1403 FMI 03 code is not active. The
contacts of the harness connectors. Check the problem does not exist at this time.
by excessive heat, battery acid, or chafing. Repair: The initial diagnostic code was probably
B. Perform a 45 N (10 lb) pull test on each of the short at one of the harness connectors that was
wires that are associated with the sensor circuit. disconnected and reconnected. Resume normal
machine operation.
the connectors are fully seated. Observe that the STOP.
i03851071
switch to the ON position. MID 027 - CID 1403 - FMI 05
E. Operate the machine. SMCS Code: 3139-038-T3
F. Determine if the CID 1403 FMI 03 diagnostic code Conditions Which Generate This Code:
is active.
Expected Result:
Results:

active.


activated the FMI 05 diagnostic code when the g01321566
energize wire of the solenoid was disconnected. Illustration 208
Transmission Solenoids are located on the left side of the
transmission.
(1) “Transmission Solenoid 1” (forward high)
(2) “Transmission Solenoid 2” (forward low)
(3) “Transmission Solenoid 3” (reverse)
(4) “Transmission Solenoid 4” (2nd speed)
(5) “Transmission Solenoid 5” (3rd speed)
(6) “Transmission Solenoid 6” (1st speed)
(7) “Transmission Solenoid 7” (low range)
(8) “Transmission Solenoid 8” (high range)
290 RENR9004-07


diagnostic code.
Expected Result:
The active code changes from an FMI “05” diagnostic

code to an FMI “06” diagnostic code when the jumper
wire is installed.
Results:

failed.
“Transmission Solenoid 3”. The FMI05 diagnostic Repair: The solenoid has failed. Repeat this Test
code means that the “Transmission/Chassis ECM” Step “CHECK THE SOLENOID” in order to verify
has determined that the current for the solenoid the solenoid failure. Replace the solenoid. Verify
circuit is below normal. that the new solenoid corrects the problem.
Some possible causes of this diagnostic code are STOP.

listed below:
• The energize circuit of the solenoid is open. remains active. The jumper wire does not affect the
• The return circuit of the solenoid is open. the cause of the problem. Proceed to Test Step 2.
• The solenoid has failed. Test Step 2. CHECK THE CIRCUIT FOR
AN OPEN
Before performing this procedure, inspect the switch to the OFF position.
circuit. Poor connections can often be the cause B. Disconnect the machine harness connector J1
of a problem in an electrical circuit. Verify that from the “Transmission/Chassis ECM”.
connections are secure and that all connections C. The jumper wire that was installed in the previous
are in good condition. If a problem with a Test Step remains in place.
verify that this diagnostic code is active before D. At the machine harness connector J1 for the
performing this procedure. “Transmission/Chassis ECM”, measure the
resistance from the return wire, contact J1-50
Note: The following test procedure may create other (wire 921-WH) to the energize wire, contact J1-51
diagnostic codes. Ignore these created diagnostic (wire 751-GN).
original diagnostic code has been corrected. Expected Result:
Note: The resistance of the solenoid coil should be The resistance measurement is less than 5 ohms.
8.7 ± .4 ohms at 25 °C (77.0 °F).
Results:
• OK – The measurement of the resistance is less
A. Disconnect the solenoid from the machine than 5 ohms. The circuit is not open in the machine
harness. harness. Proceed to Test Step 3.

751-GN) to contact 2 (wire 921-WH).
RENR9004-07 291

points in the circuit is not an open connection but circuit condition in the solenoid circuit. The ECM is
not a good connection. not the likely cause of the problem.
Repair: The open or the possible poor connection Reinstall the energize wire of the solenoid in the
is in supply wire 751-GN or in return wire 921-WH correct spot of the ECM connector. Proceed to the
of the machine harness. Refer to the complete next test step.
all connections are secure and that all connections • NO – The CID 1403 FMI 05 diagnostic code
STOP.
last test step.
STOP.
the energize wire of the solenoid 751-GN and DIAGNOSTIC CODE

diagnostic code.
active.
292 RENR9004-07
Results: i02918763
• YES – The CID 1403 FMI 05 diagnostic code is MID 027 - CID 1403 - FMI 06
this time. SMCS Code: 3139-038-T3
Repair: The initial diagnostic code was probably Conditions Which Generate This Code:
STOP.



g01321566
Illustration 210
Verify that all possible causes of the diagnostic code Transmission Solenoids are located on the left side of the
have been investigated. If the cause of the failure transmission.
is not found, contact your dealership's Technical (1) “Transmission solenoid 1” (forward high)
Communicator for possible consultation with (2) “Transmission solenoid 2” (forward low)
Caterpillar. This consultation may greatly reduce (3) “Transmission solenoid 3” (reverse)
repair time. If the cause of the diagnostic code is (4) “Transmission solenoid 4” (2nd speed)
not found, replace the Transmission/Chassis ECM. (6) “Transmission solenoid 6” (1st speed)
Refer to Testing and Adjusting, “Electronic Control (7) “Transmission solenoid 7” (low range)
Module (ECM) - Replace”. (8) “Transmission solenoid 8” (high range)
STOP.
g01288824
Illustration 211
Connections of “Transmission Solenoid 3”


listed below:
RENR9004-07 293
• The energize circuit of the solenoid is shorted to B. The solenoid remains disconnected from the
ground. machine harness.
• The ECM has failed. This is unlikely. C. Disconnect the machine harness connectors J1
harness connectors that are involved in the D. At the machine harness connectors for the ECM,
circuit. Poor connections can often be the cause measure the resistance from the contact J1-51
of a problem in an electrical circuit. Verify that (wire 751-GN) to frame ground. Measure the
all connections in the circuit are clean, that all resistance from the contact J1-51 (wire 751-GN) to
connections are secure and that all connections all of the other J1 and J2 contacts that are used in
are in good condition. If a problem with a the connectors of the Transmission/Chassis ECM.
verify that this diagnostic code is active before Expected Result:
Note: The following test procedure may create other ohms.
codes and clear these diagnostic codes when the Results:
Note: The resistance of the solenoid coil should be than 5000 ohms. The machine harness is correct.
8.7 ± .4 ohms at 25 °C (77.0 °F). Proceed to Test Step 3.
Test Step 1. CHECK THE SOLENOID • NOT OK – One or more of the resistance
A. Turn the disconnect switch and the key start short in the machine harness. The short is between
switch to the ON position. Do not start the engine. wire 751-GN and the circuit with the low resistance
measurement.
C. Disconnect the solenoid with the active diagnostic circuits and finding short circuits, refer to Testing
code from the machine harness. and Adjusting, “Wiring Harness (Short Circuit) -
Expected Result: machine harness.
The active CID 1403 FMI 06 diagnostic code changes STOP.

solenoid is disconnected. Test Step 3. CHECK THE STATUS OF THE
DIAGNOSTIC CODE
Results:
• YES – The active CID 1403 FMI 06 diagnostic contacts of the harness connectors. Check the
code changes to a CID 1403 FMI 05 diagnostic wires for damage to the insulation that is caused
code when the solenoid is disconnected. The by excessive heat, battery acid, or chafing.
circuit is correct.
Repair: The solenoid has failed. Repeat this test wires that are associated with the sensor circuit.
solenoid failure. Replace the solenoid. C. Reconnect all harness connectors. Make sure that
STOP. clips for each connector are completely fastened.
• NO – The CID 1403 FMI 06 remains active when D. Turn the disconnect switch and the key start
the solenoid is disconnected. The solenoid is not switch to the ON position.
CIRCUIT OF THE SOLENOID FOR A F. Check the status of the CID 1403 FMI 06
SHORT TO GROUND diagnostic code.

294 RENR9004-07
Expected Result: CALIBRATION

The CID 1403 FMI 06 diagnostic code is still active. A. Perform the calibration procedure for the solenoid.
Results: section of this manual for the correct calibration
procedure.
• YES – The CID 1403 FMI 06diagnostic code is
still active. The diagnostic code has not been Expected Result:
corrected.
Repair: Check the circuit again. Use the Caterpillar successfully.
in order to perform a wiggle test on the machine Results:
momentary or intermittent shorts or opens in the • YES – The calibration procedure was performed
machine wiring harness. successfully. Resume normal machine operation.
STOP.
may have failed. • NO – The calibration was not successful.
It is unlikely that the ECM has failed. Verify that Repair: Repeat the calibration procedure for the
all possible causes of the diagnostic code have solenoid.
been investigated. If the cause of the failure is
not found, replace the ECM. Prior to replacing an If the second calibration procedure is not
ECM, always contact your dealership's Technical successful, replace the solenoid. After solenoid
Communicator for possible consultation with replacement, refer to Testing and Adjusting,
Caterpillar. This consultation may greatly reduce “Calibration” section of this manual for the correct
repair time. If the cause of the diagnostic code is calibration procedure. If the problem is still present
not found, replace the Transmission/Chassis ECM. after replacement and calibration of the new
Refer to Testing and Adjusting, “Electronic Control solenoid, the ECM may have failed.
STOP. dealership's Technical Communicator for possible
• NO – The CID 1403 FMI 06 is not active. The may greatly reduce repair time. If the cause of the
diagnostic code does not exist at this time. diagnostic code is not found, replace the ECM.
Repair: The initial diagnostic code was probably Module (ECM) - Replace”.
short at one of the harness connectors that was STOP.
machine operation.
STOP.
i02755564
MID 027 - CID 1403 - FMI 13


transmission solenoid (3). The FMI 13 diagnostic
code is activated when the ECM detects that the
solenoid needs calibration.

for the solenoid. If any other diagnostic codes are
RENR9004-07 295

MID 027 - CID 1404 - FMI 03


8.7 ± .4 ohms at 25 °C (77.0 °F).

SHORT
g01321566
Transmission Solenoids are located on the left side of the switch to the OFF position.
transmission.
(7) “Transmission solenoid 7” (low range) C. At the machine harness connector for the ECM, J1,
(8) “Transmission solenoid 8” (high range) measure the resistance from contact J1-52 (wire
900-PU) to all J1 and J2 contacts that are used on
the connectors of the Transmission/Chassis ECM.
Expected Result:

ohms.
Results:

g01288852
Connections of “Transmission Solenoid 4” machine harness. The short is between wire
900-PU and the circuit that has a low resistance

listed below:
296 RENR9004-07
STOP.
STOP.
DIAGNOSTIC CODE
the energize wire of the solenoid 900-PU and wires that are associated with the sensor circuit.
is active.
Expected Result:
Expected Result:
active.
Results:
Results:
Reinstall the energize wire of the solenoid into machine wiring harness.
the correct space in the connector of the ECM.
Proceed to the next test step. If the problem remains, the ECM may have failed.
• NO – The CID 1404 FMI 03 diagnostic code energize wire of the solenoid was disconnected.
code did not change when the energize wire of the
solenoid was disconnected from the ECM.

RENR9004-07 297

STOP.

g01288852
caused by a poor electrical connection or a Connections for “Transmission Solenoid 4”



g01321566
8.7 ± .4 ohms at 25 °C (77.0 °F).
Illustration 214
Transmission Solenoids are located on the left side of the Test Step 1. CHECK THE SOLENOID
transmission.
(1) “Transmission solenoid 1” (forward high) A. Disconnect the solenoid from the machine
(2) “Transmission solenoid 2” (forward low) harness.
(5) “Transmission solenoid 5” (3rd speed) B. At the machine harness connector for the
(6) “Transmission solenoid 6” (1st speed) solenoid, place a jumper wire from contact 1 (wire
(7) “Transmission solenoid 7” (low range) 900-PU) and contact 2 (wire 921-WH).
298 RENR9004-07
The active diagnostic code changes from an FMI “05”
diagnostic code to an FMI “06” diagnostic code after Repair: The open or the possible poor connection
the jumper wire is installed. is in supply wire 900-PU or in return wire 921-WH
of the machine harness. Refer to the complete
Results: Electrical System Schematic of the machine.
Check all of the connectors that are in the solenoid
• YES – The active diagnostic code changes from circuit. Ensure that all connections are clean, that
an FMI “05” diagnostic code to an FMI “06” all connections are secure and that all connections
diagnostic code after the jumper wire is installed. are in good condition. Repair the machine harness
The solenoid has failed. or replace the machine harness.

last test step.
A. Turn the key start switch and the disconnect the energize wire of the solenoid 900-PU and
connector.
the ECM.
921-WH) and the energize contact J1-52 (wire make contact with the ECM pin at J1-52 through
900-PU). the empty space in the J1 connector.
RENR9004-07 299
Results: Results:
circuit condition in the solenoid circuit. It is unlikely Repair: Check the circuit again. Use the Caterpillar
that the cause of the problem is the ECM. Electronic Technician (ET) service tool, if available,
Install the energize wire of the solenoid into the wiring harness. The wiggle test can detect
correct spot in the connector of the ECM. Proceed momentary or intermittent shorts or opens in the
to the next test step. machine wiring harness.
time.




diagnostic code.
Expected Result:

300 RENR9004-07

ground.
MID 027 - CID 1404 - FMI 06


8.7 ± .4 ohms at 25 °C (77.0 °F).

g01321566
Transmission Solenoids are located on the left side of the switch to the ON position. Do not start the engine.
transmission.
Results:

circuit is correct.

g01288852

listed below:
RENR9004-07 301

diagnostic code.
machine harness.
Results:
D. At the machine harness connectors of the ECM, corrected.
(wire 900-PU) to frame ground. Measure the Repair: Check the circuit again. Use the Caterpillar
resistance from the contact J1-52 (wire 900-PU) to Electronic Technician (ET) service tool, if available,
all of the other J1 and J2 contacts that are used in in order to perform a wiggle test on the machine
the connectors of the Transmission/Chassis ECM. wiring harness. The wiggle test can detect
wire 900-PU and the circuit with the low resistance - Replace”.
measurement.
STOP.
DIAGNOSTIC CODE
STOP.
i02572907
302 RENR9004-07


procedure.
Expected Result:

successfully.
Results:

STOP.

solenoid.
g01321566
Illustration 218
replacement, refer to Testing and Adjusting, (1) “Transmission solenoid 1” (forward high)
“Calibration” section of this manual for the correct (2) “Transmission solenoid 2” (forward low)
calibration procedure. If the problem is still present (3) “Transmission solenoid 3” (reverse)
after replacement and calibration of the new (4) “Transmission solenoid 4” (2nd speed)
solenoid, the ECM may have failed. (6) “Transmission solenoid 6” (1st speed)
Prior to replacing an ECM, always contact your (8) “Transmission solenoid 8” (high range)
STOP.
g01288881
Illustration 219

transmission solenoid 5. The FMI 03 means that the
TRansmission/Chassis ECM has determined that the
voltage of the solenoid circuit is above normal.

listed:
RENR9004-07 303
machine harness.
codes and clear these diagnostic codes when the the energize wire of the solenoid 755-OR and
connector.

TRansmission/Chassis ECM. active. A CID 1405 FMI 05 diagnostic code is now
active.
C. At the machine harness connector J1 of the ECM,
755-OR) to all J1 and J2 contacts that are used on
the connectors of the Transmission/Chassis ECM. • YES – The CID 1405 FMI 03 diagnostic code is no
Results: Reinstall the disconnected solenoid energize wire

back into the correct space in the ECM connector
• OK – Each resistance measurement is greater before proceeding to the next test step.
755-OR and the circuit that has a low resistance solenoid was disconnected from the ECM.
measurement.
304 RENR9004-07
Control Module (ECM) - Replace”. repair time. If the cause of the diagnostic code
is not found, replace the TRansmission/Chassis
STOP. ECM. Refer to Testing and Adjusting, “Electronic
machine operation.
i02919239
is active.
Expected Result:
Results:

active.


solenoid energize wire was disconnected. Illustration 220
transmission.
RENR9004-07 305


diagnostic code.
Expected Result:

wire is installed.
Results:

failed.
“transmission solenoid 5”. The FMI 05 means that Repair: The solenoid has failed. Repeat this Test
the Transmission/Chassis ECM has determined that Step “CHECK THE SOLENOID” in order to verify
the current for the solenoid circuit is below normal. the solenoid failure. Replace the solenoid. Verify
listed below: STOP.
connection is found, correct the problem and Test Step remains in place.
Note: The following test procedure may create other resistance from the return, contact J1-50 (wire
diagnostic codes. Ignore these created diagnostic 921-WH), to the energize contact J1-58 (wire
codes and clear these diagnostic codes when the 755-OR).
Expected Result:
755-OR) to contact 2 (wire 921-WH).
306 RENR9004-07

not correct. There is an open or a bad connection • YES – The CID 1405 FMI 05 diagnostic code is no
in the machine harness. A measurement of longer active. A CID 1405 FMI 06 diagnostic code
resistance that is much greater than 5 ohms but has been activated after the ECM pin is grounded.
less than 5000 ohms could indicate that one of The ECM has responded correctly to the grounded
the connection points in the circuit is not an open circuit condition in the solenoid circuit. The ECM is
connection but not a good connection. most likely not the cause of the problem.
Repair: The open or a possible poor connection is Reinstall the energize wire of the solenoid into the
in supply wire 755-OR or in return wire 921-WH correct spot in the ECM connector. Proceed to the
of the machine harness. Refer to the complete next test step.
all connections are secure and that all connections • NO – The CID 1405 FMI 05 diagnostic code
STOP.
last test step.
STOP.
the energize wire of the solenoid 755-OR and DIAGNOSTIC CODE

diagnostic code.
RENR9004-07 307
Results: i02919347


investigated. If the cause of the failure is not found,
the Transmission/Chassis ECM. Refer to Testing
- Replace”.
g01321566
Illustration 222
STOP. Transmission Solenoids are located on the left side of the
transmission.
• NO – The CID 1405 FMI 05 diagnostic code is not (1) “Transmission solenoid 1” (forward high)
active. The diagnostic code does not exist at this (2) “Transmission solenoid 2” (forward low)
time. (3) “Transmission solenoid 3” (reverse)
Repair: The initial diagnostic code was probably (6) “Transmission solenoid 6” (1st speed)
caused by a poor electrical connection at one of (7) “Transmission solenoid 7” (low range)
the harness connectors that was disconnected and (8) “Transmission solenoid 8” (high range)
STOP.
g01288881
Illustration 223


listed:
308 RENR9004-07
SHORT TO GROUND
of a problem in an electrical circuit. Verify that C. Disconnect the machine harness connectors J1
all connections in the circuit are clean, that the and J2 from the Transmission/Chassis ECM.
connections are secure and that the connections
are in good condition. If a problem with a D. At the machine harness connectors of the ECM,
connection is found, correct the problem and measure the resistance between contact J1-58
verify that this diagnostic code is active before (wire 755-OR) and frame ground. Measure the
performing this procedure. resistance between contact J1-58 (wire 755-OR)
and all of the other J1 and J2 contacts that are
Note: The following test procedure may create other used in the Transmission/Chassis ECM.
8.7 ± .4 ohms at 25 °C (77.0 °F).
Results:
code from the machine harness. wire 755-OR and the circuit with the low resistance
measurement.
Expected Result:
Repair: Repair the machine harness or replace the
The active CID 1405 FMI 06 diagnostic code changes machine harness.
solenoid is disconnected. STOP.
Results: Test Step 3. CHECK THE STATUS OF THE

DIAGNOSTIC CODE
code changes to a CID 1405 FMI 05 diagnostic A. Inspect the harness connectors. Clean the
code when the solenoid is disconnected. The contacts of the harness connectors. Check the
circuit is correct. wires for damage to the insulation that is caused
“CHECK THE SOLENOID” in order to verify the B. Perform a 45 N (10 lb) pull test on each of the
solenoid failure. Replace the solenoid. wires that are associated with the sensor circuit.
STOP. C. Reconnect all harness connectors. Make sure that

• NO – The CID 1405 FMI 06 remains active when clips for each connector are completely fastened.
the solenoid is disconnected. The solenoid is not
causing the problem. Proceed to Test Step 2. D. Turn the disconnect switch and the key start

RENR9004-07 309
F. Check the status of the CID 1405 FMI 06 Note: Before performing this procedure, verify that
diagnostic code. no other active CID 1405 diagnostic codes exist
for the solenoid. If any other diagnostic codes are
Expected Result: active for the solenoid, correct the problem before
CALIBRATION
Results:
• YES – The CID 1405 FMI 06diagnostic code is Refer to Testing and Adjusting, “Calibration”
still active. The diagnostic code has not been section of this manual for the correct calibration
corrected. procedure.
Repair: Check the circuit again. Use the Caterpillar Expected Result:
in order to perform a wiggle test on the machine The calibration procedure was performed
wiring harness. The wiggle test can detect successfully.
machine wiring harness. Results:
If the cause of the problem is not found, the ECM • YES – The calibration procedure was performed
may have failed. successfully. Resume normal machine operation.
STOP.
possible causes of the diagnostic code have been • NO – The calibration was not successful.
contact your dealership's Technical Communicator Repair: Repeat the calibration procedure for the
for possible consultation with Caterpillar. This solenoid.
cause of the diagnostic code is not found, replace If the second calibration procedure is not
the Transmission/Chassis ECM. Refer to Testing successful, replace the solenoid. After solenoid
and Adjusting, “Electronic Control Module (ECM) replacement, refer to Testing and Adjusting,
- Replace”. “Calibration” section of this manual for the correct
calibration procedure. If the problem is still present
STOP. after replacement and calibration of the new
diagnostic code does not exist at this time. Prior to replacing an ECM, always contact your
Repair: The initial diagnostic code was probably consultation with Caterpillar. This consultation
caused by a poor electrical connection or a may greatly reduce repair time. If the cause of the
short at one of the harness connectors that was diagnostic code is not found, replace the ECM.
disconnected and reconnected. Resume normal Refer to Testing and Adjusting, “Electronic Control
machine operation. Module (ECM) - Replace”.
STOP. STOP.
i02572927
MID 027 - CID 1405 - FMI 13


needs calibration.
310 RENR9004-07

MID 027 - CID 1406 - FMI 03


8.7 ± .4 ohms at 25 °C (77.0 °F).

SHORT
g01321566
transmission.
(7) “Transmission solenoid 7” (low range) C. At the machine harness connector J1 of the ECM,
(8) “Transmission solenoid 8” (high range) measure the resistance between contact J1-59
(wire 901-WH) and all J1 and J2 contacts that are
used on the Transmission/Chassis ECM.
Expected Result:

ohms.
Results:

g01288904
Connections for “Transmission Solenoid 6” machine harness. The short is between wire
901-WH and the circuit that has a low resistance

listed below:
RENR9004-07 311
STOP.
STOP.
DIAGNOSTIC CODE
the energize wire of the solenoid 901-WH and wires that are associated with the sensor circuit.
is active.
Expected Result:
Expected Result:
active.
Results:
Results:
• YES – The CID 1406 FMI 03 diagnostic code is active.
code has been activated after the energize circuit Repair: Check the circuit again. Use the Caterpillar
of the solenoid was disconnected. The ECM has Electronic Technician (ET) service tool, if available,
responded correctly to the open circuit condition in in order to perform a wiggle test on the machine
the solenoid circuit. wiring harness. The wiggle test can detect
Install the energize wire of the solenoid into the machine wiring harness.
correct space of the ECM connector. Proceed to
the next test step. If the problem remains, the ECM may have failed.
code did not change when the energize wire of the

312 RENR9004-07

STOP.

g01288904
caused by a poor electrical connection or a Connections of “Transmission Solenoid 6”



g01321566
8.7 ± .4 ohms at 25 °C (77.0 °F).
Illustration 226
Transmission Solenoids are located on the left side of the Test Step 1. CHECK THE SOLENOID
transmission.
(1) “Transmission solenoid 1” (forward high) A. Disconnect the solenoid from the machine
(2) “Transmission solenoid 2” (forward low) harness.
(5) “Transmission solenoid 5” (3rd speed) B. At the machine harness connector for the
(6) “Transmission solenoid 6” (1st speed) solenoid, place a jumper wire between contact 1
(7) “Transmission solenoid 7” (low range) (wire 901-WH) and contact 2 (wire 922-BR).
RENR9004-07 313
C. Turn the disconnect switch and the key start Repair: A resistance measurement that is much
switch to the ON position. Do not start the engine. greater than 5 ohms but less than 5000 ohms
could indicate that one of the connection points in
D. Observe the status of the CID 1406 FMI 05 the circuit is not an open connection but not a good
diagnostic code. connection.
Expected Result: The open or a possible poor connection is in

supply wire 901-WH or in return wire 922-BR of the
The active diagnostic code changes from an FMI machine harness. Refer to the complete Electrical
“05” to an FMI “06” diagnostic code when the jumper System Schematic of the machine. Check all of the
wire is installed. connectors that are in the solenoid circuit. Ensure
that all connections are clean, that all connectors
Results: are secure and that all connectors are in good
• YES – The active diagnostic code changes from the machine harness.
an FMI “05” to an FMI “06” diagnostic code when
the jumper wire is installed. The solenoid has STOP.
failed.
Repair: The solenoid has failed. Repeat this Test THE ECM
the solenoid failure. Replace the solenoid. Verify The disconnect switch and the key start switch
that the new solenoid corrects the problem. remain in the OFF position. The machine harness
connector for the solenoid and the ECM J1 connector
STOP. remain disconnected.
• NO – The CID 1406 FMI 05 diagnostic code A. Remove the jumper wire that was installed in the
remains active. The jumper wire does not affect the last test step.
causing the problem. Proceed to Test Step 2. B. At the machine harness connector J1 for the
Test Step 2. CHECK THE CIRCUIT FOR the energize wire of the solenoid 901-WH and
AN OPEN the socket at contact J1-59 from the harness
connector.
switch to the OFF position. C. Reconnect the machine harness J1 connector to
the ECM.
from the Transmission/Chassis ECM. D. Turn the disconnect switch and the key start
Test Step remains in place. E. Use a 7X-1710 Multimeter Probe that is not
D. At the machine harness connector J1 for the make contact with the ECM pin at J1-59 through
Transmission/Chassis ECM, measure the the empty space in the J1 connector.
resistance between the contact for the return
wire J1-60 (wire 922-BR) and the contact for the F. Observe the status of the active CID 1406 FMI 05
energize wire J1-59 (wire 901-WH). diagnostic code and ground the other end of the
Expected Result:
Expected Result:
Results: active. A CID 1406 FMI 06 diagnostic code becomes
• OK – The measurement of the resistance is less
than 5 ohms. The circuit is not open in the machine

not correct. There is an open or a bad connection
314 RENR9004-07
Results: Results:
circuit condition in the solenoid circuit. The ECM is Repair: Check the circuit again. Use the Caterpillar
most likely not causing the problem. Electronic Technician (ET) service tool, if available,
Reinstall the disconnected solenoid energize wire wiring harness. The wiggle test can detect
back into the correct spot in the ECM connector momentary or intermittent shorts or opens in the
before proceeding to the next test step. machine wiring harness.
time.




diagnostic code.
Expected Result:

RENR9004-07 315

ground.
MID 027 - CID 1406 - FMI 06


8.7 ± .4 ohms at 25 °C (77.0 °F).

g01321566
Transmission Solenoids are located on the left side of the switch to the ON position. Do not start the engine.
transmission.
Results:

circuit is correct.

g01288904
Connection for “Transmission Solenoid 6”

listed below:
316 RENR9004-07

diagnostic code.
machine harness.
Results:
D. At the machine harness connectors of the ECM, corrected.
measure the resistance between the contact J1-59
(wire 901-WH) and frame ground. Measure the Repair: Check the circuit again. Use the Caterpillar
resistance from the contact J1-59 (wire 901-WH) Electronic Technician (ET) service tool, if available,
to all of the other J1 and J2 contacts that are used in order to perform a wiggle test on the machine
in the Transmission/Chassis ECM. wiring harness. The wiggle test can detect
wire 901-WH and the circuit with the low resistance - Replace”.
measurement.
STOP.
DIAGNOSTIC CODE
STOP.
i02572930
RENR9004-07 317


procedure.
Expected Result:

successfully.
Results:

STOP.

solenoid.
g01321566
Illustration 230
replacement, refer to Testing and Adjusting, (1) “Transmission solenoid 1 (forward high)”
“Calibration” section of this manual for the correct (2) “Transmission solenoid 2 (forward low)”
calibration procedure. If the problem is still present (3) “Transmission solenoid 3 (reverse)”
after replacement and calibration of the new (4) “Transmission solenoid 4 (2nd speed)”
(5) “Transmission solenoid 5 (3rd speed)”
solenoid, the ECM may have failed. (6) “Transmission solenoid 6 (1st speed)”
(7) “Transmission solenoid 7 (low range)”
Prior to replacing an ECM, always contact your (8) “Transmission solenoid 8 (high range)”
STOP.
g01288939
Illustration 231


listed below:
318 RENR9004-07
machine harness.
codes and clear these diagnostic codes when the the energize wire of the solenoid 902-BR and
connector.

active.
C. At the machine harness connector J1 of the ECM,
measure the resistance between contact J1-48 Results:
(wire 902-BR) and all of the J1 and J2 contacts
that are used on the Transmission/Chassis ECM. • YES – The CID 1407 FMI 03 diagnostic code is no
Results: Install the energize wire of the solenoid into the

correct space of the ECM connector. Proceed to
• OK – Each resistance measurement is greater the next test step.
machine harness. The short is between wire code did not change when the solenoid energize
902-BR and the circuit that has a low resistance wire was disconnected from the ECM.
measurement.
RENR9004-07 319
Control Module (ECM) - Replace”. repair time. If the cause of the diagnostic code is
machine operation.
i02919734
is active.
Expected Result:
Results:

active.


solenoid energize wire was disconnected. Illustration 232
transmission.
(1) “Transmission solenoid 1 (forward high)”
(2) “Transmission solenoid 2 (forward low)”
(3) “Transmission solenoid 3 (reverse)”
(4) “Transmission solenoid 4 (2nd speed)”
(6) “Transmission solenoid 6 (1st speed)”
(8) “Transmission solenoid 8 (high range)”
320 RENR9004-07


diagnostic code.
Expected Result:

wire is installed.
Results:

Illustration 233 an FMI “05” diagnostic code to an FMI “06”
Connections of “Transmission Solenoid 7” diagnostic code when the jumper wire is installed.
The solenoid has failed.
“transmission solenoid 7”. The FMI 05 means that Repair: The solenoid has failed. Repeat this Test
the Transmission/Chassis ECM has determined that Step “CHECK THE SOLENOID” in order to verify
the current for the solenoid circuit is below normal. the solenoid failure. Replace the solenoid. Verify
listed below: STOP.
connection is found, correct the problem and test step remains in place.
Note: The following test procedure may create other resistance from the return, contact J1-50 (wire
diagnostic codes. Ignore these created diagnostic 921-WH), to the energize contact J1-48 (wire
codes and clear these diagnostic codes when the 902-BR).
Expected Result:
solenoid, place a jumper wire from contact 1 (wire • NOT OK – The resistance measurement is greater
902-BR) to contact 2 (wire 921-WH). than 5000 ohms. The resistance measurement is
not correct. There is an open or a bad connection
RENR9004-07 321
Repair: A resistance measurement that is much Results:

greater than 5 ohms but less than 5000 ohms
could indicate that one of the connection points in • YES – The CID 1407 FMI 05 diagnostic code is no
the circuit is not an open connection but not a good longer active. A CID 1407 FMI 06 diagnostic code
connection. has been activated after the ECM pin is grounded.
The open or the possible poor connection is in circuit condition in the solenoid circuit. The ECM is
supply wire 902-BR or in return wire 921-WH of the most likely not causing the problem.
machine harness. Refer to the complete Electrical
System Schematic of the machine. Check all of the Reinstall the disconnected solenoid energize wire
connectors that are in the solenoid circuit. Ensure back into the correct spot in the ECM connector
that all connections are clean, that all connections before proceeding to the next test step.
condition. Repair the machine harness or replace Proceed to Test Step 4.
STOP. remains active. The status of the active diagnostic
Test Step 3. CHECK THE OPERATION OF solenoid is grounded.
THE ECM
The disconnect switch and the key start switch the grounded condition in the solenoid circuit. The
remain in the OFF position. The machine harness operation of the ECM is not correct.
connector for the solenoid and the ECM J1 connector
remain disconnected. Prior to replacing an ECM, always contact your
A. Remove the jumper wire that was installed in the consultation with Caterpillar. This consultation may
last test step. greatly reduce repair time. If the ECM must be
B. At the machine harness connector J1 for the Control Module (ECM) - Replace”.
the energize wire of the solenoid 902-BR and STOP.
connector. Test Step 4. CHECK THE STATUS OF THE
DIAGNOSTIC CODE
C. Reconnect the machine harness J1 connector to
the ECM. A. Inspect the harness connectors. Clean the
D. Turn the disconnect switch and the key start wires for damage to the insulation that is caused
switch to the ON position. by excessive heat, battery acid, or chafing.
E. Use a 7X-1710 Multimeter Probe that is not B. Perform a 45 N (10 lb) pull test on each of the
connected to a multimeter or a similar device to wires that are associated with the sensor circuit.
make contact with the ECM pin at J1-48 through
the empty space in the J1 connector. C. Reconnect all harness connectors. Make sure that
F. Observe the status of the active CID 1407 FMI 05 clips for each connector are completely fastened.
7X-1710 Multimeter Probe to frame ground. D. Turn the disconnect switch and the key start
Expected Result:
active. A CID 1407 FMI 06 diagnostic code becomes F. Check the status of the CID 1407 FMI 05
active when the ECM pin at J1-48 is grounded. diagnostic code.
Expected Result:

322 RENR9004-07
Results: i02919865


g01321566
• NO – The CID 1407 FMI 05 diagnostic code is not transmission.
active. The diagnostic code does not exist at this (1) “Transmission solenoid 1 (forward high)”
time. (2) “Transmission solenoid 2 (forward low)”
Repair: The initial diagnostic code was probably (4) “Transmission solenoid 4 (2nd speed)”
caused by a poor electrical connection at one of (6) “Transmission solenoid 6 (1st speed)”
the harness connectors that was disconnected and (7) “Transmission solenoid 7 (low range)”
reconnected. Resume normal machine operation. (8) “Transmission solenoid 8 (high range)”
STOP.
g01288939
Illustration 235


listed below:
RENR9004-07 323
SHORT TO GROUND
of a problem in an electrical circuit. Verify that C. Disconnect the machine harness connectors J1
all connections in the circuit are clean, that all and J2 from the Transmission/Chassis ECM.
are in good condition. If a problem with a D. At the machine harness connectors of the ECM,
connection is found, correct the problem and measure the resistance from the contact J1-48
verify that this diagnostic code is active before (wire 902-BR) to frame ground. Measure the
performing this procedure. resistance from the contact J1-48 (wire 902-BR)
to all of the other J1 and J2 contacts that are used
Note: The following test procedure may create other in the Transmission/Chassis ECM.
8.7 ± .4 ohms at 25 °C (77.0 °F).
Results:
code from the machine harness. wire 902-BR and the circuit with the low resistance
measurement.
Expected Result:
The active CID 1407 FMI 06 diagnostic code changes circuits and finding short circuits, refer to Testing
to a CID 1407 FMI 05 diagnostic code when the and Adjusting, “Wiring Harness (Short Circuit) -
solenoid is disconnected. Test”. Repair the machine harness or replace the
machine harness.
Results:
STOP.
code changes to a CID 1407 FMI 05 diagnostic Test Step 3. CHECK THE STATUS OF THE
code when the solenoid is disconnected. The DIAGNOSTIC CODE
circuit is correct.
Repair: The solenoid has failed. Repeat this test contacts of the harness connectors. Check the
“CHECK THE SOLENOID” in order to verify the wires for damage to the insulation that is caused
solenoid failure. Replace the solenoid. by excessive heat, battery acid, or chafing.
STOP. B. Perform a 45 N (10 lb) pull test on each of the

the solenoid is disconnected. The solenoid is not C. Reconnect all harness connectors. Make sure that

324 RENR9004-07
Expected Result:
CALIBRATION
Results: Refer to Testing and Adjusting, “Calibration”
• YES – The CID 1407 FMI 06diagnostic code is procedure.
corrected. Expected Result:
Repair: Check the circuit again. Use the Caterpillar The calibration procedure was performed
Electronic Technician (ET) service tool, if available, successfully.
in order to perform a “wiggle test” on the wiring
harness of the machine. The wiggle test can detect Results:
machine wiring harness. • YES – The calibration procedure was performed
If the cause of the problem is not found, the ECM STOP.
may have failed.
possible causes of the diagnostic code have been Repair: Repeat the calibration procedure for the
investigated. If the cause of the failure is not found, solenoid.
for possible consultation with Caterpillar. This If the second calibration procedure is not
consultation may greatly reduce repair time. If the successful, replace the solenoid. After solenoid
cause of the diagnostic code is not found, replace replacement, refer to Testing and Adjusting,
the Transmission/Chassis ECM. Refer to Testing “Calibration” section of this manual for the correct
and Adjusting, “Electronic Control Module (ECM) calibration procedure. If the problem is still present
- Replace”. after replacement and calibration of the new
STOP.
• NO – The CID 1407 FMI 06 is not active. The dealership's Technical Communicator for possible
diagnostic code does not exist at this time. consultation with Caterpillar. This consultation
Repair: The initial diagnostic code was probably diagnostic code is not found, replace the ECM.
caused by a poor electrical connection or a Refer to Testing and Adjusting, “Electronic Control
short at one of the harness connectors that was Module (ECM) - Replace”.
STOP.
i02572933
MID 027 - CID 1407 - FMI 13


needs calibration.
RENR9004-07 325

MID 027 - CID 1408 - FMI 03


8.7 ± .4 ohms at 25 °C (77.0 °F).

SHORT
g01321566
transmission.
(1) “Transmission solenoid 1 (forward high)” B. Disconnect the machine harness connector
(2) “Transmission solenoid 2 (forward low)” from the solenoid. Disconnect the machine
(3) “Transmission solenoid 3 (reverse)” harness connectors J1 and J2 from the
(4) “Transmission solenoid 4 (2nd speed)” Transmission/Chassis ECM.
(7) “Transmission solenoid 7 (low range)” C. At the machine harness connector J1 of the ECM,
(8) “Transmission solenoid 8 (high range)” measure the resistance from contact J1-62 (wire
903-GY) to all J1 and J2 contacts that are used on
the Transmission/Chassis ECM.
Expected Result:

ohms.
Results:

g01288948
Connections for “Transmission Solenoid 8” machine harness. The short is between wire
903-GY and the circuit that has a low resistance
the Transmission/Chassis ECM has determined that Repair: Repair the machine harness or replace the
the voltage of the solenoid circuit is above normal. machine harness.
Conditions that can cause this diagnostic code are STOP.

listed below:
326 RENR9004-07
Test Step 2. CHECK THE OPERATION OF Test Step 3. CHECK THE STATUS OF THE
THE ECM DIAGNOSTIC CODE
connectors for the solenoid and the ECM remain wires for damage to the insulation that is caused
A. At the machine harness connector J1 for the ECM, B. Perform a 45 N (10 lb) pull test on each of the
use a 151-6320 Removal Tool to remove the wires that are associated with the sensor circuit.
solenoid energize wire 903-GY and the socket at
contact J1-62 from the harness connector. C. Reconnect all harness connectors. Make sure that
is active.
Expected Result:
Expected Result:
active.
Results:
Results:
Reinstall the disconnected solenoid energize wire machine wiring harness.
back into the correct space in the ECM connector
before proceeding to the next test step. If the problem remains, the ECM may have failed.
code did not change when the solenoid energize It is unlikely that the ECM has failed. Verify that all
wire was disconnected from the ECM. possible causes of the diagnostic code have been
Repair: The ECM has not responded correctly contact your dealership's Technical Communicator
to the open condition in the solenoid circuit. The for possible consultation with Caterpillar. This
operation of the ECM is not correct. consultation may greatly reduce repair time. If the
Prior to replacing an ECM, always contact your the Transmission/Chassis ECM. Refer to Testing
dealership's Technical Communicator for possible and Adjusting, “Electronic Control Module (ECM)
consultation with Caterpillar. This consultation may - Replace”.
STOP. problem does not exist at this time.
RENR9004-07 327

machine operation.
STOP.
i02919878
MID 027 - CID 1408 - FMI 05

Conditions Which Generate This Code: Illustration 239

g01288948

the current for the solenoid circuit is below normal.

listed below:

g01321566
Illustration 238 of a problem in an electrical circuit. Verify that
Transmission Solenoids are located on the left side of the all connections in the circuit are clean, that all
transmission. connections are secure and that all connections
(1) “Transmission solenoid 1 (forward high)” are in good condition. If a problem with a
(2) “Transmission solenoid 2 (forward low)” connection is found, correct the problem and
(5) “Transmission solenoid 5 (3rd speed)” performing this procedure.
(7) “Transmission solenoid 7 (low range)” Note: The following test procedure may create other
(8) “Transmission solenoid 8 (high range)” diagnostic codes. Ignore these created diagnostic

8.7 ± .4 ohms at 25 °C (77.0 °F).

harness.

903-GY) to contact 2 (wire 922-BR).
328 RENR9004-07
The active diagnostic code changes from an FMI “05”
diagnostic code to an FMI “06” diagnostic code after Repair: The open or the possible poor connection
the jumper wire is installed. is in supply wire 903-GY or in return wire 922-BR
Results: Electrical System Schematic of the machine.
• YES – The active diagnostic code changes from circuit. Ensure that all connections are clean, that
an FMI “05” diagnostic code to an FMI “06” all connections are secure and that all connections
diagnostic code when the jumper wire is installed. are in good condition. Repair the machine harness
The solenoid has failed. or replace the machine harness.

last test step.
A. Turn the key start switch and the disconnect the energize wire of the solenoid 903-GY and
connector.
the ECM.
922-BR) to the energize contact J1-62 (wire make contact with the ECM pin at J1-62 through
903-GY). the empty space in the J1 connector.
RENR9004-07 329
Results: Results:
circuit condition in the solenoid circuit. The cause Repair: Check the circuit again. Use the Caterpillar
of the problem is probably not the ECM. Electronic Technician (ET) service tool, if available,
Reinstall the disconnected solenoid energize wire wiring harness. The wiggle test can detect
back into the correct spot in the ECM connector momentary or intermittent shorts or opens in the
before proceeding to the next test step. machine wiring harness.
solenoid is grounded. It is unlikely that the ECM has failed. Verify that all
Repair: The ECM has not responded correctly to investigated. If the cause of the failure is not found,
the grounded condition in the solenoid circuit. The contact your dealership's Technical Communicator
operation of the ECM is not correct. for possible consultation with Caterpillar. This
Prior to replacing an ECM, always contact your cause of the diagnostic code is not found, replace
dealership's Technical Communicator for possible the Transmission/Chassis ECM. Refer to Testing
consultation with Caterpillar. This consultation may and Adjusting, “Electronic Control Module (ECM)
greatly reduce repair time. If the ECM must be - Replace”.
Control Module (ECM) - Replace”. STOP.
STOP. • NO – The CID 1408 FMI 05 diagnostic code is not

Test Step 4. CHECK THE STATUS OF THE time.
DIAGNOSTIC CODE
A. Inspect the harness connectors. Clean the caused by a poor electrical connection at one of
contacts of the harness connectors. Check the the harness connectors that was disconnected and
wires for damage to the insulation that is caused reconnected. Resume normal machine operation.
STOP.



diagnostic code.
Expected Result:

330 RENR9004-07
i02919894 Before performing this procedure, inspect the

SMCS Code: 3139-038-T3 all connections in the circuit are clean, that all


8.7 ± .4 ohms at 25 °C (77.0 °F).


g01321566
Illustration 240
Transmission Solenoids are located on the left side of the Expected Result:
transmission.
(1) “Transmission solenoid 1 (forward high)” The active CID 1408 FMI 06 diagnostic code changes
(2) “Transmission solenoid 2 (forward low)” to a CID 1408 FMI 05 diagnostic code when the
(3) “Transmission solenoid 3 (reverse)” solenoid is disconnected.
(6) “Transmission solenoid 6 (1st speed)” Results:
(8) “Transmission solenoid 8 (high range)” • YES – The active CID 1408 FMI 06 diagnostic
This diagnostic code is associated with the code when the solenoid is disconnected. The
“transmission solenoid 8”. The FMI 06 means that circuit is correct.
the current of the solenoid circuit is above normal. Repair: The solenoid has failed. Repeat this test
Some possible causes of this diagnostic code are solenoid failure. Replace the solenoid.
listed below:
STOP.
ground. • NO – The CID 1408 FMI 06 remains active when
• The solenoid has failed. causing the problem. Proceed to Test Step 2.
• The ECM has failed. This is unlikely. Test Step 2. CHECK THE ENERGIZE
SHORT TO GROUND
B. The solenoid remains disconnected from the

machine harness.
RENR9004-07 331
C. Disconnect the machine harness connectors J1 Results:

D. At the machine harness connectors of the ECM, still active. The diagnostic code has not been
measure the resistance from the contact J1-48 corrected.
(wire 903-GY) to frame ground. Measure the
resistance from the contact J1-48 (wire 903-GY) Repair: Check the circuit again. Use the Caterpillar
to all of the other J1 and J2 contacts that are used Electronic Technician (ET) service tool, if available,
in the Transmission/Chassis ECM. in order to perform a wiggle test on the machine
Expected Result: momentary or intermittent shorts or opens in the
ohms. If the cause of the problem is not found, the ECM
may have failed.
Results:
• OK – Each resistance measurement is greater possible causes of the diagnostic code have been
than 5000 ohms. The machine harness is correct. investigated. If the cause of the failure is not found,
Proceed to Test Step 3. contact your dealership's Technical Communicator
• NOT OK – One or more of the resistance consultation may greatly reduce repair time. If the
measurements is less than 5000 ohms. There is a cause of the diagnostic code is not found, replace
short in the machine harness. The short is between the Transmission/Chassis ECM. Refer to Testing
wire 903-GY and the circuit with the low resistance and Adjusting, “Electronic Control Module (ECM)
measurement. - Replace”.
Repair: For information on testing for short STOP.

and Adjusting, “Wiring Harness (Short Circuit) - • NO – The CID 1408 FMI 06 is not active. The
Test”. Repair the machine harness or replace the diagnostic code does not exist at this time.
machine harness.
STOP. caused by a poor electrical connection or a
Test Step 3. CHECK THE STATUS OF THE disconnected and reconnected. Resume normal
DIAGNOSTIC CODE machine operation.
A. Inspect the harness connectors. Clean the STOP.

i02572937

MID 027 - CID 1408 - FMI 13
wires that are associated with the sensor circuit. SMCS Code: 3139-038-T3
C. Reconnect all harness connectors. Make sure that Conditions Which Generate This Code:
clips for each connector are completely fastened. This diagnostic code is associated with the
D. Turn the disconnect switch and the key start is activated when the ECM detects that the solenoid
switch to the ON position. needs calibration.
Expected Result:

332 RENR9004-07
CALIBRATION i02919918
A. Perform the calibration procedure for the solenoid. MID 027 - CID 1471 - FMI 02
section of this manual for the correct calibration SMCS Code: 5737-038-ZH
procedure.
Expected Result:

successfully.
Results:

STOP.

solenoid.

successful, replace the solenoid. After solenoid
“Calibration” section of this manual for the correct
calibration procedure. If the problem is still present
after replacement and calibration of the new

STOP.
g01243832
Illustration 241
Connections for “Steer Sensor 1”
Three steering position sensors are required for

correct operation of the steering control. The steering
position sensors are located in the assembly of the
left joystick. Each sensor provides an input signal to
the Implement ECM and to the Transmission/Chassis
ECM. This diagnostic code is activated when the
ECM reads the input signal from the steering position
sensor 1 and the signal is erratic or intermittent.
RENR9004-07 333
The steering position sensor 1 receives power from • For either condition, proceed with this procedure in
the 8 volt power supply of the Implement ECM. order to verify the cause of the problem.
Steering position sensor 1 is internally connected to
the ground that is supplied by the 8 volt sensor return Before performing this procedure, inspect the
of the Transmission/Chassis ECM(ground of the harness connectors that are involved in the
ECM) and to the ground that is supplied by the 8 volt circuit. Poor connections can often be the cause
sensor return of the Implement ECM (ground of the of a problem in an electrical circuit. Verify that
ECM). The steering sensor must lose both grounds all connections in the circuit are clean, that all
in order to lose a ground connection. The illustration connections are secure and that all connections
above indicates the power and ground connections are in good condition. If a problem with a
for the steering sensor 1. connection is found, correct the problem and
The position sensor is a PWM sensor that operates at performing this procedure.
a frequency of approximately 500 hertz. The position
sensor sends a PWM input signal to the Implement Note: The following test procedure may create other
ECM and to the Transmission/Chassis ECM. The diagnostic codes. Ignore these created diagnostic
duty cycle of the signal will vary from approximately codes and clear the diagnostic codes when the
10 ± 5% at the full left position of the joystick to problem has been corrected.
approximately 90 ± 5% at the full right position of the
joystick. When the joystick is in the center position, Test Step 1. CHECK THE POWER SUPPLY
the duty cycle will be approximately 50%. CIRCUIT OF THE SENSOR
The possible causes of this diagnostic code are A. Turn the disconnect switch and the key start
listed: switch to the ON position.
• The sensor has failed. B. At the J1 harness connector for the left joystick,
insert 7X-1710 Multimeter Probes along the
• An Intermittent connection exists in the sensor contact for the power supply J1-1 (wire R800-OR)
circuit. and along ground 1 contact J1-8 (wire P967-PU).
Do not disconnect the machine harness from the
• The signal circuit is shorted to another circuit in the J1 connector.
machine harness.
C. Measure the DC voltage.
D. At the harness connectors for the left joystick,
Consider the following points when this code is remove the multimeter probe that is inserted along
active: the ground 1 contact J1-8 and insert the probe
along ground 2 contact J1-4 (wire X800-OR). The
• If a CID 0041 diagnostic code for the 8 volt power other probe remains inserted along the contact for
supply has been activated by the Implement ECM the power supply J1-1 (wire R800-OR).
(MID 082), investigate the problem and fix the
problem before proceeding with this procedure. E. Measure the DC voltage.
• The Transmission/Chassis ECM (MID 027) and the Expected Result:

Implement ECM (MID 082) receive an input signal
from the steering sensor 1. Both ECM modules can Both of the voltage measurements are approximately
activate a CID 1471 FMI 02 diagnostic code when 8.0 ± 0.4 VDC.
the signal is erratic or intermittent.
Results:
• When one of the ECM modules has activated a
CID 1471 FMI 02 diagnostic code and the other • OK – Both of the voltage measurements are
ECM module has not, the probability is likely that approximately 8.0 ± 0.4 VDC. The power and
the sensor is operating correctly. When this occurs, ground circuits for the sensor are correct. Proceed
a poor connection in the machine harness would to Test Step 2.
be suspected.
• NOT OK – Both of the voltage measurements are
• When both ECM modules have activated the less than 8.0 ± 0.4 VDC. The power supply for the
diagnostic code, either the sensor or a harness sensor is not correct.
problem could be the cause.
Repair: If both of the voltage measurements are
• If both ECM modules have activated the diagnostic not correct, the problem is most likely in the wire of
code, it is very unlikely that either ECM is causing the power circuit. This condition will cause multiple
the problem. diagnostic codes to activate.
334 RENR9004-07
Refer to the complete Electrical System Schematic Expected Result:

for the machine. Examine all of the connectors
that are in the power and ground circuits. Ensure The duty cycle of the steering sensor 1 is correct
that the connections are clean, that the connectors according to the description at the beginning of this
are secure and that the connectors are in good procedure.
condition.
Results:
For troubleshooting the ECM power supply that is
providing power to the sensor, refer to the CID 0041 • OK – The duty cycle of the sensor is correct. The
diagnostic code procedures in the troubleshooting sensor is not the cause of the problem.
section of the manual for the Implement ECM.
Reinstall the signal wire U739-BR and the socket
STOP. back to the original location at contact J1-2 in
the machine harness connector for the joystick.
• NOT OK – One of the voltage measurements is Verify that all of the wires of the joystick are in the
not correct. correct locations and that the wires are secure in
the connector before proceeding to the next step.
Repair: If one of the voltage measurements is
correct and the other voltage measurement is not Proceed to Test Step 3.
correct, there is a problem in the ground circuit that
registered the bad measurement. This condition • NOT OK – The duty cycle of the steering sensor
will not cause this diagnostic code to activate. 1 is not correct according to the description at the
There is another problem that is causing this active beginning of this procedure. The sensor has failed.
diagnostic code. However, the ground circuit must
be repaired before proceeding with this procedure. Repair: Perform this test step again in order to
verify that the sensor signal is not correct.
Do not operate the machine with only one ground
connection for the left joystick. If the signal of the steering sensor 1 is not correct
according to the description at the beginning of this
Repair the faulty ground circuit or the supply procedure, replace the assembly of the left joystick.
circuit for the power before proceeding with this After replacement of the assembly of the joystick,
procedure. verify that the operation of the new assembly of the
joystick is correct before operating the machine.
After repairing the faulty ground circuit, proceed
to Test Step 2. STOP.
Test Step 2. CHECK THE SIGNAL AT THE Test Step 3. CHECK THE SIGNAL AT
SENSOR BOTH OF THE ECM MODULES
The key start switch and the disconnect switch A. Turn the key start switch and the disconnect
remain in the OFF position. switch to the OFF position.
A. At the machine harness connector J1 for the left B. At the machine harness connector J1 for the
joystick, use a 151-6320 Removal Tool to remove Transmission/Chassis ECM, insert a multimeter
the signal wire U739-BR and the socket at contact probe along return contact J1-45 (wire X800-OR).
J1-2 from the harness connector. The machine At the machine harness connector J2 for the
harness connector J1 remains connected to the Transmission/Chassis ECM, insert a multimeter
connector for the left joystick. probe along signal contact J2-18 (wire U739-BR).
The machine harness connectors remain
B. At the back of the connector for the joystick J1, connected to the ECM.
sensor signal contact J1-2 and the ground contact C. Turn the key start switch and the disconnect
at J1-4. switch to the ON position.
C. Turn the disconnect switch and the key start D. Measure the duty cycle of the sensor at the
switch to the ON position. contacts of the ECM connector J1-45 and J2-18.
Move the joystick through the full range of the
D. Measure the duty cycle of the sensor at the sensor that is described at the beginning of this
connector contacts for the joystick J1-2 and J1-4. procedure.
sensor that is described at the beginning of this
procedure.
RENR9004-07 335
Implement ECM, insert a multimeter probe along CIRCUIT FOR A SHORT
return contact J1-45 (wire P967-PU). At the
machine harness connector J2 for the Implement Turn the key start switch and the disconnect switch
ECM, insert a multimeter probe along signal to the OFF position.
contact J2-18 (wire U739-BR). The machine
harness connectors remain connected to the A. Disconnect the J1 connector and the J2 connector
ECM. from the Implement ECM.
F. Measure the duty cycle of the sensor at the B. At the J2 machine harness connector for the
contacts of the ECM connector J1-45 and J2-18. Implement ECM, measure the resistance from the
Move the joystick through the full range of the sensor signal contact J2-18 (wire U739-BR) to all
sensor that is described at the beginning of this of the other J1 and J2 contacts that are used for
procedure. the Implement ECM.
Expected Result: C. If any of the resistance measurements in the last

test step are less than 5000 ohms, skip the next
The duty cycle of the steering sensor 1 is correct test step and proceed to the “Expected Result”
according to the description at the beginning of this step. If all of the resistance measurements in the
procedure at both of the ECM modules. last test step are above 5000 ohms, perform the
next test step.
Results:
D. Disconnect the J1 connector and the J2 connector
• OK – The duty cycle of the sensor is correct at from the Transmission/Chassis ECM.
both of the ECM modules. The machine harness
does not appear to be the cause of the problem. An E. At the J2 machine harness connector for the
intermittent open or a short could still be causing Transmission/Chassis ECM, measure the
the problem. Proceed to Test Step 4. resistance from the sensor signal contact
J2-18 (wire U739-BR) to all of the other
• NOT OK – The duty cycle of the steering sensor J1 and J2 contacts that are used for the
1 is NOT correct at one of the ECM modules Transmission/Chassis ECM.
according to the description at the beginning of
this procedure. There is a problem in the machine Expected Result:
harness.
Repair: If the sensor signal at one ECM is correct ohms.
and the sensor signal at the other ECM is not
correct, a poor connection in the circuit would be Results:
suspected.
The signal of the steering sensor 1 at one of the than 5000 ohms. The resistance checks of the
ECM modules is not correct. signal circuit do not indicate a short in the machine
of the machine. Examine all of the connectors that • NOT OK – A resistance measurement is less than
are in the section of the sensor signal circuit that 5000 ohms.
connects to the ECM that is not receiving a good
signal. Verify that the connections are clean, that Repair: There is a short in the machine harness.
all connections are secure and that all connections The short is between the signal circuit and the
are in good condition. Repair the machine harness circuit with the low resistance measurement.
STOP. of the machine. Check all of the connectors that are
• NOT OK – The duty cycle of the steering sensor are clean, that all connections are secure and that
1 is NOT correct at either of the ECM modules all connections are in good condition.
procedure. It is likely that there is a problem in the For information on testing for short circuits and
machine harness. Proceed to Test Step 4. finding short circuits, refer to Testing and Adjusting,
STOP.
336 RENR9004-07
Test Step 5. CHECK THE STATUS OF THE If the ECM must be replaced, refer to Testing and
DIAGNOSTIC CODE Adjusting, “Electronic Control Module (ECM) -
Replace”.
i02919969

MID 027 - CID 1471 - FMI 03
SMCS Code: 5737-038-ZH


is active.
Expected Result:
Results:


corrected.

“Electronic Technician (ET)” service tool to monitor
the wiring harness of the machine. Wiggling the
harness while the harness is connected to the
service tool will test for intermittent connections or
open connections.

found, an ECM that has activated this diagnostic
If both the Transmission/Chassis ECM and the

Implement ECM have activated this diagnostic
code, it is very unlikely that either ECM is causing
the problem. Illustration 242
g01243832
Connections of Steering Position Sensor 1

RENR9004-07 337
Three steering position sensors are required for • The correct operating temperature range for the
correct operation of the steering control. The steering steering sensors is −40 °C (−40.0 °F) to 75 °C
position sensors are located in the assembly of the (167.0 °F). If an FMI 03 diagnostic code or an FMI
left joystick. Each sensor provides an input signal to 08 diagnostic code become active for a steering
the Implement ECM and to the Transmission/Chassis sensor, during periods that the cab environment is
ECM. This diagnostic code is activated when the at extreme temperatures, reduce the temperature
ECM reads the input signal from the steering position of the cab environment in order to keep the steering
sensor 1 and the voltage of the signal is above sensors operating in the acceptable temperature
normal. range. After the temperature has been reduced,
verify that the CID 1471 FMI 03 diagnostic code is
The steering position sensor 1 receives power from active before performing this procedure.
the 8 volt power supply of the Implement ECM.
Steering position sensor 1 is internally connected to • The Transmission/Chassis ECM (MID 027) and the
the ground that is supplied by the 8 volt sensor return Implement ECM (MID 082) receive an input signal
of the Transmission/Chassis ECM (ground of the from the steering sensor 1. Both ECM modules can
ECM) and to the ground that is supplied by the 8 volt activate a CID 1471 FMI 03 diagnostic code when
sensor return of the Implement ECM (ground of the the signal voltage is above normal.
ECM) . The steering sensor must lose both grounds If one ECM activates a CID 1471 FMI 03 diagnostic
in order to lose a ground connection. The illustration code and the other ECM does not, it is likely that
above indicates the power and ground connections the sensor is operating correctly. When this occurs,
for the steering sensor 1. a poor connection in the machine harness would
be suspected.
The position sensor is a PWM sensor that operates at When both ECM modules have activated the
a frequency of approximately 500 hertz. The position diagnostic code, either the sensor OR a harness
sensor sends a PWM input signal to the Implement problem could be the cause.
ECM and to the Transmission/Chassis ECM. The If both ECM modules have activated the diagnostic
duty cycle of the signal will vary from approximately code, it is very unlikely that either ECM is causing
10 ± 5% at the full left position of the joystick to the problem.
approximately 90 ± 5% at the full right position of the For either condition, proceed with this procedure in
joystick. When the joystick is in the center position, order to verify the cause of the problem.
the duty cycle will be approximately 50%.
The possible causes of this diagnostic code are harness connectors that are involved in the
listed: circuit. Poor connections can often be the cause
• The supply circuit for the sensor power is open. all connections in the circuit are clean, that all
• The return circuit of the sensor is open. are in good condition. If a problem with a
• The signal circuit is open. verify that this diagnostic code is active before
• The signal circuit is shorted to another voltage
source. Note: The following test procedure may create other
• The sensor has failed. codes and clear the diagnostic codes when the
Consider the following points when this code is CIRCUIT FOR THE SENSOR
active:
• If a CID 0041 diagnostic code for the 8 volt power switch to the ON position.
supply has been activated by the Implement ECM
(MID 082), investigate the problem and fix the B. At the J1 harness connector for the left joystick,
problem before proceeding with this procedure. insert 7X-1710 Multimeter Probes along the
contact of the power supply J1-1 (wire R800-OR)
and along the ground 1 contact J1-8 (wire
P967-PU). Do not disconnect the machine
harness from the J1 connector.
C. Measure the DC voltage.

338 RENR9004-07
D. At the harness connectors for the left joystick, Repair the faulty ground circuit or the circuit for
remove the multimeter probe that is inserted along the power supply before proceeding with this
the ground 1 contact J1-8 and insert the probe procedure.
along ground 2 contact J1-4 (wire X800-OR). The
other probe remains inserted along the contact of After repairing the faulty ground circuit, proceed
the power supply J1-1 (wire R800-OR). to Test Step 2.
E. Measure the DC voltage. Test Step 2. CHECK FOR AN OPEN IN

THE SENSOR CIRCUITS OF BOTH ECM
Expected Result: MODULES
Both of the voltage measurements are approximately A. Turn the key start switch and the disconnect
8.0 ± 0.4 VDC. switch to the OFF position.
Results: B. Disconnect the machine harness connector J1

from the left joystick. At harness connector J1
• OK – Both of the voltage measurements are for the joystick, place a jumper wire between the
approximately 8.0 ± 0.4 VDC. The power and ground 2 contact J1-4 (wire X800-OR) and the
ground circuits for the sensor are correct. Proceed signal contact J1-2 (wire U739-BR).
to Test Step 2.
C. Disconnect machine harness connectors J1 and
• NOT OK – Both of the voltage measurements are J2 from the Transmission/Chassis ECM.
less than 8.0 ± 0.4 VDC. The power supply for the
sensor is not correct. D. At the harness connector for the Transmission/
Chassis ECM, measure the resistance from
Repair: If both of the voltage measurements are ground 2 return contact J1-45 (wire X800-OR) to
not correct, the problem is most likely in the power signal contact J2-18 (wire U739-BR).
circuit. Multiple diagnostic codes will be activated
along with this diagnostic code. E. Observe the resistance measurement and wiggle
Refer to the complete Electrical System Schematic Gently pull on the wires and wiggle the wires for
of the machine. Examine all of the connectors that both connectors.
are in the power and ground circuits. Ensure that
the connections are clean, that all connections F. At harness connector J1 for the joystick, move
are secure and that all connections are in good the jumper wire to the ground 1 contact J1-8
condition. (wire P967-PU) and the signal contact J1-2 (wire
U739-BR) .
For troubleshooting the ECM power supply that is
providing power to the sensor, refer to the CID 0041 G. Disconnect machine harness connectors J1 and
diagnostic code procedures in the troubleshooting J2 from the Implement ECM.
section of the manual for the Implement ECM.
H. At the harness connectors for the Implement ECM,
STOP. measure the resistance from ground 1 return
contact J1-45 (wire P967-PU) to signal contact
• NOT OK – One of the voltage measurements is J2-18 (wire U739-BR).
not correct.
I. Observe the resistance measurement and wiggle
Repair: If one of the voltage measurements is the ECM connector and the sensor connector.
correct and the other voltage measurement is not Gently pull on the wires and wiggle the wires for
correct, there is a problem in the ground circuit that both connectors.
registered the bad measurement. This condition
will not cause this diagnostic code to activate. Expected Result:
There is another problem that is caused by this
active diagnostic code, however, the ground circuit Both resistance measurements are less than 5 ohms
must be repaired before proceeding with this at all times during the manipulation of the wiring
procedure. harness and connectors.
Do not operate the machine with only one ground Results:

connection for the left joystick.
less than 5 ohms. The sensor circuit is not open
in either of the input circuits of the ECM modules.
RENR9004-07 339
• NOT OK – The resistance measurement at one or Results:

both of the ECM modules is greater than 5 ohms.
There is an open or a bad connection in one or • OK – Each resistance measurement is greater
both of the signal circuits. than 5000 ohms. The resistance checks of the
signal circuit do not indicate a short in the machine
Repair: If both of the resistance measurements harness. Proceed to Test Step 4.
are not correct, there is an open connection or a
bad connection on the sensor side of the splice for • NOT OK – A resistance measurement is less than
the signal wire U739-BR. 5000 ohms.
If one of the measurements is correct and the other Repair: There is a short in the machine harness.
measurement is not correct, there is an open or a The short is between the signal circuit and the
bad connection on the ECM side of the splice for circuit with the low resistance measurement.
the signal wire U739-BR.
In either case, refer to the complete Electrical of the machine. Check all of the connectors that are
System Schematic of the machine. Check all of the in the sensor circuit. Ensure that all connections
connectors that are in the suspected section of the are clean, that all connections are secure and that
sensor signal circuit. Ensure that all connections all connections are in good condition.
all connections are in good condition. Repair the For information on testing for short circuits and
machine harness or replace the machine harness. finding short circuits, refer to Testing and Adjusting,
STOP. machine harness or replace the machine harness.
Test Step 3. CHECK THE SIGNAL STOP.

CIRCUIT FOR A SHORT
The key start switch and the disconnect switch SENSOR
connectors remain disconnected from the Implement The key start switch and the disconnect switch
ECM and the Transmission/Chassis ECM. remain in the OFF position.
A. Remove the jumper wire that was installed in the A. Reconnect the machine harness connectors J1
last step at the connector of the joystick. and J2 to both ECM modules.
B. At the J2 machine harness connector for the B. Reconnect the machine harness connectors that
Implement ECM, measure the resistance from the are disconnected to the left joystick.
sensor signal contact J2-18 (wire U739-BR) to all
of the other J1 and J2 contacts that are used for C. At the machine harness connector J1 for the left
the Implement ECM. joystick, use a 151-6320 Removal Tool to remove
the signal wire U739-BR and the socket at contact
C. If any of the resistance measurements in the last J1-2 from the harness connector. The machine
test step are less than 5000 ohms, skip the next harness connector J1 remains connected to the
test step and proceed to the “Expected Result” connector of the left joystick.
step. If all of the resistance measurements in the
last test step are above 5000 ohms, perform the D. At the back of the connector of the joystick J1,
next test step. insert 7X-1710 Multimeter Probes along the
sensor signal contact J1-2 and the ground 2
D. At the J2 machine harness connector for the contact at J1-4.
resistance from the sensor signal contact E. Turn the disconnect switch and the key start
J2-18 (wire U739-BR) to all of the other switch to the ON position.
J1 and J2 contacts that are used for the
Transmission/Chassis ECM. F. Measure the duty cycle of the sensor at the
connector of the joystick, contacts J1-2 and J1-4.
Expected Result: Move the joystick through the full range of the
Each resistance measurement is greater than 5000 procedure.
ohms.
340 RENR9004-07
The duty cycle of the steering sensor 1 is correct • OK – The CID 1471 FMI 03 diagnostic code is
according to the description at the beginning of this not active. The diagnostic code does not exist at
procedure. this time. The initial diagnostic code was probably
Results: of the connectors that was disconnected and
• OK – The duty cycle of the sensor is correct. The
sensor is not the cause of the problem. • NOT OK – The CID 1471 FMI 03 diagnostic
Reinstall the signal wire U739-BR and the socket corrected.
back to the original location at contact J1-2 in
the machine harness connector for the joystick. Repair: Check the circuit again. Use the Caterpillar
Verify that all of the wires of the joystick are in the Electronic Technician (ET) service tool, if available,
correct locations and that all wires are secure in in order to perform a wiggle test on the machine
the connector before proceeding to the next step. wiring harness. The wiggle test can detect
Proceed to Test Step 5. machine wiring harness.
• NOT OK – The duty cycle of the steering sensor If the cause of the active diagnostic code is not
1 is not correct according to the description at the found, the ECM that has activated this diagnostic
beginning of this procedure. The sensor has failed. code may have failed.
Repair: Perform this test step again in order to If both the Transmission/Chassis ECM and the
verify that the sensor signal is not correct. Implement ECM have activated this diagnostic
If the signal of the steering sensor 1 is not correct the problem.
procedure, replace the assembly of the left joystick. Exit this procedure and perform this procedure
After replacement of the assembly of the joystick, again. If the cause of the failure is not found,
verify that the operation of the new assembly of the contact your dealership's Technical Communicator
joystick is correct before operating the machine. for possible consultation with Caterpillar. This
STOP.
Test Step 5. CHECK THE STATUS OF THE Adjusting, “Electronic Control Module (ECM) -
DIAGNOSTIC CODE Replace”.





is active.
Expected Result:

RENR9004-07 341
i02920127 The steering position sensor 1 receives power from

MID 027 - CID 1471 - FMI 04 Steering position sensor 1 is internally connected to
the ground that is supplied by the 8 volt sensor return
SMCS Code: 5737-038-ZH of the Transmission/chassis ECM (ground of the
ECM) and to the ground that is supplied by the 8 volt
Conditions Which Generate This Code: sensor return of the Implement ECM (ground of the
ECM). The steering sensor must lose both grounds
in order to lose a ground connection. The illustration
above indicates the power and ground connections
for the steering sensor 1.
The position sensor is a PWM sensor that operates

at a frequency of approximately 500 ± 80 hertz. The
position sensor sends a PWM input signal to the
ECM. The duty cycle of the signal will vary from
approximately 10 ± 5% at the full left position of the
joystick to approximately 90 ± 5% at the full right
position of the joystick. When the joystick is in the
center position, the duty cycle will be approximately
50%.

listed:
• The signal circuit is shorted to a ground source.

signal from the steering sensor 1. Both ECM modules
can activate a CID 1471 FMI 04 diagnostic code
when the signal voltage is below normal.
If one ECM has activated a CID 1471 FMI 04
diagnostic code and the other ECM has not, the
sensor is probably operating correctly. When this
occurs, a poor connection in the machine harness
would be suspected.
diagnostic code, either the sensor OR a harness
g01243832
problem.
Illustration 243 For either condition, proceed with this procedure in
Connections for Steering Position Sensor 1 order to verify the cause of the problem.
Three steering position sensors are required for Before performing this procedure, inspect the
correct operation of the steering control lever. The harness connectors that are involved in the
steering position sensors are located in the left circuit. Poor connections can often be the cause
assembly of the joystick. Each sensor provides of a problem in an electrical circuit. Verify that
an input signal to the Implement ECM and to the all connections in the circuit are clean, that all
Transmission/Chassis ECM. This diagnostic code connections are secure and that all connections
is activated when the ECM detects that the signal are in good condition. If a problem with a
voltage from the steering position sensor 1 is below connection is found, correct the problem and
normal. verify that this diagnostic code is active before
342 RENR9004-07
Note: The following test procedure may create other D. Disconnect the J1 connector and the J2 connector
diagnostic codes. Ignore these created diagnostic from the Transmission/Chassis ECM.
problem has been corrected. E. At machine harness connector J2 for the
Test Step 1. CHECK THE SENSOR contact J2-18 (wire U739-BR) to frame ground.
Measure the resistance from contact J2-18 (wire
A. Turn the disconnect switch and the key start U739-BR) to all of the other J1 and J2 contacts
switch to the ON position. that are used for the Implement ECM.
B. Disconnect the machine harness connector J1 F. At the J2 machine harness connector for the
from the left joystick. Observe the status of the Transmission/Chassis ECM, measure the
active CID 1471 FMI 04 diagnostic code. resistance from the sensor signal contact
J2-18 (wire U739-BR) to all of the other
Expected Result: J1 and J2 contacts that are used for the
The status of the CID 1471 FMI 04 diagnostic code
did not change when the connector of the joystick was Expected Result:
disconnected. A CID 1471 FMI 03 diagnostic code
has NOT been activated by either the Implement Each resistance measurement is greater than 5000
ECM or the Transmission/Chassis ECM. The CID ohms.
1471 FMI 04 diagnostic code remains active when
the connector of the joystick is disconnected. Results:
Results: • OK – Each resistance measurement is greater

than 5000 ohms. The resistance checks for the
• YES – The CID 1471 FMI 04 diagnostic code signal circuit do not indicate a short in the machine
remains active when the connector of the joystick harness. Proceed to Test Step 3.
is disconnected. The sensor is not causing the
problem. • NOT OK – One or more of the resistance
Proceed to Test Step 2. measurements is less than 5000 ohms.
• NO – The CID 1471 FMI 04 diagnostic code is no Repair: There is a short in the machine harness.
longer active when the connector of the joystick is The short is between the circuit for the signal
disconnected. A CID 1471 FMI 03 diagnostic code and the frame ground or the circuit with the low
has been activated by both of the ECM modules resistance measurement.
when the connector of the joystick is disconnected.
The machine harness and the ECM are operating Refer to the complete Electrical System Schematic
correctly. of the machine. Check all of the connectors that are
Repair: The steering sensor 1 is causing the are clean, that all connections are secure and that
problem. There is an internal short to ground in all connections are in good condition.
the left joystick. Replace the left assembly of the
joystick. After replacement of the assembly of For information on testing for short circuits and
the joystick, verify that the operation of the new finding short circuits, refer to Testing and Adjusting,
assembly of the joystick is correct before operating “Wiring Harness (Short Circuit) - Test”. Repair the
the machine. machine harness or replace the machine harness.
STOP. STOP.
Test Step 2. CHECK THE SIGNAL Test Step 3. CHECK THE STATUS OF THE
CIRCUIT FOR A SHORT TO GROUND DIAGNOSTIC CODE
A. The connector of the joystick J1 remains A. Inspect the harness connectors. Clean the
disconnected from the machine harness. contacts of the harness connectors. Check the
B. Turn the key start switch and the disconnect by excessive heat, battery acid, or chafing.
C. Disconnect the J1 and J2 machine harness wires that are associated with the sensor circuit.
connectors from the Implement ECM.
RENR9004-07 343
C. Reconnect all harness connectors. Make sure that i02920202

clips for each connector are completely fastened. MID 027 - CID 1471 - FMI 08
D. Turn the disconnect switch and the key start SMCS Code: 5737-038-ZH

is active.
Expected Result:
Results:


corrected.



the problem.

contact your dealership's Technical Communicator g01243832
consultation may greatly reduce repair time. Connections of Steering Position Sensor 1
If the ECM must be replaced, refer to Testing and Three steering position sensors are required for
Adjusting, “Electronic Control Module (ECM) - correct operation of the steering control. The steering
Replace”. position sensors are located in the assembly of the left
joystick. Each sensor provides an input signal to the
STOP. Implement ECM and to the TRansmission/Chassis
ECM. This diagnostic code is associated with the left
hand steering lever position sensor 1. The FMI 08
means that the ECM has determined that the signal
frequency or the signal pulse width is not within the
expected range.
344 RENR9004-07
The steering position sensor 1 receives power from • If one ECM has activated a CID 1471 FMI 08
the 8 volt power supply of the Implement ECM. diagnostic code and the other ECM has not, it is
Steering position sensor 1 is internally connected likely that the sensor is operating correctly. When
to the ground that is supplied by the 8 volt sensor this occurs, a poor connection in the machine
return of the Transmission/Chassis ECM (ground harness would be suspected. When both ECM
of the ECM) and to the ground that is supplied by modules have activated the diagnostic code, either
the Implement ECM 8 volt sensor return of the the sensor OR a harness problem could be the
Implement ECM (ground of the ECM). The steering cause.
sensor must lose both grounds in order to lose a
ground connection. The illustration above indicates • If both ECM modules have activated the diagnostic
the power and ground connections for the steering code, it is very unlikely that either ECM is causing
sensor 1. the problem. For either condition, proceed with
this procedure in order to verify the cause of the
The position sensor is a PWM sensor that operates problem.
at a frequency of 500 ± 80 Hz. The position sensor
sends a PWM input signal to the Implement ECM and Before performing this procedure, inspect the
to the TRansmission/Chassis ECM. The duty cycle of harness connectors that are involved in the
the signal will vary from approximately 10 ± 5% at the circuit. Poor connections can often be the cause
full left position of the joystick to approximately 90 ± of a problem in an electrical circuit. Verify that
5% at the full right position of the joystick. When the all connections in the circuit are clean, that all
joystick is in the center position, the duty cycle will be connections are secure and that all connections
approximately 50%. are in good condition. If a problem with a
The possible causes of this diagnostic code are listed verify that this diagnostic code is active before
below: performing this procedure.
• The sensor has failed. Note: The following test procedure may create other
• Intermittent connections or poor connections in the codes and clear the diagnostic codes when the
sensor circuit. problem has been corrected.
• The ECM has failed. This is unlikely. Test Step 1. CHECK THE DUTY CYCLE
AND THE SIGNAL FREQUENCY AT THE
Consider the following points when this code is SENSOR
active:
• If a CID 0041 diagnostic code for the 8 volt power to the OFF position.
supply has been activated by the Implement ECM
(MID 082), investigate the problem and fix the A. At the machine harness connector J1 for the left
problem before proceeding with this procedure. joystick, use a 151-6320 Removal Tool to remove
the signal wire (wire U739-BR) and the socket at
• The correct operating temperature range for the contact J1-2. The machine harness connector J1
steering sensors is −40 °C (−40.0 °F) to 75 °C remains connected to the left connector of the
(167.0 °F). If an FMI 03 diagnostic code or an FMI joystick.
08 diagnostic code becomes active for a steering
sensor, when the cab environment is at extreme B. At the back of the connector of the joystick J1,
temperatures, reduce the temperature of the cab insert 7X-1710 Multimeter Probes along the
environment in order to keep the steering sensors sensor signal contact J1-2 and the ground 2
operating in the acceptable temperature range. contact at J1-4.
After reducing the temperature, verify that the
CID 1471 FMI 08 diagnostic code is active before C. Turn the disconnect switch and the key start
performing this procedure. switch to the ON position.
• The Transmission/Chassis ECM (MID 027) and the D. With the joystick in a stationary position, measure
Implement ECM (MID 082) receive an input signal the frequency of the signal from the sensor.
from the steering sensor 1. Both ECM modules can
activate a CID 1471 FMI 08 diagnostic code when E. Observe the measurement of the resistance and
the signal frequency or the signal pulse width is not wiggle the connector of the joystick. Gently pull on
within the expected range. the wires and wiggle the wires.
RENR9004-07 345
F. Measure the duty cycle of the sensor at the C. Disconnect machine harness connectors J1 and
connector contacts of the joystick J1-2 and J1-4. J2 from the TRansmission/Chassis ECM.
sensor that is described at the beginning of this D. At the harness connector for the TRansmission/
procedure. Chassis ECM, measure the resistance from
ground 2 return contact J1-45 (wire X800-OR) to
G. Observe the measurement of the resistance and signal contact J2-18 (wire U739-BR).
wiggle the connector of the joystick. Gently pull on
the wires and wiggle the wires. E. Observe the resistance measurement and wiggle
Expected Result: Gently pull on the wires and wiggle the wires for
both connectors.
The frequency of the steering sensor 1 is 500 ±
80 Hz. The duty cycle of the steering sensor 1 is F. At harness connector J1 for the joystick, move
correct according to the description at the beginning the jumper wire to the ground 1 contact J1-8
of this procedure. The frequency and the duty cycle (wire P967-PU) and the signal contact J1-2 (wire
are stable during the manipulation of the harness U739-BR).
connector and the wiring.
G. Disconnect machine harness connectors J1 and
Results: J2 from the Implement ECM.
• OK – The frequency of the sensor and the duty H. At the harness connectors for the Implement ECM,
cycle of the sensor are correct and did not change measure the resistance from ground 1 return
as the harness was manipulated. The sensor is not contact J1-45 (wire P967-PU) to signal contact
causing the problem. J2-18 (wire U739-BR).
Reconnect the signal wire and the socket in the I. Observe the resistance measurement and wiggle
machine harness connector for the joystick. Verify the ECM connector and the sensor connector.
that all wires of the joystick are secure in the Gently pull on the wires and wiggle the wires for
connector before proceeding to the next step. both connectors.
Proceed to Test Step 2. Expected Result:
• NOT OK – The signal frequency and the duty Both resistance measurements are less than 5 ohms
cycle of the steering sensor 1 is NOT correct at all times during the manipulation of the wiring
according to the description at the beginning of this harness and connectors.
procedure. The sensor has failed.
Results:
Repair: Perform this test step again in order to
verify that the sensor signal is not correct. • OK – Both of the resistance measurements are
less than 5 ohms. The sensor circuit is not open
If the signal of steering sensor 1 is not correct in the input circuit of either of the ECM modules.
according to the description at the beginning of this Proceed to Test Step 3.
procedure, replace the left assembly of the joystick.
After replacement of the assembly of the joystick, • NOT OK – The resistance measurement at one or
verify that the operation of the new assembly of the both of the ECM modules is greater than 5 ohms.
joystick is correct before operating the machine. There is an open or a bad connection in one or
both of the signal circuits.
STOP.
Repair: If both of the resistance measurements
Test Step 2. CHECK FOR AN OPEN IN are not correct, there is an open connection or a
THE SENSOR CIRCUIT AT BOTH OF THE bad connection on the sensor side of the splice for
ECM MODULES the signal wire U739-BR.
A. Turn the key start switch and the disconnect If one of the measurements is correct and the other
switch to the OFF position. measurement is not correct, there is an open or a
bad connection on the ECM side of the splice for
B. Disconnect the machine harness connector J1 the signal wire U739-BR.
from the left joystick. At harness connector J1
for the joystick, place a jumper wire between the
ground 2 contact J1-4 (wire X800-OR) and the
signal contact J1-2 (wire U739-BR) .
346 RENR9004-07
In either case, refer to the complete Electrical If both the TRansmission/Chassis ECM and the
System Schematic of the machine. Check all of Implement ECM have activated this diagnostic
the connectors that are in the suspected section code, it is very unlikely that either ECM is causing
of the signal circuit of the sensor. Ensure that the problem.
are secure and that all connections are in good Exit this procedure and perform this procedure
condition. Repair the machine harness or replace again. If the cause of the failure is not found,
the machine harness. contact your dealership's Technical Communicator
STOP. consultation may greatly reduce repair time.
Replace”.



Expected Result:
Results:

diagnostic code does not exist at this time. The
initial diagnostic code was probably caused by a



RENR9004-07 347
i02839827 Three steering position sensors are required for

MID 027 - CID 1471 - FMI 14 position sensors are located in the left joystick
assembly. Each sensor provides an input signal to
SMCS Code: 5737-038-ZH the Implement ECM and to the Transmission/Chassis
ECM. The ECM expects the input signals from all
Conditions Which Generate This Code: three steering position sensors to match very closely.
The FMI 14 diagnostic code is active when the
ECM determines that the PWM input signal from the
steering position sensor 1 does not match the PWM
input signal from one of the other steering position
sensors, however, the position sensor 1 signal does
match with the third sensors signal.
The steering position sensor 1 receives power

from the Implement ECM 8 VDC power supply.
The steering position sensor 1 is internally
connected to the ground that is supplied by the
(ECM ground) and to the ground that is supplied
by the Implement ECM 8 volt sensor return (ECM
ground). The steering sensor must lose both grounds
in order to lose a ground connection. The illustration
for the steer sensor 1.

approximately 10% at the lever full left position to
approximately 90% at the lever full right position.
When the lever is in the center position, the duty
cycle will be approximately 50%.

below:

Note: If a CID 0041 diagnostic code for the 8 volt
power supply has been activated by the Implement
ECM (MID 082), investigate the problem and fix the
problem before proceeding with this procedure.
Note: The correct operating temperature range for

the steering sensors is −40 °C (−40.0 °F) to 75 °C
(167.0 °F). Return the temperature in the cab to a
normal temperature when the temperature in the cab
is extreme and a diagnostic code, an FMI 03, an FMI
08 or possibly an FMI 14, becomes active. Returning
Illustration 245
g01291021 the temperature in the cab to a normal temperature
will keep the steering position sensors operating in
Left Joystick Steer Sensors connections
the acceptable temperature range. After stabilization
of the temperature, verify that the CID 1471 FMI
14 diagnostic code is active before performing this
procedure.
348 RENR9004-07
Note: The Transmission/Chassis ECM (MID 027) F. Move the joystick through the full range of
and the Implement ECM (MID 082) receive an input operation. Record the duty cycle of the sensor at
signal from the steering sensor 1. Both ECM's can specific positions of the joystick.
activate a CID 1471 FMI 14 diagnostic code when the
signal from one steer sensor does not closely match G. Repeat the process for the other two steer position
the signal from one of the other steering sensors. sensors.
diagnostic code and the other ECM has not, it is Expected Result:
occurs, a poor connection in the machine harness The duty cycle of the three steering sensors are
would be suspected. within 5% of each other.
When both ECM's have activated the diagnostic
code, either the sensor or a harness problem could Results:
be the cause.
If both ECM's have activated the diagnostic code, it is • OK – The duty cycle has been recorded for
very unlikely that either ECM is causing the problem. comparison with the other two steering sensors.
For either condition, proceed with this procedure in With the joystick at the same position for all three
order to verify the cause of the problem. readings of the steering sensors, the duty cycle
readings are within 5% of each other. Reconnect
Note: Before performing this procedure, inspect the signal wire in the machine harness connector
the harness connectors that are involved in the for the joystick before proceeding to the next test
circuit. Poor connections can often be the cause step. Proceed to Test Step 2.
all connections in the circuit are clean, that all • NOT OK – With the joystick in the same position
connections are secure and that all connections while reading the duty cycle of the three steering
are in good condition. If a problem with a sensors one or more of the duty cycle reading
connection is found, correct the problem and varies by more the 5% from the other duty cycles.
verify that this diagnostic code is active before One or more of the steering sensors are not
performing this procedure. working properly.
Note: The following test procedure may create other Repair: Replace the left joystick assembly. After
diagnostic codes. Ignore these created diagnostic replacement of the assembly, verify that the new
codes and clear the diagnostic codes when the assembly is working correctly. Clear all logged
problem has been corrected. codes prior to confirming the function of the new
assembly.
Note: The next three test steps will measure the
duty cycle of each steering sensor in order to STOP.
determine if one signal is not closely matching
with both of the other sensor signals. Record the Test Step 2. CHECK THE STATUS OF THE
duty cycle of the sensor signal for each of the DIAGNOSTIC CODE
three sensors for comparison.
Test Step 1. CHECK THE SIGNAL AT contacts of the harness connectors. Check the
STEER SENSOR 1 wires for damage to the insulation that is caused
switch to the OFF position. B. Perform a 45 N (10 lb) pull test on each of the
B. Do not disconnect the harness connector from the
sensor. C. Reconnect all harness connectors. Make sure that
C. At the back of the joystick connector J1, insert clips for each connector are completely fastened.
signal contact J1-2 and the return contact at J1-4. D. Operate the machine.
D. Turn the disconnect switch and the key start E. Check the status of the CID 1471 FMI 14
switch to the ON position. diagnostic code.
E. Monitor the signal of the sensor with a digital Expected Result:

multimeter.
RENR9004-07 349
Results: i02920251
this time. The initial diagnostic code was probably SMCS Code: 5737-038-ZH

corrected. Clear the diagnostic code. Operate the
machine in order to learn if the code occurs again.
Repair: If the cause of the active diagnostic code

is not found, the ECM that has activated this
diagnostic code may have failed.

the problem.


Replace”.
STOP.
g01259877
Illustration 246
Connections of steering Sensor 2
350 RENR9004-07
Three steering position sensors are required for • When both ECM modules have activated the
correct operation of the steering control. The steering diagnostic code, either the sensor or a harness
position sensors are located in the left assembly of problem could be the cause.
the joystick. Each sensor provides an input signal to
the Implement ECM and to the Transmission/Chassis • If both ECM modules have activated the diagnostic
ECM. The FMI 02 diagnostic code is recorded when code, it is very unlikely that either ECM is causing
the ECM detects that the input from the “steering the problem.
position sensor 2” is erratic or intermittent.
The steering position sensor 2 receives power from order to verify the cause of the problem.
Steering position sensor 2 is connected to ground at Before performing this procedure, inspect the
the 8 volt sensor return of the Transmission/chassis harness connectors that are involved in the
ECM (ground of the ECM) and the 8 volt sensor circuit. Poor connections can often be the cause
return of the Implement ECM (ground of the ECM). of a problem in an electrical circuit. Verify that
The steering sensor must lose the 8 volt power all connections in the circuit are clean, that all
supply or both grounds in order to lose power. The connections are secure and that all connections
illustration above indicates the power and ground are in good condition. If a problem with a
connections for steering position sensor 2. connection is found, correct the problem and
The position sensor is a PWM sensor that operates at performing this procedure.
sensor sends a PWM input signal to the Implement Note: The following test procedure may create other
ECM and to the Transmission/Chassis ECM. The diagnostic codes. Ignore these created diagnostic
duty cycle of the signal will vary from approximately codes and clear the diagnostic codes when the
10 ± 5% at the full left position of the joystick to problem has been corrected.
joystick. When the joystick is in the center position, Test Step 1. CHECK THE SENSOR
the duty cycle will be approximately 50%. POWER SUPPLY
The possible causes of this diagnostic code are A. Turn the disconnect switch and the key start
listed: switch to the ON position.
• The sensor has failed. B. At the J1 harness connector for the left joystick,
• Intermittent connections or poor connections exist contact of the power supply J1-1 (wire R800-OR)
in the sensor circuit. and along ground 1 contact J1-8 (wire P967-PU).
• The signal circuit is shorted to another circuit in the J1 connector.
machine harness.
C. Measure the DC voltage of the sensor power
• The ECM has failed. This is unlikely. supply.
Consider the following points when this code is D. Reposition the multimeter probe that is along
active: ground 1 contact J1-8 (wire P967-PU) to along
ground 2 contact J1-4 (wire P967-PU). The other
• Before performing this procedure, check for an multimeter probe remains positioned along the
active CID 0041 diagnostic code for the 8 volt contact of the power supply J1-1 (wire R800-OR).
sensor power supply of the Implement ECM.
Correct any problem with the 8 volt power supply E. Measure the DC voltage of the sensor power
before performing this procedure. supply.
• The Transmission/Chassis ECM (MID 027) and the Expected Result:

Implement ECM (MID 082) receive an input signal
from the steering sensor 2. Both ECM modules can Both of the voltage measurements are approximately
activate a CID 1472 FMI 02 diagnostic code when 8.0 ± 0.4 VDC.
the signal is erratic or intermittent.
If one ECM has activated a CID 1472 FMI 02 Results:
diagnostic code and the other ECM has not, it is
likely that the sensor is operating correctly. When • OK – Both of the voltage measurements are
this occurs, a poor connection in the machine approximately 8.0 ± 0.4 VDC. The power supply for
harness would be suspected. the sensor is correct. Proceed to Test Step 2.
RENR9004-07 351
• NOT OK – The voltage measurement is less than Results:

8.0 ± 0.4 VDC. The power supply for the sensor
is not correct. • OK – The duty cycle of the sensor is correct. The
sensor is not the cause of the problem.
Repair: Either both of the wires for the sensor
ground or the supply circuit for the sensor is faulty. Reinstall the signal wire U740-BU and the socket
back to the original location at contact J1-7 in the
NOTE: If one of the voltage measurements machine harness connector for the joystick. Verify
is correct and the other measurement is not that all of the wires of the joystick are in the correct
correct, one of the ground circuits is faulty. locations. Secure the wires of the joystick in the
This condition will not cause this code to connector before proceeding to the next step.
activate, however, the faulty ground circuit
must be repaired prior to proceeding with this Proceed to Test Step 3.
procedure.
• NOT OK – The duty cycle of the steering sensor 2
Refer to the complete Electrical System Schematic is NOT correct according to the description at the
of the machine. Examine all of the connectors that beginning of this procedure. The sensor has failed.
are in the circuits. Ensure that the connections are
clean, that the connections are secure and that the Repair: Perform this test step again in order to
connections are in good condition. verify that the sensor signal is not correct.
For troubleshooting the power supply of the If the “steering sensor 2” signal is not correct
Implement ECM, refer to the CID 0041 diagnostic according to the description at the beginning of this
code procedures in the troubleshooting section of procedure, replace the left assembly of the joystick.
the manual for the Implement ECM. After replacement of the assembly of the joystick,
verify that the operation of the new assembly of the
Repair the faulty power supply circuit before joystick is correct before operating the machine.
proceeding with this procedure.
STOP.
STOP.
Test Step 3. CHECK THE SIGNAL AT
Test Step 2. CHECK THE SIGNAL AT THE BOTH OF THE ECM MODULES
SENSOR
The key start switch and the disconnect switch switch to the OFF position.
A. At the machine harness connector J1 for the left Transmission/Chassis ECM, insert a multimeter
joystick, use a 151-6320 Removal Tool to remove probe along return contact J1-45 (wire X800-OR).
the signal wire U740-BU and the socket at contact At the machine harness connector J2 for the
J1-7 from the harness connector. The machine Transmission/Chassis ECM, insert a multimeter
harness connector J1 remains connected to the probe along signal contact J2-48 (wire U740-BU).
left connector of the joystick. The machine harness connectors remain
connected to the ECM.
B. At the back of the connector J1 of the joystick,
insert 7X-1710 Multimeter Probes along the C. Turn the key start switch and the disconnect
sensor signal contact J1-7 and the ground 1 switch to the ON position.
contact at J1-8.
D. Measure the duty cycle of the sensor at the
C. Turn the disconnect switch and the key start contacts of the ECM J1-45 and J2-48. Move the
switch to the ON position. joystick through the full range of the sensor that is
described at the beginning of this procedure.
D. Measure the duty cycle of the sensor at the
connector contacts of the joystick J1-7 and J1-8. E. At the machine harness connector J1 for the
Move the joystick through the full range of the Implement ECM, insert a multimeter probe along
sensor that is described at the beginning of this return contact J1-45 (wire P967-PU). At the
procedure. machine harness connector J2 for the Implement
ECM, insert a multimeter probe along signal
Expected Result: contact J2-48 (wire U740-BU). The machine
harness connectors remain connected to the
The duty cycle of the steering sensor 2 is correct ECM.
procedure.
352 RENR9004-07
connector contacts of the ECM J1-45 and J2-48. Implement ECM, measure the resistance from the
Move the joystick through the full range of the sensor signal contact J2-48 (wire U740-BU) to all

next test step.
Results:
D. Disconnect the J1 connector and the J2 connector
• OK – The duty cycle of the sensor is correct at from the Transmission/Chassis ECM.
intermittent open or a short could still be causing Transmission/Chassis ECM, measure the
J2-48 (wire U740-BU) to all of the other
• NOT OK – The duty cycle of the steering sensor J1 and J2 contacts that are used for the
2 is NOT correct at one of the ECM modules Transmission/Chassis ECM.
harness.
suspected.
The “steering sensor 2” signal at one of the ECM than 5000 ohms. The resistance checks of the
modules is not correct. signal circuit do not indicate a short in the machine
of the machine. Examine all of the connectors • NOT OK – A resistance measurement is less than
that are in the section of the sensor signal circuit 5000 ohms.
that connects to the ECM that is not receiving
a good signal. Verify that the connections are Repair: There is a short in the machine harness.
clean, that the connections are secure and that The short is between the signal circuit and the
the connections are in good condition. Repair the circuit with the low resistance measurement.
• NOT OK – The duty cycle of the steering sensor are clean, that all connections are secure and that
2 is NOT correct at either of the ECM modules all connections are in good condition.
procedure. Most likely there is a problem in the For information on testing for short circuits and
machine harness. Proceed to Test Step 4. finding short circuits, refer to Testing and Adjusting,
Test Step 4. CHECK THE SIGNAL machine harness or replace the machine harness.
CIRCUIT FOR A SHORT
STOP.
to the OFF position. Test Step 5. CHECK THE STATUS OF THE
DIAGNOSTIC CODE
A. Disconnect the J1 connection and the J2
connector from the Implement ECM. A. Inspect the harness connectors. Clean the
RENR9004-07 353
B. Perform a 45 N (10 lb) pull test on each of the i02920271

MID 027 - CID 1472 - FMI 03
the connectors are fully seated. Observe that the SMCS Code: 5737-038-ZH

is active.
Expected Result:
Results:


corrected.


found, the ECM that has activated the diagnostic

the problem.

If the ECM must be replaced, refer to Testing and Illustration 247

g01259877
Connections for Steering Sensor 2
Replace”.
STOP.
354 RENR9004-07
Three steering position sensors are required for • The correct operating temperature range for the
correct operation of the steering control. The steering steering sensors is −40 °C (−40.0 °F) to 75 °C
position sensors are located in the left assembly of (167.0 °F). If an FMI 03 diagnostic code or an FMI
the joystick. Each sensor provides an input signal to 08 diagnostic code become active for a steering
the Implement ECM and to the Transmission/Chassis sensor, when the cab environment is at extreme
ECM. This diagnostic code is recorded when the temperatures, reduce the temperature of the cab
ECM reads the input signal from the steering position environment in order to keep the steering sensors
sensor 2 and the voltage of the signal is above operating. After the temperature has been reduced,
normal. verify that the CID 1472 FMI 03 diagnostic code is
active before performing this procedure.
The steering position sensor 2 receives power from
the 8 volt power supply of the Implement ECM. • The Transmission/Chassis ECM (MID 027) and the
Steering position sensor 2 is connected to ground at Implement ECM (MID 082) receive an input signal
the 8 volt sensor return of the Transmission/chassis from the steering sensor 2. Both ECM modules can
ECM (ground of the ECM) and the 8 volt sensor activate a CID 1472 FMI 03 diagnostic code when
return of the Implement ECM(ground of the ECM). the signal voltage is above normal.
The steering sensor must lose the 8 volt power
supply or both grounds in order to lose power. The • If one ECM has activated a CID 1472 FMI 03
illustration above indicates the power and ground diagnostic code and the other ECM has not, it is
connections for steering position sensor 2. likely that the sensor is operating correctly. When
this occurs, a poor connection in the machine
The position sensor is a PWM sensor that operates at harness would be suspected.
sensor sends a PWM input signal to the Implement • When both ECM modules have activated the
ECM and to the Transmission/Chassis ECM. The diagnostic code, either the sensor OR a harness
duty cycle of the signal will vary from approximately problem could be the cause.
10 ± 5% at the full left position of the joystick to
approximately 90 ± 5% at the full right position of the • If both ECM modules have activated the diagnostic
joystick. When the joystick is in the center position, code, it is very unlikely that either ECM is causing
the duty cycle will be approximately 50%. the problem.
The possible causes of this diagnostic code are For either condition, proceed with this procedure in
listed: order to verify the cause of the problem.
• The circuit of the sensor power supply is open. Before performing this procedure, inspect the
• The return circuit of the sensor is open. circuit. Poor connections can often be the cause
• The signal circuit is open. all connections in the circuit are clean, that all
• The signal circuit is shorted to the sensor power are in good condition. If a problem with a
supply. connection is found, correct the problem and
• The sensor has failed. performing this procedure.
• The ECM has failed. This is unlikely. Note: The following test procedure may create other
Consider the following points when this code is codes and clear the diagnostic codes when the
active: problem has been corrected.
• Before performing this procedure, check for an Test Step 1. CHECK THE SENSOR
active CID 0041 diagnostic code for the 8 volt POWER SUPPLY
sensor power supply of the Implement ECM (MID
082). Correct any problem with the 8 volt power A. Turn the disconnect switch and the key start
supply before performing this procedure. switch to the ON position.
B. At the J1 harness connector for the left joystick,

contact of the power supply J1-1 (wire R800-OR)
and along ground 1 contact J1-8 (wire P967-PU).
J1 connector.
RENR9004-07 355
C. Measure the DC voltage of the sensor power B. Disconnect the machine harness connector J1
supply. from the left joystick. At harness connector J1
for the joystick, connect a jumper wire between
D. Reposition the multimeter probe that is along ground 2 contact J1-4 (wire X800-OR) and the
ground 1 contact J1-8 (wire P967-PU) and move signal contact J1-7 (wire U740-BU).
the probe to along ground 2 contact J1-4 (wire
P967-PU). The other multimeter probe remains C. Disconnect machine harness connectors J1 and
positioned along contact of the power supply J1-1 J2 from the Transmission/Chassis ECM.
(wire R800-OR).
D. At the harness connector for the Transmission/
Expected Result: Chassis ECM, measure the resistance from return
contact J1-45 (wire X800-OR) to signal contact
Both of the voltage measurements are approximately J2-48 (wire U740-BU).
8.0 ± 0.4 VDC.
E. Observe the resistance measurement and wiggle
Results: the ECM connector and the sensor connector.
• OK – Both of the voltage measurements are both connectors.
approximately 8.0 ± 0.4 VDC. The power supply for
the sensor is correct. Proceed to Test Step 2. F. At harness connector J1 for the joystick, move
the jumper wire to the ground 1 contact J1-8
• NOT OK – One or both of the voltage (wire P967-PU) and the signal contact J1-7 (wire
measurements is less than 8.0 ± 0.4 VDC. The U740-BU).
power supply for the sensor is not correct.
G. Disconnect machine harness connectors J1 and
Repair: Either both of the circuit for the ground J2 from the Implement ECM.
of the sensor or the sensor supply circuit of the
sensor is faulty. H. At the harness connectors for the Implement
ECM, measure the resistance from return contact
NOTE: If one of the voltage measurements J1-45 (wire P967-PU) to signal contact J2-48 (wire
is correct and the other measurement is not U740-BU).
correct, one of the ground circuits is faulty.
This condition will not cause this code to I. Observe the resistance measurement and wiggle
activate. However, the faulty ground circuit the ECM connector and the sensor connector.
must be repaired before proceeding with this Gently pull on the wires and wiggle the wires for
procedure. both connectors.
Refer to the complete Electrical System Schematic Expected Result:

of the machine. Examine all of the connectors that
are in the circuits. Ensure that the connections are Both resistance measurements are less than 5 ohms
clean, that the connections are secure and that the at all times during the manipulation of the wiring
connections are in good condition. harness and connectors.
For troubleshooting the power supply of the Results:

Implement ECM, refer to the CID 0041 diagnostic
code procedures in the troubleshooting section of • OK – Both of the resistance measurements are
the manual for the Implement ECM. less than 5 ohms. The sensor circuit is not open
in either input circuit of the ECM. Proceed to Test
Repair the faulty power supply circuit before Step 3.
• NOT OK – The resistance measurement at one or
STOP. both of the ECM modules is greater than 5 ohms.
There is an open or a bad connection in one or
Test Step 2. CHECK FOR AN OPEN IN both of the signal circuits.
THE SENSOR CIRCUIT AT BOTH OF THE
ECM MODULES Repair: If both of the resistance measurements are
not correct, there is an open or a bad connection
A. Turn the key start switch and the disconnect on the sensor side of the splice for the signal wire
switch to the OFF position. U740-BU.
356 RENR9004-07
If one of the measurements is correct and the For information on testing for short circuits and
other measurement is not correct, there is an open finding short circuits, refer to Testing and Adjusting,
connection or a bad connection on the ECM side “Wiring Harness (Short Circuit) - Test”. Repair the
of the splice for the signal wire U740-BU. machine harness or replace the machine harness.
In either case, refer to the complete Electrical STOP.

System Schematic of the machine. Check all of the
connectors that are in the suspected section of the Test Step 4. CHECK THE SIGNAL AT THE
sensor signal circuit. Ensure that all connections SENSOR
all connections are in good condition. Repair the The key start switch and the disconnect switch
machine harness or replace the machine harness. remain in the OFF position.
STOP. A. Reconnect the machine harness connectors J1

and J2 to both ECM modules.
CIRCUIT FOR A SHORT B. Reconnect the machine harness connectors that
are disconnected to the left joystick.
remain in the OFF position. The machine harness C. At the machine harness connector J1 for the left
connectors remain disconnected from the Implement joystick, use a 151-6320 Removal Tool to remove
ECM and the Transmission/Chassis ECM. the signal wire U740-BU and the socket at contact
J1-7 from the harness connector. The machine
A. Remove the jumper wire that was installed in the harness connector J1 remains connected to the
last step at the connector of the joystick. left connector of the joystick.
B. At the J2 machine harness connector for the D. At the back of the connector of the joystick J1,
Implement ECM, measure the resistance from the insert 7X-1710 Multimeter Probes along the
sensor signal contact J2-48 (wire U740-BU) to all contact of the sensor signal J1-7 and the ground
of the other J1 and J2 contacts that are used for contact at J1-8.
the Implement ECM.
E. Turn the disconnect switch and the key start
C. At the J2 machine harness connector for the switch to the ON position.
resistance from the sensor signal contact F. Measure the duty cycle of the sensor at the
J2-48 (wire U740-BU) to all of the other connector contacts of the joystick J1-7 and J1-8.
J1 and J2 contacts that are used for the Move the joystick through the full range of the
Transmission/Chassis ECM. sensor that is described at the beginning of this
procedure.
Expected Result:
Expected Result:
ohms. The duty cycle of the steering sensor 2 is correct
Results: procedure.
• OK – Each resistance measurement is greater Results:

than 5000 ohms. The resistance checks of the
signal circuit do not indicate a short in the machine • OK – The duty cycle of the sensor is correct. The
harness. Proceed to Test Step 4. sensor is not the cause of the problem. Reconnect
the signal wire and the socket in the machine
• NOT OK – A resistance measurement is less than harness connector for the joystick.
5000 ohms.
Reinstall the signal wire U740-BU and the socket
Repair: There is a short in the machine harness. back to the original location at contact J1-7 in the
The short is between the signal circuit and the machine harness connector for the joystick. Verify
circuit with the low resistance measurement. that all of the wires of the joystick are in the correct
locations. Secure the wires of the joystick into the
Refer to the complete Electrical System Schematic connector. Proceed to the next step.
in the sensor circuit. Ensure that all connections Proceed to Test Step 5.
RENR9004-07 357
• NOT OK – The duty cycle of the steering sensor 2 If the cause of the active diagnostic code is not
is NOT correct according to the description at the found, the ECM that has activated this diagnostic
beginning of this procedure. The sensor has failed. code may have failed.
Repair: Perform this test step again in order to If both the Transmission/Chassis ECM and the
verify that the sensor signal is not correct. Implement ECM have activated this diagnostic
If the “steering sensor 2” signal is not correct the problem.
procedure, replace the left assembly of the joystick. Exit this procedure and perform this procedure
After replacement of the assembly of the joystick, again. If the cause of the failure is not found,
verify that the operation of the new assembly of the contact your dealership's Technical Communicator
joystick is correct before operating the machine. for possible consultation with Caterpillar. This
STOP.





is active.
Expected Result:
Results:


corrected.

358 RENR9004-07

correct operation of the steering control lever. The
MID 027 - CID 1472 - FMI 04 steering position sensors are located in the left
assembly of the joystick. Each sensor provides
SMCS Code: 5737-038-ZH an input signal to the Implement ECM and to the
Transmission/Chassis ECM. This diagnostic code is
Conditions Which Generate This Code: recorded when the ECM reads the signal from the
steering position sensor 2 and the voltage of the
signal is below normal.
The steering position sensor 2 receives power from

Steering position sensor 2 is connected to ground at
the 8 volt sensor return of the Transmission/Chassis
ECM(ground of the ECM) and the 8 volt sensor return
of the Implement ECM (ground of the ECM). The
steering sensor must lose the 8 volt power supply or
both grounds in order to lose power. The illustration
for steering position sensor 2.

approximately 10 ± 5% at the full left position of the
position of the joystick. When the joystick is in the
center position, the duty cycle will be approximately
50%.

listed:

Note: Before performing this procedure, check for an
power supply of the Implement ECM (MID 082).
Correct any problem with the 8 volt power supply
before performing this procedure.
g01259877
Illustration 248
Connections of “Steering Sensor 2”
RENR9004-07 359
Note: The Transmission/Chassis ECM (MID 027) • NO – The CID 1472 FMI 04 diagnostic code is no
and the Implement ECM (MID 082) receive an input longer active when the connector of the joystick is
signal from the steering sensor 2. Both ECM modules disconnected. A CID 1472 FMI 03 diagnostic code
can activate a CID 1472 FMI 04 diagnostic code has been activated by both of the ECM modules
when the signal voltage is below normal. when the connector of the joystick is disconnected.
If one ECM has activated a CID 1472 FMI 04 The machine harness and the ECM are operating
diagnostic code and the other ECM has not, it is correctly.
occurs, a poor connection in the machine harness Repair: The steering sensor 2 is causing the
would be suspected. problem. There is an internal short to ground in
When both ECM modules have activated the the left joystick. Replace the left assembly of the
diagnostic code, either the sensor OR a harness joystick. After replacement of the assembly of
problem could be the cause. the joystick, verify that the operation of the new
If both ECM modules have activated the diagnostic assembly of the joystick is correct before operating
code, it is very unlikely that either ECM is causing the the machine.
problem.
For either condition, proceed with this procedure in STOP.
Before performing this procedure, inspect the CIRCUIT FOR A SHORT TO GROUND
circuit. Poor connections can often be the cause A. The connector of the joystick J1 remains
of a problem in an electrical circuit. Verify that disconnected from the machine harness.
connections are secure and that all connections B. Turn the key start switch and the disconnect
are in good condition. If a problem with a switch to the OFF position.
verify that this diagnostic code is active before C. Disconnect the J1 and J2 machine harness
performing this procedure. connectors from the Implement ECM.
Note: The following test procedure may create other D. Disconnect the J1 connector and the J2 connector
diagnostic codes. Ignore these created diagnostic from the Transmission/Chassis ECM.
problem has been corrected. E. At machine harness connector J2 for the
Test Step 1. CHECK THE SENSOR contact J2-48 (wire U740-BU) to frame ground.
A. Turn the disconnect switch and the key start U740-BU) to all of the other J1 and J2 contacts
switch to the ON position. that are used for the Implement ECM.
B. Disconnect the machine harness connector J1 F. At the J2 machine harness connector for the
from the left joystick. Observe the status of the Transmission/Chassis ECM, measure the
active CID 1472 FMI 04 diagnostic code. resistance from the sensor signal contact J2-48
(wire U740-BU) to frame ground and measure the
Expected Result: resistance to all of the other J1 and J2 contacts
that are used for the Transmission/Chassis ECM.
did not change when the connector of the joystick was Expected Result:
disconnected. A CID 1472 FMI 03 diagnostic code
has NOT been activated by either the Implement Each resistance measurement is greater than 5000
ECM or the Transmission/Chassis ECM. The CID ohms.
1472 FMI 04 diagnostic code remains active when
the connector of the joystick is disconnected. Results:
Results: • OK – Each resistance measurement is greater

than 5000 ohms. The resistance checks of the
• YES – The CID 1472 FMI 04 diagnostic code signal circuit do not indicate a short in the machine
remains active when the connector of the joystick harness. Proceed to Test Step 3.
problem. Proceed to Test Step 2. • NOT OK – One or more of the resistance
360 RENR9004-07
Repair: There is a short in the machine harness. Repair: Check the circuit again. Use the Caterpillar
The short is between the signal circuit and the Electronic Technician (ET) service tool, if available,
frame ground or the signal circuit and the circuit in order to perform a wiggle test on the machine
with the low resistance measurement. wiring harness. The wiggle test can detect
Refer to the complete Electrical System Schematic machine wiring harness.
in the sensor circuit. Ensure that all connections If the cause of the active diagnostic code is not
are clean, that all connections are secure and that found, the ECM that has activated this diagnostic
all connections are in good condition. code may have failed.
For information on testing for short circuits and If both the Transmission/Chassis ECM and the
finding short circuits, refer to Testing and Adjusting, Implement ECM have activated this diagnostic
“Wiring Harness (Short Circuit) - Test”. Repair the code, it is very unlikely that either ECM is causing
machine harness or replace the machine harness. the problem.
STOP. Exit this procedure and perform this procedure

Test Step 3. CHECK THE STATUS OF THE contact your dealership's Technical Communicator
DIAGNOSTIC CODE for possible consultation with Caterpillar. This
contacts of the harness connectors. Check the If the ECM must be replaced, refer to Testing and
wires for damage to the insulation that is caused Adjusting, “Electronic Control Module (ECM) -
by excessive heat, battery acid, or chafing. Replace”.




is active.
Expected Result:
Results:


corrected.
RENR9004-07 361

MID 027 - CID 1472 - FMI 08 position sensors are located in the left assembly of
the joystick. Each sensor provides an input signal to
SMCS Code: 5737-038-ZH the ECM. This diagnostic code is associated with the
left hand steering lever position sensor 2. The FMI 08
Conditions Which Generate This Code: means that the ECM has determined that the signal
frequency or the signal pulse width is not within the
expected range.
The “steering position sensor 2” receives power

from the 8 volt power supply of the Implement ECM.
“Steering position sensor 2” is connected to ground at
ECM (ground of the ECM) and the 8 volt sensor
return of the Implement ECM(ground of the ECM).
The steering sensor must lose the 8 volt power
supply or both grounds in order to lose power. The
connections for “steering position sensor 2”.

at a frequency of 500 ± 80 Hz. The position sensor
sends a PWM input signal to the Implement ECM and
to the Transmission/Chassis ECM. The duty cycle of
the signal will vary from approximately 10 ± 5% at the
full left position of the joystick to approximately 90 ±
5% at the full right position of the joystick . When the
joystick is in the center position, the duty cycle will be
approximately 50%.

below:

• Intermittent connections or poor connections
Consider the following points when this code is
active:
• Before performing this procedure, check for an

active CID 0041 diagnostic code for the 8 volt
sensor power supply of the ECM. Correct any
problem with the 8 volt power supply before
• The correct operating temperature range for the

steering sensors is −40 °C (−40.0 °F) to 75 °C
(167.0 °F). If an FMI 03 diagnostic code or an FMI
08 diagnostic code is active for a steering sensor
at the time that the cab environment is at extreme
Illustration 249
g01259877 temperatures, reduce the temperature of the cab
environment in order to keep the steering sensors
operating in the acceptable temperature range.
After the temperature has been reduced, verify
that the CID 1472 FMI 08 diagnostic code is active
362 RENR9004-07
• The Transmission/Chassis ECM also receives F. Measure the duty cycle of the sensor at the
an input from the “steering sensor 2” signal. connector contacts for the joystick J1-7 and J1-4.
The Transmission/Chassis ECM (MID 027) will Move the joystick through the full range of the
activate a CID 1472 FMI 08 diagnostic code when sensor that is described at the beginning of this
an abnormal signal frequency or pulse width is procedure.
detected. If one ECM has activated a CID 1472
FMI 08 diagnostic code and the other ECM has G. Observe the measurement and wiggle the
not, it is likely that the sensor is operating correctly. connector of the joystick . Gently pull on the wires
When this occurs, an intermittent open in the and wiggle the wires.
machine harness would be suspected. When both
ECM modules have activated the diagnostic code, Expected Result:
either the sensor OR a harness problem could
be the cause. For either condition, proceed with The frequency of the “steering sensor 2” signal is 500
this procedure in order to verify the cause of the ± 80 Hz. The duty cycle of the “steering sensor 2” is
problem. correct according to the description at the beginning
of this procedure. The frequency and the duty cycle
Before performing this procedure, inspect the are stable during the manipulation of the harness
harness connectors that are involved in the connector and the wiring.
of a problem in an electrical circuit. Verify that Results:
connections are secure and that all connections • OK – The frequency of the signal and the duty
are in good condition. If a problem with a cycle of the sensor are correct and did not change
connection is found, correct the problem and when the harness was manipulated. The sensor is
verify that this diagnostic code is active before not causing the problem.
Reconnect the signal wire and the socket in the
Note: The following test procedure may create other machine harness connector for the joystick. Verify
diagnostic codes. Ignore these created diagnostic that all wires of the joystick are secure in the
codes and clear the diagnostic codes when the connector. Proceed to the next step.
Test Step 1. CHECK THE DUTY CYCLE
AND THE SIGNAL FREQUENCY AT THE • NOT OK – The signal frequency and the duty
SENSOR cycle of the “steering sensor 2” is not correct
Turn the key start switch and the disconnect switch procedure. The sensor has failed.
A. At the machine harness connector J1 for the left verify that the sensor signal is not correct.
joystick, use a 151-6320 Removal Tool to remove
the signal wire (wire U740-BU) and the socket at If the “steering sensor 3” signal is not correct
contact J1-7. The machine harness connector J1 according to the description at the beginning of this
remains connected to the left connector of the procedure, replace the left assembly of the joystick.
joystick. After replacement of the assembly of the joystick,
B. At the back of the connector of the joystick J1, joystick is correct before operating the machine.
sensor signal contact J1-7 and the ground contact STOP.
at J1-4.
C. Turn the disconnect switch and the key start THE SENSOR CIRCUIT AT BOTH OF THE
switch to the ON position. ECM MODULES
D. With the joystick in a stationary position, measure A. Turn the key start switch and the disconnect
the frequency of the signal from the sensor. switch to the OFF position.
E. Observe the measurement of the resistance and B. Disconnect the machine harness connector J1
wiggle the connector of the joystick. Gently pull on from the left joystick. At the sensor connection
the wires and wiggle the wires. for the machine harness J1, place a jumper wire
between the ground 1 contact J1-8 (wire P967-PU)
and the signal contact J1-7 (wire L740-BU) .
RENR9004-07 363
C. Disconnect machine harness connectors J1 and If one of the measurements is correct and the other
J2 from the Implement ECM. measurement is not correct, there is an open or a
bad connection on the ECM side of the splice for
D. At the harness connector for the Implement ECM, the machine harness for the signal wire U740-BU.
measure the resistance from return contact J1-45
(wire P967-PU) to signal contact J2-48 (wire In either case, refer to the complete Electrical
U740-BU). System Schematic of the machine. Check all of the
connectors that are in the suspected section of the
E. Observe the resistance measurement and wiggle sensor signal circuit. Ensure that all connections
the ECM connector and the sensor connector. are clean, that all connections are secure and that
Gently pull on the wires and wiggle the wires for all connections are in good condition. Repair the
both connectors. machine harness or replace the machine harness.
F. At the harness connector for the joystick, move STOP.

the jumper wire from the ground 1 contact and
connect the jumper wire to the ground 2 contact Test Step 3. CHECK THE STATUS OF THE
J1-4 (wire X800-OR). The other end of the jumper DIAGNOSTIC CODE
wire remains connected to the signal contact J1-7
(wire L740-BU). A. Inspect the harness connectors. Clean the
G. Disconnect machine harness connectors J1 and wires for damage to the insulation that is caused
J2 from the Transmission/Chassis ECM. by excessive heat, battery acid, or chafing.
H. At the harness connector for the Transmission/ B. Perform a 45 N (10 lb) pull test on each of the
Chassis ECM, measure the resistance from return wires that are associated with the circuit.
contact J1-45 (wire X800-OR) to signal contact
J2-48 (wire U740-BU). C. Reconnect all harness connectors in order to
I. Observe the resistance measurement and wiggle Observe that the clips for each connector are
the ECM connector and the sensor connector. completely fastened.
both connectors. D. Turn the disconnect switch and the key start
Expected Result:
Both resistance measurements are less than 5 ohms
at all times during the manipulation of the wiring F. Check the status of the CID 1472 FMI 08.
harness and the connectors.
Expected Result:
Results:
less than 5 ohms. The sensor circuit is not open Results:
in either of the input circuits of the ECM modules.
Proceed to Test Step 3. • OK – The CID 1472 FMI 08 is not active. The
• NOT OK – The resistance measurement at one or initial diagnostic code was probably caused by a
both of the ECM modules is greater than 5 ohms. poor connection or a short at one of the connectors
There is an open or a bad connection in one or that was disconnected and reconnected. Resume
both of the signal circuits. normal operation. STOP.
Repair: If both of the resistance measurements • NOT OK – The CID 1473 FMI 08 is active. The
are not correct, there is an open connection or a diagnostic code has not been corrected.
bad connection on the sensor side of the splice of
the machine harness for the signal wire U740-BU. Repair: Check the circuit again. Use the Caterpillar
Refer to the complete Electrical System Schematic in order to perform a wiggle test on the machine
of the machine. Check all of the connectors wiring harness. The wiggle test can detect
that are in the sensor signal circuit. Ensure that momentary or intermittent shorts or opens in the
all connections are clean, that all connectors machine wiring harness.
condition.
364 RENR9004-07
If the cause of the active diagnostic code is not i02920617

code may have failed. MID 027 - CID 1472 - FMI 14
If both the Transmission/Chassis ECM and the SMCS Code: 5737-038-ZH
code, it is very unlikely that either ECM is causing Conditions Which Generate This Code:
the problem.


Replace”.
STOP.
g01291021
Illustration 250
Connections of “Left Joystick Steering” Sensors
RENR9004-07 365
Three steering sensors are required for correct Note: The Transmission/Chassis ECM (MID 027)
operation of the steering control. The steering and the Implement ECM (MID 082) receive an
sensors are located in the assembly of the left input signal from the “steering sensor 1”. Both ECM
joystick. Each sensor provides an input signal to the modules can activate a CID 1472 FMI 14 diagnostic
ECM. The ECM expects the input signals from all code when the signal from one steering sensor does
three steering sensors to match very closely. The not closely match the signal from one of the other
FMI 14 diagnostic code is active when the ECM steering sensors and the sensor does match the
determines that the PWM input signal from the signal from the third steering sensor.
“steering position sensor 2” does not match the PWM If one ECM has activated a CID 1472 FMI 14
input signal from one of the other steering sensors. diagnostic code and the other ECM has not, it is
However, the signal of the “steering position sensor likely that the sensor is operating correctly. When this
2” does match with the third sensors signal. occurs, a poor connection in the machine harness
would be suspected.
The “steering position sensor 2” receives power When both ECM modules have activated the
from the 8 volt power supply of the Implement ECM. diagnostic code, either the sensor or a harness
“Steering position sensor 2” is connected to ground at problem could be the cause.
the 8 volt sensor return for the Transmission/Chassis If both ECM modules have activated the diagnostic
ECM (ground of the ECM) and the 8 volt sensor code, it is very unlikely that either ECM is causing the
return of the Implement ECM(ground of the ECM). problem.
The steering sensor must lose the 8 volt power For either condition, proceed with this procedure in
supply or both grounds in order to lose power. The order to verify the cause of the problem.
connections for “steering position sensor 2”. Note: Before performing this procedure, inspect
The position sensor is a PWM sensor that operates circuit. Poor connections can often be the cause
at a frequency of approximately 500 ± 80 hertz. The of a problem in an electrical circuit. Verify that
position sensor sends a PWM input signal to the all connections in the circuit are clean, that all
Implement ECM and to the Transmission/Chassis connections are secure and that all connections
ECM. The duty cycle of the signal will vary from are in good condition. If a problem with a
approximately 10% at the full left position of the lever connection is found, correct the problem and
to approximately 90% at the full right position of the verify that this diagnostic code is active before
lever. When the lever is in the center position, the performing this procedure.
duty cycle will be approximately 50%.
The possible causes of this diagnostic code are listed diagnostic codes. Ignore these created diagnostic
below: codes and clear the diagnostic codes when the
Note: The next three test steps will measure the
• The ECM has failed. This is unlikely. duty cycle of each steering sensor in order to
determine if one signal is not closely matching
Note: Before performing this procedure, check for an with both of the other sensor signals. Record
active MID 027 CID 0041 diagnostic code at the 8 the duty cycle of the sensor for each of the three
volt power supply of the Transmission/Chassis ECM. sensors for comparison.
before performing this procedure. Test Step 1. CHECK THE SIGNAL AT
STEERING SENSOR 1
Note: The correct operating temperature range for
the steering sensors is −40 °C (−40.0 °F) to 75 °C A. Turn the key start switch and the disconnect
(167.0 °F). If an FMI 03, FMI 08 or FMI 14 diagnostic switch to the OFF position.
code becomes active for a steering sensor when the
cab environment is at extreme temperatures, reduce B. Do not disconnect the harness connector from the
temperature of the cab environment. Reducing the sensor.
temperature of the cab will keep the steering sensors
operating in the acceptable temperature range. After C. At the machine harness connector J1 for the
the temperature has returned to normal, verify that left joystick, use a 151-6320 Removal Tool to
the CID 1472 FMI 14 diagnostic code is active before remove the signal wire of “steering sensor 1” (wire
performing this procedure. U739-BR) and the socket at contact J1-2. The
machine harness connector J1 remains connected
to the connector of the left joystick.
366 RENR9004-07
D. At the back of the connector of the joystick J1, Results:

contact of the sensor signal J1-2 and the return • OK – The duty cycle has been recorded for
contact at J1-4. comparison with the other two steering sensors.
E. Turn the disconnect switch and the key start machine harness connector for the joystick before
switch to the ON position. proceeding to the next test step. Proceed to Test
Step 3.
F. Monitor the signal of the sensor with a digital
multimeter. Test Step 3. CHECK THE SIGNAL AT
STEERING SENSOR 3
G. Move the joystick through the full range of
operation. Record the duty cycle of the sensor at Turn the key start switch and the disconnect switch
specific positions of the joystick. to the OFF position.
Expected Result: A. At the machine harness connector J3 for the left

The duty cycle of the “steering sensor 1” has been the “steering sensor 3” signal wire U741-OR
noted at specific positions of the joystick. and the socket at contact J3-1 from the harness
connector. The machine harness connector J3
Results: remains connected to the connector of the left
joystick.
• OK – The duty cycle has been recorded for
comparison with the other two steering sensors. B. At the back of the connectors of the joystick J1
Reconnect the signal wire and the socket in the and J3, insert 7X-1710 Multimeter Probes along
machine harness connector for the joystick before the sensor signal contact J3-1 and the return
proceeding to the next test step. Proceed to Test contact at J3-3.
Step 2.
Test Step 2. CHECK THE SIGNAL AT switch to the ON position.
SENSOR 2
D. Monitor the signal of the sensor with a digital
Turn the key start switch and the disconnect switch multimeter.
E. Move the joystick through the full range of
A. At the machine harness connector J1 for the left operation. Record the duty cycle of the sensor at
joystick, use a 151-6320 Removal Tool to remove specific positions of the joystick.
the signal wire of “steering sensor 2” U740-BU
and the socket at contact J1-7 from the harness Expected Result:
connector. The machine harness connector J1
remains connected to the connector of the left After comparison of the duty cycles of all three
joystick. steering sensors at the same specific positions of the
joystick, each duty cycle of the sensor is within 5% or
B. At the back of the connector of the joystick J1, less of the signals from the other sensors.
contact of the sensor signal J1-7 and the return Results:
contact at J1-8.
• OK – There is a 5% or less deviation between
C. Turn the disconnect switch and the key start the PWM duty cycle signals for the three steering
switch to the ON position. sensors with the joystick in the same position.
multimeter. • NOT OK – When the joystick is the same position,
one or more of the PWM duty cycle signals
E. Move the joystick through the full range of deviates more than 5% when compared to the
operation. Record the duty cycle of the sensor at signals from the other two steering sensors. There
specific positions of the joystick. is a problem with a steering sensor.
Expected Result:
The duty cycle of the “steering sensor 2” has been

noted at specific positions of the joystick.
RENR9004-07 367
Repair: One of the steering sensors is not If the ECM must be replaced, refer to Testing and
operating correctly. Replace the assembly of the Adjusting, “Electronic Control Module (ECM) -
left joystick. After replacement of the assembly Replace”.
of the joystick, verify that the new assembly is
working correctly before operating the machine. STOP.
STOP.
i02921007
Test Step 4. CHECK THE STATUS OF THE MID 027 - CID 1473 - FMI 02
DIAGNOSTIC CODE
contacts of the harness connectors. Check the Conditions Which Generate This Code:



diagnostic code.
Expected Result:
Results:


corrected.
Repair: If the cause of the active diagnostic code


the problem.

g01260039
Illustration 251
368 RENR9004-07
Three steering position sensors are required for Note: The Transmission/Chassis ECM (MID 027)
correct operation of the steering control. The steering and the Implement ECM (MID 082) receive an
position sensors are located in the assembly of the input signal from the “steering sensor 3”. Both ECM
left joystick. Each sensor provides an input signal to modules can activate a CID 1473 FMI 02 diagnostic
the Implement ECM and to the Transmission/Chassis code when the signal is erratic or intermittent.
ECM. This diagnostic code is recorded when the If one ECM has activated a CID 1473 FMI 02
ECM reads the input signal from the “steering position diagnostic code and the other ECM has not, it is
sensor 3” and the signal is erratic or intermittent. likely that the sensor is operating correctly. When this
The “steering position sensor 3” receives power from would be suspected.
the 8 volt power supply of the Transmission/Chassis When both ECM modules have activated the
ECM. The “steering sensor 3” is internally connected diagnostic code, either the sensor or a harness
to the ground from the 5 volt sensor return of the problem could be the cause.
Transmission/Chassis ECM (ground of the ECM) and If both ECM modules have activated the diagnostic
to the ground from the 5 volt sensor return of the code, it is very unlikely that either ECM is causing the
Transmission/Chassis ECM (ground of the ECM). problem.
The steering sensor must lose the 8 volt power For either condition, proceed with this procedure in
supply or both grounds in order to lose power. The order to verify the cause of the problem.
connections for steering position sensor 3. Before performing this procedure, inspect the
The position sensor is a PWM sensor that operates at circuit. Poor connections can often be the cause
a frequency of approximately 500 hertz. The position of a problem in an electrical circuit. Verify that
sensor sends a PWM input signal to the Implement all connections in the circuit are clean, that all
ECM and to the Transmission/Chassis ECM. The connections are secure and that all connections
duty cycle of the signal will vary from approximately are in good condition. If a problem with a
10 ± 5% at the full left position of the joystick to connection is found, correct the problem and
approximately 90 ± 5% at the full right position of the verify that this diagnostic code is active before
joystick. When the joystick is in the center position, performing this procedure.
The possible causes of this diagnostic code are listed diagnostic codes. Ignore these created diagnostic
below: codes and clear the diagnostic codes when the
• Intermittent connections or poor connections exist POWER SUPPLY
in the sensor circuit.
• The signal circuit is shorted to another circuit in the switch to the ON position.
machine harness.
B. At the machine harness connectors for the left
• The ECM has failed. This is unlikely. joystick, insert 7X-1710 Multimeter Probes
along the contact for the power supplyJ3-2 (wire
Consider the following points when this code is T998-BR) and along ground 3 contact J1-3 (wire
active: L731-BR). Do not disconnect the machine harness
from the connectors of the joystick.
Note: Before this procedure is performed, check for
an active MID 027 CID 0041 diagnostic code for the 8 C. Measure the DC voltage of the sensor power
volt sensor power supply of the Transmission/Chassis supply.
ECM. Correct any problem with the 8 volt power
supply before performing this procedure. D. Reposition the multimeter probe that is along
ground 3 contact J1-3 (wire L731-BR) to along
ground 4 contact J3-3 (wire 998-BR). The other
multimeter probe remains positioned along the
contact of the power supply J3-2 (wire T998-BR).
E. Measure the DC voltage of the sensor power

supply.
RENR9004-07 369
Expected Result: C. Turn the disconnect switch and the key start
Both of the voltage measurements are approximately
8.0 ± 0.4 VDC. D. Measure the duty cycle of the sensor at the
connector contacts of the joystick J3-1 and J3-3.
Results: Move the joystick through the full range of the
• OK – Both of the voltage measurements procedure.
are approximately 8.0 ± 0.4 VDC. The
Transmission/Chassis ECM power supply for the Expected Result:
sensor is correct. Proceed to Test Step 2.
The duty cycle of the steering sensor 3 is correct
• NOT OK – One or both of the voltage according to the description at the beginning of this
measurements is not 8.0 ± 0.4 VDC. The procedure.
Transmission/Chassis ECM power supply for the
sensor is not correct. Results:
Repair: Either both of the wires for the sensor • OK – The duty cycle of the sensor is correct. The
ground or the sensor supply circuit is faulty. sensor is not the cause of the problem.
NOTE: If one of the voltage measurements Reinstall the signal wire U741-OR and the socket
is correct and the other measurement is not back to the original location at contact J3-1 in the
correct, one of the ground circuits is faulty. machine harness connector for the joystick. Verify
This condition will not cause this code to that all of the wires of the joystick are in the correct
activate, however, the faulty ground circuit locations. Secure the connector before proceeding
must be repaired before proceeding with this to the next step.
procedure.
of the machine . Examine all of the connectors that • NOT OK – The duty cycle of the steering sensor
are in the circuits. Ensure that the connections are 3 is not correct according to the description at the
clean, that the connectors are secure and that the beginning of this procedure. The sensor has failed.
connectors are in good condition.
For troubleshooting the power supply of the verify that the sensor signal is not correct.
Transmission/Chassis ECM, refer to the CID 0041
diagnostic code procedures in the troubleshooting If the steering sensor 3 signal is not correct
section of the manual for the Transmission/Chassis according to the description at the beginning of this
ECM. procedure, replace the assembly of the left joystick.
After replacement of the assembly of the joystick,
Repair the faulty power supply circuit before verify that the operation of the new assembly of the
proceeding with this procedure. joystick is correct before operating the machine.
STOP. STOP.
Test Step 2. CHECK THE SIGNAL AT THE Test Step 3. CHECK THE SIGNAL AT
SENSOR BOTH OF THE ECM MODULES
The key start switch and the disconnect switch A. Turn the key start switch and the disconnect
remain in the OFF position. switch to the OFF position.
A. At the machine harness connector J3 for the left B. At the machine harness connector J1 for the
joystick, use a 151-6320 Removal Tool to remove Implement ECM, insert a multimeter probe along
the signal wire U741-OR and the socket at contact return contact J1-21 (998-BR). At the machine
J3-1 from the harness connector. The machine harness connector J2 for the Implement ECM,
harness connector J3 remains connected to the insert a multimeter probe along signal contact
connector of the left joystick. J2-34 (wire U741-OR). The machine harness
connectors remain connected to the ECM.
B. At the back of the connectors for the joystick J3
and J1, insert 7X-1710 Multimeter Probes along C. Turn the key start switch and the disconnect
the sensor signal contact J3-1 and the ground 4 switch to the ON position.
contact at J3-3.
370 RENR9004-07
D. Measure the duty cycle of the sensor at the • NOT OK – The duty cycle of the steering sensor
connector contacts of the ECM J1-21 and J2-34. 3 is not correct at either of the ECM modules
Move the joystick through the full range of the according to the description at the beginning of
sensor that is described at the beginning of this this procedure. Most likely the problem is in the
procedure. machine harness. Proceed to Test Step 4.
Transmission/Chassis ECM, insert a multimeter CIRCUIT FOR A SHORT
probe along return contact J1-21 (L731-BR). At the
machine harness connector J2 for the Implement Turn the key start switch and the disconnect switch
ECM, insert a multimeter probe along the contact to the OFF position.
for the signal wire J2-34 (wire U741-OR). The
machine harness connectors remain connected A. Disconnect the J1 and the J2 connectors from the
to the ECM. Implement ECM.
connector contacts of the ECM J1-21 and J2-34. Implement ECM, measure the resistance from the
Move the joystick through the full range of the sensor signal contact J2-34 (wire U741-OR) to all

next test step.
Results:
D. Disconnect the J1 and the J2 connectors from the
• OK – The duty cycle of the sensor is correct at Transmission/Chassis ECM.
intermittent open or the short could still be causing Transmission/Chassis ECM, measure the
J2-34 (wire U741-OR) to all of the other
• NOT OK – The duty cycle of the steering sensor 3 J1 and J2 contacts that are used for the
is not correct at one or both of the ECM modules Transmission/Chassis ECM.
harness.
suspected.
The steering sensor 3 signal at one of the ECM than 5000 ohms. The resistance checks of the
modules is not correct. signal circuit do not indicate a short in the machine
of the machine. Examine all of the connectors • NOT OK – A resistance measurement is less than
that are in the section of the sensor signal circuit 5000 ohms.
that connects to the ECM that is not receiving
a good signal. Verify that the connections are Repair: There is a short in the machine harness.
clean, that the connections are secure and that The short is between the signal circuit and the
the connections are in good condition. Repair the circuit with the low resistance measurement.
RENR9004-07 371
For information on testing for short circuits and Exit this procedure and perform this procedure
finding short circuits, refer to Testing and Adjusting, again. If the cause of the failure is not found,
“Wiring Harness (Short Circuit) - Test”. Repair the contact your dealership's Technical Communicator
machine harness or replace the machine harness. for possible consultation with Caterpillar. This
STOP.





is active.
Expected Result:
Results:


corrected.


found, the ECM that has activated the diagnostic

the problem.
372 RENR9004-07
i02921015 Three steering sensors are required for correct

operation of the steering control. The steering
MID 027 - CID 1473 - FMI 03 sensors are located in the assembly of the left
SMCS Code: 5737-038-ZH Implement ECM and to the Transmission/Chassis
ECM. This diagnostic code is recorded when the
Conditions Which Generate This Code: ECM reads the input signal from the “steering
position sensor 3” and the voltage of the signal is
above normal.
The “steering position sensor 3” receives power from

the 8 volt power supply of the Transmission/Chassis
ECM. The “steering sensor 3” is connected
to ground at the 5 volt sensor return of the
Transmission/Chassis ECM (ground of the ECM) and
ECM (ground of the ECM). The steering sensor must
lose the 8 volt power supply or both grounds in order
to lose power. The illustration above indicates the
power and ground connections for “steering position
sensor 3”.
The position sensor is a PWM sensor that operates at

sensor sends a PWM input signal to the Implement
ECM and to the Transmission/Chassis ECM. The
duty cycle of the signal will vary from approximately
10 ± 5% at the full left position of the joystick to
joystick. When the joystick is in the center position,

below:
• The power supply circuit for the sensor is faulty.

• The return circuit of the sensor is open.
• The signal circuit is open.
• The signal circuit is shorted to a voltage source.
Consider the following points when this code is
active:
Perform this procedure after checking for an active

MID 027 CID 0041 diagnostic code for the 8 volt
sensor power supply of the Transmission/Chassis
Illustration 252
g01260039 supply before performing this procedure.
RENR9004-07 373
Note: The correct operating temperature range for D. Reposition the multimeter probe that is along
the steering sensors is −40 °C (−40.0 °F) to 75 °C ground 3 contact J1-3 (wire L731-BR) to along
(167.0 °F). If an FMI 03 or an FMI 08 diagnostic code ground 4 contact J3-3 (wire 998-BR). The other
becomes active for a steering sensor when the cab multimeter probe remains positioned along the
environment is at extreme temperatures, reduce the contact for the power supply J3-2 (wire T998-BR).
temperature of the cab environment in order to keep
the steering sensors operating in the acceptable E. Measure the DC voltage of the sensor power
temperature range. After reducing the temperature, supply.
verify that the CID 1473 FMI 03 diagnostic code is
active before performing this procedure. Expected Result:
Note: The Transmission/Chassis ECM (MID 027) Both of the voltage measurements are approximately
and the Implement ECM (MID 082) receive an 8.0 ± 0.4 VDC.
input signal from the “steering sensor 3”. Both ECM
modules can activate a CID 1473 FMI 03 diagnostic Results:
code when the signal is erratic or intermittent.
If one ECM has activated a CID 1473 FMI 03 • OK – Both of the voltage measurements are
diagnostic code and the other ECM has not, it is approximately 8.0 ± 0.4 VDC. The power supply
likely that the sensor is operating correctly. When this for the Transmission/Chassis ECM for the sensor
occurs, a poor connection in the machine harness is correct. Proceed to Test Step 2.
would be suspected.
When both ECM modules have activated the • NOT OK – One or both of the voltage
diagnostic code, either the sensor or a harness measurements is not 8.0 ± 0.4 VDC. The power
problem could be the cause. supply for the Transmission/Chassis ECM for the
If both ECM modules have activated the diagnostic sensor is not correct.
problem. Repair: Either the circuit for the ground connection
For either condition, proceed with this procedure in of the sensor or the circuit for the supply connection
order to verify the cause of the problem. of the sensor is faulty.
Before performing this procedure, inspect the NOTE: If one of the voltage measurements
harness connectors that are involved in the is correct and the other measurement is not
circuit. Poor connections can often be the cause correct, one of the ground circuits is faulty.
of a problem in an electrical circuit. Verify that This condition will not cause this code to
all connections in the circuit are clean, that all activate. However, the faulty ground circuit
connections are secure and that all connections must be repaired before proceeding with this
are in good condition. If a problem with a procedure.
verify that this diagnostic code is active before Refer to the complete Electrical System Schematic
performing this procedure. of the machine. Examine all of the connectors that
are in the circuits. Ensure that the connections are
Note: The following test procedure may create other clean, that all connectors are secure and that all
diagnostic codes. Ignore these created diagnostic connections are good condition.
problem has been corrected. For troubleshooting the power supply of the
Transmission/Chassis ECM, refer to the CID 0041
Test Step 1. CHECK THE SENSOR diagnostic code procedures in the troubleshooting
POWER SUPPLY section of the manual for the Transmission/Chassis
ECM.
switch to the ON position. Repair the faulty power supply circuit before
B. At the J3 and J1 harness connectors for the left
joystick, insert 7X-1710 Multimeter Probes along STOP.
the power supply contact J3-2 (wire T998-BR)
and along ground 2 contact J1-4 (wire X800-OR). Test Step 2. CHECK FOR AN OPEN IN
Do not disconnect the machine harness from the THE SENSOR CIRCUIT AT BOTH OF THE
connectors of the joystick. ECM MODULES
C. Measure the DC voltage of the sensor power A. Turn the key start switch and the disconnect
supply. switch to the OFF position.
374 RENR9004-07
B. Disconnect the machine harness connectors Refer to the complete Electrical System Schematic
J3 and J1 from the left joystick. At the harness of the machine. Check all of the connectors
connectors for the joystick, place a jumper wire that are in the sensor signal circuit. Ensure that
between the contact for the signal J3-1 (wire all connections are clean, that all connections
U741-OR) and the ground 3 contact J1-3 (wire are secure and that all connections are in good
L731-BR) . condition. Repair the machine harness or replace
J2 from the Transmission/Chassis ECM. If one of the measurements is correct and the other
measurement is not correct, there is an open or a
D. At the harness connector for the Transmission/ bad connection on the ECM side of the splice of
Chassis ECM, measure the resistance from return the machine harness for the signal wire U741-OR.
contact J1-21 (wire L731-BR) to signal contact
J2-34 (wire U741-OR). In either case, refer to the complete Electrical
E. Observe the resistance measurement and wiggle connectors that are in the suspected section of the
the ECM connector and the sensor connector. sensor signal circuit. Ensure that all connections
Gently pull on the wires and wiggle the wires for are clean, that all connections are secure and that
both connectors. all connections are in good condition. Repair the
F. At the harness connectors for the joystick, move
the jumper wire from the ground 3 contact and STOP.
connect the jumper wire to ground 4 contact J3-3
(wire 998-BR). The other end of the jumper wire Test Step 3. CHECK THE SIGNAL
remains connected to the signal contact J3-1 (wire CIRCUIT FOR A SHORT
U741-OR).
G. Disconnect machine harness connectors J1 and remain in the OFF position. The machine harness
J2 from the Implement ECM. connectors remain disconnected from the Implement
ECM and the Transmission/Chassis ECM.
H. At the harness connector for the Implement
ECM, measure the resistance from return contact A. Remove the jumper wire that was installed in the
J1-21 (wire 998-BR) to signal contact J2-34 (wire last step at the connector of the joystick.
U741-OR).
B. At the J2 machine harness connector for the
I. Observe the resistance measurement and wiggle Implement ECM, measure the resistance from the
the ECM connector and the sensor connector. sensor signal contact J2-34 (wire U741-OR) to all
Gently pull on the wires and wiggle the wires for of the other J1 and J2 contacts that are used for
both connectors. the Implement ECM.
Expected Result: C. At the J2 machine harness connector for the

Both resistance measurements are less than 5 ohms resistance from the sensor signal contact
at all times during the manipulation of the wiring J2-34 (wire U741-OR) to all of the other
harness and connectors. J1 and J2 contacts that are used for the
Results:
Expected Result:
less than 5 ohms. The sensor circuit is not open Each resistance measurement is greater than 5000
in either input circuit of the ECM. Proceed to Test ohms.
Step 3.
Results:
both of the ECM modules is greater than 5 ohms. • OK – Each resistance measurement is greater
There is an open or a bad connection in one or than 5000 ohms. The resistance checks for the
both of the signal circuits. signal circuit do not indicate a short in the machine
Repair: If both of the resistance measurements
are not correct, there is an open connection or a • NOT OK – A resistance measurement is less than
bad connection on the sensor side of the splice of 5000 ohms.
the machine harness for the signal wire U741-OR.
RENR9004-07 375
Repair: There is a short in the machine harness. Results:

The short is between the signal circuit and the
circuit with the low resistance measurement. • OK – The duty cycle of the sensor is correct. The
sensor is not the cause of the problem.
of the machine. Check all of the connectors that are Reinstall the signal wire U741-OR and the socket
in the sensor circuit. Ensure that all connections back to the original location at contact J3-1 in the
are clean, that all connections are secure and that machine harness connector for the joystick. Verify
all connections are in good condition. that all of the wires of the joystick are in the correct
locations. Secure the connector before proceeding
For information on testing for short circuits and to the next step.
“Wiring Harness (Short Circuit) - Test”. Repair the Proceed to Test Step 5.
• NOT OK – The duty cycle of the steering sensor
STOP. 3 is not correct according to the description at the
beginning of this procedure. The sensor has failed.
SENSOR Repair: Perform this test step again in order to
remain in the OFF position. If the “steering sensor 3” signal is not correct
A. Reconnect the machine harness connectors J1 procedure, replace the assembly of the left joystick.
and J2 to both ECM modules. After replacement of the assembly of the joystick,
B. Reconnect the machine harness connectors of the joystick is correct before operating the machine.
left joystick that are disconnected.
STOP.
C. At the machine harness connector J3 for the left
joystick, use a 151-6320 Removal Tool to remove Test Step 5. CHECK THE STATUS OF THE
the signal wire U741-OR and the socket at contact DIAGNOSTIC CODE
J3-1 from the harness connector. The machine
harness connector J3 remains connected to the A. Inspect the harness connectors. Clean the
connector of the left joystick. contacts of the harness connectors. Check the
D. At the back of the connectors of the joystick J3 by excessive heat, battery acid, or chafing.
and J1, insert 7X-1710 Multimeter Probes along
the sensor signal contact J3-1 and the ground 3 B. Perform a 45 N (10 lb) pull test on each of the
contact at J1-3. wires that are associated with the sensor circuit.
E. Turn the disconnect switch and the key start C. Reconnect all harness connectors. Make sure that
switch to the ON position. the connectors are fully seated. Observe that the
F. Measure the duty cycle of the sensor at the
connector contacts of the joystick J3-1 and J1-3. D. Turn the disconnect switch and the key start
Move the joystick through the full range of the switch to the ON position.
procedure. E. Operate the machine.
Expected Result: F. Determine if the CID 1473 FMI 03 diagnostic code

is active.
The duty cycle of the steering sensor 3 is correct
according to the description at the beginning of this Expected Result:
procedure.
376 RENR9004-07
Results: i02921110
this time. The initial diagnostic code was probably SMCS Code: 5737-038-ZH

corrected.



the problem.


Replace”.
STOP.
g01260039
Illustration 253
RENR9004-07 377
Three steering position sensors are required for Note: The Transmission/Chassis ECM (MID 027)
correct operation of the steering control lever. and the Implement ECM (MID 082) receive an
The steering position sensors are located in the input signal from the “steering sensor 3”. Both ECM
assembly of the left joystick. Each sensor provides modules can activate a CID 1473 FMI 04 diagnostic
an input signal to the Implement ECM and to the code when the signal voltage is below normal.
Transmission/Chassis ECM. This diagnostic code is If one ECM has activated a CID 1473 FMI 04
recorded when the ECM reads the signal from the diagnostic code and the other ECM has not, it is
“steering position sensor 3” and the voltage of the likely that the sensor is operating correctly. When this
signal is below normal. occurs, a poor connection in the machine harness
would be suspected.
The “steering position sensor 3” receives power from When both ECM modules have activated the
the 8 volt power supply of the Transmission/Chassis diagnostic code, either the sensor or a harness
ECM. The “steering sensor 3” is connected problem could be the cause.
to ground at the 5 volt sensor return of the If both ECM modules have activated the diagnostic
Transmission/Chassis ECM (ground of the ECM) and code, it is very unlikely that either ECM is causing the
the 5 volt sensor return of the Transmission/Chassis problem.
ECM (ground of the ECM). The steering sensor must For either condition, proceed with this procedure in
lose the 8 volt power supply or both grounds in order order to verify the cause of the problem.
power and ground connections for “steering position Note: Before performing this procedure, inspect
sensor 3”. the harness connectors that are involved in the
The “steering sensor 3” receives power from the 8 of a problem in an electrical circuit. Verify that
volt power supply of the Transmission/Chassis ECM. all connections in the circuit are clean, that all
The “steering sensor 3” is connected to ground at connections are secure and that all connections
the 5 volt sensor return of the Transmission/Chassis are in good condition. If a problem with a
ECM (ground of the ECM) and the 8 volt sensor connection is found, correct the problem and
return of the Transmission/Chassis ECM (ground verify that this diagnostic code is active before
of the ECM). The steering sensor must lose the 8 performing this procedure.
volt power supply or both grounds in order to lose
power. The illustration above indicates the power and Note: The following test procedure may create other
ground connections for “steering sensor 3”. diagnostic codes. Ignore these created diagnostic
The position sensor is a PWM sensor that operates problem has been corrected.
position sensor sends a PWM input signal to the Test Step 1. CHECK THE SENSOR
ECM. The duty cycle of the signal will vary from A. Turn the disconnect switch and the key start
approximately 10 ± 5% at the full left position of the switch to the ON position.
position of the joystick. When the joystick is in the B. Disconnect the machine harness connector J3
center position, the duty cycle will be approximately from the left joystick. Observe the status of the
50%. active CID 1473 FMI 04 diagnostic code.
The possible causes of this diagnostic code are listed Expected Result:
below:
• The signal circuit is shorted to a ground source. did not change when the connector of the joystick
was disconnected. A CID 1473 FMI 03 diagnostic
• The sensor has failed. code has not been activated by either the Implement
ECM or the Transmission/Chassis ECM. The CID
• The ECM has failed. This is unlikely. 1473 FMI 04 diagnostic code remains active when
the connector of the joystick is disconnected.
active MID 027 CID 0041 diagnostic code for the 8 Results:
volt sensor power supply of the Transmission/Chassis
ECM. Correct any problem with the 8 volt power • YES – The CID 1473 FMI 04 diagnostic code
supply before performing this procedure. remains active when the connector of the joystick
problem. Proceed to Test Step 2.
378 RENR9004-07
• NOT OK – The CID 1473 FMI 04 diagnostic Repair: There is a short in the machine harness.
code is no longer active when the connector of The short is between the signal circuit and the
the joystick is disconnected. A CID 1473 FMI 03 frame ground or the circuit with the low resistance
diagnostic code has been activated by both of the measurement.
ECM modules when the connector of the joystick is
disconnected. The machine harness and the ECM Refer to the complete Electrical System Schematic
are operating correctly. of the machine. Check all of the connectors that are
Repair: The “steering sensor 3” is causing the are clean, that all connections are secure and that
problem. There is an internal short to ground in all connections are in good condition.
the left joystick. Replace the assembly of the left
joystick. After replacement of the assembly of For information on testing for short circuits and
the joystick, verify that the operation of the new finding short circuits, refer to Testing and Adjusting,
assembly of the joystick is correct before operating “Wiring Harness (Short Circuit) - Test”. Repair the
the machine. machine harness or replace the machine harness.
STOP. STOP.
Test Step 2. CHECK THE SIGNAL Test Step 3. CHECK THE STATUS OF THE
CIRCUIT FOR A SHORT TO GROUND DIAGNOSTIC CODE
A. The connector of the joystick J3 remains A. Inspect the harness connectors. Clean the
disconnected from the machine harness. contacts of the harness connectors. Check the
B. Turn the key start switch and the disconnect by excessive heat, battery acid, or chafing.
C. Disconnect the J1 and J2 machine harness wires that are associated with the sensor circuit.
connectors from the Implement ECM.
D. Disconnect the J1 connector and the J2 connector the connectors are fully seated. Observe that the
from the Transmission/Chassis ECM. clips for each connector are completely fastened.
E. At machine harness connector J2 for the D. Turn the disconnect switch and the key start
Implement ECM, measure the resistance from switch to the ON position.
contact J2-34 (wire U741-OR) to frame ground.
Measure the resistance from contact J2-34 (wire E. Operate the machine.
U741-OR) to all of the other J1 and J2 contacts
that are used for the Implement ECM. F. Determine if the CID 1473 FMI 04 diagnostic code
is active.
F. At the J2 machine harness connector for the
Transmission/Chassis ECM, measure the Expected Result:
resistance from the sensor signal contact J2-34
(wire U741-OR) to frame ground and measure the The CID 1473 FMI 04 diagnostic code is not active.
resistance to all of the other J1 and J2 contacts
that are used for the Transmission/Chassis ECM. Results:
Expected Result: • OK – The CID 1473 FMI 04 diagnostic code is

Each resistance measurement is greater than 5000 this time. The initial diagnostic code was probably
ohms. caused by a poor connection or a short at one
Results: reconnected. Resume normal operation. STOP.
• OK – Each resistance measurement is greater • NOT OK – The CID 1473 FMI 04 diagnostic
than 5000 ohms. The resistance checks for the code is active. The diagnostic code has not been
signal circuit do not indicate a short in the machine corrected.

RENR9004-07 379
Repair: Check the circuit again. Use the Caterpillar i02921131

in order to perform a wiggle test on the machine MID 027 - CID 1473 - FMI 08
momentary or intermittent shorts or opens in the SMCS Code: 5737-038-ZH

the problem.


Replace”.
STOP.
g01260039
Illustration 254
Connections for “Steering Sensor 3”
380 RENR9004-07
Three steering position sensors are required for Note: The Transmission/Chassis ECM (MID 027) and
correct operation of the steering control. The steering the Implement ECM (MID 082) receive an input signal
position sensors are located in the assembly of the from the “steering sensor 3”. Both ECM modules can
left joystick. Each sensor provides an input signal to activate a CID 1473 FMI 08 diagnostic code when the
the Implement ECM and to the Transmission/Chassis ECM has detected that the signal frequency or the
ECM. This diagnostic code is associated with the signal pulse width is not within the expected range.
“steering position sensor 3”. The FMI 08 means that If one ECM has activated a CID 1473 FMI 08
the ECM has detected that the signal frequency or diagnostic code and the other ECM has not, it is
that the signal pulse width is not within the expected likely that the sensor is operating correctly. When this
range. occurs, a poor connection in the machine harness
would be suspected.
The “steering position sensor 3” receives power from When both ECM modules have activated the
the 8 volt power supply of the Transmission/Chassis diagnostic code, either the sensor or a harness
ECM. The “steering sensor 3” is connected problem could be the cause.
to ground at the 5 volt sensor return of the If both ECM modules have activated the diagnostic
Transmission/Chassis ECM (ground of the ECM) and code, it is very unlikely that either ECM is causing the
the 5 volt sensor return of the Transmission/Chassis problem.
ECM (ground of the ECM). The steering sensor must For either condition, proceed with this procedure in
lose the 8 volt power supply or both grounds in order order to verify the cause of the problem.
power and ground connections for “steering position Before performing this procedure, inspect the
sensor 3”. harness connectors that are involved in the
The position sensor is a PWM sensor that operates of a problem in an electrical circuit. Verify that
at a frequency of 500 ± 80 Hz. The position sensor all connections in the circuit are clean, that all
sends a PWM input signal to the Implement ECM and connections are secure and that all connections
to the Transmission/Chassis ECM. The duty cycle of are in good condition. If a problem with a
the signal will vary from approximately 10 ± 5% at the connection is found, correct the problem and
full left position of the joystick to approximately 90 ± verify that this diagnostic code is active before
5% at the full right position of the joystick. When the performing this procedure.
joystick is in the center position, the duty cycle will be
approximately 50%. Note: The following test procedure may create other
The possible causes of this diagnostic code are listed codes and clear the diagnostic codes when the
below: problem has been corrected.
• The sensor has failed. Test Step 1. CHECK THE DUTY CYCLE
AND THE SIGNAL FREQUENCY AT THE
• Intermittent connections or poor connections in the SENSOR
sensor circuit
• The ECM has failed. This is unlikely. to the OFF position.
Consider the following points when this code is A. At the machine harness connector J3 for the
active: left joystick, use a 151-6320 Removal Tool to
remove the signal wire (wire U741-OR) and the
Note: Before performing this procedure, check for an socket at contact J3-1. The machine harness
active MID 027 CID 0041 diagnostic code for the 8 connector J3 remains connected to the connector
volt sensor power supply of the Transmission/Chassis of the left joystick.
supply before performing this procedure. B. At the back of the connectors for the joystick J3
and J1, insert 7X-1710 Multimeter Probes along
Note: The correct operating temperature range for the sensor signal contact J3-1 and the ground 4
the steering sensors is −40 °C (−40.0 °F) to 75 °C contact at J3-3.
(167.0 °F). If an FMI 03 or an FMI 08 diagnostic code
becomes active for a steering sensor when the cab C. Turn the disconnect switch and the key start
environment is at extreme temperatures, reduce the switch to the ON position.
temperature of the cab environment in order to keep
the steering sensors operating in the acceptable D. With the joystick in a stationary position, measure
temperature range. After the temperature has been the frequency of the signal from the sensor.
reduced, verify that the CID 1473 FMI 08 diagnostic
RENR9004-07 381
E. Observe the measurement and wiggle the B. Disconnect the machine harness connectors
connector of the joystick. Gently pull on the wires J3 and J1 from the left joystick. At the harness
and wiggle the wires. connectors for the joystick, place a jumper wire
between the signal contact J3-1 (wire U741-OR)
F. Measure the duty cycle of the sensor at the and the ground 3 contact J1-3 (wire L731-BR) .
connector of the joystick, contacts J3-1 and J3-3.
Move the joystick through the full range of the C. Disconnect machine harness connectors J1 and
sensor that is described at the beginning of this J2 from the Transmission/Chassis ECM.
procedure.
D. At the harness connector for the Transmission/
G. Observe the measurement and wiggle the Chassis ECM, measure the resistance from return
connector of the joystick. Gently pull on the wires contact J1-21 (wire L731-BR) to signal contact
and wiggle the wires. J2-34 (wire U741-OR).
Expected Result: E. Observe the resistance measurement and wiggle

the ECM connector. Observe that the sensor
The frequency of the “steering sensor 3” signal is 500 connector is tight. Gently pull on the wires and
± 80 Hz. The duty cycle of the “steering sensor 3” is manipulate the wires for both connectors.
correct according to the description at the beginning
of this procedure. The frequency and the duty cycle F. At the harness connectors for the joystick,
are stable during the manipulation of the harness move the jumper from the ground 3 contact.
connector and the wiring. Connect the jumper to ground 4 contact J3-3
(wire 998-BR). The other end of the jumper wire
Results: remains connected to the signal contact J3-1 (wire
U741-OR).
• OK – The signal frequency and the duty cycle
of the sensor are correct and the frequency and G. Disconnect machine harness connectors J1 and
the duty cycle did not change when the harness J2 from the Implement ECM.
is manipulated. The sensor is not causing the
problem. H. At the harness connectors for the Implement
ECM, measure the resistance from return contact
Reconnect the signal wire and the socket in the J1-21 (wire 998-BR) to signal contact J2-34 (wire
machine harness connector for the joystick. Verify U741-OR).
that all wires of the joystick are secure in the
connector. Proceed to the next step. I. Observe the resistance measurement and wiggle
Proceed to Test Step 2. Gently pull on the wires and manipulate the wires
for both connectors.
• NOT OK – The signal frequency and the duty
cycle of the “steering sensor 3” is not correct Expected Result:
procedure. The sensor has failed. Both resistance measurements are less than 5 ohms
Repair: Perform this test step again in order to harness and connectors.
Results:
If the “steering sensor 3” signal is not correct
according to the description at the beginning of this • OK – Both of the resistance measurements are
procedure, replace the assembly of the left joystick. less than 5 ohms. The sensor circuit is not open
After replacement of the assembly of the joystick, in either of the input circuits of the ECM. Proceed
verify that the operation of the new assembly for to Test Step 3.
the joystick is correct before operating the machine.
STOP. both of the ECM modules is greater than 5 ohms.
There is an open or a bad connection in one or
Test Step 2. CHECK FOR AN OPEN IN both of the signal circuits.
THE SENSOR CIRCUIT AT BOTH OF THE
ECM MODULES Repair: If both of the resistance measurements are
not correct, there is an open or a bad connection
A. Turn the key start switch and the disconnect on the sensor side of the splice for the machine
switch to the OFF position. harness of the signal wire U741-OR.
382 RENR9004-07
Refer to the complete Electrical System Schematic Repair: Check the circuit again. Use the Caterpillar
of the machine. Check all of the connectors Electronic Technician (ET) service tool, if available,
that are in the sensor signal circuit. Ensure that in order to perform a wiggle test on the machine
all connections are clean, that all connections wiring harness. The wiggle test can detect
are secure and that all connections are in good momentary or intermittent shorts or opens in the
condition. machine wiring harness.
If one of the measurements is correct and the other If the cause of the active diagnostic code is not
measurement is not correct, there is an open or a found, the ECM that has activated this diagnostic
bad connection on the ECM side of the splice for code may have failed.
the machine harness for the signal wire U741-OR.
In either case, refer to the complete Electrical Implement ECM have activated this diagnostic
System Schematic of the machine. Check all of the code, it is very unlikely that either ECM is causing
connectors that are in the suspect section of the the problem.
are clean, that all connections are secure and that Exit this procedure and perform this procedure
all connections are in good condition. Repair the again. If the cause of the failure is not found,
machine harness or replace the machine harness. contact your dealership's Technical Communicator
STOP. consultation may greatly reduce repair time.
Replace”.



Expected Result:
Results:

initial diagnostic code was probably caused by a

RENR9004-07 383
i02921179 Three steering sensors are required for correct

operation of the steering control. The steering
MID 027 - CID 1473 - FMI 14 sensors are located in the assembly of the left
SMCS Code: 5737-038-ZH Implement ECM and to the Transmission/Chassis
ECM. The ECM expects the input signals from all
Conditions Which Generate This Code: three steering sensors to match very closely. The
FMI 14 diagnostic code is activated when the ECM
determines that the PWM input signal from the
“steering position sensor 3” does not match the PWM
input signal from one of the other steering sensors,
however, the “position sensor 3” signal does match
with the third sensors signal.
The “steering position sensor 3” receives power from

the 8 volt power supply of the Transmission/Chassis
ECM. The “steering sensor 3” is connected
to ground at the 5 volt sensor return of the
Transmission/Chassis ECM (ground of the ECM) and
ECM (ground of the ECM). The steering sensor must
lose the 8 volt power supply or both grounds in order
power and ground connections for “steering position
sensor 3”.

approximately 10% at the full left position of the
joystick to approximately 90% at the full right position
of the joystick. When the lever is in the center

below:

active MID 027 CID 0041 diagnostic code for the 8
volt sensor power supply of the Transmission/Chassis
supply before performing this procedure.
Note: The correct operating temperature range

for the steering sensors is −40 °C (−40.0 °F) to
75 °C (167.0 °F). If an FMI 03, an FMI 08 or an FMI
14 diagnostic code becomes active for a steering
sensor when the cab environment is at extreme
Illustration 255
g01291021 temperatures, reduce the temperature of the cab
environment in order to keep the steering sensors
Connections of “Left Joystick steering Position Sensors”
operating in the acceptable temperature range. After
reducing the temperature in the cab, verify that the
384 RENR9004-07
Note: The Transmission/Chassis ECM (MID 027) Test Step 1. CHECK THE SIGNAL AT
and the Implement ECM (MID 082) receive an STEERING SENSOR 1
input signal from the “steering sensor 3”. Both ECM
modules can activate a CID 1473 FMI 14 diagnostic A. Turn the key start switch and the disconnect
code when the signal is erratic or intermittent. switch to the OFF position.
diagnostic code and the other ECM has not, it is B. Do not disconnect the harness connector from the
likely that the sensor is operating correctly. When this sensor.
would be suspected. C. At the machine harness connector J1 for the left
When both ECM modules have activated the joystick, use a 151-6320 Removal Tool to remove
diagnostic code, either the sensor or a harness the “steering sensor 1” signal wire (wire U739-BR)
problem could be the cause. and the socket at contact J1-2. The machine
If both ECM modules have activated the diagnostic harness connector J1 remains connected to the
code, it is very unlikely that either ECM is causing the connector of the left joystick.
problem.
For either condition, proceed with this procedure in D. At the back of the connector of the joystick J1,
order to verify the cause of the problem. insert 7X-1710 Multimeter Probes along the
sensor signal contact J1-2 and the return contact
Note: The Transmission/Chassis ECM (MID 027) at J1-4.
and the Implement ECM (MID 082) receive an
input signal from the “steering sensor 3”. Both ECM E. Turn the disconnect switch and the key start
modules can activate a CID 1473 FMI 14 diagnostic switch to the ON position.
code when the signal from one steering sensor does
not closely match the signal from one of the other F. Monitor the signal of the sensor with a digital
steering sensors and the signal of the other two does multimeter.
match the signal from the third steering sensor.
If one ECM has activated a CID 1473 FMI 14 G. Move the joystick through the full range of
diagnostic code and the other ECM has not, it is operation. Record the duty cycle of the sensor at
likely that the sensor is operating correctly. When this specific positions of the joystick.
would be suspected. Expected Result:
diagnostic code, either the sensor or a harness The duty cycle of the “steering sensor 1” has been
problem could be the cause. noted at specific positions of the joystick.
code, it is very unlikely that either ECM is causing the Results:
problem.
For either condition, proceed with this procedure in • OK – The duty cycle has been recorded for
order to verify the cause of the problem. comparison with the other two steering sensors.
Note: Before performing this procedure, inspect machine harness connector for the joystick before
the harness connectors that are involved in the proceeding to the next test step. Proceed to Test
circuit. Poor connections can often be the cause Step 2.
all connections in the circuit are clean, that all Test Step 2. CHECK THE SIGNAL AT
connections are secure and that all connections SENSOR 2
connection is found, correct the problem and Turn the key start switch and the disconnect switch
verify that this diagnostic code is active before to the OFF position.
A. At the machine harness connector J1 for the left
Note: The following test procedure may create other joystick, use a 151-6320 Removal Tool to remove
diagnostic codes. Ignore these created diagnostic the “steering sensor 2” signal wire U740-BU
codes and clear the diagnostic codes when the and the socket at contact J1-7 from the harness
problem has been corrected. connector. The machine harness connector J1
remains connected to the connector of the left
Note: The next three test steps will measure the joystick.
duty cycle of each steering sensor in order to
determine if one signal is not closely matching B. At the back of the connector of the joystick J1,
with both of the other sensor signals. Record the insert 7X-1710 Multimeter Probes along the
duty cycle of the sensor signal for each of the sensor signal contact J1-7 and the return contact
three sensors for comparison. at J1-8.
RENR9004-07 385
C. Turn the disconnect switch and the key start Results:

• OK – There is a 5% or less deviation between
D. Monitor the signal of the sensor with a digital the PWM duty cycle signals for the three steering
multimeter. sensors with the joystick in the same position.
E. Move the joystick through the full range of
operation. Record the duty cycle of the sensor at • NOT OK – When the joystick is the same position,
specific positions of the joystick. one or more of the PWM duty cycle signals
deviates more than 5% when compared to the
Expected Result: signals from the other two steering sensors. There
is a problem with a steering sensor.
The duty cycle of the “steering sensor 2” has been
noted at specific positions of the joystick. Repair: One of the steering sensors is not
operating correctly. Replace the assembly of the
Results: left joystick. After replacement of the assembly
of the joystick, verify that the new assembly is
• OK – The duty cycle has been recorded for working correctly before operating the machine.
comparison with the other two steering sensors.
Reconnect the signal wire and the socket in STOP.
the machine harness connector for the joystick.
Proceed to the next test step. Proceed to Test Step Test Step 4. CHECK THE STATUS OF THE
3. DIAGNOSTIC CODE
Test Step 3. CHECK THE SIGNAL AT A. Inspect the harness connectors. Clean the
“STEERING SENSOR 3” contacts of the harness connectors. Check the
Turn the key start switch and the disconnect switch by excessive heat, battery acid, or chafing.
A. At the machine harness connector J3 for the left wires that are associated with the sensor circuit.
the “steering sensor 3” signal wire U741-OR C. Reconnect all harness connectors. Make sure that
and the socket at contact J3-1 from the harness the connectors are fully seated. Observe that the
connector. The machine harness connector J3 clips for each connector are completely fastened.
remains connected to the connector of the left
joystick. D. Operate the machine.
B. At the back of the connectors of the joystick J1 E. Check the status of the CID 1473 FMI 14
and J3, insert 7X-1710 Multimeter Probes along diagnostic code.
the sensor signal contact J3-1 and the return
contact at J3-3. Expected Result:
C. Turn the disconnect switch and the key start The CID 1473 FMI 14 diagnostic code is not active.
Results:
multimeter. • OK – The CID 1473 FMI 14 diagnostic code is
E. Move the joystick through the full range of this time. The initial diagnostic code was probably
operation. Record the duty cycle of the sensor at caused by a poor connection or a short at one
specific positions of the joystick. of the connectors that was disconnected and
Expected Result:
After comparison of the duty cycles of all three code is active. The diagnostic code has not been
steering sensors at the same specific positions of the corrected.
joystick, each duty cycle of the sensor is within 5% or
less of the signals from the other sensors. Repair: If the cause of the active diagnostic code
386 RENR9004-07
If both the Transmission/Chassis ECM and the The CID 1482 FMI 03 diagnostic code is activated
Implement ECM have activated this diagnostic when the Transmission/Chassis ECM detects that
code, it is very unlikely that either ECM is causing the voltage of the 10 volt power supply circuit is
the problem. above normal.
Exit this procedure and perform this procedure The following conditions could cause this diagnostic
again. If the cause of the failure is not found, code to be activated:
for possible consultation with Caterpillar. This • The power supply circuit is shorted to a higher
consultation may greatly reduce repair time. voltage source.
If the ECM must be replaced, refer to Testing and • The ECM has failed. This is unlikely.
Replace”. Note: Before performing this procedure, inspect
STOP. circuit. Poor connections can often be the cause
i02921209
MID 027 - CID 1482 - FMI 03 are in good condition. If a problem with a
SMCS Code: 1439-038 verify that this diagnostic code is active before

THE COMPONENT
B. At the position sensor for the left steering cylinder,

insert a 7X-1710 Multimeter Probe along the
supply wire 799-WH at contact 1. Insert a
7X-1710 Multimeter Probe along the return wire
A202-BK at contact 2.
C. Measure the voltage between the supply, contact

1 and the return contact 2.
Expected Result:
g01304677
Illustration 256 The voltage measurement is 10.0 ± 0.4 VDC.
Connections of 10 VDC Power Supply for the Transmission/Chassis
ECM. Results:
This diagnostic code is associated with the 10 volt • OK – The voltage measurement is 10.0 ± 0.4 VDC.
sensor power supply of the Transmission/Chassis The voltage is correct. Proceed to Test Step 4.
ECM. The 10 volt sensor power supply provides a
second power supply for the right joystick and the • NOT OK – The voltage measurement is greater
power supply supplies power for the position sensor than 10.0 ± 0.4 VDC. The voltage measurement is
of the left steering cylinder. not correct. Proceed to Test Step 2.
Note: The 10 volt sensor power supply of the Test Step 2. CHECK THE POWER SUPPLY
Transmission/Chassis ECM is one of two power AT THE ECM
supplies that are used for the right joystick. The other
power source for the right joystick is supplied by the A. Turn the disconnect switch and the key start
10 volt power supply of the Implement ECM. switch to the OFF position.
RENR9004-07 387
B. At the connector for the Transmission/Chassis D. At the harness connector of the ECM J1, measure
ECM J1, use a 151-6320 Removal Tool or a the resistance from contact J1-69 (wire 799-WH) to
similar tool to remove the power supply wire and all of the other contacts that are used in connectors
the socket at contact J1-69 (wire 799-WH) from J1 and J2 for the Transmission/Chassis ECM.
the connector. The machine harness connector J1
remains connected to the ECM. Expected Result:
C. At the connector for the Transmission/Chassis Each resistance measurement is greater than 5000
ECM J1, insert a 7X-1710 Multimeter Probe ohms.
along the return wire A202-BK and the socket at
contact J1-70. Results:
D. Turn the disconnect switch and the key start • OK – Each resistance measurement is greater
switch to the ON position. than 5000 ohms. The supply circuit is not shorted
E. Use a multimeter probe in order to make contact to Test Step 4.
on the connector pin of the ECM at contact J1-69.
Measure the voltage at the ECM between the • NOT OK – One or more of the resistance
contact of the power supply J1-69 and the return measurements is less than 5000 ohms. There is a
contact J1-70. short in the machine harness.
Expected Result: Repair: The power supply circuit is shorted to a

another circuit in the machine harness. Refer to
The voltage measurement is 10.0 ± 0.4 VDC. the complete Electrical System Schematic of the
machine. Examine the supply circuit in order to
Results: determine the location of the problem.
• OK – The voltage measurement is 10.0 ± 0.4 For information on testing for short circuits and
VDC. The voltage is correct. The ECM power finding short circuits, refer to Testing and Adjusting,
supply is correct. Install the wire and the socket “Wiring Harness (Short Circuit) - Test”. Repair the
that were removed from the J1 connector back into machine harness or replace the machine harness.
the original locations. Proceed to Test Step 3.
STOP.
• NOT OK – The voltage measurement is greater
than 10.0 ± 0.4 VDC. The ECM power supply is Test Step 4. CHECK THE STATUS OF THE
not correct. DIAGNOSTIC CODE
Repair: Prior to replacing an ECM, always A. Inspect the harness connectors. Clean the
contact your dealership's Technical Communicator contacts of the harness connectors. Check the
for possible consultation with Caterpillar. This wires for damage to the insulation that is caused
consultation may greatly reduce repair time. If by excessive heat, battery acid, or chafing.
the ECM requires replacement, refer to Testing
and Adjusting, “Electronic Control Module (ECM) B. Perform a 45 N (10 lb) pull test on each of the
- Replace”. wires that are associated with the sensor circuit.
STOP. C. Reconnect all harness connectors. Make sure that

Test Step 3. CHECK FOR A SHORT clips for each connector are completely fastened.
CIRCUIT IN THE MACHINE HARNESS
The machine harness connector remains switch to the ON position.
disconnected from the position sensor.
A. Disconnect the machine harness connector J1
from the right joystick. F. Determine if the CID 1482 FMI 03 diagnostic code
is active.
B. Turn the disconnect switch and the key start
C. Disconnect the machine harness connectors J1 The CID 1482 FMI 03 diagnostic code is active.
388 RENR9004-07
Results: i02921561
• YES – The CID 1482 FMI 03 diagnostic code is MID 027 - CID 1482 - FMI 04
SMCS Code: 1439-038
Electronic Technician (ET) service tool, if available, Conditions Which Generate This Code:

may be activating the diagnostic code incorrectly.
The ECM may have failed.

greatly reduce repair time. If the ECM requires
STOP.

g01304677
caused by a poor electrical connection or a Connections of the 10 VDC Power Supply of the
short at one of the harness connectors that was Transmission/Chassis ECM.
machine operation. This diagnostic code is associated with the 10 volt
STOP. ECM. The 10 volt sensor power supply provides a
second power supply for the right joystick and the
power supply provides power for the position sensor
of the left steering cylinder.
Note: The 10 volt sensor power supply of the

Transmission/Chassis ECM is one of two power
supplies that are used for the right joystick. The other
power source for the right joystick is supplied by the
10 volt power supply of the Implement ECM.
The CID 1482 FMI 04 diagnostic code is activated

when the Transmission/Chassis ECM detects that
the voltage of the 10 volt power supply circuit is lower
than normal.
The following conditions could cause this diagnostic

code to be active:
• A component that is powered by the power supply

has failed.
• The power supply circuit is shorted to a ground

source.

RENR9004-07 389
Note: Before performing this procedure, inspect Test Step 2. CHECK THE POWER SUPPLY
the harness connectors that are involved in the AT THE ECM
of a problem in an electrical circuit. Verify that All components that are connected to the 10 VDC
all connections in the circuit are clean, that all power supply remain disconnected from the machine
connections are secure and that all connections harness.
connection is found, correct the problem and A. Turn the disconnect switch and the key start
verify that this diagnostic code is active before switch to the OFF position.
B. At the Transmission/Chassis ECM connector J1,
Note: The following test procedure may create other use a 151-6320 Removal Tool or a similar tool to
diagnostic codes. Clear the diagnostic codes when remove the power supply wire and the socket at
the problem has been corrected. contact J1-69 (wire 799-WH) from the connector.
The machine harness connector J1 remains
Test Step 1. CHECK THE COMPONENTS connected to the ECM.
A. Turn the key start switch and the disconnect C. At the connector of the Transmission/Chassis
switch to the ON position. ECM J1, insert a 7X-1710 Multimeter Probe
along the return wire A202-BK and the socket at
B. One at a time, disconnect a component that uses contact J1-70.
the 10 VDC power supply from the machine
harness. As each component is disconnected, D. Turn the disconnect switch and the key start
check the status of the CID 1482 FMI 04 diagnostic switch to the ON position.
code.
E. Use a multimeter probe in order to make contact
C. Continue disconnecting the components from the on the connector pin of the ECM at contact J1-69.
machine harness one at a time until the status of Measure the voltage at the ECM between the
the CID 1482 FMI 04 diagnostic code changes or contact of the power supply J1-69 and the return
until all of the components that are connected to contact J1-70.
the 10 volt power supply are disconnected.
Expected Result:
Expected Result:
The voltage measurement is 10.0 ± 0.4 DCV.
When one of the components is disconnected
from the machine harness, the CID 1482 FMI 04 Results:
diagnostic code is no longer active.
• OK – The voltage measurement is 10.0 ± 0.4 DCV.
Results: The voltage is correct. The power supply of the
ECM is correct. Install the wires and the sockets
• OK – The CID 1482 FMI 04 diagnostic code that were removed from the J1 connector back into
is not active when one of the components is the original locations. Proceed to Test Step 3.
disconnected. The power supply circuit is correct.
The component that was disconnected when the • NOT OK – The voltage measurement is greater
status of the CID 1482 FMI 04 diagnostic code than 10.0 ± 0.4 DCV. The ECM power supply is
changed has failed. Repeat this test step in order to not correct.
verify the component that is causing the problem.
Repair: Prior to replacing an ECM, always
Repair: Once the component that is causing the contact your dealership's Technical Communicator
problem is determined, replace the component. for possible consultation with Caterpillar. This
After the component is replaced, verify that the consultation may greatly reduce repair time. If
problem has been corrected before operating the the ECM requires replacement, refer to Testing
machine. and Adjusting, “Electronic Control Module (ECM)
- Replace”.
STOP.
STOP.
is still active. Disconnecting all of the components Test Step 3. CHECK FOR A SHORT TO
that are using the 10 VDC power supply did not GROUND
change the status of the diagnostic code. Proceed
to Test Step 2. All components that are connected to the 10 VDC
power supply remain disconnected from the machine
harness.
390 RENR9004-07
A. Turn the key start switch and the disconnect E. Operate the machine.
B. Disconnect the machine harness connectors J1 is active.
Expected Result:
C. At the harness connector for the ECM, measure
the resistance between contact for the supply The CID 1482 FMI 04 diagnostic code is active.
voltage J1-69 (wire 799-WH) and frame ground.
Measure the resistance between contact for the Results:
supply voltage J1-69 (wire 799-WH) and all of
the other contacts that are used in the J1 and J2 • YES – The CID 1482 FMI 04 diagnostic code is
connectors for the ECM. active. The problem has not been corrected.
Expected Result: Repair: Check the circuit again. Use the Caterpillar
Each resistance measurement is greater than 5000 in order to perform a wiggle test on the machine
ohms. wiring harness. The wiggle test can detect
Results: machine wiring harness.
• OK – Each resistance measurement is greater If the cause of the problem is not found, the ECM
than 5000 ohms. The circuit in the machine may be activating the diagnostic code incorrectly.
harness is correct. Proceed to Test Step 4. The ECM may have failed.
• NOT OK – One or more of the resistance Prior to replacing an ECM, always contact your
measurements is less than 5000 ohms. The circuit dealership's Technical Communicator for possible
is shorted in the machine harness. consultation with Caterpillar. This consultation may
greatly reduce repair time. If the ECM requires
Repair: The wire for the power supply 709-OR replacement, refer to Testing and Adjusting,
is shorted in the machine harness to the circuit “Electronic Control Module (ECM) - Replace”.
with the low resistance measurement. Refer to
the complete Electrical System Schematic for STOP.
your machine. Check all harness connectors that
are in the power supply circuit. Ensure that the • NO – The CID 1482 FMI 04 diagnostic code is not
connectors are clean and that the connections are active. The problem does not exist at this time.
secure.
For information on testing for short circuits and caused by a poor electrical connection or a
finding short circuits, refer to Testing and Adjusting, short at one of the harness connectors that was
“Wiring Harness (Short Circuit) - Test”. Repair the disconnected and reconnected. Resume normal
machine harness or replace the machine harness. machine operation.
STOP. STOP.

DIAGNOSTIC CODE



RENR9004-07 391
i02921629 • The switch has failed.

MID 027 - CID 1484 - FMI 03 • One or more of the switch circuits is open in the
machine harness.
• There is a short to a voltage source in one or both
Conditions Which Generate This Code: of the switch circuits.

Table 24
Status of the Inching Pedal Switch

Pedal Position N/C Contact N/O Contact
(Wire E974-GN (Wire U727-WH
- J2-45 - J2-46
Depressed Open(1) Closed (2)
g01324021
Illustration 258
Not Depressed Closed Open
Location of “Inching Pedal” switch
(1) Open to ECM return (Gnd) wire A202-BK - J1-70
(1) “Inching Pedal” position sensor (2) Closed to ECM return (Gnd) wire A202-BK - J1-70
(2) “Inching Pedal” switch


the switch.
C. The inching pedal is not depressed.
D. At the connector for the switch, measure the

resistance from the common contact of the
switch 2 (wire A202-BK) to switch contact 1 (wire
E974-GN).
g01304785
Illustration 259
Connections of “Inching Pedal” switch
E. At the connector for the switch, measure the
resistance from the common contact of the
The inching pedal switch provides two switch to switch 2 (wire A202-BK) to switch contact 4 (wire
ground inputs to the Transmission/Chassis ECM. U727-WH).
During normal operation, one of the inputs to the
switch is connected to ground through the common F. Depress the inching pedal and repeat Steps “D”
contact of the switch. The other switch input is open. and “E”.
The FMI 03 diagnostic code is activated when both Expected Result:

the switch inputs to the ECM are indicating an open
state at the same time. The contact status of the switch is correct according
to the table at the beginning of this procedure, with
Conditions that can cause this diagnostic code to be the inching pedal not depressed and with the pedal
active are listed below: depressed.
392 RENR9004-07
Results: • NOT OK – One or both of the resistance

measurements is greater than 5 ohms. There is
• YES – All of the resistance checks for the switch an open or a bad connection in the circuits of the
are correct according to the table at the beginning switch.
of this procedure. The switch is working correctly.
Proceed to Test Step 2. Repair: Check each of the circuits of the switch
individually in order to determine the circuit that
• NO – The contact states of the switch are not has the open or the poor connection.
correct according to the table at the beginning of
this procedure. The switch operation is not correct. A resistance measurement that is greater
than 5000 ohms could indicate that a wire is
Repair: Examine the wiring and the connections not connected or a wire is open. A resistance
between the switch connector and the switch for measurement that is greater than 5 ohms but
broken or for poor connections. less than 5000 ohms could indicate that one of
the connection points in the circuit is not an open
If a poor connection or broken wire is not found, connection but not a good connection.
replace the inching pedal switch. After the switch is
replaced, verify that the switch operation is correct Refer to the complete Electrical System Schematic
before operating the machine. for your machine. Check all of the connectors
that are in the sensor signal circuit. Ensure that
STOP. all connections are clean, that all connections
Test Step 2. CHECK THE SWITCH condition. Repair the machine harness or replace
CIRCUITS FOR AN OPEN CIRCUIT the machine harness.
The key start switch and the disconnect switch STOP.

remains disconnected from the switch. Test Step 3. CHECK FOR A SHORT TO A
VOLTAGE SOURCE
place a jumper wire between common contact 2 The key start switch and the disconnect switch remain
(wire A202-BK) and contact 4 (wire U727-WH). in the OFF position. The machine harness remains
disconnected from the switch. The machine harness
B. Disconnect the machine harness connectors J1 connectors for the ECM remain disconnected.
A. At the machine harness connector for the ECM
C. At the machine harness connector J2 for the ECM, J2, measure the resistance from the input contact
measure the resistance between common contact of the switch J2-45 (wire E974-GN) and all of the
of the switch J1-70 (wire A202-BK) and switch other J1 and J2 contacts that are used for the
input contact J2-46 (wire U727-WH). ECM.
D. At the machine harness connector for the switch, B. At the machine harness connector for the ECM J2,
move the connection for the jumper wire from input measure the resistance from input for the switch
contact 4 to input contact 1 (wire E974-GN). The J2-46 (wire U727-WH) and all of the other J1 and
other end of the jumper wire remains connected J2 contacts that are used for the ECM.
to common contact 2 (wire A202-BK).
Expected Result:
measure the resistance between common contact Each resistance measurement is greater than 5000
of the switch J1-70 (wire A202-BK) and switch ohms.
input contact J2-45 (wire E974-GN).
Results:
Expected Result:
Each resistance measurement is less than 5 ohms. than 5000 ohms. The machine harness is not
indicating a short. Proceed to Test Step 4.
Results:
• OK – Both of the resistance measurements are greater than 5000 ohms. There is a short in the
less than 5 ohms. The switch circuits are not open machine harness. The short is between the input
in the machine harness. Proceed to Test Step 3. wire of the switch E974-GN or the input wire of
the switch U727-WH and the circuit with the low
resistance measurement.
RENR9004-07 393
Repair: Refer to the complete Electrical System If the cause can not be found, the ECM may
Schematic for your machine. Examine all of the have failed. Verify that all possible causes of the
connectors in the faulty circuit for points in the diagnostic code have been investigated before
machine harness where a short could occur. replacement of the ECM.
For information on testing for short circuits and Prior to replacing an ECM, always contact your
finding short circuits, refer to Testing and Adjusting, dealership's Technical Communicator for possible
“Wiring Harness (Short Circuit) - Test”. Repair the consultation with Caterpillar. This consultation
machine harness or replace the machine harness. may greatly reduce repair time. If the cause of the

i02921903
MID 027 - CID 1484 - FMI 04
wires that are associated with the sensor circuit. Conditions Which Generate This Code:


diagnostic code.
Expected Result:

active.
Results:

diagnostic code does not exist at this time. g01324021
Illustration 260
Repair: The initial diagnostic code was probably Location of “Inching Pedal” switch
caused by a poor electrical connection or a (1) “Inching Pedal” position sensor
short at one of the harness connectors that was (2) “Inching Pedal” switch
machine operation.
STOP.

is still active. The diagnostic code has not been
corrected.

again. Use the Caterpillar Electronic Technician
a wiggle test on the machine wiring harness. The
wiggle test can detect momentary or intermittent
394 RENR9004-07


the switch.
C. The inching pedal is not depressed.
D. At the connector for the switch, measure the

resistance from common contact of the switch
2 (wire A202-BK) and switch contact 1 (wire
E974-GN).
g01304785
Illustration 261 E. At the connector for the switch, measure the
Connection of “Inching Pedal” switch connections resistance from common contact of the switch
2 (wire A202-BK) and switch contact 4 (wire
The inching pedal switch provides two switch to U727-WH).
ground inputs to the Transmission/Chassis ECM.
During normal operation, one of the switch inputs is F. Depress the inching pedal and repeat Steps “D”
connected to ground through the common contact of and “E”.
the switch. The other switch input is open.
Expected Result:
The FMI 04 diagnostic code is activated when the
two inputs to the switch are indicating a grounded The contact status of the switch is correct according
state at the same time. to the table at the beginning of this procedure with
the inching pedal not depressed and with the pedal
Conditions which can cause this diagnostic code to depressed.
Results:
• OK – All of the resistance checks for the switch
• One or both of the input circuits of the switch are are correct according to the table at the beginning
shorted to a ground source in the machine harness. of this procedure. The switch is working correctly.
• NOT OK – The states of contact of the switch are
Note: Before performing this procedure, inspect not correct according to the table at the beginning
the harness connectors that are involved in the of this procedure. The switch operation is not
circuit. Poor connections can often be the cause correct.
all connections in the circuit are clean, that all Repair: Examine the wiring and the connections
connections are secure and that all connections between the connector of the switch and the switch
are in good condition. If a problem with a for broken connections or poor connections.
verify that this diagnostic code is active before If a poor connection or broken wire is not found,
performing this procedure. replace the switch of the inching pedal . After the
switch is replaced, verify that the switch operation
Table 25 is correct before operating the machine.
Contact Status of the Inching Pedal Switch
STOP.
Pedal Position N/C Contact N/O Contact
(Wire E974-GN (Wire U727-WH
- J2-45 - J2-46
CIRCUITS FOR A SHORT TO GROUND
Depressed Open(1) Closed (2)
Not Depressed Closed Open
in the OFF position. The switch of the inching pedal
(1) Open to ECM return (GND) wire A202-BK - J1-70 remains disconnected from the machine harness.
(2) Closed to ECM return (GND) wire A202-BK - J1-70
RENR9004-07 395
B. At the machine harness connector of the ECM J2, B. Perform a 45 N (10 lb) pull test on each of the
measure the resistance from the input contact of wires that are associated with the sensor circuit.
the switch J2-45 (wire E974-GN) and the frame
ground. Measure the resistance from J2-45 (wire C. Reconnect all harness connectors. Make sure that
E974-GN) and all of the other J1 and J2 contacts the connectors are fully seated. Observe that the
that are used for the ECM. clips for each connector are completely fastened.
C. Observe the resistance measurement and wiggle D. Turn the disconnect switch and the key start
the wires. Manipulate the machine harness at the switch to the ON position.
ECM connectors and at the connectors of the
switch. E. Operate the machine.
D. At the machine harness connector of the ECM F. Check the status of the CID 1484 FMI 04
J2, measure the resistance from the contact diagnostic code.
of the switchJ2-46 (wire U727-WH) and frame
ground. Measure the resistance from J2-46 (wire Expected Result:
U727-WH) and all of the other J1 and J2 contacts
that are used for the ECM. The CID 1484 FMI 04 diagnostic code is not active.
E. Observe the resistance measurement and wiggle Results:

the wires. Manipulate the machine harness at the
ECM connectors and at the connectors of the • OK – The CID 1484 FMI 04 is not active. The
switch. diagnostic code does not exist at this time.
Expected Result: Repair: The initial diagnostic code was probably

Each resistance measurement is greater than 5000 short at one of the harness connectors that was
ohms at all times during the manipulation of the wires disconnected and reconnected. Resume normal
and connectors of the machine harness. machine operation.
Results: STOP.
• OK – Each resistance measurement is greater • NOT OK – The CID 1484 FMI 04 diagnostic code
than 5000 ohms. The measurements of the input is still active. The diagnostic code has not been
circuit for the switch are not indicating a short to a corrected.
ground source. Proceed to Test Step 3.
• NOT OK – Each resistance measurement is not again. Use the Caterpillar Electronic Technician
greater than 5000 ohms. There is a short in the (ET) service tool, if available, in order to perform
machine harness. The short is between the input a wiggle test on the machine wiring harness. The
circuit of the switch E974-GN or the input circuit of wiggle test can detect momentary or intermittent
the switch U727-WH and the circuit with the low shorts or opens in the machine wiring harness.
resistance measurement or frame ground.
Repair: Refer to the complete Electrical System have failed. Verify that all possible causes of the
Schematic of your machine. Examine all of the diagnostic code have been investigated before
connectors in the faulty circuit for locations in the replacement of the ECM.
machine harness that indicate a short.
For information on testing for short circuits and dealership's Technical Communicator for possible
finding short circuits, refer to Testing and Adjusting, consultation with Caterpillar. This consultation
“Wiring Harness (Short Circuit) - Test”. Repair the may greatly reduce repair time. If the cause of the
machine harness or replace the machine harness. diagnostic code is not found, replace the ECM.
STOP. Module (ECM) - Replace”.

DIAGNOSTIC CODE
396 RENR9004-07

SMCS Code: 3139-038; 5479-038 circuit. Poor connections can often be the cause

Test Step 1. CHECK THE RETURN

CIRCUIT OF THE SOLENOIDS FOR A
SHORT
B. Disconnect the machine harness connectors

from both of the secondary steering solenoids.
Disconnect the machine harness connectors J1
g01376762
Illustration 262 and J2 from the ECM.
Secondary Steering Solenoids are located in front of the cab
behind the rear valve stack. C. At the machine harness connectors for the ECM,
(1) Right solenoid for secondary steering measure the resistance from the return contact
(2) Left solenoid for secondary steering of the solenoid J1-54 (wire 925-YL) and all of
the other contacts that are used in the J1 and J2
connectors for the ECM.
Expected Result:

ohms.
Results:
• YES – Each resistance measurement is greater

does not indicate a short in the machine harness.
Proceed to test step 2.
g01305575
Illustration 263 • NO – Each resistance measurement is not greater
Connections for Solenoid 1 Return. than 5000 ohms. There is a short in the machine
harness.
This diagnostic code is associated with the “solenoid
1 return” circuit. The FMI 03 means that the Repair: The short is between wire 925-YL and the
Transmission/Chassis ECM has determined that the circuit that has a low resistance measurement.
current in the return circuit of the solenoid is above
normal. This condition is likely caused by a short to For information on testing for short circuits and
another voltage source. finding short circuits, refer to Testing and Adjusting,
Conditions that could cause this diagnostic code to machine harness or replace the machine harness.
STOP.
• The return circuit of the solenoid is shorted to
RENR9004-07 397
Test Step 2. CHECK THE OPERATION OF Test Step 3. CHECK THE STATUS OF THE
THE ECM DIAGNOSTIC CODE
connectors for the solenoids and the ECM remain wires for damage to the insulation that is caused
A. At the machine harness connector J1 for the B. Perform a 45 N (10 lb) pull test on each of the
ECM, use a 151-6320 Removal Tool to remove wires that are associated with the circuit.
the return wire 925-YL and the socket at contact
J1-54 from the harness connector. C. Reconnect all harness connectors. Make sure that
is active.
Expected Result:
Expected Result:
active. A CID 1674 FMI 05 diagnostic code is now The CID CID 1674 FMI 03 diagnostic code is not
active. active.
Results: Results:
• YES – The CID 1674 FMI 03 diagnostic code is • YES – The diagnostic code is not active at this
no longer active. A CID 1674 FMI 05 diagnostic time. The initial diagnostic code was probably
code has been activated after the energize wire caused by a poor electrical connection or a
of the solenoid was disconnected. The ECM has short at one of the harness connectors that was
responded correctly to the open circuit of the disconnected and reconnected. Resume normal
solenoid. machine operation. STOP.
Reinstall the disconnected energize wire of the • NO – The CID 1674 FMI 03 diagnostic code
solenoid into the correct connector of the ECM. remains active. The problem has not been
Proceed to the next test step. corrected.
Proceed to Test Step 3. Repair: Check the circuit again. Use the Caterpillar
• NO – The CID 1674 FMI 03 diagnostic code in order to perform a wiggle test on the machine
remains active. The status of the active diagnostic wiring harness. The wiggle test can detect
code did not change when the energize wire of the momentary or intermittent shorts or opens in the
solenoid was disconnected from the ECM. machine wiring harness.
Repair: The ECM has not responded correctly If the problem remains, the ECM may have failed.
to the open condition in the solenoid circuit. The This is unlikely because the ECM detected the
operation of the ECM is not correct. open circuit in the solenoid circuit and activated the
FMI 05 diagnostic code when the energize wire of
Prior to replacing an ECM, always contact your the solenoid was disconnected.
consultation with Caterpillar. This consultation may Verify that all possible causes of the diagnostic
greatly reduce repair time. If the ECM must be code have been investigated. Exit this procedure
replaced, refer to Testing and Adjusting, “Electronic and perform this procedure again.
STOP. contact your dealership's Technical Communicator
consultation may greatly reduce repair time. .
398 RENR9004-07
If it is determined that the ECM must be replaced, The “solenoid 1 return” circuit provides a return
refer to Testing and Adjusting, “Electronic Control path to the ECM for the left and the right secondary
Module (ECM) - Replace” steering solenoids.
STOP. Conditions that could cause this diagnostic code to

i02922341
• The return circuit for one or both solenoids is
MID 027 - CID 1674 - FMI 04 shorted to a ground source.
SMCS Code: 3139-038; 5479-038 • The ECM has failed. This is unlikely.
Conditions Which Generate This Code: Before performing this procedure, inspect the

Test Step 1. CHECK THE “SOLENOID 1

RETURN” CIRCUIT FOR A SHORT TO
GROUND
g01376762
Illustration 264 B. Disconnect the left solenoid for secondary steer
“Secondary Steering” solenoids are located in the front of the cab and the right solenoid for secondary steer from
and behind the rear valve stack. the machine harness.
(1) “Secondary steering” right solenoid
(2) “Secondary steering” left solenoid C. Disconnect the machine harness connectors J1
D. At the machine harness connectors for the ECM,

measure the resistance from the “solenoid 1
return” contact J1-54 (wire 925-YL) and the frame
ground location. Measure the resistance from
the contact J1-54 (wire 925-YL) and all of the
other J1 and J2 contacts that are used in the
Expected Result:

ohms.
g01305575
Illustration 265
Results:
Connections for “Solenoid 1 Return”
This diagnostic code is associated with the “solenoid than 50 ohms. The measurement is not indicating
1 return” circuit. The FMI 04 means that the that the “solenoid 1 return” circuit is shorted to a
Transmission/Chassis ECM has determined that the ground source. Proceed to Test Step 2.
voltage for the “solenoid 1 return” circuit is below
normal.
RENR9004-07 399
• NOT OK – One or more of the resistance Repair: Check the circuit again. Use the Caterpillar
measurements is less than 50 ohms. There is a Electronic Technician (ET) service tool, if available,
short in the machine harness. The short is between in order to perform a wiggle test on the machine
wire 925-YL and the circuit with the low resistance wiring harness. The wiggle test can detect
measurement or frame ground. momentary or intermittent shorts or opens in the
Repair: For information on testing for short circuits
and finding short circuits, refer to Testing and If the cause of the problem is not found, the ECM
Adjusting, “Wiring Harness (Short Circuit) - Test”. may have failed.
Repair the machine harness or replacethe machine
harness. It is unlikely that the ECM has failed. Verify that all
STOP. investigated. If the cause of the failure is not found,
Test Step 2. CHECK THE STATUS OF THE for possible consultation with Caterpillar. This
DIAGNOSTIC CODE consultation may greatly reduce repair time. If the
A. Inspect the harness connectors. Clean the the ECM that has activated the diagnostic code.
contacts of the harness connectors. Check the Refer to Testing and Adjusting, “Electronic Control
wires for damage to the insulation that is caused Module (ECM) - Replace”.
STOP.
i02922348

MID 027 - CID 1674 - FMI 05
clips for each connector are completely fastened. SMCS Code: 3139-038; 5479-038
D. Turn the disconnect switch and the key start Conditions Which Generate This Code:

diagnostic code.
Expected Result:
Results:


machine operation.
g01376762
Secondary Steering Solenoids are located in front of the cab
behind the rear valve stack.
• NOT OK – The CID 1674 FMI 04diagnostic code
is still active. The diagnostic code has not been (1) Right Solenoid for secondary steer
corrected. (2) Left solenoid for secondary steer
400 RENR9004-07
C. At the right solenoid for secondary steer, measure

the resistance of the solenoid coil between contact
1 and contact 2.
D. At the left solenoid for secondary steer, measure

the resistance of the solenoid coil between contact
1 and contact 2.
Expected Result:
The resistance measurement for each solenoid is

less than 50 ohms.
Results:
g01305575
Illustration 267
• OK – Each resistance measurement for each
Connections of “Solenoid 1 Return” solenoid is less than 50 ohms. Proceed to Test
Step 2.
This diagnostic code is associated with the “solenoid
1 return” circuit. The FMI 05 means that the • NOT OK – The resistance measurement for one
Transmission/Chassis ECM has determined that the or both of the solenoids is greater than 50 ohms.
current for the return circuit of the solenoid is below There is an open in one or both of the secondary
normal. steering solenoids.
The “solenoid 1 return” circuit provides a return Repair: The secondary steering solenoid with the
path to the ECM for the left and the right secondary resistance measurement that is greater than 50
steering solenoids. ohms is faulty. Replace the faulty solenoid.
Conditions that can cause this diagnostic code to be One faulty solenoid would not cause the ECM to
activated are listed below: activate the CID 1674 FMI 05 diagnostic code.
After the solenoid is replaced, verify that the CID
• The return circuit for one or both of the solenoids 1674 FMI 05 diagnostic code is still active. If the
is open. diagnostic code is still active, perform the next test
step.
• Both of the solenoids have internal open circuits at
the same time. This is unlikely. STOP.
• The ECM has failed. This is unlikely. Test Step 2. CHECK THE ENERGIZE
CIRCUITS OF THE SOLENOID
harness connectors that are involved in the Note: The purpose of this step of the test is to verify
circuit. Poor connections can often be the cause the integrity of the energize circuits. The energize
of a problem in an electrical circuit. Verify that circuits are used to check the condition of the return
all connections in the circuit are clean, that all circuit in the next test step. A problem in one or the
connections are secure and that all connections other of the energize circuits of the solenoid would
are in good condition. If a problem with a most likely not cause the ECM to activate the CID
connection is found, correct the problem and 1674 FMI 05 diagnostic code. The ECM will activate
verify that this diagnostic code is active before either a CID 2175 (secondary steer left solenoid)
performing this procedure. diagnostic code or a CID 2176 (secondary steer
right solenoid) diagnostic code for a problem in the
Note: The following test procedure may create other energize circuit for either solenoid.
codes and clear these diagnostic codes when the The disconnect switch and the key start switch
original diagnostic code has been corrected. remain in the OFF position. Both of the solenoids
remain disconnected from the machine harness.
Test Step 1. CHECK THE SOLENOIDS
A. At the machine harness connectors for both of the
A. Turn the disconnect switch and the key start secondary steering solenoids, connect a jumper
switch to the OFF position. wire between contact 1 (wire X754-GN) for the
left solenoid harness connector and contact 1
B. Disconnect the left solenoid for secondary steer (wire X755-WH) for the right solenoid harness
and the right solenoid for secondary steer from connector.
RENR9004-07 401
B. Disconnect the machine harness connector J1 B. At the machine harness connector J1 for the ECM,
from the Transmission/Chassis ECM. measure the resistance between the energize
circuit for the left solenoid, contact J1-67 (wire
C. At the machine harness connector J1 for the ECM, X754-GN) and the return contact of the solenoid
measure the resistance between the energize J1-54 (wire 925-YL).
contact of the left solenoid J1-67 (wire X754-GN)
and the energize contact of the right solenoid C. At the machine harness connectors for the left
J1-68 (wire X755-WH). solenoid for secondary steer and the right solenoid
for secondary steer, leave one end of the jumper
Expected Result: wire connected to the harness connector for the
left solenoid, contact 1 (wire X754-GN). Connect
The resistance measurement is less than 5 ohms the other end of the jumper wire to the harness
between the two energize circuits of the solenoid. connector for the right solenoid, contact 2 (wire
925-YL).
Results:
D. At the machine harness connector J1 for the ECM,
• OK – The resistance measurement is less than measure the resistance between the energize
5 ohms between the two energize circuits of the circuit for the left solenoid, contact J1-67 (wire
solenoid. The energize circuits for the secondary X754-GN) and the return contact of the solenoid
steering solenoids are correct. Proceed to Test J1-54 (wire 925-YL).
Step 3.
Expected Result:
• NOT OK – The resistance measurement for the
energize circuits of the solenoid is greater than 5 Both of the resistance measurements are less than
ohms. There is a problem in one or both of the 5.0 ohms.
solenoid energize circuits.
Results:
than 5 ohms but less than 5000 ohms could • OK – Both of the resistance measurements are
indicate that one of the connection points in the less than 5.0 ohms. The resistance measurement
circuit is not an open connection but not a good is indicating that the “return 1 solenoid” circuit is
connection. A resistance measurement that is not causing the problem. Proceed to Test Step 4.
greater than 5000 ohms could indicate that an
open is present in the circuit. • NOT OK – One or both of the resistance
measurements is greater than 5.0 ohms. the
Check each of the energize circuits of the solenoid “solenoid return 1” circuit is not correct.
for continuity in order to determine the circuit that
has an open connection or a poor connection. Repair: A resistance measurement that is greater
Refer to the complete Electrical System Schematic indicate that one of the connection points in the
of your machine. Check all of the connectors circuit is not an open connection but not a good
that are in the suspected circuit. Ensure that connection. A resistance measurement that is
all connections are clean, that all connectors greater than 5000 ohms could indicate that an
are secure and that all connectors are in good open is present in the circuit.
the machine harness. If one of the resistance measurements is OK and
the other resistance measurement is not OK, the
STOP. problem is in the section of the return circuit of the
solenoid that is between the splice of the wiring
Test Step 3. CHECK THE RETURN harness and the solenoid.
CIRCUIT FOR THE SOLENOID
If both of the resistance measurements are not
The disconnect switch and the key start switch correct, the problem is most likely in the section of
remain in the OFF position. Both of the solenoids and the return circuit of the solenoid that is between the
the ECM J1 connector remain disconnected from the splice of the wiring harness and the ECM.
machine harness.
A. At the machine harness connector for the left

solenoid for secondary steer, place a jumper wire
between contact 1 (wire X754-GN) and return
contact 2 (wire 925-YL).
402 RENR9004-07
Refer to the complete Electrical System Schematic Verify that all possible causes of the diagnostic
of your machine . Check all of the connectors code have been investigated. If the cause of the
that are in the suspected section of the “solenoid failure is not found, contact your dealership's
1 return” circuit. Ensure that all connections are Technical Communicator for possible consultation
clean, that all connections are secure and that with Caterpillar. This consultation may greatly
all connections are in good condition. Repair the reduce repair time. If the ECM must be replaced,
machine harness or replace the machine harness. refer to Testing and Adjusting, “Electronic Control
STOP.
STOP.
DIAGNOSTIC CODE
i02922406

MID 027 - CID 1960 - FMI 09
wires for damage to the insulation that is caused SMCS Code: 7631-038



diagnostic code.
Expected Result:
Results:
• OK – The CID 1674 FMI 05 diagnostic code is not

time.

reconnected. Resume normal machine operation. Illustration 268
g01305359
Connections of the “Machine Security System (MSS)” key reader

STOP.
A record is made of the diagnostic code after the
• NOT OK – The CID 1674 FMI 05 diagnostic code Transmission/Chassis ECM fails to receive the
is still active. The diagnostic code has not been information that is expected. The information comes
corrected. from the “MSS key reader”. The information is
transmitted by the “J1939 CAN data link”.
Electronic Technician (ET) service tool, if available, Note: The Machine Security System (MSS) must be
in order to perform a wiggle test on the machine installed in order for this diagnostic code to be logged.
momentary or intermittent shorts or opens in the Test Step 1. CHECK THE ET SCREENS
A. Check the active diagnostic screen and the logged
diagnostic screen for a communication error
between the ECM and the key reader.
RENR9004-07 403
Expected Result: If the voltage measurement between contact 1

and contact 2 is less than 24 DCV and the ground
The ET reports CID 1960 FMI 09 as being active, or measurement of the frame is OK, then the ground
the diagnostic code has been logged. wire 200-BK is an open connection or a bad
connection in the machine harness. Check the
Results: wiring harness. Repair the machine harness or
• YES – The electronic technician reports CID 1960
FMI 09 as being active, or the diagnostic code has STOP.
been logged.
Repair: Examine the connections on the CAN DIAGNOSTIC CODE
data link between the key reader and the
Transmission/Chassis ECM. Ensure that all A. Inspect the contacts. Clean the contacts of the
connections in the data link circuit are clean, that harness connectors.
all connections are tight and that all connections
are in good condition. B. Reconnect all harness connectors.
Proceed to Test Step 2. C. Turn the disconnect switch and the key start
• NO – The diagnostic code has not been logged or
the diagnostic is not active. D. Enter the service mode of the Caterpillar
Monitoring System. Clear all inactive diagnostic
Repair: The diagnostic code is not active at this codes.
time. Resume normal machine operation.
STOP.
F. Determine if the CID 1960 FMI 09 is active.
Test Step 2. CHECK FOR POWER TO THE
KEY READER Expected Result:
A. Disconnect the machine harness connector from The CID 1960 FMI 09 is not active.
the “MSS key” reader.
Results:
B. Turn the key start switch to the ON position. At the
machine harness connector for the key reader, • OK – The CID 1960 FMI 09 is not active. The
measure the voltage between contact 1 (wire problem does not exist at this time.
308-YL) and contact 2 (wire 200-BK). Measure
the voltage between contact 1 (wire 308-YL) and Repair: The initial diagnostic code was probably
frame ground. caused by a poor electrical connection or a
machine operation.
The voltage that is measured for each measurement
is approximately 24 DCV. STOP.
Results: • NOT OK – The CID 1960 FMI 09 is still active. The

problem has not been corrected.
• YES – The voltage that is measured for each
measurement is approximately 24 DCV. The supply Repair: Check the “CAN data link” circuit again.
voltage is correct. Proceed to Test Step 3. Perform a “wiggle test” on the machine wiring
harness. Use the Caterpillar Electronic Technician
• NO – One of the voltage measurements is not (ET) in order to perform the test. The “wiggle
correct. There is a problem in the wiring harness. test” is used to detect intermittent shorts or open
connections in the wiring harness of the machine.
Repair: If the voltage measurement between If the cause of the problem can not be found,
contact 1 and the frame ground is less than 24 the Transmission/Chassis ECM or the “MSS key
DCV, then the supply wire 308-YL is either an open reader” module may have failed.
connection or a shorted connection in the machine
harness. Check the wiring harness for signs of
damage. Repair the machine harness or replace
404 RENR9004-07
Prior to replacing the ECM or the “MSS key Note: When this diagnostic code is activated, verify
reader”, always contact your dealership's Technical that there are no active CID 0262 diagnostic codes
Communicator for possible consultation with for the 5 volt power supply of the ECM. An active
Caterpillar. This consultation may greatly reduce diagnostic code for the power supply must be cleared
repair time. If the cause of the diagnostic code is not before proceeding with this procedure.
found, replace the ECM. Refer to Troubleshooting,
“Electronic Control Module (ECM) - Replace”. Note: Before performing this procedure, inspect
the harness connectors that are involved in
STOP. the circuit. Poor connections can often be the
cause of a problem in an electrical circuit. Verify
that all connections in the circuit are clean,
i02922407
that all connections are secure and that all
MID 027 - CID 1961 - FMI 03 connections are good condition. If a problem with
a connection is found, correct the problem and
SMCS Code: 1439-038-BRK verify that this diagnostic code is active before

OF THE SENSOR

the sensor.

g01305473 measure the supply voltage between the contact
Illustration 269
Connections of the “Service Brake Accumulator” pressure sensor for the power supply A (wire L730-OR) and the
ground contact B (wire U731-BR).
“service brake accumulator” pressure sensor. Expected Result:
The FMI 03 diagnostic code means that the
Transmission/Chassis ECM has determined that the The measurement of the supply voltage is 5.0 ± 0.3
voltage or the duty cycle of the signal circuit for the VDC.
position sensor is above normal.
Results:
The position sensor is an active analog sensor that
sends a 0 to 4.5 volt signal to the ECM in order to • OK – The voltage measurement is approximately
indicate the hydraulic pressure that is in the “service 5.0 ± 0.3 VDC. The power supply for the sensor is
brake accumulator”. correct. Proceed to Test Step 2.
Conditions that can cause this diagnostic code to be • NOT OK – The voltage measurement is less than
activated are listed below: 5.0 ± 0.3 VDC. The power supply for the sensor
is not correct.
• There is a problem with the sensor power supply.
Repair: The wire of the return circuit U731-BR or
• The signal circuit for the sensor has an open or the wire of the supply circuitL730-OR has a bad
a bad connection. connection or an open in the machine harness.
Examine all of the connectors that are in the circuit.
• The signal circuit for the sensor is shorted to a Ensure that the connections are clean, that all
voltage source. connections are secure and that all connections
are in good condition.
RENR9004-07 405
Refer to the CID 0262 diagnostic code procedures Test Step 3. CHECK THE SIGNAL
in this manual for troubleshooting the power supply CIRCUIT OF THE SENSOR FOR A SHORT
(5 VDC). Correct the problem with the power
supply of the ECM. After the power supply is The sensor remains disconnected from the machine
correct, verify that this diagnostic code is still active harness. The disconnect switch and the key start
before proceeding with this procedure. switch remain in the OFF position. The machine
harness connectors remain disconnected from the
STOP. ECM.
Test Step 2. CHECK FOR AN OPEN IN A. Remove the jumper wire that was used in the last
THE SENSOR CIRCUIT test step.
The connector of the machine harness remains B. At the harness connector J1 for the ECM,
disconnected from the sensor. measure the resistance from signal contact J1-36
(wire U728-PK) to all of the other contacts that
A. Turn the key start switch and the disconnect are used for the J1 and J2 connectors on the
switch to the OFF position. Transmission/Chassis ECM.
B. At the machine harness connector for the Expected Result:

machine harness of the sensor, place a “jumper”
wire between the contact of the sensor return Each resistance measurement is greater than 5000
B (wire L731-BR) and the signal contact C (wire ohms.
U728-PK) .
Results:
J2 from the ECM. • OK – Each resistance measurement is greater
than 5000 ohms. The signal circuit is not shorted
D. At the harness connectors for the ECM, measure to another circuit in the machine harness. Proceed
the resistance from return contact J1-21 (wire to Test Step 4.
L731-BR) to signal contact J1-36 (wire U728-PK).
Expected Result: measurements is less than 5000 ohms. There is a
short in the machine harness.
Repair: The wire of the sensor signal circuit
Results: U728-PK is shorted to the circuit with the low
resistance measurement in the machine harness.
ohms. The sensor circuit is not open. Proceed to Refer to the complete Electrical System Schematic
Test Step 3. of the machine. Examine all of the connectors in
the circuits. The technician must look for locations
• NOT OK – The resistance measurement is greater that indicate that a short could occur in the machine
than 5 ohms. There is an open or a bad connection harness.
in the signal circuit.
Repair: A resistance measurement that is greater finding short circuits, refer to Testing and Adjusting,
than 5000 ohms could indicate that a wire is not “Wiring Harness (Short Circuit) - Test”. Repair the
connected or that a wire is open. A resistance machine harness or replace the machine harness.
measurement that is greater than 5 ohms but
less than 5000 ohms could indicate that one of STOP.
the connection points in the circuit is not an open
connection but not a good connection. Test Step 4. CHECK THE SIGNAL AT THE
SENSOR
of the machine. Check all of the connectors The key start switch and the disconnect switch
that are in the sensor signal circuit. Ensure that remain in the OFF position.
all connections are clean, that all connectors
are secure and that all connectors are in good A. Reconnect the machine harness connectors to the
condition. Repair the machine harness or replace sensor and to the ECM.
STOP.
406 RENR9004-07
B. At the machine harness for the sensor connector, E. Operate the machine.
use a 151-6320 Removal Tool to remove the
signal wire U728-PK and the socket at contact C F. Determine if the CID 1961 FMI 03 diagnostic code
from the harness connector. The machine harness is active.
connector remains connected to the “accumulator
pressure” sensor connector. Expected Result:
C. At the back of the sensor connector, insert The CID 1961 FMI 03 diagnostic code is not active.
signal contact C and the return contact at B. Results:
D. Turn the disconnect switch and the key start • OK – The CID 1961 FMI 03 diagnostic code is not
switch to the ON position. active. The problem has been corrected.
E. Measure the voltage of the sensor at connector Repair: The initial diagnostic code was probably
contacts C and B. caused by a poor electrical connection or a
machine operation.
The voltage of the sensor signal is in the range of
0.0 volts to 4.5 VDC. STOP.
Results: • NOT OK – The CID 1961 FMI 03 diagnostic code

is still active. The problem has not been corrected.
• OK – The voltage of the sensor signal is in the
range of 0.0 volts to 4.5 VDC. The sensor signal Repair: Perform this test step again. If the problem
voltage is in the correct range. Proceed to Test has not been corrected, Perform a “wiggle test” on
Step 5. the sensor circuit in the machine wiring harness.
Use the Caterpillar Electronic Technician (ET) in
• NOT OK – The voltage of the sensor signal is not order to perform the test. The “wiggle test” is used
in the range of 0.0 volts to 4.5 VDC. The sensor to detect intermittent shorts or open connections in
may have failed. the wiring harness of the machine.
Repair: Verify that the sensor signal is not in the If a problem is not found in the machine harness,
correct voltage range. Start the engine. Run the the ECM may have failed.
engine at low idle and check the sensor signal.
If the sensor signal is not in the correct voltage Prior to replacing an ECM, always contact your
range, the sensor has failed. dealership's Technical Communicator for possible
Replace the “service brake accumulator” pressure may greatly reduce repair time. If the cause of the
sensor. After replacement of the sensor, verify that diagnostic code is not found, replace the ECM that
the operation of the new sensor is correct before has activated the diagnostic code. Refer to Testing
operating the machine. and Adjusting, “Electronic Control Module (ECM)
- Replace”.
STOP.
STOP.
DIAGNOSTIC CODE



RENR9004-07 407
i02922408 Test Step 1. CHECK THE SIGNAL

CIRCUIT OF THE SENSOR FOR A SHORT
MID 027 - CID 1961 - FMI 04
SMCS Code: 1439-038-BRK harness. The disconnect switch and the key start
switch remain in the OFF position. The machine
Conditions Which Generate This Code: harness connectors remain disconnected from the
ECM.

B. Disconnect the “service brake accumulator”

pressure sensor from the machine harness.

D. At the harness connector J1 for the ECM,

measure the resistance between signal contact
J1-36 (wire U728-PK) and frame ground. Measure
g01305473 the resistance between signal contact J1-36
Illustration 270
(wire U728-PK) and all of the other contacts that
Connections of the “Service Brake Accumulator” pressure sensor
are used on the J1 and J2 connectors on the
“service brake accumulator” pressure sensor. Expected Result:
The FMI 04 diagnostic code means that the
Transmission/Chassis ECM has determined that the Each resistance measurement is greater than 5000
voltage or the duty cycle of the signal circuit for the ohms.
position sensor is below normal.
Results:
The position sensor is an active analog sensor that
sends a 0 to 4.5 volt signal to the ECM in order to
indicate the hydraulic pressure that is in the “service
than 5000 ohms. The measurement is not
brake accumulator”. indicating that the “accumulator pressure sensor”
circuit is shorted to a ground source. Proceed to
Conditions that can cause this diagnostic code to be Test Step 2.
• NOT OK – One or more resistance of the
• The signal circuit for the sensor is shorted to a resistance measurements is less than 5000 ohms.
ground source. There is a short in the machine harness.
• The sensor has failed. Repair: The wire for the sensor signal circuit
U728-PK is shorted to frame ground or to the
• The ECM has failed. This is unlikely. circuit with the low resistance measurement in the
machine harness.
the harness connectors that are involved in the Refer to the complete Electrical System Schematic
circuit. Poor connections can often be the cause of the machine. Check all of the connectors in
of a problem in an electrical circuit. Verify that the circuits. Examine the machine harness for
all connections in the circuit are clean, that all indications of damage. Damage to the harness
connections are secure and that all connections connector could indicate a location for a short.
connection is found, correct the problem and For information on testing for short circuits and
verify that this diagnostic code is active before finding short circuits, refer to Testing and Adjusting,
performing this procedure. “Wiring Harness (Short Circuit) - Test”. Repair the
diagnostic codes. Ignore these created diagnostic STOP.
408 RENR9004-07
Test Step 2. CHECK THE SIGNAL AT THE B. Perform a 45 N (10 lb) pull test on each of the
SENSOR wires that are associated with the sensor circuit.
The key start switch and the disconnect switch C. Reconnect all harness connectors. Make sure that
remain in the OFF position. the connectors are fully seated. Observe that the
A. Reconnect the machine harness connectors to the
sensor and to the ECM. D. Turn the disconnect switch and the key start
B. At the machine harness connector for the sensor,
use a 151-6320 Removal Tool to remove the E. Operate the machine.
signal wire U728-PK and the socket at contact C
from the harness connector. The machine harness F. Determine if the CID 1961 FMI 03 diagnostic code
connector remains connected to the “accumulator is active.
pressure sensor” connector.
Expected Result:
C. At the back of the sensor connector, insert
7X-1710 Multimeter Probes along the sensor The CID 1961 FMI 03 diagnostic code is not active.
signal contact C and the return contact at B.
Results:
switch to the ON position. • OK – The CID 1961 FMI 03 diagnostic code is not
active. The problem has been corrected.
E. Measure the voltage of the sensor at the connector
contacts C and B. Repair: The initial diagnostic code was probably
Expected Result: short at one of the harness connectors that was
The voltage of the sensor signal is in the range of machine operation.
0.0 volts to 4.5 VDC.
STOP.
Results:
• OK – The voltage of the sensor signal is in the is still active. The problem has not been corrected.
range of 0.0 volts to 4.5 VDC. The sensor signal
voltage is in the correct range. Proceed to Test Repair: Perform this test step again. If the problem
Step 3. has not been corrected, Perform a “wiggle test” on
the sensor circuit in the machine wiring harness.
• NOT OK – The voltage of the sensor signal is not Use the Caterpillar Electronic Technician (ET) in
in the range of 0.0 volts to 4.5 VDC. The sensor order to perform the test. The “wiggle test” is used
may have failed. to detect intermittent shorts or open connections in
the wiring harness of the machine.
Repair: Verify that the sensor signal is not in the
correct voltage range. Start the engine. Run the If a problem is not found in the machine harness,
engine at low idle and check the sensor signal the ECM may have failed.
again. If the sensor signal is not in the correct
voltage range, the sensor has failed. Prior to replacing an ECM, always contact your
Replace the “service brake accumulator” pressure consultation with Caterpillar. This consultation
sensor. After replacement of the sensor, verify that may greatly reduce repair time. If the cause of the
the operation of the new sensor is correct before diagnostic code is not found, replace the ECM that
operating the machine. has activated the diagnostic code. Refer to Testing
STOP. - Replace”.

DIAGNOSTIC CODE
RENR9004-07 409
i02839847 Table 26
MID 027 - CID 2113 - FMI 03 States of “Operator Present” Switch Contact
Operator Status N/O Input J1-64 N/C Input J1-63
SMCS Code: 1435-038 (wire U767-BU) (wire U766-BR)
Conditions Which Generate This Code: Operator Not Open(2) Closed(1)

Present
“Operator Closed Open
Present” Switch
(2) Open to ECM return J1-23 (A295-BK - ground).
(1) Closed to ECM return J1-23 (A295-BK - ground).
Note: The “operator present” switch provides

two inputs to the Implement ECM and to the
Transmission/Chassis ECM. If one ECM has an
active diagnostic code and the other ECM does not
have an active diagnostic code, most likely the switch
is operating correctly. This condition would indicate
that there is a problem in the machine harness. In
either case, perform this procedure in order to find
the cause of the problem.

Illustration 271
g01405089 Test Step 1. CHECK THE SWITCH INPUT
Connections for “Operator Present” Switch CIRCUITS FOR AN OPEN
This diagnostic code is associated with the “Operator A. Turn the disconnect switch and the key start
Present” switch. The switch supplies two switch to switch to the OFF position.
“ground type” inputs to the Transmission/Chassis
ECM and to the Implement ECM. The ECM expects B. Disconnect the connector of the machine harness
one of the two switch inputs to be grounded at all from the switch.
times. When the ECM detects that neither of the
switch inputs are grounded, the ECM will activate an C. At the connector of the machine harness for
FMI 03 diagnostic code for “voltage above normal”. the switch, connect a jumper wire between the
normally open (N/O) contact C (wire U767-BU)
Possible conditions that can cause this diagnostic and the normally closed (N/C) contact B (wire
code are listed: U766-BR).
• One or both of the switch circuits is open in the D. Disconnect the connectors of the machine harness
machine harness. J1 and J2 from the Transmission/Chassis ECM.
• One or both of the switch inputs is shorted to a E. At the machine harness connector of the
voltage source. Transmission/Chassis ECM J1, measure the
resistance between N/C contact J1-63 (wire
• The switch has failed. U766-BR) and N/O contact J1-64 (wire U767-BU).
• The ECM has failed. This is unlikely. Expected Result:
Note: Before performing this procedure, inspect The resistance measurement is less than 5 ohms.
circuit. Poor connections can often be the cause Results:
all connections in the circuit are clean, that all • OK – The resistance measurement is less than 5
connections are secure and that all connections ohms. The input circuits to the switch are not open
are in good condition. If a problem with a in the machine harness. Proceed to Test Step 2.
410 RENR9004-07

than 5 ohms. One of the input circuits to the switch
is open or has a poor connection in the machine • OK – The resistance measurement is less than 5
harness. ohms. The circuit for the common ground is not
open in the machine harness. Proceed to Test
Repair: There is an open or a poor connection in Step 3.
input wire to the switch U766-BR or input wire to
the switch U767-BU. Check each input circuit of • NOT OK – The resistance measurement is greater
the switch individually in order to determine the than 5 ohms. The circuit of the common ground
circuit that has the problem. is open or has a poor connection in the machine
harness.
If both of the ECMs have active diagnostic
codes, then there is most likely an open or a Repair: There is an open or a poor connection
bad connection on the switch side of the splice in ground wire of the switch A295-BK. Refer to
connection of the machine harness for the signal the complete Electrical System Schematic of the
wire. machine. Check all of the connectors that are in the
common connection to the ground circuit. Verify
If only one ECM has activated this diagnostic code, that all connection points for the circuit are clean,
there is most likely an open or a bad connection that all connection points are secure and that all
on the ECM side of the splice connection of the connection points are in good condition. Repair the
machine harness for the circuit wire to the switch. machine harness or replace the machine harness.
Refer to the complete Electrical System Schematic STOP.

of the machine. Verify that all connection points in
the suspected part of the circuits are clean, that all Test Step 3. CHECK THE HARNESS FOR
connections are secure and that all connections A SHORT
or replace the machine harness. The key start switch and the disconnect switch
STOP.
The switch for both ECMs and the connectors for
Test Step 2. CHECK THE SWITCH both ECMs remain disconnected from the machine
GROUND CIRCUIT FOR AN OPEN harness.
The disconnect switch and the key start switch remain A. Disconnect the jumper wire that was used in the
in the OFF position. The machine harness connectors last test step.
remain disconnected from the Transmission/Chassis
ECM and the switch. B. At the machine harness connector of the
A. Disconnect the machine harness connector J1 resistance between contact J1-63 (wire U766-BR)
from the Implement ECM. and all of the other contacts that are used in the
B. At the connector for the machine harness for the
switch, connect the jumper wire that was used in C. At the machine harness connector of the
the last test step between the common ground Transmission/Chassis ECM J1, measure the
contact A (wire A295-BK) and the normally closed resistance between contact J1-64 (wire U767-BU)
(N/C) contact B (wire U766-BR). and all of the other contacts that are used in the
C. At the machine harness connector for the
Implement ECM J1, measure the resistance Expected Result:
between the contact of the common ground J1-23
(wire A295-BK) and N/C contact J1-63 (wire Each resistance measurement is greater than 5000
U766-BR). ohms.
The resistance measurement is less than 5 ohms. • OK – Each resistance measurement is greater
than 5000 ohms. The input circuits to the switch
to Test Step 4.

RENR9004-07 411
Repair: There is a short circuit in a input circuit to B. Perform a 45 N (10 lb) pull test on each of the
the switch . The short is between the input circuit wires that are associated with the sensor circuit.
that revealed the low resistance measurement and
another circuit. Refer to the complete Electrical C. Reconnect all harness connectors. Make sure that
System Schematic of the machine. Check the the connectors are fully seated. Observe that the
connectors that are in the involved circuits. clips for each connector are completely fastened.
Verify that all connection points for the circuit are
clean, that all connections are secure and that D. Turn the disconnect switch and the key start
all connections are in good condition. Repair the switch to the ON position.
STOP.
Test Step 4. CHECK THE SWITCH is active.
OPERATION
Expected Result:
harness. The disconnect switch and the key start The CID 2113 FMI 03 diagnostic code is active.
Results:
A. At the connector for the switch, measure the
resistance (continuity) between common contact A • YES – The CID 2113 FMI 03 diagnostic code is
and the switch N/C contact B when an operator is active. The problem has not been corrected.
present in the operator seat and when no operator
is present in the operator seat. Repair: Repeat this procedure. Use the Caterpillar
B. At the connector for the switch, measure the in order to perform a “wiggle test” on the switch
resistance (continuity) between common contact A circuits in the machine wiring harness. The “wiggle
and the switch N/O contact C when an operator is test” can detect momentary or intermittent shorts
present in the operator seat and when no operator or opens in the machine wiring harness.
is present in the operator seat.
Expected Result: may have failed. Prior to replacing an ECM, always
The continuity checks of the switch are correct for possible consultation with Caterpillar. This
according to the table at the beginning of this consultation may greatly reduce repair time. If the
procedure. cause of the diagnostic code is not found, replace
the ECM that has activated the diagnostic code.
Results: Refer to Testing and Adjusting, “Electronic Control
• OK – The continuity checks between common
contact A and the switch contacts are correct. The STOP.
switch is operating correctly. Proceed to Test Step
5. • NO – The CID 2113 FMI 03 diagnostic code is not
common contact A and the contacts of the switch Repair: The initial diagnostic code was probably
are not correct. The switch is not working correctly. caused by a poor electrical connection or a
Repair: The “operator present” switch has failed. disconnected and reconnected. Resume normal
Replace the switch. After replacement of the machine operation.
switch, verify that the operation of the new switch
is correct before operating the machine. STOP.
STOP.

DIAGNOSTIC CODE
412 RENR9004-07
i02839845 Table 27
MID 027 - CID 2113 - FMI 04 States of Contact for “Operator Present” Switch
Operator Status N/O Input J1-64 N/C Input J1-63
SMCS Code: 1435-038 (wire U767-BU) (wire U766-BR)
Conditions Which Generate This Code: Operator Not Open(2) Closed(1)

Present
“Operator Closed Open
Present”
(2) Open to ECM return J1-23 (A295-BK - ground).
(1) Closed to ECM return J1-23 (A295-BK - ground).
Note: The “Operator Present” switch provides two

inputs to the Transmission/Chassis ECM and to the
Implement ECM. If one ECM has an active diagnostic
code and the other ECM does not have an active
diagnostic code, the switch is probably operating
correctly. This condition would indicate that there is
a problem in the machine harness. In either case,
perform this procedure in order to find the cause of
the problem.

Illustration 272
g01405089 Test Step 1. CHECK THE SWITCH
Connections for “Operator Present” Switch
This diagnostic code is associated with the “Operator switch to the ON position.
Present” switch. The switch supplies two switch to
ground types of inputs to the Transmission/Chassis B. Ensure that the diagnostic code is active.
ECM and to the Implement ECM. The ECM expects
one of the two inputs of the switch to be grounded C. Observe the status of the diagnostic code while
at all times. When the ECM detects that both of the the connector of the switch is disconnected from
inputs of the switch are grounded at the same time, the machine harness.
the ECM will activate an FMI 04 diagnostic code for
“voltage below normal”. Expected Result:
Some conditions that can cause this diagnostic code The CID 2113 FMI 04 diagnostic code will remain
are listed below: active if the switch is not the cause of the diagnostic
• One or both of the switch inputs is shorted to a code if the CID 2113 FMI 04 diagnostic code is NO
ground source. longer active and a CID 2113 FMI 03 diagnostic code
becomes active.
Results:
• OK – The CID 2113 FMI 04 diagnostic code
Note: Before performing this procedure, inspect remains active. The switch has not failed. Proceed
the harness connectors that are involved in the to Test Step 2.
of a problem in an electrical circuit. Verify that • NOT OK – The CID 2113 FMI 04 diagnostic code
all connections in the circuit are clean, that all is NO longer active. A CID 2113 FMI 03 diagnostic
connections are secure and that all connections code becomes active when the connector of the
are in good condition. If a problem with a switch is disconnected. The machine harness and
connection is found, correct the problem and the ECM are operating correctly. The switch has
verify that this diagnostic code is active before failed.
RENR9004-07 413
Repair: Replace the “Operator Present” switch. Test Step 3. CHECK THE STATUS OF THE
After replacement of the switch, verify that the DIAGNOSTIC CODE
operation of the new switch is correct before
operating the machine. A. Inspect the harness connectors. Clean the
STOP. wires for damage to the insulation that is caused
Test Step 2. CHECK THE HARNESS FOR
A SHORT B. Perform a 45 N (10 lb) pull test on each of the
harness. C. Reconnect all harness connectors. Make sure that
A. Disconnect the machine harness connectors J1 clips for each connector are completely fastened.
B. At the machine harness connector of the ECM J1, switch to the ON position.
(wire U766-BR) and frame ground. Measure the E. Operate the machine.
resistance between contact J1-63 (wire U766-BR)
to all of the other contacts that are used in the J1 F. Determine if the CID 2113 FMI 04 diagnostic code
and J2 connectors for the ECM. is active.
C. At the machine harness connector for the ECM J1, Expected Result:
(wire U767-BU) and frame ground. Measure the The CID 2113 FMI 04 diagnostic code is not active.
resistance between contact J1-64 (wire U767-BU)
to all of the other contacts that are used in the J1 Results:
and J2 connectors for the ECM.
Expected Result: not active. The diagnostic code does not exist at
Each resistance measurement is greater than 5000 caused by a poor connection or a short at one
ohms. of the connectors that was disconnected and
Results:
• OK – Each resistance measurement is greater code is active. The diagnostic code has not been
than 5000 ohms. The input circuits of the switch corrected.
to Test Step 3. Repair: Check the circuit again. Use the Caterpillar
• NOT OK – One or more of the resistance in order to perform a “wiggle test” on the machine
measurements is less than 5000 ohms. wiring harness. The “wiggle test” can detect
Repair: The input circuit of the switch is shorted to machine wiring harness.
the circuit with the low resistance measurement.
Refer to the complete Electrical System Schematic If the cause of the problem is not found, the ECM
of the machine. Check the connectors that are may have failed. Prior to replacing an ECM, always
in the involved circuits. Verify that all connection contact your dealership's Technical Communicator
points for the circuit are clean, that all connections for possible consultation with Caterpillar. This
are secure and that all connections are in good consultation may greatly reduce repair time. If the
condition. Repair the machine harness or replace cause of the diagnostic code is not found, replace
the machine harness. the ECM that has activated the diagnostic code.
STOP. Module (ECM) - Replace”.
STOP.
414 RENR9004-07
i02922455 Test Step 1. CHECK THE ENERGIZE

MID 027 - CID 2175 - FMI 03 SHORT
SMCS Code: 5479-038-ZH A. Turn the key start switch and the disconnect
B. Disconnect the machine harness connector
harness connectors J1 and J2 from the

(wire X754-GN) and all of the J1 and J2 contacts
that are used on the ECM connectors.
Expected Result:

ohms.
g01289122
Illustration 273
Results:
Connections of “Secondary Steer Left” solenoid

“secondary steer left” solenoid. The FMI 03 means Proceed to Test Step 2.
that the Transmission/Chassis ECM has determined
that the voltage of the solenoid circuit is above
normal.
greater than 5000 ohms.
Conditions that can cause this diagnostic code are Repair: There is a short in the machine harness.
listed below: The short is between the wire for the energize
circuit X754-GN and the circuit that has a low
• The energize circuit of the solenoid is shorted to resistance measurement.
• The ECM has failed. This is unlikely. finding short circuits, refer to Testing and Adjusting,
Before performing this procedure, inspect the machine harness or replace the machine harness.
circuit. Poor connections can often be the cause STOP.
all connections in the circuit are clean, that all Test Step 2. CHECK THE OPERATION OF
connections are secure and that all connections THE ECM
connection is found, correct the problem and The disconnect switch and the key start switch
verify that this diagnostic code is active before remain in the OFF position. The machine harness
performing this procedure. connectors for the solenoid and the ECM remain
disconnected.
diagnostic codes. Ignore these created diagnostic A. At the connector of the machine harness J1, use a
codes and clear these diagnostic codes when the 151-6320 Removal Tool to remove the energize
original diagnostic code has been corrected. wire of the solenoid X754-GN and the socket at
contact J1-67 from the harness connector.

RENR9004-07 415
D. Observe the status of the active CID 2175 FMI F. Determine if the CID 2175 FMI 03 diagnostic code
03 diagnostic code. is active.
The CID 2175 FMI 03 diagnostic code is no longer The CID 2175 FMI 03 diagnostic code is active.
active. Results:
Results: • YES – The CID 2175 FMI 03 diagnostic code is

active.
no longer active. A CID 2175 FMI 05 diagnostic Repair: Check the circuit again. Perform a “wiggle
code is active after the wire for the energize circuit test” on the solenoid circuit in the machine wiring
of the solenoid was disconnected. The ECM has harness. Use the Caterpillar Electronic Technician
responded correctly to the open circuit condition in (ET) in order to perform the test. The “wiggle
the solenoid circuit. test” is used to detect intermittent shorts or open
connections in the wiring harness of the machine.
Reinstall the energize wire of the solenoid into the
correct space of the ECM connector. Proceed to If the problem remains, the ECM may have failed.
the next test step. This is unlikely because the ECM detected the
Proceed to Test Step 3. activated the FMI 05 diagnostic code when the
solenoid energize wire was disconnected.
remains active. The status of the active diagnostic Verify that all possible causes of the diagnostic code
code did not change when the energize wire of the have been investigated. If the cause of the failure
solenoid was disconnected from the ECM. is not found, contact your dealership's Technical
Repair: The ECM has not responded correctly Caterpillar. This consultation may greatly reduce
to the open condition in the solenoid circuit. The repair time. If the cause of the diagnostic code is
operation of the ECM is not correct. not found, replace the Transmission/Chassis ECM.
Prior to replacing an ECM, always contact your Module (ECM) - Replace”.
consultation with Caterpillar. This consultation may STOP.
replaced, refer to Testing and Adjusting, “Electronic • NO – The CID 2175 FMI 03 code is not active. The
Control Module (ECM) - Replace”. problem does not exist at this time.
STOP. Repair: The initial diagnostic code was probably

Test Step 3. CHECK THE STATUS OF THE short at one of the harness connectors that was
DIAGNOSTIC CODE disconnected and reconnected. Resume normal
machine operation.




416 RENR9004-07
i02922465 Test Step 1. CHECK THE SOLENOID

MID 027 - CID 2175 - FMI 05 A. Disconnect the solenoid from the machine
harness.
Conditions Which Generate This Code: solenoid, place a jumper wire from contact 1 (wire
X754-GN) to contact 2 (wire 925-YL).


diagnostic code.
Expected Result:

active when the jumper wire is connected.
g01289122 Results:
Illustration 274
Connection of “Secondary Steer Left” Solenoid
This diagnostic code is associated with the code becomes active when the jumper wire is
“secondary steer left” solenoid. The FMI 05 means connected. The solenoid has failed.
that the Transmission/Chassis ECM has determined
that the current for the solenoid circuit is below Repair: The solenoid has failed. Repeat this Test
normal. Step “CHECK THE SOLENOID” in order to verify
the solenoid failure. Replace the solenoid. Verify
Conditions that could cause this diagnostic code to that the new solenoid corrects the problem.
STOP.
• The return circuit of the solenoid is open. remains active. The jumper wire does not affect the
• The solenoid has failed. causing the problem. Proceed to Test Step 2.
• The ECM has failed. This is unlikely. Test Step 2. CHECK THE CIRCUIT FOR
AN OPEN
harness connectors that are involved in the A. Turn the key start switch and the disconnect
circuit. Poor connections can often be the cause switch to the OFF position.
all connections in the circuit are clean, that all B. Disconnect the machine harness connector J1
connections are secure and that all connections from the Transmission/Chassis ECM.
connection is found, correct the problem and C. The jumper wire that was installed in the previous
verify that this diagnostic code is active before test step remains in place.
D. At the harness connector J1 for the
Note: The following test procedure may create other Transmission/Chassis ECM, measure the
diagnostic codes. Ignore these created diagnostic resistance between the return wire, contact J1-54
codes and clear these diagnostic codes when the (wire 925-YL) and the energize wire, contact
original diagnostic code has been corrected. J1-67 (wire X754-GN).
Note: The resistance of the solenoid coil should be Expected Result:
2.2 ± .2 ohms at 25 °C (77.0 °F).
RENR9004-07 417

not correct. There is an open or a bad connection • YES – The CID 2175 FMI 05 diagnostic code is no
in the machine harness. longer active. A CID 2175 FMI 06 diagnostic code
has been activated after the ECM pin is grounded.
Repair: A resistance measurement that is much The ECM has responded correctly to the grounded
greater than 5 ohms but less than 5000 ohms circuit condition in the solenoid circuit. The ECM is
could indicate that one of the connection points in most likely not causing the problem.
the circuit is not an open connection but not a good
connection. Reinstall the disconnected solenoid energize wire
back into the correct spot in the ECM connector.
The open or the possible poor connection is in the Proceed to the next test step.
supply wire X754-GN or in the return wire 925-YL
of the machine harness. Refer to the complete Proceed to Test Step 4.
Electrical System Schematic of the machine .
Check all of the connectors that are in the solenoid • NO – The CID 2175 FMI 05 diagnostic code
circuit. Ensure that all connections are clean, that remains active. The status of the active diagnostic
all connections are secure and that all connections code does not change when the ECM pin for the
are in good condition. Repair the machine harness solenoid is grounded.
STOP. the grounded condition in the solenoid circuit. The
THE ECM Prior to replacing an ECM, always contact your
The disconnect switch and the key start switch consultation with Caterpillar. This consultation may
remain in the OFF position. The machine harness greatly reduce repair time. If the ECM must be
connector for the solenoid and the ECM J1 connector replaced, refer to Testing and Adjusting, “Electronic
remain disconnected. Control Module (ECM) - Replace”.
A. Remove the jumper wire that was installed in the STOP.

last test step.
B. At the machine harness connector J1 for the DIAGNOSTIC CODE
the energize wire of the solenoid X754-GN and A. Inspect the harness connectors. Clean the
the socket at contact J1-65 from the harness contacts of the harness connectors. Check the
connector. wires for damage to the insulation that is caused
the ECM. B. Perform a 45 N (10 lb) pull test on each of the
switch to the ON position. C. Reconnect all harness connectors. Make sure that
E. Use a 7X-1710 Multimeter Probe that is not clips for each connector are completely fastened.
make contact with the ECM pin at J1-65 through D. Turn the disconnect switch and the key start
the empty space in the J1 connector. switch to the ON position.
F. Observe the status of the active CID 2175 FMI 05 E. Operate the machine.
7X-1710 Multimeter Probe to frame ground. F. Check the status of the CID 2175 FMI 05
diagnostic code.
418 RENR9004-07
The CID 2175 FMI 05 diagnostic code is active. MID 027 - CID 2175 - FMI 06
Results: SMCS Code: 5479-038-ZH
• YES – The CID 2175 FMI 05 diagnostic code Conditions Which Generate This Code:
Repair: Check the circuit again. Perform a “wiggle

test” on the machine wiring harness. Use the
Caterpillar Electronic Technician (ET) in order
to perform the test. The “wiggle test” is used to
detect intermittent shorts or open connections in
the wiring harness of the machine.

g01289122
Illustration 275
have been investigated. If the cause of the failure Connections of “Secondary Steer Left” solenoid
Communicator for possible consultation with This diagnostic code is associated with the
Caterpillar. This consultation may greatly reduce “secondary steer left” solenoid. The FMI 06 means
repair time. If the cause of the diagnostic code is that the Transmission/Chassis ECM has determined
not found, replace the Transmission/Chassis ECM. that the current of the solenoid circuit is above
Refer to Testing and Adjusting, “Electronic Control normal.
Conditions that could cause this diagnostic code to
STOP. be activated are listed below:
• NO – The CID 2175 FMI 05 diagnostic code is not • The energize circuit of the solenoid is shorted to a
active. The diagnostic code does not exist at this ground source.
time.
caused by a poor electrical connection at one of • The ECM has failed. This is unlikely.
reconnected. Resume normal machine operation. Before performing this procedure, inspect the
STOP. circuit. Poor connections can often be the cause


2.2 ± .2 ohms at 25 °C (77.0 °F).
RENR9004-07 419
Test Step 1. CHECK THE SOLENOID • NOT OK – One or more of the resistance
measurements is less than 5000 ohms. There
A. Turn the disconnect switch and the key start is a short in the machine harness. The short is
switch to the ON position. Do not start the engine. between wire X754-GN and the circuit with the low
C. Disconnect the solenoid with the active diagnostic circuits and finding short circuits, refer to Testing
code from the machine harness. and Adjusting, “Wiring Harness (Short Circuit) -
Expected Result: machine harness.
The active CID 2175 FMI 06 diagnostic code changes STOP.

solenoid is disconnected. Test Step 3. CHECK THE OPERATION OF
THE ECM
Results:
• YES – The active CID 2175 FMI 06 diagnostic remain in the OFF position. The machine harness
code changes to a CID 2175 FMI 05 diagnostic connectors for the solenoid and the ECM remain
code when the solenoid is disconnected. The disconnected.
circuit is correct.
A. At the machine harness connector J1 for the ECM,
Repair: The solenoid has failed. Repeat this test use a 151-6320 Removal Tool to remove the
“CHECK THE SOLENOID” in order to verify the energize wire of the solenoid at contact X754-GN
solenoid failure. Replace the solenoid. and the socket at contact J1-67 from the harness
connector.
STOP.
B. Reconnect the machine harness J1 and J2
• NO – The CID 2175 FMI 06 remains active when connectors to the ECM.
causing the problem. Proceed to Test Step 2. C. Turn the disconnect switch and the key start
CIRCUIT OF THE SOLENOID FOR A D. Observe the status of the active CID 2175 FMI
SHORT TO GROUND 06 diagnostic code.
A. Turn the key start switch and the disconnect Expected Result:
B. The solenoid remains disconnected from the active. A CID 2175 FMI 05 diagnostic code is now
machine harness. active.
C. Disconnect the machine harness connectors J1 Results:

D. At the machine harness connectors of the ECM, longer active. A CID 2175 FMI 05 diagnostic code
measure the resistance from the contact J1-67 has been activated after the solenoid energize
(wire X754-GN) to frame ground. Measure the circuit was disconnected. The ECM has responded
resistance between the contact J1-67 (wire correctly to the open circuit condition in the
X754-GN) and all of the other J1 and J2 contacts solenoid circuit.
that are used in the Transmission/Chassis ECM.
Reinstall the energize wire of the solenoid into the
Expected Result: correct space of the ECM connector. Proceed to
the next test step.
ohms. Proceed to Test Step 4.
Results: • NO – The CID 2175 FMI 06 diagnostic code

• OK – Each resistance measurement is greater code did not change when the energize wire of the
than 5000 ohms. The machine harness is correct. solenoid was disconnected from the ECM.
420 RENR9004-07
Repair: The ECM has not responded correctly It is unlikely that the ECM has failed. Verify that all
to the open condition in the solenoid circuit. The possible causes of the diagnostic code have been
operation of the ECM is not correct. investigated. If the cause of the failure is not found,
Prior to replacing an ECM, always contact your for possible consultation with Caterpillar. This
dealership's Technical Communicator for possible consultation may greatly reduce repair time. If the
consultation with Caterpillar. This consultation may cause of the diagnostic code is not found, replace
greatly reduce repair time. If the ECM must be the Transmission/Chassis ECM. Refer to Testing
replaced, refer to Testing and Adjusting, “Electronic and Adjusting, “Electronic Control Module (ECM)
Control Module (ECM) - Replace”. - Replace”.
STOP. STOP.
Test Step 4. CHECK THE STATUS OF THE • NO – The CID 2175 FMI 06 is not active. The
DIAGNOSTIC CODE diagnostic code does not exist at this time.
A. Inspect the harness connectors. Clean the Repair: The initial diagnostic code was probably
contacts of the harness connectors. Check the caused by a poor electrical connection or a
wires for damage to the insulation that is caused short at one of the harness connectors that was
by excessive heat, battery acid, or chafing. disconnected and reconnected. Resume normal
machine operation.
wires that are associated with the sensor circuit. STOP.

i02922511
D. Turn the disconnect switch and the key start SMCS Code: 5479-038-ZH

diagnostic code.
Expected Result:
Results:

corrected.
Repair: Check the circuit again. Perform a “wiggle g01289178

Illustration 276
test” on the machine wiring harness. Use the Connections of “Secondary Steer Right” solenoid
Caterpillar Electronic Technician (ET) in order to
perform the test. The “wiggle test” is used to detect This diagnostic code is associated with the
intermittent shorts or open connections in the “secondary steer right” solenoid. The FMI 03 means
wiring harness of the machine . that the Transmission/Chassis ECM has determined
that the voltage of the solenoid circuit is above
If the cause of the problem is not found, the ECM normal or that a voltage is present in the solenoid
may have failed. circuit when no voltage should be present.

listed below:


RENR9004-07 421
• The ECM has failed. This is unlikely. Test Step 2. CHECK THE OPERATION OF
THE ECM
harness connectors that are involved in the The disconnect switch and the key start switch
circuit. Poor connections can often be the cause remain in the OFF position. The machine harness
of a problem in an electrical circuit. Verify that connectors for the solenoid and the ECM remain
all connections in the circuit are clean, that all disconnected.
are in good condition. If a problem with a A. At the machine harness connector J1 for the ECM,
connection is found, correct the problem and use a 151-6320 Removal Tool to remove the
verify that this diagnostic code is active before wire X755-WH and the socket at contact J1-68
performing this procedure. from the harness connector.
Note: The following test procedure may create other B. Reconnect the machine harness J1 and J2
diagnostic codes. Ignore these created diagnostic connectors to the ECM.
original diagnostic code has been corrected. C. Turn the disconnect switch and the key start
2.2 ± .2 ohms at 25 °C (77.0 °F). D. Observe the status of the active CID 2176 FMI
03 diagnostic code.
CIRCUIT OF THE SOLENOID FOR A Expected Result:
SHORT
A. Turn the key start switch and the disconnect active. A CID 2176 FMI 05 diagnostic code is now
switch to the OFF position. active.
B. Disconnect the machine harness connector Results:

from the solenoid. Disconnect the connectors
of the machine harness J1 and J2 from the • YES – The CID 2176 FMI 03 diagnostic code is no
Transmission/Chassis ECM. longer active. A CID 2176 FMI 05 diagnostic code
is active after the energize circuit of the solenoid is
C. At the machine harness connector for the ECM J1, disconnected. The ECM has responded correctly
measure the resistance from contact J1-68 (wire to the open circuit condition in the solenoid circuit.
X755-WH) and all the J1 and J2 contacts that are
used on the Transmission/Chassis ECM. Install the wire for the energize circuit of the
solenoid in the correct space of the ECM. Proceed
Expected Result: to the next test step.
Each resistance measurement is greater than 5000 Proceed to Test Step 3.

ohms.
Results: remains active. The status of the active diagnostic
code does not change after the wire for the
• OK – Each resistance measurement is greater energize circuit of the solenoid is disconnected
than 5000 ohms. The machine harness is correct. from the ECM.
• NOT OK – Each resistance measurement is not to the open condition in the solenoid circuit. The
greater than 5000 ohms. operation of the ECM is not correct.
Repair: There is a short in the machine harness. Prior to replacing an ECM, always contact your
The short is between wire X755-WH and the circuit dealership's Technical Communicator for possible
that has a low resistance measurement. consultation with Caterpillar. This consultation may
For information on testing for short circuits and replaced, refer to Testing and Adjusting, “Electronic
finding short circuits, refer to Testing and Adjusting, Control Module (ECM) - Replace”.
machine harness or replace the machine harness. STOP.
STOP.
422 RENR9004-07
Test Step 3. CHECK THE STATUS OF THE Repair: The initial diagnostic code was probably
DIAGNOSTIC CODE caused by a poor electrical connection or a
A. Inspect the harness connectors. Clean the disconnected and reconnected. Resume normal
contacts of the harness connectors. Check the machine operation.

i02922567

MID 027 - CID 2176 - FMI 05
the connectors are fully seated. Observe that the SMCS Code: 5479-038-ZH

is active.
Expected Result:
Results:

active. g01289178
Illustration 277
Connections of “Secondary Steer Right” solenoid
test” on the machine wiring harness. Use the This diagnostic code is associated with the
Caterpillar Electronic Technician (ET) in order “secondary steer right” solenoid. The FMI 05 means
to perform the test. The “wiggle test” can detect that the Transmission/Chassis ECM has determined
intermittent shorts or open connections in the that the current for the solenoid circuit is below
wiring harness of the machine . normal.
If the problem remains, the ECM may have Conditions that could cause this diagnostic code to
failed. The failure of the ECM is unlikely. The be activated are listed below:
Transmission/Chassis ECM was able to active the
FMI 05 diagnostic code when the energize wire of • The energize circuit of the solenoid is open.
the solenoid was removed from the circuit.
possible causes of the diagnostic code have been • The solenoid has failed.
contact your dealership's Technical Communicator • The ECM has failed. This is unlikely.
consultation may greatly reduce repair time. If Before performing this procedure, inspect the
the ECM must be replaced, refer to Testing and harness connectors that are involved in the
Adjusting, “Electronic Control Module (ECM) - circuit. Poor connections can often be the cause
Replace”. of a problem in an electrical circuit. Verify that
STOP. connections are secure and that all connections
• NO – The CID 2176 FMI 03 code is not active. The connection is found, correct the problem and
problem does not exist at this time. verify that this diagnostic code is active before
RENR9004-07 423
Note: The following test procedure may create other D. At the machine harness connector J1 for the
diagnostic codes. Ignore these created diagnostic Transmission/Chassis ECM, measure the
codes and clear these diagnostic codes when the resistance from contact J1-54 (wire 925-YL) to the
original diagnostic code has been corrected. contact J1-68 (wire X755-WH).
Note: The resistance of the solenoid coil should be Expected Result:

2.2 ± .2 ohms at 25 °C (77.0 °F).
Results:
harness. • OK – The measurement of the resistance is less
than 5 ohms. The circuit is not open in the machine
B. At the machine harness connector for the harness. Proceed to Test Step 3.
X755-WH) to contact 2 (wire 925-YL). • NOT OK – The resistance measurement is greater
C. Turn the disconnect switch and the key start not correct. There is an open or a bad connection
switch to the ON position. Do not start the engine. in the machine harness.
D. Observe the status of the CID 2176 FMI 05 Repair: A resistance measurement that is much
diagnostic code. greater than 5 ohms but less than 5000 ohms
Expected Result: the circuit is not an open connection but not a good
connection.
active. A CID 2176 FMI 06 diagnostic code becomes The open or the possible poor connection is in
active when the jumper wire is connected. supply wire X755-WH or in the return wire 925-YL
Results: Electrical System Schematic of the machine .
• YES – The CID 2176 FMI 05 diagnostic code is circuit. Ensure that all connections are clean, that
no longer active. A CID 2176 FMI 06 diagnostic all connections are secure and that all connections
code becomes active when the jumper wire is are in good condition. Repair the machine harness
connected. The solenoid has failed. or replace the machine harness.

last test step.
AN OPEN B. At the harness connector J1 for the ECM, use a
151-6320 Removal Tool to remove the energize
A. Turn the key start switch and the disconnect wire of the solenoid X755-WH and the socket at
switch to the OFF position. contact J1-68 from the harness connector.
B. Disconnect the machine harness connector J1 C. Reconnect the machine harness J1 connector to
from the Transmission/Chassis ECM. the ECM.
C. The jumper wire that was installed in the previous D. Turn the disconnect switch and the key start
Test Step remains in place. switch to the ON position.
424 RENR9004-07
E. Use a 7X-1710 Multimeter Probe that is not D. Turn the disconnect switch and the key start
connected to a multimeter or a similar device to switch to the ON position.
make contact with the ECM pin at J1-68 through
the empty space in the J1 connector. E. Operate the machine.
F. Observe the status of the active CID 2176 FMI 05 F. Check the status of the CID 2176 FMI 05
diagnostic code and ground the other end of the diagnostic code.
7X-1710 Multimeter Probe to the frame ground.
Expected Result:
Expected Result:
active. A CID 2176 FMI 06 diagnostic code becomes Results:
Results: is active. The diagnostic code has not been
longer active. A CID 2176 FMI 06 diagnostic code Repair: Check the circuit again. Perform a “wiggle
has become active after the ECM pin is grounded. test” on the machine wiring harness. Use the
The ECM has responded correctly to the grounded Caterpillar Electronic Technician (ET) in order
circuit condition in the solenoid circuit. It is likely to perform the test. The “wiggle test” can detect
that the ECM is the cause of the problem. intermittent shorts or open connections in the
Reconnect the energize wire of the solenoid.
Proceed to the next test step. If the cause of the problem is not found in the
Proceed to Test Step 4. is unlikely as the ECM response was correct for
the grounded condition in the previous test step.
remains active. The status of the active diagnostic Verify that all possible causes of the diagnostic code
code does not change when the ECM pin for the have been investigated. If the cause of the failure
solenoid is grounded. is not found, contact your dealership's Technical
Repair: The ECM has not responded correctly to Caterpillar. This consultation may greatly reduce
the grounded condition in the solenoid circuit. The repair time. If the cause of the diagnostic code is
operation of the ECM is not correct. not found, replace the Transmission/Chassis ECM.
Prior to replacing an ECM, always contact your Module (ECM) - Replace”.
consultation with Caterpillar. This consultation may STOP.
replaced, refer to Testing and Adjusting, “Electronic • NO – The CID 2176 FMI 05 diagnostic code is not
Control Module (ECM) - Replace”. active. The diagnostic code does not exist at this
time.
STOP.
Test Step 4. CHECK THE STATUS OF THE caused by a poor electrical connection at one of
DIAGNOSTIC CODE the harness connectors that was disconnected and


RENR9004-07 425

MID 027 - CID 2176 - FMI 06 A. Turn the disconnect switch and the key start
Expected Result:

Results:

g01289178 circuit is correct.
Illustration 278
Connections of “Secondary Steer Right” solenoid Repair: The solenoid has failed. Repeat this test
This diagnostic code is associated with the solenoid failure. Replace the solenoid.
“secondary steer right” solenoid. The FMI 06 means
that the Transmission/Chassis ECM has determined STOP.
that the current of the solenoid circuit is above
normal.
Conditions that could cause this diagnostic code to causing the problem. Proceed to Test Step 2.
• The energize circuit of the solenoid is shorted to a CIRCUIT OF THE SOLENOID FOR A
ground source. SHORT TO GROUND
• The solenoid has failed. A. Turn the key start switch and the disconnect
B. The solenoid remains disconnected from the
Before performing this procedure, inspect the machine harness.
circuit. Poor connections can often be the cause C. Disconnect the machine harness connectors J1
of a problem in an electrical circuit. Verify that and J2 from the Transmission/Chassis ECM.
connections are secure and that all connections D. At the machine harness connectors for the ECM,
are in good condition. If a problem with a measure the resistance from the contact J1-68
connection is found, correct the problem and (wire X755-WH) to frame ground. Measure the
verify that this diagnostic code is active before resistance from the contact J1-68 (wire X755-WH)
performing this procedure. to all of the other J1 and J2 contacts that are used
in the Transmission/Chassis ECM.
diagnostic codes. Ignore these created diagnostic Expected Result:
original diagnostic code has been corrected. Each resistance measurement is greater than 5000
ohms.
2.2 ± .2 ohms at 25 °C (77.0 °F). Results:

426 RENR9004-07
• NOT OK – One or more of the resistance • NO – The CID 2176 FMI 06 diagnostic code
measurements is less than 5000 ohms. There remains active. The status of the active diagnostic
is a short in the machine harness. The short is code did not change when the energize wire of the
between wire X755-WH and the circuit with the low solenoid was disconnected from the ECM.
Repair: Refer to the complete Electrical System to the open condition in the solenoid circuit. The
Schematic of the machine . Check all of the operation of the ECM is not correct.
that all connections are clean, that all connections Prior to replacing an ECM, always contact your
are secure and that all connections are in good dealership's Technical Communicator for possible
condition. consultation with Caterpillar. This consultation may
For information on testing for short circuits and replaced, refer to Testing and Adjusting, “Electronic
finding short circuits, refer to Testing and Adjusting, Control Module (ECM) - Replace”.
machine harness or replace the machine harness. STOP.
STOP. Test Step 4. CHECK THE STATUS OF THE

DIAGNOSTIC CODE
THE ECM A. Inspect the harness connectors. Clean the
The disconnect switch and the key start switch wires for damage to the insulation that is caused
remain in the OFF position. The machine harness by excessive heat, battery acid, or chafing.
connectors for the solenoid and the ECM remain
disconnected. B. Perform a 45 N (10 lb) pull test on each of the
ECM, use a 151-6320 Removal Tool to remove C. Reconnect all harness connectors. Make sure that
the energize wire of the solenoid X755-WH and the connectors are fully seated. Observe that the
the socket at contact J1-68 from the harness clips for each connector are completely fastened.
connector.
B. Reconnect the machine harness J1 and J2 switch to the ON position.
switch to the ON position. F. Check the status of the CID 2176 FMI 06
diagnostic code.
06 diagnostic code. Expected Result:
Expected Result: The CID 2176 FMI 06 diagnostic code is still active.
The CID 2176 FMI 06 diagnostic code is no longer Results:

active. • YES – The CID 2176 FMI 06diagnostic code is
Results: corrected.
• YES – The CID 2176 FMI 06 diagnostic code is no Repair: Check the circuit again. Perform a “wiggle
longer active. A CID 2176 FMI 05 diagnostic code test” on the machine wiring harness. Use the
has been activated after the solenoid energize Caterpillar Electronic Technician (ET) in order
circuit was disconnected. The ECM has responded to perform the test. The “wiggle test” can detect
correctly to the open circuit condition in the intermittent shorts or open connections in the
solenoid circuit. machine wiring harness.
Reconnect the energize wire of the solenoid into If the cause of the problem is not found, the ECM
the correct space of the ECM connector. Proceed may have failed.
to the next test step.

RENR9004-07 427
It is unlikely that the ECM has failed. Verify that all When a CID 2199 diagnostic code is activated by the
possible causes of the diagnostic code have been Transmission/Chassis ECM, the ECM will activate
investigated. If the cause of the failure is not found, the secondary steering system without input from the
contact your dealership's Technical Communicator Implement ECM. This is the only condition that will
for possible consultation with Caterpillar. This cause the Transmission/Chassis ECM to activate the
consultation may greatly reduce repair time. If secondary steering system without input from the
the ECM must be replaced, refer to Testing and Implement ECM.
Replace”. During normal operation, when the Implement ECM
detects a problem in the primary steering system, the
STOP. Implement ECM will send a pulse width modulated
(PWM) signal to the Transmission/Chassis ECM
• NO – The CID 2176 FMI 06 is not active. The on the secondary steering request circuit that is
diagnostic code does not exist at this time. connected between the two controls.
Repair: The initial diagnostic code was probably When the Implement ECM sends a PWM secondary
caused by a poor electrical connection or a steer request signal to the Transmission/Chassis
short at one of the harness connectors that was ECM, the duty cycle of the PWM signal will determine
disconnected and reconnected. Resume normal which specific secondary steer system components
machine operation. will be activated. During normal operation, the
Implement ECM maintains a 20 percent duty cycle
STOP. on the request circuit. When a secondary steering
test is requested or when the Implement ECM has
i02922616
the secondary steering signal will be one of the
MID 027 - CID 2199 - FMI 03 following duty cycle signals:
SMCS Code: 7610-038-II 20 percent PWM duty cycle – Normal operation, no

request to activate.
40 percent PWM duty cycle – Request to activate
the secondary steering pump motor only.

the secondary steering pilot solenoid valves only.

the secondary steering pump and the secondary
steering pilot solenoid valves.

• There is an open in the circuit.

Illustration 279
g01305868
• The circuit is shorted to another voltage source.
Connections of “Secondary Steer Request” signal circuit
“secondary steer request” signal circuit. This Note: Before performing this procedure, inspect
circuit enables the Implement ECM to request that the harness connectors that are involved in the
the Transmission/Chassis ECM activate specific circuit. Poor connections can often be the cause
components of the secondary steering system or of a problem in an electrical circuit. Verify that
to active the complete secondary steering system all connections in the circuit are clean, that all
during times that certain machine conditions require connections are secure and that all connections
it. are in good condition. If a problem with a
The FMI 03 diagnostic code means that the verify that this diagnostic code is active before
Transmission/Chassis ECM has determined that the performing this procedure.
voltage of the circuit is above normal.
428 RENR9004-07
Note: The following test procedure may create other The open or the possible bad connection is in
diagnostic codes. Ignore these created diagnostic wire U753-BR. Refer to the complete Electrical
codes and clear the diagnostic codes when the System Schematic of the machine . Check all of
problem has been corrected. the connectors that are in the circuit. Ensure that
Test Step 1. CHECK THE CIRCUIT FOR are secure and that all connections are in good
AN OPEN condition. Repair the machine harness or replace
switch to the OFF position. STOP.
B. Disconnect the machine harness connectors J1 Test Step 2. CHECK THE CIRCUIT FOR
and J2 from the Implement ECM and from the A SHORT
C. Obtain a spare length of wire that will reach from in the OFF position. The machine harness connectors
the connectors for the Implement ECM to the for both ECM modules remain disconnected.
connectors for the Transmission/Chassis ECM .
A. Remove the spare wire that was used in the last
D. At the Implement ECM connector J2 connect one test step.
end of the spare wire to the request circuit contact
J2-19 (wire U753-BR). B. At the J2 machine harness connector for the
E. At the Transmission/Chassis ECM connector J2, resistance from the contact J2-25 (wire U753-BR)
measure the resistance between the other end to all of the other J1 and J2 contacts that are used
of the spare wire and the request circuit contact on the connectors of the Transmission/Chassis
J2-25 (wire U753-BR. ECM.
Expected Result: C. At the J2 machine harness connector for the

Implement ECM, measure the resistance from the
The resistance measurement is less than 5 ohms. contact J2-19 (wire U753-BR) to all of the other J1
and J2 contacts that are used on the connectors
Results: of the Implement ECM.
• OK – The resistance measurement is less than Expected Result:

5 ohms. The resistance measurement is not
indicating that the secondary steering request Each resistance measurement is greater than 5000
circuit is open in the machine harness. Proceed ohms.
to Test Step 2.
Results:
than 5 ohms. There is an open or a bad connection • OK – Each resistance measurement is greater
in the circuit for the secondary steering request. than 5000 ohms. The measurement does not
indicate that the request signal circuit is shorted in
Repair: A resistance measurement that is greater the machine harness. Proceed to Test Step 3.
connected or that a wire is open. A resistance • NOT OK – One or more of the resistance
measurement that is greater 5 ohms but less measurements is less than 5000 ohms.
connection points in the circuit is not an open Repair: There is a short in the machine harness.
connection but not a good connection. The short is between the request signal circuit wire
U753-BR and the circuit with the low resistance
A poor connection can cause the problem. A measurement.
connector may be loose, dirty or corroded. Inspect
the connectors that are in the circuit. Ensure that
all connectors are clean, that all connectors are
tight and that all connectors are in good condition.
RENR9004-07 429
Refer to the complete Electrical System Schematic • NO – The CID 2199 FMI 03 diagnostic code
of the machine . Examine all of the connectors remains active. The status of the active diagnostic
in circuits for points in the machine harness code does not change when the ECM pin is
that indicate the circuits could be shorted. For grounded.
information on testing for short circuits and finding
short circuits, refer to Testing and Adjusting, Repair: The ECM has not responded correctly to
“Wiring Harness (Short Circuit) - Test”. Repair the the ground condition of the circuit. The operation of
machine harness or replace the machine harness. the ECM is not correct.
STOP. Prior to replacing an ECM, always contact your

Test Step 3. CHECK THE OPERATION OF consultation with Caterpillar. This consultation may
THE ECM greatly reduce repair time. If the ECM must be
The disconnect switch and the key start switch Control Module (ECM) - Replace”.
STOP.
A. Reconnect the J1 and J2 machine harness
connectors to the Implement ECM and to the Test Step 4. CHECK THE STATUS OF THE
Transmission/Chassis ECM. DIAGNOSTIC CODE
B. At the machine harness connector J2 for the A. Inspect the harness connectors. Clean the
Transmission/Chassis ECM, use a 151-6320 contacts of the harness connectors. Check the
Removal Tool to remove the request signal wire wires for damage to the insulation that is caused
U753-BR and the socket at contact J2-25 from by excessive heat, battery acid, or chafing.
the harness connector. The machine harness
connector J2 remains connected to the ECM. B. Perform a 45 N (10 lb) pull test on each of the
switch to the ON position. C. Reconnect all harness connectors. Make sure that
D. Use a 7X-1710 Multimeter Probe that is clips for each connector are completely fastened.
not connected to a multimeter or a similar
device to make contact with the pin of the D. Turn the disconnect switch and the key start
Transmission/Chassis ECM at J2-25 through the switch to the ON position.
empty space in the J2 connector.
E. Observe the status of the active CID 2199 FMI 03
diagnostic code and ground the other end of the F. Determine if the CID 2199 FMI 03 diagnostic code
7X-1710 Multimeter Probe to frame ground. is active.
The CID 2199 FMI 03 diagnostic code is no longer The CID 2199 FMI 03 diagnostic code is not active.
active when the ECM pin at J2-25 is grounded. Results:
Results: • OK – The CID 2199 FMI 03 diagnostic code is

• YES – The CID 2199 FMI 03 diagnostic code is no this time. The initial diagnostic code was probably
longer active. A CID 2199 FMI 04 diagnostic code caused by a poor connection or a short at one
has been activated after the ECM pin is grounded. of the connectors that was disconnected and
The ECM has responded correctly to the grounded reconnected. Resume normal operation. STOP.
circuit condition. It is unlikely that the ECM is the
cause of the problem. • NOT OK – The CID 2199 FMI 03 diagnostic
Reconnect the wire into the correct spot of the corrected.
ECM connector. Proceed to the next test step.

430 RENR9004-07
Repair: Check the circuit again. Perform a “wiggle When a CID 2199 diagnostic code is activated by the
test” on the machine wiring harness. Use the Transmission/Chassis ECM, the ECM will activate
Caterpillar Electronic Technician (ET) in order the secondary steering system without input from the
to perform the test. The “wiggle test” can detect Implement ECM. This is the only condition that will
intermittent shorts or open connections in the cause the Transmission/Chassis ECM to activate the
machine wiring harness. secondary steering system without input from the
Implement ECM.
machine harness, the ECM may have failed. It is During normal operation, when the Implement ECM
unlikely as the ECM response was correct to the detects a problem in the primary steering system, the
ground condition of the previous test step. Implement ECM will send a pulse width modulated
(PWM) signal to the Transmission/Chassis ECM on
Verify that all possible causes of the diagnostic the circuit for the secondary steering request that is
code have been investigated. Exit this procedure connected between the two controls.
and perform this procedure again.
When the Implement ECM sends a PWM secondary
Prior to replacing an ECM, always contact your steering request signal to the Transmission/Chassis
dealership's Technical Communicator for possible ECM, the duty cycle of the PWM signal will determine
consultation with Caterpillar. This consultation may the specific secondary steering system components
greatly reduce repair time. If the cause of the active that will be activated. During normal operation, the
diagnostic code is not found and the ECM must be Implement ECM maintains a 20 percent duty cycle
replaced, refer to Testing and Adjusting, “Electronic on the request circuit. When a secondary steer
Control Module (ECM) - Replace”. test is requested or when the Implement ECM has
STOP. the secondary steering request signal will be one of
the following duty cycle signals:
i02922876
20 percent PWM duty cycle – Normal operation, no
MID 027 - CID 2199 - FMI 04 request to activate.
SMCS Code: 7610-038-II 40 percent PWM duty cycle – Request to activate

the secondary steer pump motor only.
the secondary steer pilot solenoid valves only.

the secondary steer pump and the secondary steer
pilot solenoid valves.

• The circuit is shorted to a ground source.

g01305868 the harness connectors that are involved in the
Illustration 280
Connections of “Secondary Steer Request” signal circuit circuit. Poor connections can often be the cause
This diagnostic code is associated with the all connections in the circuit are clean, that all
“secondary steer request” signal circuit. This circuit connections are secure and that all connections
enables the Implement ECM to request that the are in good condition. If a problem with a
Transmission/Chassis ECM activate the secondary connection is found, correct the problem and
steering system when certain machine conditions verify that this diagnostic code is active before
require it. performing this procedure.
The FMI 04 means that the Transmission/Chassis Note: The following test procedure may create other
ECM has detected that a lower than normal voltage diagnostic codes. Ignore these created diagnostic
is present in the circuit. codes and clear the diagnostic codes when the
RENR9004-07 431
Test Step 1. CHECK THE CIRCUIT FOR A A. Reconnect the machine harness connectors
SHORT TO GROUND J1 and J2 to the Implement ECM and to the
switch to the OFF position. B. Turn the disconnect switch and the key start
and J2 from the Implement ECM and from the C. At the machine harness connector J2 for the
Transmission/Chassis ECM. Transmission/Chassis ECM, use a 151-6320
Removal Tool to remove the request signal wire
C. At the J2 machine harness connector for the U753-BR and the socket at contact J2-25 from
Transmission/Chassis ECM, measure the the harness connector. The machine harness
resistance from contact J2-25 (wire U753-BR) connector J2 remains connected to the ECM.
to frame ground. Measure the resistance from
contact J2-25 (wire U753-BR) to all of the other J1 D. Turn the disconnect switch and the key start
and J2 contacts that are used on the connectors switch to the ON position.
of the Transmission/Chassis ECM.
D. At the J2 machine harness connector for the 04 diagnostic code.
Implement ECM, measure the resistance from the
contact J2-19 (wire U753-BR) to frame ground. Expected Result:
U753-BR) to all of the other J1 and J2 contacts The CID 2199 FMI 04 diagnostic code is no longer
that are used on the connectors of the Implement active. A CID 2199 FMI 03 diagnostic code is now
ECM. active.
Each resistance measurement is greater than 5000 • YES – The CID 2199 FMI 04 diagnostic code is
ohms. no longer active. A CID 2199 FMI 03 diagnostic
code has been activated after the request signal
Results: circuit was disconnected. The ECM has responded
correctly to the open circuit condition in the circuit.
than 5000 ohms. The measurement does not Reconnect the wire for the request signal into the
indicate that the request signal circuit is shorted to correct spot of the ECM connector. Proceed to the
ground in the machine harness. Proceed to Test next test step.
Step 2.
measurements is less than 5000 ohms. • NO – The CID 2199 FMI 04 diagnostic code
Repair: There is a short in the machine harness. code did not change when the wire of the signal
The short is between the request signal circuit wire request was disconnected from the ECM.
U753-BR and the circuit with the low resistance
measurement or the frame ground. Repair: The ECM has not responded correctly
Refer to the complete Electrical System Schematic operation of the ECM is not correct.
of the machine. Examine all of the connectors
in the circuit. In the machine harness, look for Prior to replacing an ECM, always contact your
points that indicate the circuits could be shorted. dealership's Technical Communicator for possible
For information on testing for short circuits and consultation with Caterpillar. This consultation may
finding short circuits, refer to Testing and Adjusting, greatly reduce repair time. If the ECM must be
“Wiring Harness (Short Circuit) - Test”. Repair the replaced, refer to Testing and Adjusting, “Electronic
machine harness or replace the machine harness. Control Module (ECM) - Replace”.
STOP. STOP.

THE ECM
432 RENR9004-07
A. Inspect the harness connectors. Clean the greatly reduce repair time. If the cause of the active
contacts of the harness connectors. Check the diagnostic code is not found and the ECM must be

i02923053
MID 027 - CID 2199 - FMI 08

is active.
Expected Result:
Results:

caused by a poor connection or a short at one g01305868
Illustration 281
of the connectors that was disconnected and Connections of “Secondary Steer Request” signal circuit
• NOT OK – The CID 2199 FMI 04 diagnostic “secondary steer request” signal circuit. This circuit
code is active. The diagnostic code has not been enables the Implement ECM to request that the
corrected. Transmission/Chassis ECM activate the “secondary
steering system” at times that certain machine
Repair: Check the circuit again. Perform a “wiggle conditions require it.
Caterpillar Electronic Technician (ET) in order The FMI 08 means that the Transmission/Chassis
to perform the test. The “wiggle test” can detect ECM has detected that the signal circuit has an
intermittent shorts or open connections in the abnormal frequency or pulse width.
When a CID 2199 diagnostic code is activated by the
If the cause of the problem is not found in the Transmission/Chassis ECM, the ECM will activate
machine harness, the ECM may have failed. It is the “secondary steer system” without input from the
unlikely as the ECM response was correct for the Implement ECM. This is the only condition that will
ground condition in the previous test step. cause the Transmission/Chassis ECM to activate
the “secondary steer system” without input from the
Verify that all possible causes of the diagnostic Implement ECM.
code have been investigated. Exit this procedure
and perform this procedure again. During normal operation, when the Implement ECM
detects a problem in the primary steering system, the
Implement ECM will send a pulse width modulated
(PWM) signal to the Transmission/Chassis ECM on
the “secondary steer request circuit” that is connected
between the two controls.
RENR9004-07 433
When the Implement ECM sends a PWM “secondary D. At the Implement ECM connector J2 connect one
steer request signal” to the Transmission/Chassis end of the spare wire to the contact for the request
ECM, the duty cycle of the PWM signal will determine circuit J2-19 (wire U753-BR).
the specific “secondary steer system” components
that will be activated. During normal operation, the E. At the Transmission/Chassis ECM connector J2,
Implement ECM maintains a 20 percent duty cycle measure the resistance between the other end
on the request circuit. When a “secondary steering of the spare wire and the request circuit contact
test” is requested or when the Implement ECM has J2-25 (wire U753-BR.
the “secondary steer request” signal will be one of F. Observe the resistance measurement and wiggle
the following duty cycle signals: the connector of the Implement ECM and the
connector of the Transmission/Chassis ECM.
20 percent PWM duty cycle – Normal operation, no Gently pull on the wires and wiggle the wires for
request to activate. both connectors.
40 percent PWM duty cycle – Request to activate Expected Result:

the “secondary steer pump” motor only.
60 percent PWM duty cycle – Request to activate at all times during the manipulation of the wiring
the “secondary steer pilot” solenoid valves only. harness and connectors.
80 percent PWM duty cycle – Request to activate Results:

the “secondary steer pump” and the “secondary steer
pilot” solenoid valves. • OK – The resistance measurement is less than
Conditions that can cause this diagnostic code to be indicating that the “secondary steer request” circuit
activated are listed below: is open in the machine harness. Proceed to Test
Step 2.
• Intermittent connections or poor connections in the
signal circuit. • NOT OK – The resistance measurement is greater
• The ECM has failed. This is unlikely. in the “secondary steer request” circuit.
Note: Before performing this procedure, inspect Repair: A resistance measurement that is greater
the harness connectors that are involved in the than 5000 ohms could indicate that a wire is not
circuit. Poor connections can often be the cause connected or that a wire is open. A resistance
of a problem in an electrical circuit. Verify that measurement that is greater 5 ohms but less
all connections in the circuit are clean, that all than 5000 ohms could indicate that one of the
connections are secure and that all connections connection points in the circuit is not an open
are in good condition. If a problem with a connection but not a good connection.
verify that this diagnostic code is active before A poor connection could be causing the problem. A
performing this procedure. connector may be loose, dirty or corroded. Inspect
the connectors that are in the circuit. Ensure that
Note: The following test procedure may create other all connectors are clean, that all connectors are
diagnostic codes. Ignore these created diagnostic tight and that all connectors are in good condition.
problem has been corrected. The open or the possible bad connection is in
wire U753-BR. Refer to the complete Electrical
Test Step 1. CHECK THE CIRCUIT FOR System Schematic of the machine . Check all of
AN OPEN the connectors that are in the circuit. Ensure that
A. Turn the key start switch and the disconnect are secure and that all connections are in good
switch to the OFF position. condition. Repair the machine harness or replace
and J2 from the Implement ECM and from the STOP.
C. Obtain a spare length of wire that will reach from THE ECM
the connectors of the Implement ECM to the
connectors of the Transmission/Chassis ECM. The disconnect switch and the key start switch
434 RENR9004-07
A. Reconnect the machine harness connectors Test Step 3. CHECK THE STATUS OF THE
J1 and J2 to the Implement ECM and to the DIAGNOSTIC CODE
B. Turn the disconnect switch and the key start contacts of the harness connectors. Check the
switch to the ON position. wires for damage to the insulation that is caused
C. At the machine harness connector J2 for the
Transmission/Chassis ECM, use a 151-6320 B. Perform a 45 N (10 lb) pull test on each of the
Removal Tool to remove the wire for the request wires that are associated with the sensor circuit.
signal U753-BR and the socket at contact J2-25
from the harness connector. The machine harness C. Reconnect all harness connectors. Make sure that
connector J2 remains connected to the ECM. the connectors are fully seated. Observe that the
switch to the ON position. D. Turn the disconnect switch and the key start
08 diagnostic code. E. Operate the machine.

is active.
active. A CID 2199 FMI 03 diagnostic code is now Expected Result:
active.
Results:
Results:
no longer active. A CID 2199 FMI 03 diagnostic • OK – The CID 2199 FMI 03 diagnostic code is
code has been activated after the request signal not active. The diagnostic code does not exist at
circuit was disconnected. The ECM has responded this time. The initial diagnostic code was probably
correctly to the open circuit condition in the circuit. caused by a poor connection or a short at one
Reconnect the “request signal” wire into the correct reconnected. Resume normal operation. STOP.
spot of the ECM connector. Proceed to the next
test step. • NOT OK – The CID 2199 FMI 03 diagnostic
Proceed to Test Step 3. corrected.
• NO – The CID 2199 FMI 08 diagnostic code Repair: Check the circuit again. Perform a “wiggle
remains active. The status of the active diagnostic test” on the machine wiring harness. Use the
code did not change when the wire for the request Caterpillar Electronic Technician (ET) in order
signal was disconnected from the ECM. to perform the test. The “wiggle test” can detect
intermittent shorts or open connections in the
Repair: The ECM has not responded correctly machine wiring harness.
operation of the ECM is not correct. If the cause of the problem is not found in the
Prior to replacing an ECM, always contact your is unlikely as the ECM response was correct for
dealership's Technical Communicator for possible the open condition in the previous test step.
consultation with “Caterpillar”. This consultation
may greatly reduce repair time. If the ECM must be Verify that all possible causes of the diagnostic
replaced, refer to Testing and Adjusting, “Electronic code have been investigated. Exit this procedure
Control Module (ECM) - Replace”. and perform this procedure again.
STOP.
RENR9004-07 435

greatly reduce repair time. If the cause of the active
diagnostic code is not found and the ECM must be
STOP.
i02923324
MID 027 - CID 2200 - FMI 00

SMCS Code: 1439-038-CD
g01254278
Illustration 283
(1) Left Steering Cylinder
(2) Right Steering Cylinder
(3) “Steering Position” Sensor Connector on the Back Side of the
Cylinders
This diagnostic code is associated with the “left

steering cylinder” position sensor. The position
sensor provides a PWM input signal to the
Transmission/Chassis ECM and to the Implement
ECM. The FMI 00 means that the ECM is receiving
a valid signal from the sensor, however, the signal is
above the high limit for the expected signal range.

frequency of approximately 500 hertz. The duty cycle
of the PWM signal that is supplied to the ECM is
g01254277
measured in very small increments. The changes in
Illustration 282 the duty cycle of the sensor can not be measured
Connections of “Left Steering Cylinder” position sensor with a digital multimeter.

below:
• Mechanical devices are broken or loose.

Note: Before performing this procedure, check for
an active CID 1482 diagnostic code for the 10 volt
436 RENR9004-07
Note: The Transmission/Chassis ECM (MID 027) Repair: Perform the maintenance that is required
and the Implement ECM (MID 082) receive an input in order to correct the problem with the mechanical
signal from the “left steer cylinder” position sensor. connections for the steering cylinder. After the
Both ECM modules can activate a CID 2200 FMI 00 problem has been corrected, verify that this
diagnostic code when the signal is above the normal diagnostic code is still active before proceeding
range. with this procedure.
diagnostic code and the other ECM has not, it is STOP.
occurs, a poor connection in the machine harness Test Step 2. CHECK THE SENSOR
would be suspected.
When both ECM modules have activated the Turn the key start switch and the disconnect switch
diagnostic code, either the sensor or a harness to the OFF position.
If both ECM modules have activated the diagnostic A. Disconnect the machine harness connector
code, it is very unlikely that either ECM is causing the from the “left steering cylinder” position sensor
problem. and disconnect the machine harness connector
For either condition, proceed with this procedure in from the “right steering cylinder” position sensor.
order to verify the cause of the problem. Mark the harness connector for the “left steering
sensor”.
the harness connectors that are involved in the B. Connect the marked connector for the “left
circuit. Poor connections are often the cause steering sensor” to the “right steering sensor”
of a problem in an electrical circuit. Verify that connector. Connect the unmarked connector for
all connections in the circuit are clean, that all the right steering sensor to the left steering sensor
connections are secure and that all connections connector.
connection is found, correct the problem and C. Turn the disconnect switch and the key start
verify that this diagnostic code is active before switch to the ON position. Do not start the engine.
D. Observe the status of the active diagnostic code
Note: The following test procedure may create other for the left steering sensor.
codes and clear the diagnostic codes when the Expected Result:
When the harness connectors are switched, the CID
Test Step 1. CHECK THE MECHANICAL 2200 FMI 00 diagnostic code for the left steering
CONNECTIONS sensor is not active. A CID 2201 FMI 00 diagnostic
code for the right steering sensor is now active.
switch to the OFF position. Results:
B. Visually inspect the mechanical connections for • YES – The CID 2200 FMI 00 diagnostic code is no
the left steering cylinder. Verify that all mechanical longer active. A CID 2201 FMI 00 diagnostic code
connections and adjustments for the steering is now active. The sensor has failed.
cylinder are in good condition. Verify that none of
the mechanical connections are loose. Repair: The “left steering cylinder” position sensor
is the cause of the problem. Replace the “left
Expected Result: steering cylinder” position sensor.
All mechanical connections for the steering cylinder BEFORE REPLACING THE STEERING
are in good condition and no mechanical connections POSITION SENSOR, RECONNECT THE
are loose. HARNESS CONNECTORS TO THE CORRECT
CONNECTORS OF THE STEERING SENSOR.
Results:
For removal of the position sensor from the steering
• OK – All mechanical connections for the steering cylinder, refer to Disassembly and Assembly,
cylinder are correct. Proceed to Test Step 2. RENR9704, “Clevis Style Cylinder Sensor -
Remove and Install”.
• NOT OK – All mechanical connections for the
steering cylinder are not correct.
RENR9004-07 437
After the replacement of the sensor, the new • NOT OK – The CID 2200 FMI 00 diagnostic
position parameters of the sensor must be code is active. The diagnostic code has not been
entered in Cat ET before the machine can be corrected.
operated. Refer to the Testing and Adjusting,
RENR9013, “Implement Electronic Control Repair: Check the circuit again. Perform a “wiggle
System”, “Position Sensor (Steering Cylinder) - test” on the machine wiring harness. Use the
Set” for the correct procedure. Caterpillar Electronic Technician (ET) in order
to perform the test. The “wiggle test” can detect
STOP. intermittent shorts or open connections in the
• NO – The status of the CID 2200 FMI 00 diagnostic
code did not change when the sensor connectors If the cause of the active diagnostic code is not
were switched. The CID 2200 FMI 00 diagnostic found, the Implement ECM may have failed.
code is still active. The sensor does not appear to
be the cause of the problem. It is unlikely that a It is unlikely that the ECM has failed. Exit this
harness condition is the cause for this code to be procedure and perform this procedure again. If the
active. cause of the failure is not found, replace the ECM.
ENSURE THAT THE MACHINE HARNESS dealership's Technical Communicator for possible
CONNECTORS ARE CONNECTED TO THE consultation with Caterpillar. This consultation
CORRECT POSITION SENSOR. THE MARKED may greatly reduce repair time. If the cause of the
HARNESS CONNECTOR IS CONNECTED diagnostic code is not found, replace the ECM that
TO THE LEFT STEERING SENSOR. THE has activated the diagnostic code. Refer to Testing
UNMARKED HARNESS CONNECTOR IS and Adjusting, “Electronic Control Module (ECM)
CONNECTED TO THE RIGHT STEERING - Replace”.
SENSOR. Proceed to Test Step 3.
STOP.
DIAGNOSTIC CODE
i02923419

MID 027 - CID 2200 - FMI 01
wires for damage to the insulation that is caused SMCS Code: 1439-038-CD



diagnostic code.
Expected Result:
Results:
• OK – The CID 2200 FMI 00 diagnostic code is g01254277

not active. The diagnostic code does not exist at Illustration 284
this time. The initial diagnostic code was probably Connections of “Left Steering Cylinder” position sensor
438 RENR9004-07

signal from the “left steer cylinder” position sensor.
Both ECM modules can activate a CID 2200 FMI 01
diagnostic code when the signal is below the normal
range.
diagnostic code and the other ECM has not, it is
would be suspected.
problem.

Illustration 285
circuit. Poor connections are often the cause
(2) Right Steering Cylinder of a problem in an electrical circuit. Verify that
(3) “Steering Position Sensor” connector on the back side of the all connections in the circuit are clean, that all
cylinders connections are secure and that all connections
This diagnostic code is associated with the “left connection is found, correct the problem and
steering cylinder” position sensor. The position verify that this diagnostic code is active before
sensor provides a PWM input signal to the performing this procedure.
ECM. Note: The following test procedure may create other
The FMI 01 means that the ECM receives a valid codes and clear the diagnostic codes when the
signal from the sensor, however, the signal is below original diagnostic code has been corrected.
the low limit of the expected signal range.
The sensor is a PWM sensor that operates at a CONNECTIONS
of the PWM signal that is supplied to the ECM is A. Turn the key start switch and the disconnect
measured in very small increments. The changes in switch to the OFF position.
the duty cycle of the sensor can not be measured
with a digital multimeter. B. Visually inspect the mechanical connections
for the “left steering cylinder”. Verify that all
The possible causes of this diagnostic code are listed mechanical connections and adjustments for the
below: steering cylinder are in good condition and verify
that none of the mechanical connections are
• Mechanical devices are broken or loose. loose.
• The sensor has failed. Expected Result:
• The ECM has failed. This is unlikely. All mechanical connections for the steering cylinder
are in good condition and no mechanical connections
are loose.
Results:
• OK – All mechanical connections for the steering

cylinder are correct. Proceed to Test Step 2.

RENR9004-07 439
Repair: Perform the maintenance that is required After replacement of the sensor, the new
in order to correct the problem with the mechanical parameters of the position sensor MUST be
connections for the steering cylinder. After the entered in Cat ET before the machine can be
problem has been corrected, verify that this operated. Refer to the Testing and Adjusting,
diagnostic code is still active before proceeding RENR9013, “Implement Electronic Control
with this procedure. System”, “Position Sensor (Steering Cylinder) -
Set” for the correct procedure.
STOP.
STOP.
Turn the key start switch and the disconnect switch code did not change when the sensor connectors
to the OFF position. were switched. The CID 2200 FMI 01 diagnostic
A. Disconnect the machine harness connector from be causing the problem. It is unlikely that a harness
the “left steering cylinder” position sensor and condition is the cause for this code to be active.
the “right steering cylinder” position sensor. Mark ENSURE THAT THE MACHINE HARNESS
the harness connector for the left steering sensor. CONNECTORS ARE CONNECTED TO THE
CORRECT POSITION SENSOR. THE MARKED
B. Connect the marked connector for the “left steering HARNESS CONNECTOR IS CONNECTED
sensor” to the connector for the “right steering TO THE LEFT STEERING SENSOR. THE
sensor”. Connect the unmarked connector for the UNMARKED HARNESS CONNECTOR IS
“right steering sensor” to the connector for the “left CONNECTED TO THE RIGHT STEERING
steering sensor”. SENSOR. Proceed to Test Step 3.
C. Turn the disconnect switch and the key start Test Step 3. CHECK THE STATUS OF THE
switch to the ON position. Do not start the engine. DIAGNOSTIC CODE
D. Observe the status of the active diagnostic code A. Inspect the harness connectors. Clean the
for the “left steering sensor”. contacts of the harness connectors. Check the
Expected Result: by excessive heat, battery acid, or chafing.
When the harness connectors are switched, the CID B. Perform a 45 N (10 lb) pull test on each of the
2200 FMI 01 diagnostic code for the “left steering wires that are associated with the sensor circuit.
sensor” is not active. A CID 2201 FMI 01 diagnostic
code for the “right steering sensor” is now active. C. Reconnect all harness connectors. Make sure that
Results: clips for each connector are completely fastened.
• YES – The CID 2200 FMI 01 diagnostic code is no D. Turn the disconnect switch and the key start
longer active. A CID 2201 FMI 01 diagnostic code switch to the ON position.
is now active. The sensor has failed.
Repair: The “left steering cylinder” position sensor
is the cause of the problem. Replace the “left F. Check the status of the CID 2200 FMI 01
steering cylinder” position sensor. diagnostic code.
BEFORE REPLACING THE “STEERING Expected Result:

POSITION SENSOR”, RECONNECT THE
HARNESS CONNECTORS TO THE CORRECT The CID 2200 FMI 01 diagnostic code is not active.
“STEERING SENSOR” CONNECTORS.
Results:
cylinder, refer to Disassembly and Assembly, • OK – The CID 2200 FMI 01 diagnostic code is
RENR 9704, “Clevis Style Cylinder Sensor - not active. The diagnostic code does not exist at
Remove and Install”. this time. The initial diagnostic code was probably
440 RENR9004-07

corrected.


found, the Implement ECM may have failed.
It is unlikely that the ECM has failed. Exit this

g01254278
has activated the diagnostic code. Refer to Testing (1) Left Steering Cylinder
and Adjusting, “Electronic Control Module (ECM) (2) Right Steering Cylinder
- Replace”. (3) Connector of “Steering Position Sensor” connector on the back
side of the cylinders
STOP.
i02923724 sensor provides a PWM input signal to the
MID 027 - CID 2200 - FMI 02 Transmission/Chassis ECM and to the Implement
ECM. The FMI 02 means that the ECM has
determined that the input signal from the sensor is
erratic, intermittent, or incorrect.
with a digital multimeter.

below:
• Mechanical devices are loose or mechanical

devices are not adjusted correctly.
• Intermittent connections or open connections in

the sensor circuit.

g01254277
Illustration 286 sensor power supply of the Transmission/Chassis
Connections of “Left Steering Cylinder” position sensor ECM. Correct any problem with the 10 volt power
RENR9004-07 441
Note: The Transmission/Chassis ECM (MID 027) will Repair: Perform the maintenance that is required
also activate a CID 2200 FMI 02 diagnostic code in order to correct the problem with the mechanical
when an erratic signal or an intermittent signal is connections for the steering cylinder. After the
detected. If one ECM has activated a CID 2200 FMI problem has been corrected, verify that this
02 diagnostic code and the other ECM has not, it is diagnostic code is still active before proceeding
likely that the sensor is operating correctly. When with this procedure.
this occurs, a poor connection or an open in the
machine harness would be suspected. When both STOP.
ECM modules have activated the diagnostic code,
a sensor problem or a harness problem could be Test Step 2. CHECK FOR POWER AT THE
the cause. For either condition, proceed with this SENSOR
procedure in order to verify the cause of the problem.
A. The key start switch and the disconnect switch
Note: Before performing this procedure, inspect remain in the OFF position.
circuit. Poor connections are often the cause B. Do not disconnect the harness connector from the
of a problem in an electrical circuit. Verify that sensor.
connections are secure and that all connections C. At the back of the harness connector for the
are in good condition. If a problem with a sensor, insert 7X-1710 Multimeter Probes along
connection is found, correct the problem and the voltage supply, contact 1 (wire 799-WH). Insert
verify that this diagnostic code is active before a multimeter probe along return contact 2 (wire
performing this procedure. A202-BK).
Note: The following test procedure may create other D. Turn the key start switch and the disconnect
diagnostic codes. Ignore these created diagnostic switch to the ON position.
original diagnostic code has been corrected. E. Measure the voltage from contact 1 to contact 2.
Test Step 1. CHECK THE MECHANICAL Expected Result:

CONNECTIONS
The voltage measurement is 10 ± 0.5 DCV.
switch to the OFF position. Results:
B. Visually inspect the mechanical connections • OK – The voltage measurement is 10 ± 0.5 DCV.
for the “left steering cylinder”. Verify that all The power supply circuit is correct. Proceed to
mechanical connections and adjustments for the Test Step 3.
steering cylinder are in good condition and verify
that none of the mechanical connections are • NOT OK – The voltage measurement is not 10 ±
loose. 0.5 DCV. The power supply circuit is not correct.
Expected Result: Repair: There is a problem with the power supply

circuit for the sensor. Refer to the complete
All mechanical connections for the steering cylinder Electrical System Schematic of the machine.
are in good condition and no mechanical connections Check all of the connections that are in the power
are loose. supply circuit and the return circuit. Ensure that
Results: are secure and that all connections are in good
• OK – All mechanical connections for the steering the machine harness.
STOP.
steering cylinder are not correct. Test Step 3. CHECK THE SENSOR
442 RENR9004-07
A. Disconnect the machine harness connector • NO – The status of the CID 2200 FMI 02 diagnostic
from the “left steering cylinder” position sensor code did not change when the sensor connectors
and disconnect the machine harness connector were switched. The CID 2200 FMI 02 diagnostic
from the “right steering cylinder” position sensor. code is still active. There is a problem in the
Mark the harness connector for the “left steering machine harness.
sensor”.
ENSURE THAT THE MACHINE HARNESS
B. Connect the marked connector for the “left steering CONNECTORS ARE CONNECTED TO THE
sensor” to the connector for the “right steering CORRECT POSITION SENSOR. THE MARKED
sensor”. Connect the unmarked connector for the HARNESS CONNECTOR IS CONNECTED
“right steering sensor” to the connector for the “left TO THE LEFT STEERING SENSOR. THE
steering sensor”. UNMARKED HARNESS CONNECTOR IS
CONNECTED TO THE RIGHT STEERING
C. Turn the disconnect switch and the key start SENSOR. Proceed to Test Step 4.
D. Observe the status of the active diagnostic code THE SIGNAL CIRCUIT
for the left steering sensor.
Before performing this Test Step, verify that the
Expected Result: machine harness connectors are connected to
the original “left and right steering cylinder”
When the harness connectors are switched, the CID position sensor connectors.
2200 FMI 02 diagnostic code for the “left steering
sensor” is not active. A CID 2201 FMI 02 diagnostic A. Turn the key start switch and the disconnect
code for the “right steering sensor” is now active. switch to the OFF position.
Results: B. Disconnect the machine harness connector from

the “left steering cylinder” position sensor.
longer active. A CID 2201 FMI 02 diagnostic code C. At the machine harness connector for the “left
is now active. The sensor has failed. steering sensor”, place a jumper wire between
return contact 2 (wire A202-BK) and signal contact
Repair: The “left steering cylinder” position sensor 3 (wire H764-GY).
steering cylinder” position sensor. D. Disconnect the machine harness connectors J1
and J2 from the Transmission/Chassis ECM and
BEFORE REPLACING THE STEERING from the Implement ECM.
POSITION SENSOR, RECONNECT THE
HARNESS CONNECTORS TO THE CORRECT E. At the Transmission/Chassis ECM, measure
“STEERING SENSOR” CONNECTORS. the resistance from return contact J1-70 (wire
A202-BK) to signal contact J2-15 (wire H764-GY).
cylinder, refer to Disassembly and Assembly, F. Obtain a spare length of wire that will reach from
RENR 9704, “Clevis Style Cylinder Sensor - the connectors of the Implement ECM to the “steer
Remove and Install”. cylinder position” sensor connector.
After replacement of the sensor, the new G. At the “steer cylinder position” sensor connector,
parameters of the sensor MUST be entered in connect one end of the spare wire to the signal
Cat ET before the machine can be operated. contact 3 (wire H764-GY).
Refer to the Testing and Adjusting, RENR9013,
“Implement Electronic Control System”, “Position H. At the connector for the Implement ECM J2,
Sensor (Steering Cylinder) - Set” for the correct measure the resistance between the other end of
procedure. the spare wire and the signal contact J2-15 (wire
H764-GY).
STOP.
Expected Result:
Each of the resistance measurements is less than

5 ohms.
RENR9004-07 443
• OK – Both of the resistance measurements are The CID 2200 FMI 02 diagnostic code is not active.
less than 5 ohms. The signal circuit is not open.
Proceed to Test Step 5. Results:
• NOT OK – One or both of the resistance • OK – The CID 2200 FMI 02 diagnostic code is
measurements is greater than 5 ohms. There is an not active. The diagnostic code does not exist at
open or a bad connection in the signal circuit. this time. The initial diagnostic code was probably
Repair: A resistance measurement that is greater of the connectors that was disconnected and
than 5000 ohms could indicate that a wire is not reconnected. Resume normal operation. STOP.
connected or that a wire is open. A resistance
measurement that is greater 5 ohms but less • NOT OK – The CID 2200 FMI 02 diagnostic
than 5000 ohms could indicate that one of the code is active. The diagnostic code has not been
connection points in the circuit is not an open corrected.
If the circuit at one of the ECM modules checks test” on the machine wiring harness. Use the
correctly and the circuit at the other ECM module Caterpillar Electronic Technician (ET) in order
indicates an open or a bad connection, most likely to perform the test. The “wiggle test” can detect
there is a problem in the machine harness on the intermittent shorts or open connections in the
ECM side of the splice. machine wiring harness.
If the resistance checks both indicate an open or If the cause of the active diagnostic code is not
a bad connection, a problem in the sensor side of found, the Implement ECM may have failed.
the splice in the machine harness is most likely
causing the problem. It is unlikely that the ECM has failed. Exit this
Refer to the complete Electrical System Schematic cause of the failure is not found, replace the ECM.
of the machine . Verify that all connection points in Prior to replacing an ECM, always contact your
the suspected part of the circuit are clean, that all dealership's Technical Communicator for possible
connections are secure and that all connections consultation with Caterpillar. This consultation
are in good condition. Repair the machine harness may greatly reduce repair time. If the cause of the
or replace the machine harness. diagnostic code is not found, replace the ECM that
STOP. and Adjusting, “Electronic Control Module (ECM)
- Replace”.





diagnostic code.
444 RENR9004-07
i02923985 This diagnostic code is associated with the “left

MID 027 - CID 2200 - FMI 03 sensor provides a PWM input signal to the
SMCS Code: 1439-038-CD ECM. The FMI 03 diagnostic code is activated when
the ECM reads the input signal from the sensor and
Conditions Which Generate This Code: the voltage of the signal is above normal.


below:
• The power supply circuit of the sensor is open.

• The signal circuit is open or the sensor is
disconnected.
• The signal circuit is shorted to the sensor power

supply.
g01254277
Illustration 288 • The sensor has failed.
Connections of “Left Steering Cylinder” position sensor
Note: The Implement (MID 083) will also activate a

CID 2200 FMI 03 diagnostic code when an above
normal signal voltage is detected. If one ECM has
an active CID 2200 FMI 03 diagnostic code and
the other ECM has not, it is likely that the sensor
is operating correctly. When this occurs, a poor
connection or an open in the machine harness
would be suspected. When both ECM modules have
activated the diagnostic code, either the sensor or
a harness problem could be the cause. For either
condition, proceed with this procedure in order to
verify the cause of the problem.
g01254278 Note: Before performing this procedure, inspect

Illustration 289 the harness connectors that are involved in the
(1) Left Steering Cylinder circuit. Poor connections are often the cause
(3) “Steering Position Sensor” connector on the back side of the
cylinders all connections in the circuit are clean, that all
RENR9004-07 445
Note: The following test procedure may create other Test Step 2. CHECK THE SENSOR
codes and clear the diagnostic codes when the Turn the key start switch and the disconnect switch
original diagnostic code has been corrected. to the OFF position.
Test Step 1. CHECK THE SUPPLY A. Disconnect the machine harness connector
VOLTAGE AT THE SENSOR from the “left steering cylinder” position sensor
and disconnect the machine harness connector
A. Turn the key start switch and the disconnect from the “right steering cylinder” position sensor.
switch to the OFF position. Mark the harness connector for the “left steering
sensor”.
sensor. B. Connect the marked connector for the “left steering
sensor” to the connector for the “right steering
C. At the back of the harness connector for the sensor”. Connect the unmarked connector for the
sensor, insert 7X-1710 Multimeter Probes along “right steering sensor” to the connector for the “left
contact for the power supply 1 (wire 799-WH). steering sensor”.
Insert a multimeter probe along return contact 2
(wire A202-BK). C. Turn the disconnect switch and the key start
switch to the ON position. D. Observe the status of the active diagnostic code
for the “left steering sensor”.
E. Measure the voltage from contact 1 to contact 2.
Expected Result:
Expected Result:
The voltage measurement is 10 ± 0.5 DCV. 2200 FMI 03 diagnostic code for the “left steering
sensor” is not active. A CID 2201 FMI 03 diagnostic
Results: code for the “right steering sensor” is now active.
• OK – The voltage measurement is 10 ± Results:

0.5 DCV. The power supply circuit of the
Transmission/Chassis ECM is correct. Proceed to • YES – The CID 2200 FMI 03 diagnostic code is no
Test Step 2. longer active. A CID 2201 FMI 03 diagnostic code
• NOT OK – The voltage measurement is not 10 ±
0.5 DCV. The power supply circuit that is coming Repair: The “left steering cylinder” position sensor
from the Transmission/Chassis ECM is not correct. is the cause of the problem. Replace the “left
steering cylinder” position sensor.
Repair: Verify that the Transmission/Chassis
ECM has not lost the power supply connection BEFORE REPLACING THE “STEERING
to the machine system. Loss of power to the POSITION SENSOR”, RECONNECT THE
Transmission/Chassis ECM can cause this code HARNESS CONNECTORS TO THE CORRECT
to activate. “STEERING SENSOR” CONNECTORS.
If the Transmission/Chassis ECM is powered up, For removal of the position sensor from the steering
check the circuit for the sensor return A202-BK or cylinder, refer to Disassembly and Assembly,
the supply wire 799-WH in the machine harness RENR 9704, “Clevis Style Cylinder Sensor -
for an open circuit or a bad connection. Remove and Install”.
Refer to the complete Electrical System Schematic After the replacement of the sensor, the new
of the machine. Examine all of the connectors that parameters for the position sensor MUST be
are in the circuit. Ensure that the connections are entered in Cat ET before the machine can be
clean, that all connections are secure and that operated. Refer to the Testing and Adjusting,
all connections are in good condition. Repair the RENR9013, “Implement Electronic Control
machine harness or replace the machine harness System”, “Position Sensor (Steering Cylinder) -
in order to restore the power supply to the sensor. Set” for the correct procedure.
STOP. STOP.
446 RENR9004-07
• NO – The status of the CID 2200 FMI 03 diagnostic Results:

code did not change when the sensor connectors
were switched. The CID 2200 FMI 03 diagnostic • OK – Both of the resistance measurements are
code is still active. There is a problem in the less than 5 ohms. The signal circuit is not open.
DISCONNECT THE SENSORS THAT WERE • NOT OK – One or both of the resistance
SWITCHED AND RECONNECT THE HARNESS measurements is greater than 5 ohms. There is an
CONNECTORS TO THE CORRECT “STEERING open or a bad connection in the signal circuit.
SENSOR” CONNECTORS. THE MARKED
HARNESS CONNECTOR IS CONNECTED Repair: A resistance measurement that is greater
TO THE “LEFT STEERING SENSOR”. THE than 5000 ohms could indicate that a wire is not
UNMARKED HARNESS CONNECTOR IS connected or that a wire is open. A resistance
CONNECTED TO THE “RIGHT STEERING measurement that is greater 5 ohms but less
SENSOR”. Proceed to Test Step 3. than 5000 ohms could indicate that one of the
Test Step 3. CHECK FOR AN OPEN IN connection but not a good connection.
THE SIGNAL CIRCUIT
If the circuit at one of the ECM modules checks
Before performing this Test Step, verify that the correctly and the circuit at the other ECM indicates
machine harness connectors are connected an open or a bad connection, most likely there is
to the original “left and right steering cylinder a problem in the machine harness on the ECM
position” sensor connectors. side of the splice.
A. Turn the key start switch and the disconnect If the resistance checks both indicate an open or
switch to the OFF position. a bad connection, a problem in the sensor side of
the splice in the machine harness is most likely
B. Disconnect the machine harness connector from causing the problem.
C. At the machine harness connector for the “left of the machine. Verify that all connection points
steering sensor”, place a jumper wire between in the suspected part of the circuit are clean,
return contact 2 (wire A202-BK) and signal contact that all connection points are secure and that all
3 (wire H764-GY). connection points are in good condition. Repair the
D. Disconnect the machine harness connectors J1
and J2 from the Transmission/Chassis ECM and STOP.
from the Implement ECM.
E. At the Transmission/Chassis ECM, measure CIRCUIT FOR A SHORT
the resistance from return contact J1-70 (wire
A202-BK) to signal contact J2-15 (wire H764-GY). The key start switch and the disconnect switch remain
in the OFF position. The harness connectors for the
F. Obtain a spare length of wire that will reach from Transmission/Chassis ECM and the connectors for
the connector of the Implement ECM to the “steer the Implement ECM remain disconnected from the
cylinder position” sensor connector. machine harness.
G. At the “steer cylinder position” sensor connector, A. Remove the jumper wire that was installed in the
connect one end of the spare wire to the signal last step.
contact 3 (wire H764-GY).
B. At the J1 and J2 machine harness connectors for
H. At the connector for the Implement ECM J2, the Implement ECM, measure the resistance from
measure the resistance between the other end of the sensor signal contact J2-15 (wire H764-GY) to
the spare wire and the signal contact J2-15 (wire all of the other J1 and J2 contacts that are used
H764-GY). for the Implement ECM.

Each of the resistance measurements is less than test step and proceed to the “Expected Result”
5 ohms. step. If all of the resistance measurements in the
last test step are above 5000 ohms, perform the
next test step.
RENR9004-07 447
D. At the disconnected J1 and J2 machine harness Results:

connectors for the Transmission/Chassis ECM,
measure the resistance from the sensor signal • OK – The CID 2200 FMI 03 diagnostic code is
contact J2-15 (wire H764-GY) to all of the not active. The diagnostic code does not exist at
other J1 and J2 contacts that are used for the this time. The initial diagnostic code was probably
Transmission/Chassis ECM. caused by a poor connection or a short at one
Expected Result: reconnected. Resume normal operation. STOP.
Each resistance measurement is greater than 5000 • NOT OK – The CID 2200 FMI 03 diagnostic
ohms. code is active. The diagnostic code has not been
corrected.
Results:
• OK – Each resistance measurement is greater test” on the machine wiring harness. Use the
than 5000 ohms. The signal circuit is not shorted. Caterpillar Electronic Technician (ET) in order
Proceed to Test Step 5. to perform the test. The “wiggle test” can detect
• NOT OK – A resistance measurement is less than machine wiring harness.
5000 ohms.
Repair: There is a short in the machine harness. found, the Implement ECM may have failed.
The short is between the signal circuit and the
circuit with the low resistance measurement. It is unlikely that the ECM has failed. Exit this
Repair the machine harness or replace the procedure and perform this procedure again. If the
machine harness. cause of the failure is not found, replace the ECM.
STOP. dealership's Technical Communicator for possible
Test Step 5. CHECK THE STATUS OF THE may greatly reduce repair time. If the cause of the
DIAGNOSTIC CODE diagnostic code is not found, replace the ECM that
A. Inspect the harness connectors. Clean the and Adjusting, “Electronic Control Module (ECM)
contacts of the harness connectors. Check the - Replace”.




is active.
Expected Result:

448 RENR9004-07
i02924260 This diagnostic code is associated with the “left

MID 027 - CID 2200 - FMI 04 sensor provides a PWM input signal to the
SMCS Code: 1439-038-CD ECM. The FMI 04 diagnostic code is activated when
the ECM reads the input signal from the sensor and
Conditions Which Generate This Code: the voltage of the signal is below normal.


below:
• The signal circuit is shorted to a ground source.

g01254277
Illustration 290 supply before performing this procedure.
Connections of “Left Steering Cylinder” position sensor
diagnostic code when the signal is below normal.
If one ECM is communicating an active CID 2200
FMI 04 diagnostic code and the other ECM is not, it is
would be suspected.
problem.

g01254278 circuit. Poor connections are often the cause
Illustration 291 of a problem in an electrical circuit. Verify that
(1) Left Steering Cylinder all connections in the circuit are clean, that all
(2) Right Steering Cylinder connections are secure and that all connections
cylinders are in good condition. If a problem with a
RENR9004-07 449
Note: The following test procedure may create other After replacement of the sensor, the new
diagnostic codes. Ignore these created diagnostic parameters of the position sensor MUST be
codes and clear the diagnostic codes when the entered in Cat ET before the machine can be
original diagnostic code has been corrected. operated. Refer to the Testing and Adjusting,
RENR9013, “Implement Electronic Control
Test Step 1. CHECK THE SENSOR System”, “Position Sensor (Steering Cylinder) -
to the OFF position. STOP.
A. Disconnect the machine harness connector • NO – The status of the CID 2200 FMI 04 diagnostic
from the “left steering cylinder” position sensor code did not change when the sensor connectors
and disconnect the machine harness connector were switched. The CID 2200 FMI 04 diagnostic
from the “right steering cylinder” position sensor. code is still active. There is a problem in the
Mark the harness connector for the “left steering machine harness.
sensor”.
B. Connect the marked connector for the “left steering CONNECTORS ARE CONNECTED TO THE
sensor” to the connector for the “right steering CORRECT POSITION SENSOR. THE MARKED
sensor” . Connect the unmarked connector for the HARNESS CONNECTOR IS CONNECTED
“right steering sensor” to the connector for the “left TO THE “LEFT STEERING SENSOR”. THE
steering sensor” . UNMARKED HARNESS CONNECTOR IS
CONNECTED TO THE “RIGHT STEERING
C. Turn the disconnect switch and the key start SENSOR”. Proceed to Test Step 2.
D. Observe the status of the active diagnostic code CIRCUIT FOR A SHORT TO GROUND
for the “left steering sensor”.
Expected Result: machine harness connectors are connected
to the original “left and right steering cylinder
When the harness connectors are switched, the CID position” sensor connectors.
sensor” is not active. A CID 2201 FMI 04 diagnostic A. Turn the key start switch and the disconnect
code for the “right steering sensor” is now active. switch to the OFF position.

longer active. A CID 2201 FMI 04 diagnostic code C. Disconnect the J1 and J2 machine harness
is now active. The sensor has failed. connectors from the Transmission/Chassis ECM
and from the Implement ECM.
Repair: The “left steering cylinder” position sensor
is the cause of the problem. Replace the “left D. At machine harness connector J2 for the
steering cylinder” position sensor. Transmission/Chassis ECM, measure the
resistance between the signal, contact J2-15
BEFORE REPLACING THE STEERING (wire H764-GY), and to the frame ground. Next,
POSITION SENSOR, RECONNECT THE measure the resistance between the signal and
HARNESS CONNECTORS TO THE CORRECT all of the contacts that are used in the machine
“STEERING SENSOR” CONNECTORS. harness connectors for the Transmission/Chassis
ECM.
cylinder, refer to Disassembly and Assembly, E. At machine harness connector J2 for the
RENR9704, “Clevis Style Cylinder Sensor - Implement ECM, measure the resistance from the
Remove and Install”. signal, contact J2-15 (wire H764-GY), to frame
ground and measure the resistance to all of the
contacts that are used in the machine harness
connectors for the Implement ECM.
Expected Result:

ohms.
450 RENR9004-07
Results: Repair: Check the circuit again. Perform a “wiggle

• OK – Each resistance measurement is greater Caterpillar Electronic Technician (ET) in order
than 5000 ohms. The machine harness is correct. to perform the test. The “wiggle test” can detect
Proceed to Test Step 3. intermittent shorts or open connections in the
measurements is less than 5000 ohms. The If the cause of the problem is not found in the
resistance measurement is indicating a short in the machine harness, the ECM may have failed.
machine harness.
Repair: There is a short in the machine harness procedure and perform this procedure again. If the
between the signal circuit and the circuit with the cause of the failure is not found, replace the ECM.
low resistance measurement. Prior to replacing an ECM, always contact your
For information on testing for short circuits and consultation with Caterpillar. This consultation
finding short circuits, refer to Testing and Adjusting, may greatly reduce repair time. If the cause of the
“Wiring Harness (Short Circuit) - Test”. Repair the diagnostic code is not found, replace the ECM that
machine harness or replace the machine harness. has activated the diagnostic code. Refer to Testing
STOP. - Replace”.

DIAGNOSTIC CODE
i02924441
MID 027 - CID 2200 - FMI 08
by excessive heat, battery acid, or chafing. SMCS Code: 1439-038-CD



is active.
Expected Result:
Results:

not active. The diagnostic code does not exist at g01254277
this time. The initial diagnostic code was probably Illustration 292
caused by a poor connection or a short at one Connections of “Left Steering Cylinder” position sensor

corrected.
RENR9004-07 451
Note: The Implement ECM (MID 082) will also

activate a CID 2200 FMI 08 diagnostic code when
an above normal signal frequency or pulse width is
detected. If one ECM has an active CID 2200 FMI
08 diagnostic code and the other ECM has not, it is
occurs, an intermittent open or a poor connection in
the machine harness would be suspected. When
both ECM modules have activated the diagnostic
code, either the sensor or a harness problem could
be the cause. For either condition, proceed with this

Illustration 293
g01254278 verify that this diagnostic code is active before
(3) “Steering Position Sensor” connector on the back side of the Note: The following test procedure may create other
cylinders diagnostic codes. Ignore these created diagnostic
This diagnostic code is associated with the “left original diagnostic code has been corrected.
sensor provides a PWM input signal to the Test Step 1. CHECK THE MECHANICAL
Transmission/Chassis ECM and to the Implement CONNECTIONS
ECM. The FMI 08 diagnostic code is active when the
ECM detects that the input signal from the sensor A. Turn the key start switch and the disconnect
has an abnormal frequency or pulse width. switch to the OFF position.
The sensor is a PWM sensor that operates at a B. Visually inspect the mechanical connections
frequency of approximately 500 hertz. The duty cycle for the “left steering cylinder”. Verify that all
of the PWM signal that is supplied to the ECM is mechanical connections and adjustments for the
measured in very small increments. The changes in steering cylinder are in good condition and verify
the duty cycle of the sensor can not be measured that none of the mechanical connections are
with a digital multimeter. loose.
The possible causes of this diagnostic code are listed Expected Result:
below:
All mechanical connections for the steering cylinder
• Mechanical devices in the cylinder assembly are are in good condition and no mechanical connections
loose. are loose.
• The sensor has failed. Results:
• Intermittent connections or poor connections in the • OK – All mechanical connections for the steering
signal circuit cylinder are correct. Proceed to Test Step 2.
• The ECM has failed. This is unlikely. • NOT OK – All mechanical connections for the
452 RENR9004-07
in order to correct the problem with the mechanical parameters for the position sensor MUST be
STOP.
STOP.
The key start switch and the disconnect switch code did not change when the sensor connectors
remain in the OFF position. were switched. The CID 2200 FMI 08 diagnostic
code is still active. There is a problem in the
A. Disconnect the machine harness connector machine harness.
from the “left steering cylinder” position sensor
and disconnect the machine harness connector ENSURE THAT THE MACHINE HARNESS
from the “right steering cylinder” position sensor. CONNECTORS ARE CONNECTED TO THE
Mark the harness connector for the “left steering CORRECT POSITION SENSOR. THE MARKED
sensor”. HARNESS CONNECTOR IS CONNECTED
TO THE “LEFT STEERING SENSOR”. THE
B. Connect the marked connector for the “left HARNESS CONNECTOR THAT IS NOT MARKED
steering sensor” to the connector for the “right IS CONNECTED TO THE “RIGHT STEERING
steering sensor” . Connect the connector that is SENSOR”. Proceed to Test Step 3.
not marked for the “right steering sensor” to the
connector for the “left steering sensor”. Test Step 3. CHECK FOR AN OPEN IN
THE SIGNAL CIRCUIT
switch to the ON position. Do not start the engine. Before performing this Test Step, verify that the
machine harness connectors are connected
D. Observe the status of the active diagnostic code to the original “left and right steering cylinder
for the left steering sensor. position” sensor connectors.
Expected Result: A. Turn the key start switch and the disconnect
2200 FMI 08 diagnostic code for the “left steering B. Disconnect the machine harness connector from
sensor” is not active. A CID 2201 FMI 08 diagnostic the “left steering cylinder” position sensor.
code for the “right steering sensor” is now active.
C. At the machine harness connector for the “left
Results: steering sensor”, place a jumper wire between
return contact 2 (wire A202-BK) and signal contact
• YES – The CID 2200 FMI 08 diagnostic code is no 3 (wire H764-GY).
is now active. The sensor has failed. D. Disconnect the machine harness connectors J1
and J2 from the Transmission/Chassis ECM and
Repair: The “left steering cylinder” position sensor from the Implement ECM.
steering cylinder” position sensor. E. At the Transmission/Chassis ECM, measure
the resistance from return contact J1-70 (wire
BEFORE REPLACING THE “STEERING A202-BK) to signal contact J2-15 (wire H764-GY).
HARNESS CONNECTORS TO THE CORRECT F. Obtain a spare length of wire that will reach from
“STEERING SENSOR” CONNECTORS. the connectors of the Implement ECM to the “steer
cylinder position” sensor connector.
cylinder, refer to Disassembly and Assembly, G. At the “steer cylinder position” sensor connector,
RENR9704, “Clevis Style Cylinder Sensor - connect one end of the spare wire to the signal
Remove and Install”. contact 3 (wire H764-GY).
RENR9004-07 453
H. At the connector for the Implement ECM J2, D. Turn the disconnect switch and the key start
measure the resistance between the other end of switch to the ON position.
the spare wire and the signal contact J2-15 (wire
H764-GY). E. Operate the machine.

is active.
5 ohms. Expected Result:
Results: The CID 2200 FMI 08 diagnostic code is not active.
• OK – Both of the measurements for the resistance Results:

are less than 5 ohms. The signal circuit is not open.
Proceed to Test Step 4. • OK – The CID 2200 FMI 08 diagnostic code is
• NOT OK – One or both of the measurements of this time. The initial diagnostic code was probably
the resistance is greater than 5 ohms. There is an caused by a poor connection or a short at one
open or a bad connection in the signal circuit. of the connectors that was disconnected and
Repair: A measurement of resistance that is
greater than 5000 ohms could indicate that a • NOT OK – The CID 2200 FMI 08 diagnostic
wire is not connected or that a wire is open. A code is active. The diagnostic code has not been
resistance measurement that is greater 5 ohms corrected.
but less than 5000 ohms could indicate that one of
the connection points in the circuit is not an open Repair: Check the circuit again. Perform a “wiggle
connection but not a good connection. test” on the machine wiring harness. Use the
If the circuit at one of the ECM modules checks to perform the test. The “wiggle test” can detect
correctly and the circuit at the other ECM indicates intermittent shorts or open connections in the
an open or a bad connection, most likely there is machine wiring harness.
a problem in the machine harness on the ECM
side of the splice. If the cause of the problem is not found in the
machine harness, the ECM may have failed.
If the both of the resistance checks indicate an
open or a bad connection, a problem in the sensor It is unlikely that the ECM has failed. Exit this
side of the splice in the machine harness is most procedure and perform this procedure again. If the
likely causing the problem. cause of the failure is not found, replace the ECM.
Refer to the complete Electrical System Schematic dealership's Technical Communicator for possible
of the machine . Verify that all connection points consultation with Caterpillar. This consultation
in the suspected part of the circuit are clean, may greatly reduce repair time. If the cause of the
that all connection points are secure and that all diagnostic code is not found, replace the ECM that
connections are in good condition. Repair the has activated the diagnostic code. Refer to Testing
machine harness or replace the machine harness. and Adjusting, “Electronic Control Module (ECM)
- Replace”.
STOP.
STOP.
DIAGNOSTIC CODE
i02924717

MID 027 - CID 2200 - FMI 13
wires for damage to the insulation that is caused SMCS Code: 1439-038-CD
wires that are associated with the sensor circuit. This diagnostic code is associated with the “left
C. Reconnect all harness connectors. Make sure that sensor provides a PWM input signal to the Implement
the connectors are fully seated. Observe that the ECM and to the Transmission/Chassis ECM. The
clips for each connector are completely fastened. FMI 13 diagnostic code is active in order to indicate
that the sensor needs calibration.
454 RENR9004-07
The sensor is a PWM sensor that operates at a Prior to replacing an ECM, always contact your
frequency of approximately 500 hertz. The duty cycle dealership's Technical Communicator for possible
of the PWM signal that is supplied to the ECM is consultation with Caterpillar. This consultation
measured in very small increments. The changes in may greatly reduce repair time. If the cause of the
the duty cycle of the sensor can not be measured diagnostic code is not found, replace the ECM.
with a digital multimeter. Refer to Testing and Adjusting, “Electronic Control
CALIBRATION
STOP.
A. Perform the calibration procedure for the
sensor. Refer to the Testing and Adjusting,
i02924831
RENR9013, “Implement Electronic Control
System”, “Calibration” for the information on the
method to access the calibration procedure.
MID 027 - CID 2200 - FMI 14
Expected Result:
successfully.
Results:

STOP.

sensor.

successful, replace the “steer cylinder position”
sensor.

cylinder, refer to Disassembly and Assembly,
RENR 9704, “Clevis Style Cylinder Sensor -
Remove and Install”. g01254277
Illustration 294
After replacement of the sensor, the parameters Connections of “Left Steering Cylinder” position sensor
of the new position sensor MUST be entered
in Cat ET before the machine can be operated.
Refer to the Testing and Adjusting, RENR9013,
“Implement Electronic Control System”, “Position
Sensor (Steering Cylinder) - Set” for the correct
procedure.
After cylinder replacement, refer to the Testing

and Adjusting, RENR9013, “Implement Electronic
Control System”, “Calibration” for the information
on the method to access the calibration procedure.
If the problem is still present after replacement and
calibration of the new sensor, the ECM may have
failed.
RENR9004-07 455



CONNECTIONS
g01254278
Illustration 295
B. Visually inspect the mechanical connections for
(2) Right Steering Cylinder the left steering cylinder. Verify that all mechanical
(3) “Steering Position Sensor” connector on the back side of the connections and adjustments for the “steering
cylinders cylinder” are in good condition and verify that none
of the mechanical connections are loose.
steering cylinder” position sensor. The position Expected Result:
sensor provides a PWM input signal to the
Transmission/Chassis ECM and to the Implement All mechanical connections for the steering cylinder
ECM. The FMI 14 diagnostic code is active during are in good condition and no mechanical connections
times that the sensor is not responding as expected. are loose.
And no external conditions that could cause this
problem have been detected by the ECM. Results:
The sensor is a PWM sensor that operates at a • OK – All mechanical connections for the steering
frequency of approximately 500 hertz. The duty cycle cylinder are correct. Proceed to Test Step 2.
measured in very small increments. The changes in • NOT OK – All mechanical connections for the
the duty cycle of the sensor can not be measured steering cylinder are not correct.
Repair: Perform the maintenance that is required
The possible causes of this diagnostic code are listed in order to correct the problem with the mechanical
below: connections for the steering cylinder. After the
problem has been corrected, verify that this
• Mechanical devices are broken or loose. diagnostic code is still active before proceeding
STOP.
an active CID 1482 diagnostic code for the 10 volt The key start switch and the disconnect switch
sensor power supply of the Transmission/Chassis remain in the OFF position.
supply before performing this procedure. A. Disconnect the machine harness connector
from the “left steering cylinder” position sensor
and disconnect the machine harness connector
from the “right steering cylinder” position sensor.
Mark the harness connector for the “left steering
sensor”.
456 RENR9004-07
B. Connect the marked connector for the “left Test Step 3. CHECK THE STATUS OF THE
steering sensor” to the connector for the “right DIAGNOSTIC CODE
steering sensor”. Connect the connector that is
not marked for the “right steering sensor” to the Before performing this Test Step, verify that the
connector for the “left steering sensor”. machine harness connectors are connected
to the original “left and right steering cylinder
C. Turn the disconnect switch and the key start position” sensor connectors.
D. Observe the status of the active diagnostic code contacts of the harness connectors. Check the
for the “left steering sensor”. wires for damage to the insulation that is caused
Expected Result:
When the harness connectors are switched, the CID wires that are associated with the sensor circuit.
sensor” is not active. A CID 2201 FMI 14 diagnostic C. Reconnect all harness connectors. Make sure that
code for the “right steering sensor” is now active. the connectors are fully seated. Observe that the
Results:
• YES – The CID 2200 FMI 14 diagnostic code is no switch to the ON position.
is now active. The sensor has failed. E. Operate the machine.
Repair: The “left steering cylinder” position sensor F. Determine if the CID 2200 FMI 14 diagnostic code
is the cause of the problem. Replace the “left is active.
steering cylinder” position sensor.
Expected Result:
BEFORE REPLACING THE STEERING
POSITION SENSOR, RECONNECT THE The CID 2200 FMI 14 diagnostic code is not active.
HARNESS CONNECTORS TO THE CORRECT
“STEERING SENSOR” CONNECTORS. Results:
For removal of the position sensor from the steering • OK – The CID 2200 FMI 14 diagnostic code is
cylinder, refer to Disassembly and Assembly, not active. The diagnostic code does not exist at
RENR 9704, “Clevis Style Cylinder Sensor - this time. The initial diagnostic code was probably
Remove and Install”. caused by a poor connection or a short at one
After replacement of the sensor, the parameters reconnected. Resume normal operation. STOP.
for the new position sensor MUST be entered
in Cat ET before the machine can be operated. • NOT OK – The CID 2200 FMI 14 diagnostic
Refer to the Testing and Adjusting, RENR9013, code is active. The diagnostic code has not been
“Implement Electronic Control System”, “Position corrected.
Sensor (Steering Cylinder) - Set” for the correct
procedure. Repair: Check the circuit again. Perform a “wiggle
STOP. Caterpillar Electronic Technician (ET) in order
• NO – The status of the CID 2200 FMI 14 diagnostic intermittent shorts or open connections in the
code did not change when the sensor connectors machine wiring harness.
were switched. The CID 2200 FMI 14 diagnostic
code is still active. There is a problem in the If the cause of the problem is not found in the
machine harness. machine harness, the ECM may have failed.

CONNECTORS ARE CONNECTED TO THE
CORRECT POSITION SENSOR. THE MARKED
HARNESS CONNECTOR IS CONNECTED
TO THE “LEFT STEERING SENSOR”. THE
HARNESS CONNECTOR THAT IS NOT MARKED
IS CONNECTED TO THE “RIGHT STEERING
SENSOR”. Proceed to Test Step 3.
RENR9004-07 457

- Replace”.
STOP.
i02925351
MID 027 - CID 2201 - FMI 00


g01254278
Illustration 297
cylinders

sensor provides a PWM input signal to the Implement
ECM and to the Transmission/Chassis ECM. The
FMI 00 means that the ECM is receiving a valid
signal from the sensor that is above the high limit for
the expected signal range.

g01254393
Illustration 296 below:
Connections of “Right Steering Cylinder” position sensor
• Mechanical devices are broken or loose.
power supply of the Implement ECM (082). Correct
any problem with the 8 volt power supply before
458 RENR9004-07
Note: The Transmission/Chassis ECM (MID 027) Repair: Perform the maintenance that is required
and the Implement ECM (MID 082) receive an input in order to correct the problem with the mechanical
signal from the “left steer cylinder” position sensor. connections for the steering cylinder. After the
Both ECM modules can activate a CID 2201 FMI 00 problem has been corrected, verify that this
diagnostic code when the signal is above the normal diagnostic code is still active before proceeding
range. with this procedure.
When one of the ECM modules has an active CID
2201 FMI 00 diagnostic code and the other ECM STOP.
does not have an active diagnostic code, it is likely
that the sensor is operating correctly. When this Test Step 2. CHECK THE SENSOR
would be suspected. Turn the key start switch and the disconnect switch
When both ECM modules have activated the to the OFF position.
problem could be the cause. A. Disconnect the machine harness connector from
If both ECM modules have activated the diagnostic the “right steering cylinder” position sensor and
code, it is very unlikely that either ECM is causing the disconnect the machine harness connector from
problem. the “left steering cylinder” position sensor. Mark
For either condition, proceed with this procedure in the harness connector for the “right steering
order to verify the cause of the problem. sensor”.
Note: Before performing this procedure, inspect B. Connect the marked connector for the “right
the harness connectors that are involved in the steering sensor” to the connector for the “left
circuit. Poor connections are often the cause steering sensor” . Connect the connector that is
of a problem in an electrical circuit. Verify that not marked for the “left steering sensor” to the
all connections in the circuit are clean, that all connector for the “right steering sensor” .
connection is found, correct the problem and switch to the ON position. Do not start the engine.
performing this procedure. D. Observe the status of the active diagnostic code
for the “right steering sensor”.
original diagnostic code has been corrected. When the harness connectors are switched, the CID
2201 FMI 00 diagnostic code for the “right steering
Test Step 1. CHECK THE MECHANICAL sensor” is not active. A CID 2200 FMI 00 diagnostic
CONNECTIONS code for the “left steering sensor” is now active.

B. Visually inspect the mechanical connections longer active. A CID 2200 FMI 00 diagnostic code
for the “left steering cylinder”. Verify that all is now active. The sensor has failed.
mechanical connections and adjustments for the
steering cylinder are in good condition and verify Repair: The “right steering cylinder” position
that none of the mechanical connections are sensor is the cause of the problem. Replace the
loose. “right steering cylinder” position sensor.
Expected Result: BEFORE REPLACING THE “STEERING

All mechanical connections for the “steering cylinder” HARNESS CONNECTORS TO THE CORRECT
are in good condition and no mechanical connections “STEERING SENSOR” CONNECTORS.
are loose.
Results: cylinder, refer to Disassembly and Assembly,
• OK – All mechanical connections for the steering Remove and Install”.

RENR9004-07 459
After replacement of the sensor, the new • NOT OK – The CID 2201 FMI 00 diagnostic
parameters for the position sensor MUST be code is active. The diagnostic code has not been
entered in Cat ET before the machine can be corrected.
RENR9013, “Implement Electronic Control Repair: Check the circuit again. Perform a “wiggle
System”, “Position Sensor (Steering Cylinder) - test” on the machine wiring harness. Use the
Set” for the correct procedure. Caterpillar Electronic Technician (ET) in order
STOP. intermittent shorts or open connections in the
code did not change when the sensor connectors If the cause of the active diagnostic code is not
were switched. The CID 2201 FMI 00 diagnostic found, the Implement ECM may have failed.
be causing the problem. It is unlikely that a harness It is unlikely that the ECM has failed. Exit this
problem is causing this code to be active. procedure and perform this procedure again. If the
ENSURE THAT THE MACHINE HARNESS Prior to replacing an ECM, always contact your
CONNECTORS ARE CONNECTED TO THE dealership's Technical Communicator for possible
CORRECT POSITION SENSOR. THE MARKED consultation with Caterpillar. This consultation
HARNESS CONNECTOR IS CONNECTED may greatly reduce repair time. If the cause of the
TO THE “RIGHT STEERING SENSOR”. THE diagnostic code is not found, replace the ECM that
HARNESS CONNECTOR THAT IS NOT MARKED has activated the diagnostic code. Refer to Testing
IS CONNECTED TO THE “LEFT STEERING and Adjusting, “Electronic Control Module (ECM)
SENSOR”. Proceed to Test Step 3. - Replace”.

DIAGNOSTIC CODE
i02925530
MID 027 - CID 2201 - FMI 01
by excessive heat, battery acid, or chafing. SMCS Code: 1439-038-CD



diagnostic code.
Expected Result:
Results:

not active. The diagnostic code does not exist at g01254393
this time. The initial diagnostic code was probably Illustration 298
caused by a poor connection or a short at one Connections of “Right Steering Cylinder” Position Sensor
460 RENR9004-07

diagnostic code when the signal is below the normal
range.
diagnostic code and the other ECM does not
have an active diagnostic code, it is likely that the
sensor is operating correctly. When this occurs, a
poor connection in the machine harness would be
suspected.
problem.
Illustration 299
g01254278 Note: Before performing this procedure, inspect
(2) Right Steering Cylinder circuit. Poor connections are often the cause
(3) “Steering Position Sensor” connector on the back side of the of a problem in an electrical circuit. Verify that
cylinders all connections in the circuit are clean, that all
This diagnostic code is associated with the “right are in good condition. If a problem with a
steering cylinder” position sensor. The position connection is found, correct the problem and
sensor provides a PWM input signal to the Implement verify that this diagnostic code is active before
ECM and to the Transmission/Chassis ECM. The FMI performing this procedure.
01 diagnostic code means that the ECM is receiving
a valid signal from the sensor. However, the signal is Note: The following test procedure may create other
below the level for the expected signal range. diagnostic codes. Ignore these created diagnostic
The sensor is a PWM sensor that operates at a original diagnostic code has been corrected.
of the PWM signal that is supplied to the ECM is Test Step 1. CHECK THE MECHANICAL
measured in very small increments. The changes in CONNECTIONS
with a digital multimeter. A. Turn the key start switch and the disconnect
below: B. Visually inspect the mechanical connections
for the “left steering cylinder”. Verify that all
• Mechanical devices are broken or loose. mechanical connections and adjustments for the
steering cylinder are in good condition and verify
• The sensor has failed. that none of the mechanical connections are
loose.
Expected Result:
active CID 0041 diagnostic code for the 8 volt sensor All mechanical connections for the steering cylinder
power supply of the Implement ECM (MID 082). are in good condition and no mechanical connections
Correct any problem with the 8 volt power supply are loose.
Results:


RENR9004-07 461
in order to correct the problem with the mechanical parameters for the position sensor MUST be
STOP.
STOP.
Turn the key start switch and the disconnect switch code did not change when the sensor connectors
to the OFF position. were switched. The CID 2201 FMI 01 diagnostic
A. Disconnect the machine harness connector from be causing the problem. It is unlikely that a harness
the “right steering cylinder” position sensor and problem is the cause for this code to be active.
the “left steering cylinder” position sensor. Mark ENSURE THAT THE MACHINE HARNESS
the harness connector for the “right steering CONNECTORS ARE CONNECTED TO THE
sensor”. CORRECT POSITION SENSOR. THE MARKED
B. Connect the marked connector for the “right TO THE “RIGHT STEERING ” SENSOR. THE
steering sensor” to the connector for the “left HARNESS CONNECTOR THAT IS NOT MARKED
steering sensor”. Connect the connector that is IS CONNECTED TO THE “LEFT STEERING”
not marked for the “left steering sensor” to the SENSOR. Proceed to Test Step 3.
connector for the “right steering sensor” .
C. Turn the disconnect switch and the key start DIAGNOSTIC CODE
D. Observe the status of the active diagnostic code contacts of the harness connectors. Check the
for the “right steering sensor”. wires for damage to the insulation that is caused
Expected Result:
When the harness connectors are switched, the CID wires that are associated with the sensor circuit.
sensor” is not active. A CID 2200 FMI 01 diagnostic C. Reconnect all harness connectors. Make sure that
code for the “left steering sensor” is now active. the connectors are fully seated. Observe that the
Results:
• YES – The CID 2201 FMI 01 diagnostic code is no switch to the ON position.
is now active. The sensor has failed. E. Operate the machine.
Repair: The “right steering cylinder” position F. Check the status of the CID 2201 FMI 01
sensor is the cause of the problem. Replace the diagnostic code.
“right steering cylinder” position sensor.
Expected Result:
BEFORE REPLACING THE “STEERING
POSITION” SENSOR, RECONNECT THE The CID 2201 FMI 01 diagnostic code is not active.
“STEERING SENSOR” CONNECTORS. Results:
For removal of the position sensor from the steering • OK – The CID 2201 FMI 01 diagnostic code is
cylinder, refer to Disassembly and Assembly, not active. The diagnostic code does not exist at
RENR9704, “Clevis Style Cylinder Sensor - this time. The initial diagnostic code was probably
Remove and Install”. caused by a poor connection or a short at one
462 RENR9004-07

corrected.


found, the Implement ECM may have failed.

g01254278
has activated the diagnostic code. Refer to Testing (1) Left Steering Cylinder
and Adjusting, “Electronic Control Module (ECM) (2) Right Steering Cylinder
- Replace”. (3) “Steering Position Sensor” connector on the back side of the
cylinders
STOP.
This diagnostic code is associated with the “right
i02925679 sensor provides a PWM input signal to the Implement
MID 027 - CID 2201 - FMI 02 ECM and to the Transmission/Chassis ECM. The
FMI 02 means that the ECM has determined that the
input signal from the sensor is erratic, intermittent,
or incorrect.

below:

devices not adjusted correctly.
• Intermittent connections or open locations in the

sensor circuit

g01254393
Illustration 300 sensor power supply of the Implement ECM. Correct
Connections of “Right Steering Cylinder” Position Sensor any problem with the 8 volt power supply before
RENR9004-07 463
Note: The Implement ECM (MID 082) will also Repair: Perform the maintenance that is required
activate a CID 2201 FMI 02 diagnostic code if an in order to correct the problem with the mechanical
erratic signal or an intermittent signal is detected. connections for the steering cylinder. After the
If one ECM has activated a CID 2201 FMI 02 problem has been corrected, verify that this
diagnostic code and the other ECM has not activated diagnostic code is still active before proceeding
a diagnostic code, it is likely that the sensor is with this procedure.
operating correctly. When this occurs, a poor
connection or an open in the machine harness STOP.
would be suspected. When both ECM modules
have activated the diagnostic code, the sensor or Test Step 2. CHECK FOR POWER AT THE
a harness problem could be the cause. For either SENSOR
condition, proceed with this procedure in order to
verify the cause of the problem. A. Turn the key start switch and the disconnect
the harness connectors that are involved in the B. Do not disconnect the harness connector from the
circuit. Poor connections are often the cause sensor.
all connections in the circuit are clean, that all C. At the back of the harness connector for the
connections are secure and that all connections sensor, insert 7X-1710 Multimeter Probes along
are in good condition. If a problem with a the voltage input A (wire R800-OR) and along the
connection is found, correct the problem and return contact B (wire P967-PU).
performing this procedure. D. Turn the key start switch and the disconnect
diagnostic codes. Ignore these created diagnostic E. Measure the voltage from contact A to contact B.
original diagnostic code has been corrected. Expected Result:
Test Step 1. CHECK THE MECHANICAL The voltage measurement is 8 ± 0.3 DCV.
CONNECTIONS
Results:
switch to the OFF position. • OK – The voltage measurement is 8 ± 0.3 DCV.
The power supply circuit is correct. Proceed to
B. Visually inspect the mechanical connections Test Step 3.
for the “right steering” cylinder. Verify that all
mechanical connections and adjustments for the • NOT OK – The voltage measurement is not 8 ±
steering cylinder are in good condition and verify 0.3 DCV. The power supply circuit is not correct.
that no mechanical connections are loose.
Expected Result: circuit for the sensor. Refer to the complete
Electrical System Schematic of the machine .
All mechanical connections for the steering cylinder Check all of the connections that are in the power
are in good condition and no mechanical connections supply circuit and the return circuit. Ensure that
are loose. all connections are clean, that all connections
Results: condition. Repair the machine harness or replace
cylinder are correct. Proceed to Test Step 2. STOP.
• NOT OK – All mechanical connections for the Test Step 3. CHECK THE SENSOR
464 RENR9004-07
A. Disconnect the machine harness connector from • NO – The status of the CID 2201 FMI 02 diagnostic
the “right steering cylinder” position sensor and code did not change when the sensor connectors
disconnect the machine harness connector from were switched. The CID 2201 FMI 02 diagnostic
the “left steering cylinder” position sensor. Mark code is still active. There is a problem in the
the harness connector for the “right steering machine harness.
sensor”.
B. Connect the marked connector for the “right CONNECTORS ARE CONNECTED TO THE
steering” sensor to the connector for the “left CORRECT POSITION SENSOR. THE MARKED
steering” sensor . Connect the connector that is HARNESS CONNECTOR IS CONNECTED
not marked for the “left steering” sensor to the TO THE “RIGHT STEERING” SENSOR. THE
connector for the “right steering” sensor. HARNESS CONNECTOR THAT IS NOT MARKED
IS CONNECTED TO THE “LEFT STEERING”
C. Turn the disconnect switch and the key start SENSOR. Proceed to Test Step 4.
D. Observe the status of the active diagnostic code THE SIGNAL CIRCUIT
for the “right steering” sensor.
Expected Result: machine harness connectors are connected
to the original “right and left steering cylinder
When the harness connectors are switched, the CID position” sensor connectors.
2201 FMI 02 diagnostic code for the “right steering”
sensor is not active. A CID 2200 FMI 02 diagnostic A. Turn the key start switch and the disconnect
code for the “left steering” sensor is now active. switch to the OFF position.

the “right steering cylinder” position sensor.
longer active. A CID 2200 FMI 02 diagnostic code C. At the machine harness connector for the “right
is now active. The sensor has failed. steering sensor”, place a jumper wire between
return contact 2 (wire P967-PU) and signal contact
Repair: The “right steering cylinder” position 3 (wire H765-WH).
sensor is the cause of the problem. Replace the
“right steering cylinder” position sensor. D. Disconnect the machine harness connectors
J1 and J2 from the Implement ECM and the
BEFORE REPLACING THE “STEERING Transmission/Chassis ECM.
HARNESS CONNECTORS TO THE CORRECT E. At the Implement ECM, measure the resistance
“STEERING SENSOR” CONNECTORS. from return contact J1-45 (wire P967-PU) to signal
contact J2-16 (wire H765-WH).
cylinder, refer to Disassembly and Assembly, F. Obtain a spare length of wire that will reach from
RENR 9704, “Clevis Style Cylinder Sensor - the connectors of the Transmission/Chassis ECM
Remove and Install”. to the “steer cylinder position” sensor connector.
After the replacement of the sensor, the new G. At the “steer cylinder position” sensor connector,
parameters for the position sensor MUST be connect one end of the spare wire to the signal
entered in Cat ET before the machine can be contact 3 (wire H765-WH).
RENR9013, “Implement Electronic Control H. At the connector for the Transmission/Chassis
System”, “Position Sensor (Steering Cylinder) - ECM J2, measure the resistance between the
Set” for the correct procedure. other end of the spare wire and the signal contact
J2-16 (wire H765-WH).
STOP.
Expected Result:

5 ohms.
RENR9004-07 465
• OK – Both of the resistance measurements are The CID 2201 FMI 02 diagnostic code is not active.
less than 5 ohms. The signal circuit is not open.
Proceed to Test Step 5. Results:
• NOT OK – One or both of the resistance • OK – The CID 2201 FMI 02 diagnostic code is
measurements is greater than 5 ohms. There is an not active. The diagnostic code does not exist at
open or a bad connection in the signal circuit. this time. The initial diagnostic code was probably
Repair: A resistance measurement that is greater of the connectors that was disconnected and
than 5000 ohms could indicate that a wire is not reconnected. Resume normal operation. STOP.
measurement that is greater 5 ohms but less • NOT OK – The CID 2201 FMI 02 diagnostic
than 5000 ohms could indicate that one of the code is active. The diagnostic code has not been
connection points in the circuit is not an open corrected.
If the circuit at one of the ECM modules is correct test” on the machine wiring harness. Use the
and the circuit at the other ECM indicates a bad Caterpillar Electronic Technician (ET) in order
connection this condition likely indicates a problem to perform the test. The “wiggle test” can detect
in the machine harness on the ECM side of the intermittent shorts or open connections in the
splice. machine wiring harness.
If the resistance checks both indicate a bad If the cause of the active diagnostic code is not
connection, a problem in the sensor side of the found, the Implement ECM may have failed.
splice in the machine harness is most likely the
cause of the problem. It is unlikely that the ECM has failed. Exit this
Refer to the complete Electrical System Schematic cause of the failure is not found, replace the ECM.
of the machine. Verify that all connection points in Prior to replacing an ECM, always contact your
the suspected part of the circuit are clean, that all dealership's Technical Communicator for possible
connections are secure and that all connections consultation with Caterpillar. This consultation
are in good condition. Repair the machine harness may greatly reduce repair time. If the cause of the
or replace the machine harness. diagnostic code is not found, replace the ECM that
STOP. and Adjusting, “Electronic Control Module (ECM)
- Replace”.





diagnostic code.
466 RENR9004-07
i02925867 This diagnostic code is associated with the “right

MID 027 - CID 2201 - FMI 03 sensor provides a PWM input signal to the Implement
ECM and to the Transmission/Chassis ECM. The FMI
SMCS Code: 1439-038-CD 03 diagnostic code is activated when the ECM reads
the input signal from the sensor and the voltage of
Conditions Which Generate This Code: the signal is above normal.


below:
• The supply circuit for the power supply is open.

disconnected.
• The signal circuit is shorted to the sensor power

supply.
g01254393
Illustration 302 • The sensor has failed.
Connections of “Right Steering Cylinder” Position Sensor
Note: The Implement ECM (MID 082) will also

activate a CID 2201 FMI 03 diagnostic code when an
above normal signal voltage is detected. If one ECM
has activated a CID 2201 FMI 03 diagnostic code
and the other ECM has not activated a diagnostic
code, it is likely that the sensor is operating correctly.
When this occurs, a poor connection or an open in
the machine harness would be suspected. When
both ECM modules have activated the diagnostic
code, either the sensor or a harness problem could
be the cause. For either condition, proceed with this
g01254278 Note: The following test procedure may create other

Illustration 303 diagnostic codes. Ignore these created diagnostic
(1) Left Steering Cylinder codes and clear the diagnostic codes when the
(2) Right Steering Cylinder original diagnostic code has been corrected. Verify
cylinders that the CID 2201 FMI 03 diagnostic code is active
Test Step 1. CHECK FOR POWER AT THE

SENSOR
RENR9004-07 467
B. Do not disconnect the harness connector from the Expected Result:

sensor.
C. At the back of the harness connector for the 2201 FMI 03 diagnostic code for the “right steering
sensor, insert 7X-1710 Multimeter Probes along sensor” is not active. A CID 2200 FMI 03 diagnostic
voltage supply A (wire R800-OR) and along return code for the “left steering sensor” is now active.
contact B (wire P967-PU).
Results:
switch to the ON position. • YES – The CID 2201 FMI 03 diagnostic code is no
E. Measure the voltage from contact A to contact B. is now active. The sensor has failed.
Expected Result: Repair: The “right steering cylinder” position

sensor is the cause of the problem. Replace the
The voltage measurement is 8.0 ± 0.5 DCV. “right steering cylinder” position sensor.
Results: BEFORE REPLACING THE “STEERING

POSITION” SENSOR, RECONNECT THE
• OK – The voltage measurement is 8.0 ± 0.5 DCV. HARNESS CONNECTORS TO THE CORRECT
The power supply circuit is correct. Proceed to “STEERING SENSOR” CONNECTORS.
Test Step 2.
• NOT OK – The voltage measurement is not 8.0 ± cylinder, refer to Disassembly and Assembly,
0.5 DCV. The power supply circuit is not correct. RENR 9704, “Clevis Style Cylinder Sensor -
circuit for the sensor. Refer to the complete After the replacement of the sensor, the new
Electrical System Schematic of the machine. parameters of the position sensor MUST be
Check all of the connections that are in the power entered in Cat ET before the machine can be
supply circuit and the return circuit. Ensure that operated. Refer to the Testing and Adjusting,
all connections are clean, that all connections RENR9013, “Implement Electronic Control
are secure and that all connections are in good System”, “Position Sensor (Steering Cylinder) -
condition. Repair the machine harness or replace Set” for the correct procedure.
STOP.
STOP.
Test Step 2. CHECK THE SENSOR code did not change when the sensor connectors
Turn the key start switch and the disconnect switch code is still active. There is a problem in the
to the OFF position. machine harness.
A. Disconnect the machine harness connector from ENSURE THAT THE MACHINE HARNESS
the “right steering cylinder” position sensor and CONNECTORS ARE CONNECTED TO THE
disconnect the machine harness connector from CORRECT POSITION SENSOR. THE MARKED
the “left steering cylinder” position sensor. Mark HARNESS CONNECTOR IS CONNECTED
the harness connector for the “right steering TO THE “RIGHT STEERING SENSOR”. THE
sensor”. HARNESS CONNECTOR THAT IS NOT MARKED
IS CONNECTED TO THE “LEFT STEERING
B. Connect the marked connector for the “right SENSOR”. Proceed to Test Step 3.
steering sensor” to the connector for the “left
steering sensor”. Connect the connector that is Test Step 3. CHECK FOR AN OPEN IN
not marked for the “left steering sensor” to the THE SIGNAL CIRCUIT
connector for the “right steering sensor” .
C. Turn the disconnect switch and the key start machine harness connectors are connected
switch to the ON position. Do not start the engine. to the original “right and left steering cylinder
position” sensor connectors.
for the right steering sensor. A. Turn the key start switch and the disconnect
468 RENR9004-07
B. Disconnect the machine harness connector from Refer to the complete Electrical System Schematic
the “right steering cylinder” position sensor. of the machine. Verify that all connection points in
the suspected part of the circuit are clean, that all
C. At the machine harness connector for the “right connections are secure and that all connections
steering sensor”, place a jumper wire between are in good condition. Repair the machine harness
return contact 2 (wire P967-PU) and signal contact or replace the machine harness.
3 (wire H765-WH).
STOP.
D. Disconnect the machine harness connectors
J1 and J2 from the Implement ECM and the Test Step 4. CHECK THE SIGNAL
Transmission/Chassis ECM. CIRCUIT FOR A SHORT
E. At the Implement ECM, measure the resistance The key start switch and the disconnect switch remain
from return contact J1-45 (wire P967-PU) to signal in the OFF position. The harness connectors of the
contact J2-16 (wire H765-WH). Transmission/Chassis ECM and the connectors for
the Implement ECM remain disconnected from the
F. Obtain a spare length of wire that will reach from machine harness.
the connectors of the Transmission/Chassis ECM
to the connector of the “steer cylinder position” A. Remove the spare wire that was installed in the
sensor . last step.
G. At the connector of the “steer cylinder position” B. At the J1 and J2 machine harness connectors for
sensor , connect one end of the spare wire to the the Implement ECM, measure the resistance from
signal contact 3 (wire H765-WH). the sensor signal contact J2-16 (wire H765-WH)
to all of the other J1 and J2 contacts that are used
H. At the connector for the Transmission/Chassis for the Implement ECM.
ECM J2, measure the resistance between the
other end of the spare wire and the signal contact C. If any of the resistance measurements in the last
J2-16 (wire H765-WH). test step are less than 3000 ohms, skip the next
test step and proceed to the “Expected Result”
Expected Result: step. If all of the resistance measurements in the
last test step are above 3000 ohms, perform the
Each of the resistance measurements is less than next test step.
5 ohms.
D. At the disconnected J1 and J2 machine harness
Results: connectors for the Transmission/Chassis ECM,
measure the resistance from the sensor signal
• OK – Both of the resistance measurements are contact J2-16 (wire H765-WH) to all of the
less than 5 ohms. The signal circuit is not open. other J1 and J2 contacts that are used for the
Proceed to Test Step 4. Transmission/Chassis ECM.
• NOT OK – One or both of the resistance Expected Result:

measurements is greater than 5 ohms. There is an
open or a bad connection in the signal circuit. Each resistance measurement is greater than 5000
ohms.
than 5000 ohms could indicate that a wire is not Results:
measurement that is greater 5 ohms but less • OK – Each resistance measurement is greater
than 5000 ohms could indicate that one of the than 5000 ohms. The signal circuit is not shorted.
connection points in the circuit is not an open Proceed to Test Step 5.
• NOT OK – A resistance measurement is less than
If the circuit at one of the ECM modules checks 5000 ohms.
correctly and the circuit at the other ECM indicates
a bad connection, a problem may exist in the Repair: There is a short in the machine harness.
machine harness on the ECM side of the splice. The short is between the signal circuit and the
If both of the resistance checks indicate a bad
connection, a problem may exist in the sensor side
of the splice of the machine harness.
RENR9004-07 469
For information on testing for short circuits and It is unlikely that the ECM has failed. Exit this
finding short circuits, refer to Testing and Adjusting, procedure and perform this procedure again. If the
“Wiring Harness (Short Circuit) - Test”. Repair the cause of the failure is not found, replace the ECM.
machine harness or replace the machine harness. Prior to replacing an ECM, always contact your
STOP. consultation with Caterpillar. This consultation
Test Step 5. CHECK THE STATUS OF THE diagnostic code is not found, replace the ECM that
DIAGNOSTIC CODE has activated the diagnostic code. Refer to Testing
A. Inspect the harness connectors. Clean the - Replace”.
wires for damage to the insulation that is caused STOP.
i02926424
wires that are associated with the sensor circuit. MID 027 - CID 2201 - FMI 04
C. Reconnect all harness connectors. Make sure that SMCS Code: 1439-038-CD
clips for each connector are completely fastened. Conditions Which Generate This Code:

is active.
Expected Result:
Results:

g01254393
Illustration 304
code is active. The diagnostic code has not been Connections of “Right Steering Cylinder” position sensor
corrected.


470 RENR9004-07

diagnostic code when the signal is below normal.
diagnostic code and the other ECM has not
activated a diagnostic code, it is likely that the
suspected.
problem.

Illustration 305
(3) “Steering Position Sensor” connector on the back side of the all connections in the circuit are clean, that all
cylinders connections are secure and that all connections
This diagnostic code is associated with the “right connection is found, correct the problem and
steering cylinder” position sensor. The position verify that this diagnostic code is active before
sensor provides a PWM input signal to the Implement performing this procedure.
04 diagnostic code is activated when the ECM reads Note: The following test procedure may create other
the input signal from the sensor and the voltage of diagnostic codes. Ignore these created diagnostic
the signal is below normal. codes and clear the diagnostic codes when the
frequency of approximately 500 hertz. The duty cycle Test Step 1. CHECK THE SENSOR
measured in very small increments. The changes in Turn the key start switch and the disconnect switch
the duty cycle of the sensor can not be measured to the OFF position.
A. Disconnect the machine harness connector from
The possible causes of this diagnostic code are listed the “right steering cylinder” position sensor and
below: disconnect the machine harness connector from
the “left steering cylinder” position sensor. Mark
• The signal circuit is shorted to a ground source. the harness connector for the “right steering
sensor”.
B. Connect the marked connector for the “right
• The ECM has failed. This is unlikely. steering sensor” to the connector for the “left
steering sensor”. Connect the connector that is
Before performing this procedure, check for an active not marked for the “left steering sensor” to the
CID 0041 diagnostic code for the 8 volt sensor power connector for the “right steering sensor” .
supply of the Implement ECM (MID 082). Correct
any problem with the 8 volt power supply before C. Turn the disconnect switch and the key start
performing this procedure. switch to the ON position. Do not start the engine.

RENR9004-07 471
Expected Result: B. Disconnect the machine harness connector from

2201 FMI 04 diagnostic code for the “right steering C. Disconnect the J1 and J2 machine harness
sensor” is not active. A CID 2200 FMI 04 diagnostic connectors from the Implement ECM and from the
code for the “left steering sensor” is now active. Transmission/Chassis ECM.
Results: D. At the J1 and J2 machine harness connectors for

the Implement ECM, measure the resistance from
• YES – The CID 2201 FMI 04 diagnostic code is no the sensor signal contact J2-16 (wire H765-WH)
longer active. A CID 2200 FMI 04 diagnostic code to frame ground and measure the resistance to all
is now active. The sensor has failed. of the other contacts that are used in the machine
harness connectors of the Implement ECM.
Repair: The “right steering cylinder” position
sensor is the cause of the problem. Replace the E. At machine harness connector J2 for the
“right steering cylinder” position sensor. Transmission/Chassis ECM, measure the
resistance from signal contact J2-16 (wire
BEFORE REPLACING THE STEERING H765-WH) to frame ground and measure the
POSITION SENSOR, RECONNECT THE resistance to all of the contacts that are used
HARNESS CONNECTORS TO THE CORRECT in the machine harness connectors for the
“STEERING SENSOR” CONNECTORS. Transmission/Chassis ECM.
For removal of the position sensor from the steering Expected Result:
RENR 9704, “Clevis Style Cylinder Sensor - Each resistance measurement is greater than 5000
Remove and Install”. ohms.
After replacement of the sensor, the new Results:

parameters of the position sensor MUST be
entered in Cat ET before the machine can be • OK – Each resistance measurement is greater
operated. Refer to the Testing and Adjusting, than 5000 ohms. The machine harness is correct.
RENR9013, “Implement Electronic Control Proceed to Test Step 3.
System”, “Position Sensor (Steering Cylinder) -
Set” for the correct procedure. • NOT OK – One or more of the resistance
measurements is less than 5000 ohms. The
STOP. resistance measurement is indicating a short in the
machine harness.
code did not change when the sensor connectors Repair: There is a short in the machine harness
were switched. The CID 2201 FMI 04 diagnostic between the signal circuit and the circuit with the
code is still active. There is a problem in the low resistance measurement.
machine harness.
ENSURE THAT THE MACHINE HARNESS finding short circuits, refer to Testing and Adjusting,
CONNECTORS ARE CONNECTED TO THE “Wiring Harness (Short Circuit) - Test”. Repair the
CORRECT POSITION SENSOR. THE MARKED machine harness or replace the machine harness.
TO THE “RIGHT STEERING SENSOR”. THE STOP.
HARNESS CONNECTOR THAT IS NOT MARKED
IS CONNECTED TO THE “LEFT STEERING Test Step 3. CHECK THE STATUS OF THE
SENSOR”. Proceed to Test Step 2. DIAGNOSTIC CODE
Test Step 2. CHECK THE SIGNAL A. Inspect the harness connectors. Clean the
CIRCUIT FOR A SHORT TO GROUND contacts of the harness connectors. Check the
Before performing this Test Step, verify that the by excessive heat, battery acid, or chafing.
to the original “right and left steering cylinder B. Perform a 45 N (10 lb) pull test on each of the
position” sensor connectors. wires that are associated with the sensor circuit.
A. Turn the key start switch and the disconnect C. Reconnect all harness connectors. Make sure that
switch to the OFF position. the connectors are fully seated. Observe that the
472 RENR9004-07
D. Turn the disconnect switch and the key start i02926428

MID 027 - CID 2201 - FMI 08
Expected Result:
Results:


corrected.

g01254393
to perform the test. The “wiggle test” can detect Illustration 306
intermittent shorts or open connections in the Connections of “Right Steering Cylinder” position sensor


- Replace”.
STOP.
g01254278
Illustration 307
cylinders
RENR9004-07 473
This diagnostic code is associated with the “right Test Step 1. CHECK THE MECHANICAL
steering cylinder” position sensor. The position CONNECTIONS
ECM and to the Transmission/Chassis ECM. The A. Turn the key start switch and the disconnect
FMI 08 diagnostic code is active during times that the switch to the OFF position.
ECM detects the input signal from the sensor has an
abnormal frequency or pulse width. B. Visually inspect the mechanical connections
for the “right steering cylinder”. Verify that all
The sensor is a PWM sensor that operates at a mechanical connections and adjustments for the
frequency of approximately 500 hertz. The duty cycle steering cylinder are in good condition and verify
of the PWM signal that is supplied to the ECM is that none of the mechanical connections are
measured in very small increments. The changes in loose.
with a digital multimeter. Expected Result:
The possible causes of this diagnostic code are listed All mechanical connections for the steering cylinder
below: are in good condition and no mechanical connections
are loose.
• Mechanical devices in the cylinder assembly are
loose. Results:
• The sensor has failed. • OK – All mechanical connections for the steering
• Intermittent connections or poor connections in the
signal circuit of the sensor • NOT OK – All mechanical connections for the
Repair: Perform the maintenance that is required
Note: Before performing this procedure, check for an in order to correct the problem with the mechanical
active CID 0041 diagnostic code for the 8 volt sensor connections for the steering cylinder. After the
power supply of the Implement ECM (MID 082). problem has been corrected, verify that this
Correct any problem with the 8 volt power supply diagnostic code is still active before proceeding
before performing this procedure. with this procedure.
Note: The Implement ECM (MID 082) will also STOP.

activate a CID 2201 FMI 08 diagnostic code when an
above normal signal voltage is detected. If one ECM Test Step 2. CHECK THE SENSOR
has activated a CID 2201 FMI 08 diagnostic code and
the other ECM has not activated a diagnostic code, it The key start switch and the disconnect switch
is likely that the sensor is operating correctly. When remain in the OFF position.
this occurs, an intermittent open or a poor connection
in the machine harness would be suspected. When A. Disconnect the machine harness connector from
both ECM modules have activated the diagnostic the “right steering cylinder” position sensor and
code, either the sensor or a harness problem could disconnect the machine harness connector from
be the cause. For either condition, proceed with this the “left steering cylinder” position sensor. Mark
procedure in order to verify the cause of the problem. the harness connector for the “right steering
sensor”.
the harness connectors that are involved in the B. Connect the marked connector for the “right
circuit. Poor connections are often the cause steering sensor” to the connector for the “left
of a problem in an electrical circuit. Verify that steering sensor” . Connect the connector that is
all connections in the circuit are clean, that all not marked for the “left steering sensor” to the
connections are secure and that all connections connector for the “right steering sensor” .
connection is found, correct the problem and C. Turn the disconnect switch and the key start
verify that this diagnostic code is active before switch to the ON position. Do not start the engine.
Note: The following test procedure may create other for the “right steering sensor”.
474 RENR9004-07
Expected Result: B. Disconnect the machine harness connector from

2201 FMI 08 diagnostic code for the “right steering C. At the machine harness connector for the “right
sensor” is not active. A CID 2200 FMI 08 diagnostic steering sensor”, place a jumper wire between
code for the “left steering sensor” is now active. return contact 2 (wire P967-PU) and signal contact
3 (wire H765-WH).
Results:
D. Disconnect the machine harness connectors J1
• YES – The CID 2201 FMI 08 diagnostic code is no and J2 from the Implement ECM and from the
longer active. A CID 2200 FMI 08 diagnostic code Transmission/Chassis ECM.
E. At the Implement ECM, measure the resistance
Repair: The “right steering cylinder” position from return contact J1-45 (wire P967-PU) to signal
sensor is the cause of the problem. Replace the contact J2-16 (wire H765-WH).
“right steering cylinder” position sensor.
F. Obtain a spare length of wire that will reach from
BEFORE REPLACING THE STEERING the connectors of the Transmission/Chassis ECM
POSITION SENSOR, RECONNECT THE to the “steer cylinder position” sensor connector.
“STEERING SENSOR” CONNECTORS. G. At the “steer cylinder position” sensor connector,
connect one end of the spare wire to the signal
For removal of the position sensor from the steering contact 3 (wire H765-WH).
RENR 9704, “Clevis Style Cylinder Sensor - H. At the connector for the Transmission/Chassis
Remove and Install”. ECM J2, measure the resistance between the
other end of the spare wire and the signal contact
After the replacement of the sensor, the new J2-16 (wire H765-WH).
parameters for the position sensor MUST be
entered in Cat ET before the machine can be Expected Result:
RENR9013, “Implement Electronic Control Each of the resistance measurements is less than
System”, “Position Sensor (Steering Cylinder) - 5 ohms.
Results:
STOP.
• NO – The status of the CID 2201 FMI 08 diagnostic less than 5 ohms. The signal circuit is not open.
code did not change when the sensor connectors Proceed to Test Step 4.
code is still active. There is a problem in the • NOT OK – One or both of the resistance
machine harness. measurements is greater than 5 ohms. There is an
open or a bad connection in the signal circuit.
CONNECTORS ARE CONNECTED TO THE Repair: A resistance measurement that is greater
CORRECT POSITION SENSOR. THE MARKED than 5000 ohms could indicate that a wire is not
HARNESS CONNECTOR IS CONNECTED connected or that a wire is open. A resistance
TO THE “RIGHT STEERING SENSOR”. THE measurement that is greater 5 ohms but less
HARNESS CONNECTOR THAT IS NOT MARKED than 5000 ohms could indicate that one of the
IS CONNECTED TO THE “LEFT STEERING connection points in the circuit is not an open
SENSOR”. Proceed to Test Step 3. connection but not a good connection.
Test Step 3. CHECK FOR AN OPEN IN If the circuit at one of the ECM modules checks
THE SIGNAL CIRCUIT correctly and the circuit at the other ECM indicates
a bad connection, most likely there is a problem in
Before performing this Test Step, verify that the the machine harness on the ECM side of the splice.
to the original “right and left steering cylinder If the resistance checks both indicate an open or
position” sensor connectors. a bad connection, a problem in the sensor side of
the splice in the machine harness is most likely the
A. Turn the key start switch and the disconnect cause of the problem.
RENR9004-07 475
Refer to the complete Electrical System Schematic It is unlikely that the ECM has failed. Exit this
of the machine. Verify that all connection points in procedure and perform this procedure again. If the
the suspected part of the circuit are clean, that all cause of the failure is not found, replace the ECM.
connections are secure and that all connections Prior to replacing an ECM, always contact your
are in good condition. Repair the machine harness dealership's Technical Communicator for possible
or replace the machine harness. consultation with Caterpillar. This consultation
STOP. diagnostic code is not found, replace the ECM that
Test Step 4. CHECK THE STATUS OF THE and Adjusting, “Electronic Control Module (ECM)
DIAGNOSTIC CODE - Replace”.

i02926447

MID 027 - CID 2201 - FMI 13
wires that are associated with the sensor circuit. SMCS Code: 1439-038-CD
C. Reconnect all harness connectors. Make sure that Conditions Which Generate This Code:
clips for each connector are completely fastened. This diagnostic code is associated with the “right
D. Turn the disconnect switch and the key start sensor provides a PWM input signal to the Implement
switch to the ON position. ECM and to the Transmission/Chassis ECM. The FMI
13 diagnostic code is active. The ECM determines
E. Operate the machine. that the sensor is in need of calibration.
F. Determine if the CID 2201 FMI 08 diagnostic code The sensor is a PWM sensor that operates at a
is active. frequency of approximately 500 hertz. The duty cycle
Expected Result: measured in very small increments. The changes in
The CID 2201 FMI 08 diagnostic code is not active. with a digital multimeter.
Results: CALIBRATION
• OK – The CID 2201 FMI 08 diagnostic code is A. Perform the calibration procedure for the
not active. The diagnostic code does not exist at sensor. Refer to the Testing and Adjusting,
this time. The initial diagnostic code was probably RENR9013, “Implement Electronic Control
caused by a poor connection or a short at one System”, “Calibration” for the information on the
of the connectors that was disconnected and method to access the calibration procedure.
Expected Result:
code is active. The diagnostic code has not been The calibration procedure was performed
corrected. successfully.
Repair: Check the circuit again. Perform a “wiggle Results:
to perform the test. The “wiggle test” can detect successfully. Resume normal machine operation.
intermittent shorts or open connections in the STOP.
machine harness, the ECM may have failed. Repair: Repeat the calibration procedure for the
sensor.

successful, replace the “steer cylinder” position
sensor.
476 RENR9004-07

After the replacement of the sensor, the new

parameters of the position sensor MUST be
entered in Cat ET before the machine can be
“Position Sensor (Steering Cylinder) - Set” section
of this manual for the correct procedure.
After cylinder replacement, refer to the Testing

and Adjusting, RENR9013, “Implement Electronic
Control System”, “Calibration” for the information
on the method to access the calibration procedure.
If the problem is still present after replacement and
calibration of the new sensor, the ECM may have
failed.

g01254278
consultation with Caterpillar. This consultation (1) Left Steering Cylinder
may greatly reduce repair time. If the cause of the (2) Right Steering Cylinder
diagnostic code is not found, replace the ECM. (3) “Steering Position Sensor” connector on the back side of the
Refer to Testing and Adjusting, “Electronic Control cylinders
This diagnostic code is associated with the “right
STOP. steering cylinder” position sensor. The position
i02926451 14 diagnostic code is active. The ECM determines
MID 027 - CID 2201 - FMI 14 that the sensor is not responding as expected. No
external conditions that could cause this problem
have been detected.

below:
• Mechanical devices are loose or not adjusted

correctly.

g01254393
Illustration 308
Connections of “Right Steering Cylinder” position sensor
RENR9004-07 477
Note: Before performing this procedure, inspect B. Connect the marked connector for the “right
the harness connectors that are involved in the steering sensor” to the connector for the “left
circuit. Poor connections are often the cause steering sensor”. Connect the connector that is
of a problem in an electrical circuit. Verify that not marked for the “left steering sensor” to the
all connections in the circuit are clean, that all connector for the “right steering sensor”.
connection is found, correct the problem and switch to the ON position. Do not start the engine.
performing this procedure. D. Observe the status of the active diagnostic code
original diagnostic code has been corrected. When the harness connectors are switched, the CID
Test Step 1. CHECK THE MECHANICAL sensor” is not active. A CID 2200 FMI 14 diagnostic
CONNECTIONS code for the “left steering sensor” is now active.

B. Visually inspect the mechanical connections longer active. A CID 2200 FMI 14 diagnostic code
for the “right steering cylinder”. Verify that all is now active. The sensor has failed.
mechanical connections and adjustments for the
steering cylinder are in good condition and verify Repair: The “right steering cylinder” position
that none of the mechanical connections are sensor is the cause of the problem. Replace the
loose. “right steering cylinder” position sensor.
Expected Result: BEFORE REPLACING THE “STEERING

POSITION” SENSOR, RECONNECT THE
All mechanical connections for the steering cylinder HARNESS CONNECTORS TO THE CORRECT
are in good condition and no mechanical connections “STEERING SENSOR” CONNECTORS.
are loose.
Results: cylinder, refer to Disassembly and Assembly,
• OK – All mechanical connections for the steering Remove and Install”.
After the replacement of the sensor, the new
• NOT OK – All mechanical connections for the parameters of the position sensor MUST be
steering cylinder are not correct. entered in Cat ET before the machine can be
Repair: Perform the maintenance that is required RENR9013, “Implement Electronic Control
in order to correct the problem with the mechanical System”, “Position Sensor (Steering Cylinder) -
connections for the steering cylinder. After the Set” for the correct procedure.
problem has been corrected, verify that this
diagnostic code is still active before proceeding STOP.
STOP. code did not change when the sensor connectors
Test Step 2. CHECK THE SENSOR code is still active. There is a problem in the
machine harness.
remain in the OFF position. ENSURE THAT THE MACHINE HARNESS
CONNECTORS ARE CONNECTED TO THE
A. Disconnect the machine harness connector from CORRECT POSITION SENSOR. THE MARKED
the “right steering cylinder” position sensor and HARNESS CONNECTOR IS CONNECTED
disconnect the machine harness connector from TO THE “RIGHT STEERING SENSOR”. THE
the “left steering cylinder” position sensor. Mark HARNESS CONNECTOR THAT IS NOT MARKED
the harness connector for the “right steering IS CONNECTED TO THE “LEFT STEERING
sensor”. SENSOR”. Proceed to Test Step 3.
478 RENR9004-07
Test Step 3. CHECK THE STATUS OF THE It is unlikely that the ECM has failed. Exit this
DIAGNOSTIC CODE procedure and perform this procedure again. If the
Before performing this Test Step, verify that the Prior to replacing an ECM, always contact your
machine harness connectors are connected dealership's Technical Communicator for possible
to the original “left and right steering cylinder consultation with Caterpillar. This consultation
position” sensor connectors. may greatly reduce repair time. If the cause of the
A. Inspect the harness connectors. Clean the has activated the diagnostic code. Refer to Testing
contacts of the harness connectors. Check the and Adjusting, “Electronic Control Module (ECM)
wires for damage to the insulation that is caused - Replace”.
STOP.
i02926529

MID 027 - CID 2252 - FMI 02
clips for each connector are completely fastened. SMCS Code: 4806-038
D. Turn the disconnect switch and the key start Conditions Which Generate This Code:

is active.
Expected Result:
Results:


code is active. The diagnostic code has not been g01256820
corrected. Illustration 310
Connections of “Machine Articulation Angle Sensor 2”

RENR9004-07 479

signal from the “articulation sensor 2”. Both ECM
modules will activate a CID 2252 FMI 02 diagnostic
code when an intermittent signal is detected.
suspected.
problem.

Illustration 311
Locations of “Machine Articulation Angle” sensor
(1) “Machine articulation angle sensor 1”
(2) “Machine articulation angle sensor 2”
(3) Mechanical linkage connections are secure and that all connections
Two articulation angle sensors are required for connection is found, correct the problem and
correct operation of the articulation on the machine. verify that this diagnostic code is active before
Each sensor will provide a PWM input to the performing this procedure.
This diagnostic code is associated with the “machine diagnostic codes. Ignore these created diagnostic
articulation angle sensor 2”. The FMI 02 means that codes and clear the diagnostic codes when the
the ECM has determined that the input data from original diagnostic code has been corrected.
the sensor is erratic, intermittent, or incorrect. The
Implement ECM, the Transmission/Chassis ECM or Note: Use a digital multimeter for the measurements
both ECM modules can activate this diagnostic code. in this procedure.
The sensor is a PWM sensor that operates at a Test Step 1. CHECK THE MECHANICAL
frequency of approximately 500 hertz. When the LINKAGE
machine is in the neutral position, the input of the duty
cycle from the sensor to the ECM is approximately A. Turn the key start switch and the disconnect
55%. When the machine is articulated to the full switch to the OFF position.
33%. When the machine is articulated to the full right B. Remove any guards or shielding for the articulation
position, the duty cycle will be approximately 74%. sensors.
The possible causes of this diagnostic code are listed C. Check the mounting bolts for the articulation
below: sensors. Ensure that the sensors are securely
mounted.
devices are not adjusted correctly. D. Visually inspect the mechanical linkage for the
• Intermittent connections or poor connections components are tight and that all mechanical
• The sensor has failed. adjustment of the linkage is correct.
• The ECM has failed. This is unlikely. Expected Result:
All mechanical linkage and adjustable components

no mechanical connections are loose.
480 RENR9004-07
Results: Test Step 3. CHECK THE SIGNAL OF THE

SENSOR
the articulation sensors is correct. Proceed to Test A. Turn the key start switch and the disconnect
Step 2. switch to the OFF position.
• NOT OK – All mechanical linkage and adjustment B. At the back of the harness connector for the
for the articulation sensors is not correct. sensor, remove the multimeter probe from contact
A (wire T998-BR) and insert the probe along the
Repair: Perform the maintenance that is required signal contact C (wire U768-BU).
in order to correct the problem with the mechanical
connections for the articulation sensors. After C. The multimeter probe along return contact B (wire
the problem has been corrected, verify that this X800-OR) remains in place.
diagnostic code is still active before proceeding
with this procedure. D. Turn the disconnect switch and the key start
STOP.
E. Monitor the signal of the sensor with a digital
Test Step 2. CHECK FOR POWER AT THE multimeter.
SENSOR
A. Turn the key start switch and the disconnect that is associated with the sensor from the
switch to the OFF position. machine, take the sensor through the full
sensor. Note:
C. At the back of the harness connector for the Expected Result:

sensor, insert 7X-1710 Multimeter Probes along
supply voltage A (wire T998-BR) and along return The sensor's signal responds in the manner that is
contact B (wire X800-OR). described at the beginning of this procedure.

• OK – The sensor's signal responds correctly. The
E. Measure the voltage from contact A to contact B. sensor is operating correctly. Proceed to Test Step
4.
Expected Result:
The voltage measurement is 8.0 ± 0.5 VDC. correctly. The sensor is NOT operating correctly.
Results: Repair: Replace the “articulation angle 2” sensor.

After the replacement of the sensor, the sensor
• OK – The voltage measurement is 8.0 ± 0.5 VDC. must be calibrated. Refer to Testing and Adjusting,
The power supply circuit is correct. Proceed to RENR9013, “Implement Electronic Control
Test Step 3. System”, “Calibrations” for information on the
method to access the articulation sensor calibration
• NOT OK – The voltage measurement is not procedure.
8.0 ± 0.5 VDC. The 8 VDC power supply of the
Transmission/Chassis ECM is not correct. STOP.
Repair: There is a problem with the power supply Test Step 4. CHECK FOR AN OPEN IN
circuit for the sensor. Refer to the complete THE SIGNAL CIRCUIT
Check all of the connections that are in the power The key start switch and the disconnect switch
supply circuit and the return circuit. Ensure that remain in the OFF position.
are secure and that all connections are in good A. Disconnect the machine harness connector from
condition. Repair the machine harness or replace the sensor.
STOP.
RENR9004-07 481
B. At the machine harness connector for the sensor, Note: This check should be performed on the ECM
place the jumper wire between return contact that has activated the diagnostic code. If both of the
B (wire X800-OR) and signal contact C (wire ECM modules have activated the diagnostic code,
U768-BU). perform this check on both of the ECM modules.
C. Disconnect the machine harness connectors J1 A. At the machine harness connector J2 for the
and J2 from the Transmission/Chassis ECM. ECM, use a 151-6320 Removal Tool to remove
the sensor signal wire U768-BU and the socket at
D. At the machine harness connectors for the contact J2-17 from the harness connector.
resistance from return contact J1-45 (wire B. Reconnect the machine harness J1 and J2
X800-OR) to signal contact J2-17 (wire U768-BU). connectors to the ECM.
E. Observe the resistance measurement and wiggle C. Turn the key start switch and the disconnect
the ECM connector and the sensor connector. switch to the ON position.
both connectors. D. Observe the status of the active CID 2252 FMI
02 diagnostic code.
Expected Result:
Expected Result:
at all times during the manipulation of the wiring The CID 2252 FMI 02 diagnostic code is no longer
harness. active. A CID 2252 FMI 03 diagnostic code is now
active.
Results:
Results:
• OK – The resistance measures less than 5 ohms.
The signal circuit is not open. Proceed to Test • YES – The CID 2252 FMI 02 diagnostic code is
Step5. no longer active. A CID 2252 FMI 03 diagnostic
code is active after the wire for the sensor signal is
• NOT OK – The resistance measurement is greater disconnected. The ECM has responded correctly
than 5 ohms. There is an open or a bad connection to the open circuit condition in the sensor circuit.
Reinstall the disconnected sensor signal wire
Repair: If both of the ECM modules have activated back into the correct spot in the ECM connector.
this diagnostic code, there is most likely an open or Proceed to the next test step.
a bad connection on the sensor side of the machine
harness splice connection for the signal wire. Proceed to Test Step 6.
If only the Transmission/Chassis ECM has • NO – The CID 2252 FMI 03 diagnostic code
activated this diagnostic code, there is most likely remains active. The status of the active diagnostic
an open or a bad connection on the ECM side code does not change when the sensor signal wire
of the machine harness splice connection for the is disconnected from the ECM.
signal wire.
In either case, refer to the complete Electrical to the open condition in the sensor circuit. The
System Schematic of the machine. Check all of the operation of the ECM is not correct.
connectors that are in the suspected section of the
sensor signal circuit. Ensure that all connections Prior to replacing an ECM, always contact your
are clean, that all connections are secure and that dealership's Technical Communicator for possible
all connections are in good condition. Repair the consultation with Caterpillar. This consultation may
machine harness or replace the machine harness. greatly reduce repair time. If the ECM must be
STOP. Control Module (ECM) - Replace”.
Test Step 5. CHECK THE OPERATION OF STOP.

THE ECM
in the OFF position. The machine harness connectors
for the sensor and the Transmission/Chassis ECM
remain disconnected.
482 RENR9004-07
A. Inspect the harness connectors. Clean the may greatly reduce repair time. If the cause of the
contacts of the harness connectors. Check the diagnostic code is not found, and the ECM must be

i02926623
MID 027 - CID 2252 - FMI 03
SMCS Code: 4806-038

diagnostic code.
Expected Result:
Results:


corrected. g01256820
Illustration 312
Repair: Check the circuit again. Perform a “wiggle Connections of “Machine Articulation Angle Sensor 2”

found, replace the sensor. After the replacement of
the sensor, the sensor must be calibrated. Refer to
this manual for the correct calibration procedure.
If the problem is still present after the replacement

of the sensor and calibration, the ECM may have
failed. This is unlikely as the ECM responded
correctly to the condition in the previous test step.

replace the ECM that activated the diagnostic
code.
RENR9004-07 483

active CID 0041 diagnostic code for the 8 volt power
supply of the ECM. Correct any problem with the 8

and the Implement ECM (MID “082”) receive an input
modules can activate a CID 2252 FMI 03 diagnostic
code when an above normal signal is detected.

suspected.

Illustration 313
g01252009 diagnostic code, either the sensor or a harness
Locations of “Articulation Angle Sensor”
(1) “Articulation angle sensor 1”
(3) Mechanical linkage code, it is very unlikely that the ECM is the cause of
the problem.
correct operation of the articulation of the machine. For either condition, proceed with this procedure in
Each sensor will provide a PWM signal to the order to verify the cause of the problem.
The FMI 03 diagnostic code is activated when the harness connectors that are involved in the
the ECM reads the input signal from the machine circuit. Poor connections can often be the cause
“articulation angle sensor 2” and the voltage of the of a problem in an electrical circuit. Verify that
signal is above normal. The Implement ECM, the all connections in the circuit are clean, that all
Transmission/Chassis ECM or both ECM modules connections are secure and that all connections
can activate this diagnostic code. are in good condition. If a problem with a
The sensor is a PWM sensor that operates at a verify that this diagnostic code is active before
frequency of approximately 500 hertz. When the performing this procedure.
cycle from the sensor to the ECM is approximately Note: The following test procedure may create other
55%. When the machine is articulated to the full diagnostic codes. Ignore these created diagnostic
left position, the duty cycle will be approximately codes and clear the diagnostic codes when the
33%. When the machine is articulated to the full right original diagnostic code has been corrected.
The possible causes of this diagnostic code are listed LINKAGE
below:
• The power supply circuit of the sensor is open. switch to the OFF position.
• The return circuit is open. B. Remove any guards or shielding for the articulation
sensors.
disconnected. C. Check the mounting bolts for the articulation
sensors. Ensure that the sensors are securely
• The signal circuit is shorted to the sensor power mounted.
supply.

484 RENR9004-07
D. Visually inspect the mechanical linkage for the Repair: There is a problem with the 8 VDC
articulation sensors. Verify that all mechanical power supply of the Transmission/Chassis ECM
components are tight and that all mechanical for the sensor. Refer to the complete Electrical
components are in good condition. Verify that the System Schematic of the machine. Check all of
adjustable linkage is correct. the connections that are in the power supply circuit
and the return circuit. Ensure that all connections
Expected Result: are clean, that all connections are secure and that
All mechanical linkage and adjustable components machine harness or replace the machine harness.
no mechanical connections are loose. STOP.
Results: Test Step 3. CHECK FOR AN OPEN IN

THE SIGNAL CIRCUIT
the articulation sensors is correct. Proceed to Test The key start switch and the disconnect switch
Step 2. remain in the OFF position.
• NOT OK – All mechanical linkage and adjustment A. Disconnect the machine harness connector from
for the articulation sensors is not correct. the sensor.
Repair: Perform the maintenance that is required B. At the machine harness connector for the sensor,
in order to correct the problem with the mechanical place the jumper wire between return contact
connections for the articulation sensors. After B (wire X800-OR) and signal contact C (wire
the problem has been corrected, verify that this U768-BU).
diagnostic code is still active before proceeding
with this procedure. C. Disconnect the machine harness connectors J1
STOP.
D. At the machine harness connectors for the
Test Step 2. CHECK THE SUPPLY Transmission/Chassis ECM , measure the
VOLTAGE AT THE SENSOR resistance from return contact J1-45 (wire
X800-OR) to signal contact J2-17 (wire U768-BU).
switch to the OFF position. E. Observe the resistance measurement and wiggle
B. Do not disconnect the harness connector from the Gently pull on the wires and wiggle the wires for
sensor. both connectors.
C. At the back of the harness connector for the Expected Result:

sensor, insert 7X-1710 Multimeter Probes
along supply voltage A (wire T998-BR). Insert The resistance measurement is less than 5 ohms
a multimeter probe along return contact B (wire at all times during the manipulation of the wiring
X800-OR). harness.

• OK – The resistance measures less than 5 ohms.
E. Measure the voltage from contact A to contact B. The resistance measurement is not indicating an
open in the circuit. Proceed to Test Step4.
Expected Result:
The voltage measurement is 8.0 ± 0.5 VDC. than 5 ohms. There is an open or a bad connection
Results:
Repair: If both of the ECM modules have active
• OK – The voltage measurement is 8.0 ± 0.5 VDC. diagnostic codes, there is most likely an open
The power supply circuit is correct. Proceed to connection or a bad connection on the sensor side
Test Step 3. of the machine harness splice connection for the
signal wire.
• NOT OK – The voltage measurement is not 8.0 ±
0.5 VDC. The power supply circuit is not correct.
RENR9004-07 485
If only the Transmission/Chassis ECM has an Refer to the complete Electrical System Schematic
active diagnostic code, there is most likely an of the machine. Check all of the connectors that are
open or a bad connection on the ECM side of the in the sensor circuit. Ensure that all connections
machine harness splice connection for the signal are clean, that all connections are secure and that
wire. all connections are in good condition.
In either case, refer to the complete Electrical For information on testing for short circuits and
System Schematic of the machine. Check all of the finding short circuits, refer to Testing and Adjusting,
connectors that are in the suspected section of the “Wiring Harness (Short Circuit) - Test”. Repair the
sensor signal circuit. Ensure that all connections machine harness or replace the machine harness.
all connections are in good condition. Repair the STOP.
Test Step 5. CHECK THE SIGNAL OF THE
STOP. SENSOR
Test Step 4. CHECK THE SIGNAL The key start switch and the disconnect switch
CIRCUIT FOR A SHORT remain in the OFF position.
The key start switch and the disconnect switch remain A. Reconnect the harness connectors for the
in the OFF position. The sensor connector and the sensor and the J1 and J2 connectors to the
harness connectors of the Transmission/Chassis Transmission/Chassis ECM and to the Implement
ECM remain disconnected from the machine harness. ECM.
A. Remove the jumper wire that was installed in the B. At the back of the harness connector for the
last step. sensor, insert the multimeter probe along contact
B (wire X800-OR) and insert the probe along the
B. Disconnect the machine harness connectors J1 signal contact C (wire U768-BU).
and J2 from the Implement ECM.
C. At the J1 and J2 machine harness connectors switch to the ON position.
for the Transmission/Chassis ECM, measure the
resistance from the sensor contact J2-17 (wire D. Monitor the signal of the sensor with a digital
U768-BU) to all of the other J1 and J2 contacts multimeter.
that are used for the Transmission/Chassis ECM.
E. Without disconnecting the sensor or the hardware
D. At the J1 and J2 machine harness connectors for that is associated with the sensor from the
the Implement ECM, measure the resistance from machine, take the sensor through the full
the sensor signal contact J2-17 (wire U768-BU) to operating range of the sensor.
all of the other J1 and J2 contacts that are used
for the Implement ECM. Note:
Each resistance measurement is greater than 5000 The sensor's signal responds in the manner that is
ohms. described at the beginning of this procedure.
Results: Results:
• OK – Each resistance measurement is greater • OK – The sensor's signal responds correctly. The
than 5000 ohms. The signal circuit is not shorted. sensor is operating correctly. Proceed to Test Step
Proceed to Test Step 5. 6.
• NOT OK – A resistance measurement is less than • NOT OK – The sensor's signal does not respond
5000 ohms. correctly. The sensor is not operating correctly.
Repair: There is a short in the machine harness. Repair: Replace the “articulation angle 2” sensor.
The short is between the signal circuit and the After the replacement of the sensor, the sensor
circuit with the low resistance measurement. must be calibrated. Refer to the Testing and
Adjusting, “Calibration” section of this manual for
the correct calibration procedure.
STOP.
486 RENR9004-07
Test Step 6. CHECK THE OPERATION OF Prior to replacing an ECM, always contact your
THE ECM dealership's Technical Communicator for possible
Note: This check should be performed on the ECM greatly reduce repair time. If the ECM must be
that has the active diagnostic code. If both of the replaced, refer to Testing and Adjusting, “Electronic
ECM modules have activated the diagnostic code, Control Module (ECM) - Replace”.
STOP.
switch to the OFF position. Test Step 7. CHECK THE STATUS OF THE
DIAGNOSTIC CODE
ECM, use a 151-6320 Removal Tool to remove A. Inspect the harness connectors. Clean the
the sensor signal U768-BU and the socket at contacts of the harness connectors. Check the
contact J2-17 from the harness connector. The J2 wires for damage to the insulation that is caused
connector remains connected to the ECM. by excessive heat, battery acid, or chafing.
C. Turn the key start switch and the disconnect B. Perform a 45 N (10 lb) pull test on each of the
D. Use a 7X-1710 Multimeter Probe that is not C. Reconnect all harness connectors. Make sure that
E. Observe the status of the active CID 2252 FMI 03 switch to the ON position.

is active.
Results:
Results:
longer active. A CID 2252 FMI 04 diagnostic code • OK – The CID 2252 FMI 03 diagnostic code is
has been activated after the ECM pin is grounded. not active. The diagnostic code does not exist at
The ECM has responded correctly to the grounded this time. The initial diagnostic code was probably
circuit condition in the solenoid circuit. It is unlikely caused by a poor connection or a short at one
that the cause of the problem is the ECM. of the connectors that was disconnected and
Reinstall the disconnected sensor signal wire back
into the correct spot in the ECM connector before • NOT OK – The CID 2252 FMI 03 diagnostic
proceeding to the next test step. code is active. The diagnostic code has not been
corrected.
• NO – The CID 2252 FMI 03 diagnostic code test” on the machine wiring harness. Use the
remains active. The status of the active diagnostic Caterpillar Electronic Technician (ET) in order
code does not change when the ECM pin for the to perform the test. The “wiggle test” can detect
sensor signal is grounded. intermittent shorts or open connections in the
the grounded condition in the sensor circuit. The If the cause of the active diagnostic code is not
operation of the ECM is not correct. found, replace the sensor. After the replacement of
the sensor, the sensor must be calibrated. Refer to
this manual for the correct calibration procedure.
RENR9004-07 487
If the problem is still present after the replacement

of the sensor, the ECM may have failed. This is
unlikely as the ECM responded correctly to the
condition change in the previous test step.

diagnostic code is not found, and the ECM must be
STOP.
i02926655
MID 027 - CID 2252 - FMI 04

SMCS Code: 4806-038
g01252009
Conditions Which Generate This Code: Illustration 315
Locations of “Articulation Angle” Sensor

correct operation of the articulation on the machine.
Each sensor provides a PWM input to the Implement
ECM and to the Transmission/Chassis ECM.
This diagnostic code is recorded when the

ECM reads the input signal from the machine
“articulation angle sensor 2” and the voltage of the
signal is below normal. The Implement ECM, the
Transmission/Chassis ECM or both ECM modules
can activate this diagnostic code.

cycle of the sensor input to the ECM is approximately
Illustration 314
g01256820 55%. When the machine is articulated to the “full left
position”, the duty cycle will be approximately 33%.
Connection of “Machine Articulation Angle Sensor 2”
When the machine is articulated to the “full right
position”, the duty cycle will be approximately 74%.

below:

488 RENR9004-07
Note: The Transmission/Chassis ECM (MID 027) Results:

signal from the “articulation sensor 2”. Both ECM • OK – All mechanical linkage and adjustment for
modules can activate a CID 2252 FMI 04 diagnostic the articulation sensors is correct. Proceed to Test
code when a below normal voltage signal is detected. Step 2.
If one ECM has an active CID 2252 FMI 04 diagnostic
code and the other ECM does not have an active • NOT OK – All mechanical linkage and adjustment
diagnostic code, it is likely that the sensor is operating for the articulation sensors is not correct.
correctly. When this occurs, a poor connection in the
machine harness would be suspected. Repair: Perform the maintenance that is required
When both ECM modules have activated the in order to correct the problem with the mechanical
diagnostic code, either the sensor or a harness connections for the articulation sensors. After
problem could be the cause. the problem has been corrected, verify that this
If both ECM modules have activated the diagnostic diagnostic code is still active before proceeding
code, it is very unlikely that either ECM is causing the with this procedure.
problem.
For either condition, proceed with this procedure in STOP.
the harness connectors that are involved in the A. Turn the disconnect switch and the key start
circuit. Poor connections can often be the cause switch to the ON position.
all connections in the circuit are clean, that all B. Ensure that the diagnostic code is active.
are in good condition. If a problem with a C. Observe the status of the diagnostic code and
connection is found, correct the problem and disconnect the sensor from the machine harness.
performing this procedure. Expected Result:
Note: The following test procedure may create other The CID 2252 FMI 04 diagnostic code is no longer
diagnostic codes. Ignore these created diagnostic active. A CID 2252 FMI 03 diagnostic code is now
codes and clear the diagnostic codes when the active.
Results:
LINKAGE • YES – The CID 2252 FMI 04 diagnostic code is no
A. Turn the key start switch and the disconnect is now active. The ECM and the circuit are correct.
switch to the OFF position. The position sensor is causing the problem.
B. Remove any guards or shielding for the articulation Repair: The sensor has failed. Replace the
sensors. “articulation angle 2” sensor. After the replacement
of the sensor, the sensor must be calibrated. Refer
C. Check the mounting bolts for the articulation to Testing and Adjusting, RENR9013, “Implement
sensors. Ensure that the sensors are securely Electronic Control System”, “Calibrations” for
mounted. information on the method to access the articulation
sensor calibration procedure.
D. Visually inspect the mechanical linkage for the
articulation sensors. Verify that all mechanical STOP.
components are tight and that all mechanical
components are in good condition. Verify that the • NO – The CID 2252 FMI 04 diagnostic code
adjustment of the linkage is correct. remains active. Disconnecting the sensor did not
affect the status of the active diagnostic code.
Expected Result: The position sensor is not causing the problem.
for the articulation sensors are in good condition and Test Step 3. CHECK THE SIGNAL
no mechanical connections are loose. CIRCUIT FOR A SHORT TO GROUND
A. The sensor remains disconnected from the
machine harness.
RENR9004-07 489
B. Turn the key start switch and the disconnect Note: This check should be performed on the ECM
switch to the OFF position. that has activated the diagnostic code. If both of
the ECM modules have an active diagnostic code,
C. Disconnect the J1 and J2 machine harness perform this check on both of the ECM modules.
connectors from the Implement ECM and the
Transmission/Chassis ECM. A. At the machine harness connector J2 for the
D. At machine harness connector J2 for the the sensor signal wire U768-BU and the socket at
Transmission/Chassis ECM, measure the contact J2-17 from the harness connector.
resistance from contact J2-17 (wire U768-BU) to
frame ground. Measure the resistance to all of the B. Reconnect the machine harness J1 and J2
contacts that are used on the connectors for the connectors to the ECM.
C. Turn the key start switch and the disconnect
E. At machine harness connector J2 for the switch to the ON position.
contact J2-17 (wire U768-BU) to frame ground. D. Observe the status of the active CID 2252 FMI
Measure the resistance to all of the contacts that 04 diagnostic code.
are used on the connectors for the Implement
ECM. Expected Result:
Expected Result: The CID 2252 FMI 04 diagnostic code is no longer

Each resistance measurement is greater than 5000 active.
ohms.
Results:
Results:
• OK – Each resistance measurement is greater no longer active. A CID 2252 FMI 03 diagnostic
than 5000 ohms. The machine harness is correct. code is active after the sensor signal wire is
Proceed to Test Step 4. disconnected. The ECM has responded correctly
to the open circuit condition in the sensor circuit.
measurements is less than 5000 ohms. There is a Reconnect the sensor signal wire back into the
short in the machine harness. correct spot in the ECM connector. Proceed to the
next test step.
Repair: There is a short in the machine harness
between the signal circuit and the circuit with the Proceed to Test Step 5.
low resistance measurement.
Refer to the complete Electrical System Schematic remains active. The status of the active diagnostic
of the machine. Check all of the connectors that are code does not change when the sensor signal wire
in the sensor circuit. Ensure that all connections is disconnected from the ECM.
all connectors are in good condition. Repair: The ECM has not responded correctly
For information on testing for short circuits and operation of the ECM is not correct.
“Wiring Harness (Short Circuit) - Test”. Repair the Prior to replacing an ECM, always contact your
machine harness or replace the machine harness. dealership's Technical Communicator for possible
STOP. greatly reduce repair time. If the ECM must be
Test Step 4. CHECK THE OPERATION OF Control Module (ECM) - Replace”.
THE ECM
STOP.
connectors for the sensor and both the Implement
ECM and the Transmission/Chassis ECM remain
disconnected.
490 RENR9004-07

DIAGNOSTIC CODE
MID 027 - CID 2252 - FMI 08
contacts of the harness connectors. Check the SMCS Code: 4806-038




is active.
Expected Result:
Results:
g01256820
Illustration 316
• OK – The CID 2252 FMI 04 diagnostic code is Connections of “Machine Articulation Angle Sensor 2”

corrected.

If the problem is still present, the ECM may have

failed. The failure of the ECM is unlikely. The
ECM response was correct for the condition of the
previous test step.
g01252009
Prior to replacing an ECM, always contact your Illustration 317
dealership's Technical Communicator for possible Locations of “Articulation Angle Sensor”
consultation with Caterpillar. This consultation (1) “Articulation angle sensor 1”
may greatly reduce repair time. If the cause of the (2) “Articulation angle sensor 2”
diagnostic code is not found, and the ECM must be (3) Mechanical linkage
Control Module (ECM) - Replace”. Two articulation angle sensors are required for
correct operation of the articulation on the machine.
STOP. Each sensor will provide a PWM signal to the
RENR9004-07 491
This diagnostic code is associated with the machine Note: The following test procedure may create other
“articulation angle sensor 2”. The FMI 08 means diagnostic codes. Ignore these created diagnostic
that the ECM has determined that the signal codes and clear the diagnostic codes when the
frequency or the signal pulse width is not within original diagnostic code has been corrected.
the expected range. The Implement ECM, the
Transmission/Chassis ECM or both ECM modules Test Step 1. CHECK THE MECHANICAL
can activate this diagnostic code. LINKAGE
machine is in the neutral position, the input for the
duty cycle for the sensor to the ECM is approximately B. Remove any guards or shielding for the articulation
55%. When the machine is articulated to the full sensors.
33%. When the machine is articulated to the full right C. Check the mounting bolts for the articulation
position, the duty cycle will be approximately 74%. sensors. Ensure that the sensors are securely
mounted.
• The sensor has failed. components are tight and that all mechanical
• Intermittent connections or poor connections adjustment of the linkage is correct.
• Mechanical devices are loose. Expected Result:
• The ECM has failed. This is unlikely. All mechanical linkage and adjustable components
Before performing this procedure, check for an active no mechanical connections are loose.
CID 0041 diagnostic code for the 8 volt sensor power
supply of the ECM. Correct any problem with the 8 Results:
Note: The Transmission/Chassis ECM (MID 027) the articulation sensors is correct. Proceed to Test
and the Implement ECM (MID 082) receive an input Step 2.
modules can activate a CID 2252 FMI 08 diagnostic • NOT OK – All mechanical linkage and adjustment
code when the signal frequency or the signal pulse for the articulation sensors is not correct.
width is not within the expected range.
If one ECM has an active CID 2252 FMI 08 diagnostic Repair: Perform the maintenance that is required
code and the other ECM does not have an active in order to correct the problem with the mechanical
diagnostic code, it is likely that the sensor is operating connections for the articulation sensors. After
correctly. When this occurs, a poor connection in the the problem has been corrected, verify that this
machine harness would be suspected. diagnostic code is still active before proceeding
When both ECM modules have activated the with this procedure.
diagnostic code, the sensor or a harness problem
could be the cause. STOP.
code, it is very unlikely that either of the ECM Test Step 2. CHECK THE SIGNAL OF THE
modules is the cause of the problem. SENSOR
order to verify the cause of the problem. A. Turn the key start switch and the disconnect
the harness connectors that are involved in the B. At the back of the harness connector for the
circuit. Poor connections can often be the cause sensor, insert 7X-1710 Multimeter Probes along
of a problem in an electrical circuit. Verify that return contact B (wire X800-OR) and insert a
all connections in the circuit are clean, that all probe along the signal contact C (wire U768-BU).
connection is found, correct the problem and switch to the ON position.
492 RENR9004-07
D. Monitor the signal of the sensor with a digital Expected Result:

multimeter.
E. Without disconnecting the sensor or the hardware at all times during the manipulation of the wiring
that is associated with the sensor from the harness.
machine, take the sensor through the full
operating range of the sensor. Results:
Expected Result: • OK – The resistance measurement is less than

The signal of the sensor responds in the manner that indicating an open in the circuit. Proceed to Test
is described at the beginning of this procedure. Step 5.
Results: • NOT OK – One or both of the resistance

measurements is greater than 5 ohms. There is an
• OK – The signal of the sensor responds correctly. open or a bad connection in the signal circuit.
The sensor is operating correctly. Proceed to Test
Step 3. Repair: If both of the ECM modules have an active
diagnostic code, then there is probably an open
• NOT OK – The signal of the sensor does not connection or a bad connection on the sensor side
respond correctly. The sensor is not operating on the signal wire at the splice of the machine
correctly. harness.
Repair: Replace the “articulation angle 2” sensor. If only the Transmission/Chassis ECM has an
After the replacement of the sensor, the sensor active diagnostic code, then there is probably an
must be calibrated. Refer to Testing and Adjusting, open connection or a bad connection on the ECM
RENR9013, “Implement Electronic Control side of the machine harness at the splice for the
System”, “Calibrations” for information on the signal wire.
method to access the articulation sensor calibration
procedure. In either case, refer to the complete Electrical
STOP. connectors that are in the suspected section of the
Test Step 3. CHECK FOR AN OPEN IN are clean, that all connectors are secure and that
THE SIGNAL CIRCUIT all connectors are in good condition. Repair the
switch to the OFF position. STOP.
B. Disconnect the machine harness connector from Test Step 4. CHECK THE OPERATION OF
the sensor. THE ECM
C. At the machine harness connector for the sensor, The key start switch and the disconnect switch remain
connect a jumper wire between return contact in the OFF position. The machine harness connectors
B (wire X800-OR) and signal contact C (wire for the sensor and the Transmission/Chassis ECM
U768-BU). remain disconnected.
D. Disconnect the machine harness connectors J1 Note: This check should be performed on the ECM
and J2 from the Transmission/Chassis ECM. that has activated the diagnostic code. If both of the
ECM modules have activated the diagnostic code,
E. At the machine harness connectors for the perform this check on both of the ECM modules.
resistance from return contact J1-45 (wire A. Remove the jumper wire that was connected in
X800-OR) to contact J2-17 (wire U768-BU). the previous test step.
F. Observe the resistance measurement and wiggle B. At the machine harness connector J2 for the
the ECM connector and the sensor connector. ECM, use a 151-6320 Removal Tool to remove
Gently pull on the wires and wiggle the wires for the sensor signal wire U768-BU and the socket at
both connectors. contact J2-17 from the harness connector.
C. Reconnect any disconnected machine harness

RENR9004-07 493
D. Turn the key start switch and the disconnect F. Check the status of the CID 2252 FMI 08.
Expected Result:
08 diagnostic code. The CID 2252 FMI 08 is not active.
The CID 2252 FMI 08 diagnostic code is no longer • OK – The CID 2252 FMI 08 is not active. The
active. A CID 2252 FMI 03 diagnostic code is now diagnostic code does not exist at this time. The
active. initial diagnostic code was probably caused by a
Results: that was disconnected and reconnected. Resume
no longer active. A CID 2252 FMI 03 diagnostic • NOT OK – The CID 2252 FMI 08 is active. The
code is active after the sensor signal wire is active diagnostic code has not been corrected.
disconnected. The ECM has responded correctly
to the open circuit condition in the sensor circuit. Repair: Check the circuit again. Perform a “wiggle
Reinstall the disconnected sensor signal wire back Caterpillar Electronic Technician (ET) in order
into the correct spot in the ECM connector before to perform the test. The “wiggle test” can detect
proceeding to the next test step. intermittent shorts or open connections in the
• NO – The CID 2252 FMI 08 diagnostic code found, replace the sensor. After the replacement of
remains active. The status of the active diagnostic the sensor, verify that the new sensor corrected
code does not change when the sensor signal wire the problem. If the problem is still present after the
is disconnected from the ECM. replacement of the sensor, the ECM may have
failed. The failure of the ECM is not likely. The
Repair: The ECM has not responded correctly ECM response was correct for the condition in the
to the open condition in the sensor circuit. The previous test step.
Prior to replacing an ECM, always contact your dealership's Technical Communicator for possible
dealership's Technical Communicator for possible consultation with Caterpillar. This consultation
consultation with Caterpillar. This consultation may may greatly reduce repair time. If the cause of the
greatly reduce repair time. If the ECM must be diagnostic code is not found, and the ECM must be
replaced, refer to Testing and Adjusting, “Electronic replaced, refer to Testing and Adjusting, “Electronic
Control Module (ECM) - Replace”. Control Module (ECM) - Replace”.
STOP. STOP.

DIAGNOSTIC CODE




494 RENR9004-07
i02926775 CALIBRATION
MID 027 - CID 2252 - FMI 13 A. Perform the calibration procedure for the sensor.
Refer to Testing and Adjusting, RENR9013,
SMCS Code: 4806-038 “Implement Electronic Control System”,
“Calibrations” for information on the method
Conditions Which Generate This Code: to access the articulation sensor calibration
procedure
Expected Result:

successfully.
Results:

STOP.

sensor.

successful, replace the position sensor. Refer to
Testing and Adjusting, RENR9013, “Implement
g01252009
Illustration 318 Electronic Control System”, “Calibrations” for
Locations of “Articulation Angle Sensor” information on the method to access the articulation
sensor calibration procedure. If the problem is still
(2) “Articulation angle sensor 2” present after replacement and calibration of the
(3) Mechanical linkage new sensor, the ECM may have failed.
Two articulation angle sensors are required for the Prior to replacing an ECM, always contact your
correct operation of the function of the articulation on dealership's Technical Communicator for possible
the machine. Each sensor will provide a PWM signal consultation with Caterpillar. This consultation
to the Implement ECM and the Transmission/Chassis may greatly reduce repair time. If the cause of the
ECM. diagnostic code is not found, replace the ECM that
The CID 2252 FMI 13 diagnostic code is recorded and Adjusting, “Electronic Control Module (ECM)
by the ECM. In the event that the ECM detects the - Replace”.
signal from the machine “articulation angle sensor 2”
is out of calibration, a record of the event is logged. STOP.
The Implement ECM and the Transmission/Chassis
ECM can activate this diagnostic code.

duty cycle of the sensor to the ECM is approximately
Note: Verify that no other CID 2252 diagnostic codes

are active. Any other active CID 2252 diagnostic
codes must be investigated and must be cleared
RENR9004-07 495
i02926836 This diagnostic code is associated with the machine

“articulation angle sensor 2”. A record is made of the
MID 027 - CID 2252 - FMI 14 FMI 14 diagnostic code. The record is made after
the ECM detects that the signal from the sensor is
SMCS Code: 4806-038 incorrect.
Conditions Which Generate This Code: The sensor is a PWM sensor that operates at a
duty cycle of the sensor to the ECM is approximately

below:
• The mechanical linkage for the position sensor is

not functioning correctly.

Note: Before performing this procedure, ensure that
g01256820
Illustration 319 there are no active CID 0041 diagnostic codes for the
Connections of “Machine Articulation Angle Sensor 2” power supply of the sensor (8 VDC). Ensure that the
power supply for the “angle sensor” is correct.


original diagnostic codes have been corrected.

LINKAGE
g01252009 A. Turn the key start switch and the disconnect

Illustration 320 switch to the OFF position.
Locations of “Articulation Angle Sensor”
(1) “Articulation angle sensor 1” B. Remove any guards or shielding for the articulation
(2) “Articulation angle sensor 2” sensors.
Two articulation angle sensors are required for correct sensors. Ensure that the sensors are securely
operation of the function for the articulation on the mounted.
machine. Each sensor will provide a PWM signal to
the Implement ECM and to the Transmission/Chassis
ECM.
496 RENR9004-07
D. Visually inspect the mechanical linkage for the • NOT OK – The calibration procedure has been
articulation sensors. Verify that all mechanical performed for the machine “articulation sensor 2”,
components are tight and that all mechanical however, the FMI 14 diagnostic code is still active.
components are in good condition. Verify that the The problem has not been corrected. Proceed to
adjustment of the linkage is correct. Test Step 3.
Expected Result: Test Step 3. CHECK THE SIGNAL

CIRCUIT OF THE SENSOR
for the articulation sensors are in good condition and A. The key start switch and the disconnect switch
no mechanical connections are loose. remain in the OFF position.
Results: B. Do not disconnect the harness connector from the

sensor.
the articulation sensors is correct. Proceed to Test C. At the back of the harness connector for the
Step 2. sensor, insert 7X-1710 Multimeter Probes along
return contact B (wire X800-OR) and insert a
• NOT OK – All mechanical linkage and adjustment multimeter probe along the signal wire C (wire
for the articulation sensors is not correct. U768-BU).
Repair: Perform the maintenance that is required D. Turn the disconnect switch and the key start
in order to correct the problem with the mechanical switch to the ON position.
connections for the articulation sensors. After
the problem has been corrected, verify that this E. Monitor the signal of the sensor with a digital
diagnostic code is still active before proceeding multimeter.
STOP. that is associated with the sensor from the
machine, articulate the machine through the full
Test Step 2. CALIBRATE THE POSITION range of operation.
SENSOR
Expected Result:
A. After the linkage for the sensor is verified to be
correct, use the Caterpillar Electronic Technician The sensor's signal responds in the manner that is
(ET) service tool to perform the calibration described at the beginning of this procedure.
procedure for the “articulation angle sensor 2”.
Refer to Testing and Adjusting, RENR9013, Results:
“Implement Electronic Control System”,
“Calibrations” for information on the method • OK – The sensor's signal responds correctly. The
to access the articulation sensor calibration sensor is operating correctly. Proceed to Test Step
procedure. 4.
Expected Result: • NOT OK – The sensor's signal does not respond

correctly. The sensor is not operating correctly.
The calibration procedure has been performed for
the machine “articulation sensor 2” and the FMI 14 Repair: Replace the “articulation angle 2” sensor.
diagnostic code is no longer active. After the replacement of the sensor, the sensor
must be calibrated. Refer to Testing and Adjusting,
Results: RENR9013, “Implement Electronic Control
System”, “Calibrations” for information on the
• OK – The calibration procedure has been method to access the articulation sensor calibration
performed for the machine “articulation sensor 2” procedure.
and the FMI 14 diagnostic code is no longer active.
STOP.
NOTE: If the position sensor has been calibrated
recently and the FMI 14 diagnostic code becomes Test Step 4. CHECK THE STATUS OF THE
active again after a short time, the linkage for the DIAGNOSTIC CODE
“articulation position” sensor is probably the cause
of the problem. Repair the linkage for the sensor or A. Turn the disconnect switch and the key start
replace the linkage for the sensor. STOP. switch to the ON position.

RENR9004-07 497
C. Check the status of the 2252 FMI 14 diagnostic This diagnostic code is associated with the
code. “differential lock” relay. The “differential lock relay”
is controlled by the ECM through an “ON/OFF”
Expected Result: output driver. The FMI 03 means that the ECM has
determined that the voltage is present in the relay
The CID 2252 FMI 14 diagnostic code is not active. circuit when the output driver is OFF.
Results: The conditions that could cause this diagnostic code

to activate are listed below:
not active. The diagnostic code does not exist at • The relay has failed.
caused by a poor connection or a short at one • The energize circuit of the relay is shorted to
of the connectors that was disconnected and another voltage source.
is still active. The diagnostic code has not been Note: Before performing this procedure, inspect
corrected. the harness connectors that are involved in the
Repair: It is unlikely that the ECM has failed. Exit of a problem in an electrical circuit. Verify that
this procedure and perform this procedure again. all connections in the circuit are clean, that all
If the cause of the failure is not found, replace connections are secure and that all connections
the ECM that activated the diagnostic code. See are in good condition. If a problem with a
Testing and Adjusting, “Electronic Control Module connection is found, correct the problem and
(ECM) - Replace”. verify that this diagnostic code is active before
STOP.
i02926840
MID 027 - CID 2304 - FMI 03 codes when the problem has been corrected.
SMCS Code: 4493-038 Test Step 1. CHECK THE RELAY
Conditions Which Generate This Code: A. Turn the key start switch and the disconnect
B. Observe the status of the active CID 2304 FMI 03

diagnostic code and disconnect the “differential
lock relay” from the machine harness.

Expected Result:


to 396 ohms at 25 °C (77 °F).
The resistance measurement between power

g01322415 contact 30 and contact 87a is less than 5 ohms. The
Illustration 321 measurement of the resistance between the power
Connections of “Differential Lock” relay contact 30 and all the other contacts of the relay is
greater then 5000 ohms.
498 RENR9004-07
Results: For information on testing for short circuits and

• YES – All of the checks for the relay are correct. “Wiring Harness (Short Circuit) - Test”. Repair the
The relay is not the cause of the problem. The machine harness or replace the machine harness.
CID 2304 FMI 03 diagnostic code is still active.
Proceed to Test Step 2. STOP.
• NO – The active CID 2304 FMI 03 diagnostic code Test Step 3. CHECK THE STATUS OF THE
became inactive when the relay was disconnected. DIAGNOSTIC CODE
The resistance checks are not correct, according
to the expected results that are listed above. The A. Inspect the harness connectors. Clean the
relay has failed. contacts of the harness connectors. Check the
Repair: Verify that the relay has failed by by excessive heat, battery acid, or chafing.
part number for the faulty relay. The relay for the B. Perform a 45 N (10 lb) pull test on each of the
backlight can be substituted. Replace the faulty wires that are associated with the circuit.
relay.
STOP. the connectors are fully seated. Observe that the
CIRCUIT OF THE RELAY FOR A SHORT D. Turn the disconnect switch and the key start
The relay remains disconnected from the machine
harness. E. Operate the machine.
A. Turn the key start switch and the disconnect F. Determine if the CID 2304 FMI 03 diagnostic code
switch to the OFF position. is active.
B. Disconnect the machine harness connectors J1 Expected Result:

A975-BU) to all of the other contacts that are used
in the machine harness connectors J1 and J2 for • YES – The CID 2304 FMI 03 diagnostic code is
the ECM. active. The problem has not been corrected.
Expected Result: Repair: Check the relay circuit again. Perform a

“wiggle test” on the wiring harness of the machine.
Each resistance measurement is greater than 5000 Use the Caterpillar Electronic Technician (ET) in
ohms. order to perform the test. The “wiggle test” can
detect intermittent shorts or open connections in
Results: the machine wiring harness.
• OK – Each resistance measurement is greater If the cause of the problem is not found, the ECM
than 5000 ohms. The energize circuit is not shorted may have failed.
to Test Step 3. Prior to replacing an ECM, always contact your
• NOT OK – Each resistance measurement is not consultation with Caterpillar. This consultation
greater than 5000 ohms. There is a short in the may greatly reduce repair time. If the ECM must
machine harness. The short is between J2-3 (wire be replaced, refer to Troubleshooting, “Electronic
A975-BU) and the circuit that has a low resistance Control Module (ECM) - Replace”.
measurement.
STOP.
Schematic of the machine. Check all of the • NO – The CID 2304 FMI 03 diagnostic code is not
connectors that are in the relay circuit. Ensure active. The problem does not exist at this time.
that all connections are clean, that all connections
condition.
RENR9004-07 499
Repair: The initial diagnostic code was probably i02926863

caused by a poor electrical connection, a short
at one of the harness connectors or a loose MID 027 - CID 2304 - FMI 05
connection at the base of the relay that was
disconnected and reconnected. Resume normal SMCS Code: 4493-038
machine operation.
S/N: B9C1-Up
STOP. S/N: B9D1-Up
S/N: B9E1-Up
S/N: B9F1-Up
S/N: B9G1-Up
S/N: D9G1-Up
S/N: B9H1-Up
S/N: B9J1-Up
S/N: B9L1-Up
S/N: B9M1-Up
S/N: B9R1-Up
S/N: B9T1-Up
S/N: D9T1-Up
S/N: B9W1-Up
S/N: D9W1-Up
g01322415
Illustration 322
Connections of “Differential Lock Relay”

“differential lock relay”. The “differential lock relay”
output driver. The FMI 05 means that the ECM has
energized the output for the relay and the current for
the relay circuit is below normal.
500 RENR9004-07
The conditions that could cause this diagnostic code Repair: The relay is the cause of the problem.
to activate are listed below: Verify that the relay has failed by substituting a
known good relay that is the same part number
• The relay has failed. as the faulty relay. The backlight relay can be
substituted. Replace the faulty relay.
• The energize circuit of the relay has an open
connection or a bad connection in the machine STOP.
harness.
• NO – The jumper wire does not affect the status of
• The ECM has failed. This is unlikely. the active CID 2304 FMI 05 diagnostic code when
the key start switch is turned ON. The relay is not
Note: Before performing this procedure, inspect causing the problem. Proceed to Test Step 2.
circuit. Poor connections can often be the cause Test Step 2. CHECK THE RELAY CIRCUIT
of a problem in an electrical circuit. Verify that FOR AN OPEN
connections are secure and that all connections The relay remains disconnected from the machine
are in good condition. If a problem with a harness. The jumper wire remains connected
connection is found, correct the problem and between contact 5 and contact 2.
performing this procedure. A. Turn the key start switch and the disconnect
other diagnostic codes to be activated. Ignore these B. Disconnect the machine harness connector J2
created diagnostic codes and clear the diagnostic from the Transmission/Chassis ECM.
C. At the machine harness connector J2 for the
Test Step 1. CHECK THE RELAY ECM, measure the resistance between contact
J2-3 (wire A975-BU) and a good ground contact
A. Turn the key start switch and the disconnect on the frame.
Expected Result:
the relay. The resistance measurement is less than 5 ohms.
C. At the harness connector for the relay, connect a Results:

jumper wire between contact 5 (wire A975-BU)
and contact 2 (wire 200-BK). • OK – The resistance measurement is less than 5
ohms. The energize circuit and the ground circuit
D. Turn the disconnect switch and the key start are not open in the machine harness. Proceed to
switch to the ON position. Test Step 3.
E. Observe the status of the active CID 2304 FMI • NOT OK – The resistance measurement is greater
05 diagnostic code. than 5 ohms. There is an open or a bad connection
in the ground circuit at the frame or the energize
Expected Result: circuit of the relay.
The active CID 2304 FMI 05 diagnostic code is no Repair: A resistance measurement that is greater
longer active when the key start switch is turned ON. than 5000 ohms could indicate that a wire is not
A CID 2304 FMI 06 diagnostic code is now active. connected or that a wire is open. A resistance
Results: than 5000 ohms could indicate that one of the
connection points or a splice in the circuit is not an
• YES – The CID 2304 FMI 05 diagnostic code is open connection but not a good connection.
no longer active. The CID 2304 FMI 06 diagnostic
code becomes active after the key start switch is Determine if the energize circuit or the return
turned ON. circuit is the cause of the problem. Disconnect the
jumper wire. Use a spare length of wire in order to
check the resistance of the energize circuit and the
ground circuit individually.
RENR9004-07 501
Refer to the complete Electrical System Schematic Prior to replacing an ECM, always contact your
of the machine. Check all of the connectors that dealership's Technical Communicator for possible
are in the circuit. Ensure that all connections are consultation with Caterpillar. This consultation
clean, that all connections are secure and that all may greatly reduce repair time. If the ECM must
connections are in good condition. be replaced, refer to Troubleshooting, “Electronic
connector for the faulty circuit. Check the wire for STOP.
an open connection or a bad connection point
by working through the circuit in order to isolate • NO – The CID 2304 FMI 05 diagnostic code is not
the location of the problem. Repair the machine active. The problem does not exist at this time.
harness or replace the machine harness.
STOP. caused by a poor electrical connection or a short
at one of the harness connectors or at the base of
Test Step 3. CHECK THE STATUS OF THE the relay that was disconnected and reconnected.
DIAGNOSTIC CODE Resume normal machine operation.

i02926884

MID 027 - CID 2304 - FMI 06
wires that are associated with the circuit. SMCS Code: 4493-038
C. Reconnect all harness connectors in order to Conditions Which Generate This Code:


is active.
Expected Result:
Results:

Repair: Check the relay circuit again. Perform a g01322415

“wiggle test” on the machine wiring harness. Use Illustration 323
the Caterpillar Electronic Technician (ET) in order Connections of “Differential Lock Relay”
intermittent shorts or open connections in the This diagnostic code is associated with the
machine wiring harness. “differential lock relay”. The “differential lock relay”
If the cause of the problem is not found, the ECM output driver. The FMI 06 means that the ECM has
may have failed. energized the output for the relay and the current for
the relay circuit is above normal.

to activate are listed below:

502 RENR9004-07
• The energize circuit of the relay is shorted to a A. Turn the key start switch and the disconnect
ground source. switch to the OFF position.
• The ECM has failed. This is unlikely. B. Disconnect the machine harness connectors J1
the harness connectors that are involved in the C. At the machine harness connector J2 for the
circuit. Poor connections can often be the cause ECM, measure the resistance from contact J2-3
of a problem in an electrical circuit. Verify that (wire A975-BU) to frame ground. Measure the
all connections in the circuit are clean, that all resistance from contact J2-3 (wire A975-BU) to all
connections are secure and that all connections of the other contacts that are used in the machine
are in good condition. If a problem with a harness connectors J1 and J2 for the ECM.
verify that this diagnostic code is active before Expected Result:
Note: The following test procedure may cause ohms.
created diagnostic codes and clear the diagnostic Results:
Test Step 1. CHECK THE RELAY than 5000 ohms. The energize circuit is not shorted
to frame ground or to another circuit in the machine
A. Turn the key start switch and the disconnect harness. Proceed to Test Step 3.
• NOT OK – Each resistance measurement is
B. Observe the status of the active CID 2304 FMI not greater than 5000 ohms. There is a short
06 diagnostic code and disconnect the machine in the machine harness. The short is between
harness connector from the relay. wire A975-BU and the ground connection at the
frame or the short might be between the voltage
Expected Result: connection and the wire with the low resistance
reading.
When the relay is disconnected from the harness, the
CID 2304 FMI 06 diagnostic code is no longer active. Repair: Refer to the complete Electrical System
A CID 2304 FMI 05 is now active. Schematic of the machine. Check all of the
Results: that all connections are clean, that all connections
• YES – When the relay is disconnected from the condition.
harness, the CID 2304 FMI 06 diagnostic code is
no longer active. A CID 2304 FMI 05 diagnostic For information on testing for short circuits and
code becomes active. The relay is the cause of finding short circuits, refer to Testing and Adjusting,
the problem. “Wiring Harness (Short Circuit) - Test”. Repair the
substituting a known good relay that is the same STOP.
part number as the faulty relay. The backlight relay
can be substituted. Replace the faulty relay. Test Step 3. CHECK THE STATUS OF THE
DIAGNOSTIC CODE
STOP.
• NO – The status of the active CID 2304 FMI 06 contacts of the harness connectors. Check the
diagnostic code did not change when the relay was wires for damage to the insulation that is caused
disconnected from the machine harness. The relay by excessive heat, battery acid, or chafing.
is not causing the problem. Proceed to Test Step 2.
Test Step 2. CHECK THE ENERGIZE wires that are associated with the circuit.
The relay remains disconnected from the machine make sure that the connectors are fully seated.
harness. Observe that the clips for each connector are
RENR9004-07 503
D. Turn the disconnect switch and the key start i02926903

MID 027 - CID 2734 - FMI 03
SMCS Code: 7332-038-BRK
Expected Result:
Results:

Repair: Check the relay circuit again. Perform a

“wiggle test” on the machine wiring harness. Use
the Caterpillar Electronic Technician (ET) in order

may have failed.

g01378651
consultation with Caterpillar. This consultation Connections of “Compression Brake” switch
be replaced, refer to Troubleshooting, “Electronic The “compression brake” switch is equipped
Control Module (ECM) - Replace”. exclusively on the 16M Motor Grader.
STOP. The “compression brake” switch is a two pole,
• NO – The CID 2304 FMI 06 diagnostic code is not two switch to ground inputs to the ECM in order to
active. The problem does not exist at this time. indicate the status of the switch. The other pole of the
switch is not used for operation with the ECM.
caused by a poor electrical connection or a short During normal operation, one of the inputs is not
at one of the harness connectors or at the base of connected to ground and the other input is connected
the relay that was disconnected and reconnected. to ground through the switch contacts. An internal
Resume normal machine operation. pull-up voltage is present at the ECM switch inputs.
When the input is grounded through the switch, the
STOP. ECM detects the ground signal.

when neither of the inputs is showing a ground signal.


• The common ground circuit is an open connection
or a bad connection.
• There is an open or a bad connection in one or

both of the switch input circuits.

504 RENR9004-07
Note: Before performing this procedure, inspect Results:

circuit. Poor connections can often be the cause • YES – All of the resistance checks for the switch
of a problem in an electrical circuit. Verify that are correct in each position of the switch according
all connections in the circuit are clean, that all to the “contact status” table. The switch is working
connections are secure and that all connections correctly. Proceed to Test Step 2.
connection is found, correct the problem and • NO – The states of the switch are not correct
verify that this diagnostic code is active before according to the “contact status table” for the
performing this procedure. switch. The switch has failed.
Note: The following test procedure may cause Repair: Replace the “compression brake” switch.
other diagnostic codes to be activated. Ignore these After the switch is replaced, verify that the
created diagnostic codes and clear the diagnostic operation of the switch is correct before operating
codes when the problem has been corrected. the machine.
Test Step 1. CHECK THE SWITCH STOP.
Table 28 Test Step 2. CHECK THE COMMON

States of Contact for “Compression Brake” Switch GROUND CIRCUIT OF THE SWITCH FOR
AN OPEN
Switch Position OFF Input J2-62 ON Input J2-61
(wire E717-GN) (wire E716-GY) The key start switch and the disconnect switch
Compression Open(2) Closed(1) remain in the OFF position. The machine harness
Brake ON remains disconnected from the switch.
Compression Closed Open
Brake OFF
measure the resistance between the common
(2) Open to common ground A202-BK. ground contact of the switch 2 (wire A202-BK)
(1) Closed to common ground A202-BK. and frame ground.
A. Turn the key start switch and the disconnect B. Observe the resistance measurement of the
switch to the OFF position. multimeter and wiggle the machine harness
connector for the switch. Gently pull on the wires
B. Disconnect the machine harness connector from and wiggle the wires.
the switch.
Expected Result:
C. With the switch in the ON position, measure the
resistance from common contact of the switch The resistance measurement is less than 5 ohms at
2 to input contact of the switch 1. Compare the all times during the manipulation of the harness.
measurement of the switch to the “contact status
table” above. Results:
D. With the switch in the ON position, measure the • OK – The resistance measurement is less than 5
resistance from common contact of the switch ohms. The common ground circuit of the switch is
2 to input contact of the switch 3. Compare the correct. Proceed to Test Step 3.
measurement of the switch to the “contact status
table” above. • NOT OK – The resistance measurement is greater
than 5 ohms. There is an open connection or a bad
E. Move the switch to the OFF position and repeat connection in the common ground circuit of the
Steps “C” and “D”. switch (wire A202-BK).
Expected Result: Repair: A resistance measurement that is greater
The resistance measurements in each switch position connected or that a wire is open. A resistance
are correct according to the “contact status table” for measurement that is greater than 5 ohms but less
the switch at the beginning of this test step. than 5000 ohms could indicate that one of the
connection points or that a splice in the ground
circuit is not an open connection but not a good
connection.
RENR9004-07 505
Refer to the complete Electrical System Schematic One at a time, connect the other end of the jumper
of the machine. Check all of the connectors that wire to each of the inputs of the switch. Check the
are in the ground circuit. Start checking the circuit resistance at the harness connector of the ECM
from the switch and work your way back to the J1 from the appropriate input contact to one of the
ground terminal connections located at the rear of ground contacts (wire A202-BK) that are used on
the cab. Ensure that all connections are clean, that the J1 connector. This will identify the input circuit
all connections are secure and that all connections that is an open connection or a bad connection.
or replace the machine harness. A resistance measurement that is greater than
5000 ohms could indicate that a wire is not
STOP. connected or that a wire is open. A resistance
measurement that is greater 5 ohms but less
Test Step 3. CHECK THE INPUT CIRCUITS than 5000 ohms could indicate that one of the
OF THE SWITCH FOR AN OPEN connection points in the circuit is not an open
remain in the OFF position. The machine harness Refer to the complete Electrical System Schematic
remains disconnected from the switch. of the machine . Check all of the connectors
A. At the machine harness connector for the switch, all connections are clean, that all connections
place a jumper wire between input contact 1 (wire are secure and that all connections are in good
E717-GN) and input contact 3 (wire E716-GY). condition. Repair the machine harness or replace
and J2 from the ECM. STOP.
C. At the machine harness connector of the ECM J2, Test Step 4. CHECK THE STATUS OF THE
measure the resistance from input contact of the DIAGNOSTIC CODE
switch J2-62 (wire E717-GN) to the input contact
of the switch J2-61 (wire E716-GY). A. Inspect the harness connectors. Clean the
D. Observe the resistance measurement of the wires for damage to the insulation that is caused
multimeter and wiggle the machine harness by excessive heat, battery acid, or chafing.
and wiggle the wires. B. Perform a 45 N (10 lb) pull test on each of the
E. Observe the resistance measurement of the
multimeter and wiggle the machine harness C. Reconnect all harness connectors. Make sure that
connector for the switch. Gently pull on the wires the connectors are fully seated. Observe that the
and wiggle the wires. Do not disconnect the clips for each connector are completely fastened.
jumper wire.
Expected Result: switch to the ON position.
The resistance measurement is less than 5 ohms at E. Operate the machine.

Results: diagnostic code.
• OK – The resistance measurement is less than 5 Expected Result:

ohms. The input circuits of the switch are not open
in the machine harness. Proceed to Test Step 4. The CID 2734 FMI 03 diagnostic code is active.

than 5 ohms. There is a problem with one or both
of the input circuits of the switch in the machine • YES – The CID 2734 FMI 03 diagnostic code
harness. is active. The diagnostic code has not been
corrected.
Repair: Refer to the illustration of the connection
diagram at the beginning of this procedure.
Connect one end of the jumper wire to the harness

connector of the switch, contact 2 (wire A202-BK.
506 RENR9004-07
Repair: Check the input circuits of the switch i02926947

again. Perform a “wiggle test” on the machine
wiring harness. Use the Caterpillar Electronic MID 027 - CID 2734 - FMI 04
Technician (ET) in order to perform the test. The
“wiggle test” can detect intermittent shorts or open SMCS Code: 7332-038-BRK
connections in the machine wiring harness.
have failed. Verify that all possible causes of the
diagnostic code have been investigated before

STOP.


g01378651
disconnected and reconnected. Resume normal Illustration 325
machine operation. Connections of “Compression Brake” switch
STOP. The “compression brake” switch is exclusively

equipped on the 16M Motor Grader.
The “compression brake” switch is a two pole,

two switch to ground inputs to the ECM in order to
indicate the status of the switch. The other pole of the
switch is not used for operation with the ECM.
During normal operation, one of the inputs is not

connected to ground and the other input is connected
to ground through the contacts of the switch. An
internal pull-up voltage is present at the inputs of
the switch. When the input is grounded through the
switch, the ECM detects the ground signal.

when both of the inputs are showing a ground signal
at the same time.



RENR9004-07 507
Note: Before performing this procedure, inspect Results:

circuit. Poor connections can often be the cause • YES – All of the resistance checks for the switch
of a problem in an electrical circuit. Verify that are correct in each of the positions of the switch,
all connections in the circuit are clean, that all according to the contact status table. The switch is
connections are secure and that all connections working correctly. Proceed to Test Step 2.
connection is found, correct the problem and • NO – The states of the switch are not correct
verify that this diagnostic code is active before according to the contact status table for the switch.
performing this procedure. The switch has failed.
Note: The following test procedure may cause Repair: Replace the “compression brake” switch.
other diagnostic codes to be activated. Ignore these After the switch is replaced, verify that the
created diagnostic codes and clear the diagnostic operation of the is switch correct before operating
codes when the problem has been corrected. the machine.
Test Step 1. CHECK THE SWITCH STOP.
Table 29 Test Step 2. CHECK THE SWITCH INPUT

States of Contact for the “Compression Brake” Switch CIRCUITS FOR A SHORT
Position of OFF Input J2-62 ON Input J2-61 The key start switch and the disconnect switch
Switch (wire E717-GN) (wire E716-GY) remain in the OFF position. The machine harness
“Compression Open(2) Closed(1) remains disconnected from the switch.
Brake” ON
“Compression Closed Open
Brake” OFF
(2) Open to common ground A202-BK. B. At the machine harness connector J2 for the ECM,
(1) Closed to common ground circuit A202-BK. measure the resistance between input contact
of the switch J2-61 (wire E716-GY) and frame
A. Turn the key start switch and the disconnect ground. Measure the resistance between the input
switch to the OFF position. contact of the switch J2-61 (wire E716-GY) and all
of the other contacts that are used in the J1 and
B. Disconnect the harness connector of the machine J2 harness connectors for the ECM.
from the switch.
C. With the switch in the ON position, measure the measure the resistance between the input contact
resistance from the common contact of the switch of the switch J2-62 (wire E717-GN) and frame
2 to the input contact of the switch1. Compare the ground. Measure the resistance between the input
measurement to the contact status table for the contact of the switch J2-62 (wire E717-GN) and all
switch (above). of the other contacts that are used in the J1 and
J2 harness connectors for the ECM.
D. With the switch in the ON position, measure the
resistance from the common contact of the switch Expected Result:
2 to the input contact of the switch 3. Compare
the measurement to the contact status table of Each resistance measurement is greater than 5000
the switch (above). ohms.
E. Move the switch to the OFF position and repeat Results:
Expected Result: than 5000 ohms. The input circuits of the switch
are not shorted to ground or to another circuit in
The resistance measurements in each position of the machine harness. Proceed to Test Step 3.
the switch agree with the contact status table for the
switch at the beginning of this test step. • NOT OK – One or more of the resistance
short to ground or to another circuit in the machine
harness.
508 RENR9004-07
Repair: The input circuit that checks the low Prior to replacing an ECM, always contact your
resistance to frame ground or to another circuit is dealership's Technical Communicator for possible
the cause of the problem. consultation with Caterpillar. This consultation
Refer to the complete Electrical System Schematic diagnostic code is not found, replace the ECM.
of the machine. Check all of the connectors Refer to Testing and Adjusting, “Electronic Control
that are in the faulty input circuit. Ensure that Module (ECM) - Replace”.
are secure and that all connections are in good STOP.
condition.
For information on testing for short circuits and diagnostic code does not exist at this time.
“Wiring Harness (Short Circuit) - Test”. Repair the Repair: The initial diagnostic code was probably
machine harness or replace the machine harness. caused by a poor electrical connection or a
STOP. disconnected and reconnected. Resume normal
machine operation.

i03618023
MID 027 - CID 3210 - FMI 03
wires that are associated with the sensor circuit. Conditions Which Generate This Code:


diagnostic code.
Expected Result:
The CID 2734 FMI 04 diagnostic code is active. g01941814

Illustration 326
Circuit of the transmission pump bypass solenoid
Results:
• YES – The CID 2734 FMI 04 diagnostic code transmission pump bypass solenoid. The FMI 03
is active. The diagnostic code has not been means that the transmission/chassis electronic
corrected. control module (ECM) has determined that the
voltage of the solenoid circuit is above normal.
again. Perform a “wiggle test” on the machine The possible causes of the diagnostic code are listed:
wiring harness. Use the Caterpillar Electronic
Technician (ET) in order to perform the test. The • The solenoid has failed.
“wiggle test” can detect intermittent shorts or open
connections in the machine wiring harness. • The energize circuit of the solenoid is shorted to
the +battery circuit.
have failed. Verify that all possible causes of the • The transmission/chassis ECM has failed. This is
diagnostic code have been investigated before unlikely.
RENR9004-07 509
Before performing this procedure, inspect the Repair: Repair the machine harness or replace
harness connectors that are involved in the the machine harness. For information on testing
circuit. Poor connections can often be the cause for short circuits and finding short circuits, refer
of a problem in an electrical circuit. Verify that to Testing and Adjusting, “Wiring Harness (Short
all connections in the circuit are clean, that all Circuit) - Test”. Repair the machine harness or
connections are secure and that all connections replace the machine harness.
connection is found, correct the problem and STOP.
performing this procedure. Test Step 2. CHECK THE RETURN
Note: The following test procedure may create other SHORT TO +BATTERY.
codes and clear these diagnostic codes when the A. The key start switch remains in the OFF position.
original diagnostic code has been corrected. Ensure
that the diagnostic code of CID 3210 FMI 03 is B. The solenoid remains disconnected from the
active before performing this procedure. machine harness.
Use a calibrated digital multimeter for the following C. The machine harness connectors J1 and J2 remain
procedures. disconnected from the transmission/chassis ECM.
System Response: D. At the machine harness for the solenoid, measure

the voltage between the contact for (wire
The diagnostic code of CID 3210 FMI 03 K927-BU) and frame ground.
will be logged in the internal memory of the
transmission/chassis ECM. Expected Result:
Test Step 1. CHECK THE ENERGIZE The voltage is approximately 0.0 ± 0.5 DCV.
SHORT TO THE +BATTERY CIRCUIT. Results:
A. Turn the key start switch and the disconnect • OK – The voltage is approximately 0.0 ± 0.5 DCV.
switch to the OFF position. The voltage is correct. Proceed to Test Step 3.
B. Disconnect the machine harness connectors from • NOT OK – Each resistance measurement is not
the solenoid and the transmission/chassis ECM. greater than 5000 ohms. There is a short in the
machine harness. The short is between wire
C. At the machine harness connector for the K927-BU and the circuit that has a low resistance
transmission/chassis ECM, measure the measurement.
resistance from contact J1-65 (wire X961-GY) to
all contacts that are used in the machine harness Repair: For information on testing for short
connectors for the transmission/chassis ECM. circuits and finding short circuits, refer to Testing
Expected Result: Test”. Repair the machine harness or replace the
machine harness.
ohms. STOP.
Results: Test Step 3. CHECK THE OPERATION OF

THE ECM
than 5000 ohms. The machine harness is correct. The disconnect switch and the key start switch remain
Proceed to Test Step 2. in the OFF position. The machine harness connectors
for the solenoid and the transmission/chassis ECM
• NOT OK – Each resistance measurement is not remain disconnected.
machine harness. The short is between J1-65 (wire A. At the machine harness connector J1 of the
X961-GY) and the circuit that has a low resistance ECM, remove the X961-GY energize wire of the
measurement. solenoid and remove the J1-65 socket from the
harness connector. Perform these removals with a
151-6320 Removal Tool.
510 RENR9004-07
B. Reconnect the machine harness J1 and J2 D. Reconnect all harness connectors. Make sure that
connectors to the ECM. the connectors are fully seated. Observe that the
switch to the ON position. E. Turn the disconnect switch and the key start
03 diagnostic code. F. Operate the machine.
Expected Result: G. Determine if the CID 3210 FMI 03 is active.
The CID 3210 FMI 03 diagnostic code is no longer Expected Result:

active. The CID 3210 FMI 03 is active.
Results: Results:
• YES – The CID 3210 FMI 03 diagnostic code is no • YES – The CID 3210 FMI 03 is active. The
longer active. A CID 3210 FMI 05 diagnostic code problem has not been corrected. The ECM may
has been activated after the solenoid energize have failed.
correctly to the open circuit condition in the Repair: It is unlikely that the ECM has failed. Exit
solenoid circuit. this procedure and perform this procedure again. If
the cause of the failure is not found, contact your
Reinstall the energize wire of the solenoid into dealership's Technical Communicator for possible
the correct space of the connector on the ECM. consultation with Caterpillar. This consultation
Proceed to Test Step 4. may greatly reduce repair time. If the ECM must
be replaced, refer to the Testing and Adjusting,
“Electronic Control Module (ECM) - Replace”
• NO – The CID 3210 FMI 03 diagnostic code Section of this manual.
code did not change when the energize wire of the STOP.
Repair: The ECM has not responded correctly problem does not exist at this time.
operation of the ECM is not correct. Repair: The initial diagnostic code was probably
Prior to replacing an ECM, always contact your short at one of the harness connectors that was
dealership's Technical Communicator for possible disconnected and reconnected. Resume normal
consultation with Caterpillar. This consultation machine operation.
be replaced, refer to the Testing and Adjusting, STOP.
Section of this manual.
STOP.

CODE IS STILL ACTIVE.
A. Inspect the contacts and clean the contacts of the
harness connectors.
B. Check the wires for damage to the insulation

that is caused by excessive heat, battery acid, or
chafing.
C. Perform a 45 N (10 lb) pull test on each of the

RENR9004-07 511

MID 027 - CID 3210 - FMI 05 Note: The resistance of the solenoid coil should be
8.7 ± .4 ohms at 25 °C (77.0 °F).
Conditions Which Generate This Code: harness.

solenoid, place a jumper wire from the contact for
(wire K927-BU) to the contact for (wire X961-GY).


diagnostic code.
Expected Result:
The active diagnostic code changes from an FMI 05

g01941814 to an FMI 06 diagnostic code when the jumper wire
Illustration 327
is installed.
Results:
transmission pump bypass solenoid. The FMI 05
• YES – The active diagnostic code changes from
means that the transmission/chassis electronic an FMI 05 to an FMI 06 diagnostic code when the
control module (ECM) has determined that the jumper wire is installed. The solenoid has failed.
current for the solenoid circuit is below normal.
Repair: The solenoid has failed. Repeat this Test
Some possible causes of this diagnostic code are Step “CHECK THE SOLENOID” in order to verify
listed below: the solenoid failure. Replace the solenoid. Verify
STOP.
• The solenoid has failed. remains active. The jumper wire does not affect the
• The ECM has failed. This is unlikely. causing the problem. Proceed to Test Step 2.
Before performing this procedure, inspect the Test Step 2. CHECK THE CIRCUIT FOR
harness connectors that are involved in the AN OPEN
of a problem in an electrical circuit. Verify that A. Turn the key start switch and the disconnect
all connections in the circuit are clean, that all switch to the OFF position.
are in good condition. If a problem with a B. Disconnect the machine harness connector J1
connection is found, correct the problem and from the transmission/chassis ECM.
performing this procedure. C. The jumper wire that was installed in the previous
test step remains in place.
diagnostic codes. Ignore these created diagnostic D. At the machine harness connector J1 for
codes and clear these diagnostic codes when the the transmission/chassis ECM, measure the
original diagnostic code has been corrected. resistance from the return contact J1-55 (wire
K927-BU) to the energize contact J1-65 (wire
Use a calibrated digital multimeter for the following X961-GY).
procedures.
Expected Result:

512 RENR9004-07

points in the circuit is not an open connection but circuit condition in the solenoid circuit. The problem
not a good connection. is probably not being caused by the ECM.
Repair: The open or the possible poor connection Reinstall the energize wire of the solenoid into the
is in supply wire X961-GY or in return wire correct spot of the connector on the ECM. Proceed
K927-BU of the machine harness. Refer to the to Test Step 4.
complete Electrical Schematic of the machine.
circuit. Ensure that all connections are clean, that • NO – The CID 3210 FMI 05 diagnostic code
all connectors are secure and that all connectors remains active. The status of the active diagnostic
are in good condition. Repair the machine harness code does not change when the ECM pin for the
or replace the machine harness. solenoid is grounded.
STOP. Repair: The ECM has not responded correctly to

the grounded condition in the solenoid circuit. The
Test Step 3. CHECK THE OPERATION OF ECM may have failed.
THE ECM
If the cause of the failure is not found, contact your
The disconnect switch and the key start switch dealership's Technical Communicator for possible
remain in the OFF position. The machine harness consultation with Caterpillar. This consultation
connector for the solenoid and the ECM J1 connector may greatly reduce repair time. If the cause of
remain disconnected. the diagnostic code is not found, replace the
A. Remove the jumper wire that was installed in the be replaced, refer to the Testing and Adjusting,
last test step. “Electronic Control Module (ECM) - Replace”
Section of this manual.
B. At the machine harness connector J1 of the
ECM, remove the X961-GY energize wire of the STOP.
solenoid and remove the J1-65 socket from the
harness connector. Perform these removals with a Test Step 4. CHECK THE STATUS OF THE
151-6320 Removal Tool. DIAGNOSTIC CODE
C. Reconnect the machine harness J1 connector to A. Inspect the contacts and clean the contacts of the
the ECM. harness connectors.
D. Turn the disconnect switch and the key start B. Check the wires for damage to the insulation
switch to the ON position. that is caused by excessive heat, battery acid, or
chafing.
E. Use a 7X-1710 Multimeter Probe that is not
connected to a multimeter or a similar device to C. Perform a 45 N (10 lb) pull test on each of the
make contact with the ECM pin at J1-65 through wires that are associated with the sensor circuit.
D. Reconnect all harness connectors. Make sure that
F. Observe the status of the active CID 3210 FMI 05 the connectors are fully seated. Observe that the
diagnostic code and ground the other end of the clips for each connector are completely fastened.
F. Operate the machine.

RENR9004-07 513
G. Check the status of the CID 3210 FMI 05 i03619280

diagnostic code.
MID 027 - CID 3210 - FMI 06
Expected Result:
Results:

Repair: Check the circuit again. Perform a wiggle

test on the machine wiring harness with the
Caterpillar Electronic Technician (Cat ET) service
tool. The wiggle test can detect intermittent shorts
or opens in the machine wiring harness.

is unlikely as the ECM responded correctly to the g01941814
Illustration 328
Verify that all possible causes of the diagnostic
code have been investigated. If the cause of the This diagnostic code is associated with the
failure is not found, contact your dealership's transmission pump bypass solenoid. The FMI 06
Technical Communicator for possible consultation means that the transmission/chassis electronic
with Caterpillar. This consultation may greatly control module (ECM) has determined that the
reduce repair time. If the cause of the diagnostic current of the solenoid circuit is above normal.
code is not found, replace the transmission/chassis
ECM. If the ECM must be replaced, refer to the Some possible causes of this diagnostic code are
Testing and Adjusting, “Electronic Control Module listed below:
(ECM) - Replace” Section of this manual.
STOP. ground.
• NO – The CID 3210 FMI 05 diagnostic code is not • The solenoid has failed.
time. • The ECM has failed. This is unlikely.
Repair: The initial diagnostic code was probably Before performing this procedure, inspect the
caused by a poor electrical connection at one of harness connectors that are involved in the
the harness connectors that was disconnected and circuit. Poor connections can often be the
reconnected. Resume normal machine operation. cause of a problem in an electrical circuit. Verify
STOP. that all connections are secure and that all the
connections are in good condition. If a problem
with a connection is found, correct the problem
and verify that this diagnostic code is active
Use a calibrated digital multimeter for the following

procedures.

514 RENR9004-07
Note: The resistance of the solenoid coil should be • OK – Each resistance measurement is greater
8.7 ± .4 ohms at 25 °C (77.0 °F). than 5000 ohms. The machine harness is correct.
switch to the ON position. Do not start the engine. • NOT OK – One or more of the resistance
measurements is less than 5000 ohms. There
B. Observe the status of the diagnostic code. is a short in the machine harness. The short is
between wire K927-BU and the circuit with the low
C. Disconnect the solenoid with the active diagnostic resistance measurement.
Expected Result: circuits and finding short circuits, refer to Testing
The active CID 3210 FMI 06 diagnostic code changes Test”. Repair the machine harness or replace the
to a CID 3210 FMI 05 diagnostic code when the machine harness.
STOP.
Results:
• YES – The active CID 3210 FMI 06 diagnostic DIAGNOSTIC CODE
code when the solenoid is disconnected. The A. Inspect the harness connectors. Clean the
circuit is correct. contacts of the harness connectors.
Repair: The solenoid has failed. Repeat this test B. Check the wires for damage to the insulation
“CHECK THE SOLENOID” in order to verify the that is caused by excessive heat, battery acid, or
solenoid failure. Replace the solenoid. chafing.
STOP. C. Perform a 45 N (10 lb) pull test on each of the

the solenoid is disconnected. The solenoid is not D. Reconnect all harness connectors. Make sure that
CIRCUIT OF THE SOLENOID FOR A E. Turn the disconnect switch and the key start
SHORT TO GROUND switch to the ON position.
A. Turn the key start switch and the disconnect F. Operate the machine.
G. Check the status of the CID 3210 FMI 06
B. The solenoid remains disconnected from the diagnostic code.
machine harness.
Expected Result:
and J2 from the transmission/chassis ECM. The CID 3210 FMI 06 diagnostic code is still active.
D. At the machine harness connectors of the ECM, Results:

(wire K927-BU) to frame ground. Measure the • YES – The CID 3210 FMI 06 diagnostic code
resistance from the contact J1-55 (wire K927-BU) is still active. The diagnostic code has not been
to all of the other J1 and J2 contacts that are used corrected.
in the connectors of the transmission/chassis
ECM. Repair: Check the circuit again. Use the Caterpillar
Electronic Technician (Cat ET) service tool, in order
Expected Result: to perform a wiggle test on the machine wiring
harness. The wiggle test can detect intermittent
Each resistance measurement is greater than 5000 shorts or opens in the machine wiring harness.
ohms.
may have failed.
RENR9004-07 515
It is unlikely that the ECM has failed. Verify that all • The transmission/chassis ECM has failed. This is
possible causes of the diagnostic code have been unlikely.
contact your dealership's Technical Communicator Before performing this procedure, inspect the
for possible consultation with Caterpillar. This harness connectors that are involved in the
consultation may greatly reduce repair time. If the circuit. Poor connections can often be the cause
cause of the diagnostic code is not found, replace of a problem in an electrical circuit. Verify that
the transmission/chassis ECM. If the ECM must all connections in the circuit are clean, that all
be replaced, refer to the Testing and Adjusting, connections are secure and that all connections
“Electronic Control Module (ECM) - Replace” are in good condition. If a problem with a
Section of this manual. connection is found, correct the problem and
STOP. performing this procedure.
• NO – The CID 3210 FMI 06 is not active. The Note: The following test procedure may create other
diagnostic code does not exist at this time. diagnostic codes. Ignore these created diagnostic
Repair: The initial diagnostic code was probably original diagnostic code has been corrected. Ensure
caused by a poor electrical connection or a that the diagnostic code of CID 3382 FMI 03 is
short at one of the harness connectors that was active before performing this procedure.
machine operation. Use a calibrated digital multimeter for the following
procedures.
STOP.
System Response:
i03619482
The diagnostic code of CID 3382 FMI 03
MID 027 - CID 3382 - FMI 03 will be logged in the internal memory of the
transmission/chassis ECM.
SMCS Code: 1387-038-JV; 5479-038-NP
Conditions Which Generate This Code: CIRCUIT OF THE SOLENOID FOR A
SHORT TO THE +BATTERY CIRCUIT.
B. Disconnect the machine harness connectors from

the solenoid and the transmission/chassis ECM.
C. At the machine harness connector for the

transmission/chassis ECM, measure the
resistance from contact J1-66 (wire 989-YL) to all
contacts that are used in the machine harness
connectors for the transmission/chassis ECM.
Expected Result:
g01942393
Illustration 329
Circuit of the fan/brake pump load sense bypass solenoid Each resistance measurement is greater than 5000
ohms.
This diagnostic code is associated with the fan/brake
pump load sense bypass solenoid. The FMI 03 Results:
means that the transmission/chassis electronic
control module (ECM) has determined that the • OK – Each resistance measurement is greater
voltage of the solenoid circuit is above normal. than 5000 ohms. The machine harness is correct.
The possible causes of the diagnostic code are listed:
• The solenoid has failed. greater than 5000 ohms. There is a short in the
machine harness. The short is between J1-66 (wire
• The energize circuit of the solenoid is shorted to 989-YL) and the circuit that has a low resistance
the +battery circuit. measurement.
516 RENR9004-07
Repair: Repair the machine harness or replace B. Reconnect the machine harness J1 and J2
the machine harness. For information on testing connectors to the ECM.
for short circuits and finding short circuits, refer
to Testing and Adjusting, “Wiring Harness (Short C. Turn the disconnect switch and the key start
Circuit) - Test”. Repair the machine harness or switch to the ON position.
STOP. 03 diagnostic code.
Test Step 2. CHECK THE RETURN Expected Result:

SHORT TO +BATTERY. The CID 3382 FMI 03 diagnostic code is no longer
A. The key start switch remains in the OFF position. active.
B. The solenoid remains disconnected from the Results:

machine harness.
C. The machine harness connectors J1 and J2 remain longer active. A CID 3382 FMI 05 diagnostic code
disconnected from the transmission/chassis ECM. has been activated after the solenoid energize
D. At the machine harness for the solenoid, measure correctly to the open circuit condition in the
the voltage between the contact for (wire solenoid circuit.
K927-BU) and frame ground.
Reinstall the energize wire of the solenoid into
Expected Result: the correct space of the connector on the ECM.
The voltage is approximately 0.0 ± 0.5 DCV.
Results: • NO – The CID 3382 FMI 03 diagnostic code

• OK – The voltage is approximately 0.0 ± 0.5 DCV. code did not change when the energize wire of the
The voltage is correct. Proceed to Test Step 3. solenoid was disconnected from the ECM.
• NOT OK – Each resistance measurement is not Repair: The ECM has not responded correctly
greater than 5000 ohms. There is a short in the to the open condition in the solenoid circuit. The
machine harness. The short is between wire operation of the ECM is not correct.
K927-BU and the circuit that has a low resistance
measurement. Prior to replacing an ECM, always contact your
Repair: For information on testing for short consultation with Caterpillar. This consultation
circuits and finding short circuits, refer to Testing may greatly reduce repair time. If the ECM must
and Adjusting, “Wiring Harness (Short Circuit) - be replaced, refer to the Testing and Adjusting,
Test”. Repair the machine harness or replace the “Electronic Control Module (ECM) - Replace”
machine harness. Section of this manual.
STOP. STOP.
Test Step 3. CHECK THE OPERATION OF Test Step 4. CHECK IF THE DIAGNOSTIC
THE ECM CODE IS STILL ACTIVE.
The disconnect switch and the key start switch remain A. Inspect the contacts and clean the contacts of the
in the OFF position. The machine harness connectors harness connectors.
for the solenoid and the transmission/chassis ECM
remain disconnected. B. Check the wires for damage to the insulation
A. At the machine harness connector J1 of the chafing.
ECM, remove the 989-YL energize wire of the
solenoid and remove the J1-66 socket from the C. Perform a 45 N (10 lb) pull test on each of the
harness connector. Perform these removals with a wires that are associated with the sensor circuit.
151-6320 Removal Tool.
RENR9004-07 517
D. Reconnect all harness connectors. Make sure that i03619542

E. Turn the disconnect switch and the key start SMCS Code: 1387-038-JV; 5479-038-NP
G. Determine if the CID 3382 FMI 03 is active.
Expected Result:
Results:
• YES – The CID 3382 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 g01942393

Illustration 330
this procedure and perform this procedure again. If
the cause of the failure is not found, contact your Circuit of the fan/brake pump load sense bypass solenoid
consultation with Caterpillar. This consultation This diagnostic code is associated with the fan/brake
may greatly reduce repair time. If the ECM must pump load sense bypass solenoid. The FMI 05
be replaced, refer to the Testing and Adjusting, means that the transmission/chassis electronic
“Electronic Control Module (ECM) - Replace” control module (ECM) has determined that the
Section of this manual. current for the solenoid circuit is below normal.
STOP. Some possible causes of this diagnostic code are

listed below:
problem does not exist at this time. • The energize circuit of the solenoid is open.
Repair: The initial diagnostic code was probably • The return circuit of the solenoid is open.
short at one of the harness connectors that was • The solenoid has failed.
machine operation. • The ECM has failed. This is unlikely.
STOP. Before performing this procedure, inspect the


Use a calibrated digital multimeter for the following

procedures.
518 RENR9004-07
Note: The resistance of the solenoid coil should be • OK – The measurement of the resistance is less
8.7 ± .4 ohms at 25 °C (77.0 °F). than 5 ohms. The circuit is not open in the machine
harness. • NOT OK – The resistance measurement is greater
B. At the machine harness connector for the not correct. There is an open or a bad connection in
solenoid, place a jumper wire from the contact for the machine harness. A resistance measurement
(wire K927-BU) to the contact for (wire 989-YL). that is much greater than 5 ohms but less than 5000
C. Turn the disconnect switch and the key start points in the circuit is not an open connection but
switch to the ON position. Do not start the engine. not a good connection.
D. Observe the status of the CID 3382 FMI 05 Repair: The open or the possible poor connection
diagnostic code. is in supply wire 989-YL or in return wire K927-BU
Expected Result: Electrical Schematic of the machine. Check all
of the connectors that are in the solenoid circuit.
The active diagnostic code changes from an FMI 05 Ensure that all connections are clean, that all
to an FMI 06 diagnostic code when the jumper wire connectors are secure and that all connectors are
is installed. in good condition. Repair the machine harness or
Results:
STOP.
• YES – The active diagnostic code changes from
an FMI 05 to an FMI 06 diagnostic code when the Test Step 3. CHECK THE OPERATION OF
jumper wire is installed. The solenoid has failed. THE ECM
Repair: The solenoid has failed. Repeat this Test The disconnect switch and the key start switch
Step “CHECK THE SOLENOID” in order to verify remain in the OFF position. The machine harness
the solenoid failure. Replace the solenoid. Verify connector for the solenoid and the ECM J1 connector
that the new solenoid corrects the problem. remain disconnected.
STOP. A. Remove the jumper wire that was installed in the

last test step.
remains active. The jumper wire does not affect the B. At the machine harness connector J1 of the
status of the diagnostic code. The solenoid is not ECM, remove the 989-YL energize wire of the
causing the problem. Proceed to Test Step 2. solenoid and remove the J1-66 socket from the
harness connector. Perform these removals with a
Test Step 2. CHECK THE CIRCUIT FOR 151-6320 Removal Tool.
AN OPEN
A. Turn the key start switch and the disconnect the ECM.
B. Disconnect the machine harness connector J1 switch to the ON position.
from the transmission/chassis ECM.
E. Use a 7X-1710 Multimeter Probe that is not
C. The jumper wire that was installed in the previous connected to a multimeter or a similar device to
test step remains in place. make contact with the ECM pin at J1-66 through
D. At the machine harness connector J1 for
the transmission/chassis ECM, measure the F. Observe the status of the active CID 3382 FMI 05
resistance from the return contact J1-55 (wire diagnostic code and ground the other end of the
K927-BU) to the energize contact J1-66 (wire 7X-1710 Multimeter Probe to frame ground.
989-YL).
Expected Result:

RENR9004-07 519
Expected Result: G. Check the status of the CID 3382 FMI 05

diagnostic code.
Results:
Results:
longer active. A CID 3382 FMI 06 diagnostic code • YES – The CID 3382 FMI 05 diagnostic code
has been activated after the ECM pin is grounded. is active. The diagnostic code has not been
The ECM has responded correctly to the grounded corrected. The ECM may have failed.
circuit condition in the solenoid circuit. The problem
is likely not being caused by the ECM. Repair: Check the circuit again. Perform a wiggle
test on the machine wiring harness with the
Reinstall the energize wire of the solenoid into the Caterpillar Electronic Technician (Cat ET) service
correct spot of the connector on the ECM. Proceed tool. The wiggle test can detect intermittent shorts
to Test Step 4. or opens in the machine wiring harness.

• NO – The CID 3382 FMI 05 diagnostic code machine harness, the ECM may have failed. This
remains active. The status of the active diagnostic is unlikely as the ECM responded correctly to the
code does not change when the ECM pin for the grounded condition in the previous test step.
Verify that all possible causes of the diagnostic
Repair: The ECM has not responded correctly to code have been investigated. If the cause of the
the grounded condition in the solenoid circuit. The failure is not found, contact your dealership's
ECM may have failed. Technical Communicator for possible consultation
with Caterpillar. This consultation may greatly
If the cause of the failure is not found, contact your reduce repair time. If the cause of the diagnostic
dealership's Technical Communicator for possible code is not found, replace the transmission/chassis
consultation with Caterpillar. This consultation ECM. If the ECM must be replaced, refer to the
may greatly reduce repair time. If the cause of Testing and Adjusting, “Electronic Control Module
the diagnostic code is not found, replace the (ECM) - Replace” Section of this manual.
be replaced, refer to the Testing and Adjusting, STOP.
Section of this manual. • NO – The CID 3382 FMI 05 diagnostic code is not
STOP. time.
Test Step 4. CHECK THE STATUS OF THE Repair: The initial diagnostic code was probably
DIAGNOSTIC CODE caused by a poor electrical connection at one of
A. Inspect the contacts and clean the contacts of the reconnected. Resume normal machine operation.
harness connectors.
STOP.
chafing.




520 RENR9004-07

MID 027 - CID 3382 - FMI 06 Note: The resistance of the solenoid coil should be
8.7 ± .4 ohms at 25 °C (77.0 °F).
SMCS Code: 1387-038-JV; 5479-038-NP
Conditions Which Generate This Code: switch to the ON position. Do not start the engine.

Expected Result:

Results:
Illustration 331
g01942393 • YES – The active CID 3382 FMI 06 diagnostic
Circuit of the fan/brake pump load sense bypass solenoid code when the solenoid is disconnected. The
circuit is correct.
This diagnostic code is associated with the fan/brake
pump load sense bypass solenoid. The FMI 06 Repair: The solenoid has failed. Repeat this test
means that the transmission/chassis electronic “CHECK THE SOLENOID” in order to verify the
control module (ECM) has determined that the solenoid failure. Replace the solenoid.
current of the solenoid circuit is above normal.
STOP.
listed below:
• The energize circuit of the solenoid is shorted to causing the problem. Proceed to Test Step 2.
ground.
• The solenoid has failed. CIRCUIT OF THE SOLENOID FOR A
SHORT TO GROUND
Before performing this procedure, inspect the switch to the OFF position.
circuit. Poor connections can often be the B. The solenoid remains disconnected from the
cause of a problem in an electrical circuit. Verify machine harness.
that all connections are secure and that all the C. Disconnect the machine harness connectors J1
connections are in good condition. If a problem and J2 from the transmission/chassis ECM.
with a connection is found, correct the problem
and verify that this diagnostic code is active D. At the machine harness connectors of the ECM,
before performing this procedure. measure the resistance from the contact J1-55
(wire K927-BU) to frame ground. Measure the
Use a calibrated digital multimeter for the following resistance from the contact J1-55 (wire K927-BU)
procedures. to all of the other J1 and J2 contacts that are used
in the connectors of the transmission/chassis
Note: The following test procedure may create other ECM.
ohms.
RENR9004-07 521
measurements is less than 5000 ohms. There the transmission/chassis ECM. If the ECM must
is a short in the machine harness. The short is be replaced, refer to the Testing and Adjusting,
between wire K927-BU and the circuit with the low “Electronic Control Module (ECM) - Replace”
resistance measurement. Section of this manual.
Repair: For information on testing for short STOP.

and Adjusting, “Wiring Harness (Short Circuit) - • NO – The CID 3382 FMI 06 is not active. The
Test”. Repair the machine harness or replace the diagnostic code does not exist at this time.
machine harness.
STOP. caused by a poor electrical connection or a
Test Step 3. CHECK THE STATUS OF THE disconnected and reconnected. Resume normal
DIAGNOSTIC CODE machine operation.

contacts of the harness connectors.

chafing.



G. Check the status of the CID 3382 FMI 06

diagnostic code.
Expected Result:
Results:

is still active. The diagnostic code has not been
corrected.

Electronic Technician (Cat ET) service tool, in order
to perform a wiggle test on the machine wiring
harness. The wiggle test can detect intermittent

may have failed.
522 RENR9004-07
Diagnostic System
Procedures
i02650508
Power Supply Circuit of

Electronic Control Module
SMCS Code: 1417-038-EK2; 1420-038-EK2
System Operation Description:
g01331075
Illustration 333
Circuit Breaker Panel located behind the door on left side of
machine behind the cab
(1) Transmission Control Breaker
(2) Alternator breaker
The Transmission Chassis ECM receives system

power through the transmission control circuit
breaker. The Transmission Chassis ECM is
connected to the machine system power at five
contacts on the J1 connector. The Transmission
Chassis ECM is connected to the machine frame
ground at four contacts on the J1 connector. Other
ground connections are used for the location code
contacts, however, these are not used for operating
grounds.
An ECM would have to lose power at each of the five

connections in order to completely lose all power for
the ECM. There are conditions that can cause the
g01331068
Illustration 332 ECM to completely lose power. An open transmission
Transmission Chassis ECM Power and Ground connections control circuit breaker will cause a loss of power. An
open or a faulty connection in certain sections of the
machine harness could cause a complete loss of
power. Open or poor ground connections can also
cause a loss of power to the ECM.
If power is completely lost to the Transmission

Chassis ECM or to another ECM on the machine,
the ECM that has lost power will not activate any
diagnostic codes. When this occurs, a large amount
of machine functions will not operate and the other
ECMs on the machine will activate multiple diagnostic
codes.
RENR9004-07 523
If multiple diagnostic codes have been activated CID 0590 FMI 09 - Engine ECM – Activated by:
within a short amount of time, always check the power Implement ECM, Transmission Chassis ECM and
circuits for the ECM controls before investigating the Messenger.
individual components. If the power circuits for the
ECM controls are OK, look for a common factor EID 0192 Level 3 - Steering System Malfunction –
for the components that have the active diagnostic Activated by: Implement ECM and Transmission
codes such as shared grounds or power circuits. Chassis ECM.
An individual component is usually not causing the
problem when more than one or two diagnostic codes The Transmission Chassis ECM is receiving +battery
are activated at the same time. power at all times. When the key start switch is in
the OFF position, the ECM is in a “sleep mode”.
The following lists give examples of multiple When the key start switch is in the ON position, the
diagnostic codes and events that will most likely be ECM immediately becomes active and will activate
activated when a particular ECM has lost power: a diagnostic code for another control module if
expected information from that module is not received
Loss of power to the Implement ECM on the data link circuits.
CID 0569 FMI 09 - Implement ECM – Activated by: If a the power circuit for the Transmission Chassis
Transmission Chassis ECM, Engine ECM and the ECM is suspected to have failed, perform the
Messenger. following procedure.
CID 0615 FMI 03 - Articulation Angle Sensor 1 – Note: The main disconnect switch is in the ON
Activated by: Transmission Chassis ECM. position.
CID 1471 FMI 03 - Steer Position Sensor 1 – Test Step 1. CHECK THE CIRCUIT
Activated by: Transmission Chassis ECM. BREAKER
CID 1472 FMI 03 - Steer Position Sensor 2 – An open “Transmission Control” circuit breaker will
Activated by: Transmission Chassis ECM. disrupt power to the Transmission Chassis ECM.
CID 2199 FMI 03 - Secondary Steer Request The key start switch is in the OFF position.
Signal – Activated by: Transmission Chassis ECM.
A. Check for an open at the 15 amp “Transmission
CID 2201 FMI 03 - Right Steering Cylinder Position Control” circuit breaker.
Sensor – Activated by: Transmission Chassis ECM.
Expected Result:
EID 0192 Level 3 - Steering System Malfunction –
Activated by: Transmission Chassis ECM. The 15 amp “Transmission Control” circuit breaker
is open.
Loss of power to the Transmission Chassis ECM
Results:
CID 0569 FMI 09 - Transmission Chassis ECM –
Activated by: Implement ECM, Engine ECM and the • YES – The circuit breaker is open.
Messenger.
Repair: Reset the open circuit breaker. Resume
CID 1473 FMI 03 - Steer Position Sensor 3 – machine operation.
Activated by: Implement ECM
STOP.
CID 2200 FMI 03 - Left Steering Cylinder Position
Sensor – Activated by: Implement ECM. • NO – The 15 amp “Transmission Control” circuit
breaker is not open. Proceed to Test Step 2.
CID 2252 FMI 03 - Articulation Angle Sensor 2 –
Activated by: Implement ECM. Test Step 2. CHECK THE SYSTEM
POWER AT THE ECM
EID 0192 Level 3 - Steering System Malfunction –
Activated by: Implement ECM. This step requires the use of a 7X-1710 Probe group
or similar tool in order to enable voltage measurement
EID 0263 Level 3 - Low Main Pump Pressure – at the ECM connector without disconnecting it.
Activated by: Implement ECM.
The key start switch is in the OFF position.
Loss of power to the Engine ECM
524 RENR9004-07
A. At machine harness connector J1 for the Expected Result:

Implement ECM, insert multimeter probes along
supply contact J1-31 (wire 126-RD) and along The Transmission Chassis ECM is performing
ground contact J1-13 (wire A202-BK). Measure normally.
the DC voltage.
Results:
B. Repeat the last step for each of the ECM supply
contacts and each of the ECM ground contacts • OK – The Transmission Chassis ECM is
that are shown in the illustration at the beginning performing normally. The diagnostic codes that
of this procedure. were active are no longer active
Expected Result: Repair: The problem was probably caused

by a poor electrical connection at one of the
Each voltage measurement measures between 18.0 harness connectors that was disconnected and
and 32 VDC. reconnected. Resume normal machine operation.
Results: STOP.
• OK – Each voltage measurement measures • NOT OK – The Transmission Chassis ECM is not
between 18.0 and 32 VDC. The voltage supply is performing normally. The ECM is still not powered.
Repair: Check the power supply circuit again.
• NOT OK – One or more of the voltage
measurements is less than 18.0 VDC. There is an If the cause of the problem is not found, the ECM
open or a bad connection in the machine harness. may have failed.
Repair: The machine harness is faulty. There is an It is unlikely that the ECM has failed. Verify that all
open or a bad connection in the machine harness possible causes of the diagnostic code have been
for either the power supply circuit wire 126-RD or investigated. If the cause of the failure is not found,
a ground wire A202-BK. contact your dealership's Technical Communicator
Refer to the complete machine Electrical System consultation may greatly reduce repair time. If
Schematic. Check all of the connectors that are the ECM must be replaced, refer to Testing and
in the suspect power or ground circuit. Ensure Adjusting, “Electronic Control Module (ECM) -
that all connections are clean, secure and in good Replace”.
the machine harness. STOP.
STOP.

ECM
contacts of the harness connectors in the power
supply circuit. Check the wires for damage to the
insulation. Verify that each connector contact is
clean, secure and in good condition.

wires that are associated with the power supply
circuit.

the connectors are fully seated and the clips for
each connector are completely fastened.
D. Turn key start switch to the ON position.
E. Check the status of the ECM.

RENR9004-07 525
i02650613 The sensor signal can also be measured as voltage.

Most PWM sensor signals will measure an RMS
Pulse Width Modulated Sensor (average) voltage of between 0.0 VDC to 5.0 VDC
depending on the duty cycle value. A low duty cycle
SMCS Code: 1439-038 results in a low voltage measurement. A high duty
cycle results in a higher voltage value. A valid duty
System Operation Description: cycle range that the ECM will accept of 10 ± 5 percent
to 90 ± 5 percent equates to a voltage range of 0.5
VDC to 4.5 VDC.
In order to aid in ECM circuit diagnostics, all of the

PWM sensor signal input circuits have an internal
“pull up voltage”. An above normal voltage is
internally connected to the ECM sensor PWM signal
input circuit through a resister.
During normal operation, the sensor signal will hold

the circuit at a certain signal amplitude, however,
circuit conditions such as a loss of power to the
component, a disconnection or an open circuit will
allow the circuit to be pulled high by the ECM pull up
voltage. This will result in an above normal voltage
condition at the ECM contact. As a result, the ECM
will activate a diagnostic code for the affected circuit.
When the ECM detects an abnormal condition in the

circuit, the ECM will activate a diagnostic code for the
PWM sensor signal circuit. The ECM will most often
monitor the circuit for the following FMI conditions:
FMI 02 – Data erratic, intermittent or incorrect
FMI 03 – Voltage above normal
g00288430
FMI 04 – Voltage below normal
Illustration 334
Typical Square Wave Pulse Width Modulated Duty Cycle Signal FMI 08 – Abnormal frequency, pulse width or period
When powered up, a position sensor will continuously FMI 13 – Out of calibration
send a Pulse Width Modulated (PWM) square wave
signal to the ECM. The frequency of the signal is most Note: The ECM may activate diagnostic codes for
often 500 hertz. Some sensors operate at 5000 hertz. other FMI conditions, however, the FMI conditions
The operating frequency stays at approximately the that are listed are the most common.
same rate during operation.
When the ECM activates an FMI 13 diagnostic code
During operation, the duty cycle of the PWM sensor for a particular sensor, a calibration procedure must
signal changes depending on the direction and be performed in order to maximize performance in
amount of movement on the axis that is being the involved system.
monitored. The duty cycle is the percentage of time
that the signal is high as compared to the total time A calibration procedure for a PWM sensor enables
for one cycle. The percentage of duty cycle signal the ECM to “map” a specific position for a cylinder
from a typical position sensor that the ECM will or pedal to a specific sensor signal. This allows the
recognize as valid is 10 ± 5 percent to 90 ± 5 percent ECM to control the component more precisely.
at the extreme ends of the axis movement. An axis
that is in the center or neutral position would result in For troubleshooting, the PWM duty cycle of
a duty cycle signal of approximately 50 ± 6 percent. the sensor can be measured using most digital
multimeters. The duty cycle would be expected to
be in the acceptable range according to the position
of the assigned axis of a particular component. The
voltage of the signal circuit can be measured also,
however, most signals from the PWM sensors are
usually measured as a duty cycle percentage.
526 RENR9004-07
For operation information on a specific machine

PWM position sensor, refer to the System Operation,
“Electrical Input Components” section of this manual.
All PWM sensors on the machine are assigned a

Component Identifier (CID) for diagnostics.
FINDING A TROUBLESHOOTING
PROCEDURE FOR A SENSOR
A. When the ECM activates a diagnostic code for
a PWM sensor, refer to the Troubleshooting,
“Diagnostic Code Procedures” section of this
manual. Go to the procedure for the CID FMI
diagnostic code that has been activated and
perform the procedure in order to isolate the
probable cause of the problem.
Expected Result:
The troubleshooting procedure has been performed.
Results:
• OK – The troubleshooting procedure has been

performed. STOP.
i02443774
Starting System
SMCS Code: 1450-038
System Operation Description:
g01331158
Illustration 335
Engine Starting System connections
RENR9004-07 527
Note: If the engine is cranking when the key start

switch is in the START position and the engine is not
starting, refer to the engine service manual for your
model machine.
Verify that there are no active CID 0444 diagnostic

codes for the starter motor relay. If a diagnostic code
for the relay is active, troubleshoot and repair the
relay circuit problem before attempting to start the
engine.
Test Step 1. Verify That The Machine

Conditions Are Correct
A. Verify that the following conditions are correct:
• The disconnect switch is in the ON position.

• The Alternator Breaker is not open.
g01331129
Illustration 336
Power Breaker Box located on left side of machine behind the Cab • The transmission is in NEUTRAL.
(2) Starter Motor Relay • The operator present switch is indicating that an
operator is in the seat.
The Transmission Chassis ECM controls the engine
starting system for the machine. The ECM monitors Expected Result:
the status of the key start switch. When the key
start switch is in the ON position or in the START One or more of the listed machine conditions was
position, a system voltage input is supplied to the not correct.
ECM through the key switch contacts.
Results:
When the Transmission Chassis ECM detects the
system voltage at the START input, the ECM will • YES – One or more of the listed machine
activate the starter motor relay in order to initiate the conditions was not correct.
engine start process provided the following machine
conditions are present: Repair: Ensure that all the listed machine
conditions are correct. Then attempt to start the
engine again.
STOP.
• The operator present switch is indicating that an • NO – All of the listed machine conditions are
operator is in the seat. correct. The engine still will not crank and no
diagnostic codes for the starter motor relay are
System battery voltage that has passed through active. Proceed to Test Step 3
the buss bar and the 150 amp alternator breaker
is present at one side of the starter motor relay Test Step 2. Check The Relay
contacts. When the starter motor relay is energized
by the ECM, system battery voltage is directed The key switch is in the OFF position.
through the closed relay contacts and on to the starter
motor solenoid. The starter motor solenoid contacts A. Enlist the aid of another technician. Remove the
will close and +battery voltage will be applied to the lower cover from the power box in order to access
starter motor in order to crank the engine for starting. the starter motor relay. Have the other technician
turn the key start switch to the START position
In the event that the engine will not crank when the while observing the starter motor relay. The relay
key start switch is in the START position, perform should create an audible “click” when the key
the following procedure. is first moved to the START position in order to
energize the relay.
528 RENR9004-07
Expected Result: Test Step 4. Check The Voltage At the

Starter Motor
The relay is being energized by the ECM.
A. Turn the key start switch to the OFF position.
Results:
B. At the starter motor, measure the system voltage
• OK – The relay is being energized by the ECM. between the +battery contact (cable 1-RD-00) and
Proceed to Test Step 3. a good frame ground contact.
• NOT OK – The relay is not being energized by the C. At the starter motor, fasten ONE clamp-on
ECM. multimeter probe to the starter solenoid power
contact (304-WH-8) and fasten the other clamp-on
Repair: There is a problem in the starter motor probe to a good frame ground.
relay circuit. Refer to the Troubleshooting section
of this manual. Perform the diagnostic code D. While observing the multimeter for a voltage
procedure for the CID 0444 FMI 05 (Starter Motor measurement, turn the key start switch to the
Relay - current below normal) in order to find the START position for a few seconds.
problem. Find the problem in the relay circuit and
repair the circuit. Expected Result:
STOP. System voltage is present at the +battery contact

(cable 1-RD-00) on the starter motor and system
Test Step 3. Check The Condition Of The voltage is present at the starter solenoid power
Batteries contact (304-WH-8) when the key switch is in the
START position.
The key switch is in the OFF position.
Results:
A. At starter motor relay inside of the power box,
measure the battery voltage between the contact • OK – The system voltage is present at the starter
that is connected to the red cable (109-RD) and solenoid contact at the right time and system
a good frame ground contact. Verify that the voltage is present at the starter motor contact.
correct voltage is present at the relay contact. If
no voltage is present, check the circuit back to Repair: The starter motor should be cranking the
the Alternator Breaker and then to the batteries engine when the key start switch is in the START
in order to determine why no system voltage is position. The starter motor has failed. Replace the
present at one side of the relay contacts. starter motor.
B. Verify that the battery connections are clean and STOP.

tight. Load test the batteries. Use a 4C-4911
Battery Load Tester. Refer to , Special Instruction, • NOT OK – There is a problem with the system
SEHS9249, “Use of 4C-4911 Battery Load Tester voltage at the starter motor or at the starter
for 6, 8 and 12 Volt Lead Acid Batteries” and solenoid connection.
Special Instruction, SEHS7633, “Battery Test
Procedure”. Repair: Investigate the circuit that is not providing
the correct voltage at the starter motor or the starter
Expected Result: motor solenoid. Repair the system voltage circuit.
The batteries pass the load test and the connections If the voltage is not present at the starter solenoid
are in good condition. when the key start switch is turned to the START
position, verify that the voltage is passing through
Results: the starter motor relay contacts. Check the relay
operation and the wire from the relay to the starter
• OK – The batteries and the connections are OK. motor solenoid contact.
STOP.
• NOT OK – The batteries do not pass the load test
or the connections are not in good condition.
Repair: Charge or replace the batteries if needed

or clean and repair the battery connections.
STOP.
RENR9004-07 529
i02443779 • The switch input circuit is open or has a poor

connection in the machine harness.
Switch Circuits
• The switch input circuit is shorted to another
SMCS Code: 1435-038; 7332-038 +battery source in the machine harness.
System Operation Description: • The ECM has failed. This is not likely
When a switch circuit is suspected of not operating
correctly, perform the following troubleshooting
procedure for the switch circuit.


the switch.
C. At the AC operator switch, use a multimeter

g01331641 to measure the resistance between the switch
Illustration 337
contact 2 and switch contact 3. Measure the
Air Conditioning Operator Switch connections resistance in the AC OFF contact state and in the
switch AC ON contact state several times each.
The air conditioning operator switch supplies one
switch to +battery input to the Transmission Chassis Expected Result:
ECM. The ECM does not monitor the switch circuits
that have one input for diagnostics. When the switch is in the AC OFF contact state, the
resistance measurement is greater than 5000 ohms.
During normal operation, the ECM internal pull down When the switch is in the AC ON contact state, the
voltage will hold the switch input circuit low until the resistance measurement is less than 5 ohms.
+battery signal from the HVAC fan selector switch
is passed through the switch contacts. The ECM Results:
detects the high +battery signal in the circuit and
determines that the switch contacts are closed. • OK – The switch operation checks correct in
both of the switch states. The switch is working
Note: For a more detailed explanation of the Air correctly. Proceed to Test Step 2.
Conditioning system operation, refer to Systems
Operation, “Features” section of this manual. • NOT OK – The switch operation is not correct.
The resistance measurement of the switch is not
If the switch circuit is open or the switch contacts changing when the state of the switch is changed.
have failed in the OFF state, the ECM will not detect The switch has failed.
that the switch contacts are closed and will not
activate the air conditioning system. Repair: Replace the switch. After replacing the
switch, verify that the operation of the new switch
If the switch input circuit is shorted to frame ground is correct before operating the machine.
or to another ground source, the HVAC fuse will open
when the switch is moved to the AC ON position. STOP.
If the switch contacts fail in the AC ON state, the Test Step 2. CHECK THE SWITCH INPUT
ECM will not detect the low in the circuit to indicate CIRCUIT FOR AN OPEN
that the contacts are open. When this occurs, the air
condition system will be active at all times. The key switch and the disconnect switch remain in
the OFF position.
Some conditions that can cause the AC operator
switch input circuit to fail are listed. A. At the machine harness connector for the switch,
connect one end of a jumper wire to contact 3
• The HVAC fuse is open due to a short to ground in (wire 567-WH). Connect the other end of the
the switch input circuit or other factors. jumper wire to a good frame ground contact.
• The switch has failed. B. Disconnect the machine harness connector J1

from the ECM.
530 RENR9004-07
C. At the machine harness connector for the ECM, Results:

measure the resistance between the switch input
contact J1-24 (wire 567-WH) and a good frame • OK – Each resistance measurement is greater
ground contact. than 5000 ohms. The machine harness is not
indicating a short to another voltage source.
Expected Result: Proceed to Test Step 4.
The resistance measurement is less than 5.0 ohms. • NOT OK – Each resistance measurement is not
Results: machine harness. The short is between the switch
input circuit wire 567-WH and the circuit with the
• OK – The resistance measurement is less than low resistance measurement.
5.0 ohms. The switch input circuit in the machine
harness is not open. Proceed to Test Step 3. Repair: Refer to the complete machine Electrical
System Schematic. Examine all of the connectors
• NOT OK – The resistance measurement is in the defective circuit for points in the machine
greater than 5.0 ohms. There is an open or a bad harness where a short could occur.
connection in the switch input circuit in the machine
harness. For information on testing for short circuits and
Repair: A resistance measurement that is much “Wiring Harness (Short Circuit) - Test”. Repair the
greater than 5.0 ohms but less than 5000 ohms machine harness or replace the machine harness.
the circuit is not open but is not a good connection. STOP.
Refer to the complete machine Electrical System Test Step 4. CHECK THE OPERATION OF
Schematic. Check all of the connectors that are in THE SWITCH
the switch input circuit. Ensure that all connections
are clean, secure and in good condition. Repair the A. Inspect the harness connectors and clean the
machine harness or replace the machine harness. contacts of all of the harness connectors that are
in the switch input circuit.
STOP.
Test Step 3. CHECK FOR A SHORT TO the connectors are fully seated and the clips for
ANOTHER VOLTAGE SOURCE each connector are completely fastened.
The key switch and the disconnect switch remain in C. Turn the disconnect switch and the key start
the OFF position. The machine harness connectors switch to the ON position.
J1 remains disconnected from the ECM.
D. Check the operation of the switch.
A. Disconnect the machine harness connector J2
from the ECM. Expected Result:
B. At the machine harness ECM connector J1, The switch is operating properly.
measure the resistance from switch input contact
J1-24 (wire 567-WH) to all of the other J1 and J2 Results:
contacts that are used for the ECM.
• OK – The switch is operating properly. The
C. While observing the resistance measurement, operation of the switch is correct at this time.
wiggle the wires and move the machine harness
around at the ECM connectors and at the switch. Repair: The initial problem was probably caused
by a poor electrical connection or a short at one of
Expected Result: the harness connectors that was disconnected and
ohms at all times during the manipulation of the STOP.
machine harness wires and connectors.
• NOT OK – The switch circuit is still not operating
correctly. The problem has not been corrected.
RENR9004-07 531
Repair: Check the switch input circuit again. Use

tool, if available, in order to perform a "Wiggle
Test" on the machine wiring harness. The wiggle
test can detect momentary or intermittent shorts or
opens in the machine wiring harness.

the ECM may have failed. Verify that all possible
causes of the problem have been investigated
before replacement of the ECM.

STOP.
532 RENR9004-07
Testing and Adjusting Section

Section

i02443782
Calibration
SMCS Code: 4800
Calibration of a component in the Power Train Control

System allows the Transmission Chassis ECM to
determine the correct output level for solenoids and
allows the ECM to determine the correct input signal
range for position sensors.
Many of the solenoids and position sensors that are

under Transmission Chassis ECM control can be
calibrated using the Caterpillar Electronic Technician
(ET) service tool.
g01332134
Illustration 338
Service - Calibrations - Choose the calibration procedure
To access the calibration procedures for the Once the specific calibration is selected, the Cat
Transmission Chassis ECM, establish the Cat ET ET display will guide you through the calibration
connection to the Transmission Chassis ECM. procedure.
Navigate to the calibration screens by clicking
“Service”, then “Calibrations”. Click on the solenoid
calibration or position sensor calibration that is
needed.
RENR9004-07 533
The Cat ET display will list initial machine conditions Reference: Service Magazine, SEPD0545, 09
that must be satisfied before the ECM will allow the October 00, “Dielectric Grease Should Not Be Used
calibration procedure to continue. Follow the specific In Electrical Connectors”.
instructions on the display in order to successfully
complete the calibration procedure. Reference: Pocket Guide, SEBD0402, “Guidelines
For Routing And Installing Wire Harness Assemblies”.
The following list details the calibrations that
can be performed for Implement ECM controlled Use this procedure under the following situation:
components.
Use the following steps to help determine if the
Solenoid Calibrations 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.
Solenoid calibrations allow the ECM to determine the
correct amount of output current that is required to
The following background information is related
initiate the opening of the affected pilot valve in order
to this procedure:
to provide optimum performance and control of the
hydraulic system.
Many of the operational procedures and the
diagnostic code procedures in this troubleshooting
To perform a solenoid calibration, select the specific
solenoid in the CAT ET screen and follow the guide will instruct you to check a specific electrical
connector.
displayed directions. Calibration procedures are
available for the following solenoids:
Intermittent electrical problems are often caused
by poor connections. Always check for an active
Transmission Clutch Solenoids – Transmission
diagnostic code before breaking any connections.
Clutch Solenoids 1 through 8
Also, always check for an active diagnostic code after
the connector is reconnected in order to verify that
Secondary Steer Solenoids – Secondary Steer
the problem disappears.
right/left solenoids
Simply disconnecting the connectors and then
Note: For a procedure for transmission clutch
reconnecting the connectors can temporarily solve
fill calibration, refer to Testing and Adjusting,
RENR8454, “Fill Time for the Transmission Clutch a problem at times. If this occurs, likely causes are
loose terminals, bent terminals, improperly crimped
- Calibrate”.
terminals, corrosion, or the harness routing that is
improper.
i03122461
The original source of the problem must then be
Electrical Connector - Inspect identified in order to ensure that the problem does
not reoccur.
SMCS Code: 7553-040-WW
Follow this procedure to thoroughly inspect the
Reference: Special Instruction, SEHS9615, connectors in order to determine if the connectors
“Servicing DT Connectors”. are the cause of the problem.
Reference: Special Instruction, REHS0148, “Listing

Of Deutsch Connector Components”
Reference: Special Instruction, SEHS9065, “Use Of

CE Connector Tools”.
Reference: Service Magazine, SEPD0342, 27

January 97, “Field Repair Of Single Wire Breaks In
Harnesses (Sealed Splice)”.
Reference: Service Magazine, SEPD0371, 28 July

97, “Protection Of Unsealed Electrical Terminations
For Machines In Corrosive Applications”.
Reference: Service Magazine, SEPD0473, 24 May

99, “New DT Connector Plugs With Improved Seal
Retention”.
534 RENR9004-07
g01135980
Illustration 339
The correct way to route a harness
The correct way to insert a plug
g00690571 g00828600
Illustration 340 Illustration 341
Proper Installation of Plug 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.
RENR9004-07 535
1. CHECK THE CONNECTORS. a. Each connector contact should withstand 45 N

(10 lb) of pull. Each wire should remain in the
a. Ensure that the connector is properly locked. connector body. This test checks whether the
Also, ensure that the two halves of the wire was properly crimped in the contact and
connector can not be pulled apart. whether the contact was properly inserted into
the connector.
b. Verify that the latch tab of the connector is
properly latched. Verify that the latch tab of the b. The DT connectors use an orange wedge to
connector is fully latched. lock the terminals in place.
Expected Result: The connector will securely c. Check in order to ensure that the orange wedge
lock. The connector and the locking mechanism is not missing and that the orange wedge is
are without cracks or breaks. installed properly on the DT connectors.
Results: Note: A Crimp Tool should ALWAYS be used in order

to crimp wires on connector contacts. Do not solder
OK – The connector will securely lock. The the terminals. Use the proper Crimp Tool.
connector and the locking mechanism are
without cracks or breaks. Proceed to test step Expected Result: Each connector contact
2. should withstand 45 N (10 lb) of pull. Each wire
remains in the connector body.
NOT OK – A problem exists with the connector.
Results:
Repair: Repair the connector or replace the
connector, as required. OK – Each connector contact withstands
45 N (10 lb) of pull. Each wire remains in the
STOP. connector body. Proceed to test step 4.
2. CHECK THE ALLEN HEAD SCREW ON THE NOT OK – A problem exists with the connector.
HARNESS CONNECTOR OF THE ECM.
Repair: Repair the wiring or replace the
a. Ensure that the connector bolt is properly connector contact.
tightened. Be careful not to tighten the bolt too
much. The bolt may break. STOP.
b. Do not exceed 6.0 N·m (53.0 lb in) of torque 4. CHECK THE WIRES FOR NICKS OR
on the connector bolt of the harness when the ABRASIONS IN THE INSULATION.
connector is being installed on the ECM.
a. Carefully inspect each wire for signs of
Expected Result: The harness connector is abrasion, nicks, or cuts.
secure and the connector bolt of the ECM is
properly torqued. The following areas are locations that should
be checked:
Results:
• Exposed insulation
OK – The harness connector is secure and
the connector is properly torqued. Proceed to • Points of rubbing wire
test step 3.
b. Check all of the hold down clamps for the
NOT OK – A problem exists with the connector. harness in order to verify that the harness is
properly clamped. Also check all of the hold
Repair: Secure the harness connector of the down clamps for the harness in order to verify
ECM. Ensure that the connector bolt is properly that the harness is not compressed by the
torqued. clamp. Pull back the harness sleeves in order
to check for a flattened portion of wire. The
STOP. flattened portion of wire is caused by the clamp
that holds the harness.
3. PERFORM A PULL TEST ON EACH
CONNECTOR CONTACT. Expected Result: The wires are free of
abrasion, nicks, or cuts and the harness is
properly clamped.
Results:
536 RENR9004-07
OK – The wires are free of abrasion, nicks, Results:

or cuts and the harness is properly clamped.
Proceed to test step 5. OK – All of the connectors are completely
coupled and all of the seals are completely
NOT OK – A problem exists with the wiring. inserted. The harness and the wiring are free of
corrosion, moisture, abrasions or pinch points.
Repair: Repair the wires or replace the wires, Proceed to test step 6.
as required.
NOT OK – A problem exists with the connector,
STOP. the wiring or the wiring harness. Moisture is
present.
5. CHECK THE CONNECTORS FOR MOISTURE
OR CORROSION. Repair: Repair the connectors or wiring and/or
replace the connectors or wiring. Ensure that
a. Ensure that the connector seals and the white all of the seals are properly in place and ensure
sealing plugs are in place. If any of the seals or that the connectors are completely coupled.
plugs are missing, replace the seal or plug. If Verify that the repair eliminates the problem by
necessary, replace the connector. operating the machine for several minutes and
by checking again for moisture.
b. Check all of the wiring harnesses in order to
verify that the harness does not make a sharp STOP.
bend out of a connector. This will deform the
connector seal and this will create a path for 6. INSPECT THE CONNECTOR CONTACTS.
the entrance of moisture. See Illustration 339.
a. Verify that the contacts are not damaged.
Note: It is normal to see some minor seal abrasion Verify that the contacts are properly aligned in
on the ECM connector seals. Minor seal abrasion will the connector and verify that the contacts are
not allow the entry of moisture. properly located in the connector.
c. Thoroughly inspect ECM connectors for Expected Result: The contacts are properly
evidence of moisture entry. If moisture or aligned and the contacts appear undamaged.
corrosion is evident in the connector, the
source of the moisture entry must be found Results:
and the source of the moisture entry must be
repaired. If the source of the moisture entry is OK – The contacts are properly aligned and
not repaired, the problem will reoccur. Simply the contacts appear undamaged. Proceed to
drying the connector will not fix the problem. test step 7.
Likely paths for the entrance of moisture are
from missing seals, improperly installed seals, NOT OK – A problem exists with the connector
nicks in exposed insulation, and improperly contacts.
mated connectors.
Repair: Repair the contacts and wiring and/or
Note: Moisture can also travel from one connector replace the contacts and wiring.
through the inside of a wire to the ECM Connector. If
moisture is found in the ECM connector, thoroughly STOP.
check all connectors and wires on the harness that
connect to the ECM. The ECM is not the source of 7. CHECK THE FIT OF THE CONTACTS.
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.
RENR9004-07 537
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.
i02634314
Wiring Harness (Open Circuit)

- Test
SMCS Code: 1408-081
An open circuit is a failure of an electrical circuit

that results in no flow of electrical current. An open
circuit is can be caused by a break in a circuit wire.
Most often, an open circuit is caused by a poor
connection or a failed connection in one of the
electrical connectors that is used in a circuit.
The following procedure is a way to check for an

open or a poor connection in a circuit.
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.
g00838765 2. Turn the key start switch and the disconnect

Illustration 342
Retention of the Connector
(1) Pin Contact 3. Disconnect the component and the ECM from the
(2) Socket Contact wiring harness.
Note: This is especially important for intermittent 4. At one of the disconnected harness connections,
problems. place a jumper wire from the contact of the
suspect wire to frame ground.
a. Use a new pin contact. Insert the pin contact
into each socket contact one at a time in order 5. At the other connector of the machine harness,
to check for a good grip on the pin contact by use the multimeter probes to measure the
the socket contact. resistance from the contact of the suspect wire to
frame ground.
b. Use a new socket contact. Insert the pin
contact into each socket contact one at a time Expected Result: The resistance is less than 5
in order to check for a good grip on the pin ohms.
contact by the socket contact. The pin contact
are located on the mating side of the connector. OK – The resistance is less than 5 ohms. The
harness circuit is correct.
c. The connector contact should stay connected
when the connector is held in the position Stop.
shown in Illustration 342. The connector
contact is the pin contact or the socket contact. NOT OK – The resistance is greater than 5000
ohms. There is an open in the machine harness.
Expected Result: The pin contacts and the
socket contacts appear to be OK. Repair: Repair the machine harness or replace
Results:
538 RENR9004-07
Stop. Once the wire or connector that is causing the

problem is found, replace the broken wire or repair
When the resistance of a good circuit is measured, the harness connector. Do not use a splice to repair a
less than 5.0 ohms of resistance is expected. In a broken wire. A splice will not keep moisture out of the
circuit that has an electrical wire or a connection connection and will create another potential problem
that is completely open (broken or no connection), area in the circuit.
the flow of electrical current through the circuit is
interrupted. A circuit that is completely open due to
i03122343
a broken wire or no connection in a connector will
measure greater than 5000 ohms of resistance. Wiring Harness (Short Circuit)
Many times a circuit is not completely open and - Test
will allow some current to pass through, however,
not enough current will pass to allow the circuit to SMCS Code: 1408-081
function properly. This can be caused by a wire that
is partially broken but still is intact enough to allow a A short circuit is a failure of an electrical circuit that
small amount of current to pass. Partial breaks in a results in undesired electrical current. Usually, a
wire are difficult to diagnose because the resistance short circuit is a bypass of the circuit across a load.
measurement may check OK through the section of For example, a short across the wires in a circuit for
wire that is still intact. Partial breaks in a wire are not a lamp produces too much current in the wires but
common. When a partial break is suspected in a wire, no current is felt at the lamp. The lamp is shorted
the current through the circuit should be checked out. The resistance in a normal circuit can vary, but
under load in order to verify that the correct amount the resistance between a particular circuit and other
of current is present. unrelated circuits is always greater than 5000 ohms.
The following procedure explains the test for a short
Most often, a resistance measurement of greater circuit:
than 5.0 ohms and less than 5000 ohms is due to a
poor connection in a circuit connector. The connector Reference: For a complete electrical schematic,
contacts may be corroded due to moisture that has refer to Electrical System Schematic for the machine
entered the connector body. A connector pin or that is being serviced.
socket may not have been seated securely in the
connector body and is not making good contact or TEST FOR A SHORT CIRCUIT.
a wire may be broken at the point where the pin or
socket is connected. When checking for problems 1. Identify the connectors and the wire numbers of
in a circuit, the connectors in the circuit should be the suspect circuits. Use the Electrical System
examined closely. Schematic of the machine to identify the circuits.
When an open is suspected in a circuit, try to isolate 2. Turn the key start switch and the disconnect
the section of the machine harness where the open is switch to the OFF position.
occurring. The complete Electrical System Schematic
for your machine must be used in order to identify 3. Disconnect the component and the ECM from the
and find the harness connectors that are in the wiring harness.
suspect circuit.
4. At the machine harness connector for the ECM,
Once the harness connectors for the circuit are place one of the multimeter probes on the contact
identified, isolate the section of the circuit that is of the suspect wire.
open. Start at either the component or the ECM end
of the circuit. With the disconnect switch and the 5. Use the other multimeter probe to check the
key start switch in the OFF position, disconnect the resistance across all other contacts in the
component or the ECM connector and use a jumper connector(s) of the ECM and frame ground.
wire to connect two of the circuit wires. Go to the
next harness connector in the circuit and disconnect Expected Result: The resistance is greater than
the connector. Check the connector contacts for 5000 ohms for all the measurements.
corrosion. Make sure the contacts are not damaged,
are clean and are securely installed in the connector OK – The resistance is greater than 5000 ohms
body. Use the electrical schematic to determine the for all the measurements. The harness circuits are
contacts for the jumpered circuit wires. Check the correct.
resistance between the two wires. A good circuit will
measure less than 5.0 ohms. Repeat the steps as Stop.
you go to the next connector in the circuit until the
faulty section of the circuit is identified.
RENR9004-07 539
NOT OK – The resistance is less than 5 ohms. Transmission Serial Number – The serial number
There is a short in the machine harness. The short will be listed for the transmission that is installed on
is between the suspected wire and the wire with the machine.
the lowest resistance measurement.
Autoshift Installation Status – Autoshift is a
Repair: Repair the machine harness or replace software enabled function. A factory password is
the machine harness. required to install this function. Factory default is “Not
Installed”.
Stop.
Transmission Shift Control Parameters –
Transmission Shifting patterns can be configured
i03122440
for the Manual Mode and the Autoshift Modes. The
Electronic Control Module parameters that can be configured are:
(ECM) - Flash Program Initial gear in the forward and reverse direction
SMCS Code: 7610-591-DTN Maximum gear in the forward and reverse direction
Perform the following procedure in order to flash Maximum Autoshift gear in the forward and reverse
program the ECM. The ECM is flashed in order to direction
upgrade the software. Flash programming of the ECM
must also be done if the ECM has been replaced. Minimum Autoshift gear in the forward and reverse
The Caterpillar Electronic Technician (ET) contains direction
the program WinFlash. WinFlash is used in order to
load software into the ECM. The following procedure Refer to Systems Operation, “Features” for more
is used in order to FLASH software into the ECM. information on the transmission parameters that can
be configured.
Note: The 171-4400 Communication Adapter II
should be used to flash ALL components on the Machine Speed Limit – This function limits machine
machine. maximum travel speed. The factory default is
“Disabled”. When enabled, this parameter will
1. Procedure limit engine driven speed for specific gears. The
parameter will not limit speed caused by other factors
a. Connect the Data Link Cable between the such as rolling downhill. The configurable range is
Communication Adapter and the Electronic 16.1 km/h (10 mph) to 80.5 km/h (50 mph). Factory
Technician. default is 80.5 km/h (50 mph).
b. Connect the Data Link Cable between the Machine Speed Correction Factor – The machine
Communication Adapter and the diagnostic travel speed is calculated using the transmission
connector of the machine. output speed and the tire size. This parameter allows
for adjustment for higher accuracy when measured
c. Use WinFlash in order to load the software. against external speed measuring devices. The
configurable adjustment range is minus (-) 8 percent
to plus (+) 8 percent of the ECM calculated value.
i02738327
The factory default is 0 percent.
Engine Pre-Lube System Installation Status –
(ECM) - Configure Engine pre-lube is a software enabled function. A
factory password is required to install this function.
SMCS Code: 7610-025-DTN The factory default is “Not Installed”. When installed,
this function will lubricate the engine before the
When an ECM is replaced, the ECM is configured engine is started.
when the software is flashed either at the factory or
at the time of installation on the machine. The saved Auto Lube System Installation Status –
configuration data from the ECM that was replaced Attachment only on the 16M. The factory default is
will restore the parameters that were configured. “Not Installed”. For all other machines, the default
is “Unavailable”. When installed, this parameter
An explanation of the configured parameters for the allows the Auto Lube Interval, Auto Lube Duration
Transmission Chassis ECM that will load factory and the Auto Lube Target Pressure parameters to
defaults when the software is flashed are listed be configured.
below:
540 RENR9004-07
Auto Lube Interval – Sets the amount of time • TDTO SAE 5W-30
between lube cycles. The configurable range is
between 2 minutes to 120 minutes in 1 minute • TDTO SAE 10W
increments. The factory default is 60 minutes.
• TDTO Artic
Auto Lube Duration – Sets the maximum amount
of time that the Auto Lube Relay will be energized in • TDTO TMS
order to reach the Auto Lube Target Pressure. The
configurable range is between 120 seconds to 240 • TDTO SAE 30W (Factory Default)
seconds in 1 second increments. The factory default
is 240 seconds. • TDTO SAE 50W
Auto Lube Target Pressure – This parameters
i03121762
detects when the system has completed a lube cycle.
The configurable range is between 17236.9 kPa
(2500 psi) to 22063.2 kPa (3200 psi) in 6.9 kPa
(1.0 psi) increments. The factory default is (ECM) - Replace
18615.9 kPa (2700 psi).
Air Conditioning System Installation Status –
Indicates whether the air conditioning system is Prior to replacement of the ECM, ensure that
enabled. The factory default for the 16M is “Installed”. replacement of the ECM is absolutely necessary.
For all other models, the factory default is “Not The ECM is seldom the cause of an active diagnostic
Installed”. code. Verify that all possible causes of the problem
have been investigated. Always check that the
Bypass Schedule Start/Stop Times – This is an proper ground and power is available to the ECM.
optional function. The bypass schedule can be set Before replacing the ECM, contact your Caterpillar
up to allow any key to operate the machine during a dealership's Technical Communicator for possible
specified time on any day of the week. The following consultation with Caterpillar.
limits will apply to setup times:
Note: Corrupted configuration software or the wrong
Do not set the start time to 00:00 and the stop time software may cause an ECM to incorrectly report
to 23:59. Doing so will disable the Machine Security diagnostic codes. Prior to replacing the ECM, flash
System. the ECM with the correct configuration software
in order to verify that the failure is not related to
When no bypass is desired, start time and stop time the corrupted software. See Testing and Adjusting,
will both be set to 0. “Electronic Control Module (ECM) - Flash Program”.
Electronic keys that are stored in the ECM will enable Note: New electronic control modules are available
machine start ups at any time. either pre-programmed for a particular machine or
the ECM is not programmed. An ECM that has not
The bypass start time and the bypass stop time been programmed must be programmed by using
parameters can be set for all seven days of the week, the Caterpillar Electronic Technician (Cat ET). See
however, bypass times can not be set up to start on Testing and Adjusting, “Electronic Control Module
one day and to stop on the next day. The start time (ECM) - Flash Program”. See step 8 in order to
must be earlier than the stop time on the same day. determine whether the ECM has been programmed.
Transmission Oil Type Configuration – When the The following “Replacement Procedure For
transmission oil is changed, the correct viscosity An ECM That Is Communicating” procedure
of the new transmission oil must be entered using is for replacement of an ECM that is capable of
either the Messenger or in the Cat ET Configuration communicating with Cat ET. This procedure can be
Screen. After the oil is changed, select the correct performed for replacement of most ECM controls on
viscosity of the new oil. Once the new oil viscosity most Caterpillar machine models.
has been entered, the Transmission Clutch Oil Fill
Calibration must be performed. For replacement of a Transmission Chassis ECM on
the M Series Motor Graders that will not communicate
The following list of oil viscosities are available for with Cat ET or will not save the configuration data
selection: to file, proceed to the “Replacement Procedure
For A Transmission Chassis ECM That Is Not
• TDTO SAE 0W-20 Communicating” procedure below.
• TDTO SAE 0W-30 Replacement Procedure For An ECM That Is

Communicating
RENR9004-07 541
g01121920
Illustration 343
1. Save the ECM configuration data. Go to the help 8. Determine whether the ECM has been
screen that is shown in illustration 343, and follow programmed. Connect the (Cat ET) to the service
the instruction in order to save the configuration tool connector. Cat ET communicates with the
data to a file. This file will be used in order to load ECM.
the configuration data to the new ECM.
Cat ET will indicate whether the ECM has
2. Turn the key start switch and the disconnect been programmed. An ECM that has not been
switch to the OFF position. programmed must be programmed by using the
WinFlash software which is contained in Cat ET.
3. Disconnect the machine harness from the ECM. See Troubleshooting, “Electronic Control Module
(ECM) - Flash Program”.
4. Remove the ECM.
Cat ET will provide access to the ECM if the ECM
5. Ensure that the replacement ECM has the correct has already been programmed.
part number.
9. Using the Cat ET service tool, select the “Service”
6. Connect the machine harness to the ECM. function from the drop-down menu. Then, select
the “Configuration” function. A list of items will
Note: Two key start ON/OFF cycles are required for appear. Each item in this list should be checked
correct initialization of the new ECM. in order to verify that the setting matches the
machine configuration. The following information
7. Turn the disconnect switch and the key start is an example of what might be viewed in order to
switch to the ON position. Wait for a minute to let verify the proper machine configuration. Select
the ECM initialize. Turn the key start switch to the “Ripper Installation Status” from the choices.
OFF position. Wait 10 seconds. Turn the key start Select the “change” button. Select “Installed” or
switch to the ON position a second time for correct “Not Installed”.
initialization of the ECM.
542 RENR9004-07
10. Select the “Service” function from the Cat ET. 3. Using the diagram for the Cat Data Link
Select “Configuration” from the choices. A list of connections, connect a jumper wire between the
items will appear. From the list, select “Ripper data link (+) contact (wire 893-GN) and the data
Auto Stow Configurations”. Select the “change” link (-) contact (wire 892-BR).
button. Select “Ripper Raise” or “Ripper Raise
And Shank In”. 4. At the service connector, measure the resistance
between data link (+) contact D (wire 893-GN) and
11. Perform all applicable system calibrations. See data link (-) contact E (wire 892-BR).
the Testing and Adjusting, “Calibration” procedure
in the service manual for your machine. Result: The resistance measurement should be
less than 5.0 ohms.
Note: Some variations in Cat ET menu may be
experienced. View the proper subject for information If the resistance measurement is greater than 5.0
about a specific Cat ET menu. ohms, there is an open or a poor connection in
the Cat Data Link circuit. Refer to the complete
Note: Performance will be affected by ANY machine Electrical System Schematic for your
calibration procedures that are omitted. Make sure machine. Check the data link circuit for opens or
that all calibration procedures are performed. Perform bad connections. Repair the data link circuit and
all calibration procedures, even if the replacement then try to establish communication with the ECM.
ECM was acquired from a similar machine. If the ECM still will not communicate, proceed to
the next step.
Replacement Procedure For A Transmission
Chassis ECM That Is Not Communicating If the resistance measurement is less than 5.0
ohms, proceed to the next step.
This procedure should be performed for an M Series
Motor Grader Transmission Chassis ECM that will 5. Disconnect the machine harness connector J2
not communicate with Cat ET or will not save the from the ECM.
configuration data to a file.
6. Remove the Transmission Chassis ECM.
Prior to replacement of the ECM, ensure that
replacement of the ECM is absolutely necessary. 7. Ensure that the replacement ECM has the correct
The ECM is seldom the cause of an active diagnostic part number.
code. Verify that all possible causes of the problem
have been investigated. Always check that the 8. Connect the machine harness to the ECM.
proper ground and power is available to the ECM.
Before replacing the ECM, contact your Caterpillar Note: Two key start ON/OFF cycles are required for
dealership's Technical Communicator for possible correct initialization of the new Implement ECM.
consultation with Caterpillar.
9. Turn the disconnect switch and the key start
Note: The first steps will verify that the Cat Data Link switch to the ON position. Wait for a minute to let
circuit between the service connector and the ECM the ECM initialize. Turn the key start switch to the
that being replaced is not causing the communication OFF position. Wait 10 seconds. Turn the key start
problem. switch to the ON position a second time for correct
initialization of the ECM.
10. Determine whether the ECM has been

programmed. Connect the (Cat ET) to the service
tool connector. Cat ET communicates with the
ECM.
Cat ET will indicate whether the ECM has

Illustration 344
g01330559 been programmed. An ECM that has not been
programmed must be programmed by using the
WinFlash software which is contained in Cat ET.
See Troubleshooting, “Electronic Control Module
1. Turn the key start switch and the disconnect
(ECM) - Flash Program”.
Cat ET will provide access to the ECM if the ECM
2. Disconnect the machine harness J1 connector
has already been programmed.
from the Transmission Chassis ECM that is being
replaced.
RENR9004-07 543
The Transmission Chassis ECM should now be

operational. The machine operating parameters that
can be configured will be set to the factory default
settings when the software is flashed to the ECM.
Check all of the machine systems for proper

operation before operating the machine.
Note: For a listing of the parameters that can be

configured in the Transmission Chassis ECM for
the Power Train System, refer to the Testing and
Configure” section of this manual.
i03617721
System Schematic
SMCS Code: 7566-DTN
The following simplified electrical schematics are

electrically correct. The schematics show the input
connections and the schematics show the output
connections for the “J1” and the “J2” connectors of
the transmission/chassis electronic control module
(ECM).
The schematics do not show all related electrical

systems or possible harness connectors. For a
complete electrical schematic, refer to Electrical
Schematic, KENR6663.
544 RENR9004-07
1
RENR9004-07
PAGES 545-548 2 FOLDOUT

RENR9004-07 549
Index Section
Index
C F
Calibration ........................................................... 532 Features .................................................................. 8

Solenoid Calibrations ....................................... 533 Air Conditioning System....................................... 8
Connector Locations.............................................. 57 Backup Alarm Operation...................................... 9
ECM Connector Contact Numbers .................... 58 Limp Home Mode................................................. 9
Operation of Transmission Shifting .................... 19
Parasitic Load Reduction ................................... 10
D Parking Brake Emergency Drive Through
Function ........................................................... 10
Data Link ............................................................... 52 Parking Brake Test............................................. 10
Data Link Diagnostics ........................................ 53 Secondary Steer System .................................... 11
Diagnostic Capabilities .......................................... 58 Secondary Steer System Test............................ 14
Messenger ......................................................... 63 Transmission Electronic Clutch Pressure Control
The Caterpillar Electronic Technician (Cat ET) .. 59 (ECPC)............................................................. 16
Diagnostic Code List............................................ 100
Component Identifier (CID) .............................. 100
Failure Mode Identifier ..................................... 103 G
Module Identifier (MID) .................................... 100
Diagnostic Code Procedures............................... 100 General Information........................................... 5, 54
Diagnostic System Procedures ........................... 522 Cab Relay Locations.......................................... 55
ECM Pull Down Voltage..................................... 55
ECM Pull Up Voltage ......................................... 54
E
Electrical Connector - Inspect.............................. 533 I

Electrical Input Components.................................. 27
Secondary Steer Request Signal....................... 34 Important Safety Information ................................... 2
Sensors.............................................................. 28 Indicator Lamp Does Not Illuminate ...................... 66
Switches............................................................. 35 Indicator Lamp Is On Continuously ....................... 68
Electrical Output Components............................... 45 Introduction............................................................ 54
Back Up Alarm Relay......................................... 46
Differential Lock Relay ....................................... 46
ECPC Transmission Proportional Solenoid L
Valves............................................................... 46
Fan/Brake Bypass Solenoid............................... 48 Location of Electrical Components ........................ 25
Outputs .............................................................. 45 Cab Relay Locations.......................................... 25
Park Brake Solenoid .......................................... 49
Secondary Steer Proportional Solenoid Valves.. 49
Secondary Steer Relay ...................................... 50 M
Starter Motor Relay............................................ 51
Transmission Pump Bypass Solenoid ............... 51 MID 027 - CID 0041 - FMI 03 .............................. 109
Electronic Control Module ..................................... 41 MID 027 - CID 0041 - FMI 04 ............................... 111
ECM Pull Down Voltage..................................... 41 MID 027 - CID 0070 - FMI 03 ............................... 113
ECM Pull Up Voltage ......................................... 41 MID 027 - CID 0070 - FMI 04 ............................... 116
Input/Output ....................................................... 42 MID 027 - CID 0096 - FMI 03 ............................... 118
Inputs ................................................................. 42 MID 027 - CID 0096 - FMI 04 .............................. 120
Outputs .............................................................. 42 MID 027 - CID 0127 - FMI 03 .............................. 122
Electronic Control Module (ECM) - Configure ..... 539 MID 027 - CID 0127 - FMI 04 .............................. 124
Electronic Control Module (ECM) - Flash MID 027 - CID 0144 - FMI 03 .............................. 126
Program ............................................................. 539 MID 027 - CID 0144 - FMI 05 .............................. 128
Electronic Control Module (ECM) - Replace........ 540 MID 027 - CID 0144 - FMI 06 .............................. 130
Emerging Symptom Information ............................ 65 MID 027 - CID 0168 - FMI 00 .............................. 131
Event Code List ..................................................... 91 MID 027 - CID 0168 - FMI 01 .............................. 134
Indications and System Response..................... 92 MID 027 - CID 0168 - FMI 02 .............................. 138
List of Event Codes For the Transmission/Chassis MID 027 - CID 0168 - FMI 03 .............................. 141
ECM ................................................................. 94 MID 027 - CID 0168 - FMI 04 .............................. 144
Troubleshooting ................................................. 94 MID 027 - CID 0177 - FMI 03 .............................. 147
Warning Levels .................................................. 92 MID 027 - CID 0177 - FMI 04 .............................. 149
MID 027 - CID 0247 - FMI 09 .............................. 151
550 RENR9004-07
Index Section
MID 027 - CID 0247 - FMI 14 .............................. 151 MID 027 - CID 1404 - FMI 13 .............................. 301
RENR9004-07 551
Index Section
MID 027 - CID 2201 - FMI 02 .............................. 462 U

MID 027 - CID 2201 - FMI 03 .............................. 466
MID 027 - CID 2201 - FMI 04 .............................. 469 Using Caterpillar Electronic Technician to Determine
MID 027 - CID 2201 - FMI 08 .............................. 472 Diagnostic Codes............................................... 107
MID 027 - CID 2201 - FMI 13 .............................. 475 Using Messenger to Determine Diagnostic
MID 027 - CID 2201 - FMI 14 .............................. 476 Codes ................................................................ 106
MID 027 - CID 2252 - FMI 02 .............................. 478
MID 027 - CID 2252 - FMI 03 .............................. 482
MID 027 - CID 2252 - FMI 04 .............................. 487 W
MID 027 - CID 2252 - FMI 08 .............................. 490
MID 027 - CID 2252 - FMI 13 .............................. 494 Wiring Harness (Open Circuit) - Test................... 537
MID 027 - CID 2252 - FMI 14 .............................. 495 Wiring Harness (Short Circuit) - Test ................... 538
MID 027 - CID 2304 - FMI 03 .............................. 497
MID 027 - CID 2304 - FMI 05 .............................. 499
MID 027 - CID 2304 - FMI 06 .............................. 501
MID 027 - CID 2734 - FMI 03 .............................. 503
MID 027 - CID 2734 - FMI 04 .............................. 506
MID 027 - CID 3210 - FMI 03 .............................. 508
MID 027 - CID 3210 - FMI 05 ............................... 511
MID 027 - CID 3210 - FMI 06 .............................. 513
MID 027 - CID 3382 - FMI 03 .............................. 515
MID 027 - CID 3382 - FMI 05 .............................. 517
MID 027 - CID 3382 - FMI 06 .............................. 520
Parking Brake System ........................................... 69

Parking Brake Symptoms .................................. 69
Recommended Actions...................................... 69
Troubleshooting the Parking Brake System....... 73
Power Supply Circuit of Electronic Control
Module ............................................................... 522
Pulse Width Modulated Sensor ........................... 525
Service Tools ......................................................... 56

Starting System ................................................... 526
Steering Direction Is Opposite of Expected
Direction............................................................... 82
Steering Does Not Function .................................. 86
Steering Movement Without Request.................... 89
Switch Circuits ..................................................... 529
Symptom Troubleshooting..................................... 65
Determine Possible Causes............................... 65
Know the Machine ............................................. 65
Provide Feedback to Caterpillar......................... 65
Test and Repair the System............................... 65
Understand the Symptom .................................. 65
Verify the Symptom............................................ 65
System Schematic............................................... 543
Systems Operation Section ..................................... 5
Table of Contents..................................................... 3
Testing and Adjusting .......................................... 532
Testing and Adjusting Section ............................. 532
Troubleshooting Section........................................ 54
©2010 Caterpillar Cat, Caterpillar, their respective logos, “Caterpillar Yellow” and the Power edge Printed in U.S.A.
All Rights Reserved trade dress, as well as corporate and product identity used herein, are trademarks
of Caterpillar and may not be used without permission.

Renr9004-07-01-All-Power Train Electronic

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Renr9004-07-01-All-Power Train Electronic

Uploaded by

Copyright:

Available Formats

RENR9004-07

Important Safety Information

The meaning of this safety alert symbol is as follows:

When replacement parts are required for this

Failure to heed this warning can lead to prema-

Table of Contents MID 027 - CID 0262 - FMI 04

Systems Operation Section

The M Series Motor Graders are equipped with a

In addition to controlling the transmission, the

• The engine starting system that is based on Illustration 3

• The Cat ET service tool through the service tool

The Transmission/Chassis ECM will activate outputs

Air Conditioning System

The transmission/chassis ECM does not monitor the

Backup Alarm Operation

Once the ECM has received the signal to activate

Parasitic Load Reduction

• 12M 4. Depress the inching pedal.

• 120M The gears 1F and 1R will be displayed on the

Parking Brake Test Parking Brake Emergency Drive

1. With the transmission in the NEUTRAL position

2. Move the parking brake switch to the

3. Depress the inching pedal. The gears 1F and 1R

4. Do not upshift or downshift. The active gear must

5. Select a direction and release the inching pedal.

6. Depress the throttle pedal in order to “drive

Result: Releasing the inching pedal while depressing

Secondary Steer System

The implement ECM monitors the steering system

When the implement ECM detects a problem in the

The implement ECM will send a request signal to the

• An active CID 2202 FMI 12 (Steering Valve Control

Secondary Steer Solenoids located in front of the cab behind the

• Steering motion is not detected when a primary

• Steering motion is detected in the wrong direction.

The transmission/chassis ECM will activate the

• An active CID 2199 (Secondary Steering Request

To begin the test, the operator holds the momentary

When the implement ECM detects that the switch

First, the implement ECM disables the primary

While the transmission/chassis ECM energizes

If the implement ECM does not detect that the

The following two modes are available for operation

• The standard mode of operation is the manual

• The attachment autoshift mode.

On an ECPC controlled transmission, the clutch

• Engine torque data from the Engine ECM

When the speed of the transmission output shaft

The ECM uses the TOS and direction data in order

During normal operation of the transmission, the

If the ECM detects that the two output speed sensor

If the ECM determines that the signals of the two

Operation of Transmission Shifting

Note: During machine operation, the selected gear

Operation of Manual Mode

Initial Gear Upshifts or downshifts can be requested while the

Maximum Gear • When (TOS) is greater than 150 rpm: When

• The FNR switch is in the NEUTRAL position. Overspeed Upshift

The ECM will deactivate the priming of the clutch

• The parking brake is disengaged.

Engine Controlled Downshift The autoshift function is an attachment function that

Autoshift Operation Selectable Range Of Autoshift Gears

The following logic is used by the ECM for operation i02912116