120M Series 2, 12M Series 2, 140M Series 2 and 160M Series 2 Motor Graders All Wheel Drive Electronic Control System Caterpillar

Illustration 1	g02072973
Schematic of the right forward clutch solenoid

This diagnostic code is associated with the right forward clutch solenoid (all wheel drive). The FMI 05 means that the ECM has determined that the current of the right forward clutch solenoid is below normal.

The possible causes of this diagnostic code are listed below:

• The energize circuit of the solenoid is open.

• The return circuit of the solenoid is open.

• The solenoid has failed.

• The ECM has failed. This is unlikely.

Note: The following test procedure may create other diagnostic codes. Ignore these created diagnostic codes and clear these diagnostic codes when the original diagnostic code has been corrected. Ensure that the diagnostic code of CID 2190 FMI 05 is active before performing this procedure.

Note: The resistance of the solenoid coil should be 8.7 ± .4 ohms at 25 °C (77.0 °F).

System Response:

The diagnostic code CID 2190 FMI 05 will be logged in the internal memory of the AWD ECM.

The AWD feature will be disabled.

Test Step 1. CHECK THE SOLENOID

1. Disconnect the solenoid from the machine harness.

2. At the machine harness connector for the solenoid, place a jumper wire from contact 1 (wire L955-OR) to contact 2 (wire A753-PU).

3. Turn the disconnect switch and the key start switch to the ON position. Do not start the engine.

4. Observe the status of the CID 2190 FMI 05 diagnostic code.

Expected Result:

The active diagnostic code changes from FMI 05 to FMI 06 when the jumper wire is installed.

Results:

• YES - The active diagnostic code changes from FMI 05 to FMI 06 when the jumper wire is installed. The solenoid has failed.

  Repair: The solenoid has failed. Repeat this Test Step "CHECK THE SOLENOID" in order to verify the solenoid failure. Replace the solenoid. Verify that the new solenoid corrects the problem.

  STOP

• NO - The CID 2190 FMI 05 diagnostic code remains active. The jumper wire does not affect the status of the diagnostic code. The solenoid is not causing the problem. Proceed to Test Step 2.

Test Step 2. CHECK THE CIRCUIT FOR AN OPEN

1. Turn the key start switch and the disconnect switch to the OFF position.

2. Disconnect the machine harness connector J2 from the AWD Controller.

3. The jumper wire that was installed in the previous Test Step remains in place.

4. At the AWD ECM connector J2 of the machine harness, measure the resistance from the contact J2-4 (wire A753-PU) to contact J2-5 (wire L955-OR).

Expected Result:

The resistance measurement is less than 5 ohms.

Results:

• OK - The resistance is less than 5 ohms. The circuit is not open in the machine harness. Proceed to Test Step 3.

• NOT OK - The resistance measurement is greater than 5000 ohms. The resistance measurement is not correct. There is an open or a bad connection in the machine harness. A resistance measurement that is much greater than 5 ohms but less than 5000 ohms could indicate that one of the connection points in the circuit is not a good connection.

  Repair: The poor connection is in wire L955-OR or in wire A753-PU of the machine harness. Refer to the Electrical System Schematic. Check all of the connectors that are in the solenoid circuit. Ensure that all connections are clean. Ensure that all connections are secure. Ensure that all connections are in good condition. Repair the machine harness or replace the machine harness.

  STOP

Test Step 3. CHECK THE OPERATION OF THE ECM

The disconnect switch and the key start switch remain in the OFF position. The machine harness connector for the solenoid and the ECM J2 connector remain disconnected.

1. Remove the jumper wire that was installed in the last test step.

2. At the machine harness connector J2 of the ECM, use a 151-6320 Removal Tool to remove the solenoid wire L955-OR and the socket at contact J2-5 from the harness connector.

3. Reconnect the machine harness J2 connector to the ECM.

4. Turn the disconnect switch and the key start switch to the ON position.

5. Use a 7X-1710 Multimeter Probe that is not connected to a multimeter or a similar device to make contact with the ECM pin at J2-5 through the empty space in the J1 connector.

6. Observe the status of the active CID 2190 FMI 05 diagnostic code. Ground the other end of the 7X-1710 Multimeter Probe to frame ground.

Expected Result:

The CID 2190 FMI 05 diagnostic code is no longer active. A CID 2190 FMI 06 diagnostic code becomes active when the ECM pin at J2-5 is grounded.

Results:

• YES - The CID 2190 FMI 05 diagnostic code is no longer active. A CID 2190 FMI 06 diagnostic code has been activated after the ECM pin is grounded. The ECM has responded correctly to the grounded circuit condition in the solenoid circuit. The ECM is not likely to cause the problem.
  
  Reinstall the solenoid wire back into the correct spot in the ECM connector before proceeding to the next test step.
  
  Proceed to Test Step 4.

• NO - The CID 2190 FMI 05 diagnostic code remains active. The status of the active diagnostic code does not change when the ECM pin for the solenoid is grounded.

  Repair: The ECM has not responded correctly to the grounded condition in the solenoid circuit. The operation of the ECM is not correct.Prior to replacing an ECM, always contact your dealership's Technical Communicator for possible consultation with Caterpillar. This consultation may greatly reduce repair time. If the ECM must be replaced, refer to the Testing and Adjusting, "Electronic Control Module (ECM) - Replace" Story in this manual.

  STOP

Test Step 4. CHECK THE STATUS OF THE DIAGNOSTIC CODE

1. Inspect the harness connectors. Clean the contacts of the harness connectors. Check the wires for damage to the insulation that is caused by excessive heat, battery acid, or chafing.

2. Perform a 45 N (10 lb) pull test on each of the wires that are associated with the sensor circuit.

3. Reconnect all harness connectors. Make sure that the connectors are fully seated. Make sure that the clips for each connector are completely fastened.

4. Turn the disconnect switch and the key start switch to the ON position.

5. Operate the machine.

6. Check the status of the CID 2190 FMI 05 diagnostic code.

Expected Result:

The CID 2190 FMI 05 diagnostic code is active.

Results:

• YES - The CID 2190 FMI 05 diagnostic code is active. The diagnostic code has not been corrected. The ECM may have failed.

  Repair: Check the circuit again. Use the Caterpillar Electronic Technician (ET) service tool in order to perform a Wiggle Test on the machine wiring harness. The wiggle test can detect intermittent opens in the machine wiring harness.If the cause of the problem is not found, the ECM may have failed.It is unlikely that the ECM has failed. The ECM responded correctly to the grounded condition in the last test step.Verify that all possible causes of the diagnostic code have been investigated. If the cause of the failure is not found, replace the ECM. Prior to replacing an ECM, always contact your dealership's Technical Communicator for possible consultation with Caterpillar. This consultation may greatly reduce repair time. If the cause of the diagnostic code is not found, replace the AWD Controller. Refer to Testing and Adjusting, "Electronic Control Module (ECM) - Replace".

  STOP

• NO - The CID 2190 FMI 05 diagnostic code is not active. The diagnostic code does not exist at this time.

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

  STOP