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

Illustration 1	g02073053
Schematic of the right reverse clutch solenoid

This diagnostic code is associated with the right reverse clutch solenoid (all wheel drive). The FMI 03 means that the ECM has determined that the voltage in the circuit of the right reverse clutch solenoid is above normal.

The possible causes of the diagnostic code are listed:

• The energize circuit of the solenoid is shorted to the +Battery circuit.

• The ECM has failed. This is unlikely.

Note: The following test procedure may create other diagnostic codes. Ignore these created diagnostic codes and clear these diagnostic codes when the original diagnostic code has been corrected. Ensure that the diagnostic code of CID 2191 FMI 03 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 of CID 2191 FMI 03 will be logged in the internal memory of the All Wheel Drive (AWD) ECM.

The AWD feature will be disabled.

Test Step 1. CHECK THE ENERGIZE CIRCUIT OF THE SOLENOID FOR A SHORT

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

2. Disconnect the machine harness connector from the solenoid. Disconnect the machine harness connectors J1 and J2 from the AWD ECM.

3. At the ECM connector J1 of the machine harness, measure the resistance from contact J2-6 (wire A433-YL) to all J1 and J2 contacts that are used on the AWD ECM.

Expected Result:

Each resistance measurement is greater than 5000 ohms.

Results:

• OK - Each resistance measurement is greater than 5000 ohms. The machine harness is correct. Proceed to Test Step 2.

• NOT OK - Each resistance measurement is not greater than 5000 ohms. There is a short in the machine harness. The short is between wire A433-YL and the circuit that has a low resistance measurement.

  Repair: Repair the machine harness or replace the machine harness.

  STOP

Test Step 2. CHECK THE OPERATION OF THE ECM

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

1. At the ECM connector J2 of the machine harness, use a 151-6320 Removal Tool to remove the wire A433-YL and the socket at contact J2-6 from the harness connector.

2. Reconnect the machine harness J1 and J2 connectors to the ECM.

3. Turn the disconnect switch and turn the key start switch to the ON position.

4. Observe the status of the active CID 2191 FMI 03 diagnostic code.

Expected Result:

The CID 2191 FMI 03 diagnostic code is no longer active. A CID 2191 FMI 05 diagnostic code is now active.

Results:

• YES - The CID 2191 FMI 03 diagnostic code is no longer active. A CID 2191 FMI 05 diagnostic code was activated after the energize circuit of the solenoid was disconnected. The ECM has responded correctly to the open circuit condition in the solenoid circuit.
  
  Reinstall the Solenoid Energize wire back into the correct space in the ECM connector.
  
  Proceed to Test Step 3.

• NO - The CID 2191 FMI 03 diagnostic code remains active. The status of the active diagnostic code did not change when the Solenoid Energize wire was disconnected from the ECM.

  Repair: The ECM has not responded correctly to the open 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 3. CHECK THE STATUS OF THE DIAGNOSTIC CODE

1. Inspect the harness connectors.

   1. Clean the contacts of the harness connectors.

   2. Visually inspect 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. Verify the following:
   • The connectors are fully seated.

   • The clips for each connector are completely fastened.

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

5. Operate the machine.

6. Determine if the CID 2191 FMI 03 diagnostic code is active.

Expected Result:

The CID 2191 FMI 03 diagnostic code is active.

Results:

• YES - The CID 2191 FMI 03 diagnostic code is active.

  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 shorts and the Wiggle Test can detect intermittent opens in the machine wiring harness.If the problem remains, the ECM may have failed. However, it is unlikely that the ECM has failed. The ECM detected the open circuit condition in the solenoid circuit and the ECM activated the FMI 05 diagnostic code when the solenoid wire was disconnected.Verify that all possible causes of the diagnostic code have been investigated. Exit this procedure and perform this procedure again.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 and the ECM must be replaced, refer to Testing and Adjusting, "Electronic Control Module (ECM) - Replace".

  STOP

• NO - The CID 2191 FMI 03 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