785G Off-Highway Truck/Tractor Electrical and Hydraulic Systems Caterpillar


Solenoid Valve - Test

Usage:

785G RTL

Brake ECM

The following is a list of Diagnostic Trouble Codes (DTCs) associated with the solenoids of the machine.

Table 1
Brake ECM (MID 116) 
DTC  Code Description  System Response 
681-3  Parking Brake Solenoid : Voltage above normal  The park brake will not disengage. 
681-5  Parking Brake Solenoid : Current below normal  The park brake will not disengage. 
681-6  Parking Brake Solenoid : Current above normal  The park brake will not disengage. 
1232-3  Final Drive Oil Bypass Solenoid : Voltage above normal   
1232-5  Final Drive Oil Bypass Solenoid : Current below normal   
1232-6  Final Drive Oil Bypass Solenoid : Current above normal   
1437-3  Rear Axle Pump Drive Oil Divert Solenoid : Voltage above normal  Final Drive Oil Diverter will not work correctly. 
1437-5  Rear Axle Pump Drive Oil Divert Solenoid : Current below normal  Final Drive Oil Diverter will not work correctly. 
1437-6  Rear Axle Pump Drive Oil Divert Solenoid : Current above normal  Final Drive Oil Diverter will not work correctly. 
3971-3  Left Front Brake Solenoid : Voltage above normal  The traction control system is disabled. The diagnostic code is logged in to memory. 
3971-5  Left Front Brake Solenoid : Current below normal  The traction control system is disabled. The diagnostic code is logged in to memory. 
3971-6  Left Front Brake Solenoid : Current above normal  The traction control system is disabled. The diagnostic code is logged in to memory. 
3972-3  Left Rear Brake Solenoid : Voltage above normal  The traction control system is disabled. The diagnostic code is logged in to memory. 
3972-5  Left Rear Brake Solenoid : Current below normal  The traction control system is disabled. The diagnostic code is logged in to memory. 
3972-6  Left Rear Brake Solenoid : Current above normal  The traction control system is disabled. The diagnostic code is logged in to memory. 
3973-3  Right Front Brake Solenoid : Voltage above normal  The traction control system is disabled. The diagnostic code is logged in to memory. 
3973-5  Right Front Brake Solenoid : Current below normal  The traction control system is disabled. The diagnostic code is logged in to memory. 
3973-6  Right Front Brake Solenoid : Current above normal  The traction control system is disabled. The diagnostic code is logged in to memory. 
3974-3  Right Rear Brake Solenoid : Voltage above normal  The traction control system is disabled. The diagnostic code is logged in to memory. 
3974-5  Right Rear Brake Solenoid : Current below normal  The traction control system is disabled. The diagnostic code is logged in to memory. 
3974-6  Right Rear Brake Solenoid : Current above normal  The traction control system is disabled. The diagnostic code is logged in to memory. 
4009-3  Air Conditioner #1 Compressor Motor Bypass Solenoid : Voltage above normal   
4009-5  Air Conditioner #1 Compressor Motor Bypass Solenoid : Current below normal   
4009-6  Air Conditioner #1 Compressor Motor Bypass Solenoid : Current above normal   

Possible causes for an FMI 3 Diagnostic code are:

  • The circuit of the solenoid is shorted to another voltage source circuit.

  • The ECM has failed. A failure of the ECM is unlikely.

Possible causes for an FMI 5 Diagnostic code are:

  • There is an open in the circuit.

  • The solenoid has failed.

  • The ECM has failed. A failure of the ECM is unlikely.

Possible causes for an FMI 6 Diagnostic code are:

  • A wire is shorted to ground.

  • The solenoid has failed.

  • The ECM has failed. A failure of the ECM is unlikely.


Illustration 1g06017865
Schematic of the solenoids

The preceding diagram is a simplified schematic of the Brake ECM and the Solenoid connections. The schematic is electrically correct. However, not all the possible harness connectors are shown. Refer to the latest revision of Electrical Schematic, UENR4664 for the complete schematic.

Chassis ECM

The following is a list of Diagnostic Trouble Codes (DTCs) associated with the solenoids of the machine.

Table 2
Chassis ECM (MID 87) 
DTC  Code Description  System Response 
724-3  Hoist Raise Solenoid : Voltage above normal  Hoist System will not function as desired. 
724-5  Hoist Raise Solenoid : Current below normal  Hoist System will not function as desired. 
724-6  Hoist Raise Solenoid : Current above normal  Hoist System will not function as desired. 
725-3  Hoist Lower Solenoid : Voltage above normal  Hoist System will not function as desired. 
725-5  Hoist Lower Solenoid : Current below normal  Hoist System will not function as desired. 
725-6  Hoist Lower Solenoid : Current above normal  Hoist System will not function as desired. 
1493-3  Steering Accumulator Charging Solenoid : Voltage above normal  The machine will be slow to respond to steering requests in either direction. 
1493-5  Steering Accumulator Charging Solenoid : Current below normal  The machine will be slow to respond to steering requests in either direction. 
1493-6  Steering Accumulator Charging Solenoid : Current above normal  The machine will be slow to respond to steering requests in either direction. 
2249-3  Steering Accumulator Purge Solenoid : Voltage above normal  The solenoid is required to activate the Steering Accumulator purge relay. 
2249-5  Steering Accumulator purge Solenoid : Current below normal  The solenoid is required to activate the Steering Accumulator purge relay. 
2249-6  Steering Accumulator Purge Solenoid : Current above normal  The solenoid is required to activate the Steering Accumulator purge relay. 
4324-3  Front Brake Accumulator Purge Solenoid : Voltage above normal  The solenoid is required to activate the Front Brake Accumulator purge relay. 
4324-5  Front Brake Accumulator Purge Solenoid : Current below normal  The solenoid is required to activate the Front Brake Accumulator purge relay. 
4324-6  Front Brake Accumulator Purge Solenoid : Current above normal  The solenoid is required to activate the Front Brake Accumulator purge relay. 
4325-3  Rear Brake Accumulator Purge Solenoid : Voltage above normal  The solenoid is required to activate the Rear Brake Accumulator purge relay. 
4325-5  Rear Brake Accumulator Purge Solenoid : Current below normal  The solenoid is required to activate the Rear Brake Accumulator purge relay. 
4325-6  Rear Brake Accumulator Purge Solenoid : Current above normal  The solenoid is required to activate the Rear Brake Accumulator purge relay. 

Possible causes for an FMI 3 Diagnostic code are:

  • The circuit of the solenoid is shorted to another voltage source circuit.

  • The ECM has failed. A failure of the ECM is unlikely.

Possible causes for an FMI 5 Diagnostic code are:

  • There is an open in the circuit.

  • The solenoid has failed.

  • The ECM has failed. A failure of the ECM is unlikely.

Possible causes for an FMI 6 Diagnostic code are:

  • A wire is shorted to ground.

  • The solenoid has failed.

  • The ECM has failed. A failure of the ECM is unlikely.


Illustration 2g03676148
Schematic of the Solenoid Sensors

The preceding diagram is a simplified schematic of the Chassis ECM and the Solenoid connections. The schematic is electrically correct. However, not all the possible harness connectors are shown. Refer to Electrical Schematic, UENR4664, "785G Off-Highway Truck Electrical System" for the complete schematic.

Transmission ECM

The following is a list of Diagnostic Trouble Codes (DTCs) associated with the solenoids of the machine.

Table 3
Transmission ECM (MID 81) 
DTC  Code Description  System Response 
709-3  Transmission Lockup Clutch Solenoid : Voltage above normal  The solenoid is used to engage the Transmission Lockup Clutch. A failure of the solenoid results in clutch slippage or lack of availability of some shift positions. 
709-5  Transmission Lockup Clutch Solenoid : Current below normal  The solenoid is used to engage the Transmission Lockup Clutch. A failure of the solenoid results in clutch slippage or lack of availability of some shift positions. 
709-6  Transmission Lockup Clutch Solenoid : Current above normal  The solenoid is used to engage the Transmission Lockup Clutch. A failure of the solenoid results in clutch slippage or lack of availability of some shift positions. 
709-11  Transmission Lockup Clutch Solenoid : Other failure mode  The solenoid is used to engage the Transmission Lockup Clutch. A failure of the solenoid results in clutch slippage or lack of availability of some shift positions. 
1401-3  Transmission Solenoid 1 : Voltage above normal  The transmission clutch is engaged and cannot be released. The transmission will lock out specific gear shift positions due to this fault. Reference the table of clutch assignments for specific information.(1) 
1401-5  Transmission Solenoid 1 : Current below normal  The transmission clutch is engaged and cannot be released. The transmission will lock out specific gear shift positions due to this fault. Reference the table of clutch assignments for specific information. (1) 
1401-6  Transmission Solenoid 1 : Current above normal  The transmission clutch is engaged and cannot be released. The transmission will lock out specific gear shift positions due to this fault. Reference the table of clutch assignments for specific information. (1) 
1401-11  Transmission Solenoid 1 : Other failure mode  The transmission clutch is engaged and cannot be released. The transmission will lock out specific gear shift positions due to this fault. Reference the table of clutch assignments for specific information. (1) 
1402-3  Transmission Solenoid 2 : Voltage above normal  The transmission clutch is engaged and cannot be released. The transmission will lock out specific gear shift positions due to this fault. Reference the table of clutch assignments for specific information. (1) 
1402-5  Transmission Solenoid 2 : Current below normal  The transmission clutch is engaged and cannot be released. The transmission will lock out specific gear shift positions due to this fault. Reference the table of clutch assignments for specific information. (1) 
1402-6  Transmission Solenoid 2 : Current above normal  The transmission clutch is engaged and cannot be released. The transmission will lock out specific gear shift positions due to this fault. Reference the table of clutch assignments for specific information. (1) 
1402-11  Transmission Solenoid 2 : Other failure mode  The transmission clutch is engaged and cannot be released. The transmission will lock out specific gear shift positions due to this fault. Reference the table of clutch assignments for specific information. (1) 
1403-3  Transmission Solenoid 3 : Voltage above normal  The transmission clutch is engaged and cannot be released. The transmission will lock out specific gear shift positions due to this fault. Reference the table of clutch assignments for specific information. (1) 
1403-5  Transmission Solenoid 3 : Current below normal  The transmission clutch is engaged and cannot be released. The transmission will lock out specific gear shift positions due to this fault. Reference the table of clutch assignments for specific information. (1) 
1403-6  Transmission Solenoid 3 : Current above normal  The transmission clutch is engaged and cannot be released. The transmission will lock out specific gear shift positions due to this fault. Reference the table of clutch assignments for specific information.(1) 
1403-11  Transmission Solenoid 3 : Other failure mode  The transmission clutch is engaged and cannot be released. The transmission will lock out specific gear shift positions due to this fault. Reference the table of clutch assignments for specific information.(1) 
1404-3  Transmission Solenoid 4 : Voltage above normal  The transmission clutch is engaged and cannot be released. The transmission will lock out specific gear shift positions due to this fault. Reference the table of clutch assignments for specific information.(1) 
1404-5  Transmission Solenoid 4 : Current below normal  The transmission clutch is engaged and cannot be released. The transmission will lock out specific gear shift positions due to this fault. Reference the table of clutch assignments for specific information.(1) 
1404-6  Transmission Solenoid 4 : Current above normal  The transmission clutch is engaged and cannot be released. The transmission will lock out specific gear shift positions due to this fault. Reference the table of clutch assignments for specific information.(1) 
1404-11  Transmission Solenoid 4 : Other failure mode  The transmission clutch is engaged and cannot be released. The transmission will lock out specific gear shift positions due to this fault. Reference the table of clutch assignments for specific information.(1) 
1405-3  Transmission Solenoid 5 : Voltage above normal  The transmission clutch is engaged and cannot be released. The transmission will lock out specific gear shift positions due to this fault. 
1405-5  Transmission Solenoid 5 : Current below normal  The transmission clutch is engaged and cannot be released. The transmission will lock out specific gear shift positions due to this fault. Reference the table of clutch assignments for specific information.(1) 
1405-6  Transmission Solenoid 5 : Current above normal  The transmission clutch is engaged and cannot be released. The transmission will lock out specific gear shift positions due to this fault. Reference the table of clutch assignments for specific information.(1) 
1405-11  Transmission Solenoid 5 : Other failure mode  The transmission clutch is engaged and cannot be released. The transmission will lock out specific gear shift positions due to this fault. Reference the table of clutch assignments for specific information.(1) 
1406-3  Transmission Solenoid 6 : Voltage above normal  The transmission clutch is engaged and cannot be released. The transmission will lock out specific gear shift positions due to this fault. Reference the table of clutch assignments for specific information.(1) 
1406-5  Transmission Solenoid 6 : Current below normal  The transmission clutch is engaged and cannot be released. The transmission will lock out specific gear shift positions due to this fault. Reference the table of clutch assignments for specific information.(1) 
1406-6  Transmission Solenoid 6 : Current above normal  The transmission clutch is engaged and cannot be released. The transmission will lock out specific gear shift positions due to this fault. Reference the table of clutch assignments for specific information.(1) 
1406-11  Transmission Solenoid 6 : Other failure mode  The transmission clutch is engaged and cannot be released. The transmission will lock out specific gear shift positions due to this fault. Reference the table of clutch assignments for specific information.(1) 
(1) Reference the table "Transmission Clutch Assignments and Start-Up Speed Checks" for specific information on clutch/solenoid engagement.

Possible causes for an FMI 3 Diagnostic code are:

  • The circuit of the solenoid is shorted to another voltage source circuit.

  • The ECM has failed. A failure of the ECM is unlikely.

Possible causes for an FMI 5 Diagnostic code are:

  • There is an open in the circuit.

  • The solenoid has failed.

  • The ECM has failed. A failure of the ECM is unlikely.

Possible causes for an FMI 6 Diagnostic code are:

  • A wire is shorted to ground.

  • The solenoid has failed.

  • The ECM has failed. A failure of the ECM is unlikely.

Possible causes for an FMI 11 diagnostic code are:

  • Incorrect personality module code.

  • Invalid parameter configuration.

  • Incorrect ECM.

  • ECM is flashed with software that is incompatible with another ECM.

Table 4
Transmission Clutch Assignments and Start-Up Speed Checks 
GEAR  CLUTCHES  INPUT SPEED (RPM)  OUTPUT SPEED 0.824 ITG (RPM) 
     
              LOW  HIGH  LOW  HIGH 
NEUTRAL      X        690  710  200 
1 FORWARD  X        X    690  710  185  191 
2 FORWARD    X      X    690  710  250  257 
3 FORWARD  X      X      690  710  338  349 
4 FORWARD    X    X      690  710  457  471 
5 FORWARD  X    X        690  710  620  639 
6 FORWARD    X  X        690  710  8237  862 
REVERSE  X          X  690  710  (-172)  (-178) 


Illustration 3g03676152
Schematic of the solenoids

The preceding diagram is a simplified schematic of the Transmission ECM and the solenoid connections. The schematic is electrically correct. However, not all the possible harness connectors are shown. Refer to Electrical Schematic, UENR4664, "785G Off-Highway Truck Electrical System" for the complete schematic.

Diagnostic Trouble Code Procedure

Prior to beginning this procedure, inspect the harness connectors involved in this circuit. Poor connections can often be the cause of a problem in an electrical circuit. Verify that all connections in the circuit are clean, secure, and in good condition. Check the wiring harness for pinch points or abrasions. Look for and repair areas that indicate wires are exposed. If a problem with a connection is found, correct the problem. Verify that the diagnostic code is active before performing a troubleshooting procedure.

  1. Identify the active FMI code associated with the components.

  2. Determine which code is present and use the list below to determine which procedure to follow.

  • FMI 3 diagnostic code, proceed to Table 5.

  • FMI 5 diagnostic code, proceed to Table 6.

  • FMI 6 diagnostic code, proceed to Table 7.

  • FMI 11 diagnostic code, proceed to Table 8.

Table 5
FMI 3 Troubleshooting 
Troubleshooting Test Steps  Values  Results 
1. Check The Machine Harness For A Short

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

B. Disconnect the harness connection at the solenoid.

C. If the solenoid is connected to ECM, disconnect J1 and J2 connectors from ECM.

D. Measure the resistance of solenoid signal contact to all J1 and J2 connectors. 

Each reading is greater than 5K Ω. 
OK - All resistance readings are greater than 5K Ω .

Proceed to Test Step 2.

NOT OK - One or more readings are less than 5 Ω.

Repair - Repair or replace the machine harness.

Proceed to Test Step 2. 
2. Check If The Diagnostic Code Remains

A. Inspect the harness connectors and clean the contacts of the harness connectors.

B. Reconnect all harness connectors.

C. Turn the key switch and disconnect switch to the ON position.

D. Operate the machine.

E. Check if diagnostic code is active. 

Diagnostic code is no longer present. 
OK - Diagnostic code does not exist currently. Initial diagnostic code may have been caused by poor electrical connection or short at one of the harness connections.

Resume machine operation.

STOP

NOT OK - Diagnostic trouble code has not been corrected. If the diagnostic code has not been corrected after performing the procedure a second time, the ECM may require replacement.

Prior to replacing this component, always contact the Technical Communication at your dealership for possible consultation with Caterpillar. This consultation may greatly effect repair time.

Follow the steps in Troubleshooting, "Electronic Control Module (ECM) - Replace" if the ECM needs to be replaced.

STOP 

Table 6
FMI 5 Troubleshooting 
Troubleshooting Test Steps  Values  Results 
1. Check The Solenoid.

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

B. Disconnect the solenoid from the machine harness.

C. Place a jumper wire between contact 1 and contact 2, at the harness connector for the solenoid.

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

E. As the jumper is removed and connected to the contacts, observe any code change. 

The code changes to FMI 6 after the jumper wire is installed. 
OK - The circuit is correct, the solenoid has failed.

Repair: Replace the solenoid.

Proceed to Test Step 3.

NOT OK - The diagnostic code remains active.

Proceed to Test Step 2. 
2. Check The Machine Harness For An Open.

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

B. Disconnect the harness connectors from the ECM.

C. The jumper wire remains installed.

D. At the machine harness connector for the ECM, measure the resistance at the ECM contacts for the solenoid. 

Each reading is less than 5 Ω. 
OK - The reading is less than 5 Ω, the harness is correct.

Proceed to Test Step 3.

NOT OK - The reading is greater than 5K Ω. The circuit is open in the machine harness.

Repair : Repair or replace the machine harness.

Proceed to Test Step 3. 
3. Check If The Diagnostic Code Remains

A. Inspect the harness connectors and clean the contacts of the harness connectors.

B. Reconnect all harness connectors.

C. Turn the key switch and disconnect switch to the ON position.

D. Operate the machine.

E. Check if diagnostic code is active. 

Diagnostic code is no longer present. 
OK - Diagnostic code does not exist currently. Initial diagnostic code may have been caused by poor electrical connection or short at one of the harness connections.

Resume machine operation.

STOP

NOT OK - Diagnostic trouble code has not been corrected. If the diagnostic code has not been corrected after performing the procedure a second time, the ECM may require replacement.

Prior to replacing this component, always contact the Technical Communicator at your dealership for possible consultation with Caterpillar. This consultation may greatly effect repair time.

Follow the steps in Troubleshooting, "Electronic Control Module (ECM) - Replace" if the ECM needs to be replaced.

STOP 

Table 7
FMI 6 Troubleshooting 
Troubleshooting Test Steps  Values  Results 
1. Check The Solenoid

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

B. Disconnect the solenoid from the machine harness.

C. Place a jumper wire between contact 1 and contact 2, at the harness connector.

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

E. As the jumper is removed and connected to the contacts, observe any code change. 

The FMI 6 diagnostic code changes to an FMI 5 diagnostic code after the jumper wire is installed. 
OK - The circuit is correct. The solenoid has failed.

Repair: Replace the solenoid.

Proceed to Test Step 3.

NOT OK - The diagnostic code remains active.

Proceed to Test Step 2. 
2. Check Machine Harness For A Short To Ground

A. The machine harness remains disconnected from the solenoid.

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

C. Disconnect the harness connectors from the ECM.

D. At the harness connector for ECM, measure the resistance between the solenoid signal contact and all ground contacts. 

Each reading is greater than 5K Ω. 
OK - Machine harness is correct.

Proceed to Test Step 3.

NOT OK - One or more of the resistance measurements are less than 5 Ω. A short circuit exists in the machine harness.

Repair: Repair or replace the machine harness.

Proceed to Test Step 3. 
3. Check If The Diagnostic Code Remains

A. Inspect the harness connectors and clean the contacts of the harness connectors.

B. Reconnect all harness connectors.

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

D. Operate the machine.

E. Check if diagnostic code is active. 

Diagnostic code is no longer present. 
OK - Diagnostic code does not exist currently. Initial diagnostic code may have been caused by poor electrical connection or short at one of the harness connections.

Resume machine operation.

STOP

NOT OK - Diagnostic trouble code has not been corrected. If the diagnostic code has not been corrected after performing the procedure a second time, the ECM may require replacement.

Prior to replacing this component, always contact the Technical Communicator at your dealership for possible consultation with Caterpillar. This consultation may greatly effect repair time.

Follow the steps in Troubleshooting, "Electronic Control Module (ECM) - Replace" if the ECM needs to be replaced.

STOP 

Table 8
FMI 11 Troubleshooting 
Troubleshooting Test Steps  Values  Results 
1. Check the ECM.

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

B. Wait for 30 seconds.

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

D. Allow the self-test to run before you proceed to the next step.

E. Check the message center for an active diagnostic code. 

The diagnostic code with FMI 11 is no longer present. 
OK - The diagnostic code with FMI 11 is no longer present.

Proceed to Test Step 2.

NOT OK - The diagnostic code is still active.

Repair: Check the circuit again. Use the Cat® ET service tool to test the machine wiring harness. Manipulate the wiring harness as the output is monitored on Cat ET. This test can detect intermittent short circuits and open connections in the machine wiring harness.

Proceed to Test Step 2. 
2. Check If The Diagnostic Code Remains

A. Inspect the harness connectors and clean the contacts of the harness connectors.

B. Reconnect all harness connectors.

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

D. Operate the machine.

E. Check if diagnostic code is active. 

Diagnostic code is no longer present. 
OK - Diagnostic code does not exist currently. Initial diagnostic code may have been caused by poor electrical connection or short at one of the harness connections.

Resume machine operation.

STOP

NOT OK - Diagnostic trouble code has not been corrected. If the diagnostic code has not been corrected after performing the procedure a second time, the ECM may require replacement.

Prior to replacing this component, always contact the Technical Communication at your dealership for possible consultation with Caterpillar. This consultation may greatly effect repair time.

Follow the steps in Troubleshooting, "Electronic Control Module (ECM) - Replace" if the ECM needs to be replaced.

STOP 

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