525C Wheel Skidder, 535C Wheel Skidder and 545C Wheel Skidder Machine Systems Caterpillar

Illustration 1	g01250753
Winch Spool Out Solenoid connections

This diagnostic code is associated with the winch spool out solenoid. The FMI 05 means that the ECM has determined that the current for the circuit is below normal. The ECM controls the solenoid energize circuit through the winch spool out relay. The ECM controls the return circuit of the solenoid through the winch solenoid return relay. The ECM activates this diagnostic code when the relays have been energized and the current in the solenoid circuit is below normal.

The possible causes of this diagnostic code are listed below:

• The energize circuit of the solenoid is open in the harness or the relay.

• The solenoid has failed.

• The ECM has failed. This is unlikely.

Note: The winch solenoid return relay provides a return circuit for the winch solenoids. If a CID 1884 (spool in solenoid) or a CID 2268 (free spool solenoid ) FMI 05 diagnostic code is active along with this diagnostic code, check the solenoid return circuit and the winch solenoid return relay for a problem. Ensure that the diagnostic code CID 1885 FMI 05 is active before performing this procedure.

Note: This procedure is to be performed when the CID 1885 FMI 05 diagnostic code is active AND the winch spool out function is not working. If the winch spool out function is working and the CID 1885 FMI 05 diagnostic code is active, there is a problem in the machine harness between the spool out relay and the ECM contact J1-14 (wire F868-OR).

Test Step 1. CHECK THE POWER SUPPLY FOR THE RELAY

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

2. Disconnect the winch spool out relay from the mounting base.

3. Check the voltage at the relay base from contact 5 (wire 164-WH) to frame ground.

Expected Result:

The voltage measurement is approximately 24 VDC.

Results:

• YES - The voltage measurement is approximately 24 VDC. The relay power supply is correct. Proceed to Test Step 2.

• NO - The voltage measurement is not approximately 24 VDC. There is a problem with the voltage supply for the relay.

  Repair: The voltage supply circuit (wire 164-WH) for the relay is open in the machine harness. Ensure that the transmission fuse is not open. Refer to the complete machine Electrical System Schematic. Examine all of the connections that are in the supply circuit between the fuse and the relay. Ensure that the connections are clean, secure and in good condition. Repair the machine harness or replace the machine harness.

  STOP

Test Step 2. CHECK THE MACHINE HARNESS FROM THE RELAYS TO THE SOLENOID

The winch spool out relay remains disconnected from the mounting base.

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

2. Disconnect the winch solenoid return relay from the mounting base.

3. Disconnect the spool out solenoid from the machine harness.

4. At the harness connector for the solenoid, place a jumper wire between contact 1 (wire F868-OR) and contact 2 (wire G726-GY).

5. Measure the resistance between the winch spool out relay harness connector contact 4 (wire F868-OR) and the winch solenoid return relay harness connector contact 4 (wire G726-GY).

Expected Result:

The resistance measurement is less than 5 ohms.

Results:

• OK - The resistance measurement is less than 5 ohms. The circuit is not open between the solenoid and the relays. Proceed to Test Step 3

• NOT OK - The resistance measurement is greater than 5 ohms. The circuit is open or the circuit has a bad connection between the solenoid and the relays.

  Repair: There is an open in the return circuit of the solenoid or the energize circuit of the solenoid. The open is between the relays and the solenoid. Refer to the complete machine Electrical System Schematic. Examine all of the connections that are in the solenoid circuit between the solenoid and the relays. Ensure that the connections are clean, secure and in good condition. Repair the machine harness or replace the machine harness.

  STOP

Test Step 3. CHECK THE MACHINE HARNESS FROM THE RELAY TO THE ECM

The disconnect switch and the key start switch remain in the OFF position. The winch spool in relay remains disconnected from the mounting base.

1. Remove the jumper wire from the harness connector for the solenoid.

2. At the mounting base for the winch spool out relay, place a jumper wire between contact 4 (wire F868-OR) and contact 2 (wire A862-GY).

3. Disconnect the machine harness connectors from the ECM. Measure the resistance between harness connector contact J1-14 (wire F868-OR) and harness connector contact J2-13 (wire A862-GY.)

Expected Result:

The resistance measurement is less than 5 ohms.

Results:

• OK - The resistance measurement is less than 5 ohms. The harness is not open between the ECM and the relay. Proceed to Test Step 4.

• NOT OK - The resistance measurement is greater than 5 ohms. The circuit open or the circuit has a bad connection between the ECM and the relay.

  Repair: There is an open in the energize circuit of the solenoid. The open is between the relay and the ECM. Refer to the complete machine Electrical System Schematic. Examine all of the connections that are in the solenoid circuit between the relay and the ECM. Ensure that the connections are clean, secure and in good condition. Repair the machine harness or replace the machine harness.

  STOP

Test Step 4. CHECK THE STATUS OF THE DIAGNOSTIC CODE

1. Inspect the harness connectors and clean the contacts of the harness connectors and 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 circuit.

3. Reconnect all harness connectors making sure that the connectors are fully seated and 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 1885 FMI 05.

Expected Result:

The CID 1885 FMI 05 is active.

Results:

• YES - The CID 1885 FMI 05 is active. The diagnostic code 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 a problem is not found in the machine harness, substitute the winch spool in relay in place of the winch spool out relay. If the problem is corrected, replace the winch spool out relay. If the problem is not corrected, replace the winch spool out solenoid.If the diagnostic code is still active after checking the relay and the solenoid, the ECM may be faulty.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 ECM. See Troubleshooting, "Electronic Control Module (ECM) - Replace".

  STOP

• NO - The CID 1885 FMI 05 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