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| Illustration 1 | g02560223 |
Schematic of the position sensor (Elevator control) | |
This diagnostic code is associated with the Position Sensor (Elevator Control). The FMI 03 means that the ECM has determined that the voltage of the circuit for the sensor is above normal. Refer to Systems Operation, "Electrical Input Components" for information regarding the operation of the sensor and the location.
The output frequency of the position sensor is approximately 500 Hz. The duty cycle of the signal changes as the position sensor moves.
Elevator Forward - 5 percent to 35 percent duty cycle
Elevator Neutral - 40 percent to 60 percent duty cycle
Elevator Reverse - 65 percent to 95 percent duty cycle
The possible causes of this diagnostic code are listed below:
- The signal circuit for the sensor is open.
- The signal circuit for the sensor is shorted to the +battery circuit.
- The sensor has failed.
- The power circuit or the ground circuit has failed.
- The ECM has failed. The failure of the ECM is unlikely.
Note: The following test procedure may create other diagnostic codes. Ignore these created diagnostic codes and clear the diagnostic codes when the original diagnostic code has been corrected. Ensure that the diagnostic code of CID 0575 FMI 03 is active before performing this procedure.
Note: Use the 146-4080 Digital Multimeter for the measurements in this procedure.
System Response:
When this diagnostic code occurs, a warning (Category 1) is shown on the monitor. The diagnostic code will cause all commands for the elevator to be disabled.
Note: When this diagnostic code goes away, the operator must move the lever for the elevator to the neutral position for 2 seconds before commands will be allowed.
Test Step 1. CHECK FOR POWER AT THE SENSOR
- Do not disconnect the harness connector from the sensor.
- Turn the key start switch and the disconnect switch to the ON position.
- At the back of the harness connector for the sensor, insert a 7X-1710 Multimeter Probe along the voltage supply wire (contact 1).
- Measure the voltage from contact 1 to frame ground.
Expected Result:
The voltage is 8 VDC.
Results:
- OK - The voltage is 8 VDC. Proceed to Test Step 2.
- NOT OK - The voltage is not 8 VDC. The + battery circuit in the machine harness has failed.
Repair: Replace the machine harness or repair the machine harness.
STOP
Test Step 2. CHECK FOR PROPER GROUND AT THE SENSOR
- The machine harness remains connected to the sensor.
- Turn the key start switch and the disconnect switch to the OFF position.
- Remove the 7X-1710 Multimeter Probe from the voltage supply wire (contact 1).
- At the back of the harness connector for the sensor, insert a 7X-1710 Multimeter Probe along the ground wire (contact 2).
- Measure the resistance from contact 2 to frame ground.
Expected Result:
The resistance is less than 5 ohms.
Results:
- OK - The resistance is less than 5 ohms. The ground circuit is correct. Proceed to Test Step 3.
- NOT OK - The resistance is greater than 5 ohms. The ground circuit in the machine harness has failed.
Repair: Replace the machine harness or repair the machine harness.
STOP
Test Step 3. CHECK THE WIRING HARNESS OF THE SENSOR FOR AN OPEN CIRCUIT
- The key start switch and the disconnect switch remain in the OFF position.
- Disconnect the machine harness from the sensor.
- At the harness connector for the sensor, connect a jumper wire between contact 2 and contact 3.
- Disconnect the machine harness connector(s) from the ECM.
- At the harness connector for the ECM, measure the resistance between contact J2-26 (wire R749-BU) and contact J1-45 (wire P770-WH).
Expected Result:
The resistance measurement is less than 5 ohms.
Results:
- OK - The resistance measurement is less than 5 ohms. The circuit is correct. Proceed to Test Step 4.
- NOT OK - The resistance is greater than 5 ohms. The circuit is not correct. There is an open circuit in the wiring harness.
Repair: There is an open circuit in the wiring harness. Repair the wiring harness or replace the wiring harness.
STOP
Test Step 4. CHECK THE WIRING HARNESS OF THE SENSOR FOR A SHORT TO THE +BATTERY CIRCUIT
- The key start switch and the disconnect switch remain in the OFF position.
- The machine harness remains disconnected from the sensor. Remove the jumper wire that was installed in the previous step.
- The machine harness connector(s) remains disconnected from the ECM.
- At the machine harness connector for the ECM, measure the resistance from the signal contact J2-26 (wire R749-BU) of the machine harness to all contacts that are used in the machine harness connectors for the 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 5.
- NOT OK - One measurement or more resistance measurement is not correct. There is a short in the machine harness.
Repair: The short is between signal contact J2-26 (wire R749-BU) and the circuit with the low resistance measurement. Repair the machine harness or replace the machine harness.
STOP
Test Step 5. CHECK THE OUTPUT OF THE SENSOR
- Reconnect the machine harness connectors to the ECM. Reconnect the machine harness connector to the sensor.
- At the back of the harness connector for the sensor, insert a 7X-1710 Multimeter Probe along the signal wire (contact 3).
- At the back of the harness connector for the sensor, insert a 7X-1710 Multimeter Probe along the ground wire (contact 2).
- Turn the disconnect switch and the key start switch to the ON position.
- Measure the signal of the sensor. The proper signal is described at the beginning of this procedure.
Expected Result:
The signal from the sensor is valid.
Results:
- OK - The signal from the sensor is valid. Proceed to Test Step 6.
- NOT OK - The signal from the sensor is not valid.
Repair: The sensor has failed. Replace the sensor.
STOP
Test Step 6. CHECK IF THE DIAGNOSTIC CODE REMAINS
- Inspect the contacts of the harness connectors and clean the connectors.
- Reconnect all harness connectors.
- Turn the disconnect switch and the key start switch to the ON position.
- Operate the machine.
- Check the status of the CID 0575 FMI 03.
Expected Result:
The CID 0575 FMI 03 is active.
Results:
- YES - The CID 0575 FMI 03 is active. The diagnostic code has not been corrected. The ECM may have failed.
Repair: It is unlikely that the ECM has failed. Exit this procedure and perform this procedure again. If the cause of the diagnostic code is not found, the ECM may have failed. 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 requires replacement, See Testing and Adjusting, "Electronic Control Module (ECM) - Replace" section of this manual for additional information.
STOP
- NO - The CID 0575 FMI 03 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 or a short at one of the harness connectors that was disconnected and reconnected. Resume normal machine operation.
STOP