992K Wheel Loader Electrohydraulic System Caterpillar

Illustration 1	g02576336
Connections of the Dump Solenoid 2

This diagnostic code is associated with the Dump Solenoid 2. The code FMI 03 means that the ECM has determined that the voltage is above normal.

The possible causes of the diagnostic code are listed below:

• The solenoid has failed.

• The solenoid energizer circuit of the modulating valve is shorted to the +battery circuit.

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

System Response:

• All implement functions will stop working.

Note: Before performing this procedure, inspect the harness connectors that are involved in the circuit. Poor connections can often be the cause of a problem in an electrical circuit. Verify that all of the connections in the circuit are clean and secure. If a problem with a connection is found, correct the problem and verify that this diagnostic code is active before performing this procedure.

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 0595 FMI 03 is active before performing this procedure.

Note: A digital multimeter is required for taking measurements in this procedure.

Test Step 1. CHECK THE SOLENOID CIRCUIT FOR A SHORT TO THE +BATTERY CIRCUIT.

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

2. Disconnect the machine harness from the solenoid and the ECM.

3. At the machine harness connector for the ECM, measure the resistance from contact J1-62 wire F744-BU(Blue)to all contacts that are used in the machine harness connectors for the ECM.

Expected Result:

Each resistance measurement should be 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 contact J1-62 wire F744-BU(Blue)and the circuit with the low resistance measurement. 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 J1 connector for the ECM, use a wire removal tool to remove wire F744-BU(Blue)from contact J1-62.

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

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

4. Observe the status of the active diagnostic code.

Expected Result:

The FMI 03 changes to an FMI 05 after the wire is disconnected.

Results:

• YES - The FMI 03 changes to FMI 05 after the wire is disconnected. The ECM has responded correctly to the condition of an open circuit. Reinstall the disconnected wire to the correct space in the ECM connector before proceeding to the next Test Step. Proceed to Test Step 3.

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

  Repair: The ECM has not responded correctly to the condition of an open circuit. The operation of the ECM is not correct. Prior to replacing an ECM, always contact your dealership for possible consultation with Caterpillar. This consultation may greatly reduce repair time. If the ECM requires replacing, refer to Testing and Adjusting, "Electronic Control Module (ECM) - Replace".

  STOP

Test Step 3. CHECK IF THE DIAGNOSTIC CODE IS STILL ACTIVE.

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, corrosion, 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 in order to make sure that the connectors are fully seated. Also, make sure that the clips for each connector are fastened.

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

5. Operate the machine.

6. Determine if the diagnostic code is active.

Expected Result:

The diagnostic code is active.

Results:

• YES - The diagnostic code is active. The problem has not been corrected.

  Repair: Check the circuit again. The ECM has failed. Exit this procedure and perform this procedure again. Prior to replacing an ECM, always contact your dealership for possible consultation with Caterpillar. This consultation may greatly reduce repair time. If the ECM requires replacement, refer to Testing and Adjusting, "Electronic Control Module (ECM) - Replace".

  STOP

• NO - The diagnostic code is not active. The initial diagnostic code was probably caused by a poor connection or a short at one of the harness connectors that was disconnected and reconnected. The problem does not exist at this time. Resume normal machine operation.

  STOP