Operator Control Switch (Switch to Ground) - Test - Machines with Joystick Steering
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| Machine ECM (MID 39) | ||
|---|---|---|
| DTC | Code Description | System Response |
| 449-2 | Operator Grapple Rotate Switch : Data Erratic, Intermittent, or Incorrect | Rotation of grapple will not function.
This diagnostic code is recorded when the ECM reads the voltage from one of the grapple rotate switches as being erratic or intermittent. The ECM expects one of the switch inputs to be grounded at all times. |
| 450-2 | Operator Tong Open/Close Switch : Data Erratic, Intermittent, or Incorrect | Tongs on grapple will not open/close when commanded. |
| 621-3 | Downshift Switch : Voltage Above Normal | Machine will be unable to engage requested gear. |
| 621-4 | Downshift Switch : Voltage Below Normal | Machine will be unable to engage requested gear. |
| 622-3 | Upshift Switch : Voltage Above Normal | Machine will be unable to engage requested gear. |
| 622-4 | Upshift Switch : Voltage Below Normal | Machine will be unable to engage requested gear. |
| 623-3 | Directional Switch : Voltage Above Normal | Machine will be unable to engage requested change in direction. |
| 623-4 | Directional Switch : Voltage Below Normal | Machine will be unable to engage requested change in direction. |
| 623-3 | Directional Switch : Voltage Above Normal | Machine will be unable to engage requested change in direction. |
| 623-4 | Directional Switch : Voltage Below Normal | Machine will be unable to engage requested change in direction. |
| 2113-3 | Operator In Seat Switch (OIS): Voltage Above Normal | Movements of the machine and implements are prevented until a valid OIS switch position is sensed |
| 2113-4 | Operator In Seat Switch (OIS): Voltage Below Normal | Movements of the machine and implements are prevented until a valid OIS switch position is sensed |
Prior to beginning this procedure, inspect the harness connectors that are 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 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 and verify that this diagnostic code is active before performing a troubleshooting procedure.
Possible Causes for an FMI 2 Diagnostic code are:
- The common ground circuit is not correct.
- One of the switches is not working correctly.
- A grounded wire exists in one of the switch circuits.
- There is a short to a +battery source in one of the switch circuits.
- The ECM has failed. A failure of the Machine ECM is unlikely.
Possible Causes for an FMI 3 Diagnostic code are:
- The ground wire is open.
- A signal is permanently open.
- The switch has failed.
- The ECM has failed. A failure of the Machine ECM is unlikely.
Possible Causes for an FMI 4 Diagnostic code are:
- A switch signal is shorted to ground.
- The switch has failed.
- The ECM has failed. A failure of the Machine ECM is unlikely.
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| Grapple Rotate Switch Circuit Continuity | ||||
|---|---|---|---|---|
| Machine ECM J2 Connector | Contact Number of Joystick Handle | Wire Number | CW | CCW |
| 34 | 8 | E851-BU | X | |
| 35 | 6 | 961-BR | X | |
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| Grapple Tong Open/Close Switch Circuit Continuity | ||||
|---|---|---|---|---|
| Machine ECM J2 Connector | Contact Number of Joystick Handle | Wire Number | Open | Close |
| 32 | 12 | C906-PU | X | |
| 33 | 2 | C907-WH | X | |
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| |
| Illustration 1 | g06168358 |
|
Operator Controlled (Switch to Ground) Switch Connections | |
Note: The diagram above is a simplified schematic of the switch connections. The schematic is electrically correct, however, not all the possible harness connectors are shown. Refer to the latest revision of the Electrical Schematic for the complete schematic.
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| Implement ECM (MID 82) | ||
|---|---|---|
| DTC | Code Description | System Response |
| 1628-3 | Armrest Position Switch: Voltage Above Normal | |
| 1628-4 | Armrest Position Switch: Voltage Below Normal | |
| 3438-3 | Cab Seat Manual Swivel Switch: Voltage Above Normal | |
| 3438-4 | Cab Seat Manual Swivel Switch: Voltage Below Normal | |
Prior to beginning this procedure, inspect the harness connectors that are 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 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 and verify that this diagnostic code is active before performing a troubleshooting procedure.
Possible Causes for an FMI 3 Diagnostic code are:
- The ground wire is open.
- A signal is permanently open.
- The switch has failed.
- The ECM has failed. A failure of the Machine ECM is unlikely.
Possible Causes for an FMI 4 Diagnostic code are:
- A switch signal is shorted to ground.
- The switch has failed.
- The ECM has failed. A failure of the Machine ECM is unlikely.
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| |
| Illustration 2 | g06168345 |
|
Operator Controlled (Switch to Ground) Switch Connections | |
Note: The diagram above is a simplified schematic of the switch connections. The schematic is electrically correct, however, not all the possible harness connectors are shown. Refer to the latest revision of the Electrical Schematic for the complete schematic.
Prior to beginning this procedure, inspect the harness connectors that are 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 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 and verify that this diagnostic code is active before performing a troubleshooting procedure.
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| Troubleshooting Test Steps | Values | Results |
|---|---|---|
| 1. Identify The Active FMI Code Associated With The Sensor Circuit | Code present. |
FMI 2 diagnostic code, proceed to Test Step 2. FMI 3 diagnostic code, proceed to Test Step 4. FMI 4 diagnostic code, proceed to Test Step 9. |
| Begin Process For FMI 2 Troubleshooting HERE | ||
| 2. Check The Circuit For A Short A. Turn the key switch and disconnect switch OFF. B. Disconnect the grapple control handle from the machine harness connector. C. At the machine harness connector for the grapple control handle, measure the resistance between contact 1 202-BK(Black)and frame ground. |
The resistance is less than 5 ohms. |
OK - The resistance is correct. Proceed to Test Step 3. NOT OK - The resistance measurement is greater than 5 ohms. The ground circuit for the grapple control handle is not correct. Repair: There is an open or faulty connection in wire 202-BK(Black)between the ECM and the control handle. Refer to the complete machine Electrical System Schematic. Check the connectors and splices that are in the ground circuit for loose or corroded connections. Repair or replace the machine harness. STOP |
| 3. Check the Operation of the Switch A. The key switch and disconnect switch remain in the OFF position. B. The grapple handle remains disconnected from the harness connector. C. At the grapple control joystick connector, check the continuity between the common contact 1 (ground) and each of the contacts for the rotation switches. Check continuity from common contact 1 (ground) to each switch connector contact when the switch is depressed and when the switch is not depressed. Refer to the continuity table and the connection diagram above for the correct contact continuity. |
The switch operates correctly. |
OK - The continuity checks between common contact 1 to the other switch contacts are correct. The switches are operating correctly. STOP NOT OK - The continuity checks between common contact 1 to the other switch contacts are not correct according to the table. One of the switches is not working correctly. Repair: Replace the control handle. STOP |
| Begin Process For FMI 3 Troubleshooting HERE | ||
| 4. Check the Harness For an Open A. Turn key start switch and disconnect switch OFF. B. Disconnect the steering control from the machine harness. C. Measure the resistance between the ground contact (see schematic above) and frame ground. |
The resistance is less than 5 ohms. |
OK - The circuit is correct. Proceed to Test Step 5. NOT OK - The resistance is greater than 5K ohms. The circuit is open. The machine harness has failed. Repair: Repair or replace the machine harness. Note: A resistance that is greater than 5 ohms but less than 5K ohms indicates a loose connection or a corroded connection in the circuit. A resistance measurement that is greater than 5K ohms indicates an open in the circuit. STOP |
| 5. Check The Operation Of The Switch In The Released And Closed Position A. The machine harness remains disconnected from the switch harness assembly. B. Identify the pin locations associated with the switch using the schematic above. C. Measure the resistance across the pins with the switch in the released position. D. Close the switch. E. Measure the resistance across the pins with the switch in the closed position. |
The resistance is greater than 5K ohms with the switch in the released position. The resistance is less than 5 ohms with the switch in the closed position. |
OK - The resistance is readings are as expected. The harness circuit is correct. Proceed to Test Step 6. NOT OK- The one or more of the resistance readings are NOT as expected. A fault exists with the switch. Repair: The joystick has a faulty switch. Since the switch is integrated into the joystick, the entire joystick must be replaced. STOP |
| 6. Check the Operation of the ECM. A. The key switch remains OFF. B. Reconnect all harness connections. C. Using a wire removal tool, remove the signal wires and socket from the machine harness connector to the switch. D. Turn the key switch ON. E. Use a multimeter probe to contact both signal wire pins through the empty space in the harness connector. F. Ground the other end of the multimeter probe to frame ground. G. Observe the status of the diagnostic code. |
The FMI 3 changes to an FMI 4. |
OK - The ECM is operating correctly. Proceed to Test Step 7. NOT OK - The FMI 3 remains active. The ECM may have failed. Prior to replacing the ECM, always contact the Technical Communicator at your dealership for possible consultation with Caterpillar. This consultation may greatly reduce repair time. If the ECM requires replacement, see Troubleshooting, "ECM - Replace" STOP |
| 7. Check the Operation of the Switch. A. Turn the key switch OFF. B. Reinstall the signal wire removed in the previous step. C. Check the operation of the switch. |
The switch operates correctly. |
OK - The switch is operating correctly. Proceed to Test Step 11. NOT OK - The switch is not operating correctly. The switch has failed Repair: Replace the switch. STOP |
| Begin Process For FMI 4 Troubleshooting HERE | ||
| 8. Check The Switch Operation Of The Switch In The Released And Depressed Position A. Turn the key switch and disconnect switch OFF. B. Unplug the switch harness assembly from the machine harness. C. Identify the pin locations associated with the switch using the schematic above. D. Measure the resistance across the pins with the switch in the released position. Note the measured resistance. E. Close the switch. F. Measure the resistance across the pins with the switch in the closed position. Note the measured resistance. |
The resistance is greater than 5K ohms with the switch in the released position. The resistance is less than 5 ohms with the switch in the closed position. |
OK - The resistance is readings are as expected. The harness circuit is correct. Proceed to Test Step 9. NOT OK- The one or more of the resistance readings are NOT as expected. A fault exists with the switch. Repair: The joystick has a faulty switch. Since the switch is integrated into the joystick, the entire joystick must be replaced. STOP |
| 9. Check the Harness for a Short A. The disconnect switch and the key start switch remain in the OFF position. B. The machine harness remains disconnected from the switch harness assembly. C. Disconnect the machine harness connectors from the Machine ECM. D. At the machine harness connector for the ECM measure the resistance between one of the wires for the switch circuit and frame ground. E. Measure the resistance between the remaining switch circuit wire and ground. |
The resistances are greater than 5K ohms. |
OK - The resistance is greater than 5K ohms. The harness circuit is correct. Proceed to Test Step 10. NOT OK- The resistance less than 5 ohms. Repair: A short exists in the harness between the switch circuit. Repair or replace the machine harness. Note: A resistance that is greater than 5 ohms but less than 5K ohms would indicate a loose connection or a corroded connection in the circuit. A resistance measurement that is greater than 5K ohms would indicate an open in the circuit. STOP |
| 10. Check If The Diagnostic Code Remains A. Inspect the harness connectors and clean the contacts of the harness connectors. B. Perform a C. Reconnect all harness connectors. D. Turn key start switch and disconnect switch ON. E. Operate the machine. F. Check the status of the diagnostic code. |
The diagnostic code is not active. |
OK - The diagnostic code is still active. Repair:Check the status of the diagnostic code. If the cause of the problem is not found, the ECM may require replacement. Prior to replacing the ECM, always contact the Technical Communicator at your dealership for possible consultation with Caterpillar. This consultation may greatly reduce repair time. If the ECM requires replacement, see Troubleshooting, "ECM - Replace". STOP NOT OK - The continuity check is not correct. Repair: There is an open in the signal circuits of the machine harness. Repair or replace the machine harness. STOP |
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