Solenoid Valve - Test
The following is a list of Diagnostic Trouble Codes (DTCs) that are associated with the solenoid valves of the machine.
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| Machine ECM (MID 299) | ||
|---|---|---|
| DTC | Code Description | System Response |
| 374-3 | Swing Brake Solenoid: Voltage Above Normal | Machine swing function will be inoperable. |
| 374-5 | Swing Brake Solenoid: Current Below Normal | Machine swing function will be inoperable. |
| 374-6 | Swing Brake Solenoid: Current Above Normal | Machine swing function will be inoperable. |
| 581-3 | Power Shift Solenoid: Voltage Above Normal | Power shift function will be inoperable. |
| 581-5 | Power Shift Solenoid: Current Below Normal | Power shift function will be inoperable. |
| 581-6 | Power Shift Solenoid: Current Above Normal | Power shift function will be inoperable. |
| 598-3 | Travel Speed Solenoid: Voltage Above Normal | Machine travel speed selection is limited. |
| 598-5 | Travel Speed Solenoid: Current Below Normal | Machine travel speed selection is limited. |
| 598-6 | Travel Speed Solenoid: Current Above Normal | Machine travel speed selection is limited. |
| 732-3 | Fine Swing Solenoid : Voltage Above Normal | Machine swing function will be inoperable. |
| 732-5 | Fine Swing Solenoid : Current Below Normal | Machine swing function will be inoperable. |
| 732-6 | Fine Swing Solenoid : Current Above Normal | Machine swing function will be inoperable. |
| 735-3 | Heavy Lift Solenoid : Voltage Above Normal | Heavy lift solenoid will be inoperable. |
| 735-5 | Heavy Lift Solenoid : Current Below Normal | Heavy lift solenoid will be inoperable. |
| 735-6 | Heavy Lift Solenoid : Current Above Normal | Heavy lift solenoid will be inoperable. |
| 1160-3 | Hydraulic Lock Solenoid: Voltage Above Normal | Hydraulic lock solenoid will not function. |
| 1160-5 | Hydraulic Lock Solenoid: Current Below Normal | Hydraulic lock solenoid will not function. |
| 1160-6 | Hydraulic Lock Solenoid: Current Above Normal | Hydraulic lock solenoid will not function. |
| 1525-3 | Straight Travel Solenoid: Voltage Above Normal | Straight travel system will be inoperable. |
| 1525-5 | Straight Travel Solenoid: Current Below Normal | Straight travel system will be inoperable. |
| 1525-6 | Straight Travel Solenoid: Current Above Normal | Straight travel system will be inoperable. |
| 1530-3 | Quick Coupler Solenoid : Voltage Above Normal | Quick coupler function will be inoperable. |
| 1530-5 | Quick Coupler Solenoid : Current Below Normal | Quick coupler function will be inoperable. |
| 1530-6 | Quick Coupler Solenoid : Current Above Normal | Quick coupler function will be inoperable. |
| 1665-3 | Variable Relief Valve #1 Pressure Solenoid: Voltage Above Normal | Hydraulic pressure system disabled. |
| 1665-5 | Variable Relief Valve #1 Pressure Solenoid: Current Below Normal | Hydraulic pressure system disabled. |
| 1665-6 | Variable Relief Valve #1 Pressure Solenoid: Current Above Normal | Hydraulic pressure system disabled. |
| 1666-3 | Variable Relief Valve #2 Pressure Solenoid: Voltage Above Normal | Hydraulic pressure system disabled. |
| 1666-5 | Variable Relief Valve #2 Pressure Solenoid: Current Below Normal | Hydraulic pressure system disabled. |
| 1666-6 | Variable Relief Valve #2 Pressure Solenoid: Current Above Normal | Hydraulic pressure system disabled. |
| 1939-3 | Auxiliary Hydraulic Boost Flow Supply Solenoid : Voltage Above Normal | Possible reduction in available hydraulic pressure. |
| 1939-5 | Auxiliary Hydraulic Boost Flow Supply Solenoid : Current Below Normal | Possible reduction in available hydraulic pressure. |
| 1939-6 | Auxiliary Hydraulic Boost Flow Supply Solenoid : Current Above Normal | Possible reduction in available hydraulic pressure. |
| 2068-3 | Pump #1 Control Spool Solenoid: Voltage Above Normal | Joystick functions will be limited. Pump flow will be reduced. |
| 2068-5 | Pump #1 Control Spool Solenoid: Current Below Normal | Joystick functions will be limited. Pump flow will be reduced. |
| 2068-6 | Pump #1 Control Spool Solenoid: Current Above Normal | Joystick functions will be limited. Pump flow will be reduced. |
| 2069-3 | Pump #2 Control Spool Solenoid: Voltage Above Normal | Joystick functions will be limited. Pump flow will be reduced. |
| 2069-5 | Pump #2 Control Spool Solenoid: Current Below Normal | Joystick functions will be limited. Pump flow will be reduced. |
| 2069-6 | Pump #2 Control Spool Solenoid: Current Above Normal | Joystick functions will be limited. Pump flow will be reduced. |
| 2103-3 | Boom Regeneration Solenoid: Voltage Above Normal | Boom operations will be inoperable. |
| 2103-5 | Boom Regeneration Solenoid: Current Below Normal | Boom operations will be inoperable. |
| 2103-6 | Boom Regeneration Solenoid: Current Above Normal | Boom operations will be inoperable. |
| 2420-3 | Boom Cylinder Extend Limit Solenoid: Voltage Above Normal | Boom extend function will be inoperable. |
| 2420-5 | Boom Cylinder Extend Limit Solenoid: Current Below Normal | Boom extend function will be inoperable. |
| 2420-6 | Boom Cylinder Extend Limit Solenoid: Current Above Normal | Boom extend function will be inoperable. |
| 2421-3 | Boom Cylinder Retract Limit Solenoid: Voltage Above Normal | Boom retract operation will be inoperable. |
| 2421-5 | Boom Cylinder Retract Limit Solenoid: Current Below Normal | Boom retract operation will be inoperable. |
| 2421-6 | Boom Cylinder Retract Limit Solenoid: Current Above Normal | Boom retract operation will be inoperable. |
| 2424-3 | Bucket Cylinder Retract Limit Solenoid: Voltage Above Normal | Bucket retract operation will be inoperable. |
| 2424-5 | Bucket Cylinder Retract Limit Solenoid: Current Below Normal | Bucket retract operation will be inoperable. |
| 2424-6 | Bucket Cylinder Retract Limit Solenoid: Current Above Normal | Bucket retract operation will be inoperable. |
| 2664-3 | Boom Float Up Solenoid : Voltage Above Normal | Float function will be inoperable. |
| 2664-5 | Boom Float Up Solenoid : Current Below Normal | Float function will be inoperable. |
| 2664-6 | Boom Float Up Solenoid : Current Above Normal | Float function will be inoperable. |
| 2665-3 | Boom Float Down Solenoid : Voltage Above Normal | Float function will be inoperable. |
| 2665-5 | Boom Float Down Solenoid : Current Below Normal | Float function will be inoperable. |
| 2665-6 | Boom Float Down Solenoid : Current Above Normal | Float function will be inoperable. |
| 3038-3 | Boom Low-Pressure Relief Enable Solenoid : Voltage Above Normal | Boom functions will be limited. |
| 3038-5 | Boom Low-Pressure Relief Enable Solenoid : Current Below Normal | Boom functions will be limited. |
| 3038-6 | Boom Low-Pressure Relief Enable Solenoid : Current Above Normal | Boom functions will be limited. |
| 3575-3 | Pump #1 Flow Limitation Pressure Solenoid: Voltage Above Normal | Pump flow will be reduced. |
| 3575-5 | Pump #1 Flow Limitation Pressure Solenoid: Current Below Normal | Pump flow will be reduced. |
| 3575-6 | Pump #1 Flow Limitation Pressure Solenoid: Current Above Normal | Pump flow will be reduced. |
| 3576-3 | Pump #2 Flow Limitation Pressure Solenoid: Voltage Above Normal | Pump flow will be reduced. |
| 3576-5 | Pump #2 Flow Limitation Pressure Solenoid: Current Below Normal | Pump flow will be reduced. |
| 3576-6 | Pump #2 Flow Limitation Pressure Solenoid: Current Above Normal | Pump flow will be reduced. |
| 3633–3 | Swing Priority Solenoid : Voltage Above Normal | Machine swing function will be limited. |
| 3633–5 | Swing Priority Solenoid : Current Below Normal | Machine swing function will be limited. |
| 3633–6 | Swing Priority Solenoid : Current Above Normal | Machine swing function will be limited. |
| 4752-3 | Quick Coupler Solenoid #2 : Voltage Above Normal | Quick coupler function will be inoperable. |
| 4752-5 | Quick Coupler Solenoid #2 : Current Below Normal | Quick coupler function will be inoperable. |
| 4752-6 | Quick Coupler Solenoid #2 : Current Above Normal | Quick coupler function will be inoperable. |
Solenoids are used to shutoff, release, distribute, or mix fluids on the machine. Generally, multiple solenoids are located together on a manifold. The solenoid converts electrical energy into magnetic energy, moving a spool located inside the housing of the valve. A spring is used to hold the spool in position until the solenoid is energized.
The magnetic force that acts on the valve spool is created when a coil inside the solenoid is energized.
Possible Causes for an FMI 3 Diagnostic code are:
- The harness is shorted.
- The Machine 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.
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| Illustration 1 | g06118553 |
|
Machine ECM J1 and J2 solenoid connections | |
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| Illustration 2 | g06132664 |
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Switch Panel solenoid connections | |
The preceding diagrams are simplified schematics of the machine ECM and switch panel solenoid connections. The schematics are electrically correct. However, not all the possible harness connectors are shown. Refer to the latest revision of the Electrical Schematic to view the entire circuitry of the machine.
The following is a list of Diagnostic Trouble Codes (DTCs) that are associated with the solenoid valves of the machine.
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| Implement Control ECM (MID 272) | ||
|---|---|---|
| DTC | Code Description | System Response |
| 1593-3 | Attachment Valve #1 Extend Pressure Solenoid: Voltage Above Normal | Attachment / tool functions unavailable. |
| 1593-5 | Attachment Valve #1 Extend Pressure Solenoid: Current Below Normal | Attachment / tool functions unavailable. |
| 1593-6 | Attachment Valve #1 Extend Pressure Solenoid: Current Above Normal | Attachment / tool functions unavailable. |
| 1594-3 | Attachment Valve #2 Extend Pressure Solenoid: Voltage Above Normal | Attachment / tool functions unavailable. |
| 1594-5 | Attachment Valve #2 Extend Pressure Solenoid: Current Below Normal | Attachment / tool functions unavailable. |
| 1594-6 | Attachment Valve #2 Extend Pressure Solenoid: Current Above Normal | Attachment / tool functions unavailable. |
| 1595-3 | Attachment Valve #3 Extend Pressure Solenoid: Voltage Above Normal | Attachment / tool functions unavailable. |
| 1595-5 | Attachment Valve #3 Extend Pressure Solenoid: Current Below Normal | Attachment / tool functions unavailable. |
| 1595-6 | Attachment Valve #3 Extend Pressure Solenoid: Current Above Normal | Attachment / tool functions unavailable. |
| 1596-3 | Attachment Valve #1 Retract Pressure Solenoid: Voltage Above Normal | Attachment / tool functions unavailable. |
| 1596-5 | Attachment Valve #1 Retract Pressure Solenoid: Current Below Normal | Attachment / tool functions unavailable. |
| 1596-6 | Attachment Valve #1 Retract Pressure Solenoid: Current Above Normal | Attachment / tool functions unavailable. |
| 1597-3 | Attachment Valve #2 Retract Pressure Solenoid: Voltage Above Normal | Attachment / tool functions unavailable. |
| 1597-5 | Attachment Valve #2 Retract Pressure Solenoid: Current Below Normal | Attachment / tool functions unavailable. |
| 1597-6 | Attachment Valve #2 Retract Pressure Solenoid: Current Above Normal | Attachment / tool functions unavailable. |
| 1598-3 | Attachment Valve #3 Retract Pressure Solenoid: Voltage Above Normal | Attachment / tool functions unavailable. |
| 1598-5 | Attachment Valve #3 Retract Pressure Solenoid: Current Below Normal | Attachment / tool functions unavailable. |
| 1598-6 | Attachment Valve #3 Retract Pressure Solenoid: Current Above Normal | Attachment / tool functions unavailable. |
| 1663-3 | Attachment Valve #4 Extend Pressure Solenoid: Voltage Above Normal | Attachment / tool functions unavailable. |
| 1663-5 | Attachment Valve #4 Extend Pressure Solenoid: Current Below Normal | Attachment / tool functions unavailable. |
| 1663-6 | Attachment Valve #4 Extend Pressure Solenoid: Current Above Normal | Attachment / tool functions unavailable. |
| 1664-3 | Attachment Valve #4 Retract Pressure Solenoid: Voltage Above Normal | Attachment / tool functions unavailable. |
| 1664-5 | Attachment Valve #4 Retract Pressure Solenoid: Current Below Normal | Attachment / tool functions unavailable. |
| 1664-6 | Attachment Valve #4 Retract Pressure Solenoid: Current Above Normal | Attachment / tool functions unavailable. |
| 2422-3 | Stick Cylinder Extend Limit Solenoid: Voltage Above Normal | Stick extend will be inoperable. |
| 2422-5 | Stick Cylinder Extend Limit Solenoid: Current Below Normal | Stick extend will be inoperable. |
| 2422-6 | Stick Cylinder Extend Limit Solenoid: Current Above Normal | Stick extend will be inoperable. |
Solenoids are used to shutoff, release, distribute, or mix fluids on the machine. Generally, multiple solenoids are located together on a manifold. The solenoid converts electrical energy into magnetic energy, moving a spool located inside the housing of the valve. A spring is used to hold the spool in position until the solenoid is energized.
The magnetic force that acts on the valve spool is created when a coil inside the solenoid is energized.
Possible Causes for an FMI 3 Diagnostic code are:
- The harness is shorted.
- The Machine 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.
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| Illustration 3 | g06112943 |
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Implement Control ECM J1 solenoid connections | |
The preceding diagram is a simplified schematic of the implement control ECM solenoid connections. The schematic is electrically correct. However, not all the possible harness connectors are shown. Refer to the latest revision of the Electrical Schematic to view the entire circuitry of the machine.
Diagnostic Trouble Code Procedure
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 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 and verify that the diagnostic code is active before performing a troubleshooting procedure.
- Identify the active FMI code associated with the components.
- Determine which code is present and use the list below to determine which procedure to follow.
- FMI 3 diagnostic code, proceed to Table 3.
- FMI 5 diagnostic code, proceed to Table 4.
- FMI 6 diagnostic code, proceed to Table 5.
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| FMI 3 Troubleshooting | ||
|---|---|---|
| Troubleshooting Test Steps | Values | Results |
| 1. Check The Machine Harness For A Short A. The key start switch and the disconnect switch remain in the OFF position. B. Disconnect the harness connector from the solenoid. C. Disconnect the ECM machine harness connectors. D. Measure the resistance between the solenoid signal contact and all of the contacts that are used in the ECM. |
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: A short exists between the signal contact and the circuit with the low resistance. Repair or replace the machine harness. Note: A resistance that is greater than 5 Ω but less than 5K Ω would indicate a loose connection or a corroded connection in the circuit. A resistance measurement that is greater than 5K Ω would indicate an open in the circuit. Proceed to Test Step 2. |
| 2. Check If The Diagnostic Code Remains A. Reconnect all harness connectors. Return machine to normal operating condition. B. Turn the key start switch and the disconnect switch ON. C. Clear all diagnostic codes. D. Operate the machine. E. Stop the machine and engage the safety. F. Check if the diagnostic code is active. |
The diagnostic code is no longer present. |
OK - The diagnostic code does not exist at this time. The 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 - The 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 the ECM, always contact the Technical Communicator at your dealership for possible consultation with Caterpillar. This consultation may effect repair time. Follow the steps in Troubleshooting, "ECM - Replace" if the ECM needs to be replaced. STOP. |
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| FMI 5 Troubleshooting | ||
|---|---|---|
| Troubleshooting Test Steps | Values | Results |
| 1. Check The Solenoid. A. Turn the key start switch and the disconnect switch OFF. B. Disconnect the solenoid from the machine harness. C. At the harness connector for the solenoid, install a jumper wire between contact 1 and contact 2. D. Turn the key start switch and the disconnect switch ON. Do not start the engine. |
The FMI 5 diagnostic code changes to an FMI 6 after the jumper wire is installed. |
OK - The harness is correct. The FMI 5 diagnostic code changes to an FMI 6 when the jumper wire is installed. 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 Harness For An Open. A. Turn the key start switch and the disconnect switch OFF. 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 between the signal circuit and return circuit. Note: For solenoids that return to ground, measure the resistance between the signal circuit at the ECM harness connector and frame ground. |
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 open is in the signal circuit or the return circuit. Repair: Repair or replace the machine harness. Note: A resistance that is greater than 5 Ω but less than 5K Ω would indicate a loose connection or a corroded connection in the circuit. A resistance measurement that is greater than 5K Ω would indicate an open in the circuit. Proceed to Test Step 3. |
| 3. Check If The Diagnostic Code Remains A. Reconnect all harness connectors. Return machine to normal operating condition. B. Turn the key start switch and the disconnect switch ON. C. Clear all diagnostic codes. D. Operate the machine. E. Stop the machine and engage the safety. F. Check if the diagnostic code is active. |
The diagnostic code is no longer present. |
OK - The diagnostic code does not exist at this time. The 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 - The 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 the ECM, always contact the Technical Communicator at your dealership for possible consultation with Caterpillar. This consultation may effect repair time. Follow the steps in Troubleshooting, "ECM - Replace" if the ECM needs to be replaced. STOP. |
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| FMI 6 Troubleshooting | ||
|---|---|---|
| Troubleshooting Test Steps | Values | Results |
| 1. Check The Solenoid A. Turn the key start switch and the disconnect switch OFF. B. Disconnect the solenoid from the machine harness. C. Turn the key start switch and the disconnect switch ON. Do not start the engine. D. Observe the status of the diagnostic code. |
The FMI 6 changes to an FMI 5 after the solenoid is disconnected. |
OK - The circuit is correct. The solenoid has failed. Repair: Repeat the test. Verify the solenoid failure. 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 OFF. C. Disconnect the harness connectors from the ECM. D. At the harness connector for the ECM, measure the resistance between the solenoid signal contact and all ground contacts. |
Each reading is greater than 5K Ω. |
OK - Machine harness 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: A short circuit exists between the signal wire and the circuit with the low resistance. Repair or replace the machine harness. Note: A resistance that is greater than 5 Ω but less than 5K Ω would indicate a loose connection or a corroded connection in the circuit. A resistance measurement that is greater than 5K Ω would indicate an open in the circuit. Proceed to Test Step 3. |
| 3. Check If The Diagnostic Code Remains A. Reconnect all harness connectors. Return machine to normal operating condition. B. Turn the key start switch and the disconnect switch ON. C. Clear all diagnostic codes. D. Operate the machine. E. Stop the machine and engage the safety. F. Check if the diagnostic code is active. |
The diagnostic code is no longer present. |
OK - The diagnostic code does not exist at this time. The 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 - The 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 the ECM, always contact the Technical Communicator at your dealership for possible consultation with Caterpillar. This consultation may effect repair time. Follow the steps in Troubleshooting, "ECM - Replace" if the ECM needs to be replaced. STOP. |
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