906K, 906M, 907K, 907M, 908K and 908M Compact Wheel Loaders Electrohydraulic System Solenoid Valve - Test Caterpillar


Solenoid Valve - Test
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1.1. Machine ECM
2.1. Diagnostic Trouble Code Procedure

Machine ECM

The following is a list of Diagnostic Trouble Codes (DTCs) that are associated with the Solenoids of the machine.

Table 1
Machine ECM (MID 71) 
DTC  Code Description  System Response 
133-11  Transmission Pilot Pressure Supply Solenoid: Failure mode not identifiable  Machine drive is disabled. 
291-3  Engine Cooling Fan Solenoid: Voltage above normal  Fan will spin very slow. 
291-5  Engine Cooling Fan Solenoid: Current below normal  Fan will spin at max speed. 
291-6  Engine Cooling Fan Solenoid: Current above normal  Fan will spin at max speed. 
291-13  Engine Cooling Fan Solenoid: Out of calibration  Fan will not be spinning at designed min and max speeds. 
354-3  Raise Solenoid #1: Voltage above normal  Implement Pilot Supply is disabled and all implement motion is stopped. 
354-5  Raise Solenoid #1: Current below normal  Implement function is disabled (only the one with the active code) 
354-6  Raise Solenoid #1: Current above normal  Implement function is disabled (only the one with the active code) 
354-13  Raise Solenoid #1: Out of calibration  Excessive deadband or excessive jerk may be present when operating the implement function. 
355-3  Lower Solenoid #1: Voltage above normal  Implement Pilot Supply is disabled and all implement motion is stopped. 
355-5  Lower Solenoid #1: Current below normal  Implement function is disabled (only the one with the active code) 
355-6  Lower Solenoid #1: Current above normal  Implement function is disabled (only the one with the active code) 
355-13  Lower Solenoid #1: Out of calibration  Excessive deadband or excessive jerk may be present when operating the implement function. 
356-3  Dump Solenoid #1: Voltage above normal  Implement Pilot Supply is disabled and all implement motion is stopped. 
356-5  Dump Solenoid #1: Current below normal  Implement function is disabled (only the one with the active code) 
356-6  Dump Solenoid #1: Current above normal  Implement function is disabled (only the one with the active code) 
356-13  Dump Solenoid #1: Out of calibration  Excessive deadband or excessive jerk may be present when operating the implement function. 
357-3  Rackback Solenoid #1: Voltage above normal  Implement Pilot Supply is disabled and all implement motion is stopped. 
357-5  Rackback Solenoid #1: Current below normal  Implement function is disabled (only the one with the active code) 
357-6  Rackback Solenoid #1: Current above normal  Implement function is disabled (only the one with the active code) 
357-13  Rackback Solenoid #1: Out of calibration  Excessive deadband or excessive jerk may be present when operating the implement function. 
358-11  Implement Pilot Pressure Supply Solenoid: Failure mode not identifiable  All Implements are disabled. 
491-3  3rd Function Forward Solenoid: Voltage above normal  Implement Pilot Supply is disabled and all implement motion is stopped. 
491-5  3rd Function Forward Solenoid: Current below normal  Implement function is disabled (only the one with the active code) 
491-6  3rd Function Forward Solenoid: Current above normal  Implement function is disabled (only the one with the active code) 
492-3  3rd Function Rearward Solenoid: Voltage above normal  Implement Pilot Supply is disabled and all implement motion is stopped. 
492-5  3rd Function Rearward Solenoid: Current below normal  Implement function is disabled (only the one with the active code) 
492-6  3rd Function Rearward Solenoid: Current above normal  Implement function is disabled (only the one with the active code) 
1401-11  Transmission Solenoid 1: Failure mode not identifiable  Machines with stop-to-shift transmission will not shift into High gear 
1402-11  Transmission Solenoid 2: Failure mode not identifiable  Machines with stop-to-shift transmission will not shift to Low Gear 
2730-3  Drive Pump Forward Control Solenoid: Voltage above normal  Transmission Pilot Supply is disabled. All machine drive is disabled. 
2730-5  Drive Pump Forward Control Solenoid: Current below normal  The direction of the pump associated with this fault code is disabled. The opposite direction is still operational. 
2730-6  Drive Pump Forward Control Solenoid: Current above normal  The direction of the pump associated with this fault code is disabled. The opposite direction is still operational. 
2730-13  Drive Pump Forward Control Solenoid: Out of calibration  The direction of the pump associated with this fault code is disabled. The opposite direction is still operational. 
2731-3  Drive Pump Reverse Control Solenoid: Voltage above normal  Transmission Pilot Supply is disabled. All machine drive is disabled. 
2731-5  Drive Pump Reverse Control Solenoid: Current below normal  The direction of the pump associated with this fault code is disabled. The opposite direction is still operational. 
2731-6  Drive Pump Reverse Control Solenoid: Current above normal  The direction of the pump associated with this fault code is disabled. The opposite direction is still operational. 
2814-11  Quick Coupler Engage Solenoid: Failure mode not identifiable  Quick Coupler Engage is disabled. 
2815-11  Quick Coupler Disengage Solenoid: Failure mode not identifiable  Quick Coupler Disengage is disabled. 
3563-3  Drive Motor #1 Solenoid: Voltage above normal  Machine speed is limited. 
3563-5  Drive Motor #1 Solenoid: Current below normal  Machine speed is limited. 
3563-6  Drive Motor #1 Solenoid: Current above normal  Machine speed is limited. 
3563-13  Drive Motor #1 Solenoid: Out of Calibration  Machine speed is limited. 

Possible causes for an FMI 3 diagnostic code are:

  • The circuit of the solenoid is shorted to another voltage source circuit.

  • The 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.

Possible causes for an FMI 11 diagnostic code are:

  • There is an open in the circuit.

  • A wire is shorted to ground.

  • A wire is shorted to another voltage source circuit.

  • The solenoid has failed.

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

Possible causes for an FMI 13 diagnostic code are:

  • New software has been flashed to the ECM.

  • The ECM has been replaced.


Illustration 1g03714744
Schematic of the Solenoids

Note: The diagram above is a simplified schematic of the Machine ECM and the Solenoid connections. The schematic is electrically correct. However, not all of the possible harness connectors are shown. Refer to the latest revision of Electrical Schematic, UENR5407 for prefixes: L66, L77, L88, or Electrical Schematic, UENR5408 for prefixes: Z66, Z77, Z88, or Electrical Schematic, UENR5409 for prefixes: H66, H77, H88.

Diagnostic Trouble Code Procedure

Note: 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.

Table 2
Troubleshooting Test Steps  Values  Results 
1. Identify Active FMI Code Associated With Solenoid Circuit 
Code present. 
FMI 3 diagnostic code, proceed to Test Step 2.

FMI 5 diagnostic code, proceed to Test Step 3.

FMI 6 diagnostic code, proceed to Test Step 5.

FMI 11 diagnostic code, proceed to Test Step 7.

FMI 13 diagnostic code, proceed to Test Step 8. 
Begin Process For FMI 3 Troubleshooting HERE 
2. Check The Machine Harness For A Short

A. Turn the key start switch and the disconnect switch OFF.

B. Disconnect the harness connection at solenoid.

C. If the solenoid is connected to the ECM, disconnect all ECM connectors. If the solenoid is connected to the switch panel, disconnect all switch panel connectors.

D. Measure the resistance of solenoid signal contact to all ECM connectors, if the solenoid is wired directly to the ECM. If the solenoid is wired directly to the switch panel, measure resistance of solenoid contact to all switch panel connectors. 

Each reading is greater than 5K Ω. 
OK - All resistance readings are greater than 5K Ω .

Proceed to Test Step 9.

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 9.  
Begin Process For FMI 5 Troubleshooting HERE 
3. Check The Solenoid.

A. Turn the key start switch and the disconnect switch OFF.

B. Disconnect the solenoid from the machine harness.

C. Place a jumper wire between contact 1 and contact 2, at the harness connector for the solenoid.

D. Turn the key start switch and the disconnect switch ON. Do not start the engine.

E. As the jumper is removed and connected to the contacts, observe any code change. 

The code changes to FMI 6 after the jumper wire is installed. 
OK - The circuit is correct., the solenoid has failed.

Repair: Replace the solenoid.

After replacement of the solenoid , confirm the diagnostic code is not active.

Proceed to Test Step 9.

NOT OK - The diagnostic code remains active.

Proceed to Test Step 4. 
4. Check The Machine Harness For An Open.

A. Turn the key start switch and the disconnect switch OFF.

B. Disconnect the harness connectors from the ECM (or switch panel).

C. The jumper wire remains installed.

D. At the machine harness connector for the ECM, measure the resistance at the ECM contacts for the solenoid. 

Each reading is less than 5 Ω. 
OK - The reading is less than 5 Ω, the harness is correct.

Proceed to Test Step 9.

NOT OK - The reading is greater than 5K Ω. Circuit open in machine harness.

Repair: The open is in the wire for the solenoid signal or the return wire for the solenoid. 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 9.  
Begin Process For FMI 6 Troubleshooting HERE 
5. Check The Solenoid

A. Turn the key start switch and the disconnect switch OFF.

B. Disconnect the solenoid from the machine harness.

C. Place a jumper wire between contact 1 and contact 2, at the harness connector.

D. Turn the key start switch and the disconnect switch ON. Do not start the engine.

E. As the jumper is removed and connected to the contacts, observe any code change. 

The FMI 6 diagnostic code changes to an FMI 5 diagnostic code after the jumper wire is installed. 
OK - The circuit is correct. The solenoid has failed.

Repair: Repeat the jumper wire test. Verify the solenoid failure. Replace the solenoid.

Note: After the solenoid is replaced, confirm that the diagnostic code is no longer active.

Proceed to Test Step 9.

NOT OK - The diagnostic code remains active.

Proceed to Test Step 6. 
6. 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 (or switch panel).

D. At the harness connector for 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 9.

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 wire for the signal wire of the solenoid 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 9.  
Begin FMI 11 Troubleshooting Process HERE 
7. Check the ECM

A. Turn the key start switch and the disconnect switch OFF.

B. Wait for 30 seconds.

C. Turn the key start switch and the disconnect switch ON.

D. Allow the self test to run before you proceed to the next step.

E. Check the message center for an active diagnostic code. 

The diagnostic code with FMI 11 is no longer present. 
OK - The diagnostic code with FMI 11 is no longer present.

Proceed to Test Step 9.

NOT OK -The diagnostic code is still active.

Repair: Check the circuit again. Use the Cat ET service tool in order to test the machine wiring harness. Manipulate the wiring harness as the output is monitored on Cat ET. This test can detect intermittent short circuits and open connections in the machine wiring harness.

Proceed to Test Step 9.  
Begin Process For FMI 13 Troubleshooting HERE 
8. Calibrate The Solenoid

A. Perform the calibration procedure for the solenoid. Refer to Testing and Adjusting, "Calibration" procedure. 

The calibration procedure for the solenoid was performed successfully. 
OK - The calibration procedure for the solenoid was performed successfully. Resume normal machine operation.

Proceed to Test Step 9.

NOT OK - The calibration procedure was performed successfully.

Repair: Repeat the calibration procedure for the solenoid. See the Testing and Adjusting, "Calibration" procedure.

Proceed to Test Step 9.  
9. Check If The Diagnostic Code Remains

A. Inspect the harness connectors and clean the contacts of the harness connectors.

B. Reconnect all harness connectors.

C. Turn key switch and disconnect switch ON.

D. Operate the machine.

E. Check if diagnostic code is active. 

Diagnostic code is no longer present. 
OK - Diagnostic code does not exist at this time. 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 - 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 this component, always contact the Technical Communication at your dealership for possible consultation with AVSpare. This consultation may greatly effect repair time.

Follow the steps in Troubleshooting, "Electronic Control Module (ECM) - Replace" if the ECM needs to be replaced.

STOP 

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