TH220B, TH330B, TH340B, TH350B, TH355B, TH360B, TH460B, TH560B and TH580B Telehandlers MID 039 - CID 1128 - FMI 02 Caterpillar

Conditions Which Generate This Code:

Illustration 1	g01597813
Schematic of the position sensor (left and right) of the joystick control.

Illustration 2	g00995893
PHS Joystick (TH220B) SLA1-849 (TH330B) SLB1-1499 (TH340B) SLC1-849 (TH350B) SLD1-1399 (TH360B) SLE1-4499 (TH460B) SLF1-2099 (TH560B) SLG1-1299 (TH580B) SLH1-899 (TH355B) JRK1-Up

Illustration 3	g01189556
Schematic of the position sensor (forward and backward) of the joystick control.

Illustration 4	g01095580
PHS Joystick (TH220B) SLA850 - Up (TH330B) SLB1500 - Up (TH340B) SLC850 - Up (TH350B) SLD1400 - Up (TH360B) SLE4500 - Up (TH460B) SLF2100 - Up (TH560B) SLG1300 - Up (TH580B) SLH900 - Up

The sensor controls the X axis of the joystick. This diagnostic code is recorded when the ECM records an erratic signal or an intermittent signal from the position sensor for the joystick control. There could also be a short to the +battery circuit, a short to ground, or an open circuit.

The position sensor is a PWM sensor. The signal wire for the position sensor connects to connector contact J2-40 (wire 782-GY) of the ECM.

The possible causes for this diagnostic code are listed:

• The signal circuit is open.

• The +battery circuit from the electrical system to the sensor is open.

• The signal circuit is shorted to the +battery circuit.

• The signal circuit is shorted to ground.

Note: Ensure that CID 1128 FMI 02 is active and that the diagnostic code indicator is active.

Note: Use the 146-4080 Digital Multimeter for the measurements in this procedure.

System Response:

The diagnostic code is logged into the internal memory of the ECM.

Test Step 1. INSPECT THE SENSOR.

1. Perform a visual inspection of the sensor, the wiring for the sensor and the hardware that is associated with the sensor.

Expected Result:

There is no apparent damage to the sensor, the wiring for the sensor or the hardware that is associated with the sensor.

Results:

• OK - There is no apparent damage to the sensor, the wiring for the sensor or the hardware that is associated with the sensor. Proceed to Test Step 2.

• NOT OK - There is apparent damage to the sensor, the wiring for the sensor or the hardware that is associated with the sensor.

  Repair: Replace the joystick base.

  STOP

Test Step 2. CHECK FOR POWER AT THE SENSOR.

1. Do not disconnect the harness connector from the sensor.

2. At the back of the harness connector for the sensor, insert a 7X-1710 Multimeter Probe along the voltage supply wire (contact 1).

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

4. Measure the voltage from contact 1 to frame ground.

Expected Result:

The voltage is 12.0 DCV.

Results:

• OK - The voltage is 12.0 DCV. Proceed to Test Step 3.

• NOT OK - The voltage is not 12.0 DCV. The circuit is open.

  Repair: Verify that the fuse for the circuit is OK. Repair the machine harness or replace the machine harness.

  STOP

Test Step 3. CHECK FOR PROPER GROUND AT THE SENSOR.

1. The machine harness remains connected to the sensor.

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

3. Remove the 7X-1710 Multimeter Probe from the voltage supply wire (contact 1).

4. At the back of the harness connector for the sensor, insert a 7X-1710 Multimeter Probe along the ground wire (contact 2).

5. 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 4.

• 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 4. CHECK THE SIGNAL OF THE SENSOR.

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

2. The 7X-1710 Multimeter Probe remains along the ground wire (contact 2).

3. At the back of the harness connector for the sensor, insert the other 7X-1710 Multimeter Probe along the signal wire (contact 3 782-GY).

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

5. Monitor the signal of the sensor with the 146-4080 Digital Multimeter .

6. Without disconnecting the sensor or the hardware that is associated with the sensor from the machine, take the sensor through the full operating range of the sensor.

Expected Result:

The sensor's signal responds in the manner that is described at the beginning of this procedure. The CID 1128 FMI 00 is not active at the maximum range of the sensor.

Results:

• OK - The sensor's frequency and the sensor's duty cycle responds correctly. The sensor is operating correctly. Proceed to Test Step 5.

• NOT OK - The sensor's signal does not respond correctly. The sensor is NOT operating correctly.

  Repair: Replace the joystick base.

  STOP

Test Step 5. CHECK THE SIGNAL AT THE ECM.

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

2. Insert the 7X-1710 Multimeter Probes into the back of the ECM connector along J2-40 (wire 782-GY) and J1-70 (wire 205-BK).

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

4. Monitor the signal of the sensor with the 146-4080 Digital Multimeter .

5. Without disconnecting the sensor or the hardware that is associated with the sensor from the machine, take the sensor through the full operating range of the sensor.

Expected Result:

The sensor's signal responds in the manner that is described at the beginning of this procedure. The CID 1128 FMI 02 is not active at the maximum range of the sensor.

Results:

• OK - The sensor's frequency and the sensor's duty cycle responds correctly. The sensor is operating correctly. Proceed to Test Step 7.

• NOT OK - The sensor's signal does not respond correctly. The harness has failed. Proceed to Test Step 6.

Test Step 6. CHECK THE SIGNAL CIRCUIT FOR A SHORT IN THE HARNESS.

1. The key start switch and the disconnect switch remain in the OFF position.

2. Disconnect the machine harness connectors from the sensor and the ECM.

3. Measure the resistance between contact J2-40 (wire 782-GY) and 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 of the resistance measurements are greater than 5000 ohms. The circuit is correct. Proceed to Test Step 7.

• NOT OK - The resistance is less than 5 ohms. The signal circuit is shorted to another circuit in the harness.

  Repair: Repair the machine harness or replace the machine harness.

  STOP

Test Step 7. CHECK IF THE DIAGNOSTIC CODE REMAINS

1. Inspect the harness connectors and clean the contacts of the machine harness connectors.

2. Reconnect all harness connectors.

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

4. Operate the machine and take the sensor through the operating range of the sensor.

5. Check the status of the CID 1128 FMI 02.

Expected Result:

The CID 1128 FMI 02 is not active at the maximum range of the sensor.

Results:

• OK - The CID 1128 FMI 02 is not active at the maximum range of the sensor. The diagnostic code does not exist at this time. The initial diagnostic code was probably caused by a poor connection or a short at one of the connectors that was disconnected and reconnected. Resume normal operation.STOP

• NOT OK - The CID 1128 FMI 02 is active at the maximum range of the sensor. The diagnostic code has not been corrected. The ECM may have failed.

  Repair: It is unlikely that the ECM has failed. Exit this procedure. Perform the adjustment procedure for the sensor, if necessary. Then perform the calibration procedure for the sensor. Perform this procedure again. If the cause of the failure is not found, replace the ECM. See the Testing and Adjusting, "Electronic Control Module (ECM) - Replace".

  STOP