259D Compact Track Loader – MID 039 – CID 0096 – FMI 03

Conditions Which Generate This Code:

This diagnostic code is recorded when the Machine ECM reads the signal voltage of the fuel level sender and the voltage is too high. The possible causes of this diagnostic code are listed here:

• The sender has failed.

• The return circuit of the sender is open in the machine harness.

• The signal circuit in the machine harness is shorted to a source of positive voltage.

• The signal circuit in the machine harness is open or the sender is disconnected.

• The ECM has failed. This is unlikely.

System Response:

This failure causes the fuel gauge to always indicate an empty fuel tank or the fuel gauge may intermittently indicate an empty fuel tank.

Test Step 1. CHECK THE CONTROL AND THE HARNESS.

1. Turn the key start switch to the ON position.

2. Disconnect the machine harness connector from the fuel level sender.

3. At the machine harness connector for the sender, measure the voltage (DCV) between the signal contact 1 (wire 447-PK) and the return contact 2 (wire 200-BK).

Expected Result:

The voltage is between 0 and 5 DCV.

Results:

• OK - The voltage is between 0 and 5 DCV. The ECM and the harness are correct.

  Repair: Replace the sender.

  STOP

• NOT OK - The voltage is NOT between 0 and 5 DCV. The ECM or the harness has failed. Proceed to Test Step 2.

Test Step 2. CHECK THE RETURN CIRCUIT OF THE HARNESS.

1. The sender remains disconnected.

2. Disconnect the negative battery cable and turn the key start switch to the OFF position.

3. Disconnect the J1 machine harness connector from the ECM.

4. Measure the resistance of the return circuit between contact 2 (wire 200-BK) of the machine harness for the sender and Frame Ground.

Expected Result:

The resistance is less than 5 ohms.

Results:

• OK - The resistance is less than 5 ohms. The harness resistance is correct. Proceed to Test Step 3.

• NOT OK - The resistance is greater than 5 ohms. The ground circuit in the harness has failed. There is an open circuit between the ground contact and frame ground.

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

  STOP

Test Step 3. CHECK FOR A SHORTED HARNESS

1. The sender and the ECM remain disconnected from the machine harness.

2. The key start switch remains in the OFF position.

3. At the machine harness connector for the sender, measure the resistance between the signal contact 1 (wire 469-GN) and all sources of +battery.

Expected Result:

The resistance is greater than 5000 ohms.

Results:

• OK - The resistance is greater than 5000 ohms. The ECM has failed.

  Repair: It is unlikely that an ECM has failed. Exit this procedure. Perform this CID 0096 FMI 03 procedure again. If the failure is not found, replace the ECM. Refer to the Troubleshooting, "Electronic Control Module (ECM) - Replace".

  STOP

• NOT OK - The resistance is less than 5000 ohms. The machine harness has failed. There is a short between the +battery circuit and the signal circuit in the machine harness.

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

  STOP