259D Compact Track Loader – MID 039 – CID 2204 – FMI 03

Conditions Which Generate This Code:

This diagnostic code is associated with the Auxiliary Lever #1 Position Sensor. The FMI 03 means that the ECM has determined that the signal voltage of the PWM sensor is above normal.

The possible causes of this diagnostic code are listed:

• The power supply circuit for the sensor is open.

• The return circuit is open.

• The signal circuit is open or the sensor is disconnected.

• The signal circuit is shorted to the sensor power supply.

• The sensor has failed.

• The ECM has failed. This is unlikely.

Before performing this procedure, inspect the harness connectors that are involved in the 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. If a problem with a connection is found, correct the problem and verify that this diagnostic code is active before performing this procedure.

Note: Ensure that CID 2204 FMI 03 is active before performing this procedure.

Note: The following test procedure may create other diagnostic codes. Ignore these created diagnostic codes and clear the diagnostic codes when problem has been corrected.

Test Step 1. CHECK THE DUTY CYCLE OF THE SENSOR SIGNAL

1. Turn the key start switch to the ON position. Do not start the engine.

2. Use a multimeter that is capable of measuring duty cycle in order to check the duty cycle value of the position sensor. The ECM remains connected to the machine harness. At the machine harness connector for the ECM, insert a 7X-1710 Multimeter Probe in the back of signal contact J2-25 (wire P996-GN) and contact J1-45 (wire P770-WH).

3. Move the hydraulic lockout switch to the LOCKED position before performing the next step. If the hydraulic lockout switch is not in the LOCKED position, the next step can cause blade movement.

4. Move the sensor through the full range in order to monitor the minimum and maximum duty cycles of the sensor.

Expected Result:

With the sensor in the neutral position, the duty cycle should be approximately 50%. The high value should be approximately 90% ± 5%. The low value should be approximately 10% ± 5%.

Results:

• OK - The duty cycle values are in the correct range. The operation of the sensor is correct. Proceed to Test Step 5.

• NOT OK - The duty cycle values are not in the correct range or the increment and the decrement of the duty cycle is not stable. Proceed to Test Step 2.

Test Step 2. CHECK THE VOLTAGE AT THE SENSOR

1. The key start switch remains in the ON position.

2. Disconnect the sensor from the machine harness.

3. At the machine harness connector for the sensor, measure the voltage between contact 1 (wire P769-YL) and contact 2 (wire P770-WH).

Expected Result:

The voltage measurement is 8 ± 0.5 DCV.

Results:

• OK - The voltage measurement is 8 ± 0.5 DCV. Proceed to Test Step 3.

• NOT OK - The voltage measurement is not 8 ± 0.5 DCV.

  Repair: There may be an open in the machine harness. Check the fuse for this circuit. Ensure that the fuse is not open. If the fuse is open, replace the fuse. Clear all diagnostic codes. Check to see if the diagnostic code remains active.If the code remains active, there is an open in the solenoid supply circuit of the machine harness. Repair the machine harness or replace the machine harness.

  STOP

Test Step 3. CHECK FOR AN OPEN IN THE SIGNAL CIRCUIT

1. The key start switch remains in the ON position.

2. At the machine harness connector for the sensor, measure the voltage from signal contact 3 (wire P996-GN) to ground contact 2 (wire P770-WH).

Expected Result:

If the signal circuit and the return circuit for the sensor is correct, the ECM pull-up voltage should be indicated on the voltage measurement. The value of this voltage can vary. The presence of a voltage will indicate that the signal circuit is NOT open. The absence of a voltage indicates an open in the signal circuit.

Results:

• OK - The pull-up voltage is present when the measurement is performed. The signal circuit and the return circuit are correct. Proceed to Test Step 5.

• NOT OK - Very little or no voltage is measured. There is an open or a bad connection in the return circuit or in the signal circuit of the sensor circuit.

  Repair: Refer to the complete machine Electrical System Schematic. Check all of the connectors that are in the sensor signal circuit and the return circuit. Check that all connections are clean, secure and in good condition. Repair the machine harness or replace the machine harness.

  STOP

Test Step 4. CHECK THE SIGNAL CIRCUIT FOR A SHORT

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

2. The connector for the sensor remains disconnected from the machine harness.

3. Disconnect the machine harness connectors J1 and J2 from the ECM.

4. At the J1 and J2 machine harness connectors for the ECM, measure the resistance from the sensor signal contact J2-25 (wire P996-GN) to all of the other J1 and J2 contacts.

Expected Result:

Each resistance measurement is greater than 5000 ohms.

Results:

• OK - Each resistance measurement is greater than 5000 ohms. The sensor has failed.

  Repair: Replace the sensor. Recalibrate if necessary. Refer to Testing and Adjusting, "Calibration" procedure. Verify that the new sensor has corrected the problem.

  STOP

• NOT OK - A resistance measurement is less than 5000 ohms.

  Repair: There is a short in the machine harness. The short is between the signal circuit and the circuit with the low resistance measurement. Repair the machine harness or replace the machine harness.

  STOP

Test Step 5. CHECK THE STATUS OF THE DIAGNOSTIC CODE

1. Inspect the harness connectors. Clean the contacts for the harness connectors. Check all wires for damage from chafing, corrosion, or excessive heat.

2. Perform a 45 N (10 lb) pull test on each of the wires that are associated with the sensor circuit.

3. Reconnect all harness connectors. Make sure that the connectors are fully seated and the clips for each connector are completely fastened.

4. Reconnect the negative battery cable and turn the key start switch to the ON position.

5. Operate the machine.

6. Determine if the CID 2204 FMI 03 diagnostic code is active.

Expected Result:

The CID 2204 FMI 03 diagnostic code is not active.

Results:

• OK - The CID 2204 FMI 03 diagnostic code is not active. 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 2204 FMI 03 diagnostic code is active. The diagnostic code has not been corrected.

  Repair: It is unlikely that the ECM has failed. Exit this procedure and perform this procedure again. Exit this procedure and perform this procedure again. If the cause of the diagnostic code is not found, contact your dealership's Technical Communicator for possible consultation with Caterpillar. This consultation may greatly reduce repair time. If the ECM requires replacement, refer to Testing and Adjusting, "Electronic Control Module (ECM) - Replace"

  STOP