120M Series 2, 12M Series 2, 140M Series 2 and 160M Series 2 Motor Graders Power Train Electronic Control System Caterpillar

Illustration 1	g02117295
Circuit of the transmission pump bypass solenoid

This diagnostic code is associated with the "Transmission Pump Bypass" solenoid. The FMI 05 diagnostic code means that the "Transmission/Chassis ECM" has determined that the current for the solenoid circuit is below normal.

Some possible causes of this diagnostic code are listed below:

• The energize circuit of the solenoid is open.

• The return circuit of the solenoid is open.

• The solenoid 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, that all connections are secure and that all connections are 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: The following test procedure may create other diagnostic codes. Ignore these created diagnostic codes and clear these diagnostic codes when the original diagnostic code has been corrected.

Use a calibrated digital multimeter for the following procedures.

Test Step 1. CHECK THE SOLENOID

Note: The resistance of the solenoid coil should be 8.7 ± .4 ohms at 25 °C (77.0 °F).

1. Disconnect the solenoid from the machine harness.

2. At the machine harness connector for the solenoid, place a jumper wire from the contact for (wire K927-BU(Blue)) to the contact for (wire X961-GY(Grey)).

3. Turn the disconnect switch and the key start switch to the ON position. Do not start the engine.

4. Observe the status of the CID 3210 FMI 05 diagnostic code.

Expected Result:

The active diagnostic code changes from an FMI 05 to an FMI 06 diagnostic code when the jumper wire is installed.

Results:

• YES - The active diagnostic code changes from an FMI 05 to an FMI 06 diagnostic code when the jumper wire is installed. The solenoid has failed.

  Repair: The solenoid has failed. Repeat this Test Step "CHECK THE SOLENOID" in order to verify the solenoid failure. Replace the solenoid. Verify that the new solenoid corrects the problem.

  STOP

• NO - The CID 3210 FMI 05 diagnostic code remains active. The jumper wire does not affect the status of the diagnostic code. The solenoid is not causing the problem. Proceed to Test Step 2.

Test Step 2. CHECK THE CIRCUIT FOR AN OPEN

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

2. Disconnect the machine harness connector J1 from the "Transmission/Chassis ECM".

3. The jumper wire that was installed in the previous test step remains in place.

4. At the machine harness connector J1 for the "Transmission/Chassis ECM", measure the resistance from the return contact J1-55 (wire K927-BU(Blue)) to the energize contact J1-65 (wire X961-GY(Grey)).

Expected Result:

The resistance measurement is less than 5 ohms.

Results:

• OK - The measurement of the resistance is less than 5 ohms. The circuit is not open in the machine harness. Proceed to Test Step 3.

• NOT OK - The resistance measurement is greater than 5000 ohms. The resistance measurement is not correct. There is an open or a bad connection in the machine harness. A resistance measurement that is much greater than 5 ohms but less than 5000 ohms could indicate that one of the connection points in the circuit is not an open connection but not a good connection.

  Repair: The open or the possible poor connection is in supply wire X961-GY(Grey) or in return wire K927-BU(Blue) of the machine harness. Refer to the complete Electrical Schematic of the machine. Check all of the connectors that are in the solenoid circuit. Ensure that all connections are clean, that all connectors are secure and that all connectors are in good condition. Repair the machine harness or replace the machine harness.

  STOP

Test Step 3. CHECK THE OPERATION OF THE ECM

The disconnect switch and the key start switch remain in the OFF position. The machine harness connector for the solenoid and the ECM J1 connector remain disconnected.

1. Remove the jumper wire that was installed in the last test step.

2. At the machine harness connector J1 of the ECM, remove the X961-GY(Grey) energize wire of the solenoid and remove the J1-65 socket from the harness connector. Perform these removals with a 151-6320 Removal Tool.

3. Reconnect the machine harness J1 connector to the ECM.

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

5. Use a 7X-1710 Multimeter Probe that is not connected to a multimeter or a similar device to make contact with the ECM pin at J1-65 through the empty space in the J1 connector.

6. Observe the status of the active CID 3210 FMI 05 diagnostic code and ground the other end of the 7X-1710 Multimeter Probe to frame ground.

Expected Result:

The CID 3210 FMI 05 diagnostic code is no longer active. A CID 3210 FMI 06 diagnostic code becomes active when the ECM pin at J1-65 is grounded.

Results:

• YES - The CID 3210 FMI 05 diagnostic code is no longer active. A CID 3210 FMI 06 diagnostic code has been activated after the ECM pin is grounded. The ECM has responded correctly to the grounded circuit condition in the solenoid circuit. The problem is probably not being caused by the ECM. Reinstall the energize wire of the solenoid into the correct spot of the connector on the ECM. Proceed to Test Step 4.

• NO - The CID 3210 FMI 05 diagnostic code remains active. The status of the active diagnostic code does not change when the ECM pin for the solenoid is grounded.

  Repair: The ECM has not responded correctly to the grounded condition in the solenoid circuit. The ECM may have failed.

  If the cause of the failure is not found, contact your dealership's Technical Communicator for possible consultation with Caterpillar. This consultation may greatly reduce repair time. If the cause of the diagnostic code is not found, replace the "Transmission/Chassis ECM". If the ECM must be replaced, refer to the Testing and Adjusting, "Electronic Control Module (ECM) - Replace" Section of this manual.

  STOP

Test Step 4. CHECK THE STATUS OF THE DIAGNOSTIC CODE

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

2. Check the wires for damage to the insulation that is caused by excessive heat, battery acid, or chafing.

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

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

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

6. Operate the machine.

7. Check the status of the CID 3210 FMI 05 diagnostic code.

Expected Result:

The CID 3210 FMI 05 diagnostic code is no longer active.

Results:

• YES - The CID 3210 FMI 05 diagnostic code is not active. The diagnostic code does not exist at this time.

  Repair: The initial diagnostic code was probably caused by a poor electrical connection at one of the harness connectors that was disconnected and reconnected. Resume normal machine operation.

  STOP

• NO - The CID 3210 FMI 05 diagnostic code is active. The diagnostic code has not been corrected. The ECM may have failed.

  Repair: Check the circuit again. Perform a wiggle test on the machine wiring harness with the Caterpillar Electronic Technician (Cat ET) service tool. The wiggle test can detect intermittent shorts or opens in the machine wiring harness.

  If the cause of the problem is not found in the machine harness, the ECM may have failed. This is unlikely as the ECM responded correctly to the grounded condition in the previous test step.

  Verify that all possible causes of the diagnostic code have been investigated. If the cause of the failure is not found, contact your dealership's Technical Communicator for possible consultation with Caterpillar. This consultation may greatly reduce repair time. If the cause of the diagnostic code is not found, replace the Transmission/Chassis ECM. If the ECM must be replaced, refer to the Testing and Adjusting, "Electronic Control Module (ECM) - Replace" Section of this manual.

  STOP