CW16 Pneumatic Compactor Machine Electronic Control System Caterpillar

Solenoid Valve - Test

Usage:

Machine ECM

The following is a list of diagnostic codes (SPN) that are associated with the solenoid valves of the machine.

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Table 1
Machine ECM (MID 39)
SPN-FMI	Code Description	System Response
619-3	Parking Brake Actuator : Voltage Above Normal	Stop Machine, Disable Propel Engine Shutdown, SPN 970=01 (ON) Fault Level - 3
619-5	Parking Brake Actuator : Current below normal	Stop Machine, Disable Propel Fault Level - 3
619-6	Parking Brake Actuator : Current above normal	Stop Machine, Disable Propel Fault Level - 3
741-5	Transmission 1 Forward Solenoid Valve: Current below normal	Disable Propel Fault Level - 3
741-6	Transmission 1 Forward Solenoid Valve: Current above normal	Disable Propel Fault Level - 3
741-13	Transmission 1 Forward Solenoid Valve: Out of calibration	Limit Propel to Low Gear Not Latched Fault Level - 1
1071-5	Engine Cooling Fan Drive Output : Current Below Normal	Disable Output Fault Level - 2
1071-6	Engine Cooling Fan Drive Output : Current Above Normal	Disable Output Fault Level - 2
4216-5	Transmission Reverse Solenoid Valve: Current below normal	Disable Propel Fault Level - 3
4216-6	Transmission Reverse Solenoid Valve: Current above normal	Disable Propel Fault Level - 3
4216-13	Transmission Reverse Solenoid Valve: Special Instruction	Limit Propel to Low Gear Not Latched Fault Level - 1
4217-3	Transmission 1 Shift Solenoid Valve (Right Drive): Voltage Above Normal	Two-Speed Solenoid SB All gears Machine decelerates to a stop. Neutral reset of lever is required to enable propel function. Machine speed limited to 50%. Automatically change travel mode to Low gear. 2 Two-Speed Solenoid SG/ OC High gear/Auto Machine decelerates to a stop. Neutral reset of lever is required to enable propel function. Automatically change travel mode to low speed 2 Two-Speed Solenoid SG/ OC Low gear Machine continues to operate as normal. Operator is warned of fault presence. 2
4217-5	Transmission 1 Shift Solenoid Valve (Right Drive) : Current below normal	Limit Propel to Low Gear Not Latched Fault Level - 2
4217-6	Transmission 1 Shift Solenoid Valve (Right Drive): Current above normal	Disable Propel Fault Level - 2
6722-5	Transmission #2 Forward Solenoid Valve: Current below normal	Disable Propel Fault Level - 3
6722-6	Transmission #2 Forward Solenoid Valve: Current above normal	Disable Propel Fault Level - 3
6722-13	Transmission #2 Forward Solenoid Valve: Special Instruction	Limit Propel to Low Gear Not Latched Fault Level - 1
6723-5	Transmission #2 Reverse Solenoid Valve: Current below normal	Disable Propel Fault Level - 3
6723-6	Transmission #2 Reverse Solenoid Valve: Current above normal	Disable Propel Fault Level - 3
6723-13	Transmission #2 Reverse Solenoid Valve: Special Instruction	Limit Propel to Low Gear Not Latched Fault Level - 1

The solenoid is used to shutoff, release, distribute, or mix fluids on the machine. Generally, multiple solenoids are located together on a manifold. The solenoid converts electrical energy into magnetic energy, moving a spool located inside the housing of the valve. A spring is used to hold the spool in position until the solenoid is energized.

The magnetic force that acts on the valve spool is created when a coil inside the solenoid is energized.

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 13 diagnostic code are:

The ECM detects a solenoid that needs calibration.

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Illustration 1	g06023904
Machine ECM solenoid connections

The diagram above is a simplified schematic of the Machine ECM connections. The schematic is electrically correct. However, not all the possible harness connectors are shown.

For the full Electrical Schematic of the Pneumatic Compactors in this manual, refer to the appropriate media.

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.

Identify the active FMI code associated with the components.
Determine which code is present and use the list below to determine which procedure to follow.

FMI 5 diagnostic code, proceed to Table 2.
FMI 6 diagnostic code, proceed to Table 3.
FMI 13 diagnostic code, proceed to Table 4.

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Table 2
FMI 5 Troubleshooting
Troubleshooting Test Steps	Values	Results
1. Check The Solenoid. A. Turn the key start switch and the disconnect switch OFF. B. Disconnect the solenoid from the machine harness. C. At the harness connector for the solenoid, install a jumper wire between contact 1 and contact 2. D. Turn the key start switch and the disconnect switch ON. Do not start the engine.	The FMI 5 diagnostic code changes to an FMI 6 after the jumper wire is installed.	OK - The harness is correct. The FMI 5 diagnostic code changes to an FMI 6 when the jumper wire is installed. The solenoid has failed. Repair: Replace the solenoid. Proceed to Test Step 3. NOT OK - The diagnostic code remains active. Proceed to Test Step 2.
2. Check The Harness For An Open. A. Turn the key start switch and the disconnect switch OFF. B. Disconnect the harness connectors from the ECM. C. The jumper wire remains installed. D. At the machine harness connector for the ECM, measure the resistance between the signal circuit and return circuit. Note: For solenoids that return to ground, measure the resistance between the signal circuit at the ECM harness connector and frame ground.	Each reading is less than 5 Ω.	OK - The reading is less than 5 Ω. The harness is correct. Proceed to Test Step 3. NOT OK - The reading is greater than 5K Ω. The open is in the signal circuit or the return circuit. Repair: 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 3.
3. Check If The Diagnostic Code Remains A. Reconnect all harness connectors. Return machine to normal operating condition. B. Turn the key start switch and the disconnect switch ON. C. Clear all diagnostic codes. D. Operate the machine. E. Stop the machine and engage the safety. F. Check if the diagnostic code is active.	The diagnostic code is no longer present.	OK - The diagnostic code does not exist currently. The 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 - The 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 the ECM, always contact the Technical Communicator at your dealership for possible consultation with Caterpillar. This consultation may effect repair time. Follow the steps in Troubleshooting, "ECM - Replace" if the ECM needs to be replaced. STOP.

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Table 3
FMI 6 Troubleshooting
Troubleshooting Test Steps	Values	Results
1. Check The Solenoid A. Turn the key start switch and the disconnect switch OFF. B. Disconnect the solenoid from the machine harness. C. Turn the key start switch and the disconnect switch ON. Do not start the engine. D. Observe the status of the diagnostic code.	The FMI 6 changes to an FMI 5 after the solenoid is disconnected.	OK - The circuit is correct. The solenoid has failed. Repair: Repeat the test. Verify the solenoid failure. Replace the solenoid. Proceed to Test Step 3. NOT OK - The diagnostic code remains active. Proceed to Test Step 2.
2. 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. D. At the harness connector for the 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 3. 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 signal wire 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 3.
3. Check If The Diagnostic Code Remains A. Reconnect all harness connectors. Return machine to normal operating condition. B. Turn the key start switch and the disconnect switch ON. C. Clear all diagnostic codes. D. Operate the machine. E. Stop the machine and engage the safety. F. Check if the diagnostic code is active.	The diagnostic code is no longer present.	OK - The diagnostic code does not exist currently. The 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 - The 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 the ECM, always contact the Technical Communicator at your dealership for possible consultation with Caterpillar. This consultation may effect repair time. Follow the steps in Troubleshooting, "ECM - Replace" if the ECM needs to be replaced. STOP.

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Table 4
FMI 13 Troubleshooting
Troubleshooting Test Steps	Values	Results
1. Check The Calibration A. Perform the calibration procedure for the solenoid. Refer to the Systems Operation, Testing and Adjusting, "Propel Currents - Calibrate" in the media appropriate for your machine. Refer to Systems Operation, Testing and Adjusting, UENR2051, "Propel Currents - Calibrate" B. Observe the status of the diagnostic code.	The calibration was successful and the code is no longer active.	OK - The diagnostic code is no longer active. The calibration corrected the condition that caused the diagnostic code. STOP. NOT OK - The FMI 13 Code is active. The diagnostic code has not been corrected. Repair: Verify that the correct software has been flashed into the ECM, or that the correct ECM is installed on the machine. Then repeat the calibration. NOT OK - The 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 the ECM, always contact the Technical Communicator at your dealership for possible consultation with Caterpillar. This consultation may effect repair time. Follow the steps in Troubleshooting, "ECM - Replace" if the ECM needs to be replaced. STOP.