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Product: WHEEL LOADER

Model: 966F II WHEEL LOADER 1SL
Configuration: C7 Engine Emissions Retrofit Repower Tier III For 815B Compactor, 966D/E/F, And 966F Series II Wheel Loader 1SL00001-UP (MACHINE)

Testing and Adjusting

ELECTRONIC TRANSMISSION CONTROL SYSTEM
Media Number -SENR5922-02 Publication Date -03/10/1994 Date Updated -11/02/2009

SENR59220002

Testing And Adjusting

Introduction
Troubleshooting the electronic transmission control system requires additional information from the machine Service
Manual. The Electronic System Schematic and the Operation & Maintenance Manual are required support material.

As a guide, a simplified electronic transmission control schematic is at the end of this manual. For a complete schematic,
see the Electrical System Schematic in the machine Service Manual.

If wire insulation is punctured during troubleshooting, repair after probing. Seal the punctures with 8T-0065 Adhesive.
Cover the adhesive with two layers of 1P-0810 Tape. Remove the harness connector from the control using the single
screw in the center of the connector.

When the troubleshooting procedure instructs to REPAIR THE HARNESS, use the Electrical System Schematic in the
machine Service Manual to trace the circuit. Perform continuity checks at connectors to locate harness failures. At
component connectors, always check the ground circuit. Less than five ohms of resistance is required between the
connector ground contacts and frame ground. Excessive ground resistance, greater than five ohms, can cause incorrect
diagnosing of problems.

During troubleshooting, inspect all component and harness connections before any component is replaced. If these
connections are not clean and tight they can cause electrical problems, either permanent or intermittent (come and go).
Make sure the connections are tight before other tests are made.

Caterpillar Digital Multimeter

Use the 6V-7070 Digital Multimeter or equivalent for making continuity checks, resistance measurements or voltage
measurements. The optional 8T-3224 Needle Tip Group for the 6V-7070, is useful during troubleshooting. For instruction
on use of the 6V-7070, see Special Instruction SEHS7734.

NOTE: Except for harness tests, continuity testers (such as 8T-0500), or voltage testers (such as 5P-7277) are not
recommended for use on present-day Caterpillar electrical circuits.

Troubleshooting Using The Display On The Control (If

Equipped)
The service connector provides access to the service and clear inputs. Connector contact 1 is the service input and contact
2 is the clear input. The service connector is part of the cab harness and is located near the control. For a more exact
service connector location and connector requirements, see the Electrical System Schematic in the machine Service
Manual.
Various diagnostic functions require the grounding and/or opening of the service and clear contacts at the service
connector. During troubleshooting, it is necessary for the service person to make the proper electrical connections
between the contacts of the service code connector. These electrical connections may be made with two jumpers. Also see
the topic Service Box in the Testing And Adjusting section.

Changing Modes

Control Display Area

(1) Readout.

The control has three display modes. The different modes are identified by the mode number which is shown on readout
(1). The three display modes and the corresponding mode numbers are:

Normal Mode - "- 0 -." is shown on mode readout (1).

Service Mode - "- 1 -." is shown on mode readout (1).

Test Mode - "- 2 -." is shown on mode readout (1).

Procedure
1. Turn key switch ON. Wait for the Self Test to finish; approximately seven seconds.

2. At the same time, ground the service and clear contacts of the service connector or actuate the mode switch on the
service box. This causes the mode numbers ("- 0 -." through "- 2 -.") to scroll on mode readout (1).

NOTE: Each time "- 0 -." is shown, the scrolling stops. The service and clear contacts must be opened from ground, then
closed to ground, to scroll the modes again.

3. When the desired mode number is shown on mode readout (1), remove ground from (open) the service and clear
contacts.

Service Tool

9U-6665 Service Tool

(1) Adapter cable. (2) Mode select switch. (3) Clear switch. (4) Scroll switch.

The 9U-6665 Service Tool is helpful for the service person to make the proper electrical connections at the service
connector during troubleshooting. The service tool and wiring adapter is shown in the Service Tool illustration. Adapter
cable (1) has two connectors that are wired in parallel so that the service tool is usable on the different types of machine
harnesses.

Actuating mode switch (2) scrolls through the three display modes. Actuating scroll switch (4) scrolls the display with the
control in the service or test mode. Actuating clear switch (3) clears the fault being continuously displayed in the service
mode. To use the service tool, refer to the Tool Operating Manual, Form No. NEHS0586.

Troubleshooting Using The Electronic Control Analyzer

Programmer (ECAP)
ECAP Connections

(1) Service connector.

(2) 7X-1570 Cable.

(3) 7X-1700 Communication Adapter (with NEXG4523 Communication Adapter Software installed).

(4): 7X-1851 Cable for 8T-8697-A ECAP later or 7X-1420 Cable for 8T-8697 ECAP earlier.

(5): 8T-8697-A ECAP later (with NEXG4521 Machine Functions Dual SPM installed)

or 8T-8697 ECAP earlier (with NEXG4521 Machine Functions Dual SPM installed).
Optional (not shown): 8C-9995 Mounting Bracket and 7X-1703 Plate Group.

The ECAP service tool is not needed to determine or clear system faults, but it makes the tasks easier and faster. The
ECAP can also display the status of certain system parameters. This feature along with the ability to display system fault
history information, make the ECAP a useful troubleshooting tool.

The ECAP connects to the service connector (if equipped) located next to the harness code connector in the cab. To use
the ECAP service tool, see SEHS9343 Tool Operating Manual. The Tool Operating Manual contains all the instructions
and information needed to use the ECAP to troubleshoot the electronic transmission control system. After determining the
system faults with the ECAP, see the topic Faults Detected By The Control in the Testing And Adjusting section.

Troubleshooting Using The Caterpillar Monitoring

System Or The Computerized Monitoring System (CMS)
Transmission control diagnostic information can be shown on the monitoring system display. When using the monitoring
system for troubleshooting, all faults associated with the transmission control have a MID of 81. For more information
about use of the Caterpillar Monitoring System, see service manual SENR6717. For more information about use of the
Computerized Monitoring System (CMS), see service manual SENR5247.

Faults Detected By The Control

When the control detects a fault while in normal mode, the fault is shown on the display, if equipped, or the operator
monitor. Service mode shows the fault and is used to clear the fault from the control memory. For detailed information,
see Service Mode (Mode 1) under the topic Diagnostic Operation located in the Systems Operation section.
Initial Troubleshooting Procedure For A Control With A Display

Control Display Area

(1) Power indicator. (2) Readout (component identifier and failure more identifier). (3) Service mode indicator. (4) Fault present indicator.
Use the following procedure when a fault is detected. When a fault is detected, the readout will show the fault.

1. Enter service mode (mode 1).

2. A single fault is shown and is on-hold at this time. When no fault has occurred, the display shows "---.".

3. To see all detected faults, scroll the faults. To do so, ground the service contact of the service connector.

4. Place the desired fault on-hold (stop the scrolling). To do so, remove ground from the service contact of the service
connector when the desired fault is shown.

5. Observe fault present indicator (4):

* If fault present indicator (4) is ON, the fault shown is currently present.
* If fault present indicator (4) is OFF, the fault shown is not present at this time. The fault has occurred and then
went away, sometime in the past (intermittent).

6. To troubleshoot the fault, go to the procedure with that CID and FMI.

7. After a fault is corrected, clear the fault. To do so, momentarily ground the clear contact of the service connector while
the fault is on-hold. After clearing, the display advances to the next fault if there is one.

8. Repeat Steps 2 through 8 for any remaining faults. Return to normal mode when finished.

Initial Troubleshooting Procedure For A Control Without A Display

If the machine is equipped with the Caterpillar Monitoring System or the Computerized Monitoring System (CMS) a
detected transmission control fault will be displayed in the readout area. Use the following procedure when a fault is
detected. When a fault is detected, the service code indicator shows "SERV CODE" while in normal mode.

NOTE: For more information about use of the Caterpillar Monitoring System, see service manual SENR6717. For more
information about use of the Computerized Monitoring System (CMS), see service manual SENR5247.

1. Enter service mode.

NOTE: Diagnostic Scrolling Mode may be entered to see the detected faults, but The faults can be more easily diagnosed
using Service Mode. Service Mode allows faults to be placed on-hold for further investigation and to be cleared when the
problem has been fixed.

2. A single fault is shown and is on-hold at this time. The display toggles between the MID, the CID, and the FMI. When
no fault is available; the MID shows "---". The display does not toggle to show the CID, FMI information.

3. To see all detected faults, scroll the faults. To do so, ground the service contact of the service connector. The display
momentarily shows the MID then CID and FMI for each fault. The MID shows "End" after the last fault has been shown.

4. Place the desired fault on-hold (stop the scrolling). To do so, remove ground from the service contact of the service
connector when the desired fault is shown.

5. Make sure that the MID is "81".

6. Observe the fault present indicator:

* If the fault present indicator shows "SERV CODE", then the fault shown is currently present.
* If the fault present indicator is OFF, then the fault shown is not present at this time. The fault has occurred and
then went away, sometime in the past (intermittent).

7. To troubleshoot the fault, go to the procedure with the same CID and FMI.

8. After a fault is corrected or it is no longer needed, clear the fault. To do so, momentarily ground the clear contact of the
service connector while the fault is on-hold. After clearing, the display advances to the next available fault.
9. Repeat Steps 2 through 8 for the remaining faults. Return to normal mode when finished.

Troubleshooting Procedures:
Go to the procedure which corresponds to the CID and FMI shown on the control display. Use the operator monitor to
show the CID and FMI if the control has no display.

NOTE: Repair wiring after probing. Seal the punctures with 8T-0065 Adhesive. Cover the adhesive with two layers of 1P
-0810 Tape.

CID 168 Procedure (Electrical System Voltage)

The diagnostic circuit in the control identifies a system voltage that is either below 21.3 DCV or above 32.5 DCV.

Ensure that the fault is being displayed.

FMI F03

This fault should only be displayed with the fault present indicator ON and the engine running. If this occurs, the charging
system is charging at an excessive voltage. Check the charging system. See Starting And Charging System module,
SENR2947 in the machine Service Manual.

If this fault is displayed, with the fault present indicator ON, the engine stopped and no battery charger connected, replace
the control. See the topic Control Replacement in the Testing And Adjusting section.

FMI F04

1. CHECK BATTERY VOLTAGE - Start the engine and run at high idle for several minutes. Measure the battery voltage
at the battery posts.

* Voltage is at or above 21.3 DCV; battery voltage is correct. Go to Step 2.

* Voltage is below 21.3 DCV; the charging system is not correct. Check the charging system. See Starting And
Charging System module, SENR2947 in the machine Service Manual.

2. CHECK SYSTEM VOLTAGE AT CONTROL - Using sharp meter test leads, puncture the wire insulation near the
control connector. Measure the system voltage between wires 164-WH and 202-BK at contacts 1 and 2 of the harness
connector. The engine must be running at high idle.

* Voltage is below 21.3 DCV; harness is not correct. Repair or replace the harness.
* Voltage is at or above 21.3 DCV; system voltage is correct. Check to make sure CID 168 and FMI F04 are still
displayed and that the fault present indicator is ON. Disconnect the control harness connector and inspect contacts 1
and 2. Connect harness connector to the control. If fault still exists, with the fault present indicator ON, replace the
control. See the topic Control Replacement in the Testing And Adjusting section.

CID 190 Procedure (Engine Speed Sensor)

Service Notes: Ensure that fault being analyzed is on-hold. Ensure that the fault present indicator is ON.

The engine RPM input is a frequency type sensor input. The engine speed signal is at contact 6 of the control connector.

FMI F08

1. CHECK SENSOR RESISTANCE - Disconnect the machine harness from the sensor. At the sensor connector, measure
the resistance between the two contacts.

* Resistance is NOT between 100 and 500 Ohms; the speed sensor is faulty. Replace the sensor. Adjust the speed
sensor properly when installing it. See Speed Sensor Adjustment. Clear the fault code.
* Resistance is between 100 and 500 Ohms; the speed sensor resistance is correct. Go to Step 2.
2. CHECK SENSOR VOLTAGE - Reconnect the sensor to the machine harness. Disconnect the machine harness from
the control. Start the engine and run at low idle. At the machine harness connector, for the control, measure the voltage
(ACV) between contact 2 (ground) and contact 6.

* Voltage is greater than 3.0 ACV; the speed sensor voltage is correct. Replace the control; see Control
Replacement.
* Voltage is less than 3.0 ACV; the speed sensor voltage is NOT correct. Go to Step 3.

3. CHECK SENSOR - Remove the sensor and check for foreign material on sensor tip. Install the speed sensor and adjust
correctly, see the topic Speed Sensor Adjustment in the Testing And Adjusting section. Check the sensor voltage in the
same manner as in Step 2.

* Voltage remains less than 3.0 ACV; there is a defect. Go to Step 4.

* Voltage is now greater than 3.0 ACV. Problem is NOT present; adjustment of the speed sensor corrected the
problem. Clear the fault code.

4. CHECK HARNESS - Connect the sensor to the machine harness. The control remains disconnected from the machine
harness. At the machine harness connector, for the control, measure the resistance between contact 2 (ground) and contact
6.

* Resistance is between 100 and 500 Ohms; the machine harness resistance is correct. Replace the sensor. Adjust
the speed sensor properly when installing it. See the topic Speed Sensor Adjustment in the Testing And Adjusting
section. Clear the fault code.
* Resistance is NOT between 100 and 500 Ohms; the machine harness is shorted or open. Repair or replace the
harness. Clear the fault code.

CID 248 Procedure (Data Link)

FMI F02

This fault is recorded when the control does not receive expected information from the data link (wire 944-OR or 945-
BR).

Service Notes: Ensure that the CID 248/FMI F02 fault is on-hold and that the fault present indicator is ON.

1. INSPECT HARNESS CONNECTORS - Inspect the machine harness connections related to the data link. Make sure
that connectors are clean and tight. If necessary, repair or replace the machine harness. Check to see if the fault present
indicator remains ON for the CID 248/FMI F02 fault.

* Fault present indicator is OFF; a machine harness connection was faulty. The fault is not present now. Possibly an
intermittent connection exists in the data link circuits of the machine harness. Watch for a recurrence of this fault.
* Fault present indicator is ON; the fault remains present. Go to Step 2.

2. CHECK FOR SHORTED HARNESS - Disconnect the machine harness from the transmission control and CMS. At
the machine harness connector for the transmission control, measure the resistance between contacts 8 and 9.

* Resistance is less than 5000 Ohms (continuity); the machine harness is faulty. There is a short between frame
ground and the data link circuit in the machine harness. Repair or replace the machine harness.
* Resistance is greater than 5000 Ohms (no continuity); harness circuit resistance is correct. Go to Step 3.

3. CHECK FOR OPEN HARNESS - The transmission control and CMS remain disconnected from the machine harness.
Check the continuity of the data link circuit in the machine harness. Place a jumper between contacts 23 and 24 of the
machine harness connector for CMS. Check for continuity between contacts 8 and 9 of the machine harness connector for
the transmission control.

* There is NO continuity; the machine harness is faulty. The data link circuit (wire 944-OR or 945-BR) is open in
the machine harness. Repair or replace the machine harness.
* There is continuity; this circuit is not the cause of the fault. Go to Step 4.
4. CHECK FOR OPEN HARNESS - The transmission control and CMS remain disconnected from the machine harness.
Remove the jumper of the previous Step. Check the continuity of the data link circuit in the machine harness. Place a
jumper between contacts 8 and 9 of the machine harness connector for the transmission control. Check for continuity
between contacts 23 and 24 of the machine harness connector for CMS.

* There is NO continuity; the machine harness is faulty. The data link circuit (wire 944-OR or 945-BR) is open in
the machine harness. Repair or replace the machine harness.
* There is continuity; the data link circuit in the machine harness is correct. It is unlikely that an electronic control
is faulty. Perform the previous Steps again. If the cause is not found, replace the controls one at a time to determine
which control is the cause of the fault. See the subject Control Replacement.

CID 368 Procedure (Auto/Manual Transmission Switch), CID 627 Procedure (Park Brake
Switch), CID 621 Procedure (Downshift Switch)

Service Notes: Ensure that fault being analyzed is on-hold. Ensure that the fault present indicator is ON.

FMI F02

These faults are recorded when the control reads improper signals from the auto/manual transmission switch, the
downshift switch or the park brake switch.

The control detects the status of the switch circuits. The status is correct, when one circuit is open and one is grounded.
The status is wrong, when both circuits are open or grounded at the same time. Connector contacts 20 and 21 are for the
auto/manual switch. Connector contacts 22 and 23 are for the downshift switch. Connector contacts 3 and 4 are for the
park brake switch.

1. CHECK CIRCUIT FOR PROPER OPERATION - Disconnect the harness connector from the control. At the harness
connector, check for continuity from contact 2 (ground) to the switch input circuits with the faults. One input for the
circuit should have continuity and one should not. Place the switch in the other position and the status of each input
should change.

* Operation is correct; switch and switch harness circuitry is correct. Inspect harness connector contacts. Connect
harness connector to control and check control for the same fault, with the fault present indicator ON. If present, the
control is faulty. Replace the control, see the topic Control Replacement in the Testing And Adjusting section.
* Operation is not correct; switch or switch harness circuitry is not correct. Go to Step 2.

2. CHECK SWITCH - At the switch, check for the same operation as in Step 1.

* Operation is not correct; switch is faulty. Repair or replace the switch.

* Operation is correct; harness is faulty. Repair or replace the harness.

CID 362 (Ride Control Solenoid), CID 631 Procedure (Solenoid 1 - Reverse), CID 632 Procedure
(Solenoid 2 - Forward), CID 633 Procedure (Solenoid 3 - Gear 4), CID 634 Procedure (Solenoid 4
- Gear 3), CID 635 Procedure (Solenoid 5 - Gear 2), CID 636 Procedure (Solenoid 6 - Gear 1),
CID 688 Procedure (Dual Horsepower Solenoid)
Transmission Solenoid Location
(1) Solenoid 1 - Reverse. (2) Solenoid 2 - Forward. (3) Solenoid 3 - Gear 4. (4) Solenoid 4 - Gear 3. (5) Solenoid 5 - Gear 2. (6) Solenoid 6 - Gear
1.

Service Notes: Ensure that the fault being analyzed is on-hold. Ensure that the fault present indicator is ON. The
auto/manual switch should be in the manual position while troubleshooting solenoid circuit problems.

The following chart shows which transmission solenoids are energized in each position of the shift handle. An easy check
of the solenoids can be done by placing a steel washer next to the solenoid that should be energized. When the solenoid is
energized it becomes magnetic. The washer should be attracted to the energized solenoid. The same check can be done on
the ride control and dual horsepower solenoids.

FMI F03
This fault is recorded when the control senses there is a short to +battery in the solenoid circuit.

1. CHECK FOR SHORT TO +BATTERY - Disconnect the machine harness connector from the control. Check for
continuity from the faulty solenoid output circuit to +battery (contact 1). The connector contacts are: Reverse - 31,
Forward - 32, Gear 4 - 33, Gear 3 - 34, Gear 2 - 35, Gear 1 - 36, Ride Control - 37 and Dual Horsepower - 38. Turn the
various power circuits (headlights, heater etc.) OFF and ON during this test to check for short from these circuits to the
solenoid output circuit.

* There is NOT continuity; solenoid harness is not shorted to +battery. Go to Step 2.

* There is continuity; the solenoid harness is shorted to +battery. Repair or replace harness.

2. CHECK FOR SHORT TO OTHER SOLENOID OUTPUTS - Check for continuity from the faulty solenoid output to
the other solenoid outputs. The connector contacts are: Reverse - 31, Forward - 32, Gear 4 - 33, Gear 3 - 34, Gear 2 - 35,
Gear 1 - 36, Ride Control - 37 and Dual Horsepower - 38.

* There is NOT continuity; solenoid harness circuitry is correct. Inspect harness connector contacts. Connect
harness connector to control and check control for the same fault, with the fault present indicator ON. If present, the
control is faulty. Replace the control, see Control Replacement.
* There is continuity; the solenoid harness is shorted. Repair or replace harness.

FMI F05

This fault is recorded when the control senses there is not a complete electrical circuit for this solenoid.

CHECK FOR OPEN HARNESS - Disconnect the machine harness connector from the control. Measure the resistance
from the faulty solenoid output circuit to solenoid return (contact 39). The connector contacts are: Reverse - 31, Forward -
32, Gear 4 - 33, Gear 3 - 34, Gear 2 - 35, Gear 1 - 36, Ride Control - 37 and Dual Horsepower - 38.

* Resistance is 8.15 ± .6 Ohms; solenoid circuitry resistance is correct. Inspect harness connector contacts. Connect
harness connector to control and check control for the same fault, with the fault present indicator ON. If present, the
control is faulty. Replace the control, see the topic Control Replacement in the Testing And Adjusting section.
* Resistance is NOT 8.15 ± .6 Ohms; the solenoid or solenoid harness circuitry is faulty. Repair or replace harness
and/or solenoid.

FMI F06

This fault is recorded when the control senses there is a short to ground in the solenoid circuit.

CHECK FOR SHORT TO GROUND - Disconnect the machine harness connector from the control. Check for continuity
from the faulty solenoid output circuit to ground (contact 2). The connector contacts are: Reverse - 31, Forward - 32, Gear
4 - 33, Gear 3 - 34, Gear 2 - 35, Gear 1 - 36, Ride Control - 37 and Dual Horsepower - 38.

* There is NOT continuity; solenoid harness circuitry is correct. Inspect harness connector contacts. Connect
harness connector to control and check control for the same fault. If present, the control is faulty. Replace the
control, see the topic Control Replacement in the Testing And Adjusting section.
* There is continuity; the solenoid or solenoid harness is shorted to ground. Repair or replace harness and/or
solenoid.

FMI F12

This fault is recorded when the control senses an internal fault. If this fault is present, replace the control. See the topic
Control Replacement in the Testing And Adjusting section.

CID 617 (Air Inlet Heater Relay)

Service Notes: Ensure that the fault being analyzed is on-hold. Ensure that the fault present indicator is ON.

FMI F03
This fault is recorded when the control senses there is a short to +battery in the relay circuit.

1. CHECK FOR SHORT TO +BATTERY - Disconnect the machine harness connector from the control. Check for
continuity from connector contact 10 to contact 1 (+battery). Turn the various power circuits (headlights, heater etc.) OFF
and ON during this test to check for short from these circuits to the output circuit.

* There is NOT continuity; relay harness is not shorted to +battery. Go to Step 2.

* There is continuity; the relay harness is shorted to +battery. Repair or replace harness.

2. CHECK FOR SHORT TO OTHER SOLENOID OUTPUTS - Check for continuity from connector contact 10 to the
other solenoid outputs. The connector contacts are: Reverse - 31, Forward - 32, Gear 4 - 33, Gear 3 - 34, Gear 2 - 35, Gear
1 - 36, Ride Control - 37 and Dual Horsepower - 38.

* There is NOT continuity; relay harness circuitry is correct. Inspect harness connector contacts. Connect harness
connector to control and check control for the same fault, with the fault present indicator ON. If present, the control
is faulty. Replace the control, see Control Replacement.
* There is continuity; the relay harness is shorted. Repair or replace harness.

FMI F05

This fault is recorded when the control senses there is not a complete electrical circuit for this relay.

CHECK FOR OPEN HARNESS - Disconnect the machine harness connector from the control. Measure the resistance
from connector contact 10 to contact 39 (solenoid return).

* Resistance is 15 to 65 Ohms; relay circuitry resistance is correct. Inspect harness connector contacts. Connect
harness connector to control and check control for the same fault, with the fault present indicator ON. If present, the
control is faulty. Replace the control, see the topic Control Replacement in the Testing And Adjusting section.
* Resistance is NOT 15 to 65 Ohms; the relay or relay harness circuitry is faulty. Repair or replace harness and/or
relay.

FMI F06

This fault is recorded when the control senses there is a short to ground in the solenoid circuit.

CHECK FOR SHORT TO GROUND - Disconnect the machine harness connector from the control. Check for continuity
from connector contact 10 to contact 2 (ground).

* There is NOT continuity; relay harness circuitry is correct. Inspect harness connector contacts. Connect harness
connector to control and check control for the same fault. If present, the control is faulty. Replace the control, see
the topic Control Replacement in the Testing And Adjusting section.
* There is continuity; the relay or relay harness is shorted to ground. Repair or replace harness and/or relay.

FMI F12

This fault is recorded when the control senses an internal fault. If this fault is present, replace the control. See the topic
Control Replacement in the Testing And Adjusting section.

CID 650 Procedure (Harness Code)

NOTE: Check to see if a data link fault (CID 248/FMI F02) exists. If a data link fault is present, correct it prior to
performing these procedures.

Service Notes: Ensure that the fault being analyzed is on-hold. Ensure that the fault is present.

FMI F02
This fault is recorded when the control does not recognize the harness code received from CMS on the data link (wires
944-OR and 945-BR).

1. CHECK CMS - The transmission control receives harness code information from CMS. Check CMS for a related CMS
fault. See service manual SENR5247 Computerized Monitoring System (CMS) With VFD Circular Gauges.

* CMS has a related fault; correct the related fault per the CMS service manual. Then go to Step 2.
* CMS does not have a related fault; check the data link. Perform the troubleshooting procedure for a data link fault
(CID 248/FMI F02).

2. RECHECK FOR FAULT - Check the transmission control to see if the fault present indicator remains ON for this fault
(CID 650/FMI F02).

* Fault present indicator is ON; check the data link. Perform the troubleshooting procedure for a data link fault
(CID 248/FMI F02).
* Fault present indicator is OFF; the fault is corrected. Clear the fault. Watch for a recurrence of this fault.

CID 668 Procedure (Shift Handle) (Control Without a Display)

Disconnect the shift handle harness connectors. At the 9 contact machine harness connector check for battery voltage
between contact 2 (ground) and contact 1. Neutralizer switch must NOT be activated. If not correct, repair or replace
harness or switch. If correct turn the disconnect switch to OFF position. Use the machine Electrical System Schematic to
check the wiring harness from the shift handle to the control. Check for shorts and continuity of the harness circuits.

* Harness is NOT correct; repair or replace the harness.

* Harness is correct; check all connector contacts. Check for shift handle fault codes. If still present replace the shift
handle. If the problem is still present replace the transmission control.

CID 668 Procedure (Shift Handle) (Control With a Display)

Service Notes: Ensure that the fault being analyzed is on-hold.

NOTE: The procedure that follows is used with 105-0154 and 106-4804 Shift Handle Control Group. Use the previous
procedure "CID 668 Procedure (Shift Handle) (Control Without a Display)" to test the 107-6219 Shift Handle Control
Group.

Use test mode (mode 2) to find the area of the shift handle or shift handle harness with the fault. In test mode the control
detects faults that occur in the shift handle switches and related harness circuits.

NOTE: The neutralizer switch must NOT be activated during this test.

1. Put control into test mode (mode 2).

2. Move the shift handle through neutral and all gear and direction positions, pausing for one second in each position.
After moving the shift handle through all positions the display shows "---." if no faults exist. If a fault does exist, the
display shows the control connector contact number(s) that corresponds to the faulty shift handle circuits.

* Display shows number(s) "18" and/or "19"; shift handle and/or neutralizer switch circuits are not correct. Go to
Step 4.
* Display shows number(s) "12" through "17"; shift handle switch and/or ground circuits not correct. Go to Step 3.
* Display shows "---."; shift handle circuit fault no longer exists. Check harness and harness connections for
damage and poor connections. Clear the fault. Move the shift handle through each position several times. Wiggle
the shift handle To find intermittent problems in the handle. Check the control for the same fault (CID 668). If the
control detected the fault, replace the shift handle.

3. CHECK SHIFT HANDLE GROUND CIRCUIT - Turn the disconnect switch to OFF position. Disconnect the 9 and 10
contact shift handle connectors. At the 9 contact machine harness connector for the shift handle, check for continuity from
ground to contact 2.

* There is continuity; the shift handle ground circuit is correct. Go to Step 5.

 * There is NO continuity; the shift handle ground circuit in the harness has a fault. Repair or replace the harness.

4. CHECK SHIFT HANDLE POWER CIRCUITS - Disconnect the 9 and 10 contact shift handle connectors. At the 9
contact machine harness connector for the shift handle, check for battery voltage between contact 2 (ground) and contacts
1 and 9. Neutralizer switch must NOT be activated.

* Battery voltage measured; the shift handle power circuits are correct. Go to Step 5.
* Battery voltage is NOT measured; the power circuit harness or neutralizer switch is not correct. Repair or replace
the harness and/or switch.

5. CHECK SHIFT HANDLE - See the topic Shift Handle Test in the Testing And Adjusting section.

* Shift handle is correct; harness or harness connector problem. Go to Step 6.

* Shift handle NOT correct; there is a fault in the shift handle. Replace the shift handle.

6. CHECK HARNESS FROM SHIFT HANDLE TO CONTROL - Use the machine Electrical System Schematic to
check for shorts and continuity of the harness circuits that correspond to the connector contacts shown on the control
display.

* Harness is NOT correct; repair or replace the harness.

* Harness is correct; Check all connector contacts. Change the control to test mode and check shift handle again. If
numbers are still shown, replace the control. See the topic Control Replacement in the Testing And Adjusting
section.

CID 671 Procedure (Transmission Speed Sensor)

Service Notes: Ensure that fault being analyzed is on-hold.

The transmission RPM input is a frequency type sensor input. The transmission speed signal is at contact 5 of the control
connector.

FMI F08

1. CHECK SENSOR - Remove the sensor and check for foreign material on sensor tip. Install the speed sensor and adjust
correctly, see the topic Speed Sensor Adjustment in the Testing And Adjusting section. Clear the fault and test machine
operation. Check the control for the same fault (CID 671).

* Fault is shown; the speed sensor or harness is not correct. Go to Step 2.

* Fault is NOT shown; adjustment of the speed sensor or cleaning speed sensor tip corrected the problem. Clear the
fault code.

2. CHECK HARNESS - Connect the sensor to the machine harness. The control remains disconnected from the machine
harness. At the machine harness connector, for the control, measure the resistance between contact 2 (ground) and contact
5.

* Resistance is between 1000 and 1200 Ohms; the machine harness resistance is correct. Replace the sensor. Adjust
the speed sensor properly when installing it. See the topic Speed Sensor Adjustment in the Testing And Adjusting
section. Clear the fault code.
* Resistance is NOT between 1000 and 1200 Ohms; the machine harness is shorted or open. Repair or replace the
harness. Clear the fault code.

CID 680 Procedure (Ride Control Switch)

Service Notes: Ensure that fault being analyzed is on-hold. Ensure that the fault present indicator is ON.

FMI F02 (Machines With Air Over Hydraulic Brakes)

These faults are recorded when the control reads improper signals from the ride control switch.
The control detects the status of the ride control switch circuits. The status is correct, when the ride switch control inputs
are as specified in one of the following charts. If the status is wrong a fault is recorded.

1. CHECK CIRCUIT FOR PROPER OPERATION - Disconnect the harness connector from the control. At the harness
connector, check for continuity from contact 2 (ground) to the auto (contact 26) switch input circuit and from contact 1
(+battery) to the N/C (contact 11) and N/O (contact 10) switch input circuits. Use the following chart to check the status
of each input for all three switch positions.

* Operation is correct; switch and switch harness circuitry is correct. Inspect harness connector contacts. Connect
harness connector to control and check control for the same fault, with the fault present indicator ON. If present, the
control is faulty. Replace the control, see the topic Control Replacement in the Testing And Adjusting section.
* Operation is not correct; switch or switch harness circuitry is not correct. Go to Step 2.

2. CHECK SWITCH - At the switch, check for the same operation as in Step 1.

* Operation is not correct; switch is faulty. Repair or replace the switch.

* Operation is correct; harness is faulty. Repair or replace the harness.

FMI F02 (Machines With Hydraulic Over Hydraulic Brakes)

These faults are recorded when the control reads improper signals from the ride control switch.

The control detects the status of the ride control switch circuits. The status is correct, when the ride switch control inputs
are as specified in one of the following charts. If the status is wrong a fault is recorded.

1. CHECK CIRCUIT FOR PROPER OPERATION - Disconnect the harness connector from the control. At the harness
connector, check for continuity from contact 2 (ground) to the ride control switch inputs (contacts 24 and 26). Use the
following chart to check the status of each input for all three switch positions.

* Operation is correct; switch and switch harness circuitry is correct. Inspect harness connector contacts. Connect
harness connector to control and check control for the same fault, with the fault present indicator ON. If present, the
control is faulty. Replace the control, see the topic Control Replacement in the Testing And Adjusting section.
* Operation is not correct; switch or switch harness circuitry is not correct. Go to Step 2.
2. CHECK SWITCH - At the switch, check for the same operation as in Step 1.

* Operation is not correct; switch is faulty. Repair or replace the switch.

* Operation is correct; harness is faulty. Repair or replace the harness.

CID 685 Procedure (Service Identification Code)

Service Notes: It may be impossible to change modes or clear faults if this fault is present. If this fault is present, fault
codes may not be displayed properly.

FMI F02

CHECK HARNESS - Turn the disconnect switch to the OFF position. Disconnect the machine harness from the control.
Check the harness between the control connector and the service connector. Check for short to ground, short between
service inputs and open circuits.

* Harness is correct; the control has a fault. Inspect the contacts on the machine harness connector and connect to
the control. Check for presence of fault code 685. If fault is still present, replace the control. See the topic Control
Replacement in the Testing And Adjusting section.
* Harness is NOT correct; the harness has a fault. Repair or replace the harness.

CID 687 (Option Identification Code)

Service Notes: Ensure that the fault being analyzed is on-hold. Ensure that the fault is ACTIVE.

FMI F02

When turned ON, the control looks at the option code contacts, if the contacts do not represent a valid option code, this
fault is recorded. See the Options Code Configuration chart on the Electrical System Schematic for the machine being
serviced.

CHECK OPTION CODE - Disconnect the machine harness from the control. At the machine harness connector for the
control, check for proper option code. The proper option code can be found in the Options Code Configuration chart on
the Electrical System Schematic.

* Option code is correct; option code circuitry is correct. Inspect harness connector contacts. Connect harness to
control. Clear the fault. Turn the key switch OFF then back ON to recheck the control. If the same fault is active,
replace the control. See the topic Control Replacement in the Testing And Adjusting section.
* Option code is NOT correct; option code circuitry is faulty. Repair the option code circuits or replace the harness.
Clear the fault.

Faults Not Detected By The Control

Transmission Does Not Shift Automatically
CHECK AUTO/MANUAL SWITCH INPUT - If the transmission does not shift automatically while in AUTO mode and
there is no fault code displayed, verify that the control is getting the proper signals from the AUTO/MANUAL switch.
See machine Electrical System Schematic for proper operation of switch.

* If the control has the proper signals for automatic operation, follow the procedure for fault codes CID 190 and
CID 671.
* If the control does not have the proper signals follow the procedure for fault codes CID 368 and CID 621.

Control Display Area Is Blank (For Machines Equipped With A Control

That Has A Display)
1. CHECK FOR BATTERY VOLTAGE AT THE CONTROL - Battery voltage is the voltage measured at the battery
posts. Voltage at the control must not vary more than .5 volt from battery voltage. Using sharp meter test leads, puncture
the wire insulation and measure the system voltage between contacts 1 and 2 of the control at the harness connector. Key
switch must be in the ON position.

* Voltage measured does NOT vary from battery voltage more than .5 DCV; system voltage is correct. Disconnect
connector and inspect connector contacts. Connect harness connector to control. If the display is still blank, the
control is faulty. Replace the control, see the topic Control Replacement in the Testing And Adjusting section.
* Voltage measured does vary from battery voltage more than .5 DCV; system voltage is incorrect. Go to Step 2.

2. CHECK FOR OPEN TRANSMISSION CONTROL FUSE - Check machine fuse panel for an open transmission
control fuse.

* Fuse is open; fuse is faulty. Go to Step 3.

* Fuse is NOT open; the harness is faulty. There is an open circuit in the battery and/or ground circuits or the
connector contacts are dirty. Inspect connector contacts. Repair or replace harness.

3. CHECK FOR SHORTED HARNESS - Disconnect the machine harness connector from the control. Measure the
resistance from connector contacts 1 and 2 on the harness connector.

* There is NO continuity; the harness circuit resistance is correct. Go to Step 4.

* There is continuity; the harness is not correct. There is a short between the +battery and frame ground or between
wires in the harness. Repair or replace the harness.

4. CHECK CONTROL - Measure the resistance from harness connector contacts 1 and 2 on the control.

* Resistance is less than 100 Ohms; the control is not correct. Replace the control, see the topic Control
Replacement in the Testing And Adjusting section.
* Resistance is greater than 100 Ohms; the harness is not correct. There is an intermittent short between +battery
and frame ground. Repair or replace the harness.

Speed Sensor Adjustment

Speed Sensor
(1) Air gap. (2) Locknut.

1. Remove the speed sensor. Align a gear tooth directly in the center of the threaded sensor opening.

2. By hand, screw the sensor into the hole until the end of the sensor just makes contact with the gear tooth.

3. Turn the sensor back out 1/2 turn (180° in the counterclockwise direction). This sets air gap (1) to 0.89 mm (.035 in).

4. Tighten locknut (2) to 25 ± 5 N·m (18 ± 4 lb ft).

NOTE: Do not allow the sensor to turn as locknut (2) is tightened.

Shift Handle Test

Test For The 105-0154 And The 106-4804 Control Groups
Use the charts below to check the shift handle switches. Use a 6V-7070 Digital Multimeter on the diode scale for these
tests. The polarity of the meter leads is important for these tests. If the shift handle switches operate according to the
charts, the shift handle is good.
Use a 6V-7070 Digital Multimeter on the 200 Ohms scale for the following chart. If the shift handle switch operates
according to the chart, the shift handle is good.
Test For The 107-6219 Control Group
The 107-6219 Control Group contains electronic circuitry and cannot be tested using the 6V-7070 Digital Multimeter. If
the electronic transmission control indicates a shift circuit fault, check the associated wiring harness, before replacing the
107-6219 Control Group.

Self Test (For Controls With A Display)

Control Display Area

(1) Power indicator. (2) Readout (component identifier and failure mode identifier). (3) Service mode indicator. (4) Fault present indicator.

The self test verifies that the control is operating properly. The control performs an automatic self test each time the key
switch is turned from the OFF to the ON position.

The internal circuits and the display are automatically checked. The operator must observe the display to determine
whether or not the control is operating properly.

During the self test, the tests follow this sequence:

1. All three indicators are ON and the digital display shows "888.". The dot in the upper left corner is shown for one half
second and "888." is shown for two seconds.

2. The red and yellow indicators turn OFF. The digital display shows the one digit options identification code and the two
digit machine identification code for two seconds. The left most digit is the options identification code and the right two
digits are the machine code. The machine code is a two digit representation of the harness code received from CMS via
the data link. For the machine code of the machine being serviced, see the Operation And Maintenance Manual for that
machine.

3. The digital display shows the software version. This number identifies the software which is used within the control.

4. The digital display shows "-0-." for two seconds. This indicates that the control is in normal mode (mode 0).

5. The green indicator remains ON and the digital display shows "---." if there are no faults. If a fault has occurred the
display will show the component identifier (CID) and the failure mode identifier (FMI) codes. If the fault is present, the
fault present indicator will be ON. If the fault is not present, the fault present indicator will be OFF.

* If the control operates as described; the control is operating properly.

* If the control does not operate as described; there is a harness code problem or the control is faulty. Check the
harness code, follow the troubleshooting procedure for the harness code fault CID 650. If the fault present indicator
flashes and the display is blank, the control is faulty. Replace the control, see the topic Control Replacement in the
Testing And Adjusting section.

Control Replacement
Prior to replacement of the control, ensure that replacement is absolutely necessary. Rarely is the control the cause of a
fault. Always check that power is available to the control; battery voltage is required between control connector contacts 1
and 2 of the machine harness.

Procedure

1. Turn the key switch to the OFF position. Disconnect the machine harness from the control.

2. Remove the control.

3. Make sure the replacement control has the correct part number.

4. Connect the machine harness to the control.

5. Install the replacement control.

6. Turn the disconnect and key switches to the ON position. Make sure the control successfully completes the self test; see
Self Test.

Glossary
+Battery
+Battery refers to any of the harness wiring which is part of the circuit that connects to the positive batterypost.
+V
+V is a constant voltage that is supplied to a component to provide electrical power for its operation. +V is
provided by an electronic control module or the battery.
Abnormal
Abnormal refers to a machine condition or signal that is not normal. The presence of an abnormal condition or
signal means a problem exists and warning operation is activated which notifies the operator.
CID (Component Identifier)
The CID is a diagnostic code that tells which component or system is faulty. For example; auto/manual switch,
speed sensor, or shift handle. The CID is a three digit code that is located in the digital readout area when in normal
or service mode.
Clear
Clear refers to removing diagnostic information from the memory of the control. Before clearing information, it is
necessary that the information is on-hold and that the control is in service mode.
Connector Contact
 A connector contact is the component of a harness connector that actually makes the electrical connection.
Connector contacts are either pins or sockets.
Detected Fault
A detected fault is a fault that has been found by the control. The fault is recorded and diagnostic information is
available when in service mode.
Diagnostic
Diagnostic refers to the showing, monitoring and/or recording of information other than normal. Diagnostic
information is available from service, test or normal mode.
Display
Display refers to the indicators or digital readouts within the control display area.
Fault
A fault is a failure of a component of the system. For example; open or shorted harness, faulty switch, sensor or
control.
FMI (Failure Mode Identifier)
The FMI is a diagnostic code that tells what type of failure has occurred. For example; voltage above normal,
current below normal or abnormal frequency. The FMI is a two digit code preceded by the letter "F". This code is
located in the digital readout area when in service mode.
Hard Wired
Hard wired refers to electrical connections made within the harness that are permanent. These soldered or crimped
connections are not meant to be altered.
Hold or On-Hold
Hold or On-hold refers to holding (or locking) a set of diagnostic information that is shown in the digital display
area when in service mode. It is necessary to hold the set of diagnostic information before troubleshooting or
clearing.
Jumper
A jumper is a piece of wire used to make an electrical connection during troubleshooting.
Option Code
Option code refers to the grounded or open condition of the two option code inputs (connector contacts 25, 27 and
30). The option code tells the control what options are installed on the machine.
Scroll
Scrolling is the process of showing (within the digital display area) all available sets of diagnostic information, one
set at a time. A set of diagnostic information is shown briefly and then the display automatically advances to the
next set. After all sets are shown the sets are repeated.
Show
Show refers to information within the control display area that is viewed by the operator or service person.
Signal Wire
The signal wire is the harness wire which connects the sensor or switch to the control.
Switch Input
A switch input is any input of the control which is expecting only an open (floating) or grounded signal.
System Voltage
System voltage is the actual voltage that exists between the positive battery post and frame ground. System voltage
is also referred to as +battery voltage.
Undetected Fault
An undetected fault is a fault that exists and is not found by the control but is found by the operator or service
person.
Machine Code
The machine code is a two digit number that has been assigned to a particular harness code for a particular
machine. The machine code is shown on the control display during the Self Test. Each sales model has a specific
harness code and therefore also a specific machine code.

Electronic Transmission Control System Schematics

NOTE: The simplified system schematics that follow are for controls with a display. These schematics are electrically
correct, but do not show all the possible harness connectors. For a complete electrical system schematic, always see the
Electrical System Schematic module in the machine Service Manual.

Machines With Air Over Hydraulic Brakes

Machines With Hydraulic Over Hydraulic Brakes
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