815 Soil Compactor and 816 Landfill Compactor Systems Solenoid Valve

Solenoid Valve - Test

815 Soil Compactor and 816 Landfill Compactor Systems [M0113643]

815 Soil Compactor and 816 Landfill Compactor Systems Sensor Supply - Test

815 Soil Compactor and 816 Landfill Compactor Systems Speed Sensor - Test

HYDRAULIC SYSTEM

VALVE GP-SOLENOID

815 Soil Compactor and 816 Landfill Compactor Systems Solenoid Valve - Test

1.1. Transmission ECM

2.1. Implement ECM

3.1. Diagnostic Trouble Code Procedure

4.1. FMI 3

5.1. FMI 5

6.1. FMI 6

7.1. FMI 13

Transmission ECM

The following is a list of Diagnostic Trouble Codes (DTCs) that are associated with the solenoid valves of the machine.

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Table 1
Transmission ECM (MID 081)
J1939	CDL	Code Description	System Response
	0681-3	Parking Brake Solenoid : Voltage Above Normal	Warning and park brake released.
	0681-5	Parking Brake Solenoid : Current Below Normal	Park brake gets applied without Indicator illuminated.
	0681-6	Parking Brake Solenoid : Current Above Normal	Park brake gets applied without Indicator illuminated.
	0681-7	Parking Brake Solenoid : Not Responding Properly	The solenoid has an internal component such as a spring which is broken. The spool within the solenoid will not return to the expected location.
	1401-3	Transmission Solenoid 1 : Voltage Above Normal	The transmission clutch is engaged and cannot be released. If clutch is not used in current gear, the transmission will automatically shift to the next suitable gear (or Neutral) until the fault is cleared. After the direction selector is placed in neutral, solenoid 2 cannot be engaged, it would cause a clutch tie up and the machine would not move. If the machine was underway, the transmission clutches could be damaged.
	1401-5	Transmission Solenoid 1 : Current Below Normal	The transmission clutch is released and cannot be engaged. If the clutch is used in current gear, the transmission will automatically shift to neutral until the direction selector is placed in neutral. After the direction selector is placed in neutral, another unaffected gear may be selected.
	1401-6	Transmission Solenoid 1 : Current Above Normal	The transmission clutch is released and cannot be engaged. If the clutch is used in current gear, the transmission will automatically shift to neutral until the direction selector is placed in neutral. After the direction selector is placed in neutral, another unaffected gear may be selected.
	1401-13	Transmission Solenoid 1 : Out of Calibration	Following the installation of the new clutch plate or shift control, a calibration of the transmission is required before the machine is released for operation.
	1402-3	Transmission Solenoid 2 : Voltage Above Normal	The transmission clutch is engaged and cannot be released. If clutch is not used in current gear, the transmission will automatically shift to the next suitable gear (or Neutral) until fault is cleared.
	1402-5	Transmission Solenoid 2 : Current Below Normal	The transmission clutch is released and cannot be engaged. If the clutch is used in current gear, the transmission will automatically shift to neutral until the direction selector is placed in neutral. After the direction selector is placed in neutral, another unaffected gear may be selected.
	1402-6	Transmission Solenoid 2 : Current Above Normal	The transmission clutch is released and cannot be engaged. If the clutch is used in current gear, the transmission will automatically shift to neutral until the direction selector is placed in neutral. After the direction selector is placed in neutral, another unaffected gear may be selected.
	1402-13	Transmission Solenoid 2 : Out of Calibration	Following the installation of the new clutch plate or shift control, a calibration of the transmission is required before the machine is released for operation.
	1403-3	Transmission Solenoid 3 : Voltage Above Normal	The transmission clutch is engaged and cannot be released. If clutch is not used in current gear, the transmission will automatically shift to the next suitable gear (or Neutral) until fault is cleared.
	1403-5	Transmission Solenoid 3 : Current Below Normal	The transmission clutch is released and cannot be engaged. If the clutch is used in current gear, the transmission will automatically shift to neutral until the direction selector is placed in neutral. After the direction selector is placed in neutral, another unaffected gear may be selected.
	1403-6	Transmission Solenoid 3 : Current Above Normal	The transmission clutch is released and cannot be engaged. If the clutch is used in current gear, the transmission will automatically shift to neutral until the direction selector is placed in neutral. After the direction selector is placed in neutral, another unaffected gear may be selected.
	1403-13	Transmission Solenoid 3 : Out of Calibration	Following the installation of the new clutch plate or shift control, a calibration of the transmission is required before the machine is released for operation.
	1404-3	Transmission Solenoid 4 : Voltage Above Normal	The transmission clutch is engaged and cannot be released. If clutch is not used in current gear, the transmission will automatically shift to the next suitable gear (or Neutral) until fault is cleared.
	1404-5	Transmission Solenoid 4 : Current Below Normal	The transmission clutch is released and cannot be engaged. If the clutch is used in current gear, the transmission will automatically shift to neutral until the direction selector is placed in neutral. After the direction selector is placed in neutral, another unaffected gear may be selected.
	1404-6	Transmission Solenoid 4 : Current Above Normal	The transmission clutch is released and cannot be engaged. If the clutch is used in current gear, the transmission will automatically shift to neutral until the direction selector is placed in neutral. After the direction selector is placed in neutral, another unaffected gear may be selected.
	1404-13	Transmission Solenoid 4 : Out of Calibration	Following the installation of the new clutch plate or shift control, a calibration of the transmission is required before the machine is released for operation.
	1405-3	Transmission Solenoid 5 : Voltage Above Normal	The transmission clutch is engaged and cannot be released. If clutch is not used in current gear, the transmission will automatically shift to the next suitable gear (or Neutral) until fault is cleared.
	1405-5	Transmission Solenoid 5 : Current Below Normal	The transmission clutch is released and cannot be engaged. If the clutch is used in current gear, the transmission will automatically shift to neutral until the direction selector is placed in neutral. After the direction selector is placed in neutral, another unaffected gear may be selected.
	1405-6	Transmission Solenoid 5 : Current Above Normal	The transmission clutch is released and cannot be engaged. If the clutch is used in current gear, the transmission will automatically shift to neutral until the direction selector is placed in neutral. After the direction selector is placed in neutral, another unaffected gear may be selected.
	1405-13	Transmission Solenoid 5 : Out of Calibration	Following the installation of the new clutch plate or shift control, a calibration of the transmission is required before the machine is released for operation.
	1406-3	Transmission Solenoid 6 : Voltage Above Normal	The transmission clutch is engaged and cannot be released. If clutch is not used in current gear, the transmission will automatically shift to the next suitable gear (or Neutral) until fault is cleared.
	1406-5	Transmission Solenoid 6 : Current Below Normal	The transmission clutch is released and cannot be engaged. If the clutch is used in current gear, the transmission will automatically shift to neutral until the direction selector is placed in neutral. After the direction selector is placed in neutral, another unaffected gear may be selected.
	1406-6	Transmission Solenoid 6 : Current Above Normal	The transmission clutch is released and cannot be engaged. If the clutch is used in current gear, the transmission will automatically shift to neutral until the direction selector is placed in neutral. After the direction selector is placed in neutral, another unaffected gear may be selected.
	1406-13	Transmission Solenoid 6 : Out of Calibration	Following the installation of the new clutch plate or shift control, a calibration of the transmission is required before the machine is released for operation.

Solenoids are 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. As a result the valve is opened. 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.

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Illustration 1	g06603053
Transmission ECM solenoid connections

The preceding diagram is a simplified schematic of the Transmission ECM connections. The schematic is electrically correct. However, not all the possible harness connectors are shown. Refer to the latest revision of Electrical Schematic, M0115149 or Electrical Schematic, M0115151 for the complete schematic.

Implement ECM

The following is a list of Diagnostic Trouble Codes (DTCs) that are associated with the solenoid valves of the machine.

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Table 2
Implement ECM (MID 082)
J1939	CDL	Code Description	System Response
	0358-3	Implement Pilot Pressure Supply Solenoid : Voltage Above Normal	All implement lift and tilt commands are disabled.
	0358-5	Implement Pilot Pressure Supply Solenoid : Current Below Normal	All implement functions are disabled.
	0358-6	Implement Pilot Pressure Supply Solenoid : Current Above Normal	All implement functions are disabled.
	0497-3	Tilt Right Solenoid: Voltage above normal	Tilt Right function will be disabled.
	0497-5	Tilt Right Solenoid: Current below normal	Tilt Right function will be disabled.
	0497-6	Tilt Right Solenoid: Current above normal	Tilt Right function will be disabled.
	0497-13	Tilt Right Solenoid: Out of calibration	Tilt Right function will be disabled.
	0498-3	Tilt Left Solenoid: Voltage above normal	Tilt Left function will be disabled.
	0498-5	Tilt Left Solenoid: Current below normal	Tilt Left function will be disabled.
	0498-6	Tilt Left Solenoid: Current above normal	Tilt Left function will be disabled.
	0498-13	Tilt Left Solenoid: Out of calibration	Tilt Left function will be disabled.
	1197-3	Blade Lower Solenoid : Voltage Above Normal	The blade lowering function is disabled.
	1197-5	Blade Lower Solenoid : Current Below Normal	The blade lowering function is disabled.
	1197-6	Blade Lower Solenoid : Current Above Normal	The blade lowering function is disabled.
	1197-13	Blade Lower Solenoid : Out of Calibration	The deadband in the control lever may be excessive. The operation of the blade may be jerky. When new controller or solenoid is installed, calibration is required.
	1198-3	Blade Raise Solenoid : Voltage Above Normal	The blade raise function is disabled.
	1198-5	Blade Raise Solenoid : Current Below Normal	The blade raise function is disabled.
	1198-6	Blade Raise Solenoid : Current Above Normal	The blade raise function is disabled.
	1198-13	Blade Raise Solenoid : Out of Calibration	The deadband in the control lever may be excessive. The operation of the blade may be jerky. When new controller or solenoid is installed, calibration is required.
	2671-3	Air Conditioner Compressor Clutch Solenoid : Voltage Above Normal	Compressor is constantly on due to a short circuit to power. Compressor can be damaged if voltage exceeds operational range.
	2671-5	Air Conditioner Compressor Clutch Solenoid : Current Below Normal	Current to solenoid is not sufficient to engage compressor. Air conditioning is disabled.
	2671-6	Air Conditioner Compressor Clutch Solenoid : Current Above Normal	Current to solenoid for engaging compressor will not shut off. Air conditioning will run constantly.

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

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Illustration 2	g06606996
Implement ECM solenoid connections

The preceding diagram is a simplified schematic of the Implement ECM connections. The schematic is electrically correct. However, not all the possible harness connectors are shown. Refer to the latest revision of Electrical Schematic, M0115149 or Electrical Schematic, M0115151 for the complete schematic.

Diagnostic Trouble Code Procedure

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Table 3
Required Tools
Tool	Part Number	Description	Qty
T1	146-4080⁽¹⁾	Digital Multimeter Group	1
	8T-3224	Needle Tip Group	1
	7X-1710	Multimeter Probe Group	1
	8T-8726	Cable Assembly (Three Pin) (3-Pin Breakout)	1
T2	JERD2129	Cat^® Electronic Technician (Cat ET)	1
		Windows-based PC	1
	538-5051	Communication Adapter Gp	1
T3	6V-4148	Connector Repair Kit (Sure Seal)	1
T3	190-8900	Connector Field Repair Kit (Deutsch)	1
T4	175-3700	Connector Repair Kit Deutsch DT	1

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⁽¹⁾	This multimeter can use an RS232C cable to connect to a Laptop computer or Dataview tool gp for troubleshooting.

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 3 diagnostic code, proceed to "FMI 3".
FMI 5 diagnostic code, proceed to "FMI 5".
FMI 6 diagnostic code, proceed to "FMI 6".
FMI 13 diagnostic code, proceed to "FMI 13".

FMI 3

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Table 4
Check The Machine Harness For A Short
Troubleshooting Test Steps	Values	Results
1. The start switch and the disconnect switch remain in the OFF position. 2. Disconnect the harness connector from the solenoid. 3. Disconnect the ECM machine harness connectors. 4. Measure the resistance between the solenoid signal contact and all the contacts that are used in the ECM.	Each reading is greater than 5K Ω.	Result: All resistance readings are greater than 5K Ω. Proceed to "Check If The Diagnostic Code Remains" Table 5. Result: One or more readings are less than 5 Ω. Repair: A short exists between the signal contact 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 "Check If The Diagnostic Code Remains" Table 5.

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Table 5
Check If The Diagnostic Code Remains
Troubleshooting Test Steps	Values	Results
1. Reconnect all harness connectors. Return machine to normal operating condition. 2. Turn the start switch and the disconnect switch ON. 3. Clear all diagnostic codes. 4. Operate the machine. 5. Stop the machine and engage the safety. 6. Check if the diagnostic code is active.	The diagnostic code is no longer present.	Result: 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. Result: 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 AVSpare. This consultation may effect repair time. Follow the steps in Troubleshooting, "ECM - Replace" if the ECM needs to be replaced. STOP.

FMI 5

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Table 6
Check The Solenoid
Troubleshooting Test Steps	Values	Results
1. Turn the start switch and the disconnect switch OFF. 2. Disconnect the solenoid from the machine harness. 3. At the harness connector for the solenoid, install a jumper wire between contact 1 and contact 2. 4. Turn the 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.	Result: 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 "Check If The Diagnostic Code Remains" Table 8. Result: The diagnostic code remains active. Proceed to "Check The Harness For An Open" Table 7.

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Table 7
Check The Harness For An Open
Troubleshooting Test Steps	Values	Results
1. Turn the start switch and the disconnect switch OFF. 2. Disconnect the harness connectors from the ECM. 3. The jumper wire remains installed. 4. 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.	Result: The reading is less than 5 Ω. The harness is correct. Proceed to "Check If The Diagnostic Code Remains" Table 8. Result: 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 "Check If The Diagnostic Code Remains" Table 8.

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Table 8
Check If The Diagnostic Code Remains
Troubleshooting Test Steps	Values	Results
1. Reconnect all harness connectors. Return machine to normal operating condition. 2. Turn the start switch and the disconnect switch ON. 3. Clear all diagnostic codes. 4. Operate the machine. 5. Stop the machine and engage the safety. 6. Check if the diagnostic code is active.	The diagnostic code is no longer present.	Result: 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. Result: 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 AVSpare. This consultation may effect repair time. Follow the steps in Troubleshooting, "ECM - Replace" if the ECM needs to be replaced. STOP.

FMI 6

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Table 9
Check The Solenoid
Troubleshooting Test Steps	Values	Results
1. Turn the start switch and the disconnect switch OFF. 2. Disconnect the solenoid from the machine harness. 3. Turn the start switch and the disconnect switch ON. Do not start the engine. 4. Observe the status of the diagnostic code.	The FMI 6 changes to an FMI 5 after the solenoid is disconnected.	Result: The circuit is correct. The solenoid has failed. Repair: Repeat the test. Verify the solenoid failure. Replace the solenoid. Proceed to "Check If The Diagnostic Code Remains" Table 11. Result: The diagnostic code remains active. Proceed to "Check Machine Harness For A Short To Ground" Table 10.

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Table 10
Check Machine Harness For A Short To Ground
Troubleshooting Test Steps	Values	Results
1. The machine harness remains disconnected from the solenoid. 2. Turn the start switch and the disconnect switch OFF. 3. Disconnect the harness connectors from the ECM. 4. 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.	Result: Machine harness correct. Proceed to "Check If The Diagnostic Code Remains" Table 11. Result: 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 "Check If The Diagnostic Code Remains" Table 11.

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Table 11
Check If The Diagnostic Code Remains
Troubleshooting Test Steps	Values	Results
1. Reconnect all harness connectors. Return machine to normal operating condition. 2. Turn the start switch and the disconnect switch ON. 3. Clear all diagnostic codes. 4. Operate the machine. 5. Stop the machine and engage the safety. 6. Check if the diagnostic code is active.	The diagnostic code is no longer present.	Result: 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. Result: 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 AVSpare. This consultation may effect repair time. Follow the steps in Troubleshooting, "ECM - Replace" if the ECM needs to be replaced. STOP.

FMI 13

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Table 12
Check The Calibration
Troubleshooting Test Steps	Values	Results
1. Perform the calibration procedure for the solenoid. Refer to the calibration procedure in Testing and Adjusting, M0113649 for this machine. 2. Observe the status of the diagnostic code.	The calibration was successful and the code is no longer active.	Result: The diagnostic code is no longer active. The calibration corrected the condition that caused the diagnostic code. STOP. Result: 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. Result: 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 AVSpare. This consultation may effect repair time. Follow the steps in Troubleshooting, "ECM - Replace" if the ECM needs to be replaced. STOP.