815 Soil Compactor and 816 Landfill Compactor Systems Switch Circuits

Switch Circuits - Test

815 Soil Compactor and 816 Landfill Compactor Systems [M0113643]

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

815 Soil Compactor and 816 Landfill Compactor Systems ECM - Replace

ELECTRICAL AND STARTING SYSTEM

SWITCH GP

815 Soil Compactor and 816 Landfill Compactor Systems Relay - Test

815 Soil Compactor and 816 Landfill Compactor Systems Switch Circuits - Test

1.1. Transmission ECM

2.1. Implement ECM

3.1. Diagnostic Trouble Code Procedure

4.1. FMI 2

5.1. FMI 3

6.1. FMI 4

Transmission ECM

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

Show/hide table

Table 1
Transmission ECM (MID 081)
J1939	CDL	Code Description	System Response
	0070-2	Parking Brake Switch : Erratic, Intermittent, or Incorrect	Parking brake will not disengage when requested.
	0621-3	Downshift Switch : Voltage Above Normal	When this diagnostic code occurs, the transmission gear will be unable to be decreased.
	0621-4	Downshift Switch : Voltage Below Normal	When this diagnostic code occurs, the transmission gear will be unable to be decreased.
	0622-3	Upshift Switch : Voltage Above Normal	When this diagnostic code occurs, the transmission gear will be unable to be decreased.
	0622-4	Upshift Switch : Voltage Below Normal	When this diagnostic code occurs, the transmission gear will be unable to be decreased.
	0623-3	Directional Switch : Voltage Above Normal	The transmission will lock in neutral until a valid neutral switch position is sensed.
	0623-4	Directional Switch : Voltage Below Normal	The transmission will lock in neutral until a valid neutral switch position is sensed.
	0626-3	Steering/Transmission Lock Switch : Voltage Above Normal	When this diagnostic code occurs, there is no change in the system operation. The transmission will remain operational, even if the mechanical steering lock is in the locked position.
	0626-4	Steering/Transmission Lock Switch : Voltage Below Normal	When this diagnostic code occurs, there is no change in the system operation. The transmission will remain operational, even if the mechanical steering lock is in the locked position.
	1628-3	Armrest Position Switch : Voltage Above	Diagnostic occurs with Armrest DOWN and steering already enabled: Steering will remain enabled. Diagnostic occurs with Armrest UP: Steering will not be enabled when Armrest is lowered, unless machine speed is detected.
	1628-4	Armrest Position Switch : Voltage Below Normal	Diagnostic occurs with Armrest DOWN and steering already enabled: Steering will remain enabled. Diagnostic occurs with Armrest UP: Steering will not be enabled when Armrest is lowered, unless machine speed is detected.
	1834-2	Ignition Key Switch loss of signal	Machine start function is disabled.
	3797-3	Operator Seat Belt Switch : Voltage Above Normal	Machine start function is disabled.
	3797-4	Operator Seat Belt Switch : Voltage Below Normal	Machine start function is disabled.

Show/hide table




Illustration 1	g06603530
Schematic of the Transmission ECM switch circuits

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 switch circuits of the machine.

Show/hide table

Table 2
Implement ECM (MID 082)
J1939	CDL	Code Description	System Response
	0490-3	Implement Lockout Switch : Voltage Above Normal	All implement functions are disabled.
	0490-4	Implement Lockout Switch : Voltage Below Normal	All implement functions are disabled.
	2114-3	Blade Control Handle Trigger Switch : Voltage Above Normal	This feature shall continue to use the last known switch state until the operator implement control is returned to center. At that time the switch will transition to the Default Blade Tilt Mode. A Level 2 warning is generated.
	2114-4	Blade Control Handle Trigger Switch : Voltage Below Normal	This feature shall continue to use the last known switch state until the operator implement control is returned to center. At that time the switch will transition to the Default Blade Tilt Mode. A Level 2 warning is generated.
	2659-2	Cab Air Temperature Control Switch : Erratic, Intermittent, or Incorrect	Air conditioning is disabled. The Auto Temperature Control feature will not work properly.
	2811-3	Cab Blower Speed Control : Voltage Above Normal	HVAC system will be non-functional.
	2811-4	Cab Blower Speed Control : Voltage Below Normal	HVAC system will be non-functional.

Show/hide table




Illustration 2	g06603533
Schematic of the Implement ECM switch circuits

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

Show/hide table

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
T4	190-8900	Connector Field Repair Kit (Deutsch)	1
T5	175-3700	Connector Repair Kit Deutsch DT	1

Show/hide table

⁽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 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 this 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 2 diagnostic code, proceed to "FMI 2".
FMI 3 diagnostic code, proceed to "FMI 3".
FMI 4 diagnostic code, proceed to "FMI 4".

FMI 2

Show/hide table

Table 4
Check The Harness
Troubleshooting Test Steps	Values	Results
1. Turn the disconnect switch and the key start switch to the OFF position. 2. Inspect all harness connections. Make sure that the connectors are clean and tight. 3. Check the connectors for proper mating. Ensure that all the seals are present and in place. 4. Check the harness for signs of damage or abrasion. 5. Check the wires at the connector. Ensure that the wires are secured tightly into the connector. Take care not to pull the wire out of the connector. 6. Check the exposed wires at the connectors for nicks or signs of abrasion. 7. Check for moisture inside the connector.	The machine harness connectors are tight and free of corrosion.	Result: The machine harness connectors are tight and free of corrosion. Proceed to "Check The Harness For An Open" Table 5. Result: The machine harness connectors are in need of repair. Repair: Repair or replace the machine harness. Proceed to "Check The Switch" Table 6.

Show/hide table

Table 5
Check The Harness For An Open
Troubleshooting Test Steps	Values	Results
1. Turn the key start switch and the disconnect switch to the OFF position. 2. Disconnect the machine harness connector from the switch. 3. Disconnect the machine harness connectors from the ECM. 4. At the harness connector for the switch, place a jumper wire between the normally open (N/O) contact and the normally closed (N/C) contact. 5. At machine harness connector for the ECM, measure the resistance between the normally open (N/O) contact and the normally closed (N/C) contact.	The resistance is less than 5 Ω.	Result: The resistance is less than 5 Ω. The (N/O) and (N/C) circuits are not opened in the machine harness. Proceed to "Check The Switch" Table 6. Result: The resistance reading for the (N/O) and (N/C) circuits greater than 5K Ω. There is an open in one 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 7.

Show/hide table

Table 6
Check The Switch
Troubleshooting Test Steps	Values	Results
1. The disconnect switch and the key start switch remain in the OFF position. 2. Remove the switch from the machine harness. 3. Measure the resistance between the normally open contact and the switch return or ground. Toggle the operation of the switch and observe resistance changes. 4. Measure the resistance between the normally closed contact and the switch return or ground. Toggle the operation of the switch and observe resistance changes.	Open resistance is greater than 5K Ω. Closed resistance is less than 5 Ω.	Result: The measurements are correct. Proceed to "Check If The Diagnostic Code Remains" Table 7. Result: One or more of the measurements was incorrect. 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. Repair: Replace the switch. Proceed to "Check If The Diagnostic Code Remains" Table 7.

Show/hide table

Table 7
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 key start switch and the disconnect switch ON. 3. Clear all diagnostic codes. 4. Operate the machine. 5. Stop the machine and engage the safety lock. 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 3

Show/hide table

Table 8
Check The Harness For An Open
Troubleshooting Test Steps	Values	Results
1. Turn the key start switch and the disconnect switch to the OFF position. 2. Disconnect the machine harness connector from the switch. 3. Disconnect the machine harness connectors from the ECM. 4. At the harness connector for the switch, place a jumper wire between the normally open (N/O) contact and the normally closed (N/C) contact. 5. At machine harness connector for ECM, measure the resistance between the normally open (N/O) contact and the normally closed (N/C) contact.	The resistance is less than 5 Ω.	Result: The resistance is less than 5 Ω. The (N/O) and (N/C) circuits are not opened in the machine harness. Proceed to "Check The Circuit For A Short" Table 9. Result: The resistance reading for the (N/O) and (N/C) circuits greater than 5K Ω. There is an open in one circuit. 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. Repair: Repair or replace the machine harness. Proceed to "Check If The Diagnostic Code Remains" Table 12.

Show/hide table

Table 9
Check The Circuit For A Short
Troubleshooting Test Steps	Values	Results
1. The harness connectors for the switch and ECM remain disconnected. 2. Remove the jumper wire that was installed in the previous test step. 3. At the ECM machine harness connector, measure the resistance between the (N/O) contact and all the other contacts used in the ECM. 4. At the ECM machine harness connector, measure the resistance between the (N/C) contact and all the other contacts used in the ECM.	The resistance measurements are greater than 5K Ω.	Result: The resistance measurements are greater than 5K Ω. Proceed to "Check The Switch Ground Circuit" Table 10. Result: The resistance is less than 5K Ω. There is a short between the signal circuit and the circuit with the low-resistance measurement. 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. Repair: Repair or replace the machine harness. Proceed to "Check If The Diagnostic Code Remains" Table 12.

Show/hide table

Table 10
Check The Switch Ground Circuit
Troubleshooting Test Steps	Values	Results
1. The key start switch and disconnect switch remain in the OFF position. 2. The switch remains disconnected from the machine harness. 3. Measure the resistance between the return contact on the harness to frame ground or return circuit.	The resistance is less than 5 Ω.	Result: The ground circuit is correct. Proceed to "Check The Switch" Table 11 Result: The resistance is greater than 5K Ω. The ground circuit is open. Note: A resistance greater than 5 Ω but less than 5K Ω indicates a loose or corroded connection in the circuit. A resistance measurement greater than 5K Ω indicates an open in the circuit. Repair: Repair or replace the machine harness. Proceed to "Check If The Diagnostic Code Remains" Table 12.

Show/hide table

Table 11
Check The Switch
Troubleshooting Test Steps	Values	Results
1. The disconnect switch and the key start switch remain in the OFF position. 2. The switch remains disconnected from the machine harness. 3. Measure the resistance between the normally open contact and the switch return or ground. Toggle the operation of the switch and observe resistance changes. 4. Measure the resistance between the normally closed contact and the switch return or ground. Toggle the operation of the switch and observe resistance changes.	Open resistance is greater than 5K Ω. Closed resistance is less than 5 Ω.	Result: The measurements are correct. Proceed to "Check If The Diagnostic Code Remains" Table 12. Result: One or more of the measurements was incorrect. Note: A resistance greater than 5 Ω but less than 5K Ω indicates a loose or corroded connection in the circuit. A resistance measurement greater than 5K Ω indicates an open in the circuit. Repair: Replace the switch. Proceed to "Check If The Diagnostic Code Remains" Table 12.

Show/hide table

Table 12
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 key start switch and the disconnect switch ON. 3. Clear all diagnostic codes. 4. Operate the machine. 5. Stop the machine and engage the safety lock. 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 4

Show/hide table

Table 13
Check The Harness For A Short
Troubleshooting Test Steps	Values	Results
1. Turn the key start switch and the disconnect switch to the OFF position. 2. Disconnect the machine harness connectors from the switch. 3. Disconnect the machine harness connectors from the ECM. 4. At the ECM machine harness connector, measure the resistance between the (N/O) contact and all the other contacts used in the ECM. 5. At the ECM machine harness connector, measure the resistance between the (N/C) contact and all the other contacts used in the ECM.	The resistance measurements are greater than 5K Ω.	Result: The resistance measurements are greater than 5K Ω. Proceed to "Check The Switch" Table 14. Result: The resistance is less than 5K Ω. There is a short between the signal circuit and the circuit with the low-resistance measurement. Note: A resistance greater than 5 Ω but less than 5K Ω indicates a loose or corroded connection in the circuit. A resistance measurement greater than 5K Ω indicates an open in the circuit. Repair: Repair or replace the machine harness. Proceed to "Check If The Diagnostic Code Remains" Table 15.

Show/hide table

Table 14
Check The Switch
Troubleshooting Test Steps	Values	Results
1. The key start switch and the disconnect switch to the OFF position. 2. Disconnect the switch from the machine harness. 3. Measure the resistance between the normally open contact and the switch return or ground. Toggle the operation of the switch and observe resistance changes. 4. Measure the resistance between the normally closed contact and the switch return or ground. Toggle the operation of the switch and observe resistance changes.	Open resistance is greater than 5K Ω. Closed resistance is less than 5 Ω.	Result: The measurements are correct. Proceed to "Check If The Diagnostic Code Remains" Table 15... Result: One or more of the measurements was incorrect. Note: A resistance greater than 5 Ω but less than 5K Ω indicates a loose or a corroded connection in the circuit. A resistance measurement greater than 5K Ω indicates an open in the circuit. Repair: Replace the switch. Proceed to "Check If The Diagnostic Code Remains" Table 15.

Show/hide table

Table 15
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 key start switch and the disconnect switch ON. 3. Clear all diagnostic codes. 4. Operate the machine. 5. Stop the machine and engage the safety lock. 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.