416E, 420E and 430E Backhoe Loaders MID 039 - CID 1958 - FMI 04 Caterpillar

Conditions Which Generate This Code:

Illustration 1	g01530516
Schematic of the Position Sensor "(E-Stick)"

This diagnostic code is associated with the Position Sensor "(E-Stick)". The FMI 04 means that the ECM has determined that the voltage of the circuit for the position sensor is below normal.

The position sensor is a PWM sensor that operates at a frequency of approximately 500 hertz.

The possible causes of this diagnostic code are listed below:

• The Accugrade10 Volts DC supply is faulty or the Accugrade 10 Volts DC supply has failed.

• There is an open circuit between the Accugrade 10 Volts DC supply and the sensor.

• The signal circuit for the sensor is shorted to ground.

• The sensor is faulty or the sensor has failed.

• The ECM has failed. This is unlikely.

Note: The following test procedure may create other diagnostic codes. Ignore these created diagnostic codes and clear the diagnostic codes when the original diagnostic code has been corrected. Ensure that the diagnostic code of CID 1958 FMI 04 is active before performing this procedure.

Note: Use the 146-4080 Digital Multimeter for the measurements in this procedure.

System Response:

A level 1 warning is generated. The diagnostic code of CID 1958 FMI 04 will be logged in the internal memory of the ECM.

Note: Make sure that the Accugrade 10 Volts DC signal from the machine ECM is present and correct. Use the 146-4080 Digital Multimeter to check the signal at contact J1-69 (wire 799-WH) and J1-70 (wire J766-PU) at the J1machine harness connector for the machine ECM. DO NOT PROCEED FURTHER UNTIL THE OUTPUT FROM THE 10 VOLTS DC POWER SUPPLY IS CORRECT.

Test Step 1. INSPECT THE SENSOR.

1. Perform a visual inspection of the sensor, the wiring for the sensor and the hardware that is associated with the sensor.

Expected Result:

There is no apparent damage to the sensor, the wiring for the sensor or the hardware that is associated with the sensor.

Results:

• OK - There is no apparent damage to the sensor or to the wiring for the sensor or to the hardware that is associated with the sensor. Proceed to Test Step 2.

• NOT OK - There is apparent damage to the sensor, the wiring for the sensor or the hardware that is associated with the sensor.

  Repair: Replace the damaged part.

  Proceed to Test Step 2.

Test Step 2. CHECK THE ADJUSTMENT AND/OR THE CALIBRATION OF THE SENSOR.

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

2. Perform the calibration of the position sensor.

   Note: Make sure that you follow the correct procedure for testing the range of the sensor. See the Troubleshooting, "Calibration" section for additional information on these calibration procedures for the sensor.

3. Check the status of the diagnostic code.

Expected Result:

The CID 1956 FMI 04 diagnostic code is not active.

Results:

• OK - The diagnostic is not active. The adjustment and/or the calibration has corrected the failure. Resume normal operation.STOP

• NOT OK - The CID 1956 FMI 04 diagnostic code is still active. Exit the calibration procedure. Proceed to Test Step 3.

Test Step 3. CHECK FOR POWER AT THE SENSOR.

1. Do not disconnect the harness connector from the sensor.

2. At the back of the harness connector for the sensor, insert a 7X-1710 Multimeter Probe along contact 1 (wire 799-WH) for the voltage supply. Insert the other 7X-1710 Multimeter Probe along contact 2 (wire 799-WH) for the ground signal.

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

4. Without disconnecting the sensor or the hardware that is associated with the sensor from the machine, take the sensor through the full operating range of the sensor. In order to move the sensor through the full operating range, fully extend and retract the Bucket cylinder from stop to stop. Observe that the positive lead stays connected to contact 1 (wire 799-WH) and that the negative lead stays connected to contact 2 (wire J766-PU).

5. Monitor the voltage from contact 1 (wire 799-WH) to contact 2 (wire J766-PU).

Expected Result:

The voltage is 10 Volts DC.

Results:

• OK - The voltage is 10 Volts DC. Proceed to Test Step 4.

• NOT OK - The voltage is NOT 10 Volts DC. The circuit is open.

  Repair: Repair the machine harness or replace the machine harness.

  STOP

Test Step 4. CHECK THE SIGNAL CIRCUIT OF THE SENSOR.

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

2. Disconnect the 7X-1710 Multimeter Probe from the contact 1 (wire 799-WH). The other 7X-1710 Multimeter Probe remains along contact 2 (wire J766-PU).

3. At the back of the harness connector for the sensor, insert the first 7X-1710 Multimeter Probe along contact 3 (wire H903-PK).

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

5. Monitor the signal of the sensor with the 146-4080 Digital Multimeter .

6. Without disconnecting the sensor or the hardware that is associated with the sensor from the machine, take the sensor through the full operating range of the sensor. In order to move the sensor through the full operating range, fully extend and retract the Bucket cylinder from stop to stop.

   Note: Make sure that you follow the correct procedure for testing the range of the sensor. See the Troubleshooting, "Calibration" section for additional information on these calibration procedures for the sensor.

Expected Result:

The signal from the sensor is from about 2 Volts DC at the lower stop to about 8 Volts DC at the upper stop of the cylinder travel.

Results:

• OK - The sensor's signal responds correctly. The sensor is operating correctly. Proceed to Test Step 5.

• NOT OK - The sensor's signal does not respond correctly. The sensor is NOT operating correctly.

  Repair: Replace the sensor.

  STOP

Test Step 5. CHECK THE SIGNAL AT THE ECM.

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

2. Insert the 7X-1710 Multimeter Probes into the back of the ECM connector along J2-18 (wire H903-PK) and J1-70 (wire J766-PU).

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

4. Monitor the signal from the sensor with the 146-4080 Digital Multimeter .

5. Without disconnecting the sensor or the hardware that is associated with the sensor from the machine, take the sensor through the full operating range of the sensor. In order to move the sensor through the full operating range, fully extend and retract the Bucket cylinder from stop to stop.

   Note: Make sure that you follow the correct procedure for testing the range of the sensor. See the Troubleshooting, "Calibration" section for additional information on these calibration procedures for the sensor.

Expected Result:

The signal from the sensor is from about 2 Volts DC at the lower stop to about 8 Volts DC at the upper stop of the cylinder travel.

Results:

• OK - The sensor's signal responds correctly. The sensor is operating correctly. Proceed to Test Step 6.

• NOT OK - The sensor's signal does not respond correctly. The harness has failed.

  Repair: Repair the machine harness or replace the machine harness.

  STOP

Test Step 6. CHECK THE SIGNAL CIRCUIT FOR A SHORT IN THE HARNESS.

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

2. Disconnect the machine harness connectors from the sensor and the ECM.

3. Measure the resistance between contact J2-18 (wire H903-PK) and all contacts that are used in the machine harness connectors for the ECM.

Expected Result:

Each resistance measurement is greater than 5000 ohms.

Results:

• OK - Each of the resistance measurements are greater than 5000 ohms. The circuit is correct. Proceed to Test Step 7.

• NOT OK - The resistance is less than 5 ohms. The signal circuit is shorted to another circuit in the harness.

  Repair: Repair the machine harness or replace the machine harness.

  STOP

Test Step 7. CHECK IF THE DIAGNOSTIC CODE REMAINS

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

2. Reconnect all harness connectors.

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

4. Operate the machine and take the sensor through the operating range of the sensor.

5. Check the status of the CID 1958 FMI 04 diagnostic code.

Expected Result:

The CID 1958 FMI 04 diagnostic code is not active at the maximum range of the sensor.

Results:

• OK - The CID 1958 FMI 04 diagnostic code is not active at the maximum range of the sensor. The diagnostic code does not exist at this time. The initial diagnostic code was probably caused by a poor connection or a short at one of the connectors that was disconnected and reconnected. Resume normal operation.STOP

• NOT OK - The CID 1958 FMI 04 diagnostic code is active at the maximum range of the sensor. The diagnostic code has not been corrected. The ECM may have failed.

  Repair: It is unlikely that the ECM has failed. Exit this procedure. Perform the adjustment procedure for the sensor, if necessary. Then perform the calibration procedure for the sensor. Perform this procedure again. If the cause of the failure is not found, replace the ECM. See the Troubleshooting, "Electronic Control Module (ECM) - Replace".

  STOP