(SEBC1545 - ) - Service Information System
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Product: WHEEL LOADER
Model: 966H WHEEL LOADER BS6
Configuration: 3807254 STEEL MILL ARRANGEMENT CUSTOM PRODUCT SUPPORT LITERATURE FOR THE 966H WHEEL LOADER RYF00001-UP (MACHINE)
Troubleshooting
966H, 972H and 980H Wheel Loaders Power Train Electronic Control System
Media Number -UENR1625-01
Solenoid Valve - Test
SMCS - 5479-038
The following is a list of codes that are associated with the solenoid valves of the machine.
Transmission ECM (MID 81)
DTC Description
1401-3 Transmission Solenoid 1 :
Voltage Above Normal
1401-5 Transmission Solenoid 1 :
Current Below Normal
1401-6 Transmission Solenoid 1 :
Current Above Normal
1401- Transmission Solenoid 1 :
13 Calibration Required
1402-3 Transmission Solenoid 2 :
Voltage Above Normal
1402-5 Transmission Solenoid 2 :
Current Below Normal
1402-6 Transmission Solenoid 2 :
Current Above Normal
1402- Transmission Solenoid 2:
13 Calibration Required
1403-3 Transmission Solenoid 3 :
Voltage Above Normal
1403-5 Transmission Solenoid 3 :
Current Below Normal
1403-6 Transmission Solenoid 3 :
Current Above Normal
1403- Transmission Solenoid 3:
13 Calibration Required
1404-3 Transmission Solenoid 4 :
Voltage Above Normal
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Publication Date -01/05/2014 Date Updated -02/06/2014
i05330352
Table 1
System Response
The transmission clutch is engaged and cannot be released. Maximum
machine speed is limited to
15 km/h (9.32 mph).
The transmission clutch is released and cannot be engaged. Maximum
machine rimpull is reduced to 25% of normal operation.
The transmission clutch is released and cannot be engaged. Maximum
machine rimpull is reduced to 25% of normal operation.
Transmission clutch engagements may be rough or slow in this condition.
The transmission clutch is engaged and cannot be released. Maximum
machine speed is limited to
15 km/h (9.32 mph).
The transmission clutch is released and cannot be engaged. Maximum
machine rimpull is reduced to 25% of normal operation.
The transmission clutch is released and cannot be engaged. Maximum
machine rimpull is reduced to 25% of normal operation.
Transmission clutch engagements may be rough or slow in this condition.
The transmission clutch is engaged and cannot be released. Maximum
machine speed is limited to
15 km/h (9.32 mph).
The transmission clutch is released and cannot be engaged. Maximum
machine rimpull is reduced to 25% of normal operation.
The transmission clutch is released and cannot be engaged. Maximum
machine rimpull is reduced to 25% of normal operation.
Transmission clutch engagements may be rough or slow in this condition.
The transmission clutch is engaged and cannot be released. Maximum
machine speed is limited to
15 km/h (9.32 mph).
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1404-5 Transmission Solenoid 4 :
Current Below Normal
1404-6 Transmission Solenoid 4 :
Current Above Normal
1404- Transmission Solenoid 4:
13 Calibration Required
1405-3 Transmission Solenoid 5 :
Voltage Above Normal
1405-5 Transmission Solenoid 5 :
Current Below Normal
1405-6 Transmission Solenoid 5 :
Current Above Normal
1405- Transmission Solenoid 5:
13 Calibration Required
1406-3 Transmission Solenoid 6 :
Voltage Above Normal
1406-5 Transmission Solenoid 6 :
Current Below Normal
1406-6 Transmission Solenoid 6 :
Current Above Normal
1406- Transmission Solenoid 6:
13 Calibration Required
2129-3 Ride Control Solenoid : Voltage
Above Normal
2129-5 Ride Control Solenoid : Current
Below Normal
2129-6 Ride Control Solenoid : Current
Above Normal
2347-3 Ride Control Solenoid : Voltage
Above Normal
2347-5 Ride Control Solenoid 2: Current
Below Normal
2347-6 Ride Control Solenoid 2: Current
Above Normal
The transmission clutch is released and cannot be engaged. Maximum
machine rimpull is reduced to 25% of normal operation.
The transmission clutch is released and cannot be engaged. Maximum
machine rimpull is reduced to 25% of normal operation.
Transmission clutch engagements may be rough or slow in this condition.
The transmission clutch is engaged and cannot be released. Maximum
machine speed is limited to
15 km/h (9.32 mph).
The transmission clutch is released and cannot be engaged. Maximum
machine rimpull is reduced to 25% of normal operation.
The transmission clutch is released and cannot be engaged. Maximum
machine rimpull is reduced to 25% of normal operation.
Transmission clutch engagements may be rough or slow in this condition.
The transmission clutch is engaged and cannot be released. Maximum
machine speed is limited to
15 km/h (9.32 mph).
The transmission clutch is released and cannot be engaged. Maximum
machine rimpull is reduced to 25% of normal operation.
The transmission clutch is released and cannot be engaged. Maximum
machine rimpull is reduced to 25% of normal operation.
Transmission clutch engagements may be rough or slow in this condition.
Load sense solenoid is energized and the implement pump goes to full
stroke due to the cause of failure.
Load sense solenoid is de-energized regardless of the couple switch
position in the cab
Load sense solenoid is de-energized regardless of the couple switch
position in the cab
Load sense solenoid is energized and the implement pump goes to full
stroke due to the cause of failure.
Load sense solenoid is de-energized regardless of the couple switch
position in the cab
Load sense solenoid is de-energized regardless of the couple switch
position in the cab

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

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

Possible Causes for an FMI 3 Diagnostic code are:

The harness is shorted.

The Transmission ECM has failed. A failure of the ECM is unlikely.

Possible causes for an FMI 5 Diagnostic code are:

There is an open in the circuit.

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The solenoid has failed.

The sensor was activated in Cat ET when the component is not on the machine.

The Transmission ECM has failed. A failure of the ECM is unlikely.

Possible causes for an FMI 6 Diagnostic code are:

A wire is shorted to ground.

The solenoid has failed.

The Transmission ECM has failed. A failure of the ECM is unlikely.

Possible causes for an FMI 13 Diagnostic code are:

New software has been flashed to the ECM.

The ECM has been replaced.

Note: Prior to beginning this procedure, inspect the harness connectors that are involved in this circuit. Poor connections
can often be the cause of a problem in an electrical circuit. Verify that all connections in the circuit are clean, secure, and
in good condition. Check the wiring harness for pinch points or abrasions. Look for and repair areas that indicate wires are
exposed. If a problem with a connection is found, correct the problem and verify that the diagnostic code is active before
performing a troubleshooting procedure.

Illustration 1 g03376651

Transmission ECM J1 and J2 solenoid connections

Note: The diagrams above are simplified schematics of the Transmission ECM and the Implement ECM connections. The
schematic is electrically correct. However, not all of the possible harness connectors are shown. Refer to the latest
revision of the Electrical Schematic, UENR1687 for the complete system schematic of the 966H and 972H Wheel
Loaders Electrical System. Refer to the latest revision of the Electrical Schematic, UENR1699 for the complete schematic
of the 980H Wheel Loaders Electrical System.

Table 2

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(SEBC1545 - ) - Service Information System
Troubleshooting Test Steps
1. Identify Active FMI Code Associated
With Solenoid Circuit
2. Check The Machine Harness For A
Short
A. Turn the key start switch and the
disconnect switch OFF.
B. Disconnect the harness connection at
solenoid.
C. Disconnect the harness connection at
the machine ECM or the implement ECM,
depending on which ECM the solenoid is
connected to.
D. Measure the resistance of solenoid
signal contact to all J1 and J2 connectors,
if solenoid is wired directly to the
Transmission ECM. If the solenoid is
wired directly to the implement ECM,
measure resistance of solenoid contact to
all J1 connectors.
3. Check The Operation Of The ECM
A. The key start switch and the disconnect
switch remain OFF.
B. Use a wire removal tool to remove the
solenoid signal wire from the wiring
harness connector at the ECM.
C. Reconnect the harness connection at the
ECM.
D. Turn the disconnect switch and the key
start switch to the ON position.
Begin Process For FMI 4 Troubleshooting HERE
4. Check The Machine Harness For A
Short
A. Turn the key start switch and the
disconnect switch OFF.
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Values Results
FMI 3 diagnostic code, proceed to Test Step 2.
FMI 4 diagnostic code, proceed to Test Step 4.
FMI 5 diagnostic code, proceed to Test Step 7.
Code present.
FMI 6 diagnostic code, proceed to Test Step 10.
FMI 13 diagnostic code, proceed to Test Step 13
OK - All resistance readings are greater than 5K
.
Proceed to Test Step 3.
NOT OK - One or more readings are less than 5
.
Repair -A short exists between the signal
Each reading is greater contact and the circuit with the low resistance.
than 5K . Repair or replace the machine harness.
Note: A resistance that is greater than 5 but
less than 5K would indicate a loose
connection or a corroded connection in the
circuit. A resistance measurement that is greater
than 5K would indicate an open in the circuit.
STOP
OK - The FMI 03 changes to an FMI 05 after
the wire is disconnected. The ECM has
responded correctly to the condition of an open
circuit. Reinstall the disconnected wire to the
correct space in the ECM connector before
proceeding to Test Step 12.
NOT OK - The FMI 03 remains active. The
status of the active diagnostic code did not
change when the wire was disconnected from
the ECM.
The FMI 03 changes
to an FMI 05 after the
Repair - The ECM has not responded correctly
wire is disconnected.
to the condition of an open circuit. The operation
of the ECM is not correct. Prior to replacing the
ECM, always contact the Technical
Communication at your dealership for possible
consultation with Caterpillar. This consultation
may greatly reduce repair time.
Follow the steps in Troubleshooting, "ECM -
Replace" if the ECM needs to be replaced.
STOP
OK - All resistance readings are greater than 5K
Each reading is greater .
than 5K .
Proceed to Test Step 5.
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NOT OK - One or more readings are less than 5

B. Disconnect the harness connection at .
solenoid.
Repair -A short exists between the signal
C. Disconnect the harness connection at contact and the circuit with the low resistance.
the Transmission ECM or the implement Repair or replace the machine harness.
ECM, depending on which ECM the
solenoid is connected to. Note: A resistance that is greater than 5 but
less than 5K would indicate a loose
D. Measure the resistance of solenoid connection or a corroded connection in the
signal contact to all J1 and J2 connectors, circuit. A resistance measurement that is greater
if solenoid is wired directly to the than 5K would indicate an open in the circuit.
Transmission ECM. If the solenoid is
wired directly to the implement ECM, STOP
measure resistance of solenoid contact to
all J1 connectors.
OK - The reading is less than 5 , the harness is
correct.
5. Check The Machine Harness For An
Open
Proceed to Test Step 6.
A. The key start switch and the disconnect
NOT OK - The reading is greater than 5K .
switch remain OFF.
Circuit open in machine harness.
B. The wiring harness remains
Resistance Repair : The open is in the wire for the solenoid
disconnected at the ECM and the solenoid..
measurement is less signal or the return wire for the solenoid. Repair
than 5 . or replace the machine harness.
C. At the machine harness connector for
the solenoid, place a jumper wire from the
Note: A resistance that is greater than 5 but
two contacts for the solenoid.
less than 5K would indicate a loose
connection or a corroded connection in the
D. At the ECM harness connector measure
circuit. A resistance measurement that is greater
the resistance from the signal contact to the
than 5K would indicate an open in the circuit.
return contact.
STOP
6. Check The Solenoid.

A. Turn the key start switch and the

disconnect switch OFF. OK - The circuit is correct., that solenoid has
failed.
B. Disconnect the solenoid from the
machine harness. Repair: Replace the solenoid.

C. Place a jumper wire between contact 1 After replacement of the solenoid, confirm the
The code changes to
and contact 2, at the harness connector for diagnostic code is not active.
FMI 6 after the jumper
the solenoid.
wire is installed.
STOP
D. Turn the key start switch and the
disconnect switch ON. Do not start the NOT OK - The diagnostic code remains active.
engine.
Proceed to Test Step 12.
E. As the jumper is removed and
connected to the contacts, observe any
code change.
Begin Process For FMI 5 Troubleshooting HERE
7. Check The Solenoid. OK - The circuit is correct., that solenoid has
The code changes to failed.
A. Turn the key start switch and the FMI 6 after the jumper
disconnect switch OFF. wire is installed. Repair: Replace the solenoid.

B. Disconnect the solenoid from the After replacement of the solenoid, confirm the
machine harness. diagnostic code is not active.

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C. Place a jumper wire between contact 1 STOP

and contact 2, at the harness connector for
the solenoid. NOT OK - The diagnostic code remains active.

D. Turn the key start switch and the Proceed to Test Step 8.
disconnect switch ON. Do not start the
engine.

E. As the jumper is removed and

connected to the contacts, observe any
code change.
OK - The reading is less than 5 , the harness is
correct.
8. Check The Machine Harness For An
Proceed to Test Step 9.
Open.
NOT OK - The reading is greater than 5K .
A. Turn the key start switch and the
Circuit open in machine harness.
disconnect switch OFF.
Repair : The open is in the wire for the solenoid
B. Disconnect the harness connectors from
Each reading is less signal or the return wire for the solenoid. Repair
the ECM (or switch panel).
than 5 . or replace the machine harness.
C. The jumper wire remains installed.
Note: A resistance that is greater than 5 but
less than 5K would indicate a loose
D. At the machine harness connector for
connection or a corroded connection in the
the ECM, measure the resistance at the
circuit. A resistance measurement that is greater
ECM contacts for the solenoid.
than 5K would indicate an open in the circuit.

STOP
9. Check The Operation of the ECM.
OK - The circuit is correct., the ECM has
responded correctly to the condition of a
A. Remove the jumper wire that was
grounded circuit. The operation of the ECM is
installed in the last test step.
correct. Reinstall the disconnected wire into the
correct spot in the ECM connector before
B. At the connector for the ECM, use a
proceeding to Test Step 12.
wire removal tool to remove the signal
wire from the ECM harness connector.
NOT OK - The diagnostic code remains an FMI
5 when the multimeter probe creates a short to
C. Reconnect the machine harness
ground.
connectors to the ECM
The code changes to Repair: The ECM has not responded correctly
D. Turn the key start switch and the
FMI 6 after the jumper to the condition of a grounded circuit. The
disconnect switch ON. Do not start the
wire is installed. operation of the ECM is not correct.
engine.
Prior to replacing the ECM, always contact the
E. Use a multimeter probe that is NOT
Technical Communication at your dealership for
connected to a multimeter or a similar
possible consultation with Caterpillar. This
device to connect with the ECM. Connect
consultation may greatly reduce repair time.
at the signal wire contact through the
empty space.
Follow the steps in Troubleshooting, "ECM -
Replace" if the ECM needs to be replaced.
F. Observe the status of the diagnostic
code. Ground the other end of the
STOP
multimeter probe to frame ground.
Begin Process For FMI 6 Troubleshooting HERE
10. Check The Solenoid OK - The circuit is correct. The solenoid has
The FMI 6 diagnostic failed.
A. Turn the key start switch and the code changes to an
disconnect switch OFF. FMI 5 diagnostic code Repair: Repeat the jumper wire test. Verify the
solenoid failure. Replace the solenoid.

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(SEBC1545 - ) - Service Information System
B. Disconnect the solenoid from the
machine harness.
C. Place a jumper wire between contact 1
and contact 2, at the harness connector.
D. Turn the key start switch and the
disconnect switch ON. Do not start the
engine.
E. As the jumper is removed and
connected to the contacts, observe any
code change.
11. Check Machine Harness For A Short
To Ground
A. The machine harness remains
disconnected from the solenoid.
B. Turn the key start switch and the
disconnect switch OFF.
C. Disconnect the harness connectors from
the ECM (or switch panel).
D. At the harness connector for ECM,
measure the resistance between the
solenoid signal contact and all ground
contacts.
12. Check If The Diagnostic Code
Remains
A. Turn the key start switch and the
disconnect switch ON.
B. Clear all diagnostic codes.
C. Operate the machine.
D. Stop the machine and engage the safety
lock lever.
E. Check if diagnostic code for the
solenoid is active.
Begin Process For FMI 13 Troubleshooting HERE
13. Calibrate The Solenoid
A. Perform the calibration procedure for
the solenoid. Refer to Testing and
Adjusting, "Calibration" procedure.
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after the jumper wire
is installed. Note: After the solenoid is replaced, confirm
that the diagnostic code is no longer active.
STOP
NOT OK - The diagnostic code remains active.
Proceed to Test Step 11.
OK - Machine harness correct.
Proceed to Test Step 12.
NOT OK - One or more of the resistance
measurements are less than 5 . A short circuit
exists in the machine harness.
Repair: A short circuit exists between the wire
for the signal wire of the solenoid and the circuit
Each reading is greater
with the low resistance. Repair or replace the
than 5K .
machine harness.
Note: A resistance that is greater than 5 but
less than 5K would indicate a loose
connection or a corroded connection in the
circuit. A resistance measurement that is greater
than 5K would indicate an open in the circuit.
STOP
OK - The diagnostic code does not exist at this
time. The initial diagnostic code may have been
caused by poor electrical connection or short at
one of the harness connections. Resume machine
operation.
STOP
NOT OK - The diagnostic trouble code has not
been corrected. If the diagnostic code has not
been corrected after performing the procedure a
Code for solenoid is second time, the ECM may require replacement.
NO longer present.
Prior to replacing the ECM, contact the
Technical Communication at your dealership for
possible consultation with Caterpillar. This
consultation may greatly reduce repair time.
Refer to Troubleshooting, "ECM - Replace" if
the ECM needs to be replaced.
STOP
OK - The calibration procedure for the solenoid
The calibration was performed successfully. Resume normal
procedure for the machine operation.
solenoid was
performed STOP
successfully.
NOT OK - The calibration procedure was
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performed successfully.

Repair: Repeat the calibration procedure for the

solenoid. See the Testing and Adjusting,
"Calibration" procedure.

STOP

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