Solenoid Valve - Test

320D2 & 320D2 L Excavators PBB00001-UP (MACHINE) POWERED BY C7.1 Engine...
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Welcome: p230fdc
Product: EXCAVATOR
Model: 320D2 L EXCAVATOR PBB00238
Configuration: 320D2 & 320D2 L Excavators PBB00001-UP (MACHINE) POWERED BY C7.1 Engine
Troubleshooting
320D2 and 323D2 Excavators
Media Number -UENR3858-05 Publication Date -01/08/2015 Date Updated -10/08/2015
i05870266
Solenoid Valve - Test

SMCS - 5479-038
Machine ECM
The following is a list of codes that are associated with the solenoid valves of the machine.
Table 1
Machine ECM (MID 39)
DTC Code Description System Response
17-5 Fuel Shutoff Valve: Current Below Normal Engine will not start.
17-6 Fuel Shutoff Valve: Current Above Normal Engine will not start.
374-3 Machine swing function will be
Swing Brake Solenoid: Voltage Above Normal
inoperable.
Swing Brake Solenoid: Current Below Normal
inoperable.
Swing Brake Solenoid: Current Above Normal
inoperable.
581-3 Pump torque output will not change
Power Shift Solenoid: Voltage Above Normal
when requested.
Power Shift Solenoid: Current Below Normal
when requested.
Power Shift Solenoid: Current Above Normal
when requested.
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320D2 & 320D2 L Excavators PBB00001-UP (MACHINE) POWERED BY C7.1 Engine... Page 2 of 10
598-3 Travel Speed Solenoid: Voltage Above Normal Machine travel speed selection is
limited.
598-5 Machine travel speed selection is
Travel Speed Solenoid: Current Below Normal
limited.
598-6 Machine travel speed selection is
Travel Speed Solenoid: Current Above Normal
limited.
735-3 Machine heavy lift function will be
Heavy Lift Solenoid: Voltage Above Normal
inoperable.
Heavy Lift Solenoid: Current Below Normal
inoperable.
Heavy Lift Solenoid: Current Above Normal
inoperable.
1160-3 Machine hydraulic lock will be
Hydraulic Lock Solenoid: Voltage Above Normal
inoperable.
Hydraulic Lock Solenoid: Current Below Normal
inoperable.
Hydraulic Lock Solenoid: Current Above Normal
inoperable.
1525-5
Straight Travel Solenoid: Current Below Normal Straight travel will be inoperable.
1525-6
Straight Travel Solenoid: Current Above Normal Straight travel will be inoperable.
1530-3
Quick Coupler Solenoid: Voltage Above Normal Quick coupler function disabled.
1530-5
Quick Coupler Solenoid: Current Below Normal Quick coupler function disabled.
1530-6
Quick Coupler Solenoid: Current Above Normal Quick coupler function disabled.
1590-3 Main Pump Flow Limitation Pressure Solenoid: Attachment / tool functions unavailable.
Voltage Above Normal
Current Below Normal
Current Above Normal
1593-3 Attachment Valve #1 Extend Pressure Solenoid: Attachment / tool functions unavailable.
1596-3 Attachment Valve #1 Retract Pressure Solenoid: Attachment / tool functions unavailable.
1665-3 Variable Relief Valve #1 Pressure Solenoid: Voltage
Hydraulic pressure system disabled.
Above Normal
1665-5 Variable Relief Valve #1 Pressure Solenoid: Current
Below Normal
Above Normal
1666-3 Variable Relief Valve #2 Pressure Solenoid: Voltage

Above Normal
Below Normal
Above Normal
1931-3 Auxiliary Circuit Flow Combining Solenoid: Voltage
Above Normal
1931-5 Auxiliary Circuit Flow Combining Solenoid: Current
Below Normal
1931-6 Auxiliary Circuit Flow Combining Solenoid: Current
Above Normal
1939-3 Auxiliary Hydraulic Boost Flow Supply Solenoid: Auxiliary hydraulic flow will be
Voltage Above Normal disabled.
Current Below Normal disabled.
Current Above Normal disabled.
2275-3 Hammer Return To Tank Solenoid: Voltage Above
Hammer function will be disabled.
Normal
2275-6 Hammer Return To Tank Solenoid: Current Above
Hammer function will be disabled.
Normal
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 ECM has failed. A failure of the ECM is unlikely.
• There is an open in the circuit.
• The solenoid has failed.
• A wire is shorted to ground.
• The solenoid has failed.
Illustration 1 g03704102
Machine ECM solenoid connections
Illustration 2 g03704128
Switch panel solenoid connections
Note: The diagrams above are simplified schematics of the solenoid connections. The schematic is
electrically correct. However, not all of the possible harness connectors are shown. Refer to the latest
revision of Electrical Schematic, UENR3911 (323D2) or Electrical Schematic, UENR5878 (320D2) for the
complete schematic.
Diagnostic Trouble Code Procedure
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.
1. Identify the active FMI code associated with the components.
2. Determine which code is present and use the list below to determine which procedure to follow.
• FMI 3 diagnostic code, proceed to Table 2.
Table 2
FMI 3 Troubleshooting
Troubleshooting Test Steps Values Results

1. Check The Machine Harness OK - All resistance readings are greater than 5K Ω .
For A Short
Proceed to Test Step 2.
A. The key start switch and the
disconnect switch remain in the NOT OK - One or more readings are less than 5 Ω.
OFF position.
Repair: A short exists between the signal contact
B. Disconnect the harness and the circuit with the low resistance. Repair or
Each reading is
connector from the solenoid. replace the machine harness.
greater than 5K
Ω.
C. Disconnect the ECM machine Note: A resistance that is greater than 5 Ω but less
harness connectors. than 5K Ω would indicate a loose connection or a
corroded connection in the circuit. A resistance
D. Measure the resistance measurement that is greater than 5K Ω would
between the solenoid signal indicate an open in the circuit.
contact and all of the contacts
that are used in the ECM. Proceed to Test Step 2.
OK - The diagnostic code does not exist at this
time. The initial diagnostic code may have been
2. Check If The Diagnostic
caused by poor electrical connection or short at one
Code Remains
of the harness connections. Resume machine
operation.
A. Reconnect all harness
connectors. Return machine to
STOP.
normal operating condition.
NOT OK - The diagnostic trouble code has not
B. Turn the key start switch and
been corrected. If the diagnostic code has not been
the disconnect switch ON. The diagnostic
corrected after performing the procedure a second
code is no
time, the ECM may require replacement.
C. Clear all diagnostic codes. longer present.
Prior to replacing the ECM, always contact the
D. Operate the machine.
Technical Communicator at your dealership for
possible consultation with Caterpillar. This
E. Stop the machine and engage
consultation may effect repair time.
the safety lock lever.
Follow the steps in Troubleshooting, "ECM -
F. Check if the diagnostic code is
Replace" if the ECM needs to be replaced.
active.
STOP.
Table 3
1. Check The Solenoid. OK - The harness is correct. The FMI 5
The FMI 5 diagnostic code changes to an FMI 6 when
A. Turn the key start switch and diagnostic code the jumper wire is installed. The solenoid has
the disconnect switch OFF. changes to an FMI 6 failed.
after the jumper

B. Disconnect the solenoid from wire is installed. Repair: Replace the solenoid.
the machine harness.
C. At the harness connector for the
solenoid, install a jumper wire NOT OK - The diagnostic code remains
between contact 1 and contact 2. active.
D. Turn the key start switch and Proceed to Test Step 2.

the disconnect switch ON. Do not
start the engine.
2. Check The Harness For An
Open. OK - The reading is less than 5 Ω. The
harness is correct.
A. Turn the key start switch and
the disconnect switch OFF. Proceed to Test Step 3.
B. Disconnect the harness NOT OK - The reading is greater than 5K Ω.

connectors from the ECM. The open is in the signal circuit or the return
circuit.
C. The jumper wire remains
installed. Repair: Repair or replace the machine
Each reading is less
harness.
than 5 Ω.
D. At the machine harness
connector for the ECM, measure Note: A resistance that is greater than 5 Ω but
the resistance between the signal less than 5K Ω would indicate a loose
circuit and return circuit. connection or a corroded connection in the
circuit. A resistance measurement that is
Note: For solenoids that return to greater than 5K Ω would indicate an open in
ground, measure the resistance the circuit.
between the signal circuit at the
ECM harness connector and frame Proceed to Test Step 3.
ground.
3. Check If The Diagnostic Code OK - The diagnostic code does not exist at
Remains The diagnostic code this time. The initial diagnostic code may
is no longer present. have been caused by poor electrical
A. Reconnect all harness connection or short at one of the harness
connectors. Return machine to connections. Resume machine operation.
STOP.
the disconnect switch ON. NOT OK - The diagnostic trouble code has
not been corrected. If the diagnostic code has
C. Clear all diagnostic codes. not been corrected after performing the
procedure a second time, the ECM may
D. Operate the machine. require replacement.
E. Stop the machine and engage Prior to replacing the ECM, always contact
the safety lock lever. the Technical Communicator at your
dealership for possible consultation with
Caterpillar. This consultation may effect
F. Check if the diagnostic code is repair time.

active.
STOP.
Table 4
1. Check The Solenoid
OK - The circuit is correct. The solenoid has
A. Turn the key start switch and failed.
the disconnect switch OFF.
Repair: Repeat the test. Verify the solenoid
B. Disconnect the solenoid from failure. Replace the solenoid.
The FMI 6 changes
the machine harness.
to an FMI 5 after the
solenoid is
C. Turn the key start switch and
disconnected.
the disconnect switch ON. Do NOT OK - The diagnostic code remains
not start the engine. active.
D. Observe the status of the Proceed to Test Step 2.

diagnostic code.
OK - Machine harness correct.
2. Check Machine Harness For Proceed to Test Step 3.

A Short To Ground
NOT OK - One or more of the resistance
A. The machine harness remains measurements are less than 5 Ω. A short
disconnected from the solenoid. circuit exists in the machine harness.
B. Turn the key start switch and Repair: A short circuit exists between the
the disconnect switch OFF. signal wire and the circuit with the low
Each reading is resistance. Repair or replace the machine
C. Disconnect the harness greater than 5K Ω. harness.
connectors from the ECM.
Note: A resistance that is greater than 5 Ω but
D. At the harness connector for less than 5K Ω would indicate a loose
the ECM, measure the resistance connection or a corroded connection in the
between the solenoid signal circuit. A resistance measurement that is
contact and all ground contacts. greater than 5K Ω would indicate an open in
the circuit.

3. Check If The Diagnostic OK - The diagnostic code does not exist at this
Code Remains The diagnostic code time. The initial diagnostic code may have
is no longer present. been caused by poor electrical connection or
A. Reconnect all harness short at one of the harness connections.
320D2 & 320D2 L Excavators PBB00001-UP (MACHINE) POWERED BY C7.1 Eng... Page 10 of 10
connectors. Return machine to Resume machine operation.

STOP.
the disconnect switch ON. NOT OK - The diagnostic trouble code has
not been corrected. If the diagnostic code has
C. Clear all diagnostic codes. not been corrected after performing the
procedure a second time, the ECM may
D. Operate the machine. require replacement.
E. Stop the machine and engage Prior to replacing the ECM, always contact the
the safety lock lever. Technical Communicator at your dealership
for possible consultation with Caterpillar. This
F. Check if the diagnostic code is consultation may effect repair time.
active.
STOP.
Copyright 1993 - 2016 Caterpillar Inc. Mon Aug 29 19:21:30 CDT 2016
All Rights Reserved. p230fdc
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320D2 & 320D2 L Excavators PBB00001-UP (MACHINE) POWERED BY C7.1 Engine...

Solenoid Valve - Test

1666-3 Variable Relief Valve #2 Pressure Solenoid: Voltage

Possible causes for an FMI 3 diagnostic code are:

• The harness is shorted.

• The 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.

• The solenoid has failed.

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

Machine ECM solenoid connections

Switch panel solenoid connections

Diagnostic Trouble Code Procedure

1. Identify the active FMI code associated with the components.

• FMI 3 diagnostic code, proceed to Table 2.

• FMI 5 diagnostic code, proceed to Table 3.

• FMI 6 diagnostic code, proceed to Table 4.

Troubleshooting Test Steps Values Results

after the jumper

D. Turn the key start switch and Proceed to Test Step 2.

B. Disconnect the harness NOT OK - The reading is greater than 5K Ω.

F. Check if the diagnostic code is repair time.

D. Observe the status of the Proceed to Test Step 2.

2. Check Machine Harness For Proceed to Test Step 3.

Proceed to Test Step 3.

connectors. Return machine to Resume machine operation.

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