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Troubleshooting
966H, 972H and 980H Wheel Loaders Power Train Electronic Control System
Media Number -UENR1625-01 Publication Date -01/05/2014 Date Updated -02/06/2014

i05330340

SMCS - 1439-038

The following is a list of diagnostic codes that are associated with the PWM Sensors of the machine.

Table 1
Transmission ECM (MID 81)

DTC Code Description System Response

737-3 Left Brake Pedal Position Sensor: Voltage Above Normal

737-4 Left Brake Pedal Position Sensor: Voltage Below Normal

Left Brake Pedal Position Sensor: Abnormal Frequency, Pulse

737-8
Width, or Period

737-13 Shifting may be harsh or

Left Brake Pedal Position Sensor: Out of Calibration
sluggish.

Pulse Width Modulation (PWM) is a technique for controlling analog circuits with digital outputs. PWM is
employed in various applications ranging from measurement to communication with the Electronic Control Module
(ECM). The duty cycle of a square wave is modulated to encode a specific analog signal level. The duty cycle is the
ratio of the on-time to the period. The modulating frequency is the inverse of the period. The duty cycle is
programmed into the software of the ECU. The engineer (or programmer) sets the period in the on-chip timer
counter that provides the modulating square wave. The engineer sets the direction of the PWM output along with
the on-time in the PWM control register.

One of the advantages of the PWM sensor is that the signal remains digital all the way from the ECM to the
controlled system. No digital to analog conversion is necessary. By using a digital signal, noise effects are
minimized. Noise affects a digital signal if the noise can change a logic 1 to a logic 0 or a logic 0 to a logic 1.

Possible Causes for an FMI 3 Diagnostic code are:

The sensor supply or the ground circuit in the machine harness is open.

The signal circuit in the machine harness is shorted to the +battery.

The signal circuit in the machine harness is open or the sensor is disconnected.

The sensor has failed.

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

Possible Causes for an FMI 4 Diagnostic code are:

The sensor has failed.

The signal circuit in the machine harness is shorted to ground.

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

Possible Causes for an FMI 8 Diagnostic code are:

The sensor has failed.

Intermittent connections or poor connections.

Possible Causes for an FMI 13 Diagnostic code are:

The ECM detects the signal from the sensor as being out of calibration.

Note: Prior to beginning this procedure, use Cat ET or the machine monitors to check for an active DTC that
indicates a failure of a power supply on the ECM. If the code is present, refer to the Sensor Supply - Test story to
correct this problem before continuing.

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. If a problem with a connection is found, correct the problem and verify that the
diagnostic code is active before performing a troubleshooting procedure.

Note: Some test procedures may create additional diagnostic codes. Ignore these created diagnostic codes and clear
the codes when the original diagnostic code has been corrected.

Illustration 1 g03376645

ECM PWM Sensors

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

Table 2
Troubleshooting Test Steps Values Results
 FMI 3 diagnostic code, proceed to Test Step
2.

FMI 4 diagnostic code, proceed to Test Step

6.
1. Identify Active FMI Code
Associated With Sensor Circuit Code present
FMI 8 diagnostic code, proceed to Test Step
9.

FMI 13 diagnostic code, proceed to Test Step

17.

Begin Process For FMI 3 Troubleshooting HERE

OK - Fuse is good.
2. Check The Fuse
Proceed to Test Step 3.
A. Turn key start switch and disconnect
switch OFF.
NOT OK- Fuse is blown.
B. Check fuse.
Repair - Replace the fuse.
Fuse is good.
C. Refer to the schematic to determine
If the fuse is blown when the machine is
the fuse for the left-hand brake pedal
powered up, continue with this procedure.
sensor.
Other wise, proceed with normal machine
operation.
D. Remove the fuse. Measure the
resistance of the fuse.
STOP

3. Check The Control And The

Harness
OK - The voltage reading is correct for the
A. Turn key start switch and disconnect suspected faulty sensor.
switch ON.
Proceed to Test Step 3.
B. Disconnect the machine harness
from sensor. NOT OK- The voltage is NOT correct for
Voltage is 8.0 ± 0.5
the circuit.
VDC
C. Refer to the schematic to determine
the voltage source for the suspected Repair - There may be an open or short in
faulty sensor. the machine harness. The open or short will
be on the power or ground circuit wires.
D. Measure voltage between signal and Repair or replace the machine harness.
ground contacts at the machine harness
connector for the sensor.

4. Check For An Open In The Sensor OK - The resistance is less than 5 Ω. The
Circuit signal circuit and the ground circuits of the
sensor are not open in the machine harness.
A. The sensor remains disconnected
from the machine harness. The resistance is less Proceed to Test Step 4.
than 5 Ω at all times
B. Turn the key start switch and the during the NOT OK - Resistance reading for the signal
disconnect switch OFF. manipulation of the circuit or the return circuit is greater than 5
harness.. Ω.
C. At the harness connector for the
sensor, place a jumper wire between Repair: Check the signal circuit or the
the ground contact and the signal ground circuit for opens or bad connections.
contact.

D. Disconnect J1 and J2 harness

connectors from the ECM.
Note: A resistance that is greater than 5 Ω but
less than 5K Ω would indicate a loose
E. At machine harness connector for
connection or a corroded connection in the
sensor, measure the resistance from the
circuit. A resistance measurement that is
signal contact to return contact.
greater than 5K Ω would indicate an open in
the circuit.
F. Gently pull on the wires and move
the wires in a circular motion at ECM
STOP
connector and observe the resistance
readings. Repeat the process for the
sensor connector.

OK - The resistance is greater than 5K Ω.

5. Check Signal Circuit For A Short The harness circuit is correct..
To +Battery
Proceed to Test Step 5.
A. The Sensor and the ECM are
disconnected from the harness. NOT OK- The resistance less than 5 Ω.

B. Turn the disconnect switch and the Repair: A short exists in the harness between
key start switch OFF. the +battery and signal circuit. Repair or
Resistance greater than
replace the machine harness.
5K Ω for all readings.
C. Measure the resistance between the
signal and +battery contacts of the Note: A resistance that is greater than 5 Ω but
harness connector for the sensor. less than 5K Ω would indicate a loose
connection or a corroded connection in the
D. At machine harness connector J1 circuit. A resistance measurement that is
and J2 measure the resistance from greater than 5K Ω would indicate an open in
signal contact to all possible sources of the circuit.
+battery.
STOP
OK - The resistance is greater than 5K Ω.
The harness circuit is correct..

Repair: A short exists in the harness between

the signal circuit and the circuit with the
lower resistance measurement. Repair or
6. Check The Harness For A Short replace the machine harness.
Proceed to Test Step 22.
A. The disconnect switch and key start
switch are OFF NOT OK- The resistance less than 5 Ω.
Resistance greater than
B. The sensor and ECM disconnected Repair: A short exists in the harness between
5K Ω for all readings.
from harness. the signal circuit and the circuit with the
lower resistance measurement. Repair or
C. Measure the resistance from the replace the machine harness.
signal wire to all other J1 and J2
contacts. 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.
 STOP

Begin Process For FMI 4 Troubleshooting HERE

7. Check The Control And The

Harness
OK - The voltage reading is correct for the
A. Turn key start switch and disconnect suspected faulty sensor.
switch ON.
Proceed to Test Step 7.
B. Disconnect the machine harness
from sensor. NOT OK- The voltage is NOT correct for
Voltage is 8.0 ± 0.5
the circuit.
VDC
C. Refer to the schematic to determine
the voltage source for the suspected Repair - There may be an open or short in
faulty sensor. the machine harness. The open or short will
be on the power or ground circuit wires.
D. Measure voltage between signal and Repair or replace the machine harness.
ground contacts at the machine harness
connector for the sensor.

OK - The diagnostic changed to FMI 3 when

the sensor was disconnected.
8. Check The Sensor
Repair: Replace the sensor.
A. With FMI 4 active, disconnect the
sensor from the machine harness.
STOP
Code changes from
B. Observe Cat ET or the operator FMI 4 to FMI 3.
NOT OK - The FMI 4 diagnostic code
monitor for code change as the sensor
remains active when sensor is disconnected.
is disconnected and connected to
The sensor not the cause of the problem.
harness.
Proceed to Test Step 8.

OK - The resistance is greater than 5K Ω.

The harness circuit is correct.

Proceed to Test Step 16.

9. Check The Signal Circuit For A
Short To Ground NOT OK - The resistance is less than 5 Ω. A
short circuit exists between frame ground and
A. Turn the key start switch and the the signal circuit.
disconnect switch OFF.
Repair: Repair or replace the machine
The resistance is
B. Disconnect the J1 harness connector harness.
greater than 5K Ω.
from the ECM.
Note: A resistance that is greater than 5 Ω but
C. Measure the resistance between the less than 5K Ω would indicate a loose
signal contact for sensor and frame connection or a corroded connection in the
ground. circuit. A resistance measurement that is
greater than 5K Ω would indicate an open in
the circuit.

STOP

Begin Process For FMI 8 Troubleshooting HERE

10. Check The Control And The
Harness
OK - The voltage reading is correct for the
A. Turn key start switch and disconnect suspected faulty sensor.
switch ON.
Proceed to Test Step 10.
B. Disconnect the machine harness
from sensor. NOT OK- The voltage is NOT correct for
Voltage is 8.0 ± 0.5
the circuit.
VDC
C. Refer to the schematic to determine
the voltage source for the suspected Repair - There may be an open or short in
faulty sensor. the machine harness. The open or short will
be on the power or ground circuit wires.
D. Measure voltage between signal and Repair or replace the machine harness.
ground contacts at the machine harness
connector for the sensor.
OK - The measurement is less than 5 Ω.

Proceed to Test Step 11.

11. Check Harness For An Open
NOT OK - The measurement is greater than
A. Turn the disconnect switch and the
5K Ω. The signal circuit in the harness is
key start switch OFF
open.
B. The sensor and ECM are
Repair: Repair or replace the machine
disconnected from the harness.
The reading is less than harness.
5 Ω.
C. Connect a jumper wire from the end
Note: A resistance that is greater than 5 Ω but
of signal wire at the ECM to a known
less than 5K Ω would indicate a loose
ground.
connection or a corroded connection in the
circuit. A resistance measurement that is
D. Measure the resistance of the signal
greater than 5K Ω would indicate an open in
wire at ECM.
the circuit.

STOP

OK - Measurement is greater than 5K Ω.

Proceed to Test Step 12.

12. Check The Signal Circuit For A NOT OK - Measurement is less than 5 Ω.
Short To Ground The signal circuit in the harness is shorted to
ground.
A. Turn key start switch and disconnect
switch OFF. Repair: Repair or replace the machine
Reading is greater than harness.
B. Disconnect J1 harness connector 5K Ω.
from ECM. Note: A resistance that is greater than 5 Ω but
less than 5K Ω would indicate a loose
C. Measure resistance between signal connection or a corroded connection in the
contact for sensor and frame ground. circuit. A resistance measurement that is
greater than 5K Ω would indicate an open in
the circuit.

STOP
 OK - All measurements are greater than 5K
Ω.

Proceed to Test Step 13.

13. Check The Sensor For A Short
NOT OK - A measurement is less than 5 Ω.
To Case
The sensor has failed..
A. Turn the key start switch and the
Repair: Replace the sensor. Confirm that the
disconnect switch OFF.
The reading is greater new sensor corrects the problem.
than 5K Ω.
B. At the machine harness connector
Note: A resistance that is greater than 5 Ω but
for the sensor, measure the resistance
less than 5K Ω would indicate a loose
between each pin of sensor and an
connection or a corroded connection in the
unpainted location on case of sensor.
circuit. A resistance measurement that is
greater than 5K Ω would indicate an open in
the circuit.

STOP

14. Check The Sensor For A Short

To +Battery OK - Voltage is 0 VDC.

A. Disconnect the machine harness at Proceed to Test Step 14.

the sensor.
NOT OK - Significant voltage is present in
B. Turn the key start switch and the The voltage is 0 VDC. circuit.
disconnect switch ON.
Repair: Repair or replace the machine
C. At machine harness connector for J1 harness.
connector, measure the voltage
between the signal pin of sensor and STOP
frame ground.

OK - Voltage is 0 VDC.
15. Check The Harness For A Short
To +Battery
Proceed to Test Step 15.
A. Turn the key start switch and the
NOT OK - Significant voltage is present in
disconnect switch ON.
The voltage is 0 VDC. circuit. Circuit shorted to +battery.
B. At machine harness connector for
Repair: Replace the sensor. Verify that the
sensor, measure the voltage between
new sensor corrected the diagnostic code.
each pin of sensor and frame ground
(contacts 1, 2, and 3).
STOP

OK - Diagnostic code is NO longer active.

16. Check The Sensor
The sensor has failed.
A. Turn the key start switch and the
Repair: Replace the sensor. Verify new
disconnect switch ON.
sensor corrected the diagnostic code.
B. Use Cat ET or the operator monitor The diagnostic code is
STOP
to confirm the existence of the no longer present.
diagnostic code.
NOT OK - The diagnostic code remains
active.
C. Disconnect the sensor from machine
harness.
Proceed to Test Step 16.
 OK - The diagnostic code does not exist at
this time. The initial diagnostic code may
have been caused by a poor electrical
connection or a short at one of the harness
connections. Resume machine operation.

17. Check If The Diagnostic Code STOP

Remains.
NOT OK - The diagnostic trouble code has
A. Turn the key start switch and the not been corrected.
disconnect switch ON.
Repair: Recheck the circuit and perform this
B. Clear all diagnostic codes. procedure again. If the diagnostic code is still
The code for the sensor
active, replace the sensor. If replacing the
is NO longer present.
C. Operate the machine. sensor does not correct the problem, the
Transmission ECM may require replacement.
D. Stop machine and engage the safety
lock lever. Prior to replacing the ECM, always contact
the Technical Communicator at your
E. Check if the diagnostic code for the dealership for possible consultation with
sensor is active. Caterpillar. This consultation may greatly
reduce repair time.

Refer ro Testing and Adjusting, "ECM -

Replace" to replace the ECM.

STOP

Begin Process For FMI 13 Troubleshooting HERE

OK - The calibration procedure for the
solenoid was performed successfully. Resume
normal machine operation.

STOP
18. Calibrate The Solenoid
The calibration
NOT OK - The calibration procedure was
A. Perform the calibration procedure procedure for the
performed successfully.
for the sensor. Refer to Testing and solenoid was
Adjusting for instructions on performed successfully.
Repair: Repeat the calibration procedure for
calibrating the relevant sensor.
the solenoid. Refer to Testing and Adjusting
for instructions on calibrating the relevant
sensor.

STOP

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