3406E Engine Rebuild Kit & Related Parts for 735, 740 Articulated Truck & Ejector Arti...

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Product: ARTICULATED TRUCK

Troubleshooting
725, 730 , 730 EJECTOR, 735, 740 and 740 EJECTOR Articulated Trucks Power Train Electronic
Control System - AT
Media Number -RENR8035-10 Publication Date -01/10/2011 Date Updated -16/03/2016

i03151005

MID 027 - CID 0246 - FMI 09

Conditions Which Generate This Code:

Illustration 1 g01620034

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Illustration 2 g01620036
"Instrument Cluster" connector

This diagnostic code is generated when the Transmission/Chassis ECM does not receive communications from
the instrument cluster for a period of greater than 4 seconds.

The possible causes of this diagnostic code are listed below:

• The CAN Data Link has failed.

• The +battery is lost to the instrument cluster.

• The signal for the key start switch is lost to the instrument cluster.

• The instrument cluster has failed.

• The transmission/chassis ECM may have failed.

• The connector for the cluster may have been connected incorrectly.

Note: It has been determined that it is possible to connect the connector to the instrument cluster improperly.
Ensure that the key ways on the socket and the connector for the instrument cluster match properly.

Test Step 1. CHECK FOR +BATTERY TO THE INSTRUMENT CLUSTER

A. Start the engine and operate the engine at high idle.

B. Measure the system voltage from contact 1 to contact 2.

Expected Result:

The voltage is 18 to 30 DCV.

Results:

• OK - The voltage is 18 DCV to 30 DCV. Proceed to Test Step 2.

• NOT OK - The voltage is NOT 18 DCV to 30 DCV. Proceed to Test Step 3.

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Test Step 2. CHECK THE STATUS OF THE KEY START SWITCH.

The instrument cluster receives the input from the key start switch at contact 24 when the key start switch is in
the ON position or in the START position. When the instrument cluster detects voltage at this input, the ECM
will power up.

A. Turn the key start switch to the OFF position.

B. Connect Cat ET to the data link connector and access the status for "Ignition Switch".

C. Monitor the status while the key start switch is being cycled slowly from the ON position to the OFF
position.

Note: Cat ET may lose communications when the key start switch is in the OFF position.

Note: Cycling the key start switch several times may cause additional diagnostic codes to be logged. This
is normal. Clear any logged faults.

Expected Result:

The status of the "Ignition Switch" changes from "RUN" with the key start switch in the ON position to "Off"
with the key start switch in the OFF position.

Results:

• OK - The key start switch is functioning properly at this time.

Repair: If an intermittent connection is suspected, refer to Testing and Adjusting, "Electrical Connectors
- Inspect".

STOP

• NOT OK - The key start switch is NOT functioning properly at this time. Proceed to Test Step 3.

Test Step 3. CHECK FOR CONNECTOR DAMAGE.

A. Turn the key start switch to the OFF position.

B. Turn the battery disconnect switch to the OFF position.

C. Thoroughly inspect the ECM connectors J1 and J2. Inspect all of the other connectors. Refer to Testing
and Adjusting, "Electrical Connector Inspect" for details.

D. Perform a 45 N (10 lb) pull test on each of the wires of the ECM connector and the connector for the
instrument cluster. Perform the test on all wires that are associated with the circuit.

E. Check the ECM connector (allen head screw) for the proper torque of 2.25 ± 0.25 N·m (20 ± 2 lb in).

F. Check the harness and the wiring for abrasion and for pinch points.

Expected Result:

All connectors, pins, and sockets are completely coupled and/or inserted. The harness and wiring should be free
of corrosion, abrasion or pinch points.

Results:

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• OK - All connectors, pins, and sockets are completely coupled and/or inserted. The harness and wiring is
free of corrosion, abrasion or pinch points. Proceed to Test Step 4.

• NOT OK - All connectors, pins, and sockets are not completely coupled and/or inserted. The harness and
wiring is not free of corrosion, abrasion and pinch points.

Repair: Repair the connectors or wiring and/or replace the connectors or wiring.

STOP

Test Step 4. CHECK IF THE DIAGNOSTIC CODE REMAINS.

A. Connect the Cat ET to the service tool connector.

B. Turn the battery disconnect switch to the ON position.

C. Turn the key start switch to the ON position. The engine should be OFF.

D. Check the Cat ET for an active diagnostic code of CID-FMI 246-09.

Expected Result:

The CID-FMI 246-09 should be active.

Results:

• OK - The CID-FMI 246-09 is active. Proceed to Test Step 5.

• NOT OK - The CID-FMI 246-09 is not active.

Repair: Reset the system and troubleshoot any active diagnostic codes.

STOP

Test Step 5. CHECK THE RESISTANCE THROUGH THE HARNESS.

A. Turn the key start switch to the OFF position.

B. Disconnect the J2 connector from the ECM.

C. Disconnect the Cat ET from the service tool connector.

D. Disconnect any other module that uses the CAN Data Link.

E. Use a suitable piece of wire to short contact F and G together at the service tool connector.

F. Measure the resistance at the ECM connector between J2-64 and J2-65.

G. Measure the resistance at the connector for the instrument cluster between contacts 19 and 20.

H. Remove the jumper wire.

Expected Result:

The resistance should measure less than 5 Ohms.

Results:

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• OK - The resistance measures less than 5 Ohms. Proceed to Test Step 6.

• NOT OK - The resistance measures more than 5 Ohms. The CAN Data Link is damaged.

Repair: Repair the connectors or wiring and/or replace the connectors or wiring.

STOP

Test Step 6. CHECK THE CAN DATA LINK FOR A SHORT CIRCUIT.

A. Measure the resistance at the connector for the Transmission/Chassis ECM between J2-64 and the frame
ground.

B. Measure the resistance at the connector for the Transmission/Chassis ECM between J2-65 and the frame
ground.

C. Measure the resistance at the connector for the instrument cluster between contact 19 and frame ground.

D. Measure the resistance at the connector for the instrument cluster between contact 20 and the frame
ground.

Expected Result:

The resistance should be greater than 20,000 ohms.

Results:

• OK - The CAN Data Link appears to be operating correctly.

Repair: Reset the system and troubleshoot any active diagnostic codes. If the original condition still
exists, replace the ECM. See Testing and Adjusting, "Electronic Control Module (ECM) - Replace".

STOP

• NOT OK - The CAN Data Link is damaged.

Repair: Repair the connectors or wiring and/or replace the connectors or wiring.

STOP

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