538, 548 and 558 Forest Machine Solenoid Valve

Solenoid Valve - Test

538, 548 and 558 Forest Machine [M0066266]

538, 548 and 558 Forest Machine Sensor Supply - Test

538, 548 and 558 Forest Machine Solenoid Valve (Switch Controlled) - Test

HYDRAULIC SYSTEM

VALVE GP-SOLENOID

538, 548 and 558 Forest Machine Solenoid Valve - Test

538, 548 and 558 Forest Machine Solenoid Valve (Switch Controlled) - Test

1.1. Machine ECM

2.1. Diagnostic Trouble Code Procedure

Machine ECM

The following is a list of Diagnostic Trouble Codes (DTCs) that are associated with the solenoid valves of the machine.

Show/hide table

Table 1
Machine ECM (MID 299)
DTC	Code Description	System Response
374-3	Swing Brake Solenoid : Voltage Above Normal	Machine swing function will be inoperable.
374-5	Swing Brake Solenoid : Current Below Normal	Machine swing function will be inoperable.
374-6	Swing Brake Solenoid : Current Above Normal	Machine swing function will be inoperable.
581-3	Power Shift Solenoid : Voltage Above Normal	Power shift function will be inoperable.
581-5	Power Shift Solenoid : Current Below Normal	Power shift function will be inoperable.
581-6	Power Shift Solenoid : Current Above Normal	Power shift function will be inoperable.
598-3	Travel Speed Solenoid : Voltage Above Normal	Machine travel speed selection is limited.
598-5	Travel Speed Solenoid : Current Below Normal	Machine travel speed selection is limited.
598-6	Travel Speed Solenoid : Current Above Normal	Machine travel speed selection is limited.
732-3	Fine Swing Solenoid : Voltage Above Normal	Machine swing function will be inoperable.
732-5	Fine Swing Solenoid : Current Below Normal	Machine swing function will be inoperable.
732-6	Fine Swing Solenoid : Current Above Normal	Machine swing function will be inoperable.
735-3	Heavy Lift Solenoid : Voltage Above Normal	Heavy lift solenoid will be inoperable.
735-5	Heavy Lift Solenoid : Current Below Normal	Heavy lift solenoid will be inoperable.
735-6	Heavy Lift Solenoid : Current Above Normal	Heavy lift solenoid will be inoperable.
1138-3	Boom Cylinder Retract Solenoid : Voltage Above Normal	Boom retraction may not function correctly.
1138-5	Boom Cylinder Retract Solenoid : Current Below Normal	Boom retraction may not function correctly.
1138-6	Boom Cylinder Retract Solenoid : Current Above Normal	Boom retraction may not function correctly.
1139-3	Stick Cylinder Extend Solenoid : Voltage Above Normal	Stick extend operation may not function correctly.
1139-5	Stick Cylinder Extend Solenoid : Current Below Normal	Stick extend operation may not function correctly.
1139-6	Stick Cylinder Extend Solenoid : Current Above Normal	Stick extend operation may not function correctly.
1140-3	Stick Cylinder Retract Solenoid : Voltage Above Normal	When the stick is retracted, the function may not operate correctly.
1140-5	Stick Cylinder Retract Solenoid : Voltage Above Normal	When the stick is retracted, the function may not operate correctly.
1140-6	Stick Cylinder Retract Solenoid : Current Above Normal	When the stick is retracted, the function may not operate correctly.
1141-3	Bucket Cylinder Extend Solenoid : Voltage Above Normal	When the bucket is extended, the function may not operate correctly.
1141-5	Bucket Cylinder Extend Solenoid : Current Below Normal	When the bucket is extended, the function may not operate correctly.
1141-6	Bucket Cylinder Extend Solenoid : Current Above Normal	When the bucket is extended, the function may not operate correctly.
1142-3	Bucket Cylinder Retract Solenoid : Voltage Above Normal	When the bucket is retracted, the function may not operate correctly.
1142-5	Bucket Cylinder Retract Solenoid : Voltage Above Normal	When the bucket is retracted, the function may not operate correctly.
1142-6	Bucket Cylinder Retract Solenoid : Current Above Normal	When the bucket is retracted, the function may not operate correctly.
1143-3	Swing Right Solenoid : Voltage Above Normal	Swing function is limited.
1143-5	Swing Right Solenoid :Current Below Normal	Swing function is limited.
1143-6	Swing Right Solenoid :Current Above Normal	Swing function is limited.
1144-3	Swing Left Solenoid : Voltage Above Normal	Swing function is limited.
1144-5	Swing Left Solenoid :Current Below Normal	Swing function is limited.
1144-6	Swing Left Solenoid :Current Above Normal	Swing function is limited.
1525-3	Straight Travel Solenoid : Voltage Above Normal	Straight travel system will be inoperable.
1525-5	Straight Travel Solenoid : Current Below Normal	Straight travel system will be inoperable.
1525-6	Straight Travel Solenoid : Current Above Normal	Straight travel system will be inoperable.
1593-3	Attachment Valve #1 Extend Pressure Solenoid : Voltage Above Normal	Attachment / tool functions unavailable.
1593-5	Attachment Valve #1 Extend Pressure Solenoid : Current Below Normal	Attachment / tool functions unavailable.
1593-6	Attachment Valve #1 Extend Pressure Solenoid : Current Above Normal	Attachment / tool functions unavailable.
1594-3	Attachment Valve #2 Extend Pressure Solenoid : Voltage Above Normal	Attachment / tool functions unavailable.
1594-5	Attachment Valve #2 Extend Pressure Solenoid : Current Below Normal	Attachment / tool functions unavailable.
1594-6	Attachment Valve #2 Extend Pressure Solenoid : Current Above Normal	Attachment / tool functions unavailable.
1596-3	Attachment Valve #1 Retract Pressure Solenoid : Voltage Above Normal	Attachment / tool functions unavailable.
1596-5	Attachment Valve #1 Retract Pressure Solenoid : Current Below Normal	Attachment / tool functions unavailable.
1596-6	Attachment Valve #1 Retract Pressure Solenoid : Current Above Normal	Attachment / tool functions unavailable.
1597-3	Attachment Valve #2 Retract Pressure Solenoid : Voltage Above Normal	Attachment / tool functions unavailable.
1597-5	Attachment Valve #2 Retract Pressure Solenoid : Current Below Normal	Attachment / tool functions unavailable.
1597-6	Attachment Valve #2 Retract Pressure Solenoid : Current Above Normal	Attachment / tool functions unavailable.
1665-3	Variable Relief Valve #1 Pressure Solenoid : Voltage Above Normal	Hydraulic pressure system disabled.
1665-5	Variable Relief Valve #1 Pressure Solenoid : Current Below Normal	Hydraulic pressure system disabled.
1665-6	Variable Relief Valve #1 Pressure Solenoid : Current Above Normal	Hydraulic pressure system disabled.
2068-3	Pump #1 Control Spool Solenoid : Voltage Above Normal	Joystick functions will be limited. Pump flow will be reduced.
2068-5	Pump #1 Control Spool Solenoid : Current Below Normal	Joystick functions will be limited. Pump flow will be reduced.
2068-6	Pump #1 Control Spool Solenoid : Current Above Normal	Joystick functions will be limited. Pump flow will be reduced.
2069-3	Pump #2 Control Spool Solenoid : Voltage Above Normal	Joystick functions will be limited. Pump flow will be reduced.
2069-5	Pump #2 Control Spool Solenoid : Current Below Normal	Joystick functions will be limited. Pump flow will be reduced.
2069-6	Pump #2 Control Spool Solenoid : Current Above Normal	Joystick functions will be limited. Pump flow will be reduced.
2103-3	Boom Regeneration Solenoid : Voltage Above Normal	Boom operations will be inoperable.
2103-5	Boom Regeneration Solenoid : Current Below Normal	Boom operations will be inoperable.
2103-6	Boom Regeneration Solenoid : Current Above Normal	Boom operations will be inoperable.
3038-3	Boom Low-Pressure Relief Enable Solenoid : Voltage Above Normal	Boom functions will be limited.
3038-5	Boom Low-Pressure Relief Enable Solenoid : Current Below Normal	Boom functions will be limited.
3038-6	Boom Low-Pressure Relief Enable Solenoid : Current Above Normal	Boom functions will be limited.
3633-5	Swing Priority Solenoid : Current Below Normal	Swing function will be disabled.
3633-6	Swing Priority Solenoid : Current Above Normal	Swing function will be disabled.

Solenoid are used to shutoff, release, distribute, or mix fluids on the machine. Generally, multiple solenoids are located together on a manifold. Solenoids convert 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.

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.

Show/hide table




Illustration 1	g06026242
Machine ECM J1 and J2 solenoid connections

Show/hide table




Illustration 2	g06026254
Solenoid connections associated with the switch panel

The preceding diagrams are simplified schematics of the Machine ECM and the Switch Panel connections. The schematics are electrically correct. However, not all the possible harness connectors are shown. Refer to the latest revision of the Electrical Schematic to view the entire circuitry of the machine.

Diagnostic Trouble Code Procedure

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.

Identify the active FMI code associated with the components.
Determine which code is present and use the list below to determine which procedure to follow.

FMI 3 diagnostic code, proceed to Table 2.
FMI 5 diagnostic code, proceed to Table 3.
FMI 6 diagnostic code, proceed to Table 4.

Show/hide table

Table 2
FMI 3 Troubleshooting
Troubleshooting Test Steps	Values	Results
1. Check The Machine Harness For A Short A. The key start switch and the disconnect switch remain in the OFF position. B. Disconnect the harness connector from the solenoid. C. Disconnect the ECM machine harness connectors. D. Measure the resistance between the solenoid signal contact and all the contacts that are used in the ECM.	Each reading is greater than 5K Ω.	OK - All resistance readings are greater than 5K Ω . Proceed to Test Step 2. NOT OK - One or more readings are less than 5 Ω. Repair: A short exists between the signal contact and the circuit with the low resistance. Repair or replace the machine harness. Note: A resistance greater than 5 Ω but less than 5K Ω indicates a loose or corroded connection in the circuit. A resistance measurement greater than 5K Ω indicates an open in the circuit. Proceed to Test Step 2.
2. Check If The Diagnostic Code Remains A. Reconnect all harness connectors. Return machine to normal operating condition. B. Turn the key start switch and the disconnect switch to the ON position. C. Clear all diagnostic codes. D. Operate the machine. E. Stop the machine and engage the safety lock lever. F. Check if the diagnostic code is active.	The diagnostic code is no longer present.	OK - The diagnostic code does not exist currently. 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 second time, the ECM may require replacement. Prior to replacing the ECM, always contact the Technical Communicator at your dealership for possible consultation with AVSpare. This consultation may effect repair time. Follow the steps in Troubleshooting, "ECM - Replace" if the ECM needs to be replaced. STOP.

Show/hide table

Table 3
FMI 5 Troubleshooting
Troubleshooting Test Steps	Values	Results
1. Check The Solenoid. A. Turn the key start switch and the disconnect switch to the OFF position. B. Disconnect the solenoid from the machine harness. C. At the harness connector for the solenoid, install a jumper wire between contact 1 and contact 2. D. Turn the key start switch and the disconnect switch to the ON position. Do not start the engine.	The FMI 5 diagnostic code changes to an FMI 6 after the jumper wire is installed.	OK - The harness is correct. The FMI 5 diagnostic code changes to an FMI 6 when the jumper wire is installed. The solenoid has failed. Repair: Replace the solenoid. Proceed to Test Step 3. NOT OK - The diagnostic code remains active. Proceed to Test Step 2.
2. Check The Harness For An Open. A. Turn the key start switch and the disconnect switch to the OFF position. B. Disconnect the harness connectors from the ECM. C. The jumper wire remains installed. D. At the machine harness connector for the ECM, measure the resistance between the signal circuit and return circuit. Note: For solenoids that return to ground, measure the resistance between the signal circuit at the ECM harness connector and frame ground.	Each reading is less than 5 Ω.	OK - The reading is less than 5 Ω. The harness is correct. Proceed to Test Step 3. NOT OK - The reading is greater than 5K Ω. The open is in the signal circuit or the return circuit. Repair: Repair or replace the machine harness. Note: A resistance greater than 5 Ω but less than 5K Ω indicates a loose or corroded connection in the circuit. A resistance measurement greater than 5K Ω indicates an open in the circuit. Proceed to Test Step 3.
3. Check If The Diagnostic Code Remains A. Reconnect all harness connectors. Return machine to normal operating condition. B. Turn the key start switch and the disconnect switch to the ON position. C. Clear all diagnostic codes. D. Operate the machine. E. Stop the machine and engage the safety lock lever. F. Check if the diagnostic code is active.	The diagnostic code is no longer present.	OK - The diagnostic code does not exist currently. 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 second time, the ECM may require replacement. Prior to replacing the ECM, always contact the Technical Communicator at your dealership for possible consultation with AVSpare. This consultation may effect repair time. Follow the steps in Troubleshooting, "ECM - Replace" if the ECM needs to be replaced. STOP

Show/hide table

Table 4
FMI 6 Troubleshooting
Troubleshooting Test Steps	Values	Results
1. Check The Solenoid A. Turn the key start switch and the disconnect switch to the OFF position. B. Disconnect the solenoid from the machine harness. C. Turn the key start switch and the disconnect switch to the ON position. Do not start the engine. D. Observe the status of the diagnostic code.	The FMI 6 changes to an FMI 5 after the solenoid is disconnected.	OK - The circuit is correct. The solenoid has failed. Repair: Repeat the test. Verify the solenoid failure. Replace the solenoid. Proceed to Test Step 3. NOT OK - The diagnostic code remains active. Proceed to Test Step 2.
2. 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 to the OFF position. C. Disconnect the harness connectors from the ECM. D. At the harness connector for the ECM, measure the resistance between the solenoid signal contact and all ground contacts.	Each reading is greater than 5K Ω.	OK - Machine harness correct. Proceed to Test Step 3. NOT OK - One or more of the resistance measurements are less than 5 Ω. A short circuit exists in the machine harness. Repair: A short circuit exists between the signal wire and the circuit with the low resistance. Repair or replace the machine harness. Note: A resistance greater than 5 Ω but less than 5K Ω indicates a loose or corroded connection in the circuit. A resistance measurement greater than 5K Ω indicates an open in the circuit. Proceed to Test Step 3.
3. Check If The Diagnostic Code Remains A. Reconnect all harness connectors. Return machine to normal operating condition. B. Turn the key start switch and the disconnect switch to the ON position. C. Clear all diagnostic codes. D. Operate the machine. E. Stop the machine and engage the safety lock lever. F. Check if the diagnostic code is active.	The diagnostic code is no longer present.	OK - The diagnostic code does not exist currently. 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 second time, the ECM may require replacement. Prior to replacing the ECM, always contact the Technical Communicator at your dealership for possible consultation with AVSpare. This consultation may effect repair time. Follow the steps in Troubleshooting, "ECM - Replace" if the ECM needs to be replaced. STOP