Transmision SIS 2.0
Transmision SIS 2.0
Transmision SIS 2.0
SMCS -
Introduction PSP
202 -0006
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SEN 46- : 1
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Troubleshooting the electronic transmission control system requires additional information from the
machine Service Manual. The Electrical System Schematic and the Operation & Maintenance
Manual are required support material.
As a guide, a simplified electronic transmission control schematic is at the end of this manual. For a
complete schematic, see the Electrical System Schematic in the machine Service Manual.
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If wire insulation is punctured during troubleshooting, repair after probing. Seal the punctures with
8T-0065 Adhesive. Cover the adhesive with two layers of 1P-0810 Tape. Remove the harness
connector from the control using the single screw in the center of the connector.
When the troubleshooting procedure instructs to REPAIR THE HARNESS, use the Electrical
System Schematic in the machine Service Manual to trace the circuit. Perform continuity checks at
connectors to locate harness failures. At component connectors, always check the ground circuit.
Less than five ohms of resistance is required between the connector ground contacts and frame
ground. Excessive ground resistance, greater than five ohms, can cause incorrect diagnosing of
problems.
During troubleshooting, inspect all component and harness connections before any component is
replaced. If these connections are not clean and tight they can cause electrical problems, either
permanent or intermittent (come and go). Make sure the connections are tight before other tests are
made.
NOTE: Except for harness tests, continuity testers (such as 8T-0500), or voltage testers (such as
5P-7277) are not recommended for use on present-day Caterpillar electrical circuits.
Transmission control fault codes are shown on the Caterpillar Monitoring System message area.
For information on the use of the Caterpillar Monitoring System, see service manual SENR6717. All
faults shown on the monitor with a Module Identifier (MID) code of 81 are system faults that are or
were detected by the transmission control. Use this manual (SENR5989) to troubleshoot faults with
an MID code of 81.
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When the transmission control detects a fault, the fault information is sent via the CAT data link to
the Caterpillar Monitoring System. When the monitoring system is placed in service mode, the fault
information is shown on the message area.
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Troubleshooting Procedures:
Go to the procedure which corresponds to the CID and FMI shown on the control display in the
digital readout area.
NOTE: Repair wiring after probing. Seal the punctures with 8T0065 Adhesive. Cover the adhesive
with two layers of 1P0810 Tape.
FMI F00
This fault should only be displayed with the fault present indicator ON and the engine running. If this
occurs, the charging system is charging at an excessive voltage. Check the charging system. See
Starting And Charging System module, SENR2947 in the machine Service Manual.
If this fault is displayed, with the fault present indicator ON, the engine stopped and no battery
charger connected, replace the control. See the topic Control Replacement in the Testing And
Adjusting section.
FMI F01
1. CHECK BATTERY VOLTAGE - Start the engine and run at high idle for several minutes. Measure
the battery voltage at the battery posts.
* Voltage is below 21.3 DCV; the charging system is not correct. Check the charging system. See
Starting And Charging System module, SENR2947 in the machine Service Manual.
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2. CHECK SYSTEM VOLTAGE AT CONTROL - Using sharp meter test leads, puncture the wire
insulation near the control connector. Measure the system voltage between wires 164-WH and 202-
PSP
BK at contacts 1 and 2 of the harness connector. The engine must be running at high idle.
202 -0006
* Voltage is below 21.3 DCV; harness is not correct. Repair or replace the harness.
* Voltage is at or above 21.3 DCV; system voltage is correct. Check to make sure CID 168 and FMI
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F01 are still displayed and that the fault present indicator is ON. Disconnect the control harness
connector and inspect contacts 1 and 2. Connect harness connector to the control. If fault still
3
SEN 7:46- 1
exists, with the fault present indicator ON, replace the control. See the topic Control Replacement in
the Testing And Adjusting section.
(Engine R
CID 190 Procedure© 5 0 5 :
202 89 00
Speed Sensor)
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Service Notes: Ensure that fault being analyzed is on-hold. Ensure that the fault present indicator is
ON.
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The engine RPM input is a frequency type sensor input. The engine speed signal is at contact 6 of
the control connector.
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1. CHECK SENSOR RESISTANCE - Disconnect the machine harness from the sensor. At the
sensor connector, measure the resistance between the two contacts.
* Resistance is NOT between 100 and 1300 Ohms; the speed sensor is faulty. Replace the sensor.
Adjust the speed sensor properly when installing it. See Speed Sensor Adjustment. Clear the fault
code.
* Resistance is between 100 and 1300 Ohms; the speed sensor resistance is correct. Go to Step 2.
2. CHECK SENSOR VOLTAGE - Reconnect the sensor to the machine harness. Disconnect the
machine harness from the control. Start the engine and run at low idle. At the machine harness
connector, for the control, measure the voltage (ACV) between contact 2 (ground) and contact 6.
* Voltage is greater than 3.0 ACV; the speed sensor voltage is correct. Replace the control, see the
topic Control Replacement in the Testing And Adjusting section.
* Voltage is less than 3.0 ACV; the speed sensor voltage is NOT correct. Go to Step 3.
3. CHECK SENSOR - Remove the sensor and check for foreign material on sensor tip. Install the
speed sensor and adjust correctly, see the topic Speed Sensor Adjustment in the Testing And
Adjusting section. Check the sensor voltage in the same manner as in Step 2.
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* Voltage is now greater than 3.0 ACV. Problem is NOT present; adjustment of the speed sensor
corrected the problem. Clear the fault code.
4. CHECK HARNESS - Connect the sensor to the machine harness. The control remains
disconnected from the machine harness. At the machine harness connector, for the control,
measure the resistance between contact 2 (ground) and contact 6.
* Resistance is between 100 and 1300 Ohms; the machine harness resistance is correct. Replace
the sensor. Adjust the speed sensor properly when installing it. See the topic Speed Sensor
Adjustment in the Testing And Adjusting section. Clear the fault code.
* Resistance is NOT between 100 and 1300 Ohms; the machine harness is shorted or open. Repair
or replace the harness. Clear the fault code.
The transmission RPM input is a frequency type sensor input. The transmission speed signal is at
contact 5 of the control connector.
FMI F08
1. CHECK SENSOR - Remove the sensor and check for foreign material on sensor tip. Install the
speed sensor and adjust correctly, see the topic Speed Sensor Adjustment in the Testing And
Adjusting section. Clear the fault and test machine operation. Check the control for the same fault
(CID 191).
2. CHECK HARNESS - Connect the sensor to the machine harness. The control remains
disconnected from the machine harness. At the machine harness connector, for the control,
measure the resistance between contact 2 (ground) and contact 5.
* Resistance is between 100 and 500 Ohms; the machine harness resistance is correct. Replace
the sensor. Adjust the speed sensor properly when installing it. See the topic Speed Sensor
Adjustment in the Testing And Adjusting section. Clear the fault code.
* Resistance is NOT between 100 and 500 Ohms; the machine harness is shorted or open. Repair
or replace the harness. Clear the fault code.
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FMI F02
This fault is recorded when the control does not receive expected information from the data link
(wire 944-OR or 945-BR).
Service Notes: Ensure that the CID 248/FMI F02 fault is on-hold and that the fault present indicator
is ON.
1. INSPECT HARNESS CONNECTORS - Inspect the machine harness connections related to the
data link. Make sure that connectors are clean and tight. If necessary, repair or replace the machine
harness. Check to see if the fault present indicator remains ON for the CID 248/FMI F02 fault.
* Fault present indicator is OFF; a machine harness connection was faulty. The fault is not present
now. Possibly an intermittent connection exists in the data link circuits of the machine harness.
Watch for a recurrence of this fault.
* Fault present indicator is ON; the fault remains present. Go to Step 2.
2. CHECK FOR SHORTED HARNESS - Disconnect the machine harness from the transmission
control and the monitoring system. At the machine harness connector for the transmission control,
measure the resistance between contacts 8 and 9.
* Resistance is less than 5000 Ohms (continuity); the machine harness is faulty. There is a short
between frame ground and the data link circuit in the machine harness. Repair or replace the
machine harness.
* Resistance is greater than 5000 Ohms (no continuity); harness circuit resistance is correct. Go to
Step 3.
3. CHECK FOR OPEN HARNESS - The transmission control and the monitoring system remain
disconnected from the machine harness. Check the continuity of the data link circuit in the machine
harness. Place a jumper between contacts 23 and 24 of the machine harness connector for the
monitoring system. Check for continuity between contacts 8 and 9 of the machine harness
connector for the transmission control.
* There is NO continuity; the machine harness is faulty. The data link circuit (wire 944-OR or 945-
BR) is open in the machine harness. Repair or replace the machine harness.
* There is continuity; this circuit is not the cause of the fault. Go to Step 4.
4. CHECK FOR OPEN HARNESS - The transmission control and the monitoring system remain
disconnected from the machine harness. Remove the jumper of the previous Step. Check the
continuity of the data link circuit in the machine harness. Place a jumper between contacts 8 and 9
of the machine harness connector for the transmission control. Check for continuity between
contacts 5 and 14 of the machine harness connector for the monitoring system.
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* There is NO continuity; the machine harness is faulty. The data link circuit (wire 944-OR or 945-
BR) is open in the machine harness. Repair or replace the machine harness.
* There is continuity; the data link circuit in the machine harness is correct. It is unlikely that an
electronic control is faulty. Perform the previous Steps again. If the cause is not found, replace the
controls one at a time to determine which control is the cause of the fault. See the topic Control
Replacement in the Testing And Adjusting section the subject Control Replacement.
FMI F02
These faults are recorded when the control reads improper signals from the auto/manual
transmission switch or the downshift switch.
The control detects the status of the switch circuits. The status is correct, when one circuit is open
and one is grounded. The status is wrong, when both circuits are open or grounded at the same
time. Connector contacts 20 and 21 are for the auto/manual switch. Connector contacts 22 and 23
are for the downshift switch.
1. CHECK CIRCUIT FOR PROPER OPERATION - Disconnect the harness connector from the
control. At the harness connector, check for continuity from contact 2 (ground) to the switch input
circuits with the faults. One input for the circuit should have continuity and one should not. Place the
switch in the other position and the status of each input should change.
* Operation is correct; switch and switch harness circuitry is correct. Inspect harness connector
contacts. Connect harness connector to control and check control for the same fault, with the fault
present indicator ON. If present, the control is faulty. Replace the control, see the topic Control
Replacement in the Testing And Adjusting section.
* Operation is not correct; switch or switch harness circuitry is not correct. Go to Step 2.
2. CHECK SWITCH - At the switch, check for the same operation as in Step 1.
The following chart shows which transmission solenoids are energized in each position of the shift
handle. An easy check of the solenoids can be done by placing a steel washer next to the solenoid
that should be energized. When the solenoid is energized it becomes magnetic. The washer should
be attracted to the energized solenoid. The same check can be done on the ride control solenoid
and the air inlet heater relay.
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FMI F03
This fault is recorded when the control senses there is a short to +battery in the solenoid circuit.
1. CHECK FOR SHORT TO +BATTERY - Disconnect the machine harness connector from the
control. Check for continuity from the faulty solenoid output circuit to +battery (contact 1). The
connector contacts are: Solenoid 1 - 31, Solenoid 2 - 32, Solenoid 3 - 33, Solenoid 4 - 34, Solenoid
5 - 35, Solenoid 6 - 36 and Ride Control - 37. Turn the various power circuits (headlights, heater
etc.) OFF and ON during this test to check for short from these circuits to the solenoid output circuit.
* There is continuity; the solenoid harness is shorted to +battery. Repair or replace harness.
2. CHECK FOR SHORT TO OTHER SOLENOID OUTPUTS - Check for continuity from the faulty
solenoid output to the other solenoid outputs. The connector contacts are: Solenoid 1 - 31, Solenoid
2 - 32, Solenoid 3 - 33, Solenoid 4 - 34, Solenoid 5 - 35, Solenoid 6 - 36, Ride Control - 37 and Air
Inlet Heater-38.
* There is NOT continuity; solenoid harness circuitry is correct. Inspect harness connector contacts.
Connect harness connector to control and check control for the same fault, with the fault present
indicator ON. If present, the control is faulty. Replace the control, see Control Replacement.
* There is continuity; the solenoid harness is shorted. Repair or replace harness.
FMI F05
This fault is recorded when the control senses there is not a complete electrical circuit for this
solenoid.
CHECK FOR OPEN HARNESS - Disconnect the machine harness connector from the control.
Measure the resistance from the faulty solenoid output circuit to solenoid return (contact 39). The
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connector contacts are: Solenoid 1 - 31, Solenoid 2 - 32, Solenoid 3 - 33, Solenoid 4 - 34, Solenoid
5 - 35, Solenoid 6 - 36 and Ride Control - 37.
FMI F06
This fault is recorded when the control senses there is a short to ground in the solenoid circuit.
CHECK FOR SHORT TO GROUND - Disconnect the machine harness connector from the control.
Check for continuity from the faulty solenoid output circuit to ground (contact 2). The connector
contacts are: Solenoid 1 - 31, Solenoid 2 - 32, Solenoid 3 - 33, Solenoid 4 - 34, Solenoid 5 - 35,
Solenoid 6 - 36 and Ride Control - 37.
* There is NOT continuity; solenoid harness circuitry is correct. Inspect harness connector contacts.
Connect harness connector to control and check control for the same fault. If present, the control is
faulty. Replace the control, see the topic Control Replacement in the Testing And Adjusting section.
* There is continuity; the solenoid or solenoid harness is shorted to ground. Repair or replace
harness and/or solenoid.
FMI F03
This fault is recorded when the control senses there is a short to +battery in the relay circuit.
1. CHECK FOR SHORT TO +BATTERY - Disconnect the machine harness connector from the
control. Check for continuity from connector contact 38 to contact 1 (+battery). Turn the various
power circuits (headlights, heater etc.) OFF and ON during this test to check for short from these
circuits to the output circuit.
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2. CHECK FOR SHORT TO OTHER SOLENOID OUTPUTS - Check for continuity from connector
contact 38 to the other solenoid outputs. The connector contacts are: Solenoid 1 - 31, Solenoid 2 -
32, Solenoid 3 - 33, Solenoid 4 - 34, Solenoid 5 - 35, Solenoid 6 - 36 and Ride Control - 37.
* There is NOT continuity; relay harness circuitry is correct. Inspect harness connector contacts.
Connect harness connector to control and check control for the same fault, with the fault present
indicator ON. If present, the control is faulty. Replace the control, see the topic Control Replacement
in the Testing And Adjusting section.
* There is continuity; the relay harness is shorted. Repair or replace harness.
FMI F05
This fault is recorded when the control senses there is not a complete electrical circuit for this relay.
CHECK FOR OPEN HARNESS - Disconnect the machine harness connector from the control.
Measure the resistance from connector contact 38 to contact 39 (solenoid return).
* Resistance is NOT 15 to 65 Ohms; the relay or relay harness circuitry is faulty. Repair or replace
harness and/or relay.
FMI F06
This fault is recorded when the control senses there is a short to ground in the solenoid circuit.
CHECK FOR SHORT TO GROUND - Disconnect the machine harness connector from the control.
Check for continuity from connector contact 10 to contact 2 (ground).
* There is NOT continuity; relay harness circuitry is correct. Inspect harness connector contacts.
Connect harness connector to control and check control for the same fault. If present, the control is
faulty. Replace the control, see the topic Control Replacement in the Testing And Adjusting section.
* There is continuity; the relay or relay harness is shorted to ground. Repair or replace harness
and/or relay.
Service Notes: Ensure that the fault being analyzed is on-hold. Ensure that the fault is present.
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FMI F02
This fault is recorded when the control does not recognize the harness code received from the
Caterpillar Monitoring System on the data link (wires 944-OR and 945-BR).
1. CHECK THE MONITORING SYSTEM - The transmission control receives harness code
information from the monitor. Check monitor for a related Caterpillar Monitoring System (MID 30)
fault. See service manual SENR6717 Caterpillar Monitoring System.
* Monitor has a related fault; correct the related fault per the Caterpillar Monitoring System service
manual. Then go to Step 2.
* Monitor does not have a related fault; check the data link. Perform the troubleshooting procedure
for a data link fault (CID 248/FMI F02).
2. RECHECK FOR FAULT - Check to see if the fault present indicator remains ON for this fault (CID
650/FMI F02).
* Fault present indicator is ON; check the data link. Perform the troubleshooting procedure for a
data link fault (CID 248/FMI F02).
* Fault present indicator is OFF; the fault is corrected. Clear the fault. Watch for a recurrence of this
fault.
FMI 02/22
The control detects faults that occur in the shift handle switches, neutralizer switch and related
harness circuits. Diagnostic codes CID 660 through 667 are only shown as ACTIVE faults, only CID
668 can be an ACTIVE or INACTIVE fault.
NOTE: The neutralizer switch must NOT be activated during this test.
* ACTIVE CID is "666", "667" and/or "668"; shift handle and/or neutralizer switch circuits are not
correct. Go to Step 3.
* ACTIVE CID is "660" through "665" and "668"; shift handle switch and/or ground circuits not
correct. Go to Step 2.
PSP
* INACTIVE CID is "668"; shift handle circuit fault no longer exists. Check harness and harness
connections for damage and poor connections. Clear the fault. Move the shift handle through each
202 -0006
position several times. Wiggle the shift handle to find intermittent problems in the handle. Check the
control for the shift handle faults. If the control detected a fault, replace the shift handle.
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2. CHECK SHIFT HANDLE GROUND CIRCUIT - Turn the disconnect switch to OFF position.
3
SEN 7:46- 1
Disconnect the shift handle harness connectors. At the 9 contact machine harness connector for the
shift handle, check for continuity from ground to contact 2.
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* There is continuity; the shift handle ground circuit is correct. Go to Step 4.
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* There is NO continuity; the shift handle ground circuit in the harness has a fault. Repair or replace
the harness.
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3. CHECK SHIFT HANDLE POWER CIRCUITS - Disconnect the shift handle harness connectors.
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At 9 contact machine harness connector for the shift handle, check for battery voltage between
contact 2 (ground) and contact 1. Neutralizer switch must NOT be activated.
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* Battery voltage measured; the shift handle power circuits are correct. Go to Step 4.
* Battery voltage is NOT measured; the power circuit harness or neutralizer switch is not correct.
Repair or replace the harness and/or switch.
4. CHECK HARNESS FROM SHIFT HANDLE TO CONTROL - Use the machine Electrical System
Schematic to check for shorts and continuity of the harness circuits that correspond to the connector
contacts shown on the control display.
FMI F02
These faults are recorded when the control reads improper signals from the ride control switch.
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The control detects the status of the ride control switch circuits. The status is correct, when the ride
switch control inputs are as specified in one of the following charts. If the status is wrong a fault is
recorded.
1. CHECK CIRCUIT FOR PROPER OPERATION - Disconnect the harness connector from the
control. At the harness connector, check for continuity from contact 2 (ground) to the ride control
switch inputs (contacts 24 and 26). Use the following chart to check the status of each input for all
three switch positions.
* Operation is correct; switch and switch harness circuitry is correct. Inspect harness connector
contacts. Connect harness connector to control and check control for the same fault, with the fault
present indicator ON. If present, the control is faulty. Replace the control, see the topic Control
Replacement in the Testing And Adjusting section.
* Operation is not correct; switch or switch harness circuitry is not correct. Go to Step 2.
2. CHECK SWITCH - At the switch, check for the same operation as in Step 1.
FMI F02
When turned ON, the control looks at the option code contacts, if the contacts do not represent a
valid option code, this fault is recorded. See the Options Code Configuration chart on the Electrical
System Schematic for the machine being serviced.
CHECK OPTION CODE - Disconnect the machine harness from the control. At the machine
harness connector for the control, check for proper option code. The proper option code can be
found in the Options Code Configuration chart on the Electrical System Schematic.
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* Option code is correct; option code circuitry is correct. Inspect harness connector contacts.
Connect harness to control. Clear the fault. Turn the key switch OFF then back ON to recheck the
control. If the same fault is active, replace the control. See the topic Control Replacement in the
Testing And Adjusting section.
* Option code is NOT correct; option code circuitry is faulty. Repair the option code circuits or
replace the harness. Clear the fault.
* If the control has the proper signals for automatic operation, follow the procedure for fault codes
CID 190 and CID 191.
* If the control does not have the proper signals follow the procedure for fault codes CID 368 and
CID 621.
Speed Sensor
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2. By hand, screw the sensor into the hole until the end of the sensor just makes contact with the
gear tooth.
3. Turn the sensor back out 1/2 turn (180° in the counterclockwise direction). This sets air gap (1) to
0.89 mm (.035 in).
Control Replacement
Prior to replacement of the control, ensure that replacement is absolutely necessary. Rarely is the
control the cause of a fault. Always check that power is available to the control; battery voltage is
required between control connector contacts 1 and 2 of the machine harness.
Procedure
1. Turn the key switch to the OFF position. Disconnect the machine harness from the control.
3. Make sure the replacement control has the correct part number.
Glossary
+Battery
+Battery refers to any of the harness wiring which is part of the circuit that connects to the positive
battery post.
+V
+V is a constant voltage that is supplied to a component to provide electrical power for its operation.
+V is provided by an electronic control module or the battery.
Abnormal
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Abnormal refers to a machine condition or signal that is not normal. The presence of an abnormal
condition or signal means a problem exists and warning operation is activated which notifies the
operator.
CID (Component Identifier)
The CID is a diagnostic code that tells which component or system is faulty. For example;
auto/manual switch, speed sensor, or shift handle. The CID is a three digit code that is located in
the digital readout area when in normal or service mode.
Clear
Clear refers to removing diagnostic information from the memory of the control. Before clearing
information, it is necessary that the information is on-hold and that the control is in service mode.
Connector Contact
A connector contact is the component of a harness connector that actually makes the electrical
connection. Connector contacts are either pins or sockets.
Detected Fault
A detected fault is a fault that has been found by the control. The fault is recorded and diagnostic
information is available when in service mode.
Diagnostic
Diagnostic refers to the showing, monitoring and/or recording of information other than normal.
Diagnostic information is available from service, test or normal mode.
Display
Display refers to the indicators or digital readouts within the control display area.
Fault
A fault is a failure of a component of the system. For example; open or shorted harness, faulty
switch, sensor or control.
FMI (Failure Mode Identifier)
The FMI is a diagnostic code that tells what type of failure has occurred. For example; voltage
above normal, current below normal or abnormal frequency. The FMI is a two digit code preceded
by the letter "F". This code is located in the digital readout area when in service mode.
Hard Wired
Hard wired refers to electrical connections made within the harness that are permanent. These
soldered or crimped connections are not meant to be altered.
Hold or On-Hold
Hold or On-hold refers to holding (or locking) a set of diagnostic information that is shown in the
digital display area when in service mode. It is necessary to hold the set of diagnostic information
before troubleshooting or clearing.
Jumper
A jumper is a piece of wire used to make an electrical connection during troubleshooting.
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Option Code
Option code refers to the grounded or open condition of the two option code inputs (connector
contacts 25 and 27). The option code tells the control what options are installed on the machine.
Scroll
Scrolling is the process of showing (within the digital display area) all available sets of diagnostic
information, one set at a time. A set of diagnostic information is shown briefly and then the display
automatically advances to the next set. After all sets are shown the sets are repeated.
Show
Show refers to information within the control display area that is viewed by the operator or service
person.
Signal Wire
The signal wire is the harness wire which connects the sensor or switch to the control.
Switch Input
A switch input is any input of the control which is expecting only an open (floating) or grounded
signal.
System Voltage
System voltage is the actual voltage that exists between the positive battery post and frame ground.
System voltage is also referred to as +battery voltage.
Undetected Fault
An undetected fault is a fault that exists and is not found by the control but is found by the operator
or service person.
Machine Code
The machine code is a two digit number that has been assigned to a particular harness code for a
particular machine. The machine code is shown on the control display during the Self Test. Each
sales model has a specific harness code and therefore also a specific machine code.
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PSP-000605D2
2024/03/11
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11/3/24, 8:37
202 0006 SIS 2.0
13:37:02-05:00
SENR59890002 4
13: /03/1 05D2
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3
SEN 7:46 1
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