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catmastertech
catmastertech, Technician
Category: Construction and Road Equipment
Satisfied Customers: 2273
Experience:  Field service technician for CAT 19 years.
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I have a TH360B Cat. Telehandler with codes: 039 0668 09,

Customer Question

I have a TH360B Cat. Telehandler with codes: 039 0668 09, 039 0271 04, (###) ###-####05, 039 1788 02. Just wondering if replacing the shifter would take care of it.
Submitted: 1 year ago.
Category: Construction and Road Equipment
Expert:  catmastertech replied 1 year ago.

It is possible the shifter is the issue. I would check the harness first before spending money on a part that cannot be returned. See the troubleshooting information below for testing the system. See attachment for a partial wiring diagram.

039 Machine ECM
0668 Transmission control (shift lever) 09 "Abnormal update"

These codes are not related.

0271 Action alarm 04 "Voltage below normal or shorted low"
05 "Current below normal or open circuit"

1788 Switch (right stabilizer) 02 "Data erratic, intermittent or incorrect"

Details of the failure.

FMI 09 "Abnormal Update" - This relates to communications on the data link. FMI 09 occurs when a control is not able to get information from another control.

Some of the possible causes of a FMI 09 are listed below.

The control module is not communicating on the data link correctly.
The rate of data transmission is abnormal.
The data link has failed.
There is a mismatch of software.

Troubleshooting the fault code.

MID 039 - CID 0668 - FMI 09
This diagnostic code is recorded when the machine ECM does not receive expected information from the shift lever for more than 5 seconds.

Possible causes of the 668-9 diagnostic code are listed below:

An open, short, or a poor connection in the Cat data link circuit
Excessive noise on the data link circuit
The shifter controller has failed
The machine ECM has failed. This condition is unlikely.
System Response:

This failure results in events that are logged against an ECM that cannot be explained directly. The machine ECM cannot communicate with this ECM or the ECM appears to communicate intermittently.

Test Step 1. INSPECT THE HARNESS CONNECTIONS

Reference Testing and Adjusting, "Electrical Connector - Inspect" in this manual

Turn the disconnect switch to the OFF position.
Inspect all harness connections that are related to the Cat Data Link. Make sure that the connectors are clean and tight.
Check the connectors for proper mating. Ensure that all the seals are present and in place.
Check the harness for signs of damage or abrasion.
Check the wires at the connector. Ensure that the wires are secured tightly into the connector. Take care not to pull the wire out of the connector.
Check the exposed wires at the connectors for nicks or signs of abrasion.
Check for moisture inside the connector.
Check the connectors for dirty contacts or corroded contacts.
Check each pin and each socket of the machine harness connectors. Ensure that the contacts are properly installed. The contacts should mate correctly when the two pieces of the connector are placed together.
Expected Result:

The machine harness connectors are tight and free of corrosion.

Results:

OK - The machine harness connectors are tight and free of corrosion. Proceed to Test Step 2.
NOT OK - The machine harness connectors are in need of repair.
Repair: Repair the machine harness or replace the machine harness.

STOP

Test Step 2. CHECK FOR SHORTS TO GROUND

Reference Testing and Adjusting, "Wiring Harness (Short Circuit) - Test" in this manual

The disconnect switch remains in the OFF position.
Disconnect the machine harness connectors from all electronic control modules that use the Cat Data Link.
At the machine harness for the shift lever, measure the resistance between frame ground and connector contacts 3 (wire 893-GN) and 4 (wire 892-BR) of the Cat Data Link circuit.
Expected Result:

The resistance is greater than 5000 ohms.

Results:

OK - The resistance is greater than 5000 ohms. The harness circuit resistance is correct. Proceed to Test Step 3.
NOT OK - The resistance is less than 5000 ohms. The machine harness has failed.
Repair: There is a short between frame ground and contacts 3 (wire 893-GN) and 4 (wire 892-BR) of the Cat Data Link circuit in the machine harness. Repair the machine harness or replace the machine harness.

STOP

Test Step 3. CHECK FOR SHORT TO THE +BATTERY CIRCUIT

The disconnect switch remains in the OFF position.
All related electronic control modules remain disconnected from the machine harness.
At the machine harness connector for the shift lever, perform the checks that are listed here:
Measure the resistance between the connector contact 1 (wire 123-WH) and connector contact 3 (wire 893-GN).
Measure the resistance between connector contact 1 (wire 123-WH) and connector contact 4 (wire 892-BR).
Expected Result:

The resistance is greater than 5000 ohms.

Results:

OK - The harness circuit resistance is correct. Proceed to Test Step 4.
NOT OK - The resistance is less than 5000 ohms. The machine harness has failed.
Repair: There is a short between the +battery circuit and contacts 3 (wire 893-GN) and 4 (wire 892-BR) of the Cat Data Link circuit in the machine harness. Repair the machine harness or replace the machine harness.

STOP

Test Step 4. CHECK FOR OPEN HARNESS

Reference Testing and Adjusting, "Wiring Harness (Open Circuit) - Test" in this manual.

The disconnect switch remains in the OFF position.
All related electronic control modules remain disconnected from the machine harness.
Check the resistance of the Cat Data Link circuit in the machine harness:
Measure the resistance between connector contact 10 (wire 893-GN) of the machine ECM and connector contact 3 (wire 893-GN) of the control for the shift lever.
Measure the resistance between connector contact 20 (wire 892-BR) of the machine ECM and connector contact 4 (wire 892-BR) of the control for the shift lever.
Expected Result:

The resistance measures less than 5 ohms.

Results:

OK - The resistance is less than 5 ohms. The Cat Data Link circuit in the machine harness is correct. Proceed to Test Step 5.
NOT OK - The resistance is greater than 5 ohms. The machine harness has failed.
Repair: The Cat Data Link circuit is open in the machine harness. Repair the machine harness or replace the machine harness.

STOP

Test Step 5. CHECK THE STATUS OF THE DIAGNOSTIC CODE

Inspect and clean the contacts of the Cat data link harness connectors.
Reference Testing and Adjusting, "Electrical Connector - Inspect" in this manual

Perform a 45 N (10 lb) pull test on each of the wires that are associated with the Cat data link circuit.
Reconnect all harness connectors. Make sure that the connectors are fully seated. Observe that the clips for each connector are fastened securely.
Turn the disconnect switch and the key start switch to the ON position.
Operate the machine.
Check the status of the 668-9 diagnostic code.
Expected Result:

The 668-9 diagnostic code is not active

Results:

OK - The 668-9 diagnostic code is not active. The diagnostic code does not exist at this time.
Repair: The fault was probably caused by a poor electrical connection or a short at one of the harness connectors that was disconnected and reconnected. Resume normal machine operation.

STOP

NOT OK - The 668-9 diagnostic code is still active. The diagnostic code has not been corrected.
Repair: Perform this procedure again. If the problem persists, swap the shifter controller with a known good part.

If swapping the shifter controller does not resolve the diagnostic code, the machine ECM may have failed.

Prior to replacing an ECM, contact your dealer Technical Communicator (TC) for possible consultation with Caterpillar. This consultation may greatly reduce repair time.

If machine ECM replacement is needed, refer toTesting and Adjusting, "Electronic Control Module (ECM) - Replace" in this manual.

STOP

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