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catmastertech
catmastertech, Technician
Category: Construction and Road Equipment
Satisfied Customers: 2243
Experience:  Field service technician for CAT 19 years.
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I have a 2007 d3g that is giving me codes 254, 252, 256,

Customer Question

I have a 2007 d3g that is giving me codes 254, 252, 256, 255, 244, and 124. The hydrostat light is on and the parking brake won't turn off.
Submitted: 1 year ago.
Category: Construction and Road Equipment
Customer: replied 1 year ago.
The problem is fixed.
Customer: replied 1 year ago.
Well my guys told me it was fixed yesterday evening but now they tell me it is not. Please help
Expert:  catmastertech replied 1 year ago.

Hello, I recently had an intermittent problem with a D3G that I found the pins in the decelerator pedal sensor connector had corroded and were loosing contact. Since that is your first code, I would begin there.

Here is a list of the codes you have.

254 CID 1693 Position Sensor (Deceleration Pedal)
252 CID 0468 Position Sensor (Service Brake Pedal)
256 CID 1700 Position Sensor (Steering)
255 CID 1699 Position Sensor (Forward/Neutral/Reverse)
244 CID 0070 Rocker Switch (Parking Brake)
124 CID 0041 Sensor Power Supply (8 DCV)

Here are details about testing for this problem.

Note: The sensor does not connect directly to frame ground. The sensor connects to the return circuit of the ECM. The ECM connects the return wire to the frame ground internally.

This diagnostic code is recorded when the ECM reads the sensor signal as being above normal. There is a short to the +battery circuit.

Note: The sensor is probably out of specification, if the diagnostic code is only present under certain extreme operating conditions such as pedal "full-up" or pedal "full-down". Replace the sensor.

The possible causes of this diagnostic code are listed:

  • The +battery circuit (wire 497-BU) from the electrical system to the sensor is open.

     

  • The return circuit (wire J764-BR) is open.

     

  • The signal circuit is open or the sensor is disconnected.

     

  • The signal circuit is shorted to the +battery circuit.

     

  • The sensor has failed.

     

  • The ECM has failed. This is unlikely.

     

Note: Ensure that CID 1693 FMI 03 is on hold and that the diagnostic indicator is illuminated.

Note: The following test procedure may create other diagnostic codes. Ignore these created diagnostic codes and clear the diagnostic codes when the original diagnostic code has been corrected.

System Response:

When this diagnostic code occurs, the action lamp is ON. The diagnostic code will cause the underspeed performance to be affected.

Test Step 1. CHECK THE VOLTAGE AT THE SENSOR.

  1. Turn the disconnect switch and the key start switch to the ON position.

 

  1. Disconnect the sensor from the machine harness.

 

  1. At the machine harness connector for the sensor, measure the voltage between contact A (wire 497-BU) and contact B (wire J764-BR).

Expected Result:

The voltage measurement should be approximately + 8 volts.

Results:

  • OK - The voltage is approximately + 8 volts. Proceed to test step 4.

     

  • NOT OK - The voltage is not approximately + 8 volts.

    Repair: There is an open in the machine harness or the ECM has failed. It is unlikely that the ECM has failed.

    Proceed to test step 2.

Test Step 2. CHECK FOR AN OPEN IN THE SUPPLY CIRCUIT.

  1. The key start switch and the disconnect switch remain in the ON position.

 

  1. The sensor remains disconnected from the machine harness.

 

  1. At the machine harness connector for the sensor, measure the voltage from contact A (wire 497-BU) to ground.

Expected Result:

The voltage measurement should be approximately + 8 volts.

Results:

  • OK - The voltage measurement is approximately + 8 volts. Proceed to test step 3.

     

  • NOT OK - The voltage measurement is not approximately + 8 volts.

    Repair: The supply circuit is not correct. Repair the circuit or replace the circuit.

    STOP

Test Step 3. CHECK FOR AN OPEN IN THE RETURN CIRCUIT.

  1. Turn the key start switch and the disconnect switch to the OFF position.

 

  1. The sensor remains disconnected from the machine harness.

 

  1. Disconnect the machine harness connector J1 from the ECM.

 

  1. At the machine harness connector for the sensor, install a jumper wire from contact B (wire J764-BR) to ground.

 

  1. At the machine harness connector for the ECM, measure the resistance from contact J1-12 (wire J764-BR) to ground.

Expected Result:

The resistance measurement should measure less than 5 ohms.

Results:

  • OK - The resistance measurement is less than 5 ohms. The harness is correct. The ECM may have failed.

    Repair: It is unlikely that the ECM has failed. Recheck the status of the diagnostic code. If the diagnostic code remains present, exit this procedure and perform this procedure again. If the cause of the diagnostic code is not found, replace the ECM. See Testing and Adjusting, "Electronic Control Module (ECM) - Replace".

    STOP

  • NOT OK - The resistance that is measured is not correct.

    Repair: There is an open in the machine harness. The open is in the return circuit. Repair the harness or replace the harness.

    STOP

Test Step 4. CHECK FOR AN OPEN IN THE SIGNAL CIRCUIT.

  1. Turn the key start switch and the disconnect switch to the OFF position.

 

  1. Disconnect the J1 and J2 machine harness connector from the ECM.

 

  1. At the machine harness connector for the sensor, install a jumper wire from contact C (wire M730-YL) to contact B (wire J764-BR).

 

  1. At the machine harness connector J1 and J2, measure the resistance from contact J1-25 (wire M730-YL) to contact J1-12 (wire J764-BR).

Expected Result:

The resistance should measure less than 5 ohms.

Results:

  • OK - The resistance measures less than 5 ohms. Proceed to 5.

     

  • NOT OK - The resistance measurement is greater than 5 ohms.

    Repair: There is an open in the signal circuit. Repair the harness or replace the harness.

    STOP

Test Step 5. CHECK THE SIGNAL CIRCUIT FOR A SHORT.

  1. The disconnect switch and the key start switch remain in the OFF position.

 

  1. The machine harness connectors for the ECM remain disconnected.

 

  1. Remove the jumper wire from contact C (wire M730-YL) to contact B (wire J764-BR).

 

  1. At the J1 and J2 machine harness connectors for the ECM, measure the resistance for the signal contact of the sensor J1-24 (wire M730-YL) to all other J1 and J2 contacts.

Expected Result:

Each resistance measurement should be greater than 5000 ohms.

Results:

The second code is for the brake pedal sensor.

It could be a similar problem.

Here are details to test for this issue.

  • OK - Each resistance measurement is greater than 5000 ohms.

    Repair: The sensor has failed. Replace the sensor. Calibrate the sensor. See Testing and Adjusting, "Position Sensor (Deceleration Pedal) - Calibrate" for more information. Verify that the sensor corrected the problem. If the problem persists, exit this procedure and perform this procedure again. If the problem has not been found, replace the ECM. See Testing and Adjusting, "Electronic Control Module (ECM) - Replace".

    STOP

  • NOT OK - The resistance measures less than 5000 ohms.

    Repair: There is a short in the machine harness. The short is between the signal circuit and the circuit with the low resistance measurement. Repair the harness or replace the harness.

    STOP

Note: The sensor does not connect directly to frame ground. The sensor connects to the return circuit of the ECM. The ECM connects the return wire to the frame ground internally.

This diagnostic code is recorded when the ECM reads the sensor signal as being above normal. There is a short to the + 8 volt sensor power supply.

Note: The sensor is probably out of specification, if the diagnostic code is only present under certain extreme operating conditions such as pedal "full-up" or pedal "full-down". Replace the sensor.

The possible causes of this diagnostic code are listed:

The sensor power supply (wire 497-BU) from the electrical system to the sensor is open.

The return circuit (wire J764-BR) is open.

The signal circuit is open or the sensor is disconnected.

The signal circuit is shorted to the + 8 volt sensor power supply.

The sensor has failed.

The ECM has failed. This is unlikely.

Expected Result:

Each resistance measurement should be greater than 5000 ohms.

Results:

Test Step 5. CHECK THE SIGNAL CIRCUIT FOR A SHORT.

Expected Result:

The resistance should measure less than 5 ohms.

Results:

Test Step 4. CHECK FOR AN OPEN IN THE SIGNAL CIRCUIT.

Expected Result:

The resistance measurement should measure less than 5 ohms.

Results:

Test Step 3. CHECK FOR AN OPEN IN THE RETURN CIRCUIT.

Expected Result:

The voltage measurement should be approximately 8 DCV.

Results:

Test Step 2. CHECK FOR AN OPEN IN THE SUPPLY CIRCUIT.

Expected Result:

The voltage measurement should be approximately battery voltage.

Results:

Note: Ensure that CID 0468 FMI 03 is on hold and that the diagnostic indicator is illuminated.

Note: The following test procedure may create other diagnostic codes. Ignore these created diagnostic codes and clear the diagnostic codes when the original diagnostic code has been corrected.

System Response:

When this diagnostic code occurs, the action lamp is ON. The diagnostic code will cause the pedal to stop functioning. The diagnostic code will not affect any other machine operations.

Test Step 1. CHECK THE VOLTAGE AT THE SENSOR.

  • OK - Each resistance measurement is greater than 5000 ohms.

    Repair: The sensor has failed. Replace the sensor. Calibrate the sensor. See Testing and Adjusting, "Calibration" for more information. Verify that the sensor corrected the problem. If the problem persists, exit this procedure and perform this procedure again. If the problem has not been found, replace the ECM. See Testing and Adjusting, "Electronic Control Module (ECM) - Replace".

    STOP

  • NOT OK - The resistance measures less than 5000 ohms.

    Repair: There is a short in the machine harness. The short is between the signal circuit and the circuit with the low resistance measurement. Repair the harness or replace the harness.

    STOP

  • At the J1 and J2 machine harness connectors for the ECM, measure the resistance for the signal contact of the sensor J1-25 (wire G745-PK) to all other J1 and J2 contacts.
  • Remove the jumper wire from contact C (wire G745-PK) to contact B (wire J764-BR).
  • The machine harness connectors for the ECM remain disconnected.
  • The disconnect switch and the key start switch remain in the OFF position.
  • OK - The resistance measures less than 5 ohms. Proceed to 5.

     

  • NOT OK - The resistance measurement is greater than 5 ohms.

    Repair: There is an open in the signal circuit. Repair the harness or replace the harness.

    STOP

  • At the machine harness connector J1 and J2, measure the resistance from contact J1-25 (wire G745-PK) to contact J1-12 (wire J764-BR).
  • At the machine harness connector for the sensor, install a jumper wire from contact C (wire G745-PK) to contact B (wire J764-BR).
  • Disconnect the J1 and J2 machine harness connector from the ECM.
  • Turn the key start switch and the disconnect switch to the OFF position.
  • OK - The resistance measurement is less than 5 ohms. The harness is correct.

    Repair: The ECM may have failed. It is unlikely that the ECM has failed. Recheck the status of the diagnostic code. If the diagnostic code remains present, exit this procedure and perform this procedure again. If the cause of the diagnostic code is not found, replace the ECM. See Testing and Adjusting, "Electronic Control Module (ECM) - Replace".

    STOP

  • NOT OK - The resistance that is measured is not correct.

    Repair: There is an open in the machine harness. The open is in the return circuit with the high resistance measurement. Repair the harness or replace the harness.

    STOP

  • At the machine harness connector for the ECM, measure the resistance from contact J1-12 (wire J764-BR) to ground.
  • At the machine harness connector for the sensor, install a jumper wire from contact B (wire J764-BR) to ground.
  • Disconnect the machine harness connector J1 from the ECM.
  • The sensor remains disconnected from the machine harness.
  • Turn the key start switch and the disconnect switch to the OFF position.
  • OK - The voltage measurement is approximately 8 DCV. Proceed to test step 3.

     

  • NOT OK - The voltage measurement is 8 DCV.

    Repair: The supply circuit is not correct. Repair the circuit or replace the circuit.

    STOP

  • At the machine harness connector for the sensor, measure the voltage from contact A (wire 497-BU) to ground.
  • The sensor remains disconnected from the machine harness.
  • The key start switch and the disconnect switch remain in the ON position.
  • OK - The voltage is approximately 8 DCV. Proceed to test step 4.

     

  • NOT OK - The voltage measurement is NOT 8 DCV.

    Repair: There is an open in the machine harness or the ECM has failed. It is unlikely that the ECM has failed.

    Proceed to Test Step 2.

  • At the machine harness connector for the sensor, measure the voltage between contact A (wire 497-BU) and contact B (wire J764-BR).
  • Disconnect the sensor from the machine harness.
  • Turn the disconnect switch and the key start switch to the ON position.

If this does not help, please post the full machine serial number and any repairs you have done.

Also clear the codes and see which return after operating the machine again.

    Customer: replied 1 year ago.
    We cleared the codes yesterday and the only one that remained was 124.
    Expert:  catmastertech replied 1 year ago.

    Ok, thanks.

    Here are the two possible problems related to the 124 code.

    Conditions Which Generate This Code:

    The sensor supply is a power supply that is internal to the ECM. The sensor supply provides 8 VDC in order to operate the sensors. The control module shall monitor sensor supply voltage for a low voltage condition. If the voltage drops below 7.5 VDC, an active diagnostic code is generated. If the voltage drop continues for 5 seconds, a diagnostic code is generated. The delay will prevent a diagnostic code from being logged when the machine is started. The diagnostic code will be cleared when the voltage is above 7.5 VDC for 5 seconds. The following sensors use 8 VDC: right track speed, left track speed, center brake pedal and decelerator pedal.

    This diagnostic code will be recorded when the ECM reads the voltage for the circuit of the sensor supply as being below normal.

    The results of this diagnostic code are listed:

    • All of the associated sensors will also log diagnostic codes.

       

    • The action lamp and the action alarm is ON.

       

    • This diagnostic code will cause the transmission to shift to NEUTRAL position until the diagnostic code is corrected.

       

    The possible causes of the diagnostic code are listed:

    • The supply circuit (8 VDC) is shorted to the ground circuit in the machine harness.

       

    • The ECM has failed. This is unlikely.

       

    Test Step 1. CHECK THE SENSOR.

    1. Ensure that the diagnostic code is present. The diagnostic code should be active.

     

    1. Observe the status of the diagnostic code.

     

    1. Disconnect the machine harness from the sensor.

    Expected Result:

    The diagnostic code is NO longer active.

    Results:

    • OK - The diagnostic code is NO longer active.

      Repair: The sensor has failed. Replace the sensor.

      STOP

    • NOT OK - The diagnostic code remains active. The sensor is NOT causing the diagnostic code. Proceed to test step 2.

    Test Step 2. CHECK THE REMAINING SENSORS.

    1. Ensure that the diagnostic code is present. The diagnostic code should be active.

     

    1. Observe the status of the diagnostic code.

     

    1. One at a time, disconnect the machine harness from the remaining sensors.

    Expected Result:

    For one of the remaining sensors, the diagnostic code is NO longer active when the harness is disconnected.

    Results:

    • OK - For one of the remaining sensors, the diagnostic code is NO longer active when the harness is disconnected. The sensor has failed.

      Repair: Replace the sensor.

      STOP

    • NOT OK - The diagnostic code remains active. The sensors are NOT the cause of the diagnostic code. Proceed to test step 3.

    Test Step 3. CHECK FOR SHORT TO GROUND

    1. The sensor remains disconnected from the machine harness.

     

    1. Turn the disconnect switch to the OFF position.

     

    1. Disconnect the machine harness from the ECM.

     

    1. At the ECM, measure the resistance between the contact of the sensor supply voltage and frame ground.

    Expected Result:

    The resistance that is measured should be greater than 5000 ohms.

    Results:

    OPTION #2

    • OK - The resistance that is measured is greater than 5000 ohms.

      Repair: The harness circuit is correct. It is unlikely that the ECM has failed. Exit this diagnostic code procedure and perform this diagnostic code procedure again. Replace the ECM if the cause of the diagnostic code is NOT found. See Testing And Adjusting, "Electronic Control Module (ECM) - Replace".

      STOP

    • NOT OK - The resistance that is measured is less than 5000 ohms.

      Repair: The machine harness has failed. There is a short between frame ground and the contact for the sensor supply voltage in the machine harness. Repair the machine harness or replace the machine harness.

      STOP

    Conditions Which Generate This Code:

    The sensor supply is a power supply that is internal to the ECM. The sensor supply provides 8 DCV in order to operate the sensors. The ECM monitors the sensor supply voltage for a high voltage condition. If the voltage rises above 10 DCV for 1 second, a diagnostic code will be generated. The active diagnostic code is cleared when the voltage drops below 8.5 DCV for 5 seconds. The following sensors use 8 DCV: right track speed, left track speed, center brake pedal and decelerator pedal.

    This diagnostic code will be recorded when the ECM reads the voltage for the circuit of the sensor supply as being above normal.

    The results of this diagnostic code are listed:

    All of the associated sensors will also log diagnostic codes.

    The action lamp and the action alarm is ON.

    The transmission is shifted to the NEUTRAL position until the diagnostic code is corrected.

    The resistance that is measured should be greater than 5000 ohms.

    Results:

    Expected Result:

    Test Step 1. CHECK FOR A SHORT TO THE +BATTERY CIRCUIT.

    The possible causes of the diagnostic code are listed:

    • OK - The resistance measurement is greater than 5000 ohms.

      Repair: The harness circuit is correct. It is unlikely that the ECM has failed. Perform this diagnostic code again. Replace the ECM if the cause of the diagnostic code is NOT found. See Testing and Adjusting, "Electronic Control Module (ECM) - Replace".

      STOP

    • NOT OK - The resistance measurement is less than 5000 ohms.

      Repair: The machine harness has failed. There is a short between the +battery circuit and the circuit for the sensor power supply in the machine harness. Repair the machine harness or replace the machine harness.

      STOP

    • Perform the following measurement at the connectors of the ECM. Measure the resistance between the contacts for the +battery and the contact for the sensor supply voltage.
    • Disconnect the machine harness from the ECM.
    • Turn the key start switch and the disconnect switch to the OFF position.
    • The supply circuit (8 DCV) is shorted to the +battery circuit in the machine harness.

       

    • The ECM has failed. This is unlikely.

       

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