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catmastertech
catmastertech, Technician
Category: Heavy Equipment
Satisfied Customers: 1912
Experience:  19 years Cat, 3 years Case
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i have a 04 Cat 257B ASV skidsteer, Starts, runs, will not

Customer Question

i have a 04 Cat 257B ASV skidsteer, Starts, runs, will not move and no hyd controls, Arm rest sensor good, seat sensor good, parking brake light on arm rest light flashing, fuses good, and grounds good
Submitted: 4 years ago.
Category: Heavy Equipment
Expert:  catmastertech replied 4 years ago.

I think you are saying BOTH the park brake AND the arm rest light are on.

Here is the guide to help find your problem. Follow the test as much as you can and if you have questions, just post them here with your serial number.

 

Parking Brake Indicator and Armrest Indicator Are Flashing

Test Step 1. CHECK FOR A FLASHING PARKING BRAKE INDICATOR AND/OR A FLASHING ARMREST INDICATOR BEFORE THE SYSTEM IS ENABLED
Occupy the seat.

Place the armrest in the DOWN position.

Turn the key start switch to the ON position.

Expected Result:

The armrest indicator should be off and the parking brake indicator should be on.

Results:

OK - The armrest indicator is off and the parking brake indicator is on. Proceed to Test Step 9.

NOT OK - The armrest indicator is flashing and the parking brake indicator is flashing. Proceed to Test Step 2.

NOT OK - The parking brake indicator is flashing.

Repair: See Troubleshooting, "Parking Brake Indicator Is Flashing".

Stop.

NOT OK - The armrest indicator is flashing.

Repair: See Troubleshooting, "Armrest Indicator Is Flashing".

Stop.

Test Step 2. CHECK THE RETURN SOLENOID WIRE FOR A SHORT TO GROUND

Turn the key start switch to the OFF position.

Raise the cab. See Operation and Maintenance Manual, "Cab Tilting".

Locate the interlock ECM. The interlock ECM is located on the left side of the machine beneath the access cover on the floor of the machine.

Remove the wire harness from the ECM.

Measure the resistance from contact 3 to contact 68 (wire 201-BK and wire 975-WH) of the wire harness connector.

Expected Result:

The resistance should be greater than 5000 Ohms.

Results:

OK - The resistance is greater than 5000 Ohms. Proceed to Test Step 6.

NOT OK - The resistance is not greater than 5000 Ohms. Proceed to Test Step 3.

Test Step 3. CHECK THE HYDROSTATIC PILOT SOLENOID FOR A SHORT TO GROUND

Locate the hydrostatic pilot solenoid.

Disconnect the wire harness from the hydrostatic pilot solenoid.

Measure the resistance from contact 3 to contact 68 (wire 201-BK and wire 975-WH) of the wire harness for the ECM.

Expected Result:

The resistance should be greater than 5000 Ohms.

Results:

OK - The resistance is greater than 5000 Ohms.

Repair: The hydrostatic pilot solenoid has failed. Replace the coil for the hydrostatic pilot solenoid.

Stop.

NOT OK - The resistance is not greater than 5000 Ohms. Proceed to Test Step 4.

Test Step 4. CHECK THE WORK TOOL PILOT SOLENOID FOR A SHORT TO GROUND

Locate the work tool pilot solenoid.

Disconnect the wire harness from the work tool pilot solenoid.

Measure the resistance from contact 3 to contact 68 (wire 201-BK and wire 975-WH) of the wire harness for the ECM.

Expected Result:

The resistance should be greater than 5000 Ohms.

Results:

OK - The resistance is greater than 5000 Ohms.

Repair: The work tool pilot solenoid has failed. Replace the coil for the work tool pilot solenoid.

Stop.

NOT OK - The resistance is not greater than 5000 Ohms. Proceed to Test Step 5.

Test Step 5. CHECK THE WORK TOOL DETENT COIL FOR A SHORT TO GROUND

Locate the work tool detent coil. The detent coil is located beneath the right hand joystick. Remove the access panel in order to get to the connector.

Disconnect the wire harness from the work tool detent coil.

Measure the resistance from contact 3 to contact 68 (wire 201-BK and wire 975-WH) of the wire harness for the ECM.

Expected Result:

The resistance should be greater than 5000 Ohms.

Results:

OK - The resistance is greater than 5000 Ohms.

Repair: The work tool detent coil has failed. Replace the coil for the work tool detent coil.

Stop.

NOT OK - The resistance is not greater than 5000 Ohms.

Repair: The wire harness has failed. Repair the wire harness and/or the connector or replace the wire harness and/or the connector.

Stop.

Test Step 6. CHECK THE CIRCUIT FOR THE HYDROSTATIC PILOT SOLENOID FOR A SHORT TO THE + BATTERY TERMINAL

Measure the resistance at the wire harness connector from contact 29 (wire H416-GN) to the following contacts: contact 1, contact 11, contact 13, contact 24, contact 42, contact 47, contact 58, contact 60, contact 62 and contact 70.

Expected Result:

The resistances should be greater than 5000 Ohms.

Results:

OK - The resistances are greater than 5000 Ohms. Proceed to Test Step 7.

NOT OK - The resistance is not greater than 5000 Ohms on at least one of the readings.

Repair: The wire harness has failed. Repair the wire harness and/or the connector or replace the wire harness and/or the connector.

Stop.

Test Step 7. CHECK THE CIRCUIT OF THE WORK TOOL PILOT SOLENOID FOR A SHORT TO + BATTERY

Measure the resistance at the wire harness connector from contact 24 (wire 126-PK) to the following contacts: contact 1, contact 11, contact 13, contact 42, contact 47, contact 58, contact 60, contact 62 and contact 70.

Expected Result:

The resistances should be greater than 5000 Ohms.

Results:

OK - The resistances are greater than 5000 Ohms. Proceed to Test Step 8.

NOT OK - The resistance is not greater than 5000 Ohms on at least one of the readings.

Repair: The wire harness has failed. Repair the wire harness and/or the connector or replace the wire harness and/or the connector.

Stop.

Test Step 8. CHECK THE CIRCUIT OF THE WORK TOOL PILOT SOLENOID FOR A SHORT TO + BATTERY

Measure the resistance at the wire harness connector from contact 66 (wire 975-WH) to the following contacts: contact 1, contact 11, contact 13, contact 42, contact 47, contact 58, contact 60, contact 62 and contact 70.

Expected Result:

The resistances should be greater than 5000 Ohms.

Results:

OK - The resistances are greater than 5000 Ohms.

Repair: The ECM is very unlikely to have failed. Reconnect all connections and visually inspect the wire harness. Verify that the diagnostic code still exists. If the diagnostic code still exists perform the Test Steps again.Replace the ECM, if the cause of the diagnostic code was not found after the second attempt. See Testing and Adjusting, "Electronic Control Module (ECM) - Replace".

Stop.


NOT OK - The resistance is not greater than 5000 Ohms on at least one of the readings.

Repair: The wire harness has failed. Repair the wire harness and/or the connector or replace the wire harness and/or the connector.

Stop.

Test Step 9. CHECK FOR A FLASHING PARKING BRAKE INDICATOR AND/OR A FLASHING ARMREST INDICATOR AFTER THE SYSTEM IS ENABLED

Note: The seat will still need to be occupied and the armrest will need to be down. The key start switch will also need to be in the ON position.

Press and release the parking brake switch.

Expected Result:

The armrest indicator and the parking brake indicator should be off.

Results:

OK - The armrest indicator and the parking brake indicator are off.

Repair: There is no problem at this time.

Stop.

NOT OK - Both indicators are flashing. Proceed to Test Step 10.

NOT OK - The parking brake indicator is flashing.

Repair: See Troubleshooting, "Parking Brake Indicator Is Flashing".

Stop.

NOT OK - The armrest indicator is flashing.

Repair: See Troubleshooting, "Armrest Indicator Is Flashing".

Stop.

Test Step 10. CHECK THE RETURN SOLENOID WIRE FOR AN OPEN CIRCUIT

Turn the key start switch to the OFF position.

Raise the cab. See Operation and Maintenance Manual, "Cab Tilting".

Locate the interlock ECM. The interlock ECM is located on the left side of the machine beneath the access cover on the floor of the machine.

Remove the wire harness from the ECM.

Measure the resistance from contact 29 to contact 68 (wire H416-GN to wire 975-WH) of the wire harness connector.

Expected Result:

The resistance should be approximately 11 Ohms.

Results:

OK - The resistance is approximately 11 Ohms.

Repair: There is more than one problem. Start by troubleshooting one of the fault indicators. See Troubleshooting, "Parking Brake Indicator Is Flashing" or Troubleshooting, "Armrest Indicator Is Flashing".

Stop.

NOT OK - The resistance is considerably greater than 11 Ohms.

Repair: There is an open in the return solenoid wire. Check all connections. Repair the wire harness and/or the connector or replace the wire harness and/or the connector.

Stop.

Customer: replied 4 years ago.
The armrest indicator is flashing, and the parking brake light is steady on and will not go off.
Expert:  catmastertech replied 4 years ago.

I am surprised the machine will start with a flashing arm rest indicator. I think the problem is more to do with the arm rest indicator that the park brake. Here is the guide for the arm rest. Try these test and see if it will get you to the problem.

 

Did the other test help? Do you have the serial number? What other attachments does this machine have?

 

Armrest Indicator Is Flashing

Test Step 1. CHECK FOR A FLASHING ARMREST INDICATOR BEFORE THE SYSTEM IS ENABLED


Occupy the seat.

Place the armrest in the DOWN position.

Turn the key start switch to the ON position.


Expected Result:

The armrest indicator should be off.

Results:


OK - The armrest indicator is off. Proceed to Test Step 11.

NOT OK - The armrest indicator is flashing. Proceed to Test Step 2.

NOT OK - The armrest indicator is on.


Repair: The armrest switch is not being actuated. Adjust the switch or replace the switch.

Stop.

Test Step 2. CHECK THE ARMREST SWITCH FOR PROPER OPERATION WITH THE ARMREST IN THE DOWN POSITION


Turn the key start switch to the OFF position.

Locate the connector for the armrest switch.

Disconnect the connector for the armrest switch.

Place the armrest in the DOWN position.

Measure the resistance of the armrest switch from contact 1 to contact 2.

Measure the resistance of the armrest switch from contact 1 to contact 3.

Expected Result:

The resistance should be greater than 5000 Ohms from contacts 1 to 2. The resistance should be less than 5 Ohms from contacts 1 to 3.

Results:


OK - The resistance is greater than 5000 Ohms from contacts 1 to 2 and the resistance is less than 5 Ohms from contacts 1 to 3. Proceed to Test Step 3.

NOT OK - The resistance is less than 5000 Ohms from contacts 1 to 2 or the resistance is not less than 5 Ohms from contacts 1 to 3.

Repair: The armrest switch has failed. Replace the armrest switch.

Stop.

Test Step 3. CHECK THE ARMREST SWITCH FOR PROPER OPERATION WITH THE ARMREST IN THE UP POSITION


Place the armrest in the UP position.

Measure the resistance of the armrest switch from contact 1 to contacts 2.

Measure the resistance of the armrest switch from contact 1 to contacts 3.

Expected Result:

The resistance should be greater than 5000 Ohms from contacts 1 to 3. The resistance should be less than 5 Ohms from contacts 1 to 2.

Results:


OK - The resistance is greater than 5000 Ohms from contacts 1 to 3 and the resistance is less than 5 Ohms from contacts 1 to 2. Proceed to Test Step 4.

NOT OK - The resistance is less than 5000 Ohms from contacts 1 to 3 or the resistance is not less than 5 Ohms from contacts 1 to 2.

Repair: The armrest switch has failed. Replace the armrest switch.

Stop.

Test Step 4. CHECK WIRE 201 AT THE CONNECTOR FOR THE ARMREST FOR AN OPEN


Use the connector that had been connected to the armrest switch. Measure the resistance from contact 1 (wire 201-BK) to the machine frame.

Expected Result:

The resistance should be less than 5 Ohms.

Results:


OK - The resistance is less than 5 Ohms. Proceed to Test Step 5.

NOT OK - The resistance is not less than 5 Ohms.

Repair: The wire harness has failed. Repair the wire harness and/or the connector or replace the wire harness and/or the connector.

Stop.

Test Step 5. CHECK WIRE 984 AT THE CONNECTOR FOR THE ARMREST FOR A SHORT TO GROUND


Use the connector that had been connected to the armrest switch. Measure the resistance from contact 2 (wire 984-PK) to the machine frame or to contact 1.

Expected Result:

The resistance should be greater than 3000 Ohms.

Results:


OK - The resistance is greater than 3000 Ohms. Proceed to Test Step 6.

NOT OK - The resistance is not greater than 3000 Ohms.

Repair: The wire harness has failed. Repair the wire harness and/or the connector or replace the wire harness and/or the connector.

Stop.

Test Step 6. CHECK WIRE 983 AT THE CONNECTOR FOR THE ARMREST FOR A SHORT TO GROUND


Use the connector that had been connected to the armrest switch. Measure the resistance from contact 3 (wire 983-GN) to the machine frame or to contact 1.

Expected Result:

The resistance should be greater than 5000 Ohms.

Results:


OK - The resistance is greater than 5000 Ohms. Proceed to Test Step 7.

NOT OK - The resistance is not greater than 5000 Ohms.

Repair: The wire harness has failed. Repair the wire harness and/or the connector or replace the wire harness and/or the connector.

Stop.

Test Step 7. CHECK THE SEAT SWITCH.


Reconnect the armrest switch.

Raise the cab. See Operation and Maintenance Manual, "Cab Tilting".

Locate the connector for the seat switch.

Disconnect the connector for the seat switch.

Jumper contact 1 to contact 2 (wire G983-GN to wire G985-PU) together.

Lower the cab.

Place the armrest in the DOWN position.

Turn the key start switch to the ON position.

Expected Result:

The armrest indicator should be off.

Results:


OK - The armrest indicator is off.


Repair: The seat switch has failed. Replace the switch. DO NOT OPERATE THE MACHINE WITH THE JUMPER IN PLACE.

Stop.


NOT OK - The armrest indicator is flashing. Proceed to Test Step 8.


Test Step 8. CHECK WIRE 983 FOR AN OPEN


Raise the cab.

Remove the jumper.

Disconnect the armrest switch.

Measure the resistance from contact 3 of the connector for the armrest switch to contact 1 of the connector for the seat switch. The wire number that is being checked is 983-GN.


Expected Result:

The resistance should be less than 5 Ohms.

Results:


OK - The resistance is less than 5 Ohms. Proceed to Test Step 9.

NOT OK - The resistance is not less than 5 Ohms.


Repair: The wire harness has failed. Repair the wire harness and/or the connector or replace the wire harness and/or the connector.

Stop.

Test Step 9. CHECK WIRE 985 FOR A SHORT TO GROUND


Locate the interlock ECM. The interlock ECM is located on the left side of the machine beneath the access cover on the floor of the machine.

Disconnect the wire harness from the interlock ECM.

Measure the resistance from contact 3 to contact 58 (wire 201-BK to wire G985-PU) of the wire harness connector.


Expected Result:

The resistance should be greater than 3000 Ohms.

Results:


OK - The resistance is greater than 3000 Ohms. Proceed to Test Step 10.

NOT OK - The resistance is not greater than 3000 Ohms.


Repair: The wire harness has failed. Repair the wire harness and/or the connector or replace the wire harness and/or the connector.

Stop.

Test Step 10. CHECK WIRE 985 FOR AN OPEN


Measure the resistance from contact 58 of the connector for the ECM to contact 2 of the connector for the seat switch. The wire number that is being checked is 985-PU.


Expected Result:

The resistance should be less than 5 Ohms.

Results:


OK - The resistance is less than 5 Ohms.


Repair: The ECM is very unlikely to have failed. Reconnect all connections and visually inspect the wire harness. Verify that the diagnostic code still exists. If the diagnostic code still exists perform the Test Steps again.Replace the ECM, if the cause of the diagnostic code was not found after the second attempt. See Testing and Adjusting, "Electronic Control Module (ECM) - Replace".

Stop.


NOT OK - The resistance is not less than 5 Ohms.


Repair: The wire harness has failed. Repair the wire harness and/or the connector or replace the wire harness and/or the connector.

Stop.

Test Step 11. CHECK FOR A FLASHING ARMREST INDICATOR AFTER THE SYSTEM IS ENABLED.

Note: The seat will still need to be occupied and the armrest will need to be down. The key start switch will also need to be in the ON position.


Press and release the parking brake switch.


Expected Result:

The armrest indicator should be off.

Results:


OK - The armrest indicator is off.


Repair: There is no problem at this time.

Stop.


NOT OK - The armrest indicator is flashing. Proceed to Test Step12.


Test Step 12. CHECK THE CIRCUIT OF THE WORK TOOL PILOT SOLENOID FOR A SHORT TO GROUND


Turn the key start switch to the OFF position.

Raise the cab. See Operation and Maintenance Manual, "Cab Tilting".

Locate the interlock ECM. The interlock ECM is located on the left side of the machine beneath the access cover on the floor of the machine.

Remove the wire harness from the ECM.

Measure the resistance from contact 3 to contact 24 (wire 201-BK to wire G988-OR) of the wire harness connector.


Expected Result:

The resistance should be greater than 5000 Ohms.

Results:


OK - The resistance is greater than 5000 Ohms. Proceed to Test Step 15.

NOT OK - The resistance is not greater than 5000 Ohms. Proceed to Test Step 13.


Test Step 13. CHECK THE WORK TOOL PILOT SOLENOID FOR A SHORT TO GROUND


Locate the work tool pilot solenoid.

Disconnect the wire harness from the work tool pilot solenoid.

Measure the resistance between both of the solenoid wires to the machine frame.


Expected Result:

The resistance should be greater than 5000 Ohms.

Results:


OK - The resistance is greater than 5000 Ohms. Proceed to Test Step 14.

NOT OK - The resistance is not greater than 5000 Ohms.


Repair: The work tool pilot solenoid has failed. Replace the coil of the work tool pilot solenoid.

Stop.

Test Step 14. CHECK THE WORK TOOL DETENT COIL FOR A SHORT TO GROUND


Locate the work tool detent coil.

Disconnect the work tool detent coil from the wire harness.

Measure the resistance between both of the coil wires to the machine frame.


Expected Result:

The resistance should be greater than 5000 Ohms.

Results:


OK - The resistance is greater than 5000 Ohms.


Repair: The wire harness has shorted to ground. Repair the wire harness or replace the wire harness.

Stop.


NOT OK - The resistance is not greater than 5000 Ohms.


Repair: The work tool detent coil has failed. Replace the work tool detent coil.

Stop.

Test Step 15. CHECK THE CIRCUIT OF THE WORK TOOL PILOT SOLENOID FOR AN OPEN CIRCUIT


Measure the resistance from contact 24 to contact 68 (wire G988-OR to wire 975-WH) of the wire harness connector.


Expected Result:

The resistance should be approximately 6 Ohms.

Results:


OK - The resistance is approximately 6 Ohms.


Repair: The ECM is very unlikely to have failed. Reconnect all connections and visually inspect the wire harness. Verify that the diagnostic code still exists. If the diagnostic code still exists perform the Test Steps again.Replace the ECM, if the cause of the diagnostic code was not found after the second attempt. See Testing and Adjusting, "Electronic Control Module (ECM) - Replace".

Stop.


NOT OK - The resistance is considerably greater than 6 Ohms.


Repair: Wire 975-WH of the wire harness has an open. Repair the wire harness and/or the connector or replace the wire harness and/or the connector.

Stop.


NOT OK - The resistance is less than 3 Ohms. Proceed to Test Step 16.


Test Step 16. CHECK THE WORK TOOL PILOT SOLENOID FOR A SHORTED WINDING


Locate the work tool pilot solenoid.

Disconnect the work tool pilot solenoid from the wire harness.

Measure the resistance between the two solenoid wires.


Expected Result:

The resistance should be approximately 10.5 Ohms.

Results:


OK - The resistance is approximately 10.5 Ohms. Proceed to Test Step 17.

NOT OK - The resistance is not approximately 10.5 Ohms.


Repair: The work tool pilot solenoid has failed. Replace the coil of the work tool pilot solenoid.

Stop.

Test Step 17. CHECK THE WORK TOOL DETENT COIL FOR A SHORTED WINDING


Locate the work tool detent coil. The detent coil is located beneath the right hand joystick. Remove the access panel in order to get to the connector.

Disconnect the work tool detent coil from the wire harness.

Measure the resistance between the two wires of the coil.


Expected Result:

The resistance should be approximately 12 Ohms.

Results:


OK - The resistance is approximately 12 Ohms.


Repair: The wire harness is shorted. Repair the wire harness or replace the wire harness.

Stop.


NOT OK - The resistance is not approximately 12 Ohms.


Repair: The work tool detent coil has failed. Replace the work tool detent coil.

Stop.

Customer: replied 4 years ago.
Just the armrest indacator is flashing, I need:NOT OK - The armrest indicator is flashing.

Repair: See Troubleshooting, "Armrest Indicator Is Flashing".
Expert:  catmastertech replied 4 years ago.
That is the one I just sent, did it not go through?

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