D6N hydraulic cylinder rebuild question

[DmanD6N]

So the buzzer and exclamation are still coming on now and again. I'm not sure but it seems that they come on when I'm turning. No service code. Once when I parked the service code came on and the following numbers 623.07, 113, and 70.02. When I started working again the service code disappeared and didn't come on again.
The machine works very good. The only thing I notice is when in auto kick down it is a bit hard downshift but maybe my deceleration needs some work but I doubt it. Thanks

 

[DmanD6N]

Parking brake and direction switch are results of internet search. Am I on the right track?

 

[Nige]

623.07 relates to the direction switch.
70.02 relates to the parking brake switch.
Troubleshooting procedures attached.

Thinking back to your question about the steering filter I suggest that you get hold of an Operation & Maintenance Manual if you haven't already got one yet. Look on eBay for SEBU8124 or you can download one from Cat for around $50.

 

[DmanD6N]

I bought the maintenance and operations manual. I'll look into the trouble shooting. Thanks

 

[DmanD6N]

Is there any plastic tab or release to disconnect the harness from the ecm? Both connectors are solid and I'm scared to break something.

 

[Nige]

Do you mean disconnect the harness from the ECM.? Each connector has an Allen screw through the centre (arrowed), 4mm if my memory serves me right. You'll have to go digging in between the wires to find it.

 

[DmanD6N]

I replaced the park rocker switch inside the tiller. Cat said I could clean up the direction switch and that there are 2 microswitches there. I'm still inspecting it to understand what to clean. Sure hope that it cleans up nicely and will center properly. A new switch is only sold as a whole unit for $4600.

 

[DmanD6N]

 

[DmanD6N]

Sure would be nice to replace this switch. Tiny thing with 3 wires. It seems a bit loose.

 

[James Sorochan]

DmanD6N. For $4600 I would spend some time trying to fix it. If you can take it apart to check the micro switches you might be able to check them to see if they are faulty. They should have some sort of part numbers on them. I replaced the two micro switches on my Volvo L90 loader shifter. Cost me about $20 for the switches and a little soldering.

 

[DmanD6N]

I'm hoping to fix something for sure. There are 3 wire harnesses. One should be for gear selection. Thanks James

 

[Nige]

Did the result of diagnosing the Diagnostic Codes that I posted earlier indicate a problem with the switch in the directional control.?

 

[Nige]

Sure hope that it cleans up nicely and will center properly. A new switch is only sold as a whole unit for $4600.

If the switch responsible for the 623.07 Code is proved to be defective then it is available separately to the steering/direction control lever - Part Number 110-7882. Item #6 in the illustration below. I would think at a lot cheaper than $4600...........

 

[Nige]

I'm hoping to fix something for sure. There are 3 wire harnesses. One should be for gear selection. Thanks James

Your Diagnostic Code is nothing to do with gear selection. It is related to a limit switch that tells the ECM whether the position of the direction control lever is in forward, neutral, or reverse.

Did the result of diagnosing the Diagnostic Codes that I posted earlier indicate a problem with the switch in the directional control.?

But BEFORE going buying a new switch - and regarding 623.07 - did you do the test procedure below..?

Conditions Which Generate This Code:
This diagnostic code is recorded when status of the direction switch is wrong. When the control lever is in REVERSE, the Normally Open circuit is grounded and the Normally Closed circuit is open. When the contro lever is in FORWARD or NEUTRAL, the Normally Open circuit is open and the Normally Closed circuit is grounded. A diagnostic code is recorded when the status of the direction switch does not match the signal from the position sensor (direction selector). In these circumstances there will be no backup system for the position sensor (direction selector) if the sensor fails.

Note: Ensure that the CID 0623 FMI 07 is on hold and that the diagnostic code indicator shows "SERV CODE".

Test Step 1. CHECK THE DIRECTION SWITCH.

1. Check the screws that hold the direction switch to the console for the FTC. Tighten any loose screws.
2. If the problem persists, loosen the screws on the direction switch and rotate the switch slightly.
3. Tighten the screws. Change the direction of the machine and then determine if the diagnostic code is still present.
4. If the problem still exists, loosen the screws on the direction switch. Rotate the switch in the opposite direction slightly.
5. Tighten the screws. Change the direction of the machine and then determine if the diagnostic code is still present.

ONLY if after Steps 1 thru 5 the Code has not been eliminated would I replace the switch.
In fact if you read the Steps closely the most likely culprit is - loose screws........
The 2nd most likely is the switch slightly out of adjustment.

$4600 for a fix - my ***.....!!!

 

[Nige]

This is the location of the switch in question indicated by the red arrow as seen on your handle.
The black box to the left of it in the photo (blue arrow) is the position sensor for the direction control.

The switch functions as a backup for the sensor if the sensor was to fail. So if the switch is not working correctly there is no backup and the ECM cries wolf.

 

[DmanD6N]

Looks like that switch has been looked at before. Some scars on the screws. Even though the screws are tight there is still movement with screw and wire. The flat metal that activates the switch is sloppy. The 3 screws mentioned in troubleshooting were tight. I loosened them and tried to rotate the direction control but there is next to no movement. If the screw holes were slotted then one could expect to make adjustments.

 

[Nige]

1. With the switch installed and with the direction control lever in the NEUTRAL position measure the resistance between Pins B & C (Grey & Pink) and Pins A & C (Orange & Pink). Confirm that B to C has continuity and A to C is open circuit.
2. Move the switch to the REVERSE position. The readings should change, B to C should be O/C and A to C should have continuity.
3. Move the direction control back to NEUTRAL and check that the continuity measurements are still the same as you measured in Step 1.
4. Move the direction control to the FORWARD position. The continuity should remain the same as Step 1.

The flat metal that activates the switch is sloppy.

Do you mean the blade indicated by the arrow.?
Define sloppy. Is the blade moving/rotating on the rivets at each end.? One rivet is visible in the photo right next to the arrow.
By chance did you remove the switch and check how much force needs to be applied to the button on the end to operate it.? Should be next to nothing unless possibly it is partially seized up inside.

 

[DmanD6N]

I'll get on the testing you suggested. The blade has some side to side movement. It's not necessary to remove the switch to see if the blade engages the green button as there is enough play in the position shown in this picture.

 

[DmanD6N]

The green button gives a click when engaged. I'm kind of rooting for the switch to be faulty because if it's good then what.

 

[Nige]

It's not necessary to remove the switch to see if the blade engages the green button as there is enough play in the position shown in this picture

Right. Gotcha. I've seen those switches before in wheel loaders, they are known for being a bit flimsy to say the least.
The small difference in diameter between the screws and the holes in the switch generally provides enough wiggle room to adjust it, it only needs a hair if it needs anything.
That little roller should only need the slightest of finger pressure to operate it, and I mean really small.

The green button gives a click when engaged. I'm kind of rooting for the switch to be faulty because if it's good then what.?

The fact it's clicking means the guts inside are moving but that does not mean that they are doing what they are supposed to be doing. Do the continuity tests first and then lets go from there when you have more information.