2022 Cat 289D3 E875-2

[Phishphan1995]

So the machine only has 51hrs on it. Serial #JX911421
Its only used for snow removal and unloading pallets and moving material around at the shop.

So we had a snow event last week machine ran fine for 3 hrs then operator called and said he lost power. So I went over the site he was on. Looked things over no active codes but the E875-2 code was stored as a event. We shut machine down let it sit for a bit and finished the job.

Then today we had another snow event. The machine started and ran fine 4hrs in operator calls me says he is stuck in the middle of the road machine wont start. So he let it sit till I got there. I got in and the volts were at 11.7 I got it to start and let it idle the volts went up to 14.6 and stayed steady I started to move the machine to get it out of the road. And the volts stayed between 14.3 and 14.6 but the machine was basically in turtle alimp mode I got it down to a place where I could park it.**** it off and turned key back on volts were back at 11.7. Not sure what's going on.

There is no active codes once again. But these codes are stored. I'm not sure what to do. We are expecting more snow in 1.5 days need to get this thing running.

I'm furious I have a ma hone with 51hrs on it and having problems. I'm considering calling altorfer and raising hell the machine went out of warranty October 21st 2024. I feel like they should stand behind there product and get there ass out here and fix it. Anyone have any experience with getting them to fix it when it had that low of hrs and just out of warranty?

Any help advice would be greatly appricated

Thanks for your time!

 

[heymccall]

E875-2..low system voltage
41-4......low system voltage derate
167-4....alternator charging system sensor
458-3....tilt cylinder rod pressure sensor
2474-3..left joystick fwd/rev sensor
2475-3..right joystick fwd/rev sensor
2476-3..left joystick left/right sensor
2477-3..right joystick left/right sensor
3700-3..loader bucket inclinometer sensor

167-4 is the only real code to troubleshoot. The rest all go hand in hand with running with low voltage.

 

[Phishphan1995]

E875-2..low system voltage
41-4......low system voltage derate
167-4....alternator charging system sensor
458-3....tilt cylinder rod pressure sensor
2474-3..left joystick fwd/rev sensor
2475-3..right joystick fwd/rev sensor
2476-3..left joystick left/right sensor
2477-3..right joystick left/right sensor
3700-3..loader bucket inclinometer sensor

167-4 is the only real code to troubleshoot. The rest all go hand in hand with running with low volt

Thank you This is what I was gonna start with in the morning. Just felt overwhelmed tonight with all the codes machine stuck in the road with 5 ft piles of snow in the road and it seemed like every person that lives in that HOA was trying to come home at the same time.

Man OEM alt is pricy need to see if there is another option available.

 

[Nige]

One thing you did not mention is how well the battery holds up.

The suggested diagnostic for 167-4 specifically refers to two documents which are attached below.

 

[Phishphan1995]

One thing you did not mention is how well the battery holds up.

The suggested diagnostic for 167-4 specifically refers to two documents which are attached below.

So just had the alt load tested. It was putting out 115 amps and work fine. The battery was new as of 7-2022 so not even 3 years old. The thing to me is it starts the machine even when its at 11.7 volts I guess i would think if it was the battery it wouldnt crank the machine over. Or the machine wouldnt work for 3 to 4 hrs the start having issues. The alt guy told me to check the Relay wire so ran y the shop and figures i cant find my volt meter. Im sure one of my employees used it and didnt pur it back. So need to go get another one. I did call my sales rep and he put me in touch with field service manger. They are trying to find someone clsoe to me to send out. Sounded like they will good will the fix. But ihave to pay for travel time and millage. At this point im so damn irritated i had to come home and just take a break. I was going 18hrs yesterday didnt get to sleep till 1:30am trying to figure out what could be wrong then back out of bed at 3:30 to salt and clear a few properties before they opened up today. Been outside messing with teh machine last 2 hrs and its 12 degrees here today Needed a break.

 

[Vetech63]

Some electrical systems demand a specific voltage range. Therre is a possibility there may be some corrosion, or even a loose connection that isn't showing up until the machine is meeting certain conditions.

 

[Nige]

Loose/corroded ground or grounds somewhere.? There are a bunch of them in all sorts of weird places.
If an electrical schematic would be of help just ask.

 

[Simon C]

You may have something sucking down your battery every night as Post#5 you sais you have 11.7 volts.
That is not a good state of charge or the display is inaccurate. Will need to be proven with a meter.
Just because the battery is less than 3 years old does not mean it is good any more. Battery needs to be load tested after trickle charging or after running with engine revved for couple hours.
I have fixed quite a few of these Cat skid Steer Battery cables that were faulty. They need to be tested 1 at a time. Had 1 John Deere one that was burnt off inside with 50 hours on it.
Need to also test what kind of condition the ground cables are in as I have changed one on one of these Cats.
Simon C

 

[Simon C]

Would also be very handy to test battery charge rate before shutting it off at end of day, and if charging at 13.8 to 14.4 volts shut it off.
Disconnect negative post for the night, and see what it is in the morning before starting.
Will tell you if something is sucking it down.
Simon C

 

[Phishphan1995]

Some electrical systems demand a specific voltage range. Therre is a possibility there may be some corrosion, or even a loose connection that isn't showing up until the machine is meeting certain conditions.

I have checked most things

Loose/corroded ground or grounds somewhere.? There are a bunch of them in all sorts of weird places.
If an electrical schematic would be of help just ask.

I will take a schematic if you have one thanks.

 

[Nige]

I will take a schematic if you have one thanks.

Check your message inbox.

 

[Simon C]

If it was available, would not mind to see that schematic also. Have been off work for couple months doing physio therapy on a shoulder muscle problem. Should be working again in 2 weeks. Have had lots of time to read in between. Has not felt this good in 5 years.
Simon C

 

[Brianc383]

Loose/corroded ground or grounds somewhere.? There are a bunch of them in all sorts of weird places.
If an electrical schematic would be of help just ask.

This.

My 289D is notorious for the battery ground coming loose. Even after I built custom cables with new terminals and bolted on cables.

I know if my machine starts showing charging loss to check my cables and that normally fixes it.

 

[Phishphan1995]

So I have another issue going on. The first issue cat tech replaced the wiring harness to inclination sensor. Said it was fixed. Went to get the machine moved and when I go to high idle it just Boggs down and wants to die. The alternator is barley spinning at high idle since the engine is running so rough. Turn to low idle and it will idle and charge. Its like there is something in the fuel. But just doesn't make sense. The machine before all this would run fine for 3-4 hrs then start to act up. If it was fuel related I would of thought it would of started right away. So tech told me to change fuel filter and run some hot sauce diesel extreme through it. Then he called me back and said some of the older techs at the shop said it sounds like someone put something in the fuel because at high idle its picking it up from the bottom of the tank. But at low idle its not.

Im really not sure what the heck is going on. Does anyone have any thoughts?

I have no new codes after harness repair.

 

[Nige]

hen he called me back and said some of the older techs at the shop said it sounds like someone put something in the fuel because at high idle its picking it up from the bottom of the tank. But at low idle its not.

IMHO that's BS. The level of the fuel pickup tube in the tank is fixed therefore whatever the engine RPM the fuel is always being lifted from the same point in the tank.

When was the last time you drained the cr@p out of the tank.? There is a plug underneath for that purpose in case you were not aware.

The alternator is barley spinning at high idle since the engine is running so rough.

Do you mean the belt is slipping.? If the engine is running at High Idle RPM the alternator should be spinning at max speed. Or did you mean something else when you used the term "High Idle".?

 

[Phishphan1995]

I was not aware of a drain plug on the bottom. I have only drained the separator on the filter itself. The tech didn't even mention this to me either.


I'm assuming the tech meant high idle as engine speed turned all the way up.

Sorry this all happened Tuesday and I have not been able to make it back to the machine. I had to leave town I will be home Sunday my plan is to go to the machine on Monday. But wanted to give some time for people in hear to chime in. Before I get there.

The tech did pull a oil sample he said it looked thin and could have diesel in it. I apologize when it comes to the skid I just am not versed well on diagnosing or working on them.

He sent me this video of the machine idled up and it definitely doesn't sound right. And if you try and move it loses all power and spits and sputters and wants to die till you turn the speed down. Then it stops

 

[Nige]

I'm assuming the tech meant high idle as engine speed turned all the way up.

High Idle is the term used when the engine is turning at max RPM without load.

I was not aware of a drain plug on the bottom.

So you don't have even a basic Operation & Maintenance Manual.?
Is there not one in the pocket behind the seat.?
Draining of the fuel tank is covered in that manual.

Here are the basics that are always advised to ensure that the fuel system is clear and the fuel supply is not restricted in any way. With so few hours in its life my suspicion is that water resulting from condensation could have accumulated in the bottom of the tank.

1. Drain water/sediment from the tank. Better done when the machine has sat overnight to let everything settle. Note the position of the drain plug on your machine (there are a couple of options) and park the machine in such a way that it is at the lowest point.

2. See the attachment. While you have the tank drained remove the fuel suction line (arrowed blue) where it enters the fuel filter head and blow back into the tank with compressed air to ensure the suction line is clear.

3. Remove the entire fuel filter assembly from the machine and disassemble. Remove all the elbows, fittings, etc from the head and make sure they are not restricted. Then make sure all the fuel passages in the head are clear. Compressed air works well here also. Reassemble with a new filter element and reinstall.

4. Disconnect the fuel line from the filter to the engine after the relief valve#6 (1.5psi IIRC) and ensure that the valve opens and is passing fuel when the electric priming pump is running.

 

[Phishphan1995]

High Idle is the term used when the engine is turning at max RPM without load.


So you don't have even a basic Operation & Maintenance Manual.?
Is there not one in the pocket behind the seat.?
Draining of the fuel tank is covered in that manual.

Here are the basics that are always advised to ensure that the fuel system is clear and the fuel supply is not restricted in any way. With so few hours in its life my suspicion is that water resulting from condensation could have accumulated in the bottom of the tank.

1. Drain water/sediment from the tank. Better done when the machine has sat overnight to let everything settle. Note the position of the drain plug on your machine (there are a couple of options) and park the machine in such a way that it is at the lowest point.

2. See the attachment. While you have the tank drained remove the fuel suction line (arrowed blue) where it enters the fuel filter head and blow back into the tank with compressed air to ensure the suction line is clear.

3. Remove the entire fuel filter assembly from the machine and disassemble. Remove all the elbows, fittings, etc from the head and make sure they are not restricted. Then make sure all the fuel passages in the head are clear. Compressed air works well here also. Reassemble with a new filter element and reinstall.

4. Disconnect the fuel line from the filter to the engine after the relief valve#6 (1.5psi IIRC) and ensure that the valve opens and is passing fuel when the electric priming pump is running.

I just got home. Im going to be goingthe machine in the morning. I will look behind the seat and see if there is a manual there. When i purchased the machine we went over a lot of things that day. But unfortunatly if they did show or tell me about the manual. I did not remember it. So my plan is to drain sediment from the tank. And do teh other procedures. Im curious as to why the altorfer tech would not of mentioned this to me. Hoping this will fix my problems. I will update tomorrow Thank you for your time

 

[Nige]

I will look behind the seat and see if there is a manual there. When i purchased the machine we went over a lot of things that day. But unfortunatly if they did show or tell me about the manual. I did not remember it.

If you bought it from a dealer, even second hand, there really should have been an O&M Manual in the pocket behind the seat.
If it is not there I suggest you go back to them and ask why it's missing. FYI they can download an Adobe pdf copy of the manual from Cat in 5 minutes or less, and then email it to you. It doesn't have to be a paper one unless you insist.

 

[Phishphan1995]

If you bought it from a dealer, even second hand, there really should have been an O&M Manual in the pocket behind the seat.
If it is not there I suggest you go back to them and ask why it's missing. FYI they can download an Adobe pdf copy of the manual from Cat in 5 minutes or less, and then email it to you. It doesn't have to be a paper one unless you insist.

Ok yes I have the manuals. So it says make sure the tank is close to empty before draining. The tank is 3/4 full. And sitting on a BN new concrete road. Trying to understand is it like a fuel filter and only catches the water and sediment or will all the fuel want to come out once I take bolt out.