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I need to operate an electric motor remotely from 3 positions. the trouble is that the motor has an electromagnetic switch that I must not tinker with.I am thinking along the lines of two solenoids mounted over the switch, operated by the three remote switches, possibly though a flip/flop, push on-push off style of thing! Any sugestions ?
Re: I need to operate an electric motor remotely from 3...
Why not just use a cheap wireless remote switch, and a suitable relay to turn it on, wired across the switch, and Electromagnetic switch, Then you could, either have Three "Radio Switches, or one you can carry around. Or a simple latching relay could also be used, with a push on. push off wiring. then all buttons could be wired in parallel as could resets, and have one device again operating via a relay(s) Or gain, simply have One Contactor,operable via three paralleled buttons, any of which, can turn the contactor on & off.
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Shift motor on the transfer case, 4X4 control module, vacuum to vac solenoid. Did you hook up a scan tool an check for codes?
The electronic shift on the fly (ESOF) system is an electronic shift system that allows the operator to choose between 2 different 4-wheel drive modes as well as 2-wheel drive. The operator can switch between 2WD and 4H mode at speeds up to 88 km/h (55 mph). To engage or disengage 4L range, the vehicle speed must be less than 5 km/h (3 mph), the brake pedal pressed and the transmission must be in NEUTRAL (or the clutch pedal pressed in manual transmission vehicles).
When the mode select switch (MSS) on the instrument panel is turned, the 4WD control module (PCM) activates the electromagnetic clutch and powers the transfer case shift motor. When the shift motor reaches the desired position, as determined by the contact plate position inputs to the 4WD control module (PCM), power to the shift motor will be removed. When the transfer case front and rear output shafts are synchronized, the spring loaded lockup collar mechanically engages the mainshaft hub to the drive sprocket. Finally, the front axle integrated wheel ends (IWEs) are engaged and the electromagnetic clutch is deactivated.
Feature Inputs:
Mode select switch (MSS)
Wheel speeds (via CAN communication)
Contact plate position inputs A, B, C, D (grounded when closed, open circuit when open)
Transmission neutral
Brake ON/OFF (BOO)
Feature Outputs:
Transfer case synchronization clutch
Transfer case shift motor relays
Integrated wheel-end (IWE) vacuum solenoid
Instrument cluster indicators (via CAN communication)
Hook up a scan tool an check for DTC'S - diagnostic trouble codes in the 4X4 control module , or any other module . A simple code reader won't work nor will auto zone auto part store or any other parts store etc... The 4X4 switch is an input to the control module .What transfer case does it have , how many buttons on the 4x4 switch ,is it electronic shift on the fly ?
SECTION 308-07A: Transfer Case - General Information
2004 F-150 Workshop Manual
DESCRIPTION AND OPERATION
Procedure revision date: 06/20/2001
Transfer Case - Electronic Shift on the Fly (ESOF) Operation
The electronic shift on the fly (ESOF) system is an electronic shift 4x4 system that allows the operator to choose between two different 4x4 modes as well as 2-wheel drive. The operator can switch between 2WD and 4H mode at speeds up to 88 km/h (55 mph). To engage or disengage 4L range, the vehicle speed must be less than 5 km/h (3 mph), the brake pedal depressed, and the transmission must be in NEUTRAL.
The transfer case is equipped with an electromagnetic clutch which is located inside the case. This clutch is used to spin up the front driveline when shifting from 2WD to 4H mode at speed. When the control switch on the instrument panel is turned, the generic electronic module (GEM) recognizes that a shift has been requested and activates the electromagnetic clutch and the relays which power the transfer case shift motor. When the shift motor reaches the desired position, as determined by the contact plate position inputs to the GEM, power to the shift relays and motors will be removed. When the transfer case front and rear output shafts are synchronized, the spring loaded lockup collar mechanically engages the mainshaft hub to the drive sprocket. Finally, the front axle collar is engaged and the electromagnetic clutch is deactivated.
Shifts between 2WD and 4H can be made at any speed up to 88 km/h (55 mph). Listed below are the inputs and outputs needed by the GEM to execute a change between any of these modes.
Feature Inputs:
4WD mode switch (various resistances; go to Table 1).
Contact plate position inputs A, B, C, D (grounded when closed, open circuit when open; go to Table 4).
Feature Outputs:
4x4 shift motor relay outputs (go to Table 2).
Transfer case clutch relay (grounded when relay is activated, open circuit when relay is deactivated).
4x2/4x4 vacuum solenoid (grounded when activated, open circuit when deactivated).
Cluster indicators (ground when activated, open circuit when deactivated).
When shifting into or out of 4L, the GEM requires that the vehicle speed be less than 5 km/h (3 mph), the brake is applied, and the transmission is in NEUTRAL.
Feature Inputs:
4WD Mode Switch (various resistances; go to Table 1).
Contact Plate Position Inputs A, B, C, D (grounded when closed, open circuit when open; go to Table 4).
You should turn off the remote emergency switch. Then check the reasons, but this is based on that you can not turn off the switch.
Electromagnetic valve for generator set shutdown is out of control.
Speed regulator of diesel engine has fault.
Operational errors may be that the control panel first breaks the key switch and then presses the stop button.
There are many reasons besides above reasons, you should check clearly and remove faults one by one, then will know what is the resaon.
We also supply Cummins diesel generator, if you need to have a new generator, please conatc us: [email protected].
Does yours have
Electronic Shift on the Fly (ESOF) Operation
The electronic shift on the fly (ESOF) system is an electronic shift 4x4 system that allows the operator to choose between two different 4x4 modes as well as 2-wheel drive. The operator can switch between 2WD and 4H mode at speeds up to 88 km/h (55 mph). To engage or disengage 4L range, the vehicle speed must be less than 5 km/h (3 mph), the brake pedal depressed, and the transmission must be in NEUTRAL.
The transfer case is equipped with an electromagnetic clutch which is located inside the case. This clutch is used to spin up the front driveline when shifting from 2WD to 4H mode at speed. When the control switch on the instrument panel is turned, the generic electronic module (GEM) recognizes that a shift has been requested and activates the electromagnetic clutch and the relays which power the transfer case shift motor. When the shift motor reaches the desired position, as determined by the contact plate position inputs to the GEM, power to the shift relays and motors will be removed. When the transfer case front and rear output shafts are synchronized, the spring loaded lockup collar mechanically engages the mainshaft hub to the drive sprocket. Finally, the front axle collar is engaged and the electromagnetic clutch is deactivated.
After reading this material I would not think it was the switch . Maybe an input problem to the GEM module .
Feature Inputs:
4WD Mode Switch (various resistances; go to Table 1).
Contact Plate Position Inputs A, B, C, D (grounded when closed, open circuit when open; go to Table 4).
First you need a wiring diagram, free at http://www.bbbind.com/free_tsb.html Then you need a DVOM - digital volt ohm meter to test the circuit . Then if your not familiar with automotive electrical systems testing ,go on youtube an check out Electric Testing Techniques You Need to Know Also having a factory diagnostic trouble shooting chart would also be usefull . You could just start replacing parts , you mite get lucky . The wiper motor is a high fail part , so is the switch ..You could find the fuse is blown ! But fuse's don't usually blow without a reason . Short to ground , low resistance . ( high current flow) Also knowing how they work and what all is involved in making them work.
The Wiper/Washer System consists of the following components:
• Windshield wiper/washer switch
• Windshield wiper motor module
• Windshield wiper motor
• Windshield washer pump motor
• FRT/WPR/WSHR 25A fuse
Wiper/Washer System Operation
The windshield wiper motor module is part of the windshield wiper motor cover and controls wiper motor operation. The windshield wiper motor is a 2 speed motor and is operated at low speed in all modes except HIGH. The accessory voltage supply circuit to the windshield wiper motor assembly is used to operate the wiper motor in all of the low speed modes. The accessory voltage supply circuit to the windshield wiper/washer switch is used to supply the windshield wiper switch signal circuits and the wiper motor high speed circuit.
When the wiper/washer switch is in the LOW position voltage is supplied through a 24K ohm resistor within the switch to the windshield wiper switch signal 2 circuit, and accessory voltage is supplied to the windshield wiper switch signal 1 circuit. The reduced voltage from the wiper switch signal 2 circuit and accessory voltage from the wiper switch signal 1 circuit causes the wiper motor module to close the wiper motor accessory voltage supply circuit to the wiper motor low speed terminal.
Windshield wiper/washer system MIST operation is identical to LOW operation except that the MIST switch is a press and release type. When the wiper switch is moved to the MIST position and released, low speed wiper motor operation is started and will continue until 1 cycle is complete. If the wiper switch is moved to the MIST position and held, the windshield wiper motor will operate in the LOW mode until the switch is released.
Don't the wipers work in any mode ?
1
Did you review the Wiper/Washer System description and operation and perform the necessary inspections?
YES - Go to Step 2
NO - Go to Symptoms - Wiper/Washer Systems
2
Turn ON the ignition , with the engine OFF.
Operate the windshield wiper/washer switch through all the switch positions.
Does the windshield wiper/washer system operate normally?
YES - Go to Testing for Intermittent Conditions and Poor Connections in Wiring Systems
NO - Go to Step 3
3
Turn OFF the ignition.
Disconnect the harness connector of the windshield wiper motor.
Turn the ignition ON, with the engine OFF.
Connect a test lamp from the accessory voltage circuit of the windshield wiper motor to a good ground.
Does the test lamp illuminate?
YES - Go to Step 4
NO - Go to Step 13
4
Connect a test lamp from the accessory voltage circuit to the ground circuit of the windshield wiper motor.
Does the test lamp illuminate?
YES - Go to Step 5
NO - Go to Step 14
5
Connect a test lamp from the signal 2 circuit of the windshield wiper switch to a good ground.
Press the windshield washer switch.
Does the test lamp illuminate?
YES - Go to Step 11
NO - Go to Step 6
Let me know if you make it this far and i will send rest of diagnostic's
Pulling switch and by process off elimination verifying with meter many switches can be opened and cleaned then jumping connector to test motors may save the time as repair manual electrical diagrams have awful shortconings forgive the pun . That is how I did mine first finding positive pin in driver door switch connector testing each switch finding output etc. Also keep in mind the kid safe window lookout on drivers door if your having trouble operating all but drivers door Year make and model ? If your still need a diagram
You don't need the original switch positions. Make sure the row of switches in the motor unit are set exactly the way the remote is. The switches are normally marked + 0 -. Move all of them to the plus sign and try.
Electronic Shift On the Fly (ESOF) Operation
The ESOF system is an electronic shift 4x4 system that allows the
operator to choose between two different 4x4 modes as well as 2-wheel
drive. The operator can switch between 2WD and 4WD HIGH mode at speed.
To engage or disengage LOW Range, the vehicle speed must be less than 5
kph, the brake depressed, and the transmission must be in NEUTRAL.
The transfer case is equipped with an electromagnetic clutch which is
located inside the case. This clutch is used to spin up the front drive-line when shifting from 2WD to 4x4 High mode at speed. When the
control switch on the instrument panel is turned, the generic
electronic module (GEM) recognizes that a shift has been requested and
activates the electromagnetic clutch and the relays which power the
transfer case shift motor. When the shift motor reaches the desired
position as determined by the contact plate position inputs to the GEM,
power to the shift relays and motors will be removed. When the transfer
case front and rear output shafts are synchronized, the spring loaded
lockup collar mechanically engages the main-shaft hub to the drive
sprocket. Finally, the front axle collar is engaged and the
electromagnetic clutch is deactivated.
Shift Between 2WD and 4x4 HIGH:
Shifts between 2WD and 4x4 HIGH can be made at speed. Listed below are
the inputs and outputs needed by the GEM to execute a change between
any of these modes.
Feature Inputs: *4WD Mode Switch (Various resistances). *Contact Plate Position Inputs A, B, C, D (grounded when closed, open circuit when open).
Feature Outputs: *4x4 Shift Motor Relay Outputs *Transfer Case Clutch Relay (grounded when relay is on, open circuit when relay is off).
*4x2/4x4 Vacuum Solenoid (grounded when activated, open circuit when deactivated).
*Cluster Indicators (ground when activated, open circuit when deactivated).
Shifting Into/Out of 4WD LOW: When shifting into or out of 4WD LOW, the GEM requires that the vehicle
speed be less than 5 kph, the brake is applied, and the transmission is
in NEUTRAL.
Feature Inputs:
*4WD Mode Switch (Various resistances). *Contact Plate Position Inputs A, B, C, D (grounded when closed, open circuit when open). *VSS Sensor (Sinusoid Signal: 0.7V-20V, 2.2 Hz/mph). Brake Input (battery voltage when brake is depress, open circuit when not activated). *Transmission Range Sensor (grounded when transmission is in NEUTRAL, open circuit otherwise).
8Start/Clutch Depressed Input
Feature Outputs: *4x4 Shift Motor Relay Outputs *4x2/4x4 Vacuum Solenoid (grounded when activated, open circuit when deactivated). *Cluster Indicators (grounded when activated, open circuit when deactivated).
4WD Mode Switch
A rotary switch allows the vehicle operator to choose between 2WD, 4WD HIGH, and 4WD LOW modes of 4x4 operation.
GEM Module The Generic Electronic Module (GEM) controls the operation of the 4x4 system
Vehicle Speed Sensor The vehicle speed sensor (VSS), mounted in the rear of the transfer case, informs the GEM of the vehicle speed.
Transfer Case Shift Motor Sense Plates
The shift motor sense plate, an integral part of the electric shift motor, informs the GEM to the positions of the transfer case
Transmission Range Sensor
Located on the left side of the transmission, this sensor informs the GEM when the transmission is in the NEUTRAL position.
Electric Shift Motor
The electric shift motor, mounted externally at the rear of the
transfer case, drives a rotary cam which moves the mode fork and range
fork within the transfer case to select between the 2WD, 4WD HIGH, and
4WD LOW positions.
4x4/4x2 Vacuum Solenoids These two solenoids are attached to the upper RH side of the engine
compartment dash, and alternately route vacuum to the vacuum motor
which engages/disengages the center axle disconnect collar in the front
axle assembly.
4x4 Shift Motor Relay
A module containing two relays which under the control of the GEM,
shift the transfer case shift motor between the 2WD, 4WD HIGH, and 4WD
LOW modes.
Transfer Case Clutch Relay An electromechanical relay is used to activate the transfer case clutch within the transfer case.
Good luck and hope this helps,but start with the simple and check the fuses and wire harness. Both white/light blue stripe wires should have 12V in run. The GEM will
ground the left side (closest to engine) solenoid to disengage the
front axle. It will ground the the right side solenoid (closest to
fender) to engage the front axle. If the GEM doesn't see Neutral it
will not let the truck come out of 4Lo. If the GEM had water leaking on
it it may well be the root of the problem. The shift motor only has
power when the GEM sends it a signal to move the shift lever. Once the
shift is completed the motor shuts off. There are 2 wires that control
the shift motor. A yellow and an orange. The GEM alternates between 12v
and Ground to these wires to control which way the motor turns. The GEM
uses the transfer case shift relay module to control the power to the
motor. There are contact plates inside the shift motor assembly that
indicate the position that the shift lever is in. This is what the GEM
used to know what the T-case is doing. Any one of these components can
fail.
Looks like there's an interchanged wires in your vacuum. Both the motor and the powerhead must go together. Check it up. Leave the motor wiring connection intact. Just tinker and check the powerhead wiring connection .
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