R2900G Load Haul Dump Power Train Electronic Control System Caterpillar

Illustration 1	g01003600
Schematic of the transmission control

This diagnostic code is associated with the transmission upshift switch. The transmission upshift switch is connected to two inputs of the ECM. One contact is open and the other contact is grounded during proper operation.

This FMI 03 means that the ECM has determined that both contacts are open.

Note: The following test procedure may create other diagnostic codes. Ignore these diagnostic codes and clear the diagnostic codes when the original diagnostic code has been corrected. Ensure that the diagnostic code of CID 0622 FMI 03 is active before performing this procedure.

Test Step 1. CHECK THE GROUND CIRCUIT OF THE SWITCH IN THE HARNESS

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

2. Disconnect the machine harness connector(s) from the ECM.

3. Measure the resistance between frame ground (wire 202-BK) of the machine harness and contact 2 (wire 202-BK).

Expected Result:

The resistance is less than 5 ohms.

Results:

• OK - The resistance is less than 5 ohms. The circuit is correct. Proceed to Test Step 2.

• NOT OK - The resistance is greater than 5 ohms. The circuit is open. The machine harness has failed.

  Repair: Repair the machine harness or replace the machine harness.

  Stop.

Test Step 2. CHECK THE SWITCH CIRCUITS FOR A SHORT TO THE +BATTERY CIRCUIT

1. The machine harness connector(s) remains disconnected from the ECM.

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

3. Disconnect the connector for the switch from the machine harness.

4. At the machine harness connector for the ECM, measure the resistance from contact J1-19 (wire G768-GN) of the machine harness to all the contacts that are used in the machine harness connectors for the ECM.

5. At the machine harness connector for the ECM, measure the resistance from contact J1-23 (wire G760-WH) of the machine harness to all the contacts that are used in the machine harness connectors for the ECM.

Expected Result:

Each resistance measurement is greater than 5 ohms.

Results:

• YES - Each resistance measurement is greater than 5 ohms. The harness is correct. Proceed to Test Step 3.

• NO - One or more of the measurements were less than 5 ohms. There is a short in the machine harness.

  Repair: The short is between wire G768-GN and the circuit with the lowest resistance measurement, or the short is between wire G760-WH and the circuit with the lowest resistance measurement. Repair the machine harness or replace the machine harness.

  Stop.

Test Step 3. CHECK THE SWITCH CIRCUITS IN THE HARNESS

1. The machine harness remains disconnected from the ECM and the switch.

2. At the harness connector for the switch, connect a jumper wire between contact 5 (wire G768-GN) and contact 6 (wire G760-WH).

3. At the harness connector for the ECM, measure the resistance from contact J1-19 (wire G768-GN) to contact J1-23 (wire G760-WH).

Expected Result:

The resistance is less than 5 ohms.

Results:

• OK - The resistance is less than 5 ohms. Proceed to Test Step 4.

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

  Repair: The machine harness has failed. Repair the machine harness or replace the machine harness.

  Stop.

Test Step 4. CHECK THE OPERATION OF THE SWITCH

1. Remove the jumper that was installed in the previous Test Step.

2. The machine harness remains disconnected from the switch.

3. Connect one lead from a multimeter to contact 2 (wire 202-BK) of the harness connector for the switch.

4. Connect the other lead from a multimeter to contact 5 (wire D730-GN) of the harness connector for the switch.

5. Measure the resistance between contact 2 (wire 202-BK) and contact 5 (wire D730-GN). Note the resistance.

6. Disconnect the lead from contact 5 (wire D730-GN) and connect the lead to contact 6 (wire D731-WH).

7. Measure the resistance between contact 2 (wire 202-BK) and contact 6 (wire D731-WH).

Expected Result:

The resistance from contact 2 to contact 5 is less than 5 ohms, and the resistance from contact 2 to contact 6 is greater than 5 ohms.

Results:

• YES - The resistance from contact 2 to contact 5 is less than 5 ohms, and the resistance from contact 2 to contact 6 is greater than 5 ohms. The switch is operating correctly in the released position. Proceed to Test Step 5.

• NO - The resistance from contact 2 to contact 5 is not less than 5 ohms, or the resistance from contact 2 to contact 6 is greater than 5 ohms. The switch has failed.

  Repair: Replace the switch.

  Stop.

Test Step 5. CHECK THE OPERATION OF THE SWITCH

1. Depress the upshift switch. Hold the switch in the depressed position.

2. Connect one lead from a multimeter to contact 2 (wire 202-BK) of the harness connector for the switch.

3. Connect the other lead from a multimeter to contact 5 (wire D730-GN) of the harness connector for the switch.

4. Measure the resistance between contact 2 (wire 202-BK) and contact 5 (wire D730-GN). Note the resistance.

5. Disconnect the lead from contact 5 (wire D730-GN) and connect the lead to contact 6 (wire D731-WH).

6. Measure the resistance between contact 2 (wire 202-BK) and contact 6 (wire D731-WH).

Expected Result:

The resistance from contact 2 to contact 6 is less than 5 ohms, and the resistance from contact 2 to contact 5 is greater than 5 ohms.

Results:

• YES - The resistance from contact 2 to contact 6 is less than 5 ohms, and the resistance from contact 2 to contact 5 is greater than 5 ohms. The switch is operating correctly in the depressed position. Proceed to Test Step 6.

• NO - The resistance from contact 2 to contact 6 is not less than 5 ohms, and the resistance from contact 2 to contact 5 is not greater than 5 ohms. The switch has failed.

  Repair: Replace the switch.

  Stop.

Test Step 6. CHECK IF THE DIAGNOSTIC CODE REMAINS

1. Inspect the contacts of the harness connectors and clean the harness connectors.

2. Reconnect all the harness connectors.

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

4. Operate the machine.

5. Check the status of the CID 0622 FMI 03.

Expected Result:

The CID 0622 FMI 03 is active.

Results:

• YES - The CID 0622 FMI 03 is active. The diagnostic code has not been corrected. The ECM may have failed.

  Repair: It is unlikely that the ECM has failed. Exit this procedure and perform this procedure again. If the cause of the diagnostic code is not found, replace the ECM. Refer to Systems Operation, Troubleshooting, Testing and Adjusting, "Electronic Control Module (Power Train) - Replace" for the machine that is being serviced.

  Stop.

• NO - The CID 0622 FMI 03 is not active. The diagnostic code does not exist at this time.

  Repair: The initial diagnostic code was probably caused by a poor electrical connection or a short at one of the harness connectors that was disconnected and reconnected. Resume normal machine operation.

  Stop.