R1600H Load Haul Dump Power Train Caterpillar

Illustration 1	g02831837
Schematic of the transmission control

This diagnostic code is associated with the transmission direction control switch. The transmission direction control switch is connected to three inputs of the Power Train Electronic Control Module (ECM). Two contacts are open and the other contact is grounded during proper operation.

FMI 04 means that the ECM has determined that all three contacts are grounded.

Note: The following test procedure may create other diagnostic codes. Ignore these diagnostic codes and clear these diagnostic codes when the original diagnostic code has been corrected. Ensure that the diagnostic code of CID 0623 FMI 04 is active before performing this procedure.

Test Step 1. CHECK THE SWITCH

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

2. Disconnect the machine harness from the switch.

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

Expected Result:

CID 0623 FMI 04 has been replaced by CID 0623 FMI 03.

Results:

• YES - CID 0623 FMI 04 has been replaced by CID 0623 FMI 03. The machine harness and the ECM are correct. Proceed to Test Step 3.

• NO - CID 0623 FMI 04 is still active. Proceed to Test Step 2.

Test Step 2. CHECK THE HARNESS

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

2. The machine harness remains disconnected from the switch.

3. Disconnect the machine harness connectors from the ECM.

4. At the machine harness connector for the ECM, measure the resistance from contact J2-49 (wire G750-BU), contact J2-23 (wire G763-PU), and contact J2-28 (wire G755-GY) 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. Proceed to Test Step 3.

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

  Repair: The short is between contact J2-49 (wire G750-BU) and the circuit with the lowest resistance measurement, contact J2-23 (wire G763-PU) and the circuit with the lowest resistance measurement, or the short is between contact J2-28 (wire G755-GY) and the circuit with the lowest resistance measurement. Repair the machine harness or replace the machine harness.

  STOP

Test Step 3. CHECK THE OPERATION OF THE SWITCH (NEUTRAL POSITION)

1. The machine harness remains disconnected from the switch.

2. Move the switch to the NEUTRAL position.

3. Measure the resistance between contact 2 (wire 202-BK) and contact 1 (wire D743-PU) of the harness connector for the switch.

4. Measure the resistance between contact 2 (wire 202-BK) and contact 3 (wire D728-BU) of the harness connector for the switch.

5. Measure the resistance between contact 2 (wire 202-BK) and contact 4 (wire D729-GY) of the harness connector for the switch.

Expected Result:

The resistance from contact 1 to contact 2 is less than 5 ohms. The resistance from contact 2 to contacts 3 and 4 is greater than 5 ohms.

Results:

• YES - The resistance from contact 1 to contact 2 is less than 5 ohms. The resistance from contact 2 to contacts 3 and 4 is greater than 5 ohms. The switch is operating correctly in the NEUTRAL position. Proceed to Test Step 4.

• NO - The resistance from contact 1 to contact 2 is not less than 5 ohms. Alternatively, the resistance from contact 2 to contacts 3 and 4 is not greater than 5 ohms. The switch has failed.

  Repair: Replace the switch.

  STOP

Test Step 4. CHECK THE OPERATION OF THE SWITCH (FORWARD POSITION)

1. Move the switch to the FORWARD position.

2. Measure the resistance between contact 2 (wire 202-BK) and contact 1 (wire D734-PU) of the harness connector for the switch.

3. Measure the resistance between contact 2 (wire 202-BK) and contact 3 (wire D728-BU) of the harness connector for the switch.

4. Measure the resistance between contact 2 (wire 202-BK) and contact 4 (wire D729-GY) of the harness connector for the switch.

Expected Result:

The resistance from contact 1 to contact 2 is less than 5 ohms. The resistance from contact 2 to contacts 3 and 4 is greater than 5 ohms.

Results:

• YES - The resistance from contact 1 to contact 2 is less than 5 ohms. The resistance from contact 2 to contacts 3 and 4 is greater than 5 ohms. The switch is operating correctly in the FORWARD position. Proceed to Test Step 5.

• NO - The resistance from contact 2 to contact 3 is not less than 5 ohms. Alternatively, the resistance from contact 2 to contacts 1 and 4 is not greater than 5 ohms. The switch has failed.

  Repair: Replace the switch.

  STOP

Test Step 5. CHECK THE OPERATION OF THE SWITCH (REVERSE POSITION)

1. Move the switch to the REVERSE position.

2. Measure the resistance between contact 2 (wire 202-BK) and contact 1 (wire D734-PU) of the harness connector for the switch.

3. Measure the resistance between contact 2 (wire 202-BK) and contact 3 (wire D728-BU) of the harness connector for the switch.

4. Measure the resistance between contact 2 (wire 202-BK) and contact 4 (wire D729-GY) of the harness connector for the switch.

Expected Result:

The resistance from contact 1 to contact 2 is less than 5 ohms. The resistance from contact 2 to contacts 3 and 4 is greater than 5 ohms.

Results:

• YES - The resistance from contact 1 to contact 2 is less than 5 ohms. The resistance from contact 2 to contacts 3 and 4 is greater than 5 ohms. The switch is operating correctly in the REVERSE position. Proceed to Test Step 6.

• NO - The resistance from contact 2 to contact 4 is not less than 5 ohms. Alternatively, the resistance from contact 2 to contacts 1 and 3 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 connectors.

2. Reconnect all harness connectors.

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

4. Operate the machine.

5. Determine if CID 0623 FMI 04 is active.

Expected Result:

CID 0623 FMI 04 is active.

Results:

• YES - CID 0623 FMI 04 is active. The diagnostic code has not been corrected. The ECM may have failed.

  Repair: The ECM is unlikely to have failed. Exit this procedure and perform this procedure again. If the cause of the diagnostic code is not found, replace the ECM. Refer to Troubleshooting, Testing, and Adjusting, "Electronic Control Module (ECM) - Replace".

  STOP

• NO - CID 0623 FMI 04 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

  • A short at one of the harness connectors that was disconnected and reconnected

  Resume normal machine operation.

  STOP