R1600H Load Haul Dump Power Train Caterpillar

Illustration 1	g02832076
Schematic of the STIC lockout control limit switch

This diagnostic code is associated with the STIC lockout control limit switch. The switch is connected to two inputs of the Power Train Electronic Control Module (ECM). One contact is open and the other contact is grounded during proper operation. Refer to Table 1.

FMI 03 means that the ECM has determined that the normally open contact and the normally closed contact are both open.

The possible causes of this diagnostic code are:

• The switch has failed

• There is an open circuit

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 0626 FMI 03 is active before performing this procedure.

System Response:

When this diagnostic code occurs, there is no change in the system operation.

Test Step 1. CHECK THE OPERATION OF THE SWITCH

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

2. Disconnect the machine harness from the switch.

3. At the connector contact for the switch, measure the resistance between contact 1 (wire G748-PU) and contact 2 (wire 202-BK).

4. At the connector contact for the switch, measure the resistance between contact 3 (wire 202-BK) and contact 4 (wire G749-YL).

Expected Result:

The resistance between contact 1 (wire G748-PU) and contact 2 (wire 202-BK) is greater than 5 ohms, and the resistance between contact 3 (wire 202-BK) and contact 4 (wire G749-YL) is less than 5 ohms.

Results:

• YES - The resistance between contact 1 (wire G748-PU) and contact 2 (wire 202-BK) is greater than 5 ohms, and the resistance between contact 3 (wire 202-BK) and contact 4 (wire G749-YL) is less than 5 ohms. Proceed to Test Step 2.

• NO - The resistance measurements do not differ. The switch has failed.

  Repair: Replace the switch.

  STOP

Test Step 2. CHECK THE OPERATION OF THE SWITCH

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

2. The machine harness remains disconnected from the switch.

3. Activate the switch.

4. At the connector contact for the switch, measure the resistance between contact 1 (wire G748-PU) and contact 2 (wire 202-BK).

5. At the connector contact for the switch, measure the resistance between contact 3 (wire 202-BK) and contact 4 (wire G749-YL).

Expected Result:

The resistance between contact 1 (wire G748-PU) and contact 2 (wire 202-BK) is less than 5 ohms, and the resistance between contact 3 (wire 202-BK) and contact 4 (wire G749-YL) is greater than 5 ohms.

Results:

• YES - The resistance between contact 1 (wire G748-PU) and contact 2 (wire 202-BK) is less than 5 ohms, and the resistance between contact 3 (wire 202-BK) and contact 4 (wire G749-YL) is greater than 5 ohms. These measurements are opposite to the measurements from the previous Test Step. The switch is operating correctly. Proceed to Test Step 3.

• NO - The resistance measurements do not differ or the measurements have not changed from the previous Test Step. The switch has failed.

  Repair: Replace the switch.

  STOP

Test Step 3. CHECK THE SWITCH CIRCUIT FOR AN OPEN CIRCUIT

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

2. The machine harness remains disconnected from the switch.

3. Disconnect the machine harness from the ECM.

4. At the machine harness connector for the switch, connect a jumper wire between contact 1 (wire G748-PU) and contact 4 (wire G749-YL).

5. At the machine harness connector for the ECM, measure the resistance from contact J1-33 (wire G749-YL) to contact J1-34 (wire G748-PU).

Expected Result:

The resistance is less than 5 ohms.

Results:

• YES - The resistance is less than 5 ohms. The circuit is correct. Proceed to Test Step 4.

• NO - 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 GROUND CIRCUIT FOR AN OPEN CIRCUIT

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

2. The ECM and the switch remain disconnected from the machine harness.

3. At the machine harness for the switch, measure the resistance between contact 2 (wire 202-BK) and frame ground.

4. At the machine harness for the switch, measure the resistance between contact 3 (wire 202-BK) and frame ground.

Expected Result:

Both resistance measurements are less than 5 ohms.

Results:

• YES - Both resistance measurements are less than 5 ohms. The circuit is correct. Proceed to Test Step 5.

• NO - One or both resistance measurements are greater than 5 ohms. The machine harness has failed.

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

  STOP

Test Step 5. 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. Move the disconnect switch and key start switch to the ON position.

4. Operate the machine.

5. Check the status of CID 0626 FMI 03.

Expected Result:

CID 0626 FMI 03 is active.

Results:

• YES - The CID 0626 FMI 03 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 0626 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

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

  Resume normal machine operation.

  STOP