R3000H Load Haul Dump Power Train Caterpillar

Illustration 1	g01144458
Schematic of the remote control service brake circuit

This diagnostic code is associated with the remote control service brake relays. The relays are 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 the normally open contact and the normally closed contact are open.

This diagnostic code is active when the remote control switch on the machine is in the ON position.

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 1928 FMI 03 is active before performing this procedure.

Note: Use the 146-4080 Digital Multimeter for the measurements in this procedure.

Note: The remote control switch on the machine must be in the ON position while troubleshooting the diagnostic code.

System Response:

When this diagnostic code is active, the ECM will not disengage the parking brake.

Test Step 1. CHECK THE GROUND CIRCUIT OF RELAY 5

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

2. Remove relay 5 from the interface control module.

3. Measure the resistance between frame ground of the machine and contact 30 of relay 5 base.

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 5.

• NO - The resistance is greater than 5 ohms. The circuit is open. The machine harness has failed.

  Repair: Repair the interface control module harness or replace the interface control module.

  STOP

Test Step 2. CHECK THE GROUND CIRCUIT OF RELAY 4

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

2. Remove relay 4 from the interface control module.

3. Measure the resistance between frame ground of the machine and contact 30 of relay 4 base.

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 5.

• NO - The resistance is greater than 5 ohms. The circuit is open. The interface control module harness has failed.

  Repair: Repair the interface control module harness or replace the interface control module.

  STOP

Test Step 3. CHECK THE GROUND CIRCUIT OF RELAY 6

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

2. Remove relay 6 from the interface control module.

3. Measure the resistance between frame ground of the machine and contact 30 of relay 6 base.

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. The interface control module harness has failed.

  Repair: Repair the interface control module harness or replace the interface control module.

  STOP

Test Step 4. CHECK THE GROUND CIRCUIT BETWEEN RELAYS 4 AND 6

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

2. Measure the resistance between contact 87a of relay 6 base and contact 30 of relay 4 base.

Expected Result:

The resistance is less than 5 ohms.

Results:

• YES - The resistance is less than 5 ohms. The circuit is correct. Relay 6 has failed.

  Repair: Replace relay 6.

  STOP

• NO - The resistance is greater than 5 ohms. The circuit is open. The interface control module harness has failed.

  Repair: Repair the interface control module harness or replace the interface control module.

  STOP

Test Step 5. CHECK THE RELAY CIRCUITS FOR A SHORT TO THE +BATTERY CIRCUIT

1. Disconnect the machine harness connectors from the ECM.

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

3. At the machine harness connector for the ECM, measure the resistance from contact J2-29 (wire EL398-BR(Brown)) and contact J2-30 (wire EL300-YL(Yellow)) 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 6.

• 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 EL300-YL(Yellow) and the circuit with the lowest resistance measurement and the short is between wire EL398-BR(Brown) and the circuit with the lowest resistance measurement. Repair the machine harness or replace the machine harness. Repair the interface control module harness or replace the interface control module.

  STOP

Test Step 6. CHECK THE RELAY CIRCUITS IN THE HARNESS

1. Install relay 6.

2. The machine harness remains disconnected from the ECM and the relays 4 and 5 remain removed.

3. Connect a jumper wire between contact 87 of the base for relay 4 and contact 87a of the base for relay 5.

4. At the harness connector for the ECM, measure the resistance from contact J2-29 (wire EL398-BR(Brown)) to contact J2-30 (wire EL300-YL(Yellow)).

Expected Result:

The resistance is less than 5 ohms.

Results:

• YES - The resistance is less than 5 ohms. Proceed to Test Step 7.

• NO - The resistance is greater than 5 ohms. The circuit is open.

  Repair: The machine harness or the interface control module harness has failed. Repair the machine harness or replace the machine harness. Repair the interface control module harness or replace the interface control module.

  STOP

Test Step 7. CHECK THE OPERATION OF RELAYS 4 AND 5

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

2. Install relays 4 and 5.

3. The machine harness remains disconnected from the ECM.

4. Connect one lead from a multimeter to contact J2-30 (wire EL300-YL(Yellow)) of the harness connector for the ECM.

5. Connect the other lead from a multimeter to frame ground.

6. Measure the resistance between contact J2-30 (wire EL300-YL(Yellow)) and frame ground. Note the resistance.

7. Disconnect the lead from contact J2-30 (wire EL300-YL(Yellow)) and connect the lead to contact J2-29 (wire EL398-BR(Brown)).

8. Measure the resistance between contact J2-29 (wire EL398-BR(Brown)) and frame ground. Note the resistance.

Expected Result:

The resistance from contact J2-30 to frame ground is less than 5 ohms. The resistance from contact J2-29 to frame ground is greater than 5 ohms.

Results:

• YES - The resistance from contact J2-30 to frame ground is less than 5 ohms. The resistance from contact J2-29 to frame ground is greater than 5 ohms. The switch is operating correctly. Proceed to Test Step 8.

• NO - The resistance from contact J2-30 to frame ground is greater than 5 ohms. Relay 5 has failed. The resistance from contact J2-29 to frame ground is less than 5 ohms. Relay 4 has failed.

  Repair: Replace the failed relay.

  STOP

Test Step 8. CHECK THE OPERATION OF THE RELAY

1. The machine harness remains disconnected from the ECM.

2. Turn the disconnect switch and the key start switch to the ON position. Do not start the engine.

3. Switch the remote control transmitter on.

4. Move the parking brake switch on the remote control transmitter to the OFF position.

5. Connect one lead from a multimeter to contact J2-30 (wire EL300-YL(Yellow)) of the harness connector for the ECM.

6. Connect the other lead from a multimeter to frame ground.

7. Release the service brakes from the remote control transmitter by moving the direction control lever to the FORWARD position.

8. Measure the resistance between contact J2-30 (wire EL300-YL(Yellow)) and frame ground. Note the resistance.

9. Move the direction control lever on the remote control transmitter to the NEUTRAL position.

10. Disconnect the lead from contact J2-30 (wire EL300-YL(Yellow)) and connect the lead to contact J2-29 (wire EL398-BR(Brown)).

11. Release the service brakes from the remote control transmitter by moving the direction control lever to the FORWARD position.

12. Measure the resistance between contact J2-29 (wire EL398-BR(Brown)) and frame ground. Note the resistance.

13. Release the direction control lever on the remote control transmitter to the NEUTRAL position.

Expected Result:

The resistance from contact J2-29 to frame ground is less than 5 ohms. The resistance from contact J2-30 to frame ground is greater than 5 ohms. These measurements are the opposite of the measurements in the previous Test Step.

Results:

• YES - The resistance from contact J2-29 to frame ground is less than 5 ohms . The resistance from contact J2-30 to frame ground is greater than 5 ohms. These measurements are the opposite of the measurements in the previous Test Step. The relay is operating correctly. Proceed to Test Step 9.

• NO - The resistance measurements do not differ for both contacts, or the measurements have not changed from the previous Test Step. The relays have failed or the relay control circuits have failed.

  Repair: Replace relays 4 or 5 or repair the relay control circuits in the interface control module.

  STOP

Test Step 9. CHECK IF THE DIAGNOSTIC CODE REMAINS

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

2. Reconnect all the harness connectors.

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

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

5. Operate the machine on remote control.

6. Check the status of the CID 1928 FMI 03.

Expected Result:

The CID 1928 FMI 03 is active.

Results:

• YES - The CID 1928 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" for the machine that is being serviced.

  STOP

• NO - The CID 1928 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.

  • A poor electrical connection

  • A short at one of the harness connectors that was disconnected and reconnected
  Resume normal machine operation.

  STOP