545 Wheel Skidder Power Train Caterpillar

CID 0449 FMI 02 Control Switch (Grapple Rotation) Incorrect Signal - Test

Usage:

545 2FZ

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Illustration 1	g00558907
Schematic of the Grapple Rotate Switch (1) Grapple rotate counterclockwise. (2) Grapple rotate clockwise. (3) Grapple rotate switch. (4) Power train Electronic Control Module (ECM).

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Table 1
Circuit Continuity ⁽¹⁾
Grapple Rotate Switch - CID 0449
Connector J1 Contact No. of Power Train ECM	Connector ⁽²⁾ Contact No. of Joystick Handle	Wire No.	CW Position	HOLD Position	CCW Position
27	6	961-BR	X	O	O
38	7	F840-YL	O	X	O
33	8	E851-BU	O	O	X

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^( 1 )	Open no continuity to ground (O). Closed continuity to ground (X).
^( 2 )	Grounded is contact No. 1 wire 202-BK of the grapple control joystick handle connector.

Table 1 lists the continuity to ground of each switch circuit (input) for the three positions of the switch.

Note: Wire 202-BK is connected to the frame ground.

Grapple rotate switch (3) sends three inputs to J1 connector of power train Electronic Control Module (ECM) (4). A fault is recorded when the status of the switch inputs is invalid. One of the inputs should be grounded at all times. See Table 1. The test points for the switch are at the harness connector of the grapple control joystick handle.

Check the ground circuit of the switch.
1. Turn the key start switch and the battery disconnect switch to the OFF position.
1. Disconnect the harness connector of the grapple control joystick handle from the machine harness connector.
1. At the machine harness connector for the grapple control joystick handle, measure the resistance between contact 1 (wire 202-BK) and the frame ground.
  Expected Result: Resistance is less than 5 Ohms.
  Results:
  - OK - Resistance is less than 5 Ohms. The switch ground circuit is correct in the machine harness. Go to Step 2.
  - NOT OK - Resistance is greater than 5 Ohms. The machine harness is faulty. Wire 202-BK is open in the machine harness. Replace the machine harness or repair the machine harness. STOP.

Check the grapple rotate switch.
1. The key start switch and the battery disconnect switch remain in the OFF position.
1. Disconnect the harness connector of the grapple control joystick handle from the machine harness connector.
1. At the harness connector of the grapple control joystick handle, check continuity to ground of the open contacts of grapple rotate switch (3). At the harness connector, check continuity to the grounded contact for each position of grapple rotate switch (3). Activate each position of grapple rotate switch (3). Refer to Table 1.
  Expected Result: The continuity check agrees with Table 1.
  Results:
  - OK - Continuity check agrees with Table 1. Go to Step 3.
  - NOT OK - The continuity check does not agree with Table 1. Grapple rotate switch (3) is faulty. Replace the switch. STOP.

Check the machine harness for continuity.
1. The key start switch and the battery disconnect switch remain in the OFF position.
1. Reconnect the harness connector of the grapple control joystick handle to the machine harness.
1. Disconnect the machine harness connector J1 from power train ECM (4) .
1. At the machine harness connector J1, check continuity to ground of the open contacts of grapple rotate switch (3). At the machine harness connector J1, check the grounded contact for each position of grapple rotate switch (3). Activate each position of grapple rotate switch (3). Refer to Table 1.
  Expected Result: The continuity check agrees with Table 1.
  Results:
  - OK - Continuity check agrees with Table 1. Go to Step 4.
  - NOT OK - The continuity check does not agree with Table 1. The machine harness is faulty. Replace the machine harness or repair the machine harness. STOP.

Check if the fault is still present.
1. Inspect the contacts and clean the contacts of the harness connectors.
1. Reconnect all harness connectors.
1. Turn the battery disconnect switch to the ON position.
1. Start the engine.
1. Enter the service mode of the Caterpillar Monitoring System. Clear all inactive faults.
1. Attempt to operate the machine.
1. Stop the machine.
1. Check for the CID 0449 FMI 02 diagnostic code for grapple rotate switch (3) .
  Expected Result: The CID 0449 FMI 02 diagnostic code for grapple rotate switch (3) is active. The "SERV CODE" is showing in the display.
  Results:
  - YES - The fault has not been corrected. It is unlikely that power train ECM (4) is faulty. Replace the grapple control handle. Perform the previous steps again. If the cause of the fault is not found, replace the power train ECM. Refer to Testing and Adjusting, "Electronic Control Module (Power Train) - Replace" for more information on replacing power train ECM (4). STOP.
  - NO - Fault is NOT active. The fault does not exist at this time. The initial fault 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.