Illustration 1 | g02071833 |
Schematic of the AWD mode switch |
This diagnostic code is associated with the AWD mode switch. The AWD mode switch is connected to three inputs of the ECM. Two contacts are open and the other contact is grounded during proper operation.
This FMI 04 diagnostic code is activated when the AWD ECM detects two or more contacts that are grounded.
Note: The following test procedure may create other diagnostic codes. Clear the diagnostic codes when the original diagnostic code has been corrected. Ensure that the CID 0517 FMI 04 diagnostic code is active before performing this procedure.
Test Step 1. CHECK THE OPERATION OF THE SWITCH.
- Turn the key start switch to the OFF position.
- Turn the disconnect switch to the OFF position.
- Disconnect the machine harness connector from the switch.
Show/hide table
Table 1 Contacts     State of the Switch     Off Manual     "Creep"     Contacts 1 to 2     Greater than 5000 ohms     Greater than 5000 ohms     Less than 5 ohms     Contacts 2 to 3     Less than 5 ohms     Greater than 5000 ohms     Greater than 5000 ohms     Contacts 2 to 4     Greater than 5000 ohms     Less than 5 ohms     Greater than 5000 ohms    
- Measure the resistance that is between the contact points on the connector that is listed in Table 1. Note the resistance values.
Expected Result:
The measurements agree with the values that are listed in Table 1.
Results:
- OK - The resistances that were measured agree with the measurements that are listed in the table above. Proceed to Test Step 2.
- NOT OK - The resistance measurements do not reflect the expected measurements that are listed in the table above. The switch has failed.
Repair: Replace the switch.
STOP
Test Step 2. CHECK FOR A SHORTED HARNESS.
- The AWD mode switch remains disconnected.
- Turn the disconnect switch to the OFF position.
- Turn the key start switch to the OFF position.
- Disconnect the harness connector (J1) from the ECM.
- At the harness connector for the ECM (J1), measure the resistance between the following:
- Contact J1-13 (wire A201-BK) and all other J1 connector contacts
- Contact J1-33 (wire F747-OR) and all other J1 connector contacts
- Contact J1-34 (wire 823-GN) and all other J1 connector contacts
- Contact J1-40 (wire 718-BU) and all other J1 connector contacts
- Contact J1-13 (wire A201-BK) and all other J1 connector contacts
Expected Result:
The resistance is greater than 5000 ohms.
Results:
- OK - The resistance is greater than 5000 ohms. The harness resistance is correct. Proceed to Test Step 3.
- NOT OK - Resistance is less than 5000 ohms.
Repair: The harness has failed. Repair the harness or replace the harness.
STOP
Test Step 3. CHECK FOR AN OPEN HARNESS.
- The AWD mode switch remains disconnected from the harness.
- The key start switch and the disconnect switch are in the OFF position.
- At the harness connector for the AWD mode switch, place a jumper wire between the following contacts:
- Contact 3 (wire 823-GN) and Contact 2 (wire F747-OR)
- Contact 3 (wire 823-GN) and contact 4 (wire 718-BU)
- Contact 3 (wire 823-GN) and Contact 2 (wire F747-OR)
- The J1 connectors remain disconnected from the ECM.
- At the harness connector for the ECM, measure the resistance between the following:
- Contact J1-33 (wire F747-OR) and contact J1-13 (wire A201-BK)
- Contact J1-33 (wire F747-OR) and contact J1-13 (wire A201-BK)
- Make a note of the resistance that was measured.
- At the harness connector for the ECM, measure the resistance between the following:
- Contact J1-34 (wire 823-GN) and contact J1-13 (wire A201-BK).
- Contact J1-34 (wire 823-GN) and contact J1-13 (wire A201-BK).
- Make a note of the resistance that was measured.
- At the harness connector for the ECM, measure the resistance between the following:
- Contact J1-40 (wire 718-BU) and contact J1-13 (wire A201-BK).
- Contact J1-40 (wire 718-BU) and contact J1-13 (wire A201-BK).
- Make a note of the resistance that was measured.
Expected Result:
The resistance is less than 5 ohms for all of the measurements.
Results:
- Ok - The resistance is less than 5 ohms for all of the measurements. Proceed to Test Step 4.
- NOT OK - Resistance is greater than 5000 ohms for one or more of the measurements.
Repair: The harness has failed. Repair the harness or replace the harness.
STOP
Test Step 4. CHECK THE ECM.
- Reconnect all of the connectors to the AWD ECM.
- Turn the disconnect switch to the ON position.
- Turn the key start switch to the ON position.
- The harness remains disconnected from the switch.
- At the harness connector for the switch, measure the voltage between the following:
- Contact 1 (wire A201-BK) and contact 2 (wire F747-OR)
- Contact 1 (wire A201-BK) and contact 3 (wire 823-GN)
- Contact 1 (wire A201-BK) and contact 4 (wire 718-BU)
- Contact 1 (wire A201-BK) and contact 2 (wire F747-OR)
Expected Result:
The voltage measures approximately 12.0 ± 0.5 DCV.
Results:
- OK - The voltage measures approximately 12.0 ± 0.5 DCV. Proceed to Test Step 5.
- NOT OK - The voltage is not approximately 12.0 ± 0.5 DCV.
Repair: The voltage from the ECM is incorrect. It is unlikely that the ECM has failed. Exit this procedure and perform this troubleshooting procedure again. If the diagnostic code is not found replace the ECM. Prior to replacing an ECM, always contact your dealership's Technical Communicator for possible consultation with Caterpillar. This consultation may greatly reduce repair time. If the ECM must be replaced, refer to the Testing and Adjusting, "Electronic Control Module (ECM) - Replace" Story in this manual for additional information.
STOP
Test Step 5. CHECK IF THE DIAGNOSTIC CODE IS STILL ACTIVE.
- Perform the following:
- Visually inspect the contacts of the harness connectors.
- Clean the contacts of the harness connectors.
- Visually inspect the contacts of the harness connectors.
- Reconnect all harness connectors.
- Turn the disconnect switch to the ON position.
- Turn the key start switch to the ON position.
- Operate the machine.
- Determine if the CID 0517 FMI 04 is active.
Expected Result:
The CID 0517 FMI 04 is no longer active.
Results:
- OK - The CID 0517 FMI 04 is not active. The problem 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
- NOT OK - The CID 0517 FMI 04 is active. The problem 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. Prior to replacing an ECM, always contact your dealership's Technical Communicator for possible consultation with Caterpillar. This consultation may greatly reduce repair time. If the ECM must be replaced, refer to the Testing and Adjusting, "Electronic Control Module (ECM) - Replace" Story in this manual.
STOP
Test Step 6. CHECK THE ENERGIZE CIRCUIT OF THE SWITCH FOR A SHORT TO THE +BATTERY CIRCUIT.
- Turn the disconnect switch to the OFF position.
- Turn the key start switch to the OFF position.
- Disconnect the machine harness connectors from the switch and the ECM.
- At the machine harness connector for the ECM, measure the resistance from contact J1-1 (wire A201-BK) to all contacts that are used in the ECM.
Expected Result:
Each resistance measurement is greater than 5000 ohms.
Results:
- OK - Each resistance measurement is greater than 5000 ohms. The machine harness is correct. Proceed to Test Step 7.
- NOT OK - Each resistance measurement is not greater than 5000 ohms. There is a short in the machine harness. The short is between J1-1 (A201-BK) and the circuit that has a low resistance.
Repair: Repair the machine harness or replace the machine harness.
STOP
Test Step 7. CHECK IF THE DIAGNOSTIC CODE IS STILL ACTIVE.
- Perform the following:
- Visually inspect the contacts of the harness connectors.
- Clean the contacts of the harness connectors.
- Visually inspect the contacts of the harness connectors.
- Reconnect all harness connectors.
- Turn the disconnect switch to the ON position.
- Turn the key start switch to the ON position.
- Operate the machine.
- Determine if theCID 0517 FMI 04 is active.
Expected Result:
The CID 0517 FMI 04 is active.
Results:
- OK - The CID 0517 FMI 04 is active. The problem 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. Prior to replacing an ECM, always contact your dealership's Technical Communicator for possible consultation with Caterpillar. This consultation may greatly reduce repair time. If the ECM must be replaced, refer to the Testing and Adjusting, "Electronic Control Module (ECM) - Replace" Story in this manual for additional information.
STOP
- NOT OK - The CID 0517 FMI 04 is not active. The problem 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