TH220B, TH330B, TH340B, TH350B, TH355B, TH360B, TH460B, TH560B and TH580B Telehandlers Caterpillar

Illustration 1	g00904318

This diagnostic code is associated with the switch (implement lockout). The switch is connected to two inputs of the ECM. The inputs are "Normally Open" and "Normally Closed". One of the inputs is open and the other input is grounded during proper operation.

The FMI 02 means that the ECM has determined that the "Normally Open" and "Normally Closed" circuits are in the same state.

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 0490 FMI 02 is active before performing this procedure.

Test Step 1. CHECK THE OPERATION OF THE SWITCH

Note: The switch is in the non-actuated position.

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

2. Disconnect the machine harness connector or the wires from the switch.

3. Connect one lead from the multimeter to the common contact (2) for the switch.

4. Connect the other lead from the multimeter to the normally open contact (3) for the switch.

5. Measure the resistance between contact 2 and contact 3. Note the resistance.

6. Disconnect the lead from contact 3 and connect the lead to the normally closed contact (1).

7. Measure the resistance between contact 2 and contact 1. Note the resistance.

Expected Result:

The resistance from contact 2 to contact 3 is greater than 5000 ohms, and the resistance from contact 2 to contact 1 is less than 5 ohms.

Results:

• YES - The resistance from contact 2 to contact 3 is greater than 5000 ohms, and the resistance from contact 2 to contact 1 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. Connect one lead from the multimeter to the common contact (2) for the switch.

2. Connect the other lead from the multimeter to the normally open contact (3) for the switch.

3. Actuate the switch and measure the resistance between contact 2 and contact 3. Note the resistance.

4. Disconnect the lead from contact 3 and connect the lead to the normally closed contact (1).

5. Actuate the switch and measure the resistance between contact 2 and contact 1. Note the resistance.

Expected Result:

The resistance from contact 2 to contact 3 is less than 5 ohms, and the resistance from contact 2 to contact 1 is greater than 5000 ohms.

Results:

• YES - The resistance from contact 2 to contact 3 is less than 5 ohms, and the resistance from contact 2 to contact 1 is greater than 5000 ohms. Proceed to Test Step 3.

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

  Repair: Replace the switch.

  Stop.

Test Step 3. CHECK THE VOLTAGE AT THE SWITCH IN THE WIRE HARNESS.

1. Connect one lead from the multimeter to contact 2 (wire J764-BR) of the wire harness connector for the switch.

2. Connect the other lead from the multimeter to frame ground.

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

4. Measure the voltage between contact 2 (wire J764-BR) and frame ground.

Expected Result:

The voltage is approximately 0 DCV.

Results:

• OK - The voltage is approximately 0 DCV. The circuit is correct. Proceed to Test Step 5.

• NOT OK - The voltage is NOT approximately 0 DCV. Proceed to Test Step 4.

Test Step 4. CHECK THE HARNESS

1. Disconnect the machine harness connector(s) from the ECM.

2. Check the return circuit from contact J1-45 to contact 2 at the switch.

Expected Result:

The resistance measurement is less than 5.0 ohms.

Results:

• YES - The resistance measurement is less than 5.0 ohms. Proceed to Test Step 5.

• NO - The resistance measurement is greater than 5.0 ohms. The return circuit has failed.

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

  Stop.

Test Step 5. CHECK THE SWITCH CIRCUITS FOR A SHORT CIRCUIT.

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

2. Disconnect the machine harness connector(s) from the ECM.

3. The connector for the switch remains disconnected.

4. At the machine harness connector for the ECM, measure the resistance from contact J1-63 (wire 793-YL) and contact J1-64 (wire 774-YL) 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 5000 ohms.

Results:

• OK - Each resistance measurement is greater than 5000 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 774-YL and the circuit with the lowest resistance measurement or the short is between wire 793-YL and the circuit with the lowest resistance measurement. Repair the machine harness or replace the machine harness.

  Stop.

Test Step 6. CHECK THE SWITCH CIRCUITS IN THE HARNESS.

1. The machine harness remains disconnected from the ECM and the switch.

2. At the harness connector for the switch, connect a jumper wire between contact 3 (wire 793-YL) and contact 1 (wire 774-YL).

3. At the harness connector for the ECM, measure the resistance from contact J1-63 (wire 793-YL) to contact J1-64 (wire 774-YL).

Expected Result:

The resistance is less than 5 ohms.

Results:

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

• NOT OK - The resistance is greater than 5000 ohms. The circuit is open.

  Repair: The machine harness has failed. Repair the machine harness or replace the machine harness.

  Stop.

Test Step 7. CHECK IF THE DIAGNOSTIC CODE REMAINS.

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

2. Reconnect all harness connectors.

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

4. Operate the machine.

5. Determine if CID 0490 FMI 02 is active.

Expected Result:

The CID 0490 FMI 02 is active.

Results:

• YES - The CID 0490 FMI 02 is active. The diagnostic code 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. See Testing and Adjusting, "Electronic Control Module (ECM) - Replace".

  Stop.

• NO - The CID 0490 FMI 02 is not active. The diagnostic code is NOT present. 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.

  Stop.