938G Wheel Loader, 938G Series II Wheel Loader, IT38G Integrated Toolcarrier and IT38G Series II Integrated Toolcarrier Traction Control System MID 028 - CID 0616 - FMI 02 Caterpillar

Conditions Which Generate This Code:

Illustration 1	g00914180
Schematic of a Test/Enable Switch

This diagnostic code is associated with the test/enable switch. The switch is connected to two inputs of the ECM. The inputs are "Normally Closed".

The FMI 02 means that the ECM has determined that one of the following combinations is present.

• All of the inputs are grounded.

• Two or more of the inputs are open.

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 0616 FMI 02 is active before performing this procedure.

System Response:

The Traction Control system is inoperable.

Test Step 1. CHECK THE OPERATION OF THE SWITCH IN THE OFF POSITION.

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

2. Place the switch in the OFF position.

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

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

5. Connect the other lead to contact 3.

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

7. Disconnect the lead from contact 2 and connect the lead to contact 5.

8. Disconnect the lead from contact 3 and connect the lead to contact 4.

9. Measure the resistance between contact 5 and contact 4. Note the resistance.

Expected Result:

The resistancesare less than 5 ohms.

Results:

• YES - The resistancesare less than 5 ohms. Proceed to Test Step 2.

• NO - One of the resistancesis greater than 5 ohms. The switch has failed.

  Repair: Replace the switch.

  Stop.

Test Step 2. CHECK THE OPERATION OF THE SWITCH.

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

2. Place the switch in the ENABLE position.

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

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

5. Connect the other lead to contact 3.

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

7. Disconnect the lead from contact 2 and connect the lead to contact 5.

8. Disconnect the lead from contact 3 and connect the lead to contact 4.

9. Measure the resistance between contact 5 and contact 4. Note the resistance.

Expected Result:

The resistance from contact 2 to contact 3 is greater than 5000 ohms, and the resistance from contact 5 to contact 4 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 5 to contact 4 is less than 5 ohms. Proceed to Test Step 3.

• NO - The resistance from contact 2 to contact 3 is NOT greater than 5000 ohms or the resistance from contact 5 to contact 4 is NOT less than 5 ohms. The switch has failed.

  Repair: Replace the switch.

  Stop.

Test Step 3. CHECK THE OPERATION OF THE SWITCH IN THE TEST POSITION.

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

2. Place the switch in the TEST position.

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

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

5. Connect the other lead to contact 3.

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

7. Disconnect the lead from contact 2 and connect the lead to contact 5.

8. Disconnect the lead from contact 3 and connect the lead to contact (4).

9. Measure the resistance between contact 5 and contact 4. Note the resistance.

Expected Result:

The resistance from contact 2 to contact 3 is less than 5 ohms, and the resistance from contact 5 to contact 4 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 5 to contact 4 is greater than 5000 ohms. Proceed to Test Step 4.

• NO - The resistance from contact 2 to contact 3 is NOT less than 5 ohms or the resistance from contact 5 to contact 4 is NOT greater than 5000 ohms.

  Repair: Replace the switch.

  Stop.

Test Step 4. CHECK THE GROUND CIRCUIT OF THE SWITCH IN THE WIRE HARNESS.

1. Connect one lead from the multimeter to contact 2 (wire A219-BK) of the wire harness connector for the switch.

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

3. Measure the resistance between contact 2 (wire A219-BK) and frame ground. Note the resistance.

4. Disconnect the lead from contact 2 and connect the lead to contact 5 (wire A219-BK) of the wire harness connector for the switch.

5. Measure the resistance between contact 5 (wire A219-BK) and frame ground. Note the resistance.

Expected Result:

The resistances are less than 5 ohms.

Results:

• OK - The resistances are less than 5 ohms. The circuit is correct. Proceed to Test Step 5.

• NOT OK - The resistance is greater than 5000 ohms on one of the readings. The circuit is open. The machine harness 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 the following contacts of the machine harness to all the contacts that are used in the machine harness connectors for the ECM: J1-31 (wire E928-WH) and J1-37 (wire E927-GN)

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 the wires with the lowest resistance measurement.

  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 2 (wire A219-BK) and contact 3 (wire E928-WH).

3. At the harness connector for the ECM, measure the resistance from contact J1-2 (wire A219-BK) to contact J1-31 (wire E928-WH). Note the resistance.

4. At the harness connector for the switch, connect a jumper wire between contact 2 (wire A219-BK) and contact 4 (wire E927-GN).

5. At the harness connector for the ECM, measure the resistance from contact J1-2 (wire A219-BK) to contact J1-37 (wire E927-GN). Note the resistance.

Expected Result:

The resistances are less than 5 ohms.

Results:

• OK - The resistances are less than 5 ohms. Proceed to Test Step 7.

• NOT OK - The resistance was greater than 5000 ohms on one or more of the readings. 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 0616 FMI 02 is active.

Expected Result:

The CID 0616 FMI 02 is active.

Results:

• YES - The CID 0616 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 0616 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.