22/01/24, 13.16 SIS 2.

Relay - Test (M0122667-01)

SMCS - 4493, 775E i08269222

Chassis ECM PSP

202 -0008
The following is a list of Diagnostic Trouble Codes (DTCs) that are associated with the relays of
the machine.

Table 1
4
05: /01/2 4E12
Chassis ECM (MID 87) 1
M0 6:23+ 2
J1939 CDL

420-
Code Description

Secondary Steering
1
© 2 2266 08:00
System Response

3
Relay : Voltage
Above Normal 024 7 The "Secondary Steering System" is always energized.

420-
Secondary Steering
Cat The "Secondary Steering System" will not energize. The
5
Relay : Current
Below Normal erp system is constantly OFF.

illa
r In
Secondary Steering
420- The "Secondary Steering System" will not energize. The
Relay : Current

c.
6 system is constantly OFF.
Above Normal
Starter Motor Relay:
444- When this diagnostic code is active, the ECM will turn
Voltage Above
3 OFF the current to the failed relay.
Normal
Starter Motor Relay
444- When this diagnostic code is active, the ECM will turn
: Current Below
5 OFF the current to the failed relay.
Normal
Starter Motor Relay
444- When this diagnostic code is active, the ECM will turn
: Current Above
6 OFF the current to the failed relay.
Normal
During the duration of this diagnostic code, the
Autolube Relay : "Autolube" motor will run when NOT commanded. Under
558-
Voltage Above these conditions, the motor will fail if the motor runs for
3
Normal too long. This condition will result in excess lubing of the
truck ("quicklube").
Autolube Relay :
558- During the duration of this diagnostic code, the Autolube
Current Below
5 motor will NOT run when commanded.
Normal
Autolube Relay :
558- During the duration of this diagnostic code, the Autolube
Current Above
6 motor will NOT run when commanded.
Normal

A relay is a component that uses a small amount of electrical current to control the state of a
circuit. The circuit is either opened or closed.

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Illustration 1 g06608959
Schematic for the Secondary Steering relay circuit for 777E Off-Highway Truck

Illustration 2 g06608963
Schematic for the Starter relay circuit for 777E Off-Highway Truck

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Illustration 3 g06608970
Schematic for the "Autolube" relay circuit for 777E Off-Highway Truck

The preceding diagrams are simplified schematics of the "Chassis" ECM relay connections. The
schematic is electrically correct. However, not all the possible harness connectors are shown.
Refer to the latest revision of the Electrical System Schematic for this machine.

For detailed electrical schematic information, refer to Electrical Schematic, UENR7793 , "777E
Prime Off-Highway Truck".

Diagnostic Trouble Code Procedure

Table 2

Required Tools
Tool Part Number Description Qty
146-4080(1) Digital Multimeter Group 1
8T-3224 Needle Tip Group 1
T1
7X-1710 Multimeter Probe Group 1
8T-8726 Cable Assembly (Three Pin) (3-Pin Breakout) 1
JERD2129 Cat® Electronic Technician (Cat ET) 1
T2 Windows-based PC 1
538-5051 Communication Adapter Gp 1

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T3 6V-4148 Connector Repair Kit (Sure Seal) 1

T4 190-8900 Connector Field Repair Kit (Deutsch) 1
T5 175-3700 Connector Repair Kit Deutsch DT 1
(1) This multimeter can use an RS232C cable to connect to a Laptop computer or Dataview tool gp for troubleshooting.

Prior to beginning this procedure, inspect the harness connectors that are involved in this circuit.
Poor connections can often be the cause of a problem in an electrical circuit. Verify that all
connections in the circuit are clean, secure, and in good condition. Check the wiring harness for
pinch points or abrasions. Look for and repair areas that indicate wires are exposed. If a problem
with a connection is found, correct the problem and verify that the diagnostic code is active
before performing a troubleshooting procedure.

1. Identify the active FMI code associated with the components.

2. Determine which code is present and use the list below to determine which procedure to
follow.

FMI 3 diagnostic code, proceed to "FMI 3".

FMI 5 diagnostic code, proceed to "FMI 5".

FMI 6 diagnostic code, proceed to "FMI 6".

FMI 3
Table 3

Check The Machine Harness For A Short

Troubleshooting Test Steps Values Results
1. Turn the key start switch and Each resistance Result: All resistance measurements
disconnect switch to the OFF measurement is are greater than 5K Ω.
position. greater than 5KΩ.
Proceed to "Check If The Diagnostic
2. Disconnect the relay from the Code Remains" Table 4.
harness.
Result: One or more readings are
3. Disconnect the ECM machine less than 5 Ω.
harness connectors from the relay.
Repair: A short exists between the
4. At the ECM machine harness signal contact and the circuit with the
connector, measure the resistance low resistance. Repair or replace the
between the signal contact and all machine harness.
other contacts that are used in the
ECM. Note: A resistance greater than 5 Ω
but less than 5K Ω indicates a loose
or corroded connection in the circuit.
A resistance measurement greater
than 5K Ω indicates an open in the
circuit.

Use the Cat® ET service tool to

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monitor the output of the circuit while

manipulating the wiring harness. This
test will detect momentary shorts,
intermittent shorts, and open circuits.

Proceed to "Check If The Diagnostic

Code Remains" Table 4.

Table 4

Check If The Diagnostic Code Remains

Troubleshooting Test Steps Values Results
Result: The diagnostic code does not
exist currently. The initial diagnostic
code may have been caused by poor
electrical connection or short at one of
the harness connections. Resume
machine operation.
1. Visually inspect the harness
connectors. Clean the contacts of the STOP.
harness connectors. Visually inspect
the insulation of the wires for damage Result: The diagnostic trouble code
that is caused by excessive heat, has not been corrected. If the
battery acid, or chafing. diagnostic code has not been
corrected after performing the
2. Reconnect all harness connectors. procedure a second time, the ECM
Verify that the connectors are fully may require replacement.
seated and the clips for each
The
connector are fastened securely. Use the Cat® ET service tool to
diagnostic
monitor the output of the circuit while
code is no
3. Turn the key start switch and the manipulating the wiring harness. This
longer
disconnect switch to the ON position. test will detect momentary shorts,
present.
intermittent shorts, and open circuits.
4. Clear all diagnostic codes.
If a problem is detected, repair or
5. Operate the machine. replace the faulty wiring harness.

6. Stop the machine and engage the Prior to replacing the ECM, always
safety lock. contact the Technical Communicator
at your dealership for possible
7. Check if the diagnostic code is consultation with Caterpillar. This
active. consultation may effect repair time.

Follow the steps in Troubleshooting,

"ECM - Replace" if the ECM needs to
be replaced.

STOP.

FMI 5
Table 5

Check The Relay

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Troubleshooting Test Steps Values Results

1. Turn the key start switch and
disconnect switch to the OFF Result: The harness is correct.
position. The diagnostic code is NOT
active as the jumper wire is
2. Disconnect the relay from the installed and then removed. The
wiring harness. relay has failed.

3. At the machine harness The diagnostic code is Repair - Replace the relay.
connector for the relay, place a NOT active as the
jumper wire between the signal jumper wire is installed Proceed to "Check If The
wire and ground. and then removed. Diagnostic Code Remains" 7.

4. Turn the key start switch and Result: The diagnostic code
the disconnect switch to the ON remains active.
position. Do not start the engine.
Proceed to "Check The Harness
5. Observe the status of the For An Open" Table 6.
diagnostic code.

Table 6
Check The Harness For An Open
Troubleshooting Test Steps Values Results
Result: The resistance is less than 5
Ω. The machine harness is correct.

Proceed to "Check If The Diagnostic

1. The jumper wire, between the signal
Code Remains" 7.
wire and the return wire, remains
installed.
Result: The resistance is greater than
5K Ω. The resistance measurement is
2. Turn key start switch and disconnect
not correct. There is an open circuit in
switch to the OFF position.
the machine harness.
The
3. Disconnect the machine harness resistance is
Repair: Repair or replace the machine
connectors from the less than 5
harness.
"Transmission/Chassis" ECM. Ω.
Note: A resistance that is greater than
4. At the "Transmission/Chassis" ECM
5 Ω but less than 5K Ω would indicate a
machine harness connector, measure
loose connection or a corroded
the resistance between the signal
connection in the circuit. A resistance
contact and ground (wire 200-
measurement that is greater than 5K Ω
BK(Black)).
would indicate an open in the circuit.

Proceed to "Check If The Diagnostic

Code Remains" 7.

Table 7

Check If The Diagnostic Code Remains

Troubleshooting Test Steps Values Results

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1. Inspect the harness connectors.

Clean the contacts of the harness
connectors. Check the wires for Result: The diagnostic code does not
damage to the insulation that is exist currently. The initial diagnostic
caused by excessive heat, battery code may have been caused by poor
acid, or chafing. electrical connection or short at one of
the harness connections. Resume
2. Perform a 45 N (10 lb) pull test on machine operation.
each of the wires associated with the
circuit. STOP.

3. Reconnect all harness connectors. Result: The diagnostic trouble code

Make sure that the connectors are fully has not been corrected. If the
The
seated. Observe that the clips for each diagnostic code has not been
diagnostic
connectors are fastened securely. corrected after performing the
code is no
Return machine to normal operating procedure a second time, the ECM
longer
condition. may require replacement.
active.
4. Turn the key start switch and the Prior to replacing the ECM, always
disconnect switch to the ON position. contact the Technical Communicator at
your dealership for possible
5. Clear all diagnostic codes. consultation with Caterpillar. This
consultation may effect repair time.
6. Operate the machine.
Follow the steps in Troubleshooting,
7. Stop the machine and engage the "ECM - Replace" if the ECM needs to
parking brake. be replaced.
STOP.
8. Check if the diagnostic code is
active.

FMI 6
Table 8
Check The Relay
Troubleshooting Test
Values Results
Steps
Result: FMI 6 changes to FMI 5 when
the relay is disconnected. The harness is
1. Turn the key start switch correct. The relay has failed. Repeat this
and disconnect switch to test step to verify that the relay has
the ON position. failed.

Note: Do not start the Repair: Replace the relay.

The FMI 6 changes to
engine.
FMI 5 when the relay
Proceed to "Check The Energizer Circuit
is disconnected.
2. Disconnect the relay For a Short To Ground" Table 9.
from the machine harness.
Result: The diagnostic code remains
3. Observe the status of active.
the diagnostic code.
Proceed to "Check The Return Circuit
For A Short To Ground" Table 9.

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Table 9
Check The Energizer Circuit For A Short To Ground
Troubleshooting Test Steps Values Results
Result: Each resistance
measurement is greater than 5K
Ω. The machine harness is
correct.

Proceed to "Check If The

Diagnostic Code Remains" Table
1. Turn key switch and disconnect
10.
switch to the OFF position.
Result: Each resistance
2. The relay remains disconnected from
measurement is not greater than
the machine harness.
5K Ω. A short circuit exists
between the signal circuit and
3. Disconnect the machine harness Each resistance
the circuit with the low-resistance
connectors J1 and J2 from the measurement is
measurement.
"Transmission/Chassis" ECM. greater than 5K
Ω.
Repair: Repair or replace the
4. At the J1 and J2
machine harness.
"Transmission/Chassis" ECM machine
harness connector, measure the
Note: A resistance greater than 5
resistance between the signal contact of
Ω but less than 5K Ω indicates a
the relay and all possible sources of
loose or corroded connection in
ground.
the circuit. A resistance
measurement greater than 5K Ω
indicates an open in the circuit.

Proceed to "Check If The

Diagnostic Code Remains" Table
10.

Table 10
Check If The Diagnostic Code Remains
Troubleshooting Test Steps Values Results
1. Inspect the harness connectors. The Result: The diagnostic code does
Clean the contacts of the harness diagnostic NOT exist currently. The initial
connectors. Check the wires for code is NO diagnostic code may have been
damage to the insulation that is longer caused by poor electrical connection or
caused by excessive heat, battery present. short at one of the harness
acid, or chafing. connections. Resume machine
operation.
2. Perform a 45 N (10 lb) pull test on
each of the wires that are associated STOP.
with the circuit.
Result: The diagnostic trouble code
3. Reconnect all harness connectors. has not been corrected. If the
Confirm that the connectors are fully diagnostic code has not been
seated. Observe that the clips for corrected after performing the
each connector are fastened securely. procedure a second time, the ECM
Return machine to normal operating may require replacement.
condition.
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Prior to replacing the ECM, always

4. Turn the key start switch and the contact the Technical Communicator at
disconnect switch to the ON position. your dealership for possible
consultation with Caterpillar. This
5. Clear all diagnostic codes. consultation may effect repair time.

6. Operate the machine. Follow the steps in Troubleshooting,

"ECM - Replace" if the ECM needs to
7. Stop the machine and engage the be replaced.
parking brake.
STOP.
8. Determine if the diagnostic code is
active.

PSP-00084E12
2024/01/22
05:16:10+08:00
i08269222
© 2024 Caterpillar Inc.

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