BOLT-SPECIAL 2155640 - Caterpillar

Illustration 1 g01321348
Schematic for the Winch Drive Away SwitchThe Winch Drive Away Switch has two inputs to the ECM. The two inputs are normally open and normally closed. During normal operation, one of the inputs is open. The other input is grounded. When a circuit is measured with a voltmeter, an open circuit will measure approximately 13 DCV to ground and a closed circuit will measure approximately 0 DCV to ground. An FMI 04 diagnostic code is recorded when both of the inputs are grounded.The possible causes of this diagnostic code are listed below:
The "normally open" signal circuit (wire P782-PK) is always shorted to ground.
The "normally closed" signal circuit (wire P781-GY) is always shorted to ground.
The switch has failed.
The ECM has failed. This is unlikely. Before performing this procedure, inspect the harness connectors that are involved in the 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. If a problem with a connection is found, correct the problem and verify that this diagnostic code is active before performing this procedure.
Table 1
Status of the Switch    
MODE    Switch Position    J1-27 (N/O)
P782-PK Circuit    J1-27 (N/C)
P781-GY Circuit    
Released     Up     Open     Closed    
Pressed     Down     Closed     Open    System Response:A level 1 warning is generated.Test Step 1. CHECK THE SWITCH
Check for continuity between contact 1 and contact 2 of the switch.
Press the switch and then release the switch while checking for continuity.
Check for continuity between contact 2 and contact 3 of the switch.
Press the switch and then release the switch while checking for continuity.Expected Result:The continuity check agrees with the preceding Table.Results:
OK - The continuity check agrees with the preceding Table. Proceed to Test Step 2.
NOT OK - The continuity check does not agree with the preceding Table. The switch has failed.Repair: Replace the switch. Verify that the new switch corrects the diagnostic code.STOPTest Step 2. CHECK THE SIGNAL CIRCUITS FOR A SHORT TO GROUND
Reconnect the switch to the machine harness.
The machine harness connectors remain disconnected from the ECM.
At the machine harness connector for the ECM, check for continuity between contact J1-27 (wire P782-PK) and frame ground.
Press the switch and then release the switch while checking for continuity.
At the machine harness connector for the ECM, check for continuity between contact J1-27 (wire P781-GY) and frame ground.
Press the switch and then release the switch while checking for continuity.Expected Result:The continuity check agrees with the preceding Table.Results:
OK - The continuity check agrees with the preceding Table.Repair: If the cause of the problem is not found, contact the Technical Communicator for your dealership for possible consultation with Caterpillar. This consultation may greatly reduce repair time. If the ECM requires replacement, see Troubleshooting, "Electronic Control Module (ECM) - Replace".STOP
NOT OK - The continuity check does not agree with the preceding Table.Repair: There is a short in the machine harness. Repair the machine harness or replace the machine harness.STOP