CAP AS-RADIATOR 4324621 - Caterpillar

Illustration 1 g01689526
Starter relay
Illustration 2 g01880899
Schematic of the starter relay
This diagnostic code is associated with the start relays. The FMI 5 means that the electronic control module (ECM) has determined that the current of the relay circuit is below normal.The possible causes of this diagnostic code are listed below:
The energizer circuit of a relay is open.
The return circuit of the relay is open.
The relay has failed.
The ECM has failed. A failure of the ECM is unlikely.Note: The following test procedure may create other diagnostic codes. Clear these diagnostic codes when the problem has been corrected. Ensure that the diagnostic code of CID 444 FMI 5 is active before performing this procedure.Note: Use the digital multimeter for the measurements in this procedure.System Response:When this diagnostic code is active, the ECM will turn off the current to the failed relay.Test Step 1. CHECK THE RELAYS
Turn the disconnect switch to the ON position.
Turn the key start switch to the ON position.Note: Do not start the engine.
Disconnect both relays from the machine harness.
At the machine harness connector for the relay, place a jumper wire from contact J2-7 (wire P989-GN(Green)) to ground (wire 200-BK(Black)).
Observe the status of the CID 444 FMI 5.Expected Result:The CID 444 FMI 5 remains active. The FMI has not changed and the FMI 5 is still active.Results:
OK - The diagnostic code remains active. The jumper wire does not affect the diagnostic code. Proceed to Test Step 2.
NOT OK - The diagnostic is no longer active. The one or both relays has failed.Repair: A relay has failed. Repeat this Test Step "CHECK THE RELAY" to verify the failure of the relay. Replace the failed relay. Verify that the new relay corrects the problem.STOPTest Step 2. CHECK THE HARNESS FOR AN OPEN
Turn the disconnect switch to the OFF position.
Turn the key start switch to the OFF position.
Disconnect the machine harness connectors from the ECM.
The jumper wire that was installed in the previous test remains in place.
At the machine harness connector, measure the resistance from signal contact J2-7 (wire P989-GN(Green)) to ground (wire 200-BK(Black)).Expected Result:The resistance is less than 5.0 ohms.Results:
OK - The resistance is less than 5.0 ohms. The machine harness is correct. Proceed to Test Step 3.
NOT OK - The resistance is greater than 5000 ohms. The resistance measurement is not correct. There is an open circuit in the machine harness.Repair: Repair the machine harness or replace the machine harness.STOPTest Step 3. CHECK IF THE DIAGNOSTIC CODE REMAINS
Perform the following:
Visually inspect the harness connectors.
Clean the contacts of the harness connectors.
Visually inspect the insulation of the wires for damage that is caused by excessive heat, battery acid, or chafing.
Perform a 45 N (10 lb) pull test on each of the wires that are associated with the circuit.
Reconnect all harness connectors. Verify the following:
Connectors are fully seated.
The clips for each connector are fastened securely.
Turn the disconnect switch to the ON position.
Turn the key start switch to the ON position.
Operate the machine.
Check the status of the CID 444 FMI 5.Expected Result:The CID 444 FMI 5