GEAR-SUN 1695559 - Caterpillar

Illustration 1 g01226081
Starter motor relay connections
Illustration 2 g01226117
Starter motor relay location in the fuse enclosure (1) Starter motor relay (2) Start motor contact (3) Buss bar "C" contact (4) Main relayThis diagnostic code is associated with the starter motor relay. The FMI 05 means that the ECM has determined that the current of the relay is below normal.The possible causes of this diagnostic code are listed below:
The energize circuit of the relay is open.
The return circuit of the relay is open.
The relay has failed.
The ECM has failed. This is unlikely.Note: The following test procedure may create other diagnostic codes. Ignore these created diagnostic codes and clear these diagnostic codes when the original diagnostic code has been corrected. Ensure that the diagnostic code of CID 0444 FMI 05 is active before performing this procedure.Note: Use the 146-4080 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 relay.Note: The coil resistance of the start relay should measure 27.3 3 ohms at 20 °C (68.0 °F). Test Step 1. CHECK THE RELAY
Turn the disconnect switch and the key start switch to the ON position. Do not start the engine.
Disconnect the start relay from the machine harness.
At the machine harness connector for the relay, place a jumper wire from contact 1 (wire 306-GN) to contact 2 (wire J766-PU).
Observe the status of the CID 0444 FMI 05.Expected Result:The CID 0444 FMI 05 remains active. The FMI has not changed and the "05" is still active.Results:
YES - The diagnostic code remains active. The jumper wire does not affect the diagnostic code. Proceed to Test Step 2.
NO - The diagnostic is no longer active. The relay has failed.Repair: The relay has failed. Repeat this Test Step "CHECK THE RELAY" in order to verify the failure of the relay. Replace the relay. Verify that the new relay corrects the problem.STOPTest Step 2. CHECK THE HARNESS FOR AN OPEN
Turn the key start switch and the disconnect switch to the OFF position.
Disconnect the machine harness connector J2 from the ECM.
The jumper wire that was installed in the previous test step remains in place.
At the machine harness connector, measure the resistance from signal contact J2-7 (wire 306-GN) to contact J2-8 (wire J966-PU).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 could be an open or a faulty connector in the machine harness circuit.Repair: A resistance measurement that is more than 5.0 ohms but less than 5000 ohms may indicate a problem with one of the harness connectors in the circuit. A connector my be loose or corroded. Inspect the connectors that are in the circuit. Ensure that all connectors are clean, tight and in good condition.For a measurements above 5000 ohms, an open is in wire 306-GN or in wire J766-PU of the