KENR9023-01

October 2009

Systems Operation
Troubleshooting
Testing and Adjusting
793F and 797F Off-Highway Truck/
Tractors VIMS, Monitoring and Payload
LAJ1-Up (Machine)
SSP1-Up (Machine)

SAFETY.CAT.COM
 i03684547

Important Safety Information

Most accidents that involve product operation, maintenance and repair are caused by failure to observe
basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous
situations before an accident occurs. A person must be alert to potential hazards. This person should also
have the necessary training, skills and tools to perform these functions properly.
Improper operation, lubrication, maintenance or repair of this product can be dangerous and
could result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have
read and understood the operation, lubrication, maintenance and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings
are not heeded, bodily injury or death could occur to you or to other persons.
The hazards are identified by the Safety Alert Symbol and followed by a Signal Word such as
DANGER, WARNING or CAUTION. The Safety Alert WARNING label is shown below.

The meaning of this safety alert symbol is as follows:

Attention! Become Alert! Your Safety is Involved.
The message that appears under the warning explains the hazard and can be either written or pictorially
presented.
A non-exhaustive list of operations that may cause product damage are identified by NOTICE labels
on the product and in this publication.
Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard.
The warnings in this publication and on the product are, therefore, not all inclusive. You must
not use this product in any manner different from that considered by this manual without first
satisfying yourself that you have considered all safety rules and precautions applicable to the
operation of the product in the location of use, including site-specific rules and precautions
applicable to the worksite. If a tool, procedure, work method or operating technique that is not
specifically recommended by Caterpillar is used, you must satisfy yourself that it is safe for you
and for others. You should also ensure that the product will not be damaged or become unsafe by
the operation, lubrication, maintenance or repair procedures that you intend to use.
The information, specifications, and illustrations in this publication are on the basis of information that
was available at the time that the publication was written. The specifications, torques, pressures,
measurements, adjustments, illustrations, and other items can change at any time. These changes can
affect the service that is given to the product. Obtain the complete and most current information before you
start any job. Caterpillar dealers have the most current information available.

When replacement parts are required for this

product Caterpillar recommends using Caterpil-
lar replacement parts or parts with equivalent
specifications including, but not limited to, phys-
ical dimensions, type, strength and material.

Failure to heed this warning can lead to prema-

ture failures, product damage, personal injury or
death.

In the United States, the maintenance, replacement, or repair of the emission control devices and
systems may be performed by any repair establishment or individual of the owner's choosing.
KENR9023-01
Table of Contents
Systems Operation Section
Introduction
General Information ................................................ 5
Electronic Control Module ....................................... 8
Monitoring System
Monitoring System ................................................ 11
Warning Operation ................................................ 12
Payload System
Payload System ....................................................
Payload Management Guidelines .........................
Measurement Accuracy ........................................
Maximum Payload Speed Manager ......................
Payload Memory Capacity ....................................
Display
Display Modules ...................................................
Monitor Menu ........................................................
Operator Menu ......................................................
Payload Menu .......................................................
Settings Menu .......................................................
Service Menu ........................................................
Service Mode Menu ..............................................
Software
Service Tool Software ...........................................
VIMS 3G Connect .................................................
VIMSpc Software ..................................................
VIMSpc Payload Reports ......................................
Troubleshooting Section
Introduction
General Information ..............................................
Service Tools ........................................................
Electrical Component and Connector Locations ...
Diagnostic Capabilities .........................................
Event Code List ....................................................
Diagnostic Code Procedures
Diagnostic Code List ............................................. 69
Using Caterpillar Electronic Technician to Determine
Diagnostic Codes ................................................ 73
Using Advisor to Determine Diagnostic Codes ..... 75
MID 161 - CID 0248 - FMI 09 ............................... 76
MID 161 - CID 0296 - FMI 09 ............................... 79
MID 161 - CID 0296 - FMI 02 ............................... 81
MID 161 - CID 0296 - FMI 14 ............................... 84
MID 161 - CID 0533 - FMI 02 ............................... 84
MID 161 - CID 0533 - FMI 09 ............................... 87
MID 161 - CID 0533 - FMI 14 ............................... 89
MID 161 - CID 0590 - FMI 02 ............................... 90
MID 161 - CID 0590 - FMI 09 ............................... 92
MID 161 - CID 0590 - FMI 14 ............................... 95
MID 161 - CID 0768 - FMI 09 ............................... 95
MID 161 - CID 0768 - FMI 14 ............................... 97
MID 161 - CID 0800 - FMI 08 ............................... 98
3
Table of Contents
MID 161 - CID 0800 - FMI 11 .............................. 101
MID 161 - CID 0890 - FMI 09 ............................. 101
MID 161 - CID 1089 - FMI 09 ............................. 103
MID 161 - CID 1089 - FMI 14 ............................. 105
MID 161 - CID 1273 - FMI 02 ............................. 106
MID 161 - CID 1273 - FMI 09 ............................. 108
MID 161 - CID 1273 - FMI 14 .............................. 111
MID 161 - CID 2448 - FMI 02 .............................. 111
MID 161 - CID 2448 - FMI 09 .............................. 114
MID 161 - CID 2448 - FMI 14 .............................. 116
MID 162 - CID 0248 - FMI 09 .............................. 117
MID 162 - CID 0296 - FMI 02 .............................. 119
MID 162 - CID 0296 - FMI 09 ............................. 122
MID 162 - CID 0296 - FMI 14 ............................. 124
MID 162 - CID 0533 - FMI 02 ............................. 125
13
MID 162 - CID 0533 - FMI 09 ............................. 127
16
MID 162 - CID 0533 - FMI 14 ............................. 130
19
MID 162 - CID 0590 - FMI 02 ............................. 130
23
MID 162 - CID 0590 - FMI 09 ............................. 133
27
MID 162 - CID 0590 - FMI 14 ............................. 135
MID 162 - CID 0768 - FMI 09 ............................. 135
MID 162 - CID 0768 - FMI 14 ............................. 138
27
MID 162 - CID 0800 - FMI 09 ............................. 139
28
MID 162 - CID 0800 - FMI 14 ............................. 141
29
MID 162 - CID 0838 - FMI 03 ............................. 141
30
MID 162 - CID 0838 - FMI 04 ............................. 144
31
MID 162 - CID 0838 - FMI 08 ............................. 147
34
MID 162 - CID 0839 - FMI 03 ............................. 150
37
MID 162 - CID 0839 - FMI 04 ............................. 153
MID 162 - CID 0839 - FMI 08 ............................. 155
MID 162 - CID 0840 - FMI 03 ............................. 158
41
MID 162 - CID 0840 - FMI 04 ............................. 161
41
MID 162 - CID 0840 - FMI 08 ............................. 164
46
MID 162 - CID 0841 - FMI 03 ............................. 166
50
MID 162 - CID 0841 - FMI 04 ............................. 169
MID 162 - CID 0841 - FMI 08 ............................. 172
MID 162 - CID 1089 - FMI 08 ............................. 175
MID 162 - CID 1089 - FMI 11 .............................. 177
MID 162 - CID 1273 - FMI 02 ............................. 178
58 MID 162 - CID 1273 - FMI 09 ............................. 180
58 MID 162 - CID 1273 - FMI 14 ............................. 183
59 MID 162 - CID 2448 - FMI 02 ............................. 183
60 MID 162 - CID 2448 - FMI 09 ............................. 186
65 MID 162 - CID 2448 - FMI 14 ............................. 188
Diagnostic System Procedures
Power Supply Circuit of Electronic Control
Module .............................................................. 189
Testing and Adjusting Section
Testing and Adjusting
Payload System - Calibrate ................................ 191
Payload System - Configure ............................... 192
Electrical Connector - Inspect ............................. 193
Wiring Harness (Open Circuit) - Test .................. 197
Wiring Harness (Short Circuit) - Test .................. 197
Electronic Control Module (ECM) - Flash
Program ............................................................ 198
Electronic Control Module (ECM) - Replace ....... 198
Electronic Control Module (ECM) - Configure .... 198
Battery - Replace ................................................ 199
Off-Board Service Tool ........................................ 199
4 KENR9023-01
Table of Contents

Connector Contact Description ........................... 200

Glossary of Terms ............................................... 202
System Schematic .............................................. 206

Index Section
Index ................................................................... 212
KENR9023-01 5
Systems Operation Section

Systems Operation Section

Introduction
i03729580

General Information
SMCS Code: 7601

g01772535
Illustration 1
Connections of the data link for the Advisor

This manual is for the VIMS 3G on the Off-Highway

Truck (OHT). Throughout this manual, VIMS may
also be referred to as the monitoring system. VIMS
3G is a standard feature on some OHT. VIMS
continuously monitors all of the machine systems.
This manual describes the hardware, the software,
and the interfaces that are used with VIMS.
6 KENR9023-01
Systems Operation Section
The operator is alerted to the existence of all
abnormal machine conditions by the monitoring
system via the Advisor display module. All abnormal
conditions on the machine system are called events.
The Advisor and the modules that are on the data link
refer to these abnormal conditions as events. A high
engine coolant temperature is an example of a event.
The operator is alerted to problems in the modules
on the machine. The diagnostic type of electronic
circuit or component failures are called diagnostics.
The Advisor and the modules that are on the data
link refer to these failures as diagnostics. The signal
voltage of the coolant temperature sensor that is
above normal is an example of a diagnostic. Stored
VIMS event information is used in order to assist the
service personnel with machine maintenance and
troubleshooting.
Events are related to a machine system. The operator
needs to respond to this event in most cases. For
example, the operator needs to modify operation in
order to cool the oil temperature for the converter
when the temperature is too high. When such an
event is present, the operator is shown additional
information on the Advisor screen.
Problems with the electrical system of the machine
are called a diagnostic. A diagnostic requires a
service technician to make a repair. Use the buttons
on the Advisor display module in order to navigate to
the Active Events list in the Service menu when
a system event is present. Selecting a code and
pressing the OK button will display more information
such as the MID, the CID and the FMI. If the event
is a warning level 2 or 3, an event screen that shows
the details of the event will automatically appear on
the Advisor display. The information will appear when
the diagnostic code becomes active. When a MID
for a different system is displayed in place of a MID
for VIMS, refer to the applicable Service Manual for
that ECM.
Note: Multiple events for a single machine condition
may occur. The monitoring system can inform the
user if the actual cause of a stored event is due to a
faulty component or a true abnormal condition.
Feature Variations
VIMS 3G is designed to operate on a variety of
different machines. All of the possible functions of
VIMS are not needed on every type of machine.
Configuration software is used in order to identify
the type of machine. The configuration software also
identifies the available functions of VIMS. The display
components and the indicators that may be available
for VIMS are listed here:
The Instrument Cluster is used in order to show
changing machine conditions. The tachometer
gauge shows the engine speed information.
Gauges display information such as the
temperatures, pressures and the fluid levels.
The screen on the instrument cluster shows the
actual transmission gear and the direction.
The screen on the instrument cluster also shows
the ground speed information ([MPH (km/h)]).
The alert indicator on the instrument cluster shows
that an event has been detected and the event is
active.
The parameter name, status and operator
instructions are information that is displayed on the
Advisor display module.
Diagnostic information is stored in VIMS 3G for all
system events and diagnostics even if the these are
not present at the time of troubleshooting. A personal
computer (PC) with VIMS 3G software is used as
the VIMS service tool. Refer to the VIMS PC Users
Manual, FEB0047 for additional information.
Note: An electronic copy of the VIMSpc Users
Procedure Manual, FEBJ0047 is included on the
VIMSpc CD-ROM.
Types of Recorded Data
The occurrence of certain events, diagnostics and
machine conditions are recorded in the VIMS 3G
onboard memory. The information is organized
into seven categories. This information is used to
analyze problems with the machine. The information
is typically used at a later date by service technicians
or management. The seven categories of information
are listed here:
Event List The event list is a record of stored
events and diagnostics that have occurred on the
machine. Not all events are stored. The record
contains the last 500 events and diagnostics that
are listed in chronological order. This means that
the events are listed in the order of occurrence. The
newest events appear at the top of the list. The event
list transfers the oldest data into the event summary
list when the event list exceeds 500 records. The
event summary list is composed of the first five
occurrences, the last five occurrences and the worst
five occurrences that are recorded for any of the
events. The event summary list is limited to storing
only 500 records. Diagnostics can be identified by
the diagnostic codes (MID, CID and FMI).
All other events are Events. The event list is
accessible from the Advisor display or with VIMSpc.
KENR9023-01
Note: All diagnostic information (MID, CID and FMI)
are the diagnostic type of events. Not all events
without diagnostic information (MID, CID and FMI)
are system events. An example of a system event
without diagnostic codes is an open wire in the circuit
for the hydraulic oil level. Remember that the circuit
of a switch (2 wire) (open switch) can report a true
condition that relates to a parameter. This same
switch (2 wire) can indicate a system failure (open
wire) but the failure is reported as low hydraulic oil
level.
Snapshot The Snapshot stores a segment of
history in real time for all parameters (channels)
at a one second interval. The snapshot relates to
a set of predefined events. A snapshot is triggered
automatically for a severe event. The snapshot is
then stored in memory. The configuration software
designates the events that are considered to be
severe events. The Trigger Snapshot menu option
in the Advisor can be used in order to initiate a
snapshot manually. A snapshot consists of flight
recorder data of all of the parameters that describe
the conditions of the system. The snapshot records
data from five minutes before the event to one
minute after the event. This strategy is also applied
to snapshots that are triggered immediately after key
ON. However, a portion of the five minutes of data
that occurred prior to the event was actually captured
prior to turning the key start switch OFF. This portion
of data may have been stored hours or days before
the event that triggered the snapshot.
The VIMS has the capability of storing two sets
of snapshot information. If a snapshot is in the
process of being recorded and a second snapshot
is triggered, the second snapshot will be recorded
simultaneously .
The snapshot information is accessible only with the
VIMSpc.
Data Logger The data logger captures all of the
parameters that are monitored by the VIMS. The
data logger is recorded in one second intervals.
The operation of the data logger is similar to the
snapshot. Unlike a snapshot, the data logger can
not be triggered by an event. However, the data
logger can be automatically started and stopped by
parameters that are designated in the configuration.
The manual triggering of the data logger can only
be done by VIMSpc or the Advisor display. The
data logger can be started and stopped with a total
recording time of 60 minutes.
The information that is recorded by the data logger is
accessible only with VIMSpc. The data logger can be
reset by VIMSpc or the Advisor display.
Note: The cycle data for the Truck payload (time and
date) can be used as basic information of data logger
in place of this data logger.
7
Systems Operation Section
Trends Trend information consists of the
minimums, maximums and averages of parameter
data over time. Trend information is viewed with
VIMSpc software. The trend information can be
displayed as a graph or as columns of data. An
example of trend information is the average brake
temperature per hour. Trend information is recorded
for predefined parameters for each machine. Trend
information is recorded under the specified guidelines
that are listed here:
All one hour continuous trends begin when the key
start switch is turned to the ON position.
The data of a trend that is collected for a periodof
less than one hour when the key start switch is
turned to the OFF position is discarded.
Trend points are the average of each trend that
was captured during the past hour. Each trend
must meet the conditions that are set for that trend.
A single trend point for the designated hour is
calculated and stored when the measured trends
are averaged over one hour.
The data point or the responsible Failure Mode
Identifier (FMI) are stored according to the guidelines
that are listed here:
1. At least one Trend condition was met.
2. Conditions not met FMI 19 is stored or the actual
FMI that was responsible for the conditions that
were not met for the entire hour is stored.
Trends are accessible only with VIMSpc.
Cumulative Cumulative information is the number
of occurrences (counts) of specific events. An
example of cumulative information is total engine
revolutions or total fuel consumption over the life of
the machine or component. Cumulative information
is recorded for a standard set of parameters. The
parameters are defined in the configuration software
for each machine. The onboard system collects life
time cumulativeswith no need to reset. The onboard
system also collects cumulatives that are resettable
via the Advisor display. The situations that will cause
an automatic resetting of the cumulatives are listed
here:
New software is flashed into the VIMS 3G memory.
A configuration is loaded with any changes to the
methods of calculating and storing cumulative data.
The change indicates that a correction has actually
been made to the configuration or the VIMS ECM
has just been installed from a different application.
The new VIMS ECM may not recognize the
methods of calculating and storing cumulative data
that is used by the configuration.
8 KENR9023-01
Systems Operation Section

Resetting the cumulatives manually is not required. i03412721

If the user desires, the cumulatives may be reset
manually. The reset process clears all of the Electronic Control Module
cumulatives. The cumulative can not be reset
individually. If a reset of the cumulatives is requested, SMCS Code: 7601; 7610
all of the cumulatives will be reset.
Characteristics of the VIMS 3G
Life time cumulatives are accessible only with
VIMSpc. Cumulatives that are resettable are Electronic Control Module (ECM)
accessible with Advisor and Cat ET.

Histograms - Histogram information records the

history of a parameter since last reset. For example,
a histogram of the engine speed would indicate the
percentage of time that the engine operated within
a defined speed limit (example 0-699, 700-1299,
1300-1699, 1700-2199, 2200 up) and the time
interval (example 25 to 475 SMH or 1/1/99 to 2/2/99)
of the data gathered. Histograms can be used to
evaluate the range of operation for a parameter.

Histograms are accessible only with VIMSpc.

Payload - Payload information is recorded for the g01770577

Illustration 2
off-highway trucks, as required.
VIMS 3G ECM
Total payload data is accessible only with VIMSpc.
Basic data is available through the Advisor display The VIMS 3G system uses two ECM. The ECM are
by accessing the Payload menu option or System called the VIMS Main ECM and the VIMS Application
Parameters under the Service menu. ECM.

The Module Identifier (MID) codes for the VIMS 3G

Related Support Material
VIMS PC Users Procedure Manual, FEBJ0047
Note: An electronic copy of the VIMSpc Users
Procedure Manual, FEBJ0047 is included on the
VIMSpc CD-ROM.
ECM are listed below:
MID 161 VIMS Main ECM
MID 162 VIMS Application ECM
VIMS 3G Persistent Random Access
Memory (RAM)
The VIMS ECM store data for the machine in
persistent RAM. Persistent RAM is backed up by a
permanent battery. Table 1 is a list of the contents of
persistent RAM for VIMS after new VIMS software is
flashed to a VIMS ECM.

The following items are stored in persistent RAM:

Date
Time
Payload calibration
All data files that can be downloaded
Active events
Logged events
Configuration parameters
KENR9023-01 9
Systems Operation Section

Machine serial number

Equipment number
Note: The active events are stored in memory when
the key start switch is turned to the OFF position.

Table 1
Contents of Persistent RAM After Flashing the VIMS ECM
Machine Information Changed By Installation of New Onboard Software(1)
Serial Number of the Machine (Product Identification Number) NO
Equipment Number of the Machine (Unit Number) NO
Machine Hours (SMH) NO
Date NO
Time NO
Payload Calibration YES
Configuration Type YES(2)
The Data Files That Are Available For Download YES
Data on events YES
Data Logger YES
Changes to the configuration that were made with the Service
YES
Program Codes.
Payload Data YES
Active Events At The Time The Key Start Switch is turned
YES
To The OFF Position.
(1) The VIMS onboard software contains the source software (flash file) and the configuration software. The Caterpillar Electronic Technician
must be used to flash this software.
(2) Installation of the new configuration software or the same configuration software clears the configuration type.

(Table 2, contd)
Operator Display
Connector Pinouts for the VIMS 3G ECM
The VIMS ECM will send information to other ECM on
No. Function Type
the machine. The input and output of this information
takes place over the data link. The outputs of the 4 RS485 TxB+ Input/Output
ECM notify the operator and the service technician of
5 RS485 TxA- Input/Output
the status of the machine systems. The information
about the machine system is collected by the 6 RS485 Shield
monitoring system. The operator can view this
7 CDL Boost Enable
information via the Advisor display, the action lamp,
or the action alarm. 8 CDL+ Input/Output
9 CDL- Input/Output
Connector Pinout for the VIMS 3G ECM
10 NC
The VIMS Main ECM and the VIMS Application ECM 11 RS232 Port 1 CTS Input/Output
have the same connector pinout.
12 RS232 Port 1 RTS Input/Output
Table 2
13 RS232 Port 1 TxD Input/Output
Connector Pinouts for the VIMS 3G ECM
14 10baseT RxD- Input/Output
No. Function Type
15 10baseT RxD+ Input/Output
1 10baseT TxD- Input/Output
16 Signal Ground
2 10baseT TxD+ Input/Output
17 RS485 RxB+ Input/Output
3 Signal Ground (continued)
(continued)
10 KENR9023-01
Systems Operation Section

(Table 2, contd) (Table 2, contd)

Connector Pinouts for the VIMS 3G ECM Connector Pinouts for the VIMS 3G ECM
No. Function Type No. Function Type
18 RS485 RxA- Input/Output 55 PWM/Freq/STG 4
19 NC 56 PWM/ Freq/ STG 5 Input
20 NC 57 PWM/ Freq/ STG 6 Input
21 RS232 Port1 DSR Input/Output 58 300 mA Sinking Driver Output
22 RS232 Port1 RxD Input/Output 59 300 mA Sinking Driver Output
23 RS232 Port1 DTR Input/Output 60 300 mA Sinking Driver Output
24 Signal Ground 61 300 mA Sinking Driver Output
25 Signal Ground 62 RS232 Port 3 TxD Input/Output
26 Signal Ground 63 RS232 Port 3 RxD Input/Output
27 RS232 Port 2 TX Input/Output 64 RS232 Port 3 Gnd
28 NC 65 -Battery
29 RS232 Port 1 RI Input/Output 66 STB 1
30 RS232 Port 1 DCD Input/Output 67 -Battery
31 RS232 Port1 Gnd 68 Sensor Supply Output
32 DeviceNet Isolated 69 Sensor Supply Return
V+
70 Key Switch
33 DeviceNet CAN High Input/Output
34 J1939 CAN Low Input/Output Data
35 RS232 Port 2 RX Input/Output
The information system uses four types of data. The
36 5 V Analog Input Input four types of data are listed here:
37 5 V Analog Input Input
Sensed Data is read from the sensors and the
38 5 V Analog Input Input switches. The sensors and the switches communicate
39 5 V Analog Input Input with the VIMS ECM.
40 DeviceNet Isolated V- Input/Output Internal The data is generated within the VIMS
41 DeviceNet CAN Low Input/Output ECM. The date and time are examples of internal
data.
42 J1939 CAN Shield
43 RS232 Port 2 Gnd Communicated The data is received through
the Cat Data Link from other machine systems. For
44 NC example, the engine speed is received through the
45 PWM/Freq/STG 1 Input data Links from the Engine ECM.
46 PWM/Freq/STG 2 Input Calculated Data mathematically determined by
47 PWM/Freq/STG 3 Input the VIMS ECM. For example, the event duration is
calculated and stored in the event list.
48 DeviceNet CAN
Shield
Data Links
49 NC
50 J1939 CAN High Input/Output The five data links for the monitoring system are
listed below:
51 NC
52 +Battery
Cat Data Link This two wire data link allows
communication between the ECM and other machine
53 +Battery control systems.
54 R-Term

(continued)
KENR9023-01
CAN Data Link This three-wire data link allows
communication between ECM for a transfer of the
parameter data.
RS-232 Data Link (Service Tool) This serial
three-wire data link allows communication between
the VIMS ECM and the service tool (laptop computer).
RS-232 Data Link (Broadcast) This serial
three-wire data link allows communication between
the VIMS ECM and other off-board systems that are
not service tools. The onboard data can be passed
from the machine when a radio telemetry system is
connected to the port.
Ethernet This four wire data link allows
communication to the VIMS modules for uploading
configurations and downloading VIMS data.
Inputs
The ECM monitor the status of the machine systems
continuously. The ECM make decisions based upon
the input from the following components:
Sensors
Switches
Other ECM
Internal calculations
Monitoring System
i03413901
Monitoring System
SMCS Code: 7601
Illustration 3
g01960034
Advisor module
The monitoring system is a state-of-the-art onboard
system with the following features:
11
Systems Operation Section
Machine systems are monitored and displayed by
the Advisor module for the operator.
The productivity information for the Payload is
measured by the system. The information is
stored by the VIMS 3G. This information can be
downloaded later for analysis.
Abnormal machine conditions and/or incorrect
operation of the machine are identified. The
diagnosis of these abnormal conditions will allow
the operator to modify the operation of the machine
in order to correct the problem. The service
technician is able to schedule maintenance for
the machine if the condition is not related to the
operation of the machine.
Prognostic information that can help predict
potential problems before failures can occur.
This allows the maintenance of the machine to
be scheduled during the preventive maintenance
servicing interval.
The components of a typical monitoring system are
listed below:
Advisor module
Electronic Control Modules (ECM)
Sensors
Payload lamps
The Advisor display provides the operator with the
following information:
Operating characteristics of the machine
Diagnostics
Service information
Warning events
Modes of operation
Payload information
Instantaneous information and lifetime totals about
the machine condition and the performance of the
machine is constantly gathered by the monitoring
system. The Advisor module will display the
information on the LCD display. The operator is able
to adjust many of the settings in order to match the
machine to the desired application. The Advisor
module is also used in order to view the operating
parameters that are selected by the operator.
12 KENR9023-01
Systems Operation Section

i03552141 The following is the recommended action that should

be taken by the operator in response to different
Warning Operation warning levels:
SMCS Code: 7601 Level 1 This warning level causes the involved
alert indicator to illuminate. A level 1 warning
indicates that the operator should be aware of a
condition of one or more of the machine systems.

Level 2 This warning level indicates that the

operation of the machine should be changed or
maintenance should be performed to the machine.
Possible damage to components on the machine
may occur.

Level 2S This warning level indicates that

g01960122
Illustration 4
Instrument cluster for the 793F
(1) Action Indicator
The action indicator (1) illuminates red for certain
types of warning that are active. The indicator
will flash red for warning level notifications. If
communication between the Advisor ECM and the
instrument cluster fails, the action indicator will flash
red.
The action alarm is driven as an output directly from
the instrument cluster. If a level 3 warning is active,
the action alarm will sound pulsing ON and OFF.
The action alarm will sound these tones in order to
alert the machine operator that immediate action is
required.
The action alarm and the alert indicator react to the
highest level warning if two warnings of a different
level are active at the same time. Table 3 indicates
the response for each warning level.
the machine needs to have an immediate, safe
emergency engine shutdown. Possible injury to the
operator or severe damage to components may
occur.
Level 3 This warning level indicates that the
machine needs to have an immediate, safe
emergency engine shutdown. Possible injury to the
operator or severe damage to components may
occur.
When multiple warnings are present in the system,
the highest level warning is shown first. Press the
up key or press the down key in order to view all of
the warnings that are logged. If no keys are pressed
within five seconds, the display will return to the
highest level warning.
When a warning message is displayed on the
Advisor display module, press the OK button
in order to acknowledge the warning. This will
remove the warning message from the display for a
predetermined duration of time.

Table 3

WARNING OPERATION
Pop Up
Warning Action Action Message of
Level Alarm Indicator the Advisor
Display
Level 1 OFF OFF OFF
Flashing
Level 2 OFF ON and ON
OFF
Flashing
Pulsing ON
Level 2S ON and ON
and OFF
OFF
Flashing
Pulsing ON
Level 3 ON and ON
and OFF
OFF
KENR9023-01 13
Systems Operation Section

Payload System
i03550840

Payload System
SMCS Code: 7494; 7601

g01912957
Illustration 5
Block diagram of the Truck Payload Measurement System (TPMS)

The TPMS with second gear weighing is a Loading time

subsystem of VIMS 3G. The TPMS performs the
following functions: Empty time
Calculate the information for the payload cycle. Loaded time
Record the information for the payload cycle. Loaded travel time
Display the information for the payload cycle. Empty travel distance
In addition to the weight of the payload, the TPMS Loaded travel distance
records the data that is listed here for each payload
cycle:

Start time of the cycle

Start date of the cycle
14
Systems Operation Section
The onboard memory can record information for
approximately 2400 payload cycles. If the register
for the payload cycle becomes full, the new data
for the payload cycle is written over the data of
the oldest cycles. The onboard payload data can
be downloaded to the service tool with VIMSpc for
further analysis. After a successful download, the
onboard payload data can be reset.
Payload weight data can also be broadcast via a
user supplied radio telemetry system. If the radio
telemetry system has been enabled, the calculated
payload weight will be broadcast under the following
conditions:
A loader pass has been detected.
The truck has been shifted into second gear and
the Second Gear Reweigh feature is enabled.
A truck has travelled with a payload for a distance
that is greater than .16 km (0.1 miles).
Information about the complete cycle is also
available to broadcast at the end of the payload
cycle after the payload is dumped.
The load cycle is displayed on the Advisor
display. The calculated payload weight is displayed
automatically during loading. Payload status lamps
provide feedback to the loader operator during the
loading operation. The payload status lamps will
indicate green until the truck is fully loaded. The
payload status lamps will indicate red when the
truck is fully loaded. During the loading process, the
Advisor will display the information that is listed in
Table 4 to the truck operator.
Table 4
Message Description
Loading Continue to load the truck.
Fully Loaded The truck is fully loaded.
An additional pass is
Last Pass required in order to fully
load the truck.
The operator can access various parameters of
payload via the Advisor menus at any time during
the load cycle.
Note: The last pass indicator works correctly in
loading applications that require at least three
passes of the loader after the truck has come to a
stop for loading. If the first loader pass is used to spot
the truck then a minimum of four loader passes are
necessary for the last pass indicator to work correctly.
KENR9023-01
g01960314
Illustration 6
External payload display (Scoreboard)
The optional external payload display (1) provides
feedback to the loader operator during the loading
operation. The external payload display provides the
loader operator with a digital readout of the payload
weight.
Whenever the physical configuration of the truck
has been changed a manual calibration must be
performed. The calibration procedure is performed
when the truck is empty. The replacement of the
suspension cylinders is an example of a condition
that would require a manual calibration.
Automatic recalibration of a truck occurs when
an empty truck has stopped. This calibration will
compensate for conditions that can affect the empty
weight of the truck. Carryback weight and fuel weight
are two variable conditions that will affect the weight
of an empty truck.
Some parameters can be modified with the service
tool in order to support a wide range of machine
configurations.
Information such as total number of loads hauled
and total weight hauled can be displayed on the
Advisor display. These totals can be reset by the
operator via the Advisor display. For example, you
can use this function to reset the totals prior to a
shift change.
Onboard Features of the TPMS
The features that are listed below are the onboard
features of the TPMS.
1. Calculate information for the payload cycle
from the recorded data. Record the calculated
information for the payload cycle. The information
for the following variables is recorded for each
payload cycle.
Time stamp The Date/time that marks the
start of the payload cycle.
KENR9023-01 15
Systems Operation Section

Payload The weight of the material that is being
moved
Loading Time The amount of time that is
required to load the truck
Stopped Empty Time The total time that is
recorded for a truck that is stopped while empty
during the payload cycle
Travelling Empty Time The total time that is
recorded for a truck that is traveling while empty
during the payload cycle
Travel Empty Distance The total distance
travelled by the truck while the truck was empty.
Stopped Loaded Time This is the time that
is recorded when a truck with a full load is not
moving during the payload cycle.
Traveling Loaded Time This is the time that is
recorded when a truck with a full load is moving
during the payload cycle.
Transmission Shifts This is the total number
of transmission shifts that were made during the
payload cycle.
Used Fuel This is the total fuel that is used
during the payload cycle.
ID of the Operator This is the identification
number of the operator that had dumped the load
for that payload cycle. The operator must enter
this number via the Advisor keypad module. This
identification number may also be used to identify
the origin of the load.
Set the maximum payload weight.
Turn on/off last pass indicators.
Turn on/off Maximum Payload Speed Manager.
Set the limits for the events for the Road
Analysis Control.
6. Display payload information on the Advisor
module as the truck is being loaded.
Payload weight
Loading status messages
7. Display loading status information with the payload
status lamps as the truck is being loaded.
Loading
Last pass
Fully loaded
External payload display
8. The following payload information is made
available to broadcast:
Loader pass count
Last pass indicator
Cycle data
9. Calculate the parameters (per payload cycle) and
then display the parameters that follow.

2. Calculate resettable totals and record resettable Payload weight

totals. The totals that follow are resettable:
Payload status
The total number of loads that were hauled
since the onboard system was reset last. Haul distance.
The total weight that was hauled since the 10. Automatically adjust for the weight of an empty
onboard system was reset last. truck as operating conditions change.

Total travel distance since the onboard system
was reset last.
Total travel time since the onboard system
was reset last.
Fuel remaining onboard.
Carryback that is in the body of the truck or
carryback that is stuck to the underside of the
machine

3. Provide a means in order to download onboard

information to the off-board system for analysis.
11. Detect incorrect suspension cylinder charge
4. Provide calibration for the system via the Advisor (collapse) and cause an appropriate event.
display.

5. Allow the operator to configure the system for

specific requirements.
16 KENR9023-01
Systems Operation Section

Off-Board Features of the TPMS The target payload is based upon the Gross Machine
Weight (GMW) of the truck. The GMW is a function
The features that are listed below are features of of the configuration for the truck. The GMW includes
VIMSpc. the weight of the tires, rims and body.

1. Provide a way to download the data that is
recorded in the onboard system.
2. Provide a way to calibrate the onboard system.
3. Provide a way to view onboard payload related
information in real time.
4. Provide a way to analyze the recorded data that is
downloaded from the onboard system:
The Payload Distribution Reports of VIMS
Supervisor will indicate overloading by an individual
truck or a fleet of trucks. An acceptable payload
distribution is one that shows that the number of
loads that exceed 110% of rated payload does not
exceed more than 10% of the total loads that were
hauled. No loads exceed 120% of rated payload.
Refer to Illustrations 7 through 10 for examples of
reports that can be created with VIMS Supervisor.

VIMSpc
VIMS Supervisor
Data may be exported to a commercial
spreadsheet of the user's choice.

i03729863

Payload Management
Guidelines
SMCS Code: 7494; 7601

The conditions that affect stress on the truck are the

combination of the following factors: payload, uneven
loading, and ground speed.

Road Analysis Control

The Road Analysis Control (RAC) is an optional
feature in VIMS 3G for the Off-Highway Truck.
The RAC samples data at a rate of ten times per
second. RAC calculates the relative severity of each
haul cycle. The RAC calculates the stress that is
present on major components of the truck as a way
of monitoring the condition of the haul roads. This
calculation indicates when repairs to the haul road
are needed. This information can be used to assess
the various design configurations of the haul road.
This information can be used to determine the design
configurations that have the least effect on the life
of the truck.

Overloading
Note: The Caterpillar 10/10/20 Payload Rule for
off-highway trucks states that no more than 10% of
the payloads may exceed 1.1 times the maximum
target payload for the truck. No single payload shall
exceed 1.2 times the maximum target payload.
KENR9023-01 17
Systems Operation Section

g01959607
Illustration 7
Fleet Truck Payload Report

g01959608
Illustration 8
Overloads by Truck
18 KENR9023-01
Systems Operation Section

g01959609
Illustration 9
Overloads by Limit

g01959610
Illustration 10
Combined Overloads
KENR9023-01
Placement Of The Payload
It is important to ensure that the weight of the
payload is distributed properly in the body of the
truck. Incorrect placement of the payload in the truck
body can adversely affect the life of many of the
components of the truck. Cat trucks are designed for
a typical weight distribution of 33% of the GMW on
the front axle and 66% of the GMW on the rear axle.
The best way to determine the actual placement
of the load is with a certified truck scale. When the
truck is loaded, ensure that the loading bucket is
positioned over the marker that is used to indicate
proper placement of the load (1). Also, ensure that
the load is centered from the side to the side in the
body of the truck.
Older trucks may be retrofitted with a marker (1) in
order to indicate the proper placement of the load.
g01959611
Illustration 11
The 175-2624 Markers are available through the machine order
system. For information on proper placement of the marker on the
truck body, contact your Caterpillar Dealer. Your Caterpillar Dealer
will need the information that is listed here: the serial number of
the truck, the part number of the truck body, the sequence number
of the truck body, and the information on any modifications that
were made to the body of the truck
(1) Marker that shows the center of the load
Payload Bias
A payload that is placed correctly in the body of
the truck will improve the accuracy of payload
measurement. The payload should be placed in
the truck body so that the GMW is distributed to
the axles correctly. This is referred to as having
the correct payload bias. The payload bias can be
determined by observing the position of the load in
the truck body. Data from the suspension cylinder
pressure is a much more accurate way to measure
the payload bias. The pressure from the suspension
cylinders is monitored by VIMS and recorded as data.
Suspension cylinder pressure can be viewed with
VIMSpc in order to verify the correct payload bias.
19
Systems Operation Section
Typically, most of the problems that occur with the
payload are the result of improper positioning of truck
under the loading tool. Payloads that are not biased
correctly have the potential for causing an event to
be recorded in the RAC. Hauling payloads that are
biased incorrectly may reduce the service life of the
truck.
The Loading Floor
g01960347
Illustration 12
The area in which the truck is loaded is referred to as
the loading floor. The loading floor should be kept as
level as possible. A loading floor that does not allow
the truck to sit level during loading will affect the
accuracy of the measurement of the payload .
i03729922
Measurement Accuracy
SMCS Code: 7494; 7601
Payload Weight Measurement
Certain conditions could affect the accuracy of the
Truck Payload Measurement System (TPMS) when
the truck is loaded. Some of these conditions are
listed here:
A truck is loaded on a sloped surface that is greater
than 5%. Accuracy will become progressively
worse as the slope becomes greater.
A suspension cylinder is not properly charged. The
suspension cylinders may not cause an event even
if the charge is incorrect. However, the weighing
accuracy will be affected.
Note: Refer to Special Instruction, SEHS9411,
Suspension Cylinder Servicing for information on
servicing the suspension cylinders.
Pushing down on the load with the loading tool
during the loading process (packing the load)
Actuating the body raise lever during loading
20 KENR9023-01
Systems Operation Section

A failure to have the TPMS calibrated after
replacing components in the TPMS.
A failure to have the TPMS calibrated after any
substantial changes to the empty weight of the
truck. This does not include refueling.
Using a conveyor or a continuous feed system for
loading
Failures that are detected by VIMS may cause
the payload weight to become inaccurate. These
diagnostic events will be shown in the VIMS event
list.
The incorrect VIMS onboard software is installed.
The load is placed in the body, too far from the
center of the marker.
2. PAYLOAD WEIGHTS APPEAR TO BE
The payload configuration is set incorrectly.
Expected Result: No active diagnostic codes
are present for any of the suspension cylinder
pressure sensors.
Result:
YES - The VIMS does not indicate that a
diagnostic code is present for one or more of the
suspension cylinder pressure sensors. Proceed
to test step 2.
NO - Diagnostic codes are present for
one or more of the suspension cylinder
pressure sensors. Perform the procedure for
troubleshooting the diagnostic code. Refer to
the Troubleshooting section of this manual for
the troubleshooting procedure for the code.
STOP.
INCORRECT OCCASIONALLY.

Note: The accuracy of the TPMS is not affected a. Verify that Some of the payload measurements
if the first load is placed into the truck before the appear to be correct.
truck has stopped completely. The truck can also be
repositioned during loading. The loading phase of Expected Result: Some of the payload
the payload cycle is completed after the truck shifts measurements seem correct.
into second gear.
Result:
Reweighing in Second Gear
YES - Some of the payload measurements
There are some conditions that could affect the appear to be correct. Proceed to test step 3.
accuracy of the TPMS during the Re-Weigh process.
The conditions are listed below: NO - All payload measurements appear to
be incorrect. Proceed to test step 6.
The haul road is in need of repair. This may be 3. CHECK THE SETTINGS OF THE PAYLOAD
indicated by a Fatigue Equivalent Load Analysis
(FELA) value from the Road Analysis Control CONFIGURATION.
(RAC) of 1600 or greater.
Check the payload configuration setting by
entering the service program via the Advisor
Troubleshoot the TPMS menu. This will display the maximum payload
weight of the truck. Verify that the payload weight
NOTICE is correct for the truck.
Prior to performing this procedure use VIMSpc to ver-
ify that the Event List is free of diagnostic events that Table 5
could affect the payload measurements. Some ex- Maximum Target Weight of the Payload by Model
amples of Events that could affect the payload mea-
Model Payload Weight
surements are listed here: the body up switch, the
transmission control, the body raise switch, incorrect- Metric Tonnes Short Tons (US)
ly charged suspension cylinders, and any other event (mt)
that is payload related.
793F 218 240

1. PAYLOAD WEIGHT DOES NOT SEEM 797F 363 400

CORRECT FOR A GIVEN TRUCK.

The VIMS does not indicate that a diagnostic Expected Result: The payload configuration is
code is present for one or more of the suspension correct.
cylinder pressure sensors.
Result:
KENR9023-01
YES - The payload configuration is correct.
Proceed to test step 4.
NO - The payload configuration is incorrect.
Perform the procedure for configuring the
payload. The procedure is located in Systems
Operation, KENR9023, Truck Payload -
Configure. STOP.
4. CHECK THE PART NUMBER OF THE VIMS
ONBOARD SOFTWARE.
Verify that the correct VIMS onboard software
is installed in the VIMS ECM. Contact your
Caterpillar dealer for a list of compatible VIMS
software or reference the Service Magazine article
that listed the part numbers of the available VIMS
onboard software.
Expected Result: The correct software is installed
on the machine.
Result:
YES - The correct software is installed on the
machine. Proceed to test step 5.
NO - The software is incorrect. Install the correct
VIMS onboard software. Then perform the
Payload Calibration. The calibration procedure
for the payload is located in the manual Systems
Operation, KENR9023, Payload System -
Calibrate. STOP.
5. CHECK FOR DIAGNOSTIC EVENTS
Verify that no active diagnostic events or
intermittently active diagnostic events are
present for the suspension cylinder pressure
sensors or other components of the payload
system.
Expected Result: No active diagnostic events
are present for the suspension cylinder pressure
sensors. No diagnostic events are present in
the event list for any of the suspension cylinder
pressure sensors. There are no diagnostic events
for the drivetrain control system for the drivetrain
in the event list that are associated with the
TPMS. The related parameters for the drivetrain
are body up and body raise.
Result:
YES - No active diagnostic events are present
for any of the suspension cylinder pressure
sensors or the drivetrain control system. No
diagnostic events are listed in the event list for
any of the suspension cylinder pressure sensors
or the drivetrain control system. Proceed to test
step 7.
21
Systems Operation Section
NO - Active diagnostic events are present
for any of the suspension cylinder pressure
sensors or diagnostic events are listed in the
event list for any of the suspension cylinder
pressure sensors. Perform the procedures that
are located in the Troubleshooting section of
this manual. STOP.
6. CHECK FOR SERVICE WORK THAT MAY HAVE
AN EFFECT ON THE MEASUREMENT OF THE
PAYLOAD
Check the maintenance records of the suspect
truck for any work that was performed on the
suspension cylinders or any of the VIMS/TPMS
components that are associated with the TPMS.
This includes alterations of the truck body,
replacement of the body raise switch, replacement
of the truck body or replacement of any other
component that is related to the TPMS.
Expected Result: No work that is related to the
payload system was performed on the machine.
Result:
YES - No work that is related to the payload
system was performed on the machine. Proceed
to test step 9.
NO - Work was performed on the truck that is
related to the payload system. If the TPMS was
not calibrated after performing the replacement
of the components, proceed to Test Step 10.
The accuracy of the TPMS may have been
affected by the service work. Perform an
analysis in order to determine if the accuracy
has been affected.
7. CALIBRATE THE PAYLOAD SYSTEM.
a. Ensure that the truck body is empty. Carryback
weight of the material that is stuck in the truck
body can affect the payload measurements.
b. Operate the empty truck to a minimum ground
speed of 4 MPH on hard level ground.
c. Move the shift control lever to the neutral
position and allow the truck to coast to a stop.
Do NOT use the service brakes or the retarder.
d. After the truck stops moving, manually calibrate
the payload system. The Advisor display will
show a Calibration Complete message if the
calibration was successful.
Expected Result: The payload weights for a
given truck seem correct after performing the
calibration of the payload system.
Result:
22
Systems Operation Section
YES - The payload weights for a given truck
seem correct after performing the calibration
of the payload system. The condition that
was responsible for the incorrect payload
measurement has been eliminated. Return
the truck to service. STOP.
NO - The payload weights for a given
truck remain incorrect after performing the
calibration of the payload system. Perform
the calibration procedure again. If the weight
of the payload is incorrect after performing
the recalibration of the TPMS, proceed to
Test Step 8.
8. CHECK FOR THE CORRECT PLACEMENT OF
THE LOAD
g01959611
Illustration 13
The 175-2624 Position Load Markers are available from your
Caterpillar dealer. For information on proper placement of
the marker on the body, contact your Caterpillar dealer. Your
Caterpillar dealer will need the information that is listed here: the
serial number of the truck, the part number of the truck body,
the sequence number of the truck body , and information on
modifications that have been made to the body of the truck
(1) Load Position Marker
a. Observe the loading operation. Ensure that the
operator of loading tool is placing the load in
the truck body in the proper area. Verify that
the ratio of the suspension cylinder pressure
sensors of the loaded truck are 33% for the
front and 67% for the rear.
Expected Result: The operator is loading the
truck correctly. Refer to Illustration 13. The ratio
of the suspension cylinder pressure sensors
of the loaded truck are 33% for the front and
67% for the rear.
Result:
YES - The operator of the loading tool is
positioning the load correctly and the ratio of
the suspension cylinder pressure sensors of
the loaded truck are 33% for the front and
67% for the rear. Proceed to test step 6.
KENR9023-01
NO - The operator of the loading tool is not
positioning the load correctly in the body.
Provide the operator of the loading tool with
training or supervision in order to ensure that
the load will be placed properly. STOP.
9. CHECK THE SUSPENSION CYLINDERS.
Verify that the conditions that are listed below are
not present.
The suspension cylinders are not topping out.
The suspension cylinders are not bottoming out
when the truck is loaded.
Expected Result: The conditions that are listed
above are NOT present.
Result:
YES - The conditions that are listed above are
not present. It is possible that the cause of this
failure may be a failed sensor. Perform the
procedures that follow:
The service technician can ride in the truck
during the loading operation. During the loading
operation, observe the operation of all four of the
suspension cylinder pressure sensors. This is
done with the VIMSpc View Real Time option.
The service technician can activate a data logger.
Compare the signal outputs of the four sensors.
Verify that the suspect sensor or the suspect
suspension cylinder do not respond to the loading
of truck in the same manner as the other sensors
or the other suspension cylinders.
STOP.
NO - The conditions that are listed above are
present. It is likely that the cause of the failure
is related to an incorrectly charged suspension
cylinder. The service technician can verify the
presence of any of the conditions that are listed
above by any of the means that are listed below:
Service the suspension cylinders in accordance
with the following instructions:
Special Instruction, SEHS9411-01, Charging
Procedure for Front and Rear Suspension
Cylinders
10. STOP
KENR9023-01 23
Systems Operation Section

Time Measurements The Caterpillar 10/10/20 overload policy states: No

The smallest increment of the real time clock
measurements are 1 second. The recorded times
and dates of the real time clock will aid in identifying
the causes of any unusual cycle data.
Distance Measurements
The accuracy of the distance measurement will
depend on the actual effective rolling radius of the
tires. The TPMS does not distinguish between tires
of different sizes, manufacturers or tread depth. The
distance measurements of the TPMS are calculated
with the average size of the tire for each truck model.
Distance measurements are recorded to the nearest
0.16 km (0.1 miles).
more than 10% of the payloads may exceed 110% of
the target payload of the truck and no single payload
shall exceed 120% of the target payload of the truck.
The Maximum Payload Speed Manager compares
the actual payload weight on the truck to an overload
limit for the truck model. The weight of the payload
is determined as the truck shifts to second gear. If
the weight of the payload is greater than 120% of
the target payload the speed of the truck is reduced.
The speed of the truck is reduced through limiting
the shift range of the transmission and limiting RPM
of the engine.

i03730432

Maximum Payload Speed

Manager
SMCS Code: 7494; 7601

The Maximum Payload Speed Manager manages the

speed of the truck for the payload weight and payload
bias. When the weight of the payload exceeds the
target payload, the brakes and the steering of the
truck are at the maximum limit of performance.
Reducing the speed of an overloaded truck will help
protect the operator and the truck from damage.

Operation of the Maximum Payload

Speed Manager

g01960625
Illustration 14
10/10/20 overload policy
24
Systems Operation Section
Maximum Payload Speed Manager
Actions
Table 6
Overload Conditions and Maximum Payload
Speed Manager Actions
Condition
The weight of the payload
is within the specified limit
for the target payload.
The weight of the payload
is greater than the weight
of the target payload but
less than overload limit.
The weight of the payload
is greater than the overload
limit.
Action
No action is taken. The
truck will continue normal
operation.
An overload event is
recorded for the truck.
An overload event is
broadcast via a radio
telemetry system.
The Advisor displays a
message to the operator.
The message warns the
operator that the truck
is overloaded and the
operator is instructed to
proceed carefully.
An event for the overload
is recorded.
An event for the overload
is broadcast via a radio
telemetry system.
The Advisor displays
a warning message to
the operator in order to
indicate that the truck is
overloaded.
A category 2-S warning will
sound if the operator
proceeds without
correcting the overload
condition.
The Advisor displays
a warning message to
the operator in order to
indicate that the speed of
the truck has been limited.
The Advisor instructs the
operator to resolve the
overload condition.
The shift range of the
transmission is limited.
High idle of the engine is
limited.
The point for automatic
retarding is reduced.
KENR9023-01
The Maximum Payload Speed Manager will activate
the overload events when the weight of the payload
exceeds the overload limit regardless of the location
of the truck. The speed of the truck is limited when
the weight of the payload exceeds the overload limit
regardless of the location of the truck. The speed of
the truck is limited until the payload is dumped and
the weight of the payload is cleared. The speed of
the truck will return to normal at the beginning of the
next payload cycle.
The weight of the payload is calculated as the truck
is shifted into second gear. This is the Second Gear
Weighing. The new weight of the payload that is
determined during the Second Gear Weighing is then
used to determine if limiting the speed of the truck is
necessary.
Once the Maximum Payload Speed Manager has
determined that the truck is overload, the following
actions are initiated:
The shift range of the transmission is limited to
second gear.
High idle of the engine is limited to 1750 rpm.
The point for automatic retarding is reduced to
1750 rpm.
Note: The settings for limited performance are not
adjustable.
Example of the Operation of the Maximum
Payload Speed Manager
The Project Manager for a mine has determined that
a 20% overload for a 793F truck would be the correct
limit for the operating conditions at the mine. The
793F has a target payload of 240 tons. The Project
Manager would set the parameters of Maximum
Payload Speed Manager to the values that are listed
below:
Target Payload Setting 240 tons
Payload Overload Limit Setting 120%
With these settings, the Maximum Payload Speed
Manager will function in the manner that is listed
below:
The payload loading lamps will display a signal to
load through 240 tons.
The overload warnings will occur above 264 tons.
The engine speed will be limited to 1750 rpm in
second gear above 288 tons.
KENR9023-01 25
Systems Operation Section

Configuring the Maximum Payload
Speed Manager
The Maximum Payload Speed Manager requires the
user to input weight information for the payload that
is specific to the model of the truck. This information
is used to trigger the events that are listed below:
Overload speed limiting
Overload events
Overload warnings
a. Connect the 317-7487 Cable As between the
317-7485 Communication Adapter and the
Cat ET service tool.
b. Connect the 327-8981 Cable As between the
317-7485 Communication Adapter and the
diagnostic connector on the truck.
c. Turn the service tool ON and open the Cat ET.
d. Turn the disconnect switch and the key start
switch to the ON position.

Target Payload
The target payload is the correct payload weight for
the truck model. The target setting for the weight of
the payload determines the correct operation for the
payload monitoring systems of the truck. The setting
for the target payload is adjustable from zero to the
target weight of the truck. The target weight is 100%
of the weight of payload that is calculated from the
Gross Vehicle Weight of the truck. The setting for the
target payload is recorded in the onboard memory
of the VIMS Application ECM. The target payload
setting can be input via the Advisor or Caterpillar ET.

The service operation of Payload Configuration

is used to set this value. Refer to the Systems
Operation, KENR9023, Payload System - Configure
section in this manual for instruction on entering this
information into the system.

Setting the Payload Overload Limit

The overload limit is the percentage of overload that
is accepted before the Advisor will display a warning
message to the operator. The Maximum Payload
Speed Manager will also limit the speed of the truck,
if the weight of the payload weight is too high. The
overload limit for the payload is adjustable from
105% to 120% in increments of 1%. The setting for
the overload limit is recorded in the onboard memory
of the VIMS Application ECM. The default setting
of the overload limit is 0%. The system is disabled
when the overload limit is set to 0%. The setting
for the overload limit is located in the Settings
menu on the Advisor. Refer to Systems Operation,
KENR9023, Payload System - Configure in this
manual for instruction in order to enter the overload
setting information.

Setting the Payload Overload Limit with Cat ET

This procedure will allow the value for the Target

Payload Weight to be entered with Cat ET.

1. Use the procedure that is listed below in order

to enter the desired values for the payload with
Cat ET.
26 KENR9023-01
Systems Operation Section

g01960655
Illustration 15

e. Click on the Connect icon (1) in the tool

bar of Cat ET. This connection establishes
communication between the truck and Cat
ET. The icon for the connection is shown in
Illustration 15.

g01962193
Illustration 16

f. Select VIMS Application from the ECM

Selector dialog box and click on the OK
button. This is shown in Illustration 16. This will
display the ECM Summary screen.

g. Select the Service menu.

h. Select Configuration from the Service menu.

This will display the Configuration screen.

g01962234
Illustration 17

i. Double click on the desired parameter. Double
clicking will display the Change Parameter
Value dialog box.
j. Enter the new value of the parameter into
the New Value dialog box. Then click on the
OK button. Cat ET will prompt the user with
a confirmation message. The confirmation
message is displayed in order to confirm the
desired parameter. Click the Yes button in
order to accept the change.

Note: Repeat this procedure for both Maximum

Payload Speed Manager Parameters.

g01962253
Illustration 18
KENR9023-01 27
Systems Operation Section

i03550985 Display
Payload Memory Capacity
i03414022
SMCS Code: 7494; 7601
Display Modules
The Truck Payload Measurement System (TPMS)
has a block of memory that is allocated for recording SMCS Code: 7490; 7601
payload data. The capacity of the memory is
approximately 2400 payload cycles. This data needs
to be downloaded when the memory is full in order
Advisor Display Module
to prevent the data from being overwritten. Old data
is overwritten when the payload memory reaches
the maximum limit. The system continues to collect
the new data but the old data is lost in the process.
The payload data will always contain the most recent
operations.

Payload Memory Low

Event code 2083(1) Payload Memory Low occurs
when the payload memory becomes too low. The
memory should be downloaded and reset.

Payload Memory Full Message Illustration 20

g01921573

(1) Preset Buttons

(2) Left and Up Arrow Button
(3) Right and Down Arrow Button
(4) Back Arrow Button
(5) Home Button
(6) OK Button
(7) LCD Display
(8) Arrow that indicates more options

The Advisor display module is located on the right

side of the dash panel. The Advisor display module
interfaces with the electronic system. The Advisor
also controls the instrument cluster.

Five buttons on the right side of the Advisor display

g01960750
Illustration 19
Payload Memory Full on the Advisor
Event code 2083(2) Payload Memory Full occurs
when the payload memory is full. The operator will
receive a message on the Advisor that is shown in
Illustration 19. The memory should be downloaded
and reset. New payload data will overwrite old
payload data after this event occurs.
module are the user interface. The buttons are
used in order to navigate through the menus on the
Advisor. The following information will explain the
function of each button:
Presets (1) The five buttons on the left side of the
Advisor function as presets. Once a button is set as
a preset, the operator can navigate to any screen.
Then, the operator can press the preset in order to
return to the desired screen.

Left and Up (2) This button is used for the following

purposes: navigation button, data information, and a
decrease in a setting value.

Right and Down (3) This button is used for

the following purposes: navigation button, data
information, and a increase in a setting value.

Back Button (4) This button is used in order to

return to the previous screen.
28 KENR9023-01
Systems Operation Section

Home Button (5) This button is used in order to

return to the Home Menu from any screen.

OK Button (6) This button is used to make

selections on the screen. Also, use this button in
order to confirm a password entry or use the button
to save an operator profile.

Display (7) This display area shows the numerous

menus and submenus in order to navigate from
one screen to another screen. Also, this display
area depends on the menu or the submenu that
is selected in order to show the information in the
system, system status, and operator warnings.
More Options (8) Additional information is
available on the subject that is highlighted on the
display screen. Use the appropriate arrow button in
order to view the information.
Use the arrow buttons to highlight the desired
selection in order to navigate through the menus and
submenus. Then press the OK button. Also, use
the arrow buttons in order to highlight a mode or
parameter setting. Then, press the OK button in
order to select that option.
i03417942
g01949999
Illustration 22
The Monitor Parameter Screen 1 screen
The Monitor menu option allows the user to view
four parameters. Use the navigation buttons in order
to select the parameter. Also, use the navigation
buttons to view a different parameter. Press the OK
button in order to attain a list of available parameters.
Refer to Systems Operation, KENR9023, Menu
Contents in this manual in order to view the complete
list of available parameters. The list of parameters is
under the Monitor heading.

Monitor Menu
SMCS Code: 7490; 7601

g01954519
Illustration 21
Select Monitor from the menu.

The Monitor menu option is entered by selecting

Monitor from the Home menu. The Home menu
can be displayed from any screen by pressing the
Home button. Press the up button or the down button
until the Monitor is highlighted in order to select the
menu. Then, press the OK button in order to select
the Monitor menu.
KENR9023-01 29
Systems Operation Section

i03417955

Operator Menu
SMCS Code: 7490; 7601

g01959149
Illustration 24
Select Operator.

The profile of the operator is entered by selecting

Operator from the Home menu. Press the up arrow
button or the down arrow button until Operator is
highlighted. Then press the OK button. Refer to
Illustration 24.

Note: The Home menu can be displayed from any

screen by pressing the Home button.

The following screen will now be displayed.

g01959147
Illustration 23
The selection menu for the operator

The Operator menu allows the user to perform the Illustration 25

g01959154
following:
The Operator screen

Select a profile. The Operator menu contains the following options:

Create a profile. Select Profile
Delete a profile. Edit/Save Current
Edit a current profile. Create Profile
Save a current profile. Delete Profile
The profile of an operator is a saved set of
preferences that is identified by a name. Once the Factory Set
profile is created, the operator may associate various
To access the Operator menu option, press the
display settings and settings for the power train to
up arrow button or the down arrow button until the
that profile. After all of the parameters have been
desired category is highlighted. Then press the OK
adjusted to the preference of the operator, you may
button. The following explains the usage of each
then save the parameters for future usage.
menu option.
30 KENR9023-01
Systems Operation Section

Select a Profile This procedure recalls the default settings. The

From the Operator menu, use the appropriate arrow
button to highlight the Select Profile option. Then
press the OK button in order to display a list of
existing profiles. Again, use the appropriate arrow
button to highlight the desired profile. Then press the
OK button in order to select that profile.
Note: A maximum of 10 profiles may be used.
default settings are then the active settings and the
Advisor display and the instrument cluster will reflect
the default settings. Once the default settings have
been activated, the settings may be viewed without
saving using the Edit/Save Current option.
The default settings will not be saved with the current
profile unless the operator saves the default settings
to a profile by using the Edit/Save Current option.

Create a Profile i03417961

From the Operator menu, use the appropriate arrow Payload Menu
button to highlight the Create Profile option. Then
press the OK button in order to display the Create SMCS Code: 7490; 7601
Profile screen. Follow the screens in order to create
a new name. The screen will give directions in order
to save the name to the list of profiles. This procedure
creates a profile. The Settings menu can then be
used to adjust parameters. These parameters may
then be saved to the new profile that is using the
Edit/Save Current option.

Note: A maximum of 10 profiles may be used.

Delete a Profile
From the Operator menu, use the appropriate arrow
button to highlight the Delete Profile option. Then
press the OK button in order to display a list of Illustration 26
g01959173
existing profiles. Use the appropriate arrow button to
Select Payload on the menu.
highlight the profile for deleting. Then press the OK
button in order to delete that profile. This procedure
The Payload menu option is entered by selecting
deletes the selected profile from the list of stored
Payload from the Home menu. Press the up button
profiles.
or the down button until the Payload is highlighted
in order to select the menu. Then, press the OK
Edit/Save Current button in order to select the Payload menu.

From the Operator menu, use the appropriate arrow The following screen will now be displayed.
button to highlight the Edit/Save Current option.
Then, press the OK button in order to view the
settings that are associated with the current profile.

This procedure will cause the current settings of the

selected profile to be displayed on the screen. The
settings that are displayed are the current settings.

The operator may exit this display without saving by

pressing the back button. The operator may save
the settings to memory by selecting SAVE and
then pressing the OK button. The settings will not
change unless you successfully save the settings.

Factory Set Illustration 27

g01959175

From the Operator menu, use the appropriate arrow The Payload screen
button to highlight the Factory Set option. Then
press the OK button in order to make the default
settings active.
KENR9023-01 31
Systems Operation Section

The Payload menu option allows the operator to

view the information for the payload in the form of an
analog gauge. The operator can view the menu in
order to monitor the loading of the payload.

Note: The Home menu can be displayed from any

screen by pressing the Home button.

i03417981

Settings Menu
SMCS Code: 7490; 7601

g01960888
Illustration 28
Settings menu
32
Systems Operation Section
The Settings menu allows the user to view and to
adjust parameters for the following:
Display Setup
Brake
Chassis
Machine
Transmission
VIMS
Operating conditions, preferences of the operator,
and requirements for operating efficiency determine
the need to adjust the parameters. Parameters that
are displayed are determined by the configuration
and the options on the machine. The options on
the machine can determine the software versions
that are contained in the Electronic Control Modules
(ECM). The Advisor menu display may change
according to the software versions that are used for
the ECM on the machine.
Note: Caterpillar Electronic Technician (Cat ET) may
also be used in order to change settings.
g01959183
Illustration 29
Select Settings from the screen.
The Settings menu option is entered by selecting
Settings from the Home menu. Press the up arrow
button or the down arrow button until Settings is
highlighted in order to select the Settings menu.
Then press the OK button. Refer to Illustration 29.
Note: The Home menu can be displayed from any
screen by pressing the Home button.
The following screen will now be displayed.
KENR9023-01
g01959423
Illustration 30
The Settings screen
The Settings menu organizes the parameters into
six categories. These categories have adjustable
parameters. The menu options are displayed on
the left half of the screen, and the information is
displayed on the right half of the screen.
In order to make adjustments to the associated
parameters, the Advisor must be placed in the
Service mode. Refer to the Systems Operation,
KENR9023, Service Mode section of this manual
for more information. Press the up arrow button or
the down arrow button until the desired parameter
is highlighted. Then press the OK button in order
to access the parameter. Follow the instructions
on the screen in order to make adjustments to the
parameter.
Display Setup
From the Display Setup menu, use the appropriate
up arrow button or the down arrow button in order to
highlight the desired parameter. Then press the OK
button. This will allow access to that parameter's
screen. Then follow the instructions on the screen in
order to adjust the parameter. All of the parameters in
this category relate to the preferences of the operator
in regard to the Advisor display. The following
parameters may be adjusted:
Language
Units
Contrast
Lights ON
Lights OFF
Date Format
Time Format
KENR9023-01 33
Systems Operation Section

Brake VIMS
From the Brake menu, press the OK button From the VIMS menu, use the appropriate up
in order to view the desired information. This will arrow button or the down arrow button to view the
allow access to that screen. All of the information in desired information. Then press the OK button.
this category relates to the retarder. The following This will allow access to that screen. The VIMS
information may be viewed: menu contains the VIMS Payload and the VIMS
Conditional Logger menu. The following information
Desired Engine Retard Speed may be viewed:

Chassis VIMS Payload

From the Chassis menu, use the appropriate up Payload Target Weight
arrow button or the down arrow button to view the
desired information. Then press the OK button. Payload Ovrld Limit
This will allow access to that screen. The following
information may be viewed: Payload Last Pass Status

Autolube Interval Set VIMS Conditional Logger

Body Up Gear Limit Conditional Logger

Machine
From the Machine menu, use the appropriate up
arrow button or the down arrow button in order to
highlight the desired parameter. Then press the OK
button. This will allow access to that screen. The
following information may be viewed:

Product ID
Equipment ID

Transmission
From the Transmission menu, use the appropriate
up arrow button or the down arrow button to view
the desired information. Then press the OK button.
This will allow access to that screen. The following
information may be viewed:

Top Gear Limit

Machine Overload Speed Limit
Machine Loaded Speed Limit
Machine Ovrld Speed Limit
Machine Speed Limit
Fuel Economy Mode
34 KENR9023-01
Systems Operation Section

i03418103

Service Menu
SMCS Code: 7490; 7601

g01369412
Illustration 31
KENR9023-01 35
Systems Operation Section

The Service menu option is entered by selecting Diagnostics

Service from the Home Menu. Press the up arrow
button or the down arrow button until Service is From the Service menu, use the appropriate
highlighted in order to select the Service menu. arrow button to highlight the Diagnostics option.
Then press the OK button. Refer to Illustration 32. Then press the OK button in order to access the
Diagnostics option. The Diagnostics option will
Note: The Home Menu can be displayed from any display the following:
screen by pressing the Home button.
Active Events
Logged Events
Trigger Snapshot
Data Logger Start
Data Logger Reset

Active Events
The Active Events menu option shows the control
module and the service hours for each event. Press
g01959581 the OK button in order to view the information for
Illustration 32
the active event. The following is a list of information
Select the Service menu. that is displayed for the active event:

The following screen will now be displayed. Electronic Control Module

Event Code
Date of occurrence
Time of occurrence
Warning Level
Number of occurrences

Logged Events
The Logged Events menu option shows the list
g01959583 of events and diagnostic codes that have been
Illustration 33
recorded. Press the OK button in order to view the
The Service menu information of the event or code. Use the left arrow
button or the right arrow button in order to move to
The Service menu contains seven categories. The the next logged event or the next code.
following is a list of the available options:

Diagnostics Trigger Snapshot

The Trigger Snapshot menu option allows the user
Calibrations to manually initiate a snapshot of the system. This
snapshot will be in addition to the snapshots that
System Information are already programmed. The snapshot will remain
active until the time has elapsed.
Tattletale
System Tests
Service Parameters
The following explains the usage of each menu
option.
36
Systems Operation Section
Data Logger Start
The Data Logger Start menu option allows the user
to initiate the data logger. If the information for the
data logger is being downloaded from the machine,
the data logger can not be started. The operator
can initiate the data logger. Then, the operator can
stop the data logger. This action can be performed
numerous times until the total time for logging the
data is thirty minutes. The status of the data logger
is shown in the right portion of the screen on the
Advisor. The menu item Data Logger Stop will
change back to Data Logger Start when the data
logger is no longer recording data. The menu items
do not change when the service tool starts the data
logger. The remaining storage time of the data
logger is shown on the message area when the user
highlights the Data Logger Reset menu item on the
Advisor display. The format of the time is shown in
minutes:seconds.
Data Logger Reset
The Data Logger Reset menu option allows the
user to reset the data logger. This option clears all
of the logged information. Select the Data Logger
Reset menu item. The Advisor shows the time that
is available for the data logger on the right side of
the screen. Thirty minutes will be available after the
data logger has been reset.
Note: The Data Logger is the only onboard file that
can be reset through the Advisor display. The Advisor
must be in the Service Mode or the Caterpillar
Electronic Technician (ET) must be connected to the
data link in order to reset the data logger. Also, this
is true in order to perform other service functions.
The VIMSpc software is not needed in order to reset
the data logger.
Calibrations
The Calibrations menu option is displayed under
the Service menu. Once the Calibrations option
is displayed on the Service menu the user can
access this function by pressing the OK button. The
Calibrations option will allow calibrations.
From the Service menu, use the appropriate
arrow button to highlight the Calibrations option.
Then press the OK button in order to access the
Calibrations option. The Calibrations option
will divide all calibrations into two categories. The
following is a list of available options:
Truck Payload
Inclinometer
KENR9023-01
Use the appropriate arrow button to highlight the
desired calibration from the list. Then press the OK
button. Follow the directions that are displayed on
the screen in order to perform the calibration.
Note: Using Advisor to calibrate components is
similar to using theCaterpillar Electronic Technician
(Cat ET).
System Information
The System Information menu option allows the
user to view the information for the electronic control
modules that are a part of the machine. When the
System Information menu is selected a submenu is
displayed. The submenu displays the modules.
From the Service menu, use the appropriate arrow
button to highlight the System Information option.
Then press the OK button in order to access the
menu. The following is a list of the electronic control
modules:
Advisor
Engine
Chassis
Brake
VIMS
Use the appropriate up arrow button or the down
arrow button in order to highlight the desired ECM.
Then, press the OK button in order to access the
information for the ECM. This information contains
the following:
Serial number of the ECM
Part number of the software
Release date of the software
Description of the software
Tattletale
From the Service menu, use the appropriate arrow
button to highlight the Tattle Tale option. Then,
press the OK button in order to access the Tattle
Tale option. The following options are available
under the tattletale:
Active
Brake Oil Temperature
Engine Coolant Temperature
Engine Speed
KENR9023-01 37
Systems Operation Section

Torque Converter Temperature VIMS

Fuel Level
Any option from the prior list can be selected. The
Active option will display the tattletale value for
each gauge. The five specific options will display that
tattletale value for the gauge that is specified.
Note: The tattletale is password protected. The value
for each gauge is protected from being cleared.
System Tests
From the Service menu, use the appropriate arrow
button to highlight the System Tests option. Then,
press the OK button in order to access the System
Tests option. The option will display the following
tests:
Stall Diagnostic Test
Self Test
Note: Make sure that the wheels are properly blocked
before the test is initiated.
See the Testing and Adjusting, Self Test section of
this manual for more information on the self test.
Service Parameters
From the Service menu, use the appropriate arrow
button to highlight the Service Parameters option.
Then, press the OK button in order to access the
Service Parameters option. The following options
will be displayed:
Sort By Type
The Sort By Type menu option allows the user to
view the parameters that are associated with different
components. Use the appropriate up arrow button
or the down arrow button in order to highlight the
Sort By Type option. Then, press the OK button.
A list of the types of parameters is displayed. Use
the up arrow button and the down arrow button and
then press the OK button in order to select the
desired type. The following types of parameters can
be chosen:
Temperatures
Pressures
Speeds
Filter Switches
Operator Inputs
Sensor Duty Cycles
Totals
All Parameters
The All Parameters menu option allows the user to
view the entire list of parameters. Use the appropriate
up arrow button or the down arrow button in order
to highlight the All Parameters option. Then, press
the OK button. The entire list of parameters is
displayed.

Sort By ECM i03418282

Sort By Type Service Mode Menu

All parameters SMCS Code: 7490; 7601

Sort By ECM
The Sort By ECM menu option allows the user to
view the parameters that are associated with each
ECM. Use the appropriate up arrow button or the
down arrow button in order to highlight the Sort By
ECM option. Then, press the OK button. All of
the parameters for the specific ECM are listed. The
following electronic control modules can be chosen:

Advisor
Engine
g01959421
Illustration 34
Chassis
Select Service Mode.
Brake
38 KENR9023-01
Systems Operation Section

The Service mode menu is used in order to enable or

disable the ability to alter parameters for the machine.
The Service mode is password protected. The
Service Mode menu option is entered by selecting
Service Mode from the Home menu. Press the up
button or the down button until the Service Mode is
highlighted in order to select the menu. Then, press
the OK button in order to select the Service Mode
menu. .

Note: The Home menu can be displayed from any

screen by pressing the Home button

g01959455
Illustration 35
The Service Mode screen

The password entry screen will appear if the

password has been entered in Caterpillar Electronic
Technician (Cat ET). The Advisor will enter the
service mode after the password has been entered
correctly.

A service tool must be used to program the password

into the display. The password cannot be changed
within the Advisor.

Configuration of the Password in

Cat ET
1. Connect Cat ET to the machine. Select the
Monitor Electronic Control Module (ECM).
KENR9023-01 39
Systems Operation Section

g01959465
Illustration 36
A typical Configuration screen is shown.

2. Select Configuration from the Service menu.

g01959468
Illustration 37
A typical Configuration screen is shown.
40 KENR9023-01
Systems Operation Section

3. Select Service Mode Enable Code and click the

Change button. A screen will appear for entering
a password.

g01959469
Illustration 38
A typical Change Parameter Value screen is shown.

4. Enter a password.

g01959471
Illustration 39
A typical Configuration screen is shown.

5. The password is shown in Cat ET.

KENR9023-01
Software
i03550863
Service Tool Software
SMCS Code: 7494; 7601
There are two off-board VIMS software programs that
are available for use with the service tool.
VIMSpc software (current)
VIMS 3G Connect software
VIMSpc software (current) works in conjunction with
VIMS 3G Connect in order to perform analysis,
create reports, and download data for machines that
are equipped with VIMS 3G.
VIMSpc is a software tool that is used to analyze
data. VIMSpc does not need to be connected
to the machine in order to analyze data that is
collected from the machine. After the machine data
is downloaded to a database, VIMSpc software can
be used to generate reports that provide a historical
record of the operating conditions for the machine
in the work environment as well as the operating
parameters of the machine in the work environment.
These reports can be used to monitor trends in the
work environment for the machine , and the operation
of the machine during work.
VIMS 3G Connect is a software tool that is used
when connected to a machine that is equipped
with VIMS 3G. VIMS 3G Connect allows the user
to download files, configure parameters and to
view operating parameters of the machine in real
time. This can be a very useful tool for monitoring
conditions on the machine as conditions change in
the work environment.
i03551001
VIMS 3G Connect
SMCS Code: 7601; 7620
VIMS 3G Connect is a software program that is
used in order to communicate with a machine.
VIMS 3G Connect is designed to run in a virtual
machine with Microsoft Virutal PC 2007. The virtual
machine provides a completely separate instance
of the Microsoft XP operating system that is already
configured to work with VIMS 3G.
The minimum hardware requirements for the system
are the following:
2 gigabytes of available hard drive space
1 gigabyte of RAM
41
Systems Operation Section
Download Recommendations
The payload system has a certain amount of memory
space that is available for storing the payload data.
This data needs to be downloaded on a regular basis
for sites that wish to keep records of the payload
data. The frequency of the scheduled downloads is
dependent on the factors that are listed below:
The number of shifts
The amount of loading
The VIMS begins to write over the old payload data
once approximately 2400 payload cycles have been
recorded.
The old data is overwritten when the payload memory
reaches the maximum limit. This means that the
system continues to collect the new data. However,
the old data is lost in the process. The oldest data is
lost and the new data is stored. This ensures that the
payload memory will always contain data from the
most recent operations.
Downloading the payload data prior to making
changes to the onboard time due to daylight savings
time is recommended. This should prevent erroneous
payload data from being stored due to the change
of the onboard time.
Communicate With a Machine
Connect Machine
The Connect Machine option of the File menu
allows the user to establish communications with a
machine.
g01964618
Illustration 40
Connect Machine
Select the Connect Machine option from the File
menu. The Trying to Connect message is displayed
at the bottom of the Application window. After the
VIMSpc software establishes communication with the
machine, the baud rate of connection is displayed on
the status bar. The connection icon that is located
on the status bar will indicate the connection. The
arrows have become green.
42 KENR9023-01
Systems Operation Section

Disconnect Machine VIMS Onboard Software Update

The Disconnect Machine option of the File menu
allows the user to abort communications with a
machine.
Worksheet
This worksheet should be completed prior to flashing
any new VIMS onboard software. This worksheet will
help prevent the loss of stored on board data. This
worksheet will also help prevent the loss of user
settings in the configuration.

Note: The service program codes (SPC) can be used

to access the information that is required to complete
this worksheet. Refer to the System Operation,
KENR9023, Electronic Control Module section for
g01964624
Illustration 41 more information on the service program codes.
Disconect Machine

Select the Disconnect Machine option from the

File menu. After the VIMSpc software aborts
communications with the machine, the connection
icon that is located on the status bar will indicate that
the connection has been disconnected. The arrows
become red.

Install Configuration Software

Installing configuration software is a common service
procedure for machines that are equipped with the
VIMS 3G. This process is accomplished by using
the WinFlash program and the appropriate onboard
software. WinFlash is a program that is included
with the Electronic Technician Software. Contact the
product support group of the appropriate Business
Unit for a list of flash software that is compatible with
a given machine.

Electronic Control Module (ECM) (Flash

Program)
The following procedure is used in order to FLASH
software into the VIMS 3G ECM.

1. Procedure

a. Connect the Data Link Cable between the

Communication Adapter and the Cat ET.

b. Connect the Data Link Cable between the

Communication Adapter and the diagnostic
connector of the machine.

c. Turn the disconnect switch and the key start

switch to the ON position.

d. Use WinFlash in order to load the software.

KENR9023-01 43
Systems Operation Section

g01964626
Illustration 42
44 KENR9023-01
Systems Operation Section

g01964627
Illustration 43
KENR9023-01
Note: Verify that a copy of the current VIMS onboard
software is available, before the new VIMS onboard
software is flashed.
Note: A print of the VIMS 3G Connect Machine
Status Display screen may be used instead of the
VIMS Software Update Checklist that is shown in
Illustrations 42 and 43. This print can be used to
reference important information about the setup of
the machine. Perform the following procedure to
make a file that can be printed.
Procedure to Save a Print of the Machine
Status Screen
1. Connect VIMS 3G Connect to the machine and
establish communication.
g01964864
Illustration 44
Machine Status
2. access the Machine Status screen.
3. In order to place the print in the clipboard the
program should not be in the Full Screen mode.
The steps that follow will configure the screen in
the correct mode for saving a print.
g01964873
Illustration 45
Alt + Enter
a. Press the Alt key, that is located on the
right of the keyboard, and the Enter key
simultaneously.
b. Click the mouse in an area that is outside of
the virtual machine window. Any area on the
Windows desk top will work.
45
Systems Operation Section
Illustration 46
g01964914
Shift + Print Screen
c. Press the Shift key and the Print Screen key
simultaneously.
4. Open one of the programs that follow:
Windows Paintbrush
Clipboard Viewer
Microsoft Word
WordPad
5. Click on the Edit menu and use the Paste
command. alternatively, press Ctrl key and the
V key simultaneously in order to place the image
into the program that has been selected .
6. Click on the File menu and select the Save As
option.
7. Enter a name for the file in the Save As dialog box.
Note: A name that contains the serial number of the
machine, or the equipment number of the machine
will make it easy to locate.
8. Select a directory in order to save the file.
9. Click on the Save button in the Save As dialog
box
The file is now saved.
Downloading Data From The
Machine
Downloading data from the VIMS system is one of
the most common functions that are performed with
the VIMS 3G Connect program.
Use the following procedure to download the onboard
data:
1. Connect the 305-5528 Cable As to the data
communications port of the machine and the serial
communications port of the service tool. The port
is located in the cab of the machine. An additional
port is located outside of the cab.
46 KENR9023-01
Systems Operation Section

2. Turn the key start switch or the VIMS service The VIMSpc software will operate with any of the
keyswitch to the ON position. The engine does not Microsoft Windows operating systems.
need to be running in order to activate the VIMS.

3. Turn on the PC.

Recommendation for the System
The minimum hardware requirements are listed
below:

A computer with a Pentium II Processor or higher

32 megabytes of RAM

g00642209 2 gigabytes of available hard drive space

Illustration 47
Select Download.... 12X speed CD-ROM drive
4. Select Download... from the Data menu. The 3.5 inch 1.44 megabyte floppy disk drive
Download dialog box is displayed.
Super VGA monitor or display
RS232 port with 16550AF UART
Built in pointing device or a mouse

VIMSpc Features
The occurrence of certain events and machine
conditions are recorded in the onboard memory.
The information is organized into categories. This
information is used to analyze problems with the
machine. The information is typically used at a later
date by service technicians or management. The
Illustration 48
g01964653 categories of information are listed here:
The Download list
Event List The event list is a record of stored
events and diagnostics that have occurred on the
5. Select the desired items from Download list. machine. Not all events are stored. The record
contains the last 500 events (data or system) that
Note: Choosing Reset After Download permanently
are listed in chronological order. This means that
clears the machine's memory. the events are listed in the order of occurrence. The
newest events appear at the top of the list. The event
6. Click on the Download push button in order to
list transfers the oldest data into the event summary
start downloading. The Download push button list when the event list exceeds 500 records. The
is replaced by the Cancel push button during
event summary list is composed of the first five
the download. This allows the user to cancel the
occurrences, the last five occurrences and the worst
download. five occurrences that are recorded for any of the data
events. The event summary list is limited to storing
i03548464 only 500 records. System events can be identified
by the diagnostic codes (MID, CID and FMI).
VIMSpc Software
All other events are data events. The event list is
SMCS Code: 7494; 7601 accessible from the Advisor display or with VIMSpc.

VIMSpc is a software program that will utilize the data

that is recorded by the Electronic Control Module
(ECM) on a machine. This data is used in order to
analyze current problems, to trace the history of the
machine and the fleet, and also to identify potential
problems on a machine. Payload data is used in
order to trace the productivity of a machine over a
period of time.
KENR9023-01
Note: All events that contain diagnostic information
(MID, CID and FMI) are the diagnostic type of system
events. Not all events without diagnostic information
(MID, CID and FMI) are data events. An example
of a system event without diagnostic codes is an
open wire in the circuit for the hydraulic oil level.
Remember that the circuit of a switch (2 wire) (open
switch) can report a true condition that relates to a
parameter. This same switch (2 wire) can indicate a
system failure (open wire) but the failure is reported
as low hydraulic oil level.
Snapshot The Snapshot stores a segment of
history in real time for all parameters (channels)
at a one second interval. The snapshot relates to
a set of predefined events. A snapshot is triggered
automatically for a severe event. The snapshot is
then stored in memory. The configuration software
designates the events that are considered to be
severe events. The Trigger Snapshot menu option
in the Advisor can be used in order to initiate a
snapshot manually. A snapshot consists of a flight
recording of all of the parameters that describe the
conditions of the system. The snapshot records data
from five minutes before the event to one minute
after the event. This strategy is also applied to
snapshots that are triggered immediately after key
ON. However, a portion of the five minutes of data
that occurred prior to the event was actually captured
prior to turning the key start switch OFF. This portion
of data may have been stored hours or days before
the event that triggered the snapshot.
The VIMS has the capability of storing two sets of
snapshot information. If a snapshot is in the process
of being recorded and a second snapshot is triggered
the second snapshot is ignored.
The snapshot information is accessible only with
VIMSpc.
Data Logger The data logger captures all of the
parameters that are monitored by the VIMS. The
data logger is recorded in one second intervals. The
operation of the data logger is similar to the snapshot.
The data logger can be triggered automatically. The
manual triggering of the data logger can only be done
by VIMS 3G Connect or the Advisor display. The data
logger can be started multiple times and stopped
multiple times.
The information that is recorded by the data logger is
accessible only with VIMSpc. The data logger can be
reset by VIMS 3G Connect or the Advisor display.
47
Systems Operation Section
Trends Trend information consists of the
minimums, maximums and averages of parameter
data over time. Trend information is viewed with
VIMSpc software. The trend information is displayed
as a graph or the trend information is displayed as
columns of data. An example of trend information
is the average brake temperature per hour. Trend
information is recorded for predefined parameters for
each machine. Trend information is recorded under
the specified guidelines that are listed here:
All one hour continuous trends begin when the key
start switch is turned to the ON position.
The data of the trend that is collected during a
period less than one hour when the key start switch
is turned to the OFF position is discarded.
Trend points are the average of each trend that
was captured during the past hour. Each trend
must meet the conditions that are set for that trend.
A single trend point for the designated hour is
calculated and stored when the measured trends
are averaged over one hour.
The data point or the responsible failure mode
identifier are stored according to the guidelines that
are listed here:
1. At least one Trend condition was met.
2. FMI 19 conditions not met is stored or the actual
FMI that was responsible for the conditions that
were not met for the entire hour is stored.
Trends are accessible only with VIMSpc.
Cumulative Cumulative information is the number
of occurrences (counts) of specific events. An
example of cumulative information is total engine
revolutions or total fuel consumption over the life of
the machine or component. Cumulative information
is recorded for a standard set of parameters. The
parameters are defined in the configuration software
for each machine. The onboard system collects
life-time cumulatives with no need to reset. The
situations that will cause an automatic resetting of
the cumulatives are listed here:
New onboard software is flashed into the onboard
memory.
A configuration is loaded with any changes to the
methods of calculating and storing cumulative data.
The change indicates that a correction has actually
been made to the configuration or the VIMS ECM
has just been installed from a different application.
The newly installed VIMS ECM may not recognize
the methods of calculating and storing cumulative
data that is used by the configuration.
The disconnect switch is in the OPEN position.
48 KENR9023-01
Systems Operation Section

Resetting of cumulatives manually is not required.

If the user desires, the cumulatives may be reset
manually. The reset process clears all cumulatives.
Because there is only one choice, cumulatives can
not be reset individually. If a reset of cumulatives is
requested, all the cumulatives will be reset.

Cumulatives are accessible only with VIMSpc.

Histograms - Histogram information records the

history of a parameter since last reset. For example,
a histogram of the engine speed would indicate the
percentage of time that the engine operated within
a defined speed limit (example 0-699, 700-1299,
1300-1699, 1700-2199, 2200 up) and the time
interval (example 25 to 475 SMH or 1/1/99 to 2/2/99)
of the data gathered. Histograms can be used to
evaluate the range of operation for a parameter.

Histograms are accessible only with VIMSpc .

Payload - Payload information is recorded for the Illustration 49

g01910793
off-highway trucks, as required. (1) Menu bar
(2) Tool Bar
Total payload data is accessible only with VIMSpc.
Basic data is available through the Advisor display The user can use the pull down menus of the menu
by accessing the Payload menu option or System bar to move through the VIMSpc applications or
Parameters under the Service menu. the user can use the icons in the tool bar to move
through the program.
VIMSpc Software and the Truck
Payload System Drop-Down Menus (Menu Bar)

The functions of the VIMSpc software that are
associated with the Truck Payload System will be
discussed in the following sections.
Refer to the VIMSpc Users Procedure Manual,
FEBJ0047 for additional information on the VIMSpc
software that is not addressed within this manual.
Accessing The Menu Options
Place the cursor over the desired menu and press
the left mouse button. Then select the desired menu
from the options that are displayed on the drop-down
menu and click on the left mouse button.

Note: An electronic copy of the VIMSpc Users

Procedure Manual, FEBJ0047 is included on the
VIMSpc CD-ROM.

Application Window of VIMSpc

All of the VIMSpc applications are accessed through
the application window of VIMSpc that is shown in
Illustration 49.

g00731961
Illustration 50
Selecting the menu
KENR9023-01 49
Systems Operation Section

g00731978
Illustration 51
Selecting a menu option from the drop-down menu

Note: After the main menu is open you can move

directly to the desired menu by typing the underlined
letter for that menu.

Tool Bar

The tool bar allows quick access to commonly used

menu items. The tool bar is located on the application
window of VIMSpc below the menu bar.

g01910814
Illustration 52
Tool Bar
(3) Select Machine (6) Truck Payload (9) Help
(4) Download Data (7) Report Preferences
(5) Active Data Logger (8) System Preferences

System Preferences Setup

g00642205
Illustration 53

The System Preferences option allows the user to

setup system preferences of the VIMSpcsoftware.
50
Systems Operation Section
g00642207
Illustration 54
The System Preferences are configured with the
following procedure:
1. Select System Preferences from the Setup
menu. This will display the System Preferences
dialog box.
2. Click on one of the Select Machine options.
3. Select any of the Communication options.
Refer to the VIMSpc Users Procedure Manual,
FEBJ0047 for additional information.
4. Click on the Default Paths push button in order
to display the Setup Default Paths dialog box.
Refer to the VIMSpc Users Procedure Manual,
FEBJ0047 for additional information.
5. Click on the Regional Settings push button in
order to display the Regional Settingsdialog box.
Refer to the VIMSpc Users Procedure Manual,
FEBJ0047 for additional information.
i03550941
VIMSpc Payload Reports
SMCS Code: 7494; 7601
Truck Payload Analysis Criteria
The Truck Payload Analysis Criteria option allows
you to view the criteria values. This option also allows
you to modify the criteria values. The criteria values
affect various aspects of the truck payload report.
The criteria consist of the information that is listed
below:
Maximum Values These values are used to
determine the values that are displayed in the
Criteria Sectionof the Summary report.
KENR9023-01
Graph Average Values These values are used
in the graphical report of the truck payload report.
These values provide a benchmark that compares
performance to the normal values.
Target Range These values are used in the
Load Distribution Histogram report. Efficiency is the
percentage of loads that are desired within the target
range minimum and the target range maximum.
Histogram These values are used to define the
interval of the cells. The intervals will start at the
minimum reading. The interval will continue to the
maximum reading.
Modifying the Truck Payload Analysis
Criteria
Perform the procedure that is listed below in order to
edit the Truck Payload Analysis Criteria:
1. Click on the Report option on the Menu bar.
Illustration 55
g01964967
2. Select the Production option. Then, select
Truck. Then select the Analysis Setup option.
The Truck Payload Analysis Criteria dialog box
will be shown. The fields are disabled in order to
indicate that you may not modify the fields.
Illustration 56
g01964968
3. Select the Model of the criteria in order to view
the criteria.
4. Click the Edit push button in order to modify the
fields. Clicking the Edit button will enable the
edit mode.
5. Enter the values into the field.
KENR9023-01 51
Systems Operation Section

6. Click on the Save push button in order to save To generate a Truck Payload Report
the changes. This disables the field from further
updates. Once the changes are saved, the
changes cannot be cancelled.

7. Click on the Cancel push button in order to

discard the changes. This will cause the Cancel
Changes Confirmation dialog box to be displayed.

g00732108
Illustration 58

1. Select Production from the Report menu, then

select Truck, then select Payload. The Truck
Payload Report dialog box is displayed.

g00732107
Illustration 57

8. Click on the Yes button in order to save the

changes. Click on the NO push button in order to
discard the changes. Click on the Cancel push
button in order to return to the Truck Payload
Analysis Criteria dialog box.

9. Click on the Close push button in order to

exit. The service tool will return to the VIMSpc
Application window.

Truck Payload Reports Illustration 59

g01964969

The Truck Payload reports allow you to define the

2. In the Type of Report section, select either
data filters for all truck payload reports. The available
Summary, Detail, Graphical or Load
filters are listed below:
Distribution Histogram.
Report Type 3. If report type is Detail or Graphical, select a
template.
Output destination
4. In the Time Range section, select a time range
Cycle criteria according to real Date/Time, Service Meter Hours
(SMH), or Shift.
There are four types of truck payload reports:
5. In the Output To section, select a reporting
Summary This report is a single page of
method.
productivity totals and averages. It is useful for
determining the overall productivity of a machine over
Preview This is a preview of the report on the
any time range.
screen.
Detail This report creates a table of payload cycles
Printer This sends the report to the printer.
for the truck. This is useful for analyzing the detailed
characteristics of a truck over a small time range.
Export This saves the report as a data file
Graphical This report creates a graph over time
Note: Use the Select Machines... push-button to
of the key cycle parameters. This is useful for doing
select a different machine for which to generate a
productivity trend studies. Graphs included are Cycle
report.
Time, Fuel Used, Load Time, Load Weight, and
Stop Time. Baseline values are configured in Truck
6. In the Summary and Detail Criteria, enter the Load
Payload Analysis Criteria.
Weight, Load Time, or Stopped Time ranges that
you want to include in the report. Check the Apply
Load Distribution Histogram This reports is
box to filter records according to this criterion.
a vertical bar histogram of Load Weights. The
parameters of the histogram are configured in the
Truck Payload Analysis Criteria.
52 KENR9023-01
Systems Operation Section

These criteria are useful for eliminating cycles that

are misrepresentative of the actual operation of
the machine. Cycles that do not meet these criteria
are excluded from all calculations. The criteria
may only be used on Summary and Detail reports.

7. Click the Generate push-button to produce the

report.

Truck Payload Summary Report

The following is a description of the various sections
of the Truck Payload Summary report. Values on
truck payload reports are calculated from only those
cycles that start in the specified time range (or shift),
and meet the specified Summary and Detail Criteria.

Time Distribution

g00732110
Illustration 60

Operational Time Distribution

g00732120
Illustration 61

Each time is displayed in numbers of hours: minutes:
seconds, as well as the percentage of the total time in
the period. For the operations times, the percentage
is the percentage of the operational hours, not the
total hours in the period.
Operational Hours The sum of the cycle times for
all cycles that meet the report criteria.
Non-Operational Hours The time in the
selected period without any cycle activity. If shift
based, this includes only time in the selected
shifts. Non-Operations Hours = Period Time -
Operational Hours.
Note: The Period is calculated from the Time Range
selection. Because the report includes all cycles that
start in the selected time range, some portion of the
last cycle time may not be counted in the Period but
is counted in the Operational Hours. This may result
in Operational Hours greater than the Period Hours,
and a negative value for Non-Operational Hours.
Loading Time The sum of load times for all cycles
that meet the report criteria.
Hauling Time The sum of empty travel time and
loaded travel time for all cycles that meet the report
criteria.

Total Hours in the Period The total time in the Waiting Time The sum of empty stop time and
selected time range. If shift based, this includes only loaded stop time for all cycles that meet the report
time in the selected shifts. If the last selected shift criteria.
on the last selected day overflows to the next day,
that complete shift is counted, though a part of it lies
outside the selected date range.
KENR9023-01 53
Systems Operation Section

Criteria Analysis

g00732119
Illustration 62

The criteria are set in Truck Payload Analysis

Criteria. For each criterion, the count is the number
of cycles found with a value greater than the criterion
maximum value.

Production Data

g00732118
Illustration 63

Each item is calculated based on the payload cycle

data. Only cycles that meet the specified report
criteria are considered.

Fuel Usage

g00732117
Illustration 64

Each average value is based on the total fuel used

for all cycles that meet the report criteria, divided by
the divisors listed below:

Per Hour = Fuel / Operational Hour

Per Cycle = Fuel / Number of Cycles
Per Distance (mile or km) = Fuel / Travel Distance.
54 KENR9023-01
Systems Operation Section

Averages

g00732116
Illustration 65

Speed Each average speed is calculated from the

respective totals as follows:

Cycle = Travel Distance / Cycle Time

Loaded = Loaded Travel Distance / (Loaded Stop
Time + Loaded Travel Time)

Empty = Empty Travel Distance / (Empty Stop

Time + Empty Travel Time)

Moving = Travel Distance / (Loaded Travel Time +

Empty Travel Time)

Cycle The averages related to cycle information,

as follows:

Cycle Time = Operational Time / Number of Cycles

Cycles Per Hour = Number of Cycles / Operational
Hours

Distance = Cycle Distance / Number of Cycles

Total Cycles = Number of Cycles (not an average).
Production Averages that are based on the total
payload weight, as follows:

Per Hour = Weight / Operational Hours

Per Cycle = Weight / Number of Cycles
Per Distance (mile or km) = Weight / Travel
Distance.

Payload Distribution

g00732114
Illustration 66

Count and percentage of payload weights under
target, within target range, and over target range.
The target percentage is the desired percent of loads
within target range. The range is specified in Truck
Payload Analysis Criteria.
Truck Payload Detail Reports
There are several different Truck Payload Detail
templates. The Export All Data template includes all
information available in the database for each cycle.
KENR9023-01
Illustration 67
Units are included in the column headers. Totals
and Averages for each column are displayed at the
bottom of the last page of the report.
Truck Payload Graphical Reports
Illustration 68
There are several different Truck Payload Graphical
templates. For each graph, the X-axis represents
time. One point is plotted for each day. Each point
includes only those cycles that start in the specified
time range (or shift) for that day.
55
Systems Operation Section
g00732113
g00732112
The Y-axis value is displayed above each point.
Times are displayed in MM:SS format; other units are
labeled on the Y-axis. A solid line is drawn between
the data points. The Y-axis is calculated from the
daily (or shift) totals, as follows:
56 KENR9023-01
Systems Operation Section

Cycle Time: Cycle Time / Number of Cycles

Fuel Used: Fuel Used / Operational Hours
Load Time: Load Time / Number of Cycles
Load Weight: Load Weight / Operational Hours
Stop Time: (Empty Stop Time + Loaded Stop Time)
/ Number of Cycles

A dashed horizontal line is drawn at the graph

average value as specified in the Truck Payload
Analysis Criteria.

The Y-axis is auto-scaled to maximize the viewing

space for the data.

Truck Payload Load Distribution

Histogram Report
This report is a vertical bar histogram of payload
weights for the selected time range.

g00732111
Illustration 69

g00732121
Illustration 70
Truck Payload Distribution report
KENR9023-01 57
Systems Operation Section

The Y axis always represents the percentage of the

total counts. It is automatically scaled according to
the largest bar.

The X-axis represents cycle load weight, in either

U.S. or Metric tonnage. The cell range is displayed
below each bar, per settings in Truck Payload
Analysis Criteria. A cell range of 158.00 through
167.00 includes all values greater than or equal to
158 and less than 167. The number at the top of each
bar is the percentage for that bar.

Note: It is possible for a number such as 0.1 or 0.0

to be displayed with no bar X-axis. This is because
the bar is so small it cannot be seen, and in the case
of 0.0, the percentage of total counts rounds down
to zero. If a number is displayed, there is at least 1
count in that cell.

Two dashed vertical lines indicate the lower and

upper boundaries of the target range, per the
Target Range in Truck Payload Analysis Criteria.
58 KENR9023-01
Troubleshooting Section

Troubleshooting Section When you are removing the machine harness from
any ECM, use the single screw in the center of the
harness connector.

Introduction i03730901

i03421002
Service Tools
General Information SMCS Code: 0785

SMCS Code: 7601 The following service tools should be used to aid in
troubleshooting the electrical system.
The diagnostics for the ECM of a system may be
accessed through the Advisor display. Diagnostics Table 7
may also be accessed through the Caterpillar Service Tools
Electronic Technician (Cat ET). Troubleshooting a
system will require additional information from the Part Number Part
Service Manual for the machine. The additional 257-9140 Digital Multimeter
manuals that may be required are the Testing and
Adjusting, the Electrical System Schematic, the Parts 146-4080(1) Digital Multimeter Gp
Manual and the Operation and Maintenance Manual 8T-3224 Needle Tip Group
for the machine that is to be serviced.
7X-1710 Multimeter Probe Group
As a reference, a simplified system schematic 8T-8726 Cable Assembly (3 Pin) (3-Pin
is included at the end of this manual. For an Breakout)
accurate representation of the machine that is being
6V-3000 Connector Repair Kit (Sure Seal)
diagnosed, refer to Electrical System Schematic in
the Service Manual for the machine that is being 190-8900 Connector Repair Kit(Deutsch)
serviced.
175-3700 Connector Repair Kit(Deutsch DT)
When the troubleshooting procedure instructs you (1) This multimeter is capable of using an RS232C cable in
to REPAIR THE HARNESS OR REPLACE THE order to connect to a Laptop computer or Dataview tool gp
for troubleshooting.
HARNESS, use the Electrical System Schematic for
the machine that is being serviced in order to trace
the circuit. Perform continuity checks at the harness
connectors in order to locate harness failures. At
the connectors of the components, always check
the ground circuit. There must be less than five
ohms of resistance between any system ground
and the frame ground. Excessive ground resistance
that is greater than five ohms can cause incorrect
diagnosing of problems.

During troubleshooting, inspect all connections before

any component is replaced. If these connections are
not clean and tight, permanent electrical problems or
intermittent electrical problems can result. Check that
the wires are pushed into the connectors completely.
Make sure that the connections are tight before other
tests are made.

If wire insulation is punctured during troubleshooting,

repair the damage. Seal the damaged wires with
8T-0065 RTV Silicone Sealant. Cover the sealant
with two layers of 1P-0810 Tape.

Failure of an electrical component may cause the

failure of other components. Also, failure of an
electrical component may be caused by the failure
of other components. Always attempt to correct the
cause of an electrical system failure before you
replace a component.
KENR9023-01
Illustration 71
g01298310
Connections for the Communication Adapter III and the Caterpillar
Electronic Technician (Cat ET)
The components that are needed in order to use the
Communication Adapter II and the CAT ET in order to determine
diagnostic codes are listed:
(1) 317-7487 Cable AsCable
(2) 317-7485 Communication Adapter
(3) 327-8981 Cable As
(4) Current version of Cat ET software and an IBM compatible
personal computer
Reference: Refer to Special Publication, NEHS1032,
Communications Adapter III User's Manual Contains
Software.
Note: Cat ET is a software program that can be used
on an IBM compatible personal computer.
In order to use Cat ET, the following materials must
be ordered: Special Publication, JERD2124, ET
Single Use Program License, Special Publication,
JEHP1026, Information and Requirements Sheet,
Data Subscription, and Special Publication,
JERD2142, Data Subscription. The Special
Publication, JEHP1026, Information and
Requirements Sheet lists the required hardware and
the features of Cat ET.
For instructions on servicing Sure Seal connectors,
refer to Special Instruction, SMHS7531. For
instructions on servicing the Deutsch DT Type
connectors, refer to Special Instruction, SEHS9615.
59
Troubleshooting Section
Cat ET is not required in order to view the diagnostic
codes. Cat ET is not required in order to clear
the diagnostic codes. However, the process of
determining the diagnostic codes is easier and
faster by using Cat ET. Cat ET may also display
information about the history of a diagnostic code
and the parameter status of a diagnostic code.
These features allow Cat ET to be a useful tool for
troubleshooting.
Cat ET is used to communicate to the Electronic
Control Module (ECM) over the data link by
connecting to the machine diagnostic connector. For
more information about connectors and the locations
of the connectors, refer to Troubleshooting, Electrical
Components and Connector Locations and the
Electrical System Schematic in your machine's
Service Manual.
For instructions on servicing Sure Seal connectors,
refer to Special Instruction, SMHS7531. For
instructions on servicing Deutsch connectors, refer
to Special Instruction, SEHS9615.
Use the digital multimeter in order to test continuity
and voltage. Refer to the instructions that are
provided in the manual for the multimeter in order
to operate the multimeter safely. The 7X-1710
Multimeter Probe is used to measure the voltage
at a connector without separating the connection.
The probe cables are pushed into the back of the
connector along the wire. The 8T-8726 Adapter
Cable has a breakout (3 pin). The adapter cable is
used for measurements in the sensor circuit.
Note: Although Caterpillar recommends the use of
the 8T-0500 Continuity Tester and the 5P-7277
Voltage Tester in order to test a harness, Caterpillar
does not recommend the use of 8T-0500 Continuity
Tester or the 5P-7277 Voltage Tester for electronic
circuits.
i03414000
Electrical Component and
Connector Locations
SMCS Code: 7553-546-WW
The Electrical System Schematic, Parts Manual and
Operation and Maintenance Manual for the vehicle
that is being serviced should be used to locate
electrical components and connectors.
The following information is a guide to reading
the tables on the back of the Electrical System
Schematic.
60 KENR9023-01
Troubleshooting Section

The Component Location table uses white circles
to mark the locations in the profile of the vehicle
and in the area views. Alphabetical letters in the
Machine Location column indicate a general area
of the vehicle. Refer to the corresponding footnote
at the end of the table for a description of the
location.
The Harness Connector Location table uses
white circles to mark the locations in the general
view and in the area views. Alphabetical letters in
the Machine Location column indicate a general
area of the vehicle. Refer to the corresponding
footnote at the end of the table for a description
of the location.
Flash the Electronic Control Module (ECM). This is
done with the WINflash program. Refer to Service
Manual, KENR9023, Electronic Control Module
(ECM) - Flash Program.
Print reports.
The following list contains some of the diagnostic
functions and programming functions that are
performed by the service tools.
The failures of the ECM system are displayed.
The status of most of the inputs and the outputs
are displayed.

i03729924
The settings for the ECM are displayed.

Diagnostic Capabilities Display the status of the input and output

parameters in real time.
SMCS Code: 1400
Display the clock hour of the internal diagnostic
clock.
Caterpillar Electronic Technician
(Cat ET) The number of occurrences and the clock hour
of the first occurrence and the last occurrence is
displayed for each logged diagnostic code.

The definition for each logged diagnostic code and

each event is displayed.

Load new flash software.

Refer to Service Manual, KENR9023, Diagnostic
Code List for the list of diagnostic codes for the ECM.

Active diagnostic codes

Logged diagnostic codes

Illustration 72
g01967656
Event Codes
Cat ET is a software program that is used to access Logged Event Codes
data. The service technician can use Cat ET in order
to perform maintenance on the machine. Some of
the options that are available with Cat ET are listed
below:

View diagnostic codes. Refer to Service Manual,

KENR9023, Using the Caterpillar Electronic
Technician to Determine Diagnostic Codes.

View the active event codes and logged event

codes.

View the status of parameters.

Clear the active diagnostic codes and clear logged
diagnostic codes.

Perform the calibration of machine systems.

KENR9023-01 61
Troubleshooting Section

g01961184
Illustration 73
Typical Cat ET screen for logged events

An indicator for logged events is provided. The

indicator allows the service technician to keep track
of event codes that are intermittent. The data for the
logged event will include the following information:

An Event Identifier (EID)

A text description of the problem
The number of occurrences of the problem
A time stamp will display the first occurrence of the
problem.

A time stamp will display the last occurrence of the

problem.

Status Groups For Cat ET

The Status groups are lists of machine parameters.
The status of the parameters are shown in real time.
62 KENR9023-01
Troubleshooting Section

g01961185
Illustration 74
Typical Cat ET Status Screen

Configure the VIMS 3G Outputs

Use Cat ET in order to configure the outputs for
VIMS.

Procedure

1. Connect a laptop computer with Cat ET to

the service connector of the machine via the Illustration 76
g00895419

communication adapter. Select Configuration F5.

2. Turn the disconnect key and the key start switch
to the ON position.
3. Start Cat ET and establish communication with
the machine.
4. Select the Configuration option of the Service
menu or press the F5 key. This will display the
Configuration screen. Refer to Illustration 77.

g00895412
Illustration 75
Select Service.
KENR9023-01 63
Troubleshooting Section

g01207504
Illustration 77

5. Select the parameter. You may configure the

output diagnostics for the parameters that are
listed in Table 8.
64 KENR9023-01
Troubleshooting Section

Table 8
Output Parameters of the VIMS 3G Application ECM
Description Values

Front Axle Strut Pressure to Payload Weight Ratio 793F (3209)(1)

Configuration 797F (13385)(1)
Empty Machine Wt xxx.xxx(2)
Empty Machine Rear Axle Weight Distribution xx.x(2)
Loaded Machine Rear Axle Weight Distribution xx.x(2)
Machine Tire Weight-Speed Machine Speed Limit xx.x(2)
Machine Weight-Speed Averaging Duration x(2)
Machine Speed Limit Activation Front Tires Weight-Speed xxxx(2)
Threshold
Machine Speed Limit Deactivation Front Tires Weight-Speed xxxx(2)
Threshold
Machine Speed Limit Activation Rear Tires Weight-Speed xxxx(2)
Threshold
Machine Speed Limit Deactivation Rear Tires Weight-Speed xxxx(2)
Threshold
Green TPMS Lamp Installation Configuration Installed
Incandescent lamp
LED
Red TPMS Lamp Installation Configuration Installed
Incandescent lamp
LED
Tire Analysis System Installation Status Not Installed
Road Analysis System Installation Status Not Installed
Road Analysis Severity Selection "0"
(1) The values for each model are the standard value. Do not adjust the values unless you have authorization.
(2) These values are configurable only if TKPH is activated through the attachment code.

6. Click on the Change button that is located on the 7. Click on the down arrow on the right hand side of
Configuration screen. This will display a dialog the dialog box. This will display the settings that
box. are available for the parameter.

8. Highlight the new value and click on the OK

button. This will cause Cat ET to display the
following message:

g01961187
Illustration 79

Illustration 78
g01967694 9. Click on the Yes button in order to change the
parameter setting. Click on the No button in order
to cancel the change of the parameter setting.
KENR9023-01 65
Troubleshooting Section

i03553153 Indications and System Response

Event Code List Caterpillar Monitoring System
SMCS Code: 7569
The monitoring system will alert the operator when
Event codes alert the operator that an abnormal an event code is active. Event codes are activated in
operating condition has occurred on the machine. An one of three warning levels according to the severity
example of a VIMS event could be a high temperature of the condition. The response of the monitoring
on a tire. system to these warning levels is shown in the
following table.
When an Electronic Control Module (ECM) activates
an event code, the operator will be alerted by the
Caterpillar Monitoring System. The active event
will be logged by the ECM. An event code can be
viewed with the Caterpillar Monitoring System or the
Caterpillar Electronic Technician (Cat ET).

Warning Levels
The ECM will assign a warning level to an active
event code. Event codes are one of four levels. The
level is according to the severity of the abnormal
condition. Each warning level requires a specific
response from the operator. The warning levels and
the required operator response are listed below.

Warning Level 1
Warning level 1 alerts the operator that a machine
system requires attention. The operator should check
the involved system condition or the operator should
perform maintenance on the involved system at the
earliest possible time.

Warning Level 2
Warning level 2 requires changing the operation of
the machine or performing a maintenance procedure.
Failure to correct a problem that has caused this
warning may result in damage to the components
that are involved in the system.

Warning Level 2S
Warning Level 2S requires an immediate change in
machine operation in order to avoid possible damage
to the system.

Warning Level 3
Warning level 3 requires an immediate safe shutdown
of the machine in order to avoid damage to the
machine or injury to personnel around the machine.
The problem that caused the event must be corrected
before machine operation can resume.
66 KENR9023-01
Troubleshooting Section

Table 9
WARNING OPERATION
Warning Indications (1)

Warning Alert
Action Action Required Operator Action Possible Result (4)
Category Indicator
Lamp Alarm
Flashes
(2)
Flashes Sounds

No immediate action required. The

1 X No harmful or damaging effects.
system needs attention soon.
Change machine operation or
2 X X Damage to system components
perform maintenance to the system.
Immediately change the machine Severe damage to system
2-S X X X (5)
operation. components
Immediately perform a safe Operator injury or severe damage
3 X X X (3)
engine shutdown. to components.
(1) The active warning indications are marked with an X.
(4) This is the possible result if the operator does not take action.
(2) At a 10 Hz rate.
(5) The alarm is on continuously.
(3) Pulsating alarm

Electronic Technician Service Tool
When an abnormal operating condition occurs in
the power train, the status screen on the Caterpillar
Electronic Technician Cat ET indicates that there is
an active event.
Event codes are displayed on Cat ET in the following
format:
EXXXX Description of the code
Note: Always clear logged event codes after
investigating and correcting the problem which
generated the code.
Troubleshooting
Perform the following steps in order to troubleshoot
an event:
1. Obtain the following information from the operator:

The E means that the code is an event code. The
XXXX is a numeric identifier. The numeric identifier
is followed by a description of the code.
Active event codes are listed in ascending numerical
order. The code with the lowest number is listed first.
The active event code is removed from the list when
the condition is no longer present.
Logged Event Codes
Every event code is logged in the ECM memory.
Logged event codes are listed in chronological order.
The most recent code is listed first.
A logged code is cleared from memory when one of
the following conditions occur:
The service technician manually clears the code.
The code does not recur for 1000 hours.
A new code is logged and there are already ten
logged codes in memory. In this case, the oldest
logged code is cleared.
The event and the time of the event
Determine the engine's operating conditions at
the time of the event. Conditions such as engine
rpm and load may be important.
Determine if there are any systems that were
installed by the dealer or by the customer that
could cause the event.
2. Verify that the event is not due to normal machine
operation. Verify that the event is not due to error
of the operator.
3. Check all fluid levels and all oil levels.
4. Troubleshoot and repair the cause of any active
diagnostic codes.
Power Train Event Code List
The following table lists the event codes that apply
to the power train control system. The recommended
operator response is listed. Use the Cat ET service
tool in order to determine the event codes that are
active or logged.
KENR9023-01 67
Troubleshooting Section

Table 10
MID 161
(VIMS Main ECM Event Codes)
Warning
Event Code Warning Description Required Operator Action
Level
558 1 VIMS Snapshot Stored
559 1 Event List Memory Low Download Data
1087 1 VIMS Trend Memory Low Download and Reset Data
1088 2 VIMS Trend Memory Full Download and Reset Data
1189 1 File System Memory Low Download Soon
1189 2 File System Memory Full Download immediately
2139 1 VIMS Snapshot Memory Full Download and Reset Data
1 Unknown Event Service Soon
2 Unknown Event Service Required
3 Unknown Event Shutdown Safely
68 KENR9023-01
Troubleshooting Section

Table 11
MID 162
(VIMS Application ECM Event Codes)
Warning
Event Code Warning Description Required Operator Action
Level
237 2 Machine Overloaded Dump Load Safely
689 2 High Front Tire Temp Slow Down
690 2 High Rear Tire Temp Slow Down
691 2 Speed Limited - High Tire Temp Slow Down
697 1 Negative High Peak Frame Bias Slow Down, Avoid Area
697 2 Negative High Peak Frame Bias Slow Down; Avoid Area
698 1 Positive High Peak Frame Rack Slow Down; Avoid Area
698 2 Positive High Peak Frame Rack Slow Down; Avoid Area
699 1 Negative High Peak Frame Rack Slow Down; Avoid Area
699 2 Negative High Peak Frame Rack Slow Down; Avoid Area
700 1 Negative High Peak Frame Pitch Slow Down; Avoid Area
700 2 Negative High Peak Frame Pitch Slow Down; Avoid Area
777 1 Positive High Peak Frame Bias Slow Down; Avoid Area
777 2 Positive High Peak Frame Bias Slow Down; Avoid Area
779 1 Positive High Peak Frame Pitch Slow Down; Avoid Area
779 2 Positive High Peak Frame Pitch Slow Down; Avoid Area
1189 1 File System Memory Low Download Soon
1189 2 File System Memory Full Download Immediately
2079 2 LF Suspension Cylinder Prs Low Service Required
2080 2 RF Suspension Cylinder Prs Low Service Required
2081 2 LR Suspension Cylinder Prs Low Service Required
2082 2 RR Suspension Cylinder Prs Low Service Required
2083 1 Payload Memory Low Download and Reset Data
2083 2 Payload Memory Full Download and Reset Data
2126 1 Machine Overloaded Dump Load Safely
2126 2 Machine Overloaded Dump Load Safely
1 Unknown Event Service Soon
2 Unknown Event Service Required
3 Unknown Event Shutdown Safely
KENR9023-01 69
Troubleshooting Section

Diagnostic Code Table 12

Procedures Diagnostic Codes For the VIMS 3G Main

ECM (MID 161)(1)
Perform the procedure that corresponds to
i03421494 the CID and the FMI of the diagnostic code
during troubleshooting.
Diagnostic Code List CID / FMI Description
SMCS Code: 7569 CID 0248 Cat Data Link

Use the Caterpillar Electronic Technician (Cat ET) FMI 09 Abnormal Update Rate
or the Advisor in order to determine the diagnostic CID 296 Transmission Control
codes. After determining the diagnostic codes,
refer to the corresponding test procedure for more FMI 02 Erratic / Incorrect
information. Perform the procedure that corresponds FMI 09 Abnormal Update Rate
to the Component Identifier (CID) and the Failure
Mode Identifier (FMI) of the diagnostic code. Table FMI 14 Special Instruction
12 is a list of possible diagnostic codes for the VIMS CID 0533 Brake Control
3G Main Electronic Control Module (VIMS 3G Main
ECM). Table 13 is a list of possible diagnostic codes FMI 02 Erratic / Incorrect
for the VIMS 3G Application ECM. FMI 09 Abnormal Update Rate
FMI 14 Special Instruction
CID 0590 Engine Control
FMI 02 Erratic / Incorrect
FMI 09 Abnormal Update Rate
FMI 14 Special Instruction
CID 768 RS-485 Data Link
FMI 09 Abnormal Update Rate
FMI 14 Special Instruction
CID 800 VIMS Main Control
FMI 08 Abnormal Frequency, Pulse Width, or Period
FMI 11 Configuration File Needed
CID 0890 Telemetry Data Link
FMI 09 Abnormal Update Rate
CID 1089 VIMS Application Control
FMI 09 Abnormal Update Rate
FMI 14 Special Instruction
CID 1273 chassis Control
FMI 02 Erratic / Incorrect
FMI 09 Abnormal Update Rate
FMI 14 Special Instruction
CID 2448 Graphical Display
FMI 02 Erratic / Incorrect
FMI 09 Abnormal Update Rate
FMI 14 Special Instruction
(1) The MID for the VIMS 3G Main ECM is 161. This table pertains
only to faults with a MID of 161.
70 KENR9023-01
Troubleshooting Section

Table 13 (Table 13, contd)

Diagnostic Codes For the VIMS 3G Application Diagnostic Codes For the VIMS 3G Application
ECM (MID 162)(1) ECM (MID 162)(1)
Perform the procedure that corresponds to Perform the procedure that corresponds to
the CID and the FMI of the diagnostic code the CID and the FMI of the diagnostic code
during troubleshooting. during troubleshooting.
CID / FMI Description CID / FMI Description
CID 0248 Cat Data Link FMI 08 Abnormal Frequency, Pulse Width, or Period
FMI 09 Abnormal Update Rate CID 1089 VIMS Application Control
CID 0296 Transmission Control FMI 08 Abnormal Frequency, Pulse Width, or Period
FMI 02 Erratic / Incorrect FMI 11 Configuration File Needed
FMI 09 Abnormal Update Rate CID 1273 chassis Control
FMI 14 Special Instruction FMI 02 Erratic / Incorrect
CID 0533 Brake Control FMI 09 Abnormal Update Rate
FMI 02 Erratic / Incorrect FMI 14 Special Instruction
FMI 09 Abnormal Update Rate CID 2448 Graphical Display
FMI 14 Special Instruction FMI 02 Erratic / Incorrect
CID 0590 Engine Control FMI 09 Abnormal Update Rate
FMI 02 Erratic / Incorrect FMI 14 Special Instruction
(1) The MID for the VIMS 3G Application ECM is 162. This table
FMI 09 Abnormal Update Rate
pertains only to faults with a MID of 162.
FMI 14 Special Instruction
CID 768 RS-485 Data Link Module Identifier (MID)
FMI 09 Abnormal Update Rate
Diagnostics from other ECM are read by the
FMI 14 Special Instruction monitoring system. Other ECM will transfer
diagnostic information on the Cat Data Link to the
CID 800 VIMS Main Control
monitoring system.
09 Abnormal Update Rate
The Module Identifier (MID) identifies the ECM that
14 Special Instruction
detected the fault. Each ECM on the machine has
CID 0838 Left Front Strut Pressure Sensor a unique MID. Use Table 14 in order to match the
MID for each diagnostic code to a specific ECM. The
FMI 03 Voltage Above Normal
chart for the Module Identifier (MID) is located on
FMI 04 Voltage Below Normal the Electrical System Schematic for your machine.
Refer to the chart on the schematic if the MID is
FMI 08 Abnormal Frequency, Pulse Width, or Period
not shown on the display of your machine. After the
CID 0839 Right Front Strut Pressure Sensor operator determines the ECM that has detected the
failure, refer to the service manual module for that
FMI 03 Voltage Above Normal
particular ECM for more troubleshooting information.
FMI 04 Voltage Below Normal The Service Manual for the machine will include
troubleshooting information for the ECM.
FMI 08 Abnormal Frequency, Pulse Width, or Period
CID 0840 Left Rear Strut Pressure Sensor
FMI 03 Voltage Above Normal
FMI 04 Voltage Below Normal
FMI 08 Abnormal Frequency, Pulse Width, or Period
CID 0841 Right Rear Strut Pressure Sensor
FMI 03 Voltage Above Normal
FMI 04 Voltage Below Normal
(continued)
KENR9023-01 71
Troubleshooting Section

Table 14 Table 15

Description of the Module Identifier Failure Mode Identifier Definitions

MID Description
FMI Failure Description
036 Engine ECM
00 Data valid but above normal operating range
053 Advisor
01 Data valid but below normal operating range
087 Chassis ECM
02 Data erratic, intermittent or incorrect
116 Brake ECM
03 Voltage above normal or shorted high
161 VIMS Main ECM
04 Voltage below normal or shorted low
162 VIMS Application ECM
05 Current below normal or open circuit
06 Current above normal or grounded circuit
Failure Mode Identifier 07 Mechanical system not responding properly
The codes for the Failure Mode Identifier (FMI) are 08 Abnormal frequency, pulse, or period
defined by the Society Of Automotive Engineers Inc.
(SAE). The Table 15 contains the CAT definitions for 09 Abnormal update
the FMI. Diagram 80 illustrates FMI codes that can 10 Abnormal rate of change
be generated from a sensor that has failed.
11 Failure mode not identifiable
12 Bad device or component
13 Out of calibration
14 Special Instruction

Detailed FMI Explanation

FMI 00 Data Valid But Above Normal Operating
Range Every electronic control system sets a
high limit for the expected operating range of the
signal. The high limit includes over range signals.
This could be a high temperature. A sensor that is still
operating but sending a signal above the expected
g00493694
Illustration 80 limit will cause a FMI 00 to be stored.
Range of possible FMI codes generated from a failed sensor
Some of the possible causes of a FMI 00 are listed
below.

The signal is above normal.

The signal is shorted to the +battery circuit.
The sensor needs to be calibrated.
This is an example of a sensor that needs calibration.
A Pulse Width Modulation (PWM) signal with an 80%
duty cycle is a valid signal. If the PWM signal has a
duty cycle of 81% the sensor is still working, but the
sensor signal is above the expected signal limits.

FMI 01 Data Valid But Below Normal Operating

Range Every electronic control system sets a low
limit for the expected operating range of the signal.
The limit includes signals that are under the lower
limit. The low signal could be the oil pressure signal.
The sensor is still working but sending a signal below
the expected limit will cause a FMI 01 to be stored.
72
Troubleshooting Section
Some of the possible causes of a FMI 01 are listed
below.
The signal is below the normal range.
The timing is retarded.
This is an example of a PWM sensor. This sensor
is not expected to generate a PWM signal below a
duty cycle of 5% with 0 psi air pressure. If the sensor
generates a signal with a duty cycle of 4% when the
engine is shutdown, the sensor is working but it is
sending a signal that is below the expected limit. This
will cause a FMI 01 to be stored.
FMI 02 Data Erratic, Intermittent or Incorrect
The signal from a component is present. The control
that reads the diagnostic information can not read
the signal properly. The signal appears to be gone,
unstable or invalid. The data can be correct or
incorrect intermittently. Also, this condition relates to
communication between controls. This is an example
of communication between controls. When the
monitoring system is looking for the engine speed
from the engine ECM over the Cat Data Link.
There is a failed connection.
The signal is intermittent or erratic.
The software has been changed.
The signal is noisy.
The signal is out of range.
FMI 03 Voltage Above Normal or Shorted High
The component or system voltage is higher than the
limit. FMI 03 most often relates to a signal circuit.
Some of the components that could cause a FMI 03
are listed below.
The sensor or the switch has failed.
The harness is damaged.
The ECM has failed.
Some of the possible causes of a FMI 03 are listed
below.
A sensor that has failed and the voltage output is
high.
Any wiring harness that has a sensor signal wire
shorted to a high voltage. A high voltage is any
voltage that is greater than the sensor supply
voltage.
KENR9023-01
A wiring harness that has an open circuit in the
sensor signal wire will cause the control to pull up.
When this occurs the input circuit is pulled up to
the supply voltage.
A control that has failed will also cause a FMI 03.
This is very unlikely.
FMI 04 The Voltage is Below Normal or the Voltage
is Shorted Low The component or system voltage
is lower than the limit. FMI 04 most often relates to
a signal circuit.
Some of the components that could cause a FMI 04
are listed below.
The sensor or the switch has failed.
The harness is damaged.
The ECM has failed.
Some of the possible causes of a FMI 04 are listed
below.
A sensor that has failed and the voltage output is
low.
Any wiring harness that has a sensor signal wire
shorted to ground.
A failed ECM will also cause a FMI 04. This is very
unlikely.
FMI 05 Current Below Normal or Open Circuit
The current through the component or the system is
lower than the limit. FMI 05 is most often related to
a driver circuit.
Some of the possible causes of a FMI 05 are listed
below.
There is an open circuit or a poor harness
connection.
There is an open relay.
There is a switch in the open position.
FMI 06 Current Above Normal or Grounded
Circuit The current through the component or the
system is higher than the limit. FMI 06 is most often
related to a driver circuit. This fault is very similar to
FMI 04.
Some of the possible causes of a FMI 06 are listed
below.
There is a short to ground in the harness
connection.
There is a shorted relay.
KENR9023-01
A failed control will also cause a FMI 06. This is
very unlikely.
FMI 07 Mechanical System Not Responding
Properly The control detects a signal that is sent to
a mechanical system and the response is not correct.
Some of the possible causes of a FMI 07 are listed
below.
The component responds improperly.
The component is stuck in a position.
The component has failed.
The engine is shut down.
The machine is being used improperly.
FMI 08 Abnormal Frequency, Pulse Width or
Period This occurs when the signal is not in the
expected range. FMI 08 can also relate to a faulty
sensor.
Some of the possible causes of a FMI 08 are listed
below.
The harness connections are intermittent or poor.
The engine misfired.
The signal is noisy due to nearby interference.
There are loose mechanical devices.
FMI 09 Abnormal Update This relates to
communications on the data link. FMI 09 occurs
when a control is not able to get information from
another control.
Some of the possible causes of a FMI 09 are listed
below.
The control module is not communicating on the
data link correctly.
The rate of data transmission is abnormal.
The data link has failed.
There is a mismatch of software.
FMI 10 Abnormal Rate of Change This relates to
a signal that changes too fast. The rate of change is
outside of the expected limit.
FMI 11 Failure Mode Not Identifiable The
control identifies more than one FMI as being
responsible for a single failure.
Some of the possible causes of a FMI 11 are listed
below.
73
Troubleshooting Section
There is a mechanical failure.
There is damage to multiple circuits.
FMI 12 Bad Device or Component The electronic
control sends a signal and the electronic control
expects a response. The control receives no
response or the response is incorrect.
Some of the possible causes of a FMI 12 are listed
below.
There is a failure of the electronic control.
There is a failure on the data link.
There are one or more controls with mismatched
software.
FMI 13 Out of Calibration The electrical signal is
not within limits for a specific mechanical condition.
Some of the possible causes of a FMI 13 are listed
below.
Calibration is required.
The data is out of range.
FMI 14 Special Instruction FMI 14 is used to
report a problem in the configuration between 2 ECM.
This may happen even when the 2 ECM are sending
and receiving all the correct parameters but it has
been determined that the software in the 2 ECM is not
correct. The software for the ECM must be updated.
i03418121
Using Caterpillar Electronic
Technician to Determine
Diagnostic Codes
SMCS Code: 0785-UE; 7569
Connect the Caterpillar Electronic Technician (Cat
ET) to the machine. Turn the key for the machine to
the RUN position. Start the Cat ET. The Cat ET will
initiate communications with each Electronic Control
Module (ECM) on the machine. After communication
has been established, the Cat ET will list each ECM.
Choose the desired ECM. After the diagnostic codes
have been determined with the Cat ET, refer to the
test procedure for the corresponding diagnostic code.
Reference: Troubleshooting, KENR9023, Service
Tools
Active Diagnostic Codes
74 KENR9023-01
Troubleshooting Section

g00859671
Illustration 81
Typical Cat ET screen for active diagnostic codes

The following procedures may cause new diagnostic

codes to be logged. Therefore, before any procedures
are performed make a list of all the active diagnostic
codes in order to determine the system problems.
Clear the diagnostic codes that were caused by the
procedure, when each procedure is complete.

Note: Before performing a procedure, always check

all the circuit breakers. Repair the cause of any circuit
breaker that is tripped.

A screen is provided in Cat ET for active diagnostic

codes. The screen will display the diagnostic codes
that are active. Active diagnostic information shall
include a Component Identifier (CID), a Failure Mode
Identifier (FMI) and a text description of the problem.

Logged Diagnostic Codes

KENR9023-01 75
Troubleshooting Section

g00859762
Illustration 82
Typical Cat ET screen for logged diagnostic codes

A screen is provided in Cat ET for logged diagnostic i03413924

codes. The screen will display diagnostic codes that
are logged. The Cat ET will log diagnostic codes that Using Advisor to Determine
are intermittent. The diagnostic data that is logged Diagnostic Codes
shall include a CID, a FMI and a text description of the
problem. Also, the diagnostic data that is logged shall SMCS Code: 7490
include the number of occurrences of the problem
and two time stamps. The time stamp displays the
first occurrence of the problem. The time stamp also
displays the most recent occurrence of the problem.

Diagnostics are logged in non-volatile memory. On

powerup, the ECM will clear any diagnostic codes
that have not been detected or active within the last
150 hours of machine operation.

g01959583
Illustration 83
The Diagnostics menu on the Advisor
76 KENR9023-01
Troubleshooting Section

Perform the following in order to access the i03476125

Diagnotics screen from the Service Menu:
MID 161 - CID 0248 - FMI 09
1. Use the appropriate Arrow button in order to
highlight the Diagnostics option. SMCS Code: 7610-038

2. Press the OK button in order to access the Conditions Which Generate This Code:
Diagnostics screen.

The Diagnostics screen shows a complete list of all

active diagnostic codes and logged diagnostic codes.
Each line on the list shows the following:

MID
CID
FMI
The display also shows the following:

Number of occurrences
The time (service hour) of the first occurrence
The time of the last occurrence of the code or event
The fact that the code is currently active
Perform the following in order to access the codes
and events from the Diagnotics screen:

1. Use the appropriate Arrow button to highlight a

specific code (line on the list).

2. Press the OK button in order to display the line's

detailed view.

The detailed view will display a text message. The

text message will include the following:

The reporting ECM (MID)

Identity of the component that has failed (CID)
An explanation of the failure
Note: The codes and the events that are displayed in
the Diagnostics option may be viewed at any time. If
a password has been set, it will be necessary to enter
the password in order to clear the Logged codes.
g01969413
Illustration 84
Schematic of the data link
This diagnostic code is recorded when the VIMS 3G
Main ECM receives expected information through the
Cat Data Link with an abnormal update rate.

System Response:

This failure results in events that are logged to the

VIMS 3G Main ECM that can not be explained
directly.
KENR9023-01
Test Step 1. VERIFY THE HARDWARE
AND THE SOFTWARE PART NUMBERS.
A. Verify that the following information is correct:
The part number of the VIMS 3G Main ECM
onboard software
The part number of the VIMS 3G Main ECM
Note: Consult the Business Unit that produces
the product for the correct part numbers of the
configuration software.
Expected Result:
All part numbers are correct.
Results:
OK All part numbers are correct. Proceed to
Test Step 2.
NOT OK All part numbers are NOT correct.
Repair: The installed VIMS 3G Main ECM has the
wrong part number or the incorrect configuration
software is installed. Replace the incorrect VIMS
3G Main ECM with an ECM that has the correct part
number. Refer to the Service Manual, KENR9023
, Electronic Control Module (ECM) - Replace.
Flash the correct configuration software. Refer
to the Service Manual, KENR9023 , Electronic
Control Module (ECM) - Flash Program.
STOP.
Test Step 2. INSPECT THE HARNESS
CONNECTIONS.
A. Turn the disconnect switch to the OFF position.
B. Inspect all harness connections that are related to
the Cat Data Link. Make sure that the connectors
are clean and tight.
C. Check the connectors for proper mating. Ensure
that all the seals are present and in place.
D. Check the harness for signs of damage or
abrasion.
E. Check the wires at the connector. Ensure that the
wires are secured tightly into the connector. Take
care not to pull the wire out of the connector.
F. Check the exposed wires at the connectors for
nicks or signs of abrasion.
G. Check for moisture inside the connector.
H. Check the connectors for dirty contacts or
corroded contacts.
77
Troubleshooting Section
I. Check each pin and each socket of the machine
harness connectors. Ensure that the contacts
are properly installed. The contacts should mate
correctly when the two pieces of the connector
are placed together.
Expected Result:
The machine harness connectors are tight and free
of corrosion.
Results:
OK The machine harness connectors are tight
and free of corrosion. Proceed to Test Step 3.
NOT OK The machine harness connectors are
in need of repair.
Repair: Repair the machine harness or replace the
machine harness.
STOP.
Test Step 3. CHECK FOR SHORTS TO
GROUND
A. The disconnect switch remains in the OFF
position.
B. Disconnect all ECM from the Cat Data Link.
C. At the machine harness for the VIMS 3G Main
ECM, measure the resistance between frame
ground and connector contacts 8 (wire 893-GN)
and 9 (wire 892-BR) of the Cat Data Link circuit.
Expected Result:
The resistance is greater than 5000 ohms.
Results:
OK The resistance is greater than 5000 ohms.
The harness circuit resistance is correct. Proceed
to Test Step 4.
NOT OK The resistance is less than 5000 ohms.
The machine harness has failed.
Repair: There is a short between frame ground
and the Cat Data Link circuit in the machine
harness. Repair the machine harness or replace
the machine harness.
STOP.
Test Step 4. CHECK FOR SHORT TO
+BATTERY
A. The disconnect switch remains in the OFF
position.
78
Troubleshooting Section
B. All of the related ECM remain disconnected from
the machine harness.
C. At the machine harness connector for the VIMS
3G Main ECM, perform the checks that are listed
here:
Measure the resistance between the +Battery
connector contact 52 (wire 170-RD) and
connector contact 8 (wire 893-GN).
Measure the resistance between connector
contact 52 (wire 170-RD) and connector contact
9 (wire 892-BR).
Expected Result:
The resistance is greater than 5000 ohms.
Results:
OK The harness circuit resistance is correct.
Proceed to Test Step 5.
NOT OK The resistance is less than 5000 ohms.
The machine harness has failed.
Repair: There is a short between the +battery
and the Cat Data Link circuit in the machine
harness. Repair the machine harness or replace
the machine harness.
STOP.
Test Step 5. CHECK FOR OPEN HARNESS
A. The disconnect switch remains in the OFF
position.
B. Ensure that all of the ECM are disconnected from
the machine harness.
C. Check the continuity of the Cat Data Link circuit
in the machine harness:
Measure the resistance between connector
contact 8 (wire 893-GN) of the VIMS 3G Main
ECM and connector contact J1-8 (wire 893-GN)
of the Engine ECM.
Measure the resistance between connector
contact 9 (wire 892-BR) of the VIMS 3G Main
ECM and connector contact J1-9 (wire 892-BR)
of the Engine ECM.
Expected Result:
The resistance measures less than 5 ohms.
KENR9023-01
Results:
OK The resistance is less than 5 ohms. The Cat
Data Link circuit in the machine harness is correct.
Proceed to Test Step 6.
NOT OK The resistance is greater than 5 Ohms.
The machine harness has failed.
Repair: The Cat Data Link circuit is open in the
machine harness. Repair the machine harness or
replace the machine harness.
STOP.
Test Step 6. CHECK FOR ADDITIONAL
DIAGNOSTIC CODES FOR THE OTHER
ECM.
A. Reconnect all of the ECM that use the Cat Data
Link.
B. Turn the disconnect switch and the key start
switch to the ON position.
C. Check the Event List for diagnostic codes that are
logged against the other ECM.
Expected Result:
Diagnostic codes are not present for the other ECM
in the event list.
Results:
OK Diagnostic codes are not present for the
other ECM in the event list.
Repair: The VIMS 3G Main ECM has failed. Exit
this procedure. Perform this procedure again.
If the failure is not found, replace the VIMS 3G
Main ECM. Refer to Service Manual, KENR9023,
Electronic Control Module (ECM) - Replace.
STOP.
NOT OK Diagnostic codes are present for the
other ECM in the event list.
Repair: Perform the troubleshooting procedure for
the other diagnostic codes.
STOP.
KENR9023-01 79
Troubleshooting Section

i03583620 System Response:

MID 161 - CID 0296 - FMI 09
SMCS Code: 7610-038-DTN
Conditions Which Generate This Code:
This failure results in events that are logged
against the Transmission ECM that can not be
explained directly. The VIMS 3G Main ECM cannot
communicate with the Transmission ECM or the
Transmission ECM appears to communicate
intermittently.

Test Step 1. VERIFY THE HARDWARE

AND THE SOFTWARE PART NUMBERS.
A. Verify that the following information is correct:

The part number of the VIMS 3G Main ECM

onboard software

The part number of the flash software for the

Transmission ECM

The part number of the VIMS 3G Main ECM

The part number of the Transmission ECM
Note: Consult the Business Unit that produces
the product for the correct part numbers of the
configuration software.

Expected Result:

All part numbers are correct.

Results:

OK All part numbers are correct. Proceed to

Test Step 2.

NOT OK All part numbers are NOT correct.

g01969413
Illustration 85
Schematic of the data link
This diagnostic code is recorded when the VIMS 3G
Main ECM does not receive expected information
from the Transmission ECM through the Cat Data
Link at the correct update rate.
Repair: The installed VIMS 3G Main ECM or the
Transmission ECM has the wrong part number or
the incorrect configuration software is installed.
Replace the incorrect VIMS 3G Main ECM or the
Transmission ECM with an ECM that has the
correct part number. Refer to Service Manual,
KENR9023, Electronic Control Module (ECM) -
Replace. Flash the correct configuration software.
Refer to Service Manual, KENR9023, Electronic
Control Module (ECM) - Flash Program.
STOP.
Test Step 2. INSPECT THE HARNESS
CONNECTIONS.
A. Turn the disconnect switch to the OFF position.

B. Inspect all harness connections that are related to

the Cat Data Link. Make sure that the connectors
are clean and tight.

C. Check the connectors for proper mating. Ensure

that all the seals are present and in place.
80
Troubleshooting Section
D. Check the harness for signs of damage or
abrasion.
E. Check the wires at the connector. Ensure that the
wires are secured tightly into the connector. Take
care not to pull the wire out of the connector.
F. Check the exposed wires at the connectors for
nicks or signs of abrasion.
G. Check for moisture inside the connector.
H. Check the connectors for dirty contacts or
corroded contacts.
I. Check each pin and each socket of the machine
harness connectors. Ensure that the contacts
are properly installed. The contacts should mate
correctly when the two pieces of the connector
are placed together.
Expected Result:
The machine harness connectors are tight and free
of corrosion.
Results:
OK The machine harness connectors are tight
and free of corrosion. Proceed to Test Step 3.
NOT OK The machine harness connectors are
in need of repair.
Repair: Repair the machine harness or replace the
machine harness.
STOP.
Test Step 3. CHECK FOR SHORTS TO
GROUND
A. The disconnect switch remains in the OFF
position.
B. Disconnect all ECM from the Cat Data Link.
C. At the machine harness for the VIMS 3G Main
ECM, measure the resistance between frame
ground and connector contacts 8 (wire 893-GN)
and 9 (wire 892-BR) of the Cat Data Link circuit.
Expected Result:
The resistance is greater than 5000 ohms.
Results:
OK The resistance is greater than 5000 ohms.
The harness circuit resistance is correct. Proceed
to Test Step 4.
KENR9023-01
NOT OK The resistance is less than 5000 ohms.
The machine harness has failed.
Repair: There is a short between frame ground
and the Cat Data Link circuit in the machine
harness. Repair the machine harness or replace
the machine harness.
STOP.
Test Step 4. CHECK FOR SHORT TO
+BATTERY
A. The disconnect switch remains in the OFF
position.
B. All of the related ECM remain disconnected from
the machine harness.
C. At the machine harness connector for the
Transmission ECM, perform the checks that are
listed here:
Measure the resistance between the +Battery
connector contact J1-31 (wire 126-RD) and
connector contact J1-10 (wire 893-GN).
Measure the resistance between connector
contact J1-31 (wire 126-RD) and connector
contact J1-20 (wire 892-BR).
Expected Result:
The resistance is greater than 5000 ohms.
Results:
OK The harness circuit resistance is correct.
Proceed to Test Step 5.
NOT OK The resistance is less than 5000 ohms.
The machine harness has failed.
Repair: There is a short between the +battery
and the Cat Data Link circuit in the machine
harness. Repair the machine harness or replace
the machine harness.
STOP.
Test Step 5. CHECK FOR OPEN HARNESS
A. The disconnect switch remains in the OFF
position.
B. Ensure that all of the ECM are disconnected from
the machine harness.
C. Check the continuity of the Cat Data Link circuit
in the machine harness:
KENR9023-01 81
Troubleshooting Section

Measure the resistance between connector Repair: Perform the troubleshooting procedure for
contact 8 (wire 893-GN) of the VIMS 3G the other diagnostic codes.
Main ECM and connector contact J1-10 (wire
893-GN) of the Transmission ECM. STOP.

Measure the resistance between connector i03661145

contact 9 (wire 892-BR) of the VIMS 3G
Main ECM and connector contact J1-20 (wire
892-BR) of the Transmission ECM.
MID 161 - CID 0296 - FMI 02
SMCS Code: 7610-038-DTN
Expected Result:
Conditions Which Generate This Code:
The resistance measures less than 5 ohms.

Results:

OK The resistance is less than 5 ohms. The Cat

Data Link circuit in the machine harness is correct.
Proceed to Test Step 6.

NOT OK The resistance is greater than 5 Ohms.

The machine harness has failed.

Repair: The Cat Data Link circuit is open in the

machine harness. Repair the machine harness or
replace the machine harness.

STOP.

Test Step 6. CHECK FOR ADDITIONAL

DIAGNOSTIC CODES FOR THE OTHER
ECM.
A. Reconnect all of the ECM that use the Cat Data
Link.

B. Turn the disconnect switch and the key start

switch to the ON position.

C. Check the Event List for diagnostic codes that are

logged against the other ECM.

Expected Result:

Diagnostic codes are not present for the other ECM

in the event list.

Results:

OK Diagnostic codes are not present for the

other ECM in the event list.

Repair: The Transmission ECM has failed. It is

unlikely that the Transmission ECM has failed. Exit Illustration 86
g01969413
this procedure. Perform this procedure again. If the
Schematic of the data link
failure is not found, replace the Transmission ECM.

STOP. This diagnostic code is recorded when the VIMS 3G

Main ECM receives data from the Transmission ECM
that is erratic or incorrect.
NOT OK Diagnostic codes are present for the
other ECM in the event list.
82
Troubleshooting Section
System Response:
This failure results in events that are logged
against the Transmission ECM that can not be
explained directly. The VIMS 3G Main ECM cannot
communicate with the Transmission ECM or the
Transmission ECM appears to communicate
intermittently.
Test Step 1. VERIFY THE HARDWARE
AND THE SOFTWARE PART NUMBERS.
A. Verify that the following information is correct:
The part number of the VIMS 3G Main ECM
onboard software
The part number of the flash software for the
Transmission ECM
The part number of the VIMS 3G Main ECM
The part number of the Transmission ECM
Note: Consult the Business Unit that produces
the product for the correct part numbers of the
configuration software.
Expected Result:
All part numbers are correct.
Results:
OK All part numbers are correct. Proceed to
Test Step 2.
NOT OK All part numbers are NOT correct.
Repair: The installed VIMS 3G Main ECM or the
Transmission ECM has the wrong part number or
the incorrect configuration software is installed.
Replace the incorrect VIMS 3G Main ECM or the
Transmission ECM with an ECM that has the
correct part number. Refer to Service Manual,
KENR9023, Electronic Control Module (ECM) -
Replace. Flash the correct configuration software.
Refer to Service Manual, KENR9023, Electronic
Control Module (ECM) - Flash Program.
STOP.
Test Step 2. INSPECT THE HARNESS
CONNECTIONS.
A. Turn the disconnect switch to the OFF position.
B. Inspect all harness connections that are related to
the Cat Data Link. Make sure that the connectors
are clean and tight.
C. Check the connectors for proper mating. Ensure
that all the seals are present and in place.
KENR9023-01
D. Check the harness for signs of damage or
abrasion.
E. Check the wires at the connector. Ensure that the
wires are secured tightly into the connector. Take
care not to pull the wire out of the connector.
F. Check the exposed wires at the connectors for
nicks or signs of abrasion.
G. Check for moisture inside the connector.
H. Check the connectors for dirty contacts or
corroded contacts.
I. Check each pin and each socket of the machine
harness connectors. Ensure that the contacts
are properly installed. The contacts should mate
correctly when the two pieces of the connector
are placed together.
Expected Result:
The machine harness connectors are tight and free
of corrosion.
Results:
OK The machine harness connectors are tight
and free of corrosion. Proceed to Test Step 3.
NOT OK The machine harness connectors are
in need of repair.
Repair: Repair the machine harness or replace the
machine harness.
STOP.
Test Step 3. CHECK FOR SHORTS TO
GROUND
A. The disconnect switch remains in the OFF
position.
B. Disconnect all ECM from the Cat Data Link.
C. At the machine harness for the VIMS 3G Main
ECM, measure the resistance between frame
ground and connector contacts 8 (wire 893-GN)
and 9 (wire 892-BR) of the Cat Data Link circuit.
Expected Result:
The resistance is greater than 5000 ohms.
Results:
OK The resistance is greater than 5000 ohms.
The harness circuit resistance is correct. Proceed
to Test Step 4.
KENR9023-01
NOT OK The resistance is less than 5000 ohms.
The machine harness has failed.
Repair: There is a short between frame ground
and the Cat Data Link circuit in the machine
harness. Repair the machine harness or replace
the machine harness.
STOP.
Test Step 4. CHECK FOR SHORT TO
+BATTERY
A. The disconnect switch remains in the OFF
position.
B. All of the related ECM remain disconnected from
the machine harness.
C. At the machine harness connector for the
Transmission ECM, perform the checks that are
listed here:
Measure the resistance between the +Battery
connector contact J1-31 (wire 126-RD) and
connector contact J1-10 (wire 893-GN).
Measure the resistance between connector
contact J1-31 (wire 126-RD) and connector
contact J1-20 (wire 892-BR).
Expected Result:
The resistance is greater than 5000 ohms.
Results:
OK The harness circuit resistance is correct.
Proceed to Test Step 5.
NOT OK The resistance is less than 5000 ohms.
The machine harness has failed.
Repair: There is a short between the +battery
and the Cat Data Link circuit in the machine
harness. Repair the machine harness or replace
the machine harness.
STOP.
Test Step 5. CHECK FOR OPEN HARNESS
A. The disconnect switch remains in the OFF
position.
B. Ensure that all of the ECM are disconnected from
the machine harness.
C. Check the continuity of the Cat Data Link circuit
in the machine harness:
83
Troubleshooting Section
Measure the resistance between connector
contact 8 (wire 893-GN) of the VIMS 3G
Main ECM and connector contact J1-10 (wire
893-GN) of the Transmission ECM.
Measure the resistance between connector
contact 9 (wire 892-BR) of the VIMS 3G
Main ECM and connector contact J1-20 (wire
892-BR) of the Transmission ECM.
Expected Result:
The resistance measures less than 5 ohms.
Results:
OK The resistance is less than 5 ohms. The Cat
Data Link circuit in the machine harness is correct.
Proceed to Test Step 6.
NOT OK The resistance is greater than 5 Ohms.
The machine harness has failed.
Repair: The Cat Data Link circuit is open in the
machine harness. Repair the machine harness or
replace the machine harness.
STOP.
Test Step 6. CHECK FOR ADDITIONAL
DIAGNOSTIC CODES FOR THE OTHER
ECM.
A. Reconnect all of the ECM that use the Cat Data
Link.
B. Turn the disconnect switch and the key start
switch to the ON position.
C. Check the Event List for diagnostic codes that are
logged against the other ECM.
Expected Result:
Diagnostic codes are not present for the other ECM
in the event list.
Results:
OK Diagnostic codes are not present for the
other ECM in the event list.
Repair: The Transmission ECM has failed. It is
unlikely that the Transmission ECM has failed. Exit
this procedure. Perform this procedure again. If the
failure is not found, replace the Transmission ECM.
STOP.
NOT OK Diagnostic codes are present for the
other ECM in the event list.
84 KENR9023-01
Troubleshooting Section

Repair: Perform the troubleshooting procedure for i03479747

the other diagnostic codes.
MID 161 - CID 0533 - FMI 02
STOP.
SMCS Code: 7610-038-BRK

i03661400 Conditions Which Generate This Code:

MID 161 - CID 0296 - FMI 14
SMCS Code: 7610-038-DTN

Conditions Which Generate This Code:

This diagnostic code is recorded when the software is

not matched between two Electronic Control Modules
(ECM). This may happen when the software for one
ECM has been updated, but the software for another
ECM must be updated in order to match the first
ECM.

System Response:

This failure results in events that are logged

to the VIMS 3G Main ECM that can not be
explained directly. The VIMS 3G Main ECM cannot
communicate correctly with the Transmission ECM.

Refer to Service Manual, KENR9023, Electronic

Control Module (ECM) - Flash Program and follow
the instructions in order to Flash the correct software
to both of the ECM.

Results:

STOP.

g01969413
Illustration 87
Schematic of the data link

This diagnostic code is recorded when the VIMS 3G

Main ECM receives data from the Brake ECM that is
erratic or incorrect.

System Response:

This failure results in events that are logged against

the Brake ECM that can not be explained directly.
The VIMS 3G Main ECM cannot communicate
with the Brake ECM or the Brake ECM appears to
communicate intermittently.
KENR9023-01
Test Step 1. VERIFY THE HARDWARE
AND THE SOFTWARE PART NUMBERS.
A. Verify that the following information is correct:
The part number of the VIMS 3G Main ECM
onboard software
The part number of the flash software for the
Brake ECM
The part number of the VIMS 3G Main ECM
The part number of the Brake ECM
Note: Consult the Business Unit that produces
the product for the correct part numbers of the
configuration software.
Expected Result:
All part numbers are correct.
Results:
OK All part numbers are correct. Proceed to
Test Step 2.
NOT OK All part numbers are NOT correct.
Repair: The installed VIMS 3G Main ECM or
the Brake ECM has the wrong part number or
the incorrect configuration software is installed.
Replace the incorrect VIMS 3G Main ECM or the
brake ECM with an ECM that has the correct part
number. Refer to Service Manual, KENR9023,
Electronic Control Module (ECM) - Replace.
Flash the correct configuration software. Refer to
Service Manual, KENR9023, Electronic Control
Module (ECM) - Flash Program.
STOP.
Test Step 2. INSPECT THE HARNESS
CONNECTIONS.
A. Turn the disconnect switch to the OFF position.
B. Inspect all harness connections that are related to
the Cat Data Link. Make sure that the connectors
are clean and tight.
C. Check the connectors for proper mating. Ensure
that all the seals are present and in place.
D. Check the harness for signs of damage or
abrasion.
E. Check the wires at the connector. Ensure that the
wires are secured tightly into the connector. Take
care not to pull the wire out of the connector.
85
Troubleshooting Section
F. Check the exposed wires at the connectors for
nicks or signs of abrasion.
G. Check for moisture inside the connector.
H. Check the connectors for dirty contacts or
corroded contacts.
I. Check each pin and each socket of the machine
harness connectors. Ensure that the contacts
are properly installed. The contacts should mate
correctly when the two pieces of the connector
are placed together.
Expected Result:
The machine harness connectors are tight and free
of corrosion.
Results:
OK The machine harness connectors are tight
and free of corrosion. Proceed to Test Step 3.
NOT OK The machine harness connectors are
in need of repair.
Repair: Repair the machine harness or replace the
machine harness.
STOP.
Test Step 3. CHECK FOR SHORTS TO
GROUND
A. The disconnect switch remains in the OFF
position.
B. Disconnect all ECM from the Cat Data Link.
C. At the machine harness for the VIMS 3G Main
ECM, measure the resistance between frame
ground and connector contacts 8 (wire 893-GN)
and 9 (wire 892-BR) of the Cat Data Link circuit.
Expected Result:
The resistance is greater than 5000 ohms.
Results:
OK The resistance is greater than 5000 ohms.
The harness circuit resistance is correct. Proceed
to Test Step 4.
NOT OK The resistance is less than 5000 ohms.
The machine harness has failed.
86
Troubleshooting Section
Repair: There is a short between frame ground
and the Cat Data Link circuit in the machine
harness. Repair the machine harness or replace
the machine harness.
STOP.
Test Step 4. CHECK FOR SHORT TO
+BATTERY
A. The disconnect switch remains in the OFF
position.
B. All of the related ECM remain disconnected from
the machine harness.
C. At the machine harness connector for the Brake
ECM, perform the checks that are listed here:
Measure the resistance between the +Battery
connector contact J1-31 (wire 176-RD) and
connector contact J1-10 (wire 893-GN).
Measure the resistance between connector
contact J1-31 (wire 176-RD) and connector
contact J1-20 (wire 892-BR).
Expected Result:
The resistance is greater than 5000 ohms.
Results:
OK The harness circuit resistance is correct.
Proceed to Test Step 5.
NOT OK The resistance is less than 5000 ohms.
The machine harness has failed.
Repair: There is a short between the +battery
and the Cat Data Link circuit in the machine
harness. Repair the machine harness or replace
the machine harness.
STOP.
Test Step 5. CHECK FOR OPEN HARNESS
A. The disconnect switch remains in the OFF
position.
B. Ensure that all of the ECM are disconnected from
the machine harness.
C. Check the continuity of the Cat Data Link circuit
in the machine harness:
Measure the resistance between connector
contact 8 (wire 893-GN) of the VIMS 3G
Main ECM and connector contact J1-10 (wire
893-GN) of the Brake ECM.
KENR9023-01
Measure the resistance between connector
contact 9 (wire 892-BR) of the VIMS 3G
Main ECM and connector contact J1-20 (wire
892-BR) of the Brake ECM.
Expected Result:
The resistance measures less than 5 ohms.
Results:
OK The resistance is less than 5 ohms. The Cat
Data Link circuit in the machine harness is correct.
Proceed to Test Step 6.
NOT OK The resistance is greater than 5 Ohms.
The machine harness has failed.
Repair: The Cat Data Link circuit is open in the
machine harness. Repair the machine harness or
replace the machine harness.
STOP.
Test Step 6. CHECK FOR ADDITIONAL
DIAGNOSTIC CODES FOR THE OTHER
ECM.
A. Reconnect all of the ECM that use the Cat Data
Link.
B. Turn the disconnect switch and the key start
switch to the ON position.
C. Check the Event List for diagnostic codes that are
logged against the other ECM.
Expected Result:
Diagnostic codes are not present for the other ECM
in the event list.
Results:
OK Diagnostic codes are not present for the
other ECM in the event list.
Repair: The Brake ECM has failed. It is unlikely
that the Brake ECM has failed. Exit this procedure.
Perform this procedure again. If the failure is not
found, replace the Brake ECM.
STOP.
NOT OK Diagnostic codes are present for the
other ECM in the event list.
Repair: Perform the troubleshooting procedure for
the other diagnostic codes.
STOP.
KENR9023-01 87
Troubleshooting Section

i03480605 Test Step 1. VERIFY THE HARDWARE

AND THE SOFTWARE PART NUMBERS.
MID 161 - CID 0533 - FMI 09
A. Verify that the following information is correct:
SMCS Code: 7610-038-BRK
The part number of the VIMS 3G Main ECM
Conditions Which Generate This Code: onboard software

The part number of the flash software for the

Brake ECM

The part number of the VIMS 3G Main ECM

The part number of the Brake ECM
Note: Consult the Business Unit that produces
the product for the correct part numbers of the
configuration software.

Expected Result:

All part numbers are correct.

Results:

OK All part numbers are correct. Proceed to

Test Step 2.

NOT OK All part numbers are NOT correct.

Repair: The installed VIMS 3G Main ECM or
the Brake ECM has the wrong part number or
the incorrect configuration software is installed.
Replace the incorrect VIMS 3G Main ECM or the
brake ECM with an ECM that has the correct part
number. Refer to the Service Manual, KENR9023,
Electronic Control Module (ECM) - Replace.
Flash the correct configuration software. Refer
to the Service Manual, KENR9023, Electronic
Control Module (ECM) - Flash Program.

STOP.

Test Step 2. INSPECT THE HARNESS

CONNECTIONS.
A. Turn the disconnect switch to the OFF position.
g01969413
Illustration 88 B. Inspect all harness connections that are related to
Schematic of the data link the Cat Data Link. Make sure that the connectors
are clean and tight.
This diagnostic code is recorded when the VIMS 3G
Main ECM does not receive expected information C. Check the connectors for proper mating. Ensure
from the Brake ECM through the Cat Data Link at that all the seals are present and in place.
the correct update rate.
D. Check the harness for signs of damage or
System Response: abrasion.

This failure results in events that are logged against
the Brake ECM that can not be explained directly.
The VIMS 3G Main ECM cannot communicate
with the Brake ECM or the Brake ECM appears to
communicate intermittently.
E. Check the wires at the connector. Ensure that the
wires are secured tightly into the connector. Take
care not to pull the wire out of the connector.
88
Troubleshooting Section
F. Check the exposed wires at the connectors for
nicks or signs of abrasion.
G. Check for moisture inside the connector.
H. Check the connectors for dirty contacts or
corroded contacts.
I. Check each pin and each socket of the machine
harness connectors. Ensure that the contacts
are properly installed. The contacts should mate
correctly when the two pieces of the connector
are placed together.
Expected Result:
The machine harness connectors are tight and free
of corrosion.
Results:
OK The machine harness connectors are tight
and free of corrosion. Proceed to Test Step 3.
NOT OK The machine harness connectors are
in need of repair.
Repair: Repair the machine harness or replace the
machine harness.
STOP.
Test Step 3. CHECK FOR SHORTS TO
GROUND
A. The disconnect switch remains in the OFF
position.
B. Disconnect all ECM from the Cat Data Link.
C. At the machine harness for the VIMS 3G Main
ECM, measure the resistance between frame
ground and connector contacts 8 (wire 893-GN)
and 9 (wire 892-BR) of the Cat Data Link circuit.
Expected Result:
The resistance is greater than 5000 ohms.
Results:
OK The resistance is greater than 5000 ohms.
The harness circuit resistance is correct. Proceed
to Test Step 4.
NOT OK The resistance is less than 5000 ohms.
The machine harness has failed.
KENR9023-01
Repair: There is a short between frame ground
and the Cat Data Link circuit in the machine
harness. Repair the machine harness or replace
the machine harness.
STOP.
Test Step 4. CHECK FOR SHORT TO
+BATTERY
A. The disconnect switch remains in the OFF
position.
B. All of the related ECM remain disconnected from
the machine harness.
C. At the machine harness connector for the Brake
ECM, perform the checks that are listed here:
Measure the resistance between the +Battery
connector contact J1-31 (wire 176-RD) and
connector contact J1-10 (wire 893-GN).
Measure the resistance between connector
contact J1-31 (wire 176-RD) and connector
contact J1-20 (wire 892-BR).
Expected Result:
The resistance is greater than 5000 ohms.
Results:
OK The harness circuit resistance is correct.
Proceed to Test Step 5.
NOT OK The resistance is less than 5000 ohms.
The machine harness has failed.
Repair: There is a short between the +battery
and the Cat Data Link circuit in the machine
harness. Repair the machine harness or replace
the machine harness.
STOP.
Test Step 5. CHECK FOR OPEN HARNESS
A. The disconnect switch remains in the OFF
position.
B. Ensure that all of the ECM are disconnected from
the machine harness.
C. Check the continuity of the Cat Data Link circuit
in the machine harness:
Measure the resistance between connector
contact 8 (wire 893-GN) of the VIMS 3G
Main ECM and connector contact J1-10 (wire
893-GN) of the Brake ECM.
KENR9023-01 89
Troubleshooting Section

Measure the resistance between connector i03480607

contact 9 (wire 892-BR) of the VIMS 3G
Main ECM and connector contact J1-20 (wire
892-BR) of the Brake ECM.
Expected Result:
The resistance measures less than 5 ohms.
Results:
OK The resistance is less than 5 ohms. The Cat
Data Link circuit in the machine harness is correct.
Proceed to Test Step 6.
MID 161 - CID 0533 - FMI 14
SMCS Code: 7610-038-BRK
Conditions Which Generate This Code:
This diagnostic code is recorded when the software is
not matched between two Electronic Control Modules
(ECM). This may happen when the software for one
ECM has been updated, but the software for another
ECM must be updated in order to match the first
ECM.

NOT OK The resistance is greater than 5 Ohms. System Response:

The machine harness has failed.
Repair: The Cat Data Link circuit is open in the
machine harness. Repair the machine harness or
replace the machine harness.
This failure results in events that are logged
to the VIMS 3G Main ECM that can not be
explained directly. The VIMS 3G Main ECM cannot
communicate correctly with the Brake ECM.

STOP. Refer to Service Manual, KENR9023, Electronic

Control Module (ECM) - Flash Program and follow
Test Step 6. CHECK FOR ADDITIONAL the instructions in order to Flash the correct software
DIAGNOSTIC CODES FOR THE OTHER to both of the ECM.
ECM.
Results:
A. Reconnect all of the ECM that use the Cat Data
Link. STOP.

B. Turn the disconnect switch and the key start

switch to the ON position.

C. Check the Event List for diagnostic codes that are

logged against the other ECM.

Expected Result:

Diagnostic codes are not present for the other ECM

in the event list.

Results:

OK Diagnostic codes are not present for the

other ECM in the event list.

Repair: The Brake ECM has failed. It is unlikely

that the Brake ECM has failed. Exit this procedure.
Perform this procedure again. If the failure is not
found, replace the Brake ECM.

STOP.

NOT OK Diagnostic codes are present for the

other ECM in the event list.

Repair: Perform the troubleshooting procedure for

the other diagnostic codes.

STOP.
90 KENR9023-01
Troubleshooting Section

i03480608 Test Step 1. VERIFY THE HARDWARE

AND THE SOFTWARE PART NUMBERS.
MID 161 - CID 0590 - FMI 02
A. Verify that the following information is correct:
SMCS Code: 1901-038; 7610-038-ENG
The part number of the VIMS 3G Main ECM
Conditions Which Generate This Code: onboard software

The part number of the flash software for the

Engine ECM

The part number of the VIMS 3G Main ECM

The part number of the Engine ECM
Note: Consult the Business Unit that produces
the product for the correct part numbers of the
configuration software.

Expected Result:

All part numbers are correct.

Results:

OK All part numbers are correct. Proceed to

Test Step 2.

NOT OK All part numbers are NOT correct.

Repair: The installed VIMS 3G Main ECM or
the Engine ECM has the wrong part number or
the incorrect configuration software is installed.
Replace the incorrect VIMS 3G Main ECM or the
Engine ECM with an ECM that has the correct
part number. Refer to Service Manual, Electronic
Control Module (ECM) - Replace. Flash the
correct configuration software. Refer to Service
Manual, Electronic Control Module (ECM) - Flash
Program.

STOP.

Test Step 2. INSPECT THE HARNESS

CONNECTIONS.
A. Turn the disconnect switch to the OFF position.
g01969413
Illustration 89 B. Inspect all harness connections that are related to
Schematic of the data link the Cat Data Link. Make sure that the connectors
are clean and tight.
This diagnostic code is recorded when the VIMS 3G
Main ECM receives data from the Engine ECM that C. Check the connectors for proper mating. Ensure
is erratic or incorrect. that all the seals are present and in place.

System Response: D. Check the harness for signs of damage or

This failure results in events that are logged against
the Engine ECM that can not be explained directly.
The VIMS 3G Main ECM cannot communicate with
the Engine ECM or the Engine ECM appears to
communicate intermittently.
abrasion.
E. Check the wires at the connector. Ensure that the
wires are secured tightly into the connector. Take
care not to pull the wire out of the connector.
KENR9023-01
F. Check the exposed wires at the connectors for
nicks or signs of abrasion.
G. Check for moisture inside the connector.
H. Check the connectors for dirty contacts or
corroded contacts.
I. Check each pin and each socket of the machine
harness connectors. Ensure that the contacts
are properly installed. The contacts should mate
correctly when the two pieces of the connector
are placed together.
Expected Result:
The machine harness connectors are tight and free
of corrosion.
Results:
OK The machine harness connectors are tight
and free of corrosion. Proceed to Test Step 3.
NOT OK The machine harness connectors are
in need of repair.
Repair: Repair the machine harness or replace the
machine harness.
STOP.
Test Step 3. CHECK FOR SHORTS TO
GROUND
A. The disconnect switch remains in the OFF
position.
B. Disconnect all ECM from the Cat Data Link.
C. At the machine harness for the VIMS 3G Main
ECM, measure the resistance between frame
ground and connector contacts 8 (wire 893-GN)
and 9 (wire 892-BR) of the Cat Data Link circuit.
Expected Result:
The resistance is greater than 5000 ohms.
Results:
OK The resistance is greater than 5000 ohms.
The harness circuit resistance is correct. Proceed
to Test Step 4.
NOT OK The resistance is less than 5000 ohms.
The machine harness has failed.
91
Troubleshooting Section
Repair: There is a short between frame ground
and the Cat Data Link circuit in the machine
harness. Repair the machine harness or replace
the machine harness.
STOP.
Test Step 4. CHECK FOR SHORT TO
+BATTERY
A. The disconnect switch remains in the OFF
position.
B. All of the related ECM remain disconnected from
the machine harness.
C. At the machine harness connector for the Engine
ECM, perform the checks that are listed here:
Measure the resistance between the +Battery
connector contact J1-52 (wire 150-RD) and
connector contact J1-8 (wire 893-GN).
Measure the resistance between connector
contact J1-52 (wire 150-RD) and connector
contact J1-9 (wire 892-BR).
Expected Result:
The resistance is greater than 5000 ohms.
Results:
OK The harness circuit resistance is correct.
Proceed to Test Step 5.
NOT OK The resistance is less than 5000 ohms.
The machine harness has failed.
Repair: There is a short between the +battery
and the Cat Data Link circuit in the machine
harness. Repair the machine harness or replace
the machine harness.
STOP.
Test Step 5. CHECK FOR OPEN HARNESS
A. The disconnect switch remains in the OFF
position.
B. Ensure that all of the ECM are disconnected from
the machine harness.
C. Check the continuity of the Cat Data Link circuit
in the machine harness:
Measure the resistance between connector
contact 8 (wire 893-GN) of the VIMS 3G Main
ECM and connector contact J1-8 (wire 893-GN)
of the Engine ECM.
92 KENR9023-01
Troubleshooting Section

Measure the resistance between connector i03480609

contact 9 (wire 892-BR) of the VIMS 3G Main
ECM and connector contact J1-9 (wire 892-BR) MID 161 - CID 0590 - FMI 09
of the Engine ECM.
SMCS Code: 1901-038; 7610-038-ENG
Expected Result:
Conditions Which Generate This Code:
The resistance measures less than 5 ohms.

Results:

OK The resistance is less than 5 ohms. The Cat

Data Link circuit in the machine harness is correct.
Proceed to Test Step 6.

NOT OK The resistance is greater than 5 Ohms.

The machine harness has failed.

Repair: The Cat Data Link circuit is open in the

machine harness. Repair the machine harness or
replace the machine harness.

STOP.

Test Step 6. CHECK FOR ADDITIONAL

DIAGNOSTIC CODES FOR THE OTHER
ECM.
A. Reconnect all of the ECM that use the Cat Data
Link.

B. Turn the disconnect switch and the key start

switch to the ON position.

C. Check the Event List for diagnostic codes that are

logged against the other ECM.

Expected Result:

Diagnostic codes are not present for the other ECM

in the event list.

Results:

OK Diagnostic codes are not present for the

other ECM in the event list.

Repair: The Engine ECM has failed. It is unlikely g01969413

that the Engine ECM has failed. Exit this procedure.
Perform this procedure again. If the failure is not
found, replace the Engine ECM.
STOP.
NOT OK Diagnostic codes are present for the
other ECM in the event list.
Repair: Perform the troubleshooting procedure for
the other diagnostic codes.
STOP.
Illustration 90
Schematic of the data link
This diagnostic code is recorded when the VIMS 3G
Main ECM does not receive expected information
from the Engine ECM through the Cat Data Link at
the correct update rate.
System Response:
This failure results in events that are logged against
the Engine ECM that can not be explained directly.
The VIMS 3G Main ECM cannot communicate with
the Engine ECM or the Engine ECM appears to
communicate intermittently.
KENR9023-01
Test Step 1. VERIFY THE HARDWARE
AND THE SOFTWARE PART NUMBERS.
A. Verify that the following information is correct:
The part number of the VIMS 3G Main ECM
onboard software
The part number of the flash software for the
Engine ECM
The part number of the VIMS 3G Main ECM
The part number of the Engine ECM
Note: Consult the Business Unit that produces
the product for the correct part numbers of the
configuration software.
Expected Result:
All part numbers are correct.
Results:
OK All part numbers are correct. Proceed to
Test Step 2.
NOT OK All part numbers are NOT correct.
Repair: The installed VIMS 3G Main ECM or
the Engine ECM has the wrong part number or
the incorrect configuration software is installed.
Replace the incorrect VIMS 3G Main ECM or the
Engine ECM with an ECM that has the correct part
number. Refer to Service Manual, KENR9023,
Electronic Control Module (ECM) - Replace.
Flash the correct configuration software. Refer to
Service Manual, KENR9023, Electronic Control
Module (ECM) - Flash Program.
STOP.
Test Step 2. INSPECT THE HARNESS
CONNECTIONS.
A. Turn the disconnect switch to the OFF position.
B. Inspect all harness connections that are related to
the Cat Data Link. Make sure that the connectors
are clean and tight.
C. Check the connectors for proper mating. Ensure
that all the seals are present and in place.
D. Check the harness for signs of damage or
abrasion.
E. Check the wires at the connector. Ensure that the
wires are secured tightly into the connector. Take
care not to pull the wire out of the connector.
93
Troubleshooting Section
F. Check the exposed wires at the connectors for
nicks or signs of abrasion.
G. Check for moisture inside the connector.
H. Check the connectors for dirty contacts or
corroded contacts.
I. Check each pin and each socket of the machine
harness connectors. Ensure that the contacts
are properly installed. The contacts should mate
correctly when the two pieces of the connector
are placed together.
Expected Result:
The machine harness connectors are tight and free
of corrosion.
Results:
OK The machine harness connectors are tight
and free of corrosion. Proceed to Test Step 3.
NOT OK The machine harness connectors are
in need of repair.
Repair: Repair the machine harness or replace the
machine harness.
STOP.
Test Step 3. CHECK FOR SHORTS TO
GROUND
A. The disconnect switch remains in the OFF
position.
B. Disconnect all ECM from the Cat Data Link.
C. At the machine harness for the VIMS 3G Main
ECM, measure the resistance between frame
ground and connector contacts 8 (wire 893-GN)
and 9 (wire 892-BR) of the Cat Data Link circuit.
Expected Result:
The resistance is greater than 5000 ohms.
Results:
OK The resistance is greater than 5000 ohms.
The harness circuit resistance is correct. Proceed
to Test Step 4.
NOT OK The resistance is less than 5000 ohms.
The machine harness has failed.
94
Troubleshooting Section
Repair: There is a short between frame ground
and the Cat Data Link circuit in the machine
harness. Repair the machine harness or replace
the machine harness.
STOP.
Test Step 4. CHECK FOR SHORT TO
+BATTERY
A. The disconnect switch remains in the OFF
position.
B. All of the related ECM remain disconnected from
the machine harness.
C. At the machine harness connector for the Engine
ECM, perform the checks that are listed here:
Measure the resistance between the +Battery
connector contact J1-52 (wire 150-RD) and
connector contact J1-8 (wire 893-GN).
Measure the resistance between connector
contact J1-52 (wire 150-RD) and connector
contact J1-9 (wire 892-BR).
Expected Result:
The resistance is greater than 5000 ohms.
Results:
OK The harness circuit resistance is correct.
Proceed to Test Step 5.
NOT OK The resistance is less than 5000 ohms.
The machine harness has failed.
Repair: There is a short between the +battery
and the Cat Data Link circuit in the machine
harness. Repair the machine harness or replace
the machine harness.
STOP.
Test Step 5. CHECK FOR OPEN HARNESS
A. The disconnect switch remains in the OFF
position.
B. Ensure that all of the ECM are disconnected from
the machine harness.
C. Check the continuity of the Cat Data Link circuit
in the machine harness:
Measure the resistance between connector
contact 8 (wire 893-GN) of the VIMS 3G Main
ECM and connector contact J1-8 (wire 893-GN)
of the Engine ECM.
KENR9023-01
Measure the resistance between connector
contact 9 (wire 892-BR) of the VIMS 3G Main
ECM and connector contact J1-9 (wire 892-BR)
of the Engine ECM.
Expected Result:
The resistance measures less than 5 ohms.
Results:
OK The resistance is less than 5 ohms. The Cat
Data Link circuit in the machine harness is correct.
Proceed to Test Step 6.
NOT OK The resistance is greater than 5 Ohms.
The machine harness has failed.
Repair: The Cat Data Link circuit is open in the
machine harness. Repair the machine harness or
replace the machine harness.
STOP.
Test Step 6. CHECK FOR ADDITIONAL
DIAGNOSTIC CODES FOR THE OTHER
ECM.
A. Reconnect all of the ECM that use the Cat Data
Link.
B. Turn the disconnect switch and the key start
switch to the ON position.
C. Check the Event List for diagnostic codes that are
logged against the other ECM.
Expected Result:
Diagnostic codes are not present for the other ECM
in the event list.
Results:
OK Diagnostic codes are not present for the
other ECM in the event list.
Repair: The Engine ECM has failed. It is unlikely
that the Engine ECM has failed. Exit this procedure.
Perform this procedure again. If the failure is not
found, replace the Engine ECM.
STOP.
NOT OK Diagnostic codes are present for the
other ECM in the event list.
Repair: Perform the troubleshooting procedure for
the other diagnostic codes.
STOP.
KENR9023-01
i03480611
MID 161 - CID 0590 - FMI 14
SMCS Code: 1901-038; 7610-038-ENG
Conditions Which Generate This Code:
This diagnostic code is recorded when the software is
not matched between two Electronic Control Modules
(ECM). This may happen when the software for one
ECM has been updated, but the software for another
ECM must be updated in order to match the first
ECM.
System Response:
This failure results in events that are logged
to the VIMS 3G Main ECM that can not be
explained directly. The VIMS 3G Main ECM cannot
communicate correctly with the Engine ECM.
Refer to Service Manual, KENR9023, Electronic
Control Module (ECM) - Flash Program and follow
the instructions in order to Flash the correct software
to both of the ECM.
Results:
STOP.
i03663631
MID 161 - CID 0768 - FMI 09
SMCS Code: 7601-038
Conditions Which Generate This Code:
g01966493
Illustration 91
Schematic of the RS-485 network
95
Troubleshooting Section
This diagnostic code is recorded if the VIMS 3G Main
ECM has detected an abnormal update rate from the
RS-485 Data Link communication.
System Response:
This failure results in events that are logged
to the VIMS 3G Main ECM that can not be
explained directly. The VIMS 3G Main ECM cannot
communicate correctly with the RS-485 data link.
Test Step 1. VERIFY THE HARDWARE
AND THE SOFTWARE PART NUMBERS.
A. Verify that the following information is correct:
The part number of the VIMS 3G Main ECM
onboard software
The part number of the VIMS 3G Main ECM
Note: Consult the Business Unit that produces
the product for the correct part numbers of the
configuration software.
Expected Result:
All part numbers are correct.
Results:
OK All part numbers are correct. Proceed to
Test Step 2.
NOT OK All part numbers are NOT correct.
Repair: The installed VIMS 3G Main ECM has the
wrong part number or the incorrect configuration
software is installed. Replace the incorrect VIMS
3G Main ECM with an ECM that has the correct
part number. Refer to Service Manual, KENR9023,
Electronic Control Module (ECM) - Replace.
Flash the correct configuration software. Refer to
Service Manual, KENR9023, Electronic Control
Module (ECM) - Flash Program.
STOP.
Test Step 2. INSPECT THE HARNESS
CONNECTIONS.
A. Turn the disconnect switch to the OFF position.
B. Inspect all harness connections that are related
to the RS-485 data link. Make sure that the
connectors are clean and tight.
C. Check the connectors for proper mating. Ensure
that all the seals are present and in place.
D. Check the harness for signs of damage or
abrasion.
96
Troubleshooting Section
E. Check the wires at the connector. Ensure that the
wires are secured tightly into the connector. Take
care not to pull the wire out of the connector.
F. Check the exposed wires at the connectors for
nicks or signs of abrasion.
G. Check for moisture inside the connector.
H. Check the connectors for dirty contacts or
corroded contacts.
I. Check each pin and each socket of the machine
harness connectors. Ensure that the contacts
are properly installed. The contacts should mate
correctly when the two pieces of the connector
are placed together.
Expected Result:
The machine harness connectors are tight and free
of corrosion.
Results:
OK The machine harness connectors are tight
and free of corrosion. Proceed to Test Step 4.
NOT OK The machine harness connectors are
in need of repair.
Repair: Repair the machine harness or replace the
machine harness.
STOP.
Test Step 3. CHECK THE 120 OHM
TERMINATING RESISTORS
A. The disconnect switch remains in the OFF
position.
B. Disconnect both of the VIMS 3G ECM from the
RS-485 data link.
C. At the machine harness for the VIMS 3G Main
ECM , measure the resistance between connector
contacts that follow:
Contact 4 (939-WH) and Contact 5 (940-BU)
Contact 17 (920-BR) and Contact 18 (921-YL)
Expected Result:
The resistance is approximately 60 ohms.
Results:
OK The resistance is approximately 60 ohms.
The terminating resistors are correct. Proceed to
Test Step 5.
KENR9023-01
NOT OK The resistance is not approximately
60 ohms. The machine harness has failed or the
terminating resistor has failed.
Repair: Repair the machine harness or replace
the terminating resistor.
STOP.
Test Step 4. CHECK FOR SHORTS TO
GROUND
A. The disconnect switch remains in the OFF
position.
B. Disconnect both of the VIMS 3G ECM from the
RS-485 data link.
C. At the machine harness for the VIMS 3G Main
ECM , measure the resistance between frame
ground and connector contacts that follow:
Contact 4 (939-WH)
Contact 5 (940-BU)
Contact 6 (969-GY)
Contact 17 (920-BR)
Contact 18 (921-YL)
Expected Result:
The resistance is greater than 5000 ohms.
Results:
OK The resistance is greater than 5000 ohms.
The harness circuit resistance is correct. Proceed
to Test Step 5.
NOT OK The resistance is less than 5000 ohms.
The machine harness has failed.
Repair: There is a short between frame ground
and the RS-485 data link circuit in the machine
harness. Repair the machine harness or replace
the machine harness.
STOP.
Test Step 5. CHECK FOR SHORT TO
+BATTERY
A. The disconnect switch remains in the OFF
position.
B. All of the related ECM remain disconnected from
the machine harness.
KENR9023-01 97
Troubleshooting Section

C. At the machine harness connector for the VIMS Results:

3G Main ECM , perform the checks that are listed
here:
Measure the resistance between the +Battery
connector contact 52 (wire 170-RD) on the
VIMS 3G Main ECM connector and connector
contacts that follow:
OK The resistance is less than 5 ohms. The
RS-485 data link circuit in the machine harness is
correct. Proceed to Test Step 7.
NOT OK The resistance is greater than 5 Ohms.
The machine harness has failed.

Contact 4 (939-WH) Repair: The RS-485 data link circuit is open in the
machine harness. Repair the machine harness or
Contact 5 (940-BU) replace the machine harness.

Contact 6 (969-GY) STOP.

Contact 17 (920-BR) Test Step 7. CHECK FOR ADDITIONAL

DIAGNOSTIC CODES FOR THE OTHER
Contact 18 (921-YL) ECM.
Expected Result: A. Reconnect all of the ECM that use the RS-485
data link.
The resistance is greater than 5000 ohms.
B. Turn the disconnect switch and the key start
Results: switch to the ON position.

OK The harness circuit resistance is correct. C. Check the Event List for diagnostic codes that are
Proceed to Test Step 6. logged against the other ECM.

NOT OK The resistance is less than 5000 ohms. Expected Result:

The machine harness has failed.
Repair: There is a short between the +battery
and the Cat Data Link circuit in the machine
harness. Repair the machine harness or replace
the machine harness.
STOP.
Diagnostic codes are not present for the other ECM
in the event list.
Results:
NOT OK Diagnostic codes are present for the
other ECM in the event list.

Test Step 6. CHECK FOR OPEN HARNESS Repair: Perform the troubleshooting procedure for
the other diagnostic codes.
A. The disconnect switch remains in the OFF
position. STOP.

B. Ensure that the VIMS 3G ECM are disconnected

i03661389
from the machine harness.

C. Check the continuity of the RS-485 data link circuit

in the connections that follow:
Table 16
VIMS 3G Main ECM VIMS 3G Application ECM
Contact 4 (939-WH) to Contact 17 (939-WH)
Contact 5 (940-BU) to Contact 18 (940-BU)
Contact 6 (969-GY) to Contact 6 (969-GY)
Contact 17 (920-BR) to Contact 4 (920-BR)
Contact 18 (921-YL) to Contact 5 (921-YL)
MID 161 - CID 0768 - FMI 14
SMCS Code: 7601-038
Conditions Which Generate This Code:
This diagnostic code is recorded when the software is
not matched between two Electronic Control Modules
(ECM). This may happen when the software for one
ECM has been updated, but the software for another
ECM must be updated in order to match the first
ECM.

Expected Result:

The resistance measures less than 5 ohms.

98 KENR9023-01
Troubleshooting Section

System Response: i03664903

This failure results in events that are logged MID 161 - CID 0800 - FMI 08
to the VIMS 3G Main ECM that can not be
explained directly. The VIMS 3G Main ECM cannot SMCS Code: 7601-038
communicate correctly with the RS-485 data link.
Conditions Which Generate This Code:
Refer to Service Manual, KENR9023, Electronic
Control Module (ECM) - Flash Program and follow
the instructions in order to Flash the correct software
to the VIMS 3G Main ECM.

Results:

STOP.

g01969413
Illustration 92
Schematic of the data link

System Response:

This diagnostic code is recorded when the VIMS 3G

Main ECM has an abnormal frequency, pulse period,
or pulse width.

Test Step 1. VERIFY THE HARDWARE

AND THE SOFTWARE PART NUMBERS.
A. Verify that the following information is correct:
KENR9023-01
The part number of the VIMS 3G Main ECM
onboard software
The part number of the VIMS 3G Main ECM
Note: Consult the Business Unit that produces
the product for the correct part numbers of the
configuration software.
Expected Result:
All part numbers are correct.
Results:
OK All part numbers are correct. Proceed to
Test Step 2.
NOT OK All part numbers are NOT correct.
Repair: The installed VIMS 3G Main ECM has the
wrong part number or the incorrect configuration
software is installed. Replace the incorrect VIMS
3G Main ECM with an ECM that has the correct
part number. Refer to Service Manual, KENR9023,
Electronic Control Module (ECM) - Replace.
Flash the correct configuration software. Refer to
Service Manual, KENR9023, Electronic Control
Module (ECM) - Flash Program.
STOP.
Test Step 2. INSPECT THE HARNESS
CONNECTIONS.
A. Turn the disconnect switch to the OFF position.
B. Inspect all harness connections that are related to
the Cat Data Link. Make sure that the connectors
are clean and tight.
C. Check the connectors for proper mating. Ensure
that all the seals are present and in place.
D. Check the harness for signs of damage or
abrasion.
E. Check the wires at the connector. Ensure that the
wires are secured tightly into the connector. Take
care not to pull the wire out of the connector.
F. Check the exposed wires at the connectors for
nicks or signs of abrasion.
G. Check for moisture inside the connector.
H. Check the connectors for dirty contacts or
corroded contacts.
99
Troubleshooting Section
I. Check each pin and each socket of the machine
harness connectors. Ensure that the contacts
are properly installed. The contacts should mate
correctly when the two pieces of the connector
are placed together.
Expected Result:
The machine harness connectors are tight and free
of corrosion.
Results:
OK The machine harness connectors are tight
and free of corrosion. Proceed to Test Step 3.
NOT OK The machine harness connectors are
in need of repair.
Repair: Repair the machine harness or replace the
machine harness.
STOP.
Test Step 3. CHECK FOR SHORTS TO
GROUND
A. The disconnect switch remains in the OFF
position.
B. Disconnect all ECM from the Cat Data Link.
C. At the machine harness for the VIMS 3G Main
ECM, measure the resistance between frame
ground and connector contacts 8 (wire 893-GN)
and 9 (wire 892-BR) of the Cat Data Link circuit.
Expected Result:
The resistance is greater than 5000 ohms.
Results:
OK The resistance is greater than 5000 ohms.
The harness circuit resistance is correct. Proceed
to Test Step 4.
NOT OK The resistance is less than 5000 ohms.
The machine harness has failed.
Repair: There is a short between frame ground
and the Cat Data Link circuit in the machine
harness. Repair the machine harness or replace
the machine harness.
STOP.
Test Step 4. CHECK FOR SHORT TO
+BATTERY
A. The disconnect switch remains in the OFF
position.
100
Troubleshooting Section
B. All of the related ECM remain disconnected from
the machine harness.
C. At the machine harness connector for the VIMS
3G Main ECM, perform the checks that are listed
here:
Measure the resistance between the +Battery
connector contact 52 (wire 170-RD) on the
VIMS 3G Main ECM and connector contact 8
(wire 893-GN).
Measure the resistance between the +Battery
connector contact 52 (wire 170-RD) on the
VIMS 3G Main ECM and connector contact 9
(wire 892-BR).
Expected Result:
The resistance is greater than 5000 ohms.
Results:
OK The harness circuit resistance is correct.
Proceed to Test Step 5.
NOT OK The resistance is less than 5000 ohms.
The machine harness has failed.
Repair: There is a short between the +battery
and the Cat Data Link circuit in the machine
harness. Repair the machine harness or replace
the machine harness.
STOP.
Test Step 5. CHECK FOR OPEN HARNESS
A. The disconnect switch remains in the OFF
position.
B. Ensure that all of the ECM are disconnected from
the machine harness.
C. Check the continuity of the Cat Data Link circuit
in the machine harness:
Measure the resistance between connector
contact 8 (wire 893-GN) of the VIMS 3G Main
ECM and connector contact 8 (wire 893-GN) of
the Engine ECM.
Measure the resistance between connector
contact 9 (wire 892-BR) of the VIMS 3G Main
ECM and connector contact 9 (wire 892-BR) of
the VIMS 3G Application ECM.
Expected Result:
The resistance measures less than 5 ohms.
KENR9023-01
Results:
OK The resistance is less than 5 ohms. The Cat
Data Link circuit in the machine harness is correct.
Proceed to Test Step 6.
NOT OK The resistance is greater than 5 Ohms.
The machine harness has failed.
Repair: The Cat Data Link circuit is open in the
machine harness. Repair the machine harness or
replace the machine harness.
STOP.
Test Step 6. CHECK FOR ADDITIONAL
DIAGNOSTIC CODES FOR THE OTHER
ECM.
A. Reconnect all of the ECM that use the Cat Data
Link.
B. Turn the disconnect switch and the key start
switch to the ON position.
C. Check the Event List for diagnostic codes that are
logged against the other ECM.
Expected Result:
Diagnostic codes are not present for the other ECM
in the event list.
Results:
OK Diagnostic codes are not present for the
other ECM in the event list.
Repair: The VIMS 3G Main ECM has failed.
It is unlikely that the ECM has failed. Exit this
procedure. Perform this procedure again. If the
failure is not found, replace the ECM. Refer to the
Service Manual, KENR9023, Electronic Control
Module (ECM) - Replace.
STOP.
NOT OK Diagnostic codes are present for the
other ECM in the event list.
Repair: Follow the procedure for the other
diagnostic codes that are present.
STOP.
KENR9023-01 101
Troubleshooting Section

i03665160

MID 161 - CID 0800 - FMI 11

SMCS Code: 7601-038

Conditions Which Generate This Code:

This diagnostic code is recorded when the Electronic

Control Module (ECM) has not been flashed with the
correct configuration file.

System Response:

This failure results in events that are logged to the

VIMS 3G Main ECM when the ECM is not configured
correctly.

Refer to Service Manual, KENR9023, Electronic

Control Module (ECM) - Flash Program and follow
the instructions in order to Flash the correct software
to the ECM.

Results:

STOP.

i03480627

MID 161 - CID 0890 - FMI 09

SMCS Code: 7610-038

Conditions Which Generate This Code:

g01968775
Illustration 93

This diagnostic code is recorded when Telemetry Expected Result:

data link communication with the VIMS 3G Main
ECM has an abnormal update rate.
Test Step 1. VERIFY THAT THE
BROADCAST SYSTEM IS FUNCTIONING
CORRECTLY.
A. Verify that the broadcast system (transmitter) is
operating correctly.
The broadcast system (transmitter) is operating
correctly.
Results:
YES The broadcast system (transmitter) is
operating correctly. proceed to Test Step 2.
NO The broadcast system (transmitter) is NOT
operating correctly.
102 KENR9023-01
Troubleshooting Section

Repair: Repair the broadcast system. Contact 13 (wire N957-PK).

STOP. Contact 22 (wire N960-OR).
Test Step 2. CHECK FOR AN OPEN IN Contact 23 (wire N970-YL).
THE MACHINE HARNESS
Contact 30 (wire N973-BR).
A. Turn the key start switch and the disconnect
switch to the OFF position. Expected Result:

B. Disconnect the connector from the VIMS 3G Main All the measurements are greater than 5000 ohms.
ECM.
Results:
C. Disconnect the RS232 port from the broadcast
system. OK All the measurements are greater than 5000
ohms. The machine harness is correct. The VIMS
D. Measure the resistance of the circuits that are 3G Main ECM has failed.
listed below:
Repair: It is unlikely that the VIMS 3G Main
Table 17 ECM has failed. Exit this procedure and perform
VIMS 3G Main ECM RS232 broadcast port this procedure again. If the failure is not found,
replace the VIMS 3G Main ECM. Refer to the
contact 13 (wire contact 5 (wire Service Manual, Electronic Control Module (ECM)
to
N957-PK) N957-PK) - Replace .
contact 22 (wire contact 7 (wire
to STOP.
N960-OR) N960-OR)
contact 31 (wire contact 8 (wire
N976-PU)
to
N976-PU) NOT OK A measurement is less than 5000
ohms. The machine harness has failed.
contact 23 (wire contact 9 (wire
to
N970-YL) N970-YL) Repair: Repair the machine harness or replace the
contact 30 (wire contact 10 (wire
machine harness.
to
N973-BR) N973-BR)
STOP.
Expected Result:

All the measurements are less than 5.0 ohms.

Results:

OK All the measurements are less than 5.0

ohms. proceed to test step 3.

NOT OK All the measurements are greater than

5000 ohms. The machine harness has failed.

Repair: Repair the machine harness or replace the

machine harness.

STOP.

Test Step 3. CHECK THE MACHINE

HARNESS FOR A SHORT TO GROUND.
A. The machine harness remains disconnected
from the VIMS 3G Main ECM and the broadcast
system.

B. Measure the resistance from frame ground to the

contacts on the connector for the VIMS 3G Main
ECM contacts that follow:
KENR9023-01
i03480629
MID 161 - CID 1089 - FMI 09
SMCS Code: 7601-038
Conditions Which Generate This Code:
g01969413
Illustration 94
Schematic of the data link
This diagnostic code is recorded when the VIMS 3G
Main ECM has an abnormal update rate with the
VIMS 3G Application ECM through the Cat data link.
System Response:
This failure results in events that are logged against
the VIMS 3G Application ECM that can not be
explained directly. The VIMS 3G Main ECM cannot
communicate with the VIMS 3G Application ECM
or the VIMS 3G Application ECM appears to
communicate intermittently.
103
Troubleshooting Section
Test Step 1. VERIFY THE HARDWARE
AND THE SOFTWARE PART NUMBERS.
A. Verify that the following information is correct:
The part number of the VIMS 3G Main ECM
onboard software
The part number of the flash software for the
VIMS 3G Application ECM
The part number of the VIMS 3G Main ECM
The part number of the VIMS 3G Application
ECM
Note: Consult the Business Unit that produces
the product for the correct part numbers of the
configuration software.
Expected Result:
All part numbers are correct.
Results:
OK All part numbers are correct. Proceed to
Test Step 2.
NOT OK All part numbers are NOT correct.
Repair: The installed VIMS 3G Main ECM or the
VIMS 3G Application ECM has the wrong part
number or the incorrect configuration software is
installed. Replace the incorrect VIMS 3G Main
ECM or the VIMS 3G Application ECM with an
ECM that has the correct part number. Refer
to Service Manual, Electronic Control Module
(ECM) - Replace. Flash the correct configuration
software. Refer to Service Manual, Electronic
Control Module (ECM) - Flash Program.
STOP.
Test Step 2. INSPECT THE HARNESS
CONNECTIONS.
A. Turn the disconnect switch to the OFF position.
B. Inspect all harness connections that are related to
the Cat Data Link. Make sure that the connectors
are clean and tight.
C. Check the connectors for proper mating. Ensure
that all the seals are present and in place.
D. Check the harness for signs of damage or
abrasion.
E. Check the wires at the connector. Ensure that the
wires are secured tightly into the connector. Take
care not to pull the wire out of the connector.
104
Troubleshooting Section
F. Check the exposed wires at the connectors for
nicks or signs of abrasion.
G. Check for moisture inside the connector.
H. Check the connectors for dirty contacts or
corroded contacts.
I. Check each pin and each socket of the machine
harness connectors. Ensure that the contacts
are properly installed. The contacts should mate
correctly when the two pieces of the connector
are placed together.
Expected Result:
The machine harness connectors are tight and free
of corrosion.
Results:
OK The machine harness connectors are tight
and free of corrosion. Proceed to Test Step 3.
NOT OK The machine harness connectors are
in need of repair.
Repair: Repair the machine harness or replace the
machine harness.
STOP.
Test Step 3. CHECK FOR SHORTS TO
GROUND
A. The disconnect switch remains in the OFF
position.
B. Disconnect all ECM from the Cat Data Link.
C. At the machine harness for the VIMS 3G Main
ECM, measure the resistance between frame
ground and connector contacts 8 (wire 893-GN)
and 9 (wire 892-BR) of the Cat Data Link circuit.
Expected Result:
The resistance is greater than 5000 ohms.
Results:
OK The resistance is greater than 5000 ohms.
The harness circuit resistance is correct. Proceed
to Test Step 4.
NOT OK The resistance is less than 5000 ohms.
The machine harness has failed.
KENR9023-01
Repair: There is a short between frame ground
and the Cat Data Link circuit in the machine
harness. Repair the machine harness or replace
the machine harness.
STOP.
Test Step 4. CHECK FOR SHORT TO
+BATTERY
A. The disconnect switch remains in the OFF
position.
B. All of the related ECM remain disconnected from
the machine harness.
C. At the machine harness connector for the VIMS
3G Application ECM, perform the checks that are
listed here:
Measure the resistance between the +battery
connector contact 52 (wire 170-RD) and
connector contact 8 (wire 893-GN).
Measure the resistance between connector
contact 52 (wire 170-RD) and connector contact
9 (wire 892-BR).
Expected Result:
The resistance is greater than 5000 ohms.
Results:
OK The harness circuit resistance is correct.
Proceed to Test Step 5.
NOT OK The resistance is less than 5000 ohms.
The machine harness has failed.
Repair: There is a short between the +battery
and the Cat Data Link circuit in the machine
harness. Repair the machine harness or replace
the machine harness.
STOP.
Test Step 5. CHECK FOR OPEN HARNESS
A. The disconnect switch remains in the OFF
position.
B. Ensure that all of the ECM are disconnected from
the machine harness.
C. Check the continuity of the Cat Data Link circuit
in the machine harness:
Measure the resistance between connector
contact 8 (wire 893-GN) of the VIMS 3G Main
ECM and connector contact 8 (wire 893-GN) of
the VIMS 3G Application ECM.
KENR9023-01 105
Troubleshooting Section

Measure the resistance between connector i03661346

contact 9 (wire 892-BR) of the VIMS 3G Main
ECM and connector contact 9 (wire 892-BR) of
the VIMS 3G Application ECM.
Expected Result:
The resistance measures less than 5 ohms.
Results:
OK The resistance is less than 5 ohms. The Cat
Data Link circuit in the machine harness is correct.
Proceed to Test Step 6.
MID 161 - CID 1089 - FMI 14
SMCS Code: 7601-038
Conditions Which Generate This Code:
This diagnostic code is recorded when the software is
not matched between two Electronic Control Modules
(ECM). This may happen when the software for one
ECM has been updated, but the software for another
ECM must be updated in order to match the first
ECM.

NOT OK The resistance is greater than 5 Ohms. System Response:

The machine harness has failed.
Repair: The Cat Data Link circuit is open in the
machine harness. Repair the machine harness or
replace the machine harness.
This failure results in events that are logged to the
VIMS 3G Main ECM that can not be explained directly.
The VIMS 3G Main ECM cannot communicate
correctly with the VIMS 3G Application ECM.

STOP. Refer to Service Manual, KENR9023, Electronic

Control Module (ECM) - Flash Program and follow
Test Step 6. CHECK FOR ADDITIONAL the instructions in order to Flash the correct software
DIAGNOSTIC CODES FOR THE OTHER to both of the ECM.
ECM.
Results:
A. Reconnect all of the ECM that use the Cat Data
Link. STOP.

B. Turn the disconnect switch and the key start

switch to the ON position.

C. Check the Event List for diagnostic codes that are

logged against the other ECM.

Expected Result:

Diagnostic codes are not present for the other ECM

in the event list.

Results:

OK Diagnostic codes are not present for the

other ECM in the event list.

Repair: The VIMS 3G Application ECM has failed.

It is unlikely that the VIMS 3G Application ECM has
failed. Exit this procedure. Perform this procedure
again. If the failure is not found, replace the VIMS
3G Application ECM.

STOP.

NOT OK Diagnostic codes are present for the

other ECM in the event list.

Repair: Perform the troubleshooting procedure for

the other diagnostic codes.

STOP.
106 KENR9023-01
Troubleshooting Section

i03480631 Test Step 1. VERIFY THE HARDWARE

AND THE SOFTWARE PART NUMBERS.
MID 161 - CID 1273 - FMI 02
A. Verify that the following information is correct:
SMCS Code: 7610-038-CS
The part number of the VIMS 3G Main ECM
Conditions Which Generate This Code: onboard software

The part number of the flash software for the

Chassis ECM

The part number of the VIMS 3G Main ECM

The part number of the Chassis ECM
Note: Consult the Business Unit that produces
the product for the correct part numbers of the
configuration software.

Expected Result:

All part numbers are correct.

Results:

OK All part numbers are correct. Proceed to

Test Step 2.

NOT OK All part numbers are NOT correct.

Repair: The installed VIMS 3G Main ECM or
the Chassis ECM has the wrong part number or
the incorrect configuration software is installed.
Replace the incorrect VIMS 3G Main ECM or the
Chassis ECM with an ECM that has the correct
part number. Refer to Service Manual, KENR9023,
Electronic Control Module (ECM) - Replace.
Flash the correct configuration software. Refer to
Service Manual, KENR9023, Electronic Control
Module (ECM) - Flash Program.

STOP.

Test Step 2. INSPECT THE HARNESS

g01969413
Illustration 95
Schematic of the data link
This diagnostic code is recorded when the VIMS 3G
Main ECM receives data that is erratic or incorrect
from the chassis ECM through the Cat data link.
CONNECTIONS.
A. Turn the disconnect switch to the OFF position.
B. Inspect all harness connections that are related to
the Cat Data Link. Make sure that the connectors
are clean and tight.
C. Check the connectors for proper mating. Ensure
that all the seals are present and in place.

System Response: D. Check the harness for signs of damage or

This failure results in events that are logged against
the Chassis ECM that can not be explained directly.
The VIMS 3G Main ECM cannot communicate with
the Chassis ECM or the Chassis ECM appears to
communicate intermittently.
abrasion.
E. Check the wires at the connector. Ensure that the
wires are secured tightly into the connector. Take
care not to pull the wire out of the connector.
KENR9023-01
F. Check the exposed wires at the connectors for
nicks or signs of abrasion.
G. Check for moisture inside the connector.
H. Check the connectors for dirty contacts or
corroded contacts.
I. Check each pin and each socket of the machine
harness connectors. Ensure that the contacts
are properly installed. The contacts should mate
correctly when the two pieces of the connector
are placed together.
Expected Result:
The machine harness connectors are tight and free
of corrosion.
Results:
OK The machine harness connectors are tight
and free of corrosion. Proceed to Test Step 3.
NOT OK The machine harness connectors are
in need of repair.
Repair: Repair the machine harness or replace the
machine harness.
STOP.
Test Step 3. CHECK FOR SHORTS TO
GROUND
A. The disconnect switch remains in the OFF
position.
B. Disconnect all ECM from the Cat Data Link.
C. At the machine harness for the VIMS 3G Main
ECM, measure the resistance between frame
ground and connector contacts 8 (wire 893-GN)
and 9 (wire 892-BR) of the Cat Data Link circuit.
Expected Result:
The resistance is greater than 5000 ohms.
Results:
OK The resistance is greater than 5000 ohms.
The harness circuit resistance is correct. Proceed
to Test Step 4.
NOT OK The resistance is less than 5000 ohms.
The machine harness has failed.
107
Troubleshooting Section
Repair: There is a short between frame ground
and the Cat Data Link circuit in the machine
harness. Repair the machine harness or replace
the machine harness.
STOP.
Test Step 4. CHECK FOR SHORT TO
+BATTERY
A. The disconnect switch remains in the OFF
position.
B. All of the related ECM remain disconnected from
the machine harness.
C. At the machine harness connector for the Chassis
ECM, perform the checks that are listed here:
Measure the resistance between the +Battery
connector contact J1-31 (wire 173-RD) and
connector contact J1-10 (wire 893-GN).
Measure the resistance between connector
contact J1-31 (wire 173-RD) and connector
contact J1-20 (wire 892-BR).
Expected Result:
The resistance is greater than 5000 ohms.
Results:
OK The harness circuit resistance is correct.
Proceed to Test Step 5.
NOT OK The resistance is less than 5000 ohms.
The machine harness has failed.
Repair: There is a short between the +battery
and the Cat Data Link circuit in the machine
harness. Repair the machine harness or replace
the machine harness.
STOP.
Test Step 5. CHECK FOR OPEN HARNESS
A. The disconnect switch remains in the OFF
position.
B. Ensure that all of the ECM are disconnected from
the machine harness.
C. Check the continuity of the Cat Data Link circuit
in the machine harness:
Measure the resistance between connector
contact 8 (wire 893-GN) of the VIMS 3G
Main ECM and connector contact J1-10 (wire
893-GN) of the Chassis ECM.
108 KENR9023-01
Troubleshooting Section

Measure the resistance between connector i03480634

contact 9 (wire 892-BR) of the VIMS 3G
Main ECM and connector contact J1-20 (wire MID 161 - CID 1273 - FMI 09
892-BR) of the Chassis ECM.
SMCS Code: 7610-038-CS
Expected Result:
Conditions Which Generate This Code:
The resistance measures less than 5 ohms.

Results:

OK The resistance is less than 5 ohms. The Cat

Data Link circuit in the machine harness is correct.
Proceed to Test Step 6.

NOT OK The resistance is greater than 5 Ohms.

The machine harness has failed.

Repair: The Cat Data Link circuit is open in the

machine harness. Repair the machine harness or
replace the machine harness.

STOP.

Test Step 6. CHECK FOR ADDITIONAL

DIAGNOSTIC CODES FOR THE OTHER
ECM.
A. Reconnect all of the ECM that use the Cat Data
Link.

B. Turn the disconnect switch and the key start

switch to the ON position.

C. Check the Event List for diagnostic codes that are

logged against the other ECM.

Expected Result:

Diagnostic codes are not present for the other ECM

in the event list.

Results:

OK Diagnostic codes are not present for the

other ECM in the event list.

Repair: The Chassis ECM has failed. It is g01969413

unlikely that the Chassis ECM has failed. Exit this
procedure. Perform this procedure again. If the
failure is not found, replace the Chassis ECM.
STOP.
NOT OK Diagnostic codes are present for the
other ECM in the event list.
Illustration 96
Schematic of the data link
This diagnostic code is recorded when the VIMS 3G
Main ECM receives data at an abnormal update rate
from the chassis ECM through the Cat data link.
System Response:

Repair: Perform the troubleshooting procedure for This failure results in events that are logged against
the other diagnostic codes. the Chassis ECM that can not be explained directly.
The VIMS 3G Main ECM cannot communicate with
STOP. the Chassis ECM or the Chassis ECM appears to
communicate intermittently.
KENR9023-01
Test Step 1. VERIFY THE HARDWARE
AND THE SOFTWARE PART NUMBERS.
A. Verify that the following information is correct:
The part number of the VIMS 3G Main ECM
onboard software
The part number of the flash software for the
Chassis ECM
The part number of the VIMS 3G Main ECM
The part number of the Chassis ECM
Note: Consult the Business Unit that produces
the product for the correct part numbers of the
configuration software.
Expected Result:
All part numbers are correct.
Results:
OK All part numbers are correct. Proceed to
Test Step 2.
NOT OK All part numbers are NOT correct.
Repair: The installed VIMS 3G Main ECM or
the Chassis ECM has the wrong part number or
the incorrect configuration software is installed.
Replace the incorrect VIMS 3G Main ECM or the
Chassis ECM with an ECM that has the correct
part number. Refer to Service Manual, KENR9023,
Electronic Control Module (ECM) - Replace.
Flash the correct configuration software. Refer to
Service Manual, KENR9023, Electronic Control
Module (ECM) - Flash Program.
STOP.
Test Step 2. INSPECT THE HARNESS
CONNECTIONS.
A. Turn the disconnect switch to the OFF position.
B. Inspect all harness connections that are related to
the Cat Data Link. Make sure that the connectors
are clean and tight.
C. Check the connectors for proper mating. Ensure
that all the seals are present and in place.
D. Check the harness for signs of damage or
abrasion.
E. Check the wires at the connector. Ensure that the
wires are secured tightly into the connector. Take
care not to pull the wire out of the connector.
109
Troubleshooting Section
F. Check the exposed wires at the connectors for
nicks or signs of abrasion.
G. Check for moisture inside the connector.
H. Check the connectors for dirty contacts or
corroded contacts.
I. Check each pin and each socket of the machine
harness connectors. Ensure that the contacts
are properly installed. The contacts should mate
correctly when the two pieces of the connector
are placed together.
Expected Result:
The machine harness connectors are tight and free
of corrosion.
Results:
OK The machine harness connectors are tight
and free of corrosion. Proceed to Test Step 3.
NOT OK The machine harness connectors are
in need of repair.
Repair: Repair the machine harness or replace the
machine harness.
STOP.
Test Step 3. CHECK FOR SHORTS TO
GROUND
A. The disconnect switch remains in the OFF
position.
B. Disconnect all ECM from the Cat Data Link.
C. At the machine harness for the VIMS 3G Main
ECM, measure the resistance between frame
ground and connector contacts 8 (wire 893-GN)
and 9 (wire 892-BR) of the Cat Data Link circuit.
Expected Result:
The resistance is greater than 5000 ohms.
Results:
OK The resistance is greater than 5000 ohms.
The harness circuit resistance is correct. Proceed
to Test Step 4.
NOT OK The resistance is less than 5000 ohms.
The machine harness has failed.
110
Troubleshooting Section
Repair: There is a short between frame ground
and the Cat Data Link circuit in the machine
harness. Repair the machine harness or replace
the machine harness.
STOP.
Test Step 4. CHECK FOR SHORT TO
+BATTERY
A. The disconnect switch remains in the OFF
position.
B. All of the related ECM remain disconnected from
the machine harness.
C. At the machine harness connector for the Chassis
ECM, perform the checks that are listed here:
Measure the resistance between the +Battery
connector contact J1-31 (wire 173-RD) and
connector contact J1-10 (wire 893-GN).
Measure the resistance between connector
contact J1-31 (wire 173-RD) and connector
contact J1-20 (wire 892-BR).
Expected Result:
The resistance is greater than 5000 ohms.
Results:
OK The harness circuit resistance is correct.
Proceed to Test Step 5.
NOT OK The resistance is less than 5000 ohms.
The machine harness has failed.
Repair: There is a short between the +battery
and the Cat Data Link circuit in the machine
harness. Repair the machine harness or replace
the machine harness.
STOP.
Test Step 5. CHECK FOR OPEN HARNESS
A. The disconnect switch remains in the OFF
position.
B. Ensure that all of the ECM are disconnected from
the machine harness.
C. Check the continuity of the Cat Data Link circuit
in the machine harness:
Measure the resistance between connector
contact 8 (wire 893-GN) of the VIMS 3G
Main ECM and connector contact J1-10 (wire
893-GN) of the Chassis ECM.
KENR9023-01
Measure the resistance between connector
contact 9 (wire 892-BR) of the VIMS 3G
Main ECM and connector contact J1-20 (wire
892-BR) of the Chassis ECM.
Expected Result:
The resistance measures less than 5 ohms.
Results:
OK The resistance is less than 5 ohms. The Cat
Data Link circuit in the machine harness is correct.
Proceed to Test Step 6.
NOT OK The resistance is greater than 5 Ohms.
The machine harness has failed.
Repair: The Cat Data Link circuit is open in the
machine harness. Repair the machine harness or
replace the machine harness.
STOP.
Test Step 6. CHECK FOR ADDITIONAL
DIAGNOSTIC CODES FOR THE OTHER
ECM.
A. Reconnect all of the ECM that use the Cat Data
Link.
B. Turn the disconnect switch and the key start
switch to the ON position.
C. Check the Event List for diagnostic codes that are
logged against the other ECM.
Expected Result:
Diagnostic codes are not present for the other ECM
in the event list.
Results:
OK Diagnostic codes are not present for the
other ECM in the event list.
Repair: The Chassis ECM has failed. It is
unlikely that the Chassis ECM has failed. Exit this
procedure. Perform this procedure again. If the
failure is not found, replace the Chassis ECM.
STOP.
NOT OK Diagnostic codes are present for the
other ECM in the event list.
Repair: Perform the troubleshooting procedure for
the other diagnostic codes.
STOP.
KENR9023-01 111
Troubleshooting Section

i03480644 i03480646

MID 161 - CID 1273 - FMI 14 MID 161 - CID 2448 - FMI 02
SMCS Code: 7610-038-CS SMCS Code: 7490-038

Conditions Which Generate This Code: Conditions Which Generate This Code:

This diagnostic code is recorded when the software is

not matched between two Electronic Control Modules
(ECM). This may happen when the software for one
ECM has been updated, but the software for another
ECM must be updated in order to match the first
ECM.

System Response:

This failure results in events that are logged

to the VIMS 3G Main ECM that can not be
explained directly. The VIMS 3G Main ECM cannot
communicate correctly with the Chassis ECM.

Refer to Service Manual, KENR9023, Electronic

Control Module (ECM) - Flash Program and follow
the instructions in order to Flash the correct software
to both of the ECM.

Results:

STOP.

g01969413
Illustration 97
Schematic of the data link

This diagnostic code is recorded when the VIMS 3G

Main ECM receives data through the Cat data link
from the Advisor module that is erratic or incorrect.

System Response:

This failure results in events that are logged against

the Advisor module that can not be explained directly.
The VIMS 3G Main ECM cannot communicate with
the Advisor module or the Advisor module appears to
communicate intermittently.
112
Troubleshooting Section
Test Step 1. VERIFY THE HARDWARE
AND THE SOFTWARE PART NUMBERS.
A. Verify that the following information is correct:
The part number of the VIMS 3G Main ECM
onboard software
The part number of the flash software for the
Advisor module
The part number of the VIMS 3G Main ECM
The part number of the Advisor module
Note: Consult the Business Unit that produces
the product for the correct part numbers of the
configuration software.
Expected Result:
All part numbers are correct.
Results:
OK All part numbers are correct. Proceed to
Test Step 2.
NOT OK All part numbers are NOT correct.
Repair: The installed VIMS 3G Main ECM or the
Advisor module has the wrong part number or
the incorrect configuration software is installed.
Replace the incorrect VIMS 3G Main ECM or the
Advisor module with an ECM that has the correct
part number. Refer to Service Manual, KENR9023,
Electronic Control Module (ECM) - Replace.
Flash the correct configuration software. Refer
to the Service Manual, KENR9023, Electronic
Control Module (ECM) - Flash Program.
STOP.
Test Step 2. INSPECT THE HARNESS
CONNECTIONS.
A. Turn the disconnect switch to the OFF position.
B. Inspect all harness connections that are related to
the Cat Data Link. Make sure that the connectors
are clean and tight.
C. Check the connectors for proper mating. Ensure
that all the seals are present and in place.
D. Check the harness for signs of damage or
abrasion.
E. Check the wires at the connector. Ensure that the
wires are secured tightly into the connector. Take
care not to pull the wire out of the connector.
KENR9023-01
F. Check the exposed wires at the connectors for
nicks or signs of abrasion.
G. Check for moisture inside the connector.
H. Check the connectors for dirty contacts or
corroded contacts.
I. Check each pin and each socket of the machine
harness connectors. Ensure that the contacts
are properly installed. The contacts should mate
correctly when the two pieces of the connector
are placed together.
Expected Result:
The machine harness connectors are tight and free
of corrosion.
Results:
OK The machine harness connectors are tight
and free of corrosion. Proceed to Test Step 3.
NOT OK The machine harness connectors are
in need of repair.
Repair: Repair the machine harness or replace the
machine harness.
STOP.
Test Step 3. CHECK FOR SHORTS TO
GROUND
A. The disconnect switch remains in the OFF
position.
B. Disconnect all ECM from the Cat Data Link.
C. At the machine harness for the VIMS 3G Main
ECM, measure the resistance between frame
ground and connector contacts 8 (wire 893-GN)
and 9 (wire 892-BR) of the Cat Data Link circuit.
Expected Result:
The resistance is greater than 5000 ohms.
Results:
OK The resistance is greater than 5000 ohms.
The harness circuit resistance is correct. Proceed
to Test Step 4.
NOT OK The resistance is less than 5000 ohms.
The machine harness has failed.
KENR9023-01
Repair: There is a short between frame ground
and the Cat Data Link circuit in the machine
harness. Repair the machine harness or replace
the machine harness.
STOP.
Test Step 4. CHECK FOR SHORT TO
+BATTERY
A. The disconnect switch remains in the OFF
position.
B. All of the related ECM remain disconnected from
the machine harness.
C. At the machine harness connector for the Advisor
module, perform the checks that are listed here:
Measure the resistance between the +Battery
connector contact 1 (wire 108-RD) and
connector contact 8 (wire 893-GN).
Measure the resistance between the +Battery
connector contact 1 (wire 108-RD) and
connector contact 9 (wire 892-BR).
Expected Result:
The resistance is greater than 5000 ohms.
Results:
OK The harness circuit resistance is correct.
Proceed to Test Step 5.
NOT OK The resistance is less than 5000 ohms.
The machine harness has failed.
Repair: There is a short between the +battery
and the Cat Data Link circuit in the machine
harness. Repair the machine harness or replace
the machine harness.
STOP.
Test Step 5. CHECK FOR OPEN HARNESS
A. The disconnect switch remains in the OFF
position.
B. Ensure that all of the ECM are disconnected from
the machine harness.
C. Check the continuity of the Cat Data Link circuit
in the machine harness:
Measure the resistance between connector
contact 8 (wire 893-GN) of the VIMS 3G Main
ECM and connector contact 8 (wire 893-GN)
of the Advisor module.
113
Troubleshooting Section
Measure the resistance between connector
contact 9 (wire 892-BR) of the VIMS 3G Main
ECM and connector contact 9 (wire 892-BR) of
the Advisor module.
Expected Result:
The resistance measures less than 5 ohms.
Results:
OK The resistance is less than 5 ohms. The Cat
Data Link circuit in the machine harness is correct.
Proceed to Test Step 6.
NOT OK The resistance is greater than 5 Ohms.
The machine harness has failed.
Repair: The Cat Data Link circuit is open in the
machine harness. Repair the machine harness or
replace the machine harness.
STOP.
Test Step 6. CHECK FOR ADDITIONAL
DIAGNOSTIC CODES FOR THE OTHER
ECM.
A. Reconnect all of the ECM that use the Cat Data
Link.
B. Turn the disconnect switch and the key start
switch to the ON position.
C. Check the Event List for diagnostic codes that are
logged against the other ECM.
Expected Result:
Diagnostic codes are not present for the other ECM
in the event list.
Results:
OK Diagnostic codes are not present for the
other ECM in the event list.
Repair: The Advisor module has failed. It is
unlikely that the Advisor module has failed. Exit
this procedure. Perform this procedure again. If the
failure is not found, replace the Advisor module.
STOP.
NOT OK Diagnostic codes are present for the
other ECM in the event list.
Repair: Perform the troubleshooting procedure for
the other diagnostic codes.
STOP.
114 KENR9023-01
Troubleshooting Section

i03480647 Test Step 1. VERIFY THE HARDWARE

AND THE SOFTWARE PART NUMBERS.
MID 161 - CID 2448 - FMI 09
A. Verify that the following information is correct:
SMCS Code: 7490-038
The part number of the VIMS 3G Main ECM
Conditions Which Generate This Code: onboard software

The part number of the flash software for the

Advisor module

The part number of the VIMS 3G Main ECM

The part number of the Advisor module
Note: Consult the Business Unit that produces
the product for the correct part numbers of the
configuration software.

Expected Result:

All part numbers are correct.

Results:

OK All part numbers are correct. Proceed to

Test Step 2.

NOT OK All part numbers are NOT correct.

Repair: The installed VIMS 3G Main ECM or the
Advisor module has the wrong part number or
the incorrect configuration software is installed.
Replace the incorrect VIMS 3G Main ECM or the
Advisor module with an ECM that has the correct
part number. Refer to Service Manual, KENR9023,
Electronic Control Module (ECM) - Replace.
Flash the correct configuration software. Refer
to the Service Manual, KENR9023, Electronic
Control Module (ECM) - Flash Program.

STOP.

Test Step 2. INSPECT THE HARNESS

g01969413
Illustration 98
Schematic of the data link
This diagnostic code is recorded when the VIMS 3G
Main ECM receives data through the Cat data link
from the Advisor module at an abnormal update rate.
CONNECTIONS.
A. Turn the disconnect switch to the OFF position.
B. Inspect all harness connections that are related to
the Cat Data Link. Make sure that the connectors
are clean and tight.
C. Check the connectors for proper mating. Ensure
that all the seals are present and in place.

System Response: D. Check the harness for signs of damage or

This failure results in events that are logged against
the Advisor module that can not be explained directly.
The VIMS 3G Main ECM cannot communicate with
the Advisor module or the Advisor module appears to
communicate intermittently.
abrasion.
E. Check the wires at the connector. Ensure that the
wires are secured tightly into the connector. Take
care not to pull the wire out of the connector.
KENR9023-01
F. Check the exposed wires at the connectors for
nicks or signs of abrasion.
G. Check for moisture inside the connector.
H. Check the connectors for dirty contacts or
corroded contacts.
I. Check each pin and each socket of the machine
harness connectors. Ensure that the contacts
are properly installed. The contacts should mate
correctly when the two pieces of the connector
are placed together.
Expected Result:
The machine harness connectors are tight and free
of corrosion.
Results:
OK The machine harness connectors are tight
and free of corrosion. Proceed to Test Step 3.
NOT OK The machine harness connectors are
in need of repair.
Repair: Repair the machine harness or replace the
machine harness.
STOP.
Test Step 3. CHECK FOR SHORTS TO
GROUND
A. The disconnect switch remains in the OFF
position.
B. Disconnect all ECM from the Cat Data Link.
C. At the machine harness for the VIMS 3G Main
ECM, measure the resistance between frame
ground and connector contacts 8 (wire 893-GN)
and 9 (wire 892-BR) of the Cat Data Link circuit.
Expected Result:
The resistance is greater than 5000 ohms.
Results:
OK The resistance is greater than 5000 ohms.
The harness circuit resistance is correct. Proceed
to Test Step 4.
NOT OK The resistance is less than 5000 ohms.
The machine harness has failed.
115
Troubleshooting Section
Repair: There is a short between frame ground
and the Cat Data Link circuit in the machine
harness. Repair the machine harness or replace
the machine harness.
STOP.
Test Step 4. CHECK FOR SHORT TO
+BATTERY
A. The disconnect switch remains in the OFF
position.
B. All of the related ECM remain disconnected from
the machine harness.
C. At the machine harness connector for the Advisor
module, perform the checks that are listed here:
Measure the resistance between the +Battery
connector contact 1 (wire 108-RD) and
connector contact 8 (wire 893-GN).
Measure the resistance between the +Battery
connector contact 1 (wire 108-RD) and
connector contact 9 (wire 892-BR).
Expected Result:
The resistance is greater than 5000 ohms.
Results:
OK The harness circuit resistance is correct.
Proceed to Test Step 5.
NOT OK The resistance is less than 5000 ohms.
The machine harness has failed.
Repair: There is a short between the +battery
and the Cat Data Link circuit in the machine
harness. Repair the machine harness or replace
the machine harness.
STOP.
Test Step 5. CHECK FOR OPEN HARNESS
A. The disconnect switch remains in the OFF
position.
B. Ensure that all of the ECM are disconnected from
the machine harness.
C. Check the continuity of the Cat Data Link circuit
in the machine harness:
Measure the resistance between connector
contact 8 (wire 893-GN) of the VIMS 3G Main
ECM and connector contact 8 (wire 893-GN)
of the Advisor module.
116 KENR9023-01
Troubleshooting Section

Measure the resistance between connector i03480651

contact 9 (wire 892-BR) of the VIMS 3G Main
ECM and connector contact 9 (wire 892-BR) of
the Advisor module.
Expected Result:
The resistance measures less than 5 ohms.
Results:
OK The resistance is less than 5 ohms. The Cat
Data Link circuit in the machine harness is correct.
Proceed to Test Step 6.
MID 161 - CID 2448 - FMI 14
SMCS Code: 7490-038
Conditions Which Generate This Code:
This diagnostic code is recorded when the software is
not matched between two Electronic Control Modules
(ECM). This may happen when the software for one
ECM has been updated, but the software for another
ECM must be updated in order to match the first
ECM.

NOT OK The resistance is greater than 5 Ohms. System Response:

The machine harness has failed.
Repair: The Cat Data Link circuit is open in the
machine harness. Repair the machine harness or
replace the machine harness.
This failure results in events that are logged
to the VIMS 3G Main ECM that can not be
explained directly. The VIMS 3G Main ECM cannot
communicate correctly with the Advisor display.

STOP. Refer to Service Manual, KENR9023, Electronic

Control Module (ECM) - Flash Program and follow
Test Step 6. CHECK FOR ADDITIONAL the instructions in order to Flash the correct software
DIAGNOSTIC CODES FOR THE OTHER to both of the ECM.
ECM.
Results:
A. Reconnect all of the ECM that use the Cat Data
Link. STOP.

B. Turn the disconnect switch and the key start

switch to the ON position.

C. Check the Event List for diagnostic codes that are

logged against the other ECM.

Expected Result:

Diagnostic codes are not present for the other ECM

in the event list.

Results:

OK Diagnostic codes are not present for the

other ECM in the event list.

Repair: The Advisor module has failed. It is

unlikely that the Advisor module has failed. Exit
this procedure. Perform this procedure again. If the
failure is not found, replace the Advisor module.

STOP.

NOT OK Diagnostic codes are present for the

other ECM in the event list.

Repair: Perform the troubleshooting procedure for

the other diagnostic codes.

STOP.
KENR9023-01 117
Troubleshooting Section

i03480653 Test Step 1. VERIFY THE HARDWARE

AND THE SOFTWARE PART NUMBERS.
MID 162 - CID 0248 - FMI 09
A. Verify that the following information is correct:
SMCS Code: 7610-038
The part number of the VIMS 3G Application
Conditions Which Generate This Code: ECM onboard software

The part number of the VIMS 3G Application

ECM

Note: Consult the Business Unit that produces

the product for the correct part numbers of the
configuration software.

Expected Result:

All part numbers are correct.

Results:

OK All part numbers are correct. Proceed to

Test Step 2.

NOT OK All part numbers are NOT correct.

Repair: The installed VIMS 3G Application ECM
has the wrong part number or the incorrect
configuration software is installed. Replace the
incorrect VIMS 3G Application ECM with an ECM
that has the correct part number. Refer to Service
Manual, KENR9023 , Electronic Control Module
(ECM) - Replace. Flash the correct configuration
software. Refer to Service Manual, KENR9023
, Electronic Control Module (ECM) - Flash
Program.

STOP.

Test Step 2. INSPECT THE HARNESS

CONNECTIONS.
A. Turn the disconnect switch to the OFF position.

B. Inspect all harness connections that are related to

the Cat Data Link. Make sure that the connectors
are clean and tight.
g01969413
Illustration 99 C. Check the connectors for proper mating. Ensure
Schematic of the data link that all the seals are present and in place.

This diagnostic code is recorded when the VIMS
3G Application ECM receives expected information
through the Cat Data Link with an abnormal update
rate.
System Response:
D. Check the harness for signs of damage or
abrasion.
E. Check the wires at the connector. Ensure that the
wires are secured tightly into the connector. Take
care not to pull the wire out of the connector.

This failure results in events that are logged to the F. Check the exposed wires at the connectors for
VIMS 3G Application ECM that can not be explained nicks or signs of abrasion.
directly.
G. Check for moisture inside the connector.
118
Troubleshooting Section
H. Check the connectors for dirty contacts or
corroded contacts.
I. Check each pin and each socket of the machine
harness connectors. Ensure that the contacts
are properly installed. The contacts should mate
correctly when the two pieces of the connector
are placed together.
Expected Result:
The machine harness connectors are tight and free
of corrosion.
Results:
OK The machine harness connectors are tight
and free of corrosion. Proceed to Test Step 3.
NOT OK The machine harness connectors are
in need of repair.
Repair: Repair the machine harness or replace the
machine harness.
STOP.
Test Step 3. CHECK FOR SHORTS TO
GROUND
A. The disconnect switch remains in the OFF
position.
B. Disconnect all ECM from the Cat Data Link.
C. At the machine harness for the VIMS 3G
Application ECM, measure the resistance
between frame ground and connector contacts
8 (wire 893-GN) and 9 (wire 892-BR) of the Cat
Data Link circuit.
Expected Result:
The resistance is greater than 5000 ohms.
Results:
OK The resistance is greater than 5000 ohms.
The harness circuit resistance is correct. Proceed
to Test Step 4.
NOT OK The resistance is less than 5000 ohms.
The machine harness has failed.
Repair: There is a short between frame ground
and the Cat Data Link circuit in the machine
harness. Repair the machine harness or replace
the machine harness.
STOP.
KENR9023-01
Test Step 4. CHECK FOR SHORT TO
+BATTERY
A. The disconnect switch remains in the OFF
position.
B. All of the related ECM remain disconnected from
the machine harness.
C. At the machine harness connector for the VIMS
3G Application ECM, perform the checks that are
listed here:
Measure the resistance between the +Battery
connector contact 52 (wire 170-RD) and
connector contact 8 (wire 893-GN).
Measure the resistance between connector
contact 52 (wire 170-RD) and connector contact
9 (wire 892-BR).
Expected Result:
The resistance is greater than 5000 ohms.
Results:
OK The harness circuit resistance is correct.
Proceed to Test Step 5.
NOT OK The resistance is less than 5000 ohms.
The machine harness has failed.
Repair: There is a short between the +battery
and the Cat Data Link circuit in the machine
harness. Repair the machine harness or replace
the machine harness.
STOP.
Test Step 5. CHECK FOR OPEN HARNESS
A. The disconnect switch remains in the OFF
position.
B. Ensure that all of the ECM are disconnected from
the machine harness.
C. Check the continuity of the Cat Data Link circuit
in the machine harness:
Measure the resistance between connector
contact 8 (wire 893-GN) of the VIMS 3G
Application ECM and connector contact 8 (wire
893-GN) of the VIMS 3G Main ECM.
Measure the resistance between connector
contact 9 (wire 892-BR) of the VIMS 3G
Application ECM and connector contact 9 (wire
892-BR) of the VIMS 3G Main ECM.
KENR9023-01 119
Troubleshooting Section

Expected Result: i03665184

The resistance measures less than 5 ohms. MID 162 - CID 0296 - FMI 02
Results: SMCS Code: 7610-038-DTN

OK The resistance is less than 5 ohms. The Cat Conditions Which Generate This Code:
Data Link circuit in the machine harness is correct.
Proceed to Test Step 6.

NOT OK The resistance is greater than 5 Ohms.

The machine harness has failed.

Repair: The Cat Data Link circuit is open in the

machine harness. Repair the machine harness or
replace the machine harness.

STOP.

Test Step 6. CHECK FOR ADDITIONAL

DIAGNOSTIC CODES FOR THE OTHER
ECM.
A. Reconnect all of the ECM that use the Cat Data
Link.

B. Turn the disconnect switch and the key start

switch to the ON position.

C. Check the Event List for diagnostic codes that are

logged against the other ECM.

Expected Result:

Diagnostic codes are not present for the other ECM

in the event list.

Results:

OK Diagnostic codes are not present for the

other ECM in the event list.

Repair: The VIMS 3G Application ECM has

failed. Exit this procedure. Perform this procedure
again. If the failure is not found, replace the VIMS
3G Application ECM. Refer to Service Manual,
KENR9023, Electronic Control Module (ECM) -
Replace. g01969413
Illustration 100
STOP. Schematic of the data link

NOT OK Diagnostic codes are present for the
other ECM in the event list.
Repair: Perform the troubleshooting procedure for
the other diagnostic codes.
STOP.
This diagnostic code is recorded when the VIMS
3G Application ECM receives communication from
the Transmission ECM that is erratic, intermittent,
or incorrect.
System Response:
This failure results in events that are logged to the
VIMS 3G Application ECM that can not be explained
directly. The communication from the Transmission
ECM is not correct.
120
Troubleshooting Section
Test Step 1. VERIFY THE HARDWARE
AND THE SOFTWARE PART NUMBERS.
A. Verify that the following information is correct:
The part number of the VIMS 3G Application
ECM onboard software
The part number of the VIMS 3G Application
ECM
The part number of the Transmission ECM
onboard software
The part number of the Transmission ECM
Note: Consult the Business Unit that produces
the product for the correct part numbers of the
configuration software.
Expected Result:
All part numbers are correct.
Results:
OK All part numbers are correct. Proceed to
Test Step 2.
NOT OK All part numbers are NOT correct.
Repair: The installed ECM has the wrong part
number or the incorrect configuration software
is installed. Replace the incorrect ECM with an
ECM that has the correct part number. Refer to
Service Manual, KENR9023, Electronic Control
Module (ECM) - Replace. Flash the correct
configuration software. Refer to the Service
Manual, KENR9023, Electronic Control Module
(ECM) - Flash Program.
STOP.
Test Step 2. INSPECT THE HARNESS
CONNECTIONS.
A. Turn the disconnect switch to the OFF position.
B. Inspect all harness connections that are related to
the Cat Data Link. Make sure that the connectors
are clean and tight.
C. Check the connectors for proper mating. Ensure
that all the seals are present and in place.
D. Check the harness for signs of damage or
abrasion.
E. Check the wires at the connector. Ensure that the
wires are secured tightly into the connector. Take
care not to pull the wire out of the connector.
KENR9023-01
F. Check the exposed wires at the connectors for
nicks or signs of abrasion.
G. Check for moisture inside the connector.
H. Check the connectors for dirty contacts or
corroded contacts.
I. Check each pin and each socket of the machine
harness connectors. Ensure that the contacts
are properly installed. The contacts should mate
correctly when the two pieces of the connector
are placed together.
Expected Result:
The machine harness connectors are tight and free
of corrosion.
Results:
OK The machine harness connectors are tight
and free of corrosion. Proceed to Test Step 3.
NOT OK The machine harness connectors are
in need of repair.
Repair: Repair the machine harness or replace the
machine harness.
STOP.
Test Step 3. CHECK FOR SHORTS TO
GROUND
A. The disconnect switch remains in the OFF
position.
B. Disconnect all ECM from the Cat Data Link.
C. At the machine harness for the VIMS 3G
Application ECM, measure the resistance
between frame ground and connector contacts
8 (wire 893-GN) and 9 (wire 892-BR) of the Cat
Data Link circuit.
Expected Result:
The resistance is greater than 5000 ohms.
Results:
OK The resistance is greater than 5000 ohms.
The harness circuit resistance is correct. Proceed
to Test Step 4.
NOT OK The resistance is less than 5000 ohms.
The machine harness has failed.
KENR9023-01
Repair: There is a short between frame ground
and the Cat Data Link circuit in the machine
harness. Repair the machine harness or replace
the machine harness.
STOP.
Test Step 4. CHECK FOR SHORT TO
+BATTERY
A. The disconnect switch remains in the OFF
position.
B. All of the related ECM remain disconnected from
the machine harness.
C. At the machine harness connector for the VIMS
3G Application ECM, perform the checks that are
listed here:
Measure the resistance between the +Battery
connector contact 52 (wire 170-RD) and
connector contact 8 (wire 893-GN).
Measure the resistance between connector
contact 52 (wire 170-RD) and connector contact
9 (wire 892-BR).
Expected Result:
The resistance is greater than 5000 ohms.
Results:
OK The harness circuit resistance is correct.
Proceed to Test Step 5.
NOT OK The resistance is less than 5000 ohms.
The machine harness has failed.
Repair: There is a short between the +battery
and the Cat Data Link circuit in the machine
harness. Repair the machine harness or replace
the machine harness.
STOP.
Test Step 5. CHECK FOR OPEN HARNESS
A. The disconnect switch remains in the OFF
position.
B. Ensure that all of the ECM are disconnected from
the machine harness.
C. Check the continuity of the Cat Data Link circuit
in the machine harness:
Measure the resistance between connector
contact 8 (wire 893-GN) of the VIMS 3G
Application ECM and connector contact J1-10
(wire 893-GN) of the Transmission ECM.
121
Troubleshooting Section
Measure the resistance between connector
contact 9 (wire 892-BR) of the VIMS 3G
Application ECM and connector contact J1-20
(wire 892-BR) of the Transmission ECM.
Expected Result:
The resistance measures less than 5 ohms.
Results:
OK The resistance is less than 5 ohms. The Cat
Data Link circuit in the machine harness is correct.
Proceed to Test Step 6.
NOT OK The resistance is greater than 5 Ohms.
The machine harness has failed.
Repair: The Cat Data Link circuit is open in the
machine harness. Repair the machine harness or
replace the machine harness.
STOP.
Test Step 6. CHECK FOR ADDITIONAL
DIAGNOSTIC CODES FOR THE OTHER
ECM.
A. Reconnect all of the ECM that use the Cat Data
Link.
B. Turn the disconnect switch and the key start
switch to the ON position.
C. Check the Event List for diagnostic codes that are
logged against the other ECM.
Expected Result:
Diagnostic codes are not present for the other ECM
in the event list.
Results:
OK Diagnostic codes are not present for the
other ECM in the event list.
Repair: The Transmission ECM has failed. Exit
this procedure. Perform this procedure again. If the
failure is not found, replace the Transmission ECM.
Refer to Service Manual, KENR9023, Electronic
Control Module (ECM) - Replace.
STOP.
NOT OK Diagnostic codes are present for the
other ECM in the event list.
Repair: Perform the troubleshooting procedure for
the other diagnostic codes.
STOP.
122 KENR9023-01
Troubleshooting Section

i03583780 Test Step 1. VERIFY THE HARDWARE

AND THE SOFTWARE PART NUMBERS.
MID 162 - CID 0296 - FMI 09
A. Verify that the following information is correct:
SMCS Code: 7610-038-DTN
The part number of the VIMS 3G Application
Conditions Which Generate This Code: ECM onboard software

The part number of the VIMS 3G Application

ECM

The part number of the Transmission ECM

onboard software

The part number of the Transmission ECM

Note: Consult the Business Unit that produces
the product for the correct part numbers of the
configuration software.

Expected Result:

All part numbers are correct.

Results:

OK All part numbers are correct. Proceed to

Test Step 2.

NOT OK All part numbers are NOT correct.

Repair: The installed ECM has the wrong part
number or the incorrect configuration software
is installed. Replace the incorrect ECM with an
ECM that has the correct part number. Refer to
Service Manual, KENR9023, Electronic Control
Module (ECM) - Replace. Flash the correct
configuration software. Refer to the Service
Manual, KENR9023, Electronic Control Module
(ECM) - Flash Program.

STOP.

Test Step 2. INSPECT THE HARNESS

CONNECTIONS.
A. Turn the disconnect switch to the OFF position.
g01969413
Illustration 101 B. Inspect all harness connections that are related to
Schematic of the data link the Cat Data Link. Make sure that the connectors
are clean and tight.
This diagnostic code is recorded when the VIMS 3G
Application ECM records an abnormal update rate C. Check the connectors for proper mating. Ensure
from the Transmission ECM. that all the seals are present and in place.

System Response: D. Check the harness for signs of damage or

This failure results in events that are logged to the
VIMS 3G Application ECM that can not be explained
directly. The communication from the Transmission
ECM is not correct.
abrasion.
E. Check the wires at the connector. Ensure that the
wires are secured tightly into the connector. Take
care not to pull the wire out of the connector.
KENR9023-01
F. Check the exposed wires at the connectors for
nicks or signs of abrasion.
G. Check for moisture inside the connector.
H. Check the connectors for dirty contacts or
corroded contacts.
I. Check each pin and each socket of the machine
harness connectors. Ensure that the contacts
are properly installed. The contacts should mate
correctly when the two pieces of the connector
are placed together.
Expected Result:
The machine harness connectors are tight and free
of corrosion.
Results:
OK The machine harness connectors are tight
and free of corrosion. Proceed to Test Step 3.
NOT OK The machine harness connectors are
in need of repair.
Repair: Repair the machine harness or replace the
machine harness.
STOP.
Test Step 3. CHECK FOR SHORTS TO
GROUND
A. The disconnect switch remains in the OFF
position.
B. Disconnect all ECM from the Cat Data Link.
C. At the machine harness for the VIMS 3G
Application ECM, measure the resistance
between frame ground and connector contacts
8 (wire 893-GN) and 9 (wire 892-BR) of the Cat
Data Link circuit.
Expected Result:
The resistance is greater than 5000 ohms.
Results:
OK The resistance is greater than 5000 ohms.
The harness circuit resistance is correct. Proceed
to Test Step 4.
NOT OK The resistance is less than 5000 ohms.
The machine harness has failed.
123
Troubleshooting Section
Repair: There is a short between frame ground
and the Cat Data Link circuit in the machine
harness. Repair the machine harness or replace
the machine harness.
STOP.
Test Step 4. CHECK FOR SHORT TO
+BATTERY
A. The disconnect switch remains in the OFF
position.
B. All of the related ECM remain disconnected from
the machine harness.
C. At the machine harness connector for the VIMS
3G Application ECM, perform the checks that are
listed here:
Measure the resistance between the +Battery
connector contact 52 (wire 170-RD) and
connector contact 8 (wire 893-GN).
Measure the resistance between connector
contact 52 (wire 170-RD) and connector contact
9 (wire 892-BR).
Expected Result:
The resistance is greater than 5000 ohms.
Results:
OK The harness circuit resistance is correct.
Proceed to Test Step 5.
NOT OK The resistance is less than 5000 ohms.
The machine harness has failed.
Repair: There is a short between the +battery
and the Cat Data Link circuit in the machine
harness. Repair the machine harness or replace
the machine harness.
STOP.
Test Step 5. CHECK FOR OPEN HARNESS
A. The disconnect switch remains in the OFF
position.
B. Ensure that all of the ECM are disconnected from
the machine harness.
C. Check the continuity of the Cat Data Link circuit
in the machine harness:
Measure the resistance between connector
contact 8 (wire 893-GN) of the VIMS 3G
Application ECM and connector contact J1-10
(wire 893-GN) of the Transmission ECM.
124 KENR9023-01
Troubleshooting Section

Measure the resistance between connector i03661329

contact 9 (wire 892-BR) of the VIMS 3G
Application ECM and connector contact J1-20
(wire 892-BR) of the Transmission ECM.
Expected Result:
The resistance measures less than 5 ohms.
Results:
OK The resistance is less than 5 ohms. The Cat
Data Link circuit in the machine harness is correct.
Proceed to Test Step 6.
MID 162 - CID 0296 - FMI 14
SMCS Code: 7610-038-DTN
Conditions Which Generate This Code:
This diagnostic code is recorded when the software is
not matched between two Electronic Control Modules
(ECM). This may happen when the software for one
ECM has been updated, but the software for another
ECM must be updated in order to match the first
ECM.

NOT OK The resistance is greater than 5 Ohms. System Response:

The machine harness has failed.
Repair: The Cat Data Link circuit is open in the
machine harness. Repair the machine harness or
replace the machine harness.
This failure results in events that are logged to the
VIMS 3G Application ECM that can not be explained
directly. The VIMS 3G Application ECM cannot
communicate correctly with the Transmission ECM.

STOP. Refer to Service Manual, KENR9023, Electronic

Control Module (ECM) - Flash Program and follow
Test Step 6. CHECK FOR ADDITIONAL the instructions in order to Flash the correct software
DIAGNOSTIC CODES FOR THE OTHER to both of the ECM.
ECM.
Results:
A. Reconnect all of the ECM that use the Cat Data
Link. STOP.

B. Turn the disconnect switch and the key start

switch to the ON position.

C. Check the Event List for diagnostic codes that are

logged against the other ECM.

Expected Result:

Diagnostic codes are not present for the other ECM

in the event list.

Results:

OK Diagnostic codes are not present for the

other ECM in the event list.

Repair: The Transmission ECM has failed. Exit

this procedure. Perform this procedure again. If the
failure is not found, replace the Transmission ECM.
Refer to Service Manual, KENR9023, Electronic
Control Module (ECM) - Replace.

STOP.

NOT OK Diagnostic codes are present for the

other ECM in the event list.

Repair: Perform the troubleshooting procedure for

the other diagnostic codes.

STOP.
KENR9023-01 125
Troubleshooting Section

i03480657 Test Step 1. VERIFY THE HARDWARE

AND THE SOFTWARE PART NUMBERS.
MID 162 - CID 0533 - FMI 02
A. Verify that the following information is correct:
SMCS Code: 7610-038-BRK
The part number of the VIMS 3G Application
Conditions Which Generate This Code: ECM onboard software

The part number of the flash software for the

Brake ECM

The part number of the VIMS 3G Application

ECM

The part number of the Brake ECM

Note: Consult the Business Unit that produces
the product for the correct part numbers of the
configuration software.

Expected Result:

All part numbers are correct.

Results:

OK All part numbers are correct. Proceed to

Test Step 2.

NOT OK All part numbers are NOT correct.

Repair: The installed VIMS 3G Application ECM
or the Brake ECM has the wrong part number or
the incorrect configuration software is installed.
Replace the incorrect VIMS 3G Application ECM
or the brake ECM with an ECM that has the correct
part number. Refer to Service Manual, KENR9023,
Electronic Control Module (ECM) - Replace.
Flash the correct configuration software. Refer to
Service Manual, KENR9023, Electronic Control
Module (ECM) - Flash Program.

STOP.

Test Step 2. INSPECT THE HARNESS

CONNECTIONS.

g01969413
Illustration 102
Schematic of the data link
This diagnostic code is recorded when the VIMS 3G
Application ECM receives data from the Brake ECM
that is erratic or incorrect.
System Response:
This failure results in events that are logged against
the Brake ECM that can not be explained directly.
The VIMS 3G Application ECM cannot communicate
with the Brake ECM or the Brake ECM appears to
communicate intermittently.
A. Turn the disconnect switch to the OFF position.
B. Inspect all harness connections that are related to
the Cat Data Link. Make sure that the connectors
are clean and tight.
C. Check the connectors for proper mating. Ensure
that all the seals are present and in place.
D. Check the harness for signs of damage or
abrasion.
E. Check the wires at the connector. Ensure that the
wires are secured tightly into the connector. Take
care not to pull the wire out of the connector.
126
Troubleshooting Section
F. Check the exposed wires at the connectors for
nicks or signs of abrasion.
G. Check for moisture inside the connector.
H. Check the connectors for dirty contacts or
corroded contacts.
I. Check each pin and each socket of the machine
harness connectors. Ensure that the contacts
are properly installed. The contacts should mate
correctly when the two pieces of the connector
are placed together.
Expected Result:
The machine harness connectors are tight and free
of corrosion.
Results:
OK The machine harness connectors are tight
and free of corrosion. Proceed to Test Step 3.
NOT OK The machine harness connectors are
in need of repair.
Repair: Repair the machine harness or replace the
machine harness.
STOP.
Test Step 3. CHECK FOR SHORTS TO
GROUND
A. The disconnect switch remains in the OFF
position.
B. Disconnect all ECM from the Cat Data Link.
C. At the machine harness for the VIMS 3G
Application ECM, measure the resistance
between frame ground and connector contacts
8 (wire 893-GN) and 9 (wire 892-BR) of the Cat
Data Link circuit.
Expected Result:
The resistance is greater than 5000 ohms.
Results:
OK The resistance is greater than 5000 ohms.
The harness circuit resistance is correct. Proceed
to Test Step 4.
NOT OK The resistance is less than 5000 ohms.
The machine harness has failed.
KENR9023-01
Repair: There is a short between frame ground
and the Cat Data Link circuit in the machine
harness. Repair the machine harness or replace
the machine harness.
STOP.
Test Step 4. CHECK FOR SHORT TO
+BATTERY
A. The disconnect switch remains in the OFF
position.
B. All of the related ECM remain disconnected from
the machine harness.
C. At the machine harness connector for the Brake
ECM, perform the checks that are listed here:
Measure the resistance between the +Battery
connector contact J1-31 (wire 176-RD) and
connector contact J1-10 (wire 893-GN).
Measure the resistance between connector
contact J1-31 (wire 176-RD) and connector
contact J1-20 (wire 892-BR).
Expected Result:
The resistance is greater than 5000 ohms.
Results:
OK The harness circuit resistance is correct.
Proceed to Test Step 5.
NOT OK The resistance is less than 5000 ohms.
The machine harness has failed.
Repair: There is a short between the +battery
and the Cat Data Link circuit in the machine
harness. Repair the machine harness or replace
the machine harness.
STOP.
Test Step 5. CHECK FOR OPEN HARNESS
A. The disconnect switch remains in the OFF
position.
B. Ensure that all of the ECM are disconnected from
the machine harness.
C. Check the continuity of the Cat Data Link circuit
in the machine harness:
Measure the resistance between connector
contact 8 (wire 893-GN) of the VIMS 3G
Application ECM and connector contact J1-10
(wire 893-GN) of the Brake ECM.
KENR9023-01 127
Troubleshooting Section

Measure the resistance between connector i03480658

contact 9 (wire 892-BR) of the VIMS 3G
Application ECM and connector contact J1-20 MID 162 - CID 0533 - FMI 09
(wire 892-BR) of the Brake ECM.
SMCS Code: 7610-038-BRK
Expected Result:
Conditions Which Generate This Code:
The resistance measures less than 5 ohms.

Results:

OK The resistance is less than 5 ohms. The Cat

Data Link circuit in the machine harness is correct.
Proceed to Test Step 6.

NOT OK The resistance is greater than 5 Ohms.

The machine harness has failed.

Repair: The Cat Data Link circuit is open in the

machine harness. Repair the machine harness or
replace the machine harness.

STOP.

Test Step 6. CHECK FOR ADDITIONAL

DIAGNOSTIC CODES FOR THE OTHER
ECM.
A. Reconnect all of the ECM that use the Cat Data
Link.

B. Turn the disconnect switch and the key start

switch to the ON position.

C. Check the Event List for diagnostic codes that are

logged against the other ECM.

Expected Result:

Diagnostic codes are not present for the other ECM

in the event list.

Results:

OK Diagnostic codes are not present for the

other ECM in the event list.

Repair: The Brake ECM has failed. It is unlikely g01969413

that the Brake ECM has failed. Exit this procedure.
Perform this procedure again. If the failure is not
found, replace the Brake ECM.
STOP.
NOT OK Diagnostic codes are present for the
other ECM in the event list.
Illustration 103
Schematic of the data link
This diagnostic code is recorded when the VIMS 3G
Application ECM receives communication from the
Brake ECM at an abnormal update rate.
System Response:

Repair: Perform the troubleshooting procedure for This failure results in events that are logged against
the other diagnostic codes. the Brake ECM that can not be explained directly.
The VIMS 3G Application ECM cannot communicate
STOP. with the Brake ECM or the Brake ECM appears to
communicate intermittently.
128
Troubleshooting Section
Test Step 1. VERIFY THE HARDWARE
AND THE SOFTWARE PART NUMBERS.
A. Verify that the following information is correct:
The part number of the VIMS 3G Application
ECM onboard software
The part number of the flash software for the
Brake ECM
The part number of the VIMS 3G Application
ECM
The part number of the Brake ECM
Note: Consult the Business Unit that produces
the product for the correct part numbers of the
configuration software.
Expected Result:
All part numbers are correct.
Results:
OK All part numbers are correct. Proceed to
Test Step 2.
NOT OK All part numbers are NOT correct.
Repair: The installed VIMS 3G Application ECM
or the Brake ECM has the wrong part number or
the incorrect configuration software is installed.
Replace the incorrect VIMS 3G Application ECM
or the brake ECM with an ECM that has the correct
part number. Refer to Service Manual, KENR9023,
Electronic Control Module (ECM) - Replace.
Flash the correct configuration software. Refer to
Service Manual, KENR9023, Electronic Control
Module (ECM) - Flash Program.
STOP.
Test Step 2. INSPECT THE HARNESS
CONNECTIONS.
A. Turn the disconnect switch to the OFF position.
B. Inspect all harness connections that are related to
the Cat Data Link. Make sure that the connectors
are clean and tight.
C. Check the connectors for proper mating. Ensure
that all the seals are present and in place.
D. Check the harness for signs of damage or
abrasion.
E. Check the wires at the connector. Ensure that the
wires are secured tightly into the connector. Take
care not to pull the wire out of the connector.
KENR9023-01
F. Check the exposed wires at the connectors for
nicks or signs of abrasion.
G. Check for moisture inside the connector.
H. Check the connectors for dirty contacts or
corroded contacts.
I. Check each pin and each socket of the machine
harness connectors. Ensure that the contacts
are properly installed. The contacts should mate
correctly when the two pieces of the connector
are placed together.
Expected Result:
The machine harness connectors are tight and free
of corrosion.
Results:
OK The machine harness connectors are tight
and free of corrosion. Proceed to Test Step 3.
NOT OK The machine harness connectors are
in need of repair.
Repair: Repair the machine harness or replace the
machine harness.
STOP.
Test Step 3. CHECK FOR SHORTS TO
GROUND
A. The disconnect switch remains in the OFF
position.
B. Disconnect all ECM from the Cat Data Link.
C. At the machine harness for the VIMS 3G
Application ECM, measure the resistance
between frame ground and connector contacts
8 (wire 893-GN) and 9 (wire 892-BR) of the Cat
Data Link circuit.
Expected Result:
The resistance is greater than 5000 ohms.
Results:
OK The resistance is greater than 5000 ohms.
The harness circuit resistance is correct. Proceed
to Test Step 4.
NOT OK The resistance is less than 5000 ohms.
The machine harness has failed.
KENR9023-01
Repair: There is a short between frame ground
and the Cat Data Link circuit in the machine
harness. Repair the machine harness or replace
the machine harness.
STOP.
Test Step 4. CHECK FOR SHORT TO
+BATTERY
A. The disconnect switch remains in the OFF
position.
B. All of the related ECM remain disconnected from
the machine harness.
C. At the machine harness connector for the Brake
ECM, perform the checks that are listed here:
Measure the resistance between the +Battery
connector contact J1-31 (wire 176-RD) and
connector contact J1-10 (wire 893-GN).
Measure the resistance between connector
contact J1-31 (wire 176-RD) and connector
contact J1-20 (wire 892-BR).
Expected Result:
The resistance is greater than 5000 ohms.
Results:
OK The harness circuit resistance is correct.
Proceed to Test Step 5.
NOT OK The resistance is less than 5000 ohms.
The machine harness has failed.
Repair: There is a short between the +battery
and the Cat Data Link circuit in the machine
harness. Repair the machine harness or replace
the machine harness.
STOP.
Test Step 5. CHECK FOR OPEN HARNESS
A. The disconnect switch remains in the OFF
position.
B. Ensure that all of the ECM are disconnected from
the machine harness.
C. Check the continuity of the Cat Data Link circuit
in the machine harness:
Measure the resistance between connector
contact 8 (wire 893-GN) of the VIMS 3G
Application ECM and connector contact J1-10
(wire 893-GN) of the Brake ECM.
129
Troubleshooting Section
Measure the resistance between connector
contact 9 (wire 892-BR) of the VIMS 3G
Application ECM and connector contact J1-20
(wire 892-BR) of the Brake ECM.
Expected Result:
The resistance measures less than 5 ohms.
Results:
OK The resistance is less than 5 ohms. The Cat
Data Link circuit in the machine harness is correct.
Proceed to Test Step 6.
NOT OK The resistance is greater than 5 Ohms.
The machine harness has failed.
Repair: The Cat Data Link circuit is open in the
machine harness. Repair the machine harness or
replace the machine harness.
STOP.
Test Step 6. CHECK FOR ADDITIONAL
DIAGNOSTIC CODES FOR THE OTHER
ECM.
A. Reconnect all of the ECM that use the Cat Data
Link.
B. Turn the disconnect switch and the key start
switch to the ON position.
C. Check the Event List for diagnostic codes that are
logged against the other ECM.
Expected Result:
Diagnostic codes are not present for the other ECM
in the event list.
Results:
OK Diagnostic codes are not present for the
other ECM in the event list.
Repair: The Brake ECM has failed. It is unlikely
that the Brake ECM has failed. Exit this procedure.
Perform this procedure again. If the failure is not
found, replace the Brake ECM.
STOP.
NOT OK Diagnostic codes are present for the
other ECM in the event list.
Repair: Perform the troubleshooting procedure for
the other diagnostic codes.
STOP.
130 KENR9023-01
Troubleshooting Section

i03480662 i03480663

MID 162 - CID 0533 - FMI 14 MID 162 - CID 0590 - FMI 02
SMCS Code: 7610-038-BRK SMCS Code: 1901-038; 7610-038-ENG

Conditions Which Generate This Code: Conditions Which Generate This Code:

This diagnostic code is recorded when the software is

not matched between two Electronic Control Modules
(ECM). This may happen when the software for one
ECM has been updated, but the software for another
ECM must be updated in order to match the first
ECM.

System Response:

This failure results in events that are logged to the

VIMS 3G Application ECM that can not be explained
directly. The VIMS 3G Application ECM cannot
communicate correctly with the Brake ECM.

Refer to Service Manual, KENR9023, Electronic

Control Module (ECM) - Flash Program and follow
the instructions in order to Flash the correct software
to both of the ECM.

Results:

STOP.

g01969413
Illustration 104
Schematic of the data link

This diagnostic code is recorded when the VIMS 3G

Application ECM receives data from the Engine ECM
that is erratic or incorrect.

System Response:

This failure results in events that are logged against

the Engine ECM that can not be explained directly.
The VIMS 3G Application ECM cannot communicate
with the Engine ECM or the Engine ECM appears to
communicate intermittently.
KENR9023-01
Test Step 1. VERIFY THE HARDWARE
AND THE SOFTWARE PART NUMBERS.
A. Verify that the following information is correct:
The part number of the VIMS 3G Application
ECM onboard software
The part number of the flash software for the
Engine ECM
The part number of the VIMS 3G Application
ECM
The part number of the Engine ECM
Note: Consult the Business Unit that produces
the product for the correct part numbers of the
configuration software.
Expected Result:
All part numbers are correct.
Results:
OK All part numbers are correct. Proceed to
Test Step 2.
NOT OK All part numbers are NOT correct.
Repair: The installed VIMS 3G Application ECM
or the Engine ECM has the wrong part number or
the incorrect configuration software is installed.
Replace the incorrect VIMS 3G Application ECM
or the Engine ECM with an ECM that has the
correct part number. Refer to Service Manual,
Electronic Control Module (ECM) - Replace.
Flash the correct configuration software. Refer to
Service Manual, Electronic Control Module (ECM)
- Flash Program.
STOP.
Test Step 2. INSPECT THE HARNESS
CONNECTIONS.
A. Turn the disconnect switch to the OFF position.
B. Inspect all harness connections that are related to
the Cat Data Link. Make sure that the connectors
are clean and tight.
C. Check the connectors for proper mating. Ensure
that all the seals are present and in place.
D. Check the harness for signs of damage or
abrasion.
E. Check the wires at the connector. Ensure that the
wires are secured tightly into the connector. Take
care not to pull the wire out of the connector.
131
Troubleshooting Section
F. Check the exposed wires at the connectors for
nicks or signs of abrasion.
G. Check for moisture inside the connector.
H. Check the connectors for dirty contacts or
corroded contacts.
I. Check each pin and each socket of the machine
harness connectors. Ensure that the contacts
are properly installed. The contacts should mate
correctly when the two pieces of the connector
are placed together.
Expected Result:
The machine harness connectors are tight and free
of corrosion.
Results:
OK The machine harness connectors are tight
and free of corrosion. Proceed to Test Step 3.
NOT OK The machine harness connectors are
in need of repair.
Repair: Repair the machine harness or replace the
machine harness.
STOP.
Test Step 3. CHECK FOR SHORTS TO
GROUND
A. The disconnect switch remains in the OFF
position.
B. Disconnect all ECM from the Cat Data Link.
C. At the machine harness for the VIMS 3G
Application ECM, measure the resistance
between frame ground and connector contacts
8 (wire 893-GN) and 9 (wire 892-BR) of the Cat
Data Link circuit.
Expected Result:
The resistance is greater than 5000 ohms.
Results:
OK The resistance is greater than 5000 ohms.
The harness circuit resistance is correct. Proceed
to Test Step 4.
NOT OK The resistance is less than 5000 ohms.
The machine harness has failed.
132
Troubleshooting Section
Repair: There is a short between frame ground
and the Cat Data Link circuit in the machine
harness. Repair the machine harness or replace
the machine harness.
STOP.
Test Step 4. CHECK FOR SHORT TO
+BATTERY
A. The disconnect switch remains in the OFF
position.
B. All of the related ECM remain disconnected from
the machine harness.
C. At the machine harness connector for the Engine
ECM, perform the checks that are listed here:
Measure the resistance between the +Battery
connector contact J1-52 (wire 150-RD) and
connector contact J1-8 (wire 893-GN).
Measure the resistance between connector
contact J1-52 (wire 150-RD) and connector
contact J1-9 (wire 892-BR).
Expected Result:
The resistance is greater than 5000 ohms.
Results:
OK The harness circuit resistance is correct.
Proceed to Test Step 5.
NOT OK The resistance is less than 5000 ohms.
The machine harness has failed.
Repair: There is a short between the +battery
and the Cat Data Link circuit in the machine
harness. Repair the machine harness or replace
the machine harness.
STOP.
Test Step 5. CHECK FOR OPEN HARNESS
A. The disconnect switch remains in the OFF
position.
B. Ensure that all of the ECM are disconnected from
the machine harness.
C. Check the continuity of the Cat Data Link circuit
in the machine harness:
Measure the resistance between connector
contact 8 (wire 893-GN) of the VIMS 3G
Application ECM and connector contact J1-8
(wire 893-GN) of the Engine ECM.
KENR9023-01
Measure the resistance between connector
contact 9 (wire 892-BR) of the VIMS 3G
Application ECM and connector contact J1-9
(wire 892-BR) of the Engine ECM.
Expected Result:
The resistance measures less than 5 ohms.
Results:
OK The resistance is less than 5 ohms. The Cat
Data Link circuit in the machine harness is correct.
Proceed to Test Step 6.
NOT OK The resistance is greater than 5 Ohms.
The machine harness has failed.
Repair: The Cat Data Link circuit is open in the
machine harness. Repair the machine harness or
replace the machine harness.
STOP.
Test Step 6. CHECK FOR ADDITIONAL
DIAGNOSTIC CODES FOR THE OTHER
ECM.
A. Reconnect all of the ECM that use the Cat Data
Link.
B. Turn the disconnect switch and the key start
switch to the ON position.
C. Check the Event List for diagnostic codes that are
logged against the other ECM.
Expected Result:
Diagnostic codes are not present for the other ECM
in the event list.
Results:
OK Diagnostic codes are not present for the
other ECM in the event list.
Repair: The Engine ECM has failed. It is unlikely
that the Engine ECM has failed. Exit this procedure.
Perform this procedure again. If the failure is not
found, replace the Engine ECM.
STOP.
NOT OK Diagnostic codes are present for the
other ECM in the event list.
Repair: Perform the troubleshooting procedure for
the other diagnostic codes.
STOP.
KENR9023-01
i03480665
MID 162 - CID 0590 - FMI 09
SMCS Code: 1901-038; 7610-038-ENG
Conditions Which Generate This Code:
g01969413
Illustration 105
Schematic of the data link
This diagnostic code is recorded when the VIMS
3G Application ECM does not receive expected
information from the Engine ECM through the Cat
Data Link at the correct update rate.
System Response:
This failure results in events that are logged against
the Engine ECM that can not be explained directly.
The VIMS 3G Application ECM cannot communicate
with the Engine ECM or the Engine ECM appears to
communicate intermittently.
133
Troubleshooting Section
Test Step 1. VERIFY THE HARDWARE
AND THE SOFTWARE PART NUMBERS.
A. Verify that the following information is correct:
The part number of the VIMS 3G Application
ECM onboard software
The part number of the flash software for the
Engine ECM
The part number of the VIMS 3G Application
ECM
The part number of the Engine ECM
Note: Consult the Business Unit that produces
the product for the correct part numbers of the
configuration software.
Expected Result:
All part numbers are correct.
Results:
OK All part numbers are correct. Proceed to
Test Step 2.
NOT OK All part numbers are NOT correct.
Repair: The installed VIMS 3G Application ECM
or the Engine ECM has the wrong part number or
the incorrect configuration software is installed.
Replace the incorrect VIMS 3G Application ECM or
the Engine ECM with an ECM that has the correct
part number. Refer to Service Manual, KENR9023,
Electronic Control Module (ECM) - Replace.
Flash the correct configuration software. Refer to
Service Manual, KENR9023, Electronic Control
Module (ECM) - Flash Program.
STOP.
Test Step 2. INSPECT THE HARNESS
CONNECTIONS.
A. Turn the disconnect switch to the OFF position.
B. Inspect all harness connections that are related to
the Cat Data Link. Make sure that the connectors
are clean and tight.
C. Check the connectors for proper mating. Ensure
that all the seals are present and in place.
D. Check the harness for signs of damage or
abrasion.
E. Check the wires at the connector. Ensure that the
wires are secured tightly into the connector. Take
care not to pull the wire out of the connector.
134
Troubleshooting Section
F. Check the exposed wires at the connectors for
nicks or signs of abrasion.
G. Check for moisture inside the connector.
H. Check the connectors for dirty contacts or
corroded contacts.
I. Check each pin and each socket of the machine
harness connectors. Ensure that the contacts
are properly installed. The contacts should mate
correctly when the two pieces of the connector
are placed together.
Expected Result:
The machine harness connectors are tight and free
of corrosion.
Results:
OK The machine harness connectors are tight
and free of corrosion. Proceed to Test Step 3.
NOT OK The machine harness connectors are
in need of repair.
Repair: Repair the machine harness or replace the
machine harness.
STOP.
Test Step 3. CHECK FOR SHORTS TO
GROUND
A. The disconnect switch remains in the OFF
position.
B. Disconnect all ECM from the Cat Data Link.
C. At the machine harness for the VIMS 3G
Application ECM, measure the resistance
between frame ground and connector contacts
8 (wire 893-GN) and 9 (wire 892-BR) of the Cat
Data Link circuit.
Expected Result:
The resistance is greater than 5000 ohms.
Results:
OK The resistance is greater than 5000 ohms.
The harness circuit resistance is correct. Proceed
to Test Step 4.
NOT OK The resistance is less than 5000 ohms.
The machine harness has failed.
KENR9023-01
Repair: There is a short between frame ground
and the Cat Data Link circuit in the machine
harness. Repair the machine harness or replace
the machine harness.
STOP.
Test Step 4. CHECK FOR SHORT TO
+BATTERY
A. The disconnect switch remains in the OFF
position.
B. All of the related ECM remain disconnected from
the machine harness.
C. At the machine harness connector for the Engine
ECM, perform the checks that are listed here:
Measure the resistance between the +Battery
connector contact J1-52 (wire 150-RD) and
connector contact J1-8 (wire 893-GN).
Measure the resistance between connector
contact J1-52 (wire 150-RD) and connector
contact J1-9 (wire 892-BR).
Expected Result:
The resistance is greater than 5000 ohms.
Results:
OK The harness circuit resistance is correct.
Proceed to Test Step 5.
NOT OK The resistance is less than 5000 ohms.
The machine harness has failed.
Repair: There is a short between the +battery
and the Cat Data Link circuit in the machine
harness. Repair the machine harness or replace
the machine harness.
STOP.
Test Step 5. CHECK FOR OPEN HARNESS
A. The disconnect switch remains in the OFF
position.
B. Ensure that all of the ECM are disconnected from
the machine harness.
C. Check the continuity of the Cat Data Link circuit
in the machine harness:
Measure the resistance between connector
contact 8 (wire 893-GN) of the VIMS 3G
Application ECM and connector contact J1-8
(wire 893-GN) of the Engine ECM.
KENR9023-01 135
Troubleshooting Section

Measure the resistance between connector i03480667

contact 9 (wire 892-BR) of the VIMS 3G
Application ECM and connector contact J1-9
(wire 892-BR) of the Engine ECM.
Expected Result:
The resistance measures less than 5 ohms.
Results:
OK The resistance is less than 5 ohms. The Cat
Data Link circuit in the machine harness is correct.
Proceed to Test Step 6.
MID 162 - CID 0590 - FMI 14
SMCS Code: 1901-038-ENG; 7610-038-ENG
Conditions Which Generate This Code:
This diagnostic code is recorded when the software is
not matched between two Electronic Control Modules
(ECM). This may happen when the software for one
ECM has been updated, but the software for another
ECM must be updated in order to match the first
ECM.

NOT OK The resistance is greater than 5 Ohms. System Response:

The machine harness has failed.
Repair: The Cat Data Link circuit is open in the
machine harness. Repair the machine harness or
replace the machine harness.
This failure results in events that are logged to the
VIMS 3G Application ECM that can not be explained
directly. The VIMS 3G Application ECM cannot
communicate correctly with the Engine ECM.

STOP. Refer to Service Manual, KENR9023, Electronic

Control Module (ECM) - Flash Program and follow
Test Step 6. CHECK FOR ADDITIONAL the instructions in order to Flash the correct software
DIAGNOSTIC CODES FOR THE OTHER to both of the ECM.
ECM.
Results:
A. Reconnect all of the ECM that use the Cat Data
Link. STOP.

B. Turn the disconnect switch and the key start i03665200

switch to the ON position.
MID 162 - CID 0768 - FMI 09
C. Check the Event List for diagnostic codes that are
logged against the other ECM. SMCS Code: 7601-038

Expected Result: Conditions Which Generate This Code:

Diagnostic codes are not present for the other ECM

in the event list.

Results:

OK Diagnostic codes are not present for the

other ECM in the event list.

Repair: The Engine ECM has failed. It is unlikely

that the Engine ECM has failed. Exit this procedure.
Perform this procedure again. If the failure is not
found, replace the Engine ECM.

STOP.

NOT OK Diagnostic codes are present for the

other ECM in the event list.

Repair: Perform the troubleshooting procedure for

the other diagnostic codes.
g01966493
Illustration 106
STOP.
Schematic of the RS-485 network
136
Troubleshooting Section
This diagnostic code is recorded if the VIMS 3G
Application ECM has detected an abnormal update
rate from the RS-485 Data Link communication.
System Response:
This failure results in events that are logged to the
VIMS 3G Application ECM that can not be explained
directly. The VIMS 3G Application ECM cannot
communicate correctly with the RS-485 data link.
Test Step 1. VERIFY THE HARDWARE
AND THE SOFTWARE PART NUMBERS.
A. Verify that the following information is correct:
The part number of the VIMS 3G Application
ECM onboard software
The part number of the VIMS 3G Application
ECM
Note: Consult the Business Unit that produces
the product for the correct part numbers of the
configuration software.
Expected Result:
All part numbers are correct.
Results:
OK All part numbers are correct. Proceed to
Test Step 2.
NOT OK All part numbers are NOT correct.
Repair: The installed VIMS 3G Application ECM
has the wrong part number or the incorrect
configuration software is installed. Replace the
incorrect VIMS 3G Application ECM with an
ECM that has the correct part number. Refer to
Service Manual, KENR9023, Electronic Control
Module (ECM) - Replace. Flash the correct
configuration software. Refer to Service Manual,
KENR9023, Electronic Control Module (ECM) -
Flash Program.
STOP.
Test Step 2. INSPECT THE HARNESS
CONNECTIONS.
A. Turn the disconnect switch to the OFF position.
B. Inspect all harness connections that are related
to the RS-485 data link. Make sure that the
connectors are clean and tight.
C. Check the connectors for proper mating. Ensure
that all the seals are present and in place.
KENR9023-01
D. Check the harness for signs of damage or
abrasion.
E. Check the wires at the connector. Ensure that the
wires are secured tightly into the connector. Take
care not to pull the wire out of the connector.
F. Check the exposed wires at the connectors for
nicks or signs of abrasion.
G. Check for moisture inside the connector.
H. Check the connectors for dirty contacts or
corroded contacts.
I. Check each pin and each socket of the machine
harness connectors. Ensure that the contacts
are properly installed. The contacts should mate
correctly when the two pieces of the connector
are placed together.
Expected Result:
The machine harness connectors are tight and free
of corrosion.
Results:
OK The machine harness connectors are tight
and free of corrosion. Proceed to Test Step 4.
NOT OK The machine harness connectors are
in need of repair.
Repair: Repair the machine harness or replace the
machine harness.
STOP.
Test Step 3. CHECK THE 120 OHM
TERMINATING RESISTORS
A. The disconnect switch remains in the OFF
position.
B. Disconnect both of the VIMS 3G ECM from the
RS-485 data link.
C. At the machine harness for the VIMS 3G Main
ECM , measure the resistance between connector
contacts that follow:
Contact 4 (939-WH) and Contact 5 (940-BU)
Contact 17 (920-BR) and Contact 18 (921-YL)
Expected Result:
The resistance is approximately 60 ohms.
KENR9023-01 137
Troubleshooting Section

Results: B. All of the related ECM remain disconnected from

the machine harness.
OK The resistance is approximately 60 ohms.
The terminating resistors are correct. Proceed to C. At the machine harness connector for the VIMS
Test Step 5. 3G Application ECM, perform the checks that are
listed here:
NOT OK The resistance is not approximately
60 ohms. The machine harness has failed or the Measure the resistance between the +Battery
terminating resistor has failed. connector contact 52 (wire 956-RD) on the
VIMS Main connector and connector contacts
Repair: Repair the machine harness or replace that follow:
the terminating resistor.
Contact 4 (939-WH)
STOP.
Contact 5 (940-BU)
Test Step 4. CHECK FOR SHORTS TO
GROUND Contact 6 (969-GY)
A. The disconnect switch remains in the OFF Contact 17 (920-BR)
position.
Contact 18 (921-YL)
B. Disconnect both of the VIMS 3G ECM from the
RS-485 data link. Expected Result:

C. At the machine harness for the VIMS 3G Main The resistance is greater than 5000 ohms.
ECM , measure the resistance between frame
ground and connector contacts that follow: Results:

Contact 4 (939-WH) OK The harness circuit resistance is correct.

Proceed to Test Step 6.
Contact 5 (940-BU)
NOT OK The resistance is less than 5000 ohms.
Contact 6 (969-GY) The machine harness has failed.

Contact 17 (920-BR) Repair: There is a short between the +battery

and the Cat Data Link circuit in the machine
Contact 18 (921-YL) harness. Repair the machine harness or replace
the machine harness.
Expected Result:
STOP.
The resistance is greater than 5000 ohms.
Test Step 6. CHECK FOR OPEN HARNESS
Results:
A. The disconnect switch remains in the OFF
OK The resistance is greater than 5000 ohms. position.
The harness circuit resistance is correct. Proceed
to Test Step 5. B. Ensure that the VIMS 3G ECM are disconnected
from the machine harness.
NOT OK The resistance is less than 5000 ohms.
The machine harness has failed. C. Check the continuity of the RS-485 data link circuit
in the connections that follow:
Repair: There is a short between frame ground
and the RS-485 data link circuit in the machine
harness. Repair the machine harness or replace
the machine harness.

STOP.

Test Step 5. CHECK FOR SHORT TO

+BATTERY
A. The disconnect switch remains in the OFF
position.
138 KENR9023-01
Troubleshooting Section

Table 18 i03661308

VIMS 3G Main ECM

VIMS 3G Application
ECM
MID 162 - CID 0768 - FMI 14
Contact 4 (939-WH) to Contact 17 (939-WH) SMCS Code: 7601-038
Contact 5 (940-BU) to Contact 18 (940-BU) Conditions Which Generate This Code:
Contact 6 (969-GY) to Contact 6 (969-GY)
This diagnostic code is recorded when the software is
Contact 17 (920-BR) to Contact 4 (920-BR) not matched between two Electronic Control Modules
Contact 18 (921-YL) to Contact 5 (921-YL) (ECM). This may happen when the software for one
ECM has been updated, but the software for another
ECM must be updated in order to match the first
Expected Result: ECM.
The resistance measures less than 5 ohms. System Response:
Results: This failure results in events that are logged to the
VIMS 3G Application ECM that can not be explained
OK The resistance is less than 5 ohms. The directly. The VIMS 3G Application ECM cannot
RS-485 data link circuit in the machine harness is communicate correctly with the RS-485 data link.
correct. Proceed to Test Step 7.
Refer to Service Manual, KENR9023, Electronic
NOT OK The resistance is greater than 5 Ohms. Control Module (ECM) - Flash Program and follow
The machine harness has failed. the instructions in order to Flash the correct software
to the VIMS 3G Main ECM.
Repair: The RS-485 data link circuit is open in the
machine harness. Repair the machine harness or Results:
replace the machine harness.

STOP.
STOP.

Test Step 7. CHECK FOR ADDITIONAL

DIAGNOSTIC CODES FOR THE OTHER
ECM.
A. Reconnect all of the ECM that use the RS-485
data link.

B. Turn the disconnect switch and the key start

switch to the ON position.

C. Check the Event List for diagnostic codes that are

logged against the other ECM.

Expected Result:

Diagnostic codes are not present for the other ECM

in the event list.

Results:

OK Diagnostic codes are not present for the

other ECM in the event list.

Repair: The VIMS 3G Application ECM has failed.

It is unlikely that the ECM has failed. Exit this
procedure. Perform this procedure again. If the
failure is not found, replace the ECM.

STOP.
KENR9023-01
i03583866
MID 162 - CID 0800 - FMI 09
SMCS Code: 7601-038
Conditions Which Generate This Code:
g01969413
Illustration 107
Schematic of the data link
This diagnostic code is recorded when the VIMS 3G
Application ECM has an abnormal update rate with
the VIMS 3G Main ECM through the Cat data link.
System Response:
This failure results in events that are logged against
the VIMS 3G Application ECM that can not be
explained directly. The VIMS 3G Application ECM
cannot communicate with the VIMS 3G Main
ECM or the VIMS 3G Application ECM appears to
communicate intermittently.
139
Troubleshooting Section
Test Step 1. VERIFY THE HARDWARE
AND THE SOFTWARE PART NUMBERS.
A. Verify that the following information is correct:
The part number of the VIMS 3G Application
ECM onboard software
The part number of the VIMS 3G Main ECM
onboard software
The part number of the VIMS 3G Application
ECM
The part number of the VIMS 3G Main ECM
Note: Consult the Business Unit that produces
the product for the correct part numbers of the
configuration software.
Expected Result:
All part numbers are correct.
Results:
OK All part numbers are correct. Proceed to
Test Step 2.
NOT OK All part numbers are NOT correct.
Repair: The installed VIMS 3G Application ECM or
the VIMS 3G Main ECM has the wrong part number
or the incorrect configuration software is installed.
Replace the incorrect VIMS 3G Application ECM
or the VIMS 3G Main ECM with an ECM that has
the correct part number. Refer to Service Manual,
Electronic Control Module (ECM) - Replace.
Flash the correct configuration software. Refer to
Service Manual, Electronic Control Module (ECM)
- Flash Program.
STOP.
Test Step 2. INSPECT THE HARNESS
CONNECTIONS.
A. Turn the disconnect switch to the OFF position.
B. Inspect all harness connections that are related to
the Cat Data Link. Make sure that the connectors
are clean and tight.
C. Check the connectors for proper mating. Ensure
that all the seals are present and in place.
D. Check the harness for signs of damage or
abrasion.
E. Check the wires at the connector. Ensure that the
wires are secured tightly into the connector. Take
care not to pull the wire out of the connector.
140
Troubleshooting Section
F. Check the exposed wires at the connectors for
nicks or signs of abrasion.
G. Check for moisture inside the connector.
H. Check the connectors for dirty contacts or
corroded contacts.
I. Check each pin and each socket of the machine
harness connectors. Ensure that the contacts
are properly installed. The contacts should mate
correctly when the two pieces of the connector
are placed together.
Expected Result:
The machine harness connectors are tight and free
of corrosion.
Results:
OK The machine harness connectors are tight
and free of corrosion. Proceed to Test Step 3.
NOT OK The machine harness connectors are
in need of repair.
Repair: Repair the machine harness or replace the
machine harness.
STOP.
Test Step 3. CHECK FOR SHORTS TO
GROUND
A. The disconnect switch remains in the OFF
position.
B. Disconnect all ECM from the Cat Data Link.
C. At the machine harness for the VIMS 3G
Application ECM, measure the resistance
between frame ground and connector contacts
8 (wire 893-GN) and 9 (wire 892-BR) of the Cat
Data Link circuit.
Expected Result:
The resistance is greater than 5000 ohms.
Results:
OK The resistance is greater than 5000 ohms.
The harness circuit resistance is correct. Proceed
to Test Step 4.
NOT OK The resistance is less than 5000 ohms.
The machine harness has failed.
KENR9023-01
Repair: There is a short between frame ground
and the Cat Data Link circuit in the machine
harness. Repair the machine harness or replace
the machine harness.
STOP.
Test Step 4. CHECK FOR SHORT TO
+BATTERY
A. The disconnect switch remains in the OFF
position.
B. All of the related ECM remain disconnected from
the machine harness.
C. At the machine harness connector for the VIMS
3G Application ECM, perform the checks that are
listed here:
Measure the resistance between the +battery
connector contact 52 (wire 170-RD) and
connector contact 8 (wire 893-GN) of the VIMS
3G Application ECM.
Measure the resistance between connector
contact 52 (wire 170-RD) and connector contact
9 (wire 892-BR) of the VIMS 3G Application
ECM.
Expected Result:
The resistance is greater than 5000 ohms.
Results:
OK The harness circuit resistance is correct.
Proceed to Test Step 5.
NOT OK The resistance is less than 5000 ohms.
The machine harness has failed.
Repair: There is a short between the +battery
and the Cat Data Link circuit in the machine
harness. Repair the machine harness or replace
the machine harness.
STOP.
Test Step 5. CHECK FOR OPEN HARNESS
A. The disconnect switch remains in the OFF
position.
B. Ensure that all of the ECM are disconnected from
the machine harness.
C. Check the continuity of the Cat Data Link circuit
in the machine harness:
KENR9023-01 141
Troubleshooting Section

Measure the resistance between connector Repair: Perform the troubleshooting procedure for
contact 8 (wire 893-GN) on the VIMS 3G the other diagnostic codes.
Application ECM and connector contact 8 (wire
893-GN) on the VIMS 3G Main ECM. STOP.

Measure the resistance between connector i03660823

contact 9 (wire 892-BR) on the VIMS 3G
Application ECM and connector contact 9 (wire
892-BR) on the VIMS 3G Main ECM.
Expected Result:
The resistance measures less than 5 ohms.
Results:
OK The resistance is less than 5 ohms. The Cat
Data Link circuit in the machine harness is correct.
Proceed to Test Step 6.
NOT OK The resistance is greater than 5 Ohms.
The machine harness has failed.
Repair: The Cat Data Link circuit is open in the
machine harness. Repair the machine harness or
replace the machine harness.
STOP.
Test Step 6. CHECK FOR ADDITIONAL
DIAGNOSTIC CODES FOR THE OTHER
ECM.
A. Reconnect all of the ECM that use the Cat Data
Link.
B. Turn the disconnect switch and the key start
switch to the ON position.
MID 162 - CID 0800 - FMI 14
SMCS Code: 7601-038
Conditions Which Generate This Code:
This diagnostic code is recorded when the software is
not matched between two Electronic Control Modules
(ECM). This may happen when the software for one
ECM has been updated, but the software for another
ECM must be updated in order to match the first
ECM.
System Response:
This failure results in events that are logged to the
VIMS 3G Application ECM that can not be explained
directly. The VIMS 3G Application ECM cannot
communicate correctly with the VIMS 3G Main ECM.
Refer to Service Manual, KENR9023, Electronic
Control Module (ECM) - Flash Program and follow
the instructions in order to Flash the correct software
to both of the ECM.
Results:
STOP.
i03480672

C. Check the Event List for diagnostic codes that are MID 162 - CID 0838 - FMI 03
logged against the other ECM.
SMCS Code: 1439-038-CD; 7201-038-PXS
Expected Result:
Conditions Which Generate This Code:
Diagnostic codes are not present for the other ECM
in the event list.

Results:

OK Diagnostic codes are not present for the

other ECM in the event list.

Repair: The VIMS 3G Application ECM has failed.

It is unlikely that the VIMS 3G Application ECM has
failed. Exit this procedure. Perform this procedure
again. If the failure is not found, replace the VIMS
3G Application ECM.

STOP. Illustration 108

g01873443

Schematic of the suspension cylinder pressure sensor

NOT OK Diagnostic codes are present for the
other ECM in the event list.
142
Troubleshooting Section
CID 0838 identifies the Left Front Strut Pressure
sensor. The output frequency of the sensor changes
as the pressure in the suspension cylinder changes.
The sensor is powered by the machine electrical
system.
Note: In addition to the Suspension Cylinder
Pressure Sensor troubleshooting procedure, the
VIMS diagnostics are helpful in troubleshooting
sensors.
Use this procedure to troubleshoot the suspect
performance of suspension cylinder pressure sensors
or any failure that is associated with the suspension
cylinder pressure sensors.
Note: This test checks for sensor voltages at the
sensor when all the circuits are connected. Unless
you are directed otherwise, do not disconnect any
components. Troubleshoot the circuit as is before
disconnecting any circuits. Disconnecting the sensor
from the harness before measuring the voltage may
alter a poor connection. This will make the proof of
cause difficult or impossible.
Table 19
Tools Needed
9U-7330 or Equivalent Multimeter
7X-1710 Multimeter Probe
Locate the suspect sensor. Identify the sensor wires
and connector contacts. DO NOT DISCONNECT
ANY HARNESS CONNECTORS AT THIS TIME.
Turn the key start switch to the ON position. Shut off
the engine, unless it is necessary for the engine to
be running. The truck can be empty or the truck can
be loaded.
Test Step 1. CHECK THE SENSOR
SUPPLY VOLTAGE.
A. At the sensor connector, identify the +V and
Ground circuits.
B. Insert the 7X-1710 Multimeter Probe leads into
the back of the sensor's connector along side of
+V and ground circuit wires.
C. Measure the system voltage.
Expected Result:
The voltage is between 22.0 DCV and 29.5 DCV.
Results:
YES The voltage is between 22.0 DCV and 29.5
DCV. The system voltage is present. proceed to
Test Step 2.
KENR9023-01
NO The voltage is less than 22.0 DCV. The
circuit is not correct.
Repair: Trace the +V and Ground circuits in the
machine harness. Repair the machine harness
or replace the machine harness. If the machine
harness has not failed the sensor is the cause of
the failure. Replace the sensor. A failed sensor is
unlikely.
STOP.
Test Step 2. CHECK THE SENSOR
SIGNAL VOLTAGE.
A. At the sensor connector, identify the signal and
ground circuits.
B. Insert the 7X-1710 Multimeter Probe leads into
the back of the sensor's connector along side of
the signal and ground circuit wires.
C. Measure the signal voltage.
Expected Result:
The signal voltage is between approximately 1.0
DCV and 9.0 DCV.
Results:
The voltage is greater than 9.0 DCV The signal
voltage is not correct. Proceed to Test Step 3.
The voltage is less than 1.0 DCV. The signal
voltage is not correct. Proceed to Test Step 4.
The voltage is between 1.0 DCV and 9.0 DCV
The signal circuit is correct. Proceed to Test Step 5.
Test Step 3. CHECK THE SIGNAL
CIRCUIT FOR A SHORT TO +BATTERY.
A. Disconnect the sensor from the machine harness.
B. At the machine harness connector for the sensor,
measure the voltage between the signal contact
and the ground contact.
Expected Result:
The voltage is above 9.0 DCV.
Results:
YES The voltage is above 9.0 DCV.
KENR9023-01
Repair: The signal circuit is shorted to the +battery
or the VIMS ECM has failed. Trace the Signal
circuit and the Ground circuits in the harness.
Repair the harness or replace the harness. If the
harness is correct, the VIMS electronic control
module has failed. Replace the VIMS ECM.
STOP.
NO The voltage is between 1.0 and 9.0 DCV.
The voltage is correct.
Repair: The sensor has failed. Replace the sensor.
STOP.
Test Step 4. CHECK THE SIGNAL
CIRCUIT FOR A SHORT TO GROUND.
A. Disconnect the sensor from the machine harness.
B. At the machine harness connector for the sensor,
measure the voltage between the signal contact
and the ground contact.
Expected Result:
The voltage is less than 1.0 DCV.
Results:
YES The voltage is less than 1.0 DCV.
Repair: Possible causes
The incorrect VIMS onboard software is installed.
The Signal circuit is shorted to ground in the
machine harness.
The VIMS electronic control module has failed.
Verify the possible causes in the order that is listed
below:
1. Verify that the correct VIMS onboard software
is installed. Install the correct VIMS onboard
software.
2. If the software is correct, trace the signal circuit
and the ground circuit in the harness. Repair
the harness or replace the harness.
3. If the harness is correct, the VIMS electronic
control module has failed. Replace the VIMS
electronic control module.
STOP.
NO The voltage is between 1.0 and 9.0 DCV.
The voltage is correct.
143
Troubleshooting Section
Repair: The sensor has failed. Replace the sensor.
STOP.
Test Step 5. CHECK THE FREQUENCY
OF THE SENSOR SIGNAL.
A. Remove the SENSOR from the suspension
cylinder. This is done so the sensor can not
sense the pressure within the suspension
cylinder. DO NOT DISCONNECT THE HARNESS
CONNECTOR.
B. At the machine harness connector of the
sensor, identify the signal and ground circuits.
DO NOT DISCONNECT THE HARNESS
CONNECTOR OR RECONNECT THE HARNESS
CONNECTOR.
C. Insert the 7X-1710 Multimeter Probe leads into
the back of the sensor's connector along side of
the signal and ground circuit wires.
D. Measure the frequency between the signal and
the ground contacts.
Expected Result:
The frequency is between 186 Hz and 214 Hz.
Results:
YES The frequency is between 186 Hz and
214 Hz when ambient temperature is between
10 C (50 F) and 40 C (104 F). The sensor is
generating a valid frequency. If the problem of
incorrect payload measurement persists proceed
to Test Step 6.
NO The frequency is NOT between 186 Hz and
214 Hz. The sensor is generating an incorrect
frequency.
Repair: The sensor has failed. Replace the sensor.
STOP.
Test Step 6. MOVE THE SENSOR.
A. substitute the suspect sensor with a sensor that
is functioning correctly. For example, substitute
a good left rear suspension cylinder pressure
sensor with the suspect right rear suspension
cylinder pressure sensor.
144
Troubleshooting Section
B. Verify that the problem followed the suspect
sensor to the other suspension cylinder. The
service technician can verify that the problem
followed the suspect sensor by riding in the
truck during the loading operation. The service
technician can observe the performance of the
four suspension cylinder pressure sensors by
using the VIMSpc View Real Time option. The
service technician can also activate a data logger.
Compare the signal outputs of the four sensors.
Verify that the suspect sensor does not respond
to the loading of the truck in the same manner as
the other sensors.
Expected Result:
The problem followed the sensor to the other
suspension cylinder.
Results:
YES The problem followed the sensor to the
other suspension cylinder. The sensor has failed.
Repair: Replace the sensor.
STOP.
NO The problem did not follow the sensor to the
other suspension cylinder. The suspension cylinder
is causing the failure. Proceed to Test Step 7.
Test Step 7. CHECK THE SUSPENSION
CYLINDERS.
Verify that the conditions that are listed below are
not present.
The suspension cylinders are NOT sticking when
the truck is empty.
The suspension cylinders are NOT bottoming out
when the truck is loaded.
The service technician can verify that the conditions
that are listed above are present by riding in the truck
during the loading operation. The service technician
can observe the operation of the four suspension
cylinder pressure sensors with the VIMSpc View
Real Time option. The service technician may
also activate a data logger in order to observe the
performance of the suspension cylinder. Compare
the signal outputs of the four sensors. Verify that the
sensor responds to the loading of the truck in the
same manner as the other sensors.
Expected Result:
The conditions that are listed above are not present.
KENR9023-01
Results:
YES The conditions that are listed above are not
present.
Repair: Perform the Troubleshooting, Payload
System procedure that is located in this manual.
STOP.
NO The conditions that are listed above are
present.
Repair: Service the suspension cylinder
in accordance with the Special Instruction,
SEHS9411, Charging Procedure for Front and
Rear Suspension Cylinders.
STOP.
i03480673
MID 162 - CID 0838 - FMI 04
SMCS Code: 1439-038-CD; 7201-038-PXS
Conditions Which Generate This Code:
g01873443
Illustration 109
Schematic of the suspension cylinder pressure sensor
CID 0838 identifies the Left Front Strut Pressure
sensor. The output frequency of the sensor changes
as the pressure in the suspension cylinder changes.
The sensor is powered by the machine electrical
system.
Note: In addition to the Suspension Cylinder
Pressure Sensor troubleshooting procedure, the
VIMS diagnostics are helpful in troubleshooting
sensors.
Use this procedure to troubleshoot the suspect
performance of suspension cylinder pressure sensors
or any failure that is associated with the suspension
cylinder pressure sensors.
KENR9023-01
Note: This test checks for sensor voltages at the
sensor when all the circuits are connected. Unless
you are directed otherwise, do not disconnect any
components. Troubleshoot the circuit as is before
disconnecting any circuits. Disconnecting the sensor
from the harness before measuring the voltage may
alter a poor connection. This will make the proof of
cause difficult or impossible.
Table 20
Tools Needed
9U-7330 or Equivalent Multimeter
7X-1710 Multimeter Probe
Locate the suspect sensor. Identify the sensor wires
and connector contacts. DO NOT DISCONNECT
ANY HARNESS CONNECTORS AT THIS TIME.
Turn the key start switch to the ON position. Shut off
the engine, unless it is necessary for the engine to
be running. The truck can be empty or the truck can
be loaded.
Test Step 1. CHECK THE SENSOR
SUPPLY VOLTAGE.
A. At the sensor connector, identify the +V and
Ground circuits.
B. Insert the 7X-1710 Multimeter Probe leads into
the back of the sensor's connector along side of
+V and ground circuit wires.
C. Measure the system voltage.
Expected Result:
The voltage is between 22.0 DCV and 29.5 DCV.
Results:
YES The voltage is between 22.0 DCV and 29.5
DCV. The system voltage is present. proceed to
Test Step 2.
NO The voltage is less than 22.0 DCV. The
circuit is not correct.
Repair: Trace the +V and Ground circuits in the
machine harness. Repair the machine harness
or replace the machine harness. If the machine
harness has not failed the sensor is the cause of
the failure. Replace the sensor. A failed sensor is
unlikely.
STOP.
Test Step 2. CHECK THE SENSOR
SIGNAL VOLTAGE.
A. At the sensor connector, identify the signal and
ground circuits.
145
Troubleshooting Section
B. Insert the 7X-1710 Multimeter Probe leads into
the back of the sensor's connector along side of
the signal and ground circuit wires.
C. Measure the signal voltage.
Expected Result:
The signal voltage is between approximately 1.0
DCV and 9.0 DCV.
Results:
The voltage is greater than 9.0 DCV The signal
voltage is not correct. Proceed to Test Step 3.
The voltage is less than 1.0 DCV. The signal
voltage is not correct. Proceed to Test Step 4.
The voltage is between 1.0 DCV and 9.0 DCV
The signal circuit is correct. Proceed to Test Step 5.
Test Step 3. CHECK THE SIGNAL
CIRCUIT FOR A SHORT TO +BATTERY.
A. Disconnect the sensor from the machine harness.
B. At the machine harness connector for the sensor,
measure the voltage between the signal contact
and the ground contact.
Expected Result:
The voltage is above 9.0 DCV.
Results:
YES The voltage is above 9.0 DCV.
Repair: The signal circuit is shorted to the +battery
or the VIMS ECM has failed. Trace the Signal
circuit and the Ground circuits in the harness.
Repair the harness or replace the harness. If the
harness is correct, the VIMS electronic control
module has failed. Replace the VIMS ECM.
STOP.
NO The voltage is between 1.0 and 9.0 DCV.
The voltage is correct.
Repair: The sensor has failed. Replace the sensor.
STOP.
Test Step 4. CHECK THE SIGNAL
CIRCUIT FOR A SHORT TO GROUND.
A. Disconnect the sensor from the machine harness.
B. At the machine harness connector for the sensor,
measure the voltage between the signal contact
and the ground contact.
146
Troubleshooting Section
Expected Result:
The voltage is less than 1.0 DCV.
Results:
YES The voltage is less than 1.0 DCV.
Repair: Possible causes
The incorrect VIMS onboard software is installed.
The Signal circuit is shorted to ground in the
machine harness.
The VIMS electronic control module has failed.
Verify the possible causes in the order that is listed
below:
1. Verify that the correct VIMS onboard software
is installed. Install the correct VIMS onboard
software.
2. If the software is correct, trace the signal circuit
and the ground circuit in the harness. Repair
the harness or replace the harness.
3. If the harness is correct, the VIMS electronic
control module has failed. Replace the VIMS
electronic control module.
STOP.
NO The voltage is between 1.0 and 9.0 DCV.
The voltage is correct.
Repair: The sensor has failed. Replace the sensor.
STOP.
Test Step 5. CHECK THE FREQUENCY
OF THE SENSOR SIGNAL.
A. Remove the SENSOR from the suspension
cylinder. This is done so the sensor can not
sense the pressure within the suspension
cylinder. DO NOT DISCONNECT THE HARNESS
CONNECTOR.
B. At the machine harness connector of the
sensor, identify the signal and ground circuits.
DO NOT DISCONNECT THE HARNESS
CONNECTOR OR RECONNECT THE HARNESS
CONNECTOR.
C. Insert the 7X-1710 Multimeter Probe leads into
the back of the sensor's connector along side of
the signal and ground circuit wires.
D. Measure the frequency between the signal and
the ground contacts.
KENR9023-01
Expected Result:
The frequency is between 186 Hz and 214 Hz.
Results:
YES The frequency is between 186 Hz and
214 Hz when ambient temperature is between
10 C (50 F) and 40 C (104 F). The sensor is
generating a valid frequency. If the problem of
incorrect payload measurement persists proceed
to Test Step 6.
NO The frequency is NOT between 186 Hz and
214 Hz. The sensor is generating an incorrect
frequency.
Repair: The sensor has failed. Replace the sensor.
STOP.
Test Step 6. MOVE THE SENSOR.
A. substitute the suspect sensor with a sensor that
is functioning correctly. For example, substitute
a good left rear suspension cylinder pressure
sensor with the suspect right rear suspension
cylinder pressure sensor.
B. Verify that the problem followed the suspect
sensor to the other suspension cylinder. The
service technician can verify that the problem
followed the suspect sensor by riding in the
truck during the loading operation. The service
technician can observe the performance of the
four suspension cylinder pressure sensors by
using the VIMSpc View Real Time option. The
service technician can also activate a data logger.
Compare the signal outputs of the four sensors.
Verify that the suspect sensor does not respond
to the loading of the truck in the same manner as
the other sensors.
Expected Result:
The problem followed the sensor to the other
suspension cylinder.
Results:
YES The problem followed the sensor to the
other suspension cylinder. The sensor has failed.
Repair: Replace the sensor.
STOP.
NO The problem did not follow the sensor to the
other suspension cylinder. The suspension cylinder
is causing the failure. Proceed to Test Step 7.
KENR9023-01
Test Step 7. CHECK THE SUSPENSION
CYLINDERS.
Verify that the conditions that are listed below are
not present.
The suspension cylinders are NOT sticking when
the truck is empty.
The suspension cylinders are NOT bottoming out
when the truck is loaded.
The service technician can verify that the conditions
that are listed above are present by riding in the truck
during the loading operation. The service technician
can observe the operation of the four suspension
cylinder pressure sensors with the VIMSpc View
Real Time option. The service technician may
also activate a data logger in order to observe the
performance of the suspension cylinder. Compare
the signal outputs of the four sensors. Verify that the
sensor responds to the loading of the truck in the
same manner as the other sensors.
Expected Result:
The conditions that are listed above are not present.
Results:
YES The conditions that are listed above are not
present.
Repair: Perform the Troubleshooting, Payload
System procedure that is located in this manual.
STOP.
NO The conditions that are listed above are
present.
Repair: Service the suspension cylinder
in accordance with the Special Instruction,
SEHS9411, Charging Procedure for Front and
Rear Suspension Cylinders.
STOP.
147
Troubleshooting Section
i03481723
MID 162 - CID 0838 - FMI 08
SMCS Code: 1439-038-CD; 7201-038-PXS
Conditions Which Generate This Code:
g01873443
Illustration 110
Schematic of the suspension cylinder pressure sensor
CID 0838 identifies the Left Front Strut Pressure
sensor. The output frequency of the sensor changes
as the pressure in the suspension cylinder changes.
The sensor is powered by the machine electrical
system.
Note: In addition to the Suspension Cylinder
Pressure Sensor troubleshooting procedure, the
VIMS diagnostics are helpful in troubleshooting
sensors.
Use this procedure to troubleshoot the suspect
performance of suspension cylinder pressure sensors
or any failure that is associated with the suspension
cylinder pressure sensors.
Note: This test checks for sensor voltages at the
sensor when all the circuits are connected. Unless
you are directed otherwise, do not disconnect any
components. Troubleshoot the circuit as is before
disconnecting any circuits. Disconnecting the sensor
from the harness before measuring the voltage may
alter a poor connection. This will make the proof of
cause difficult or impossible.
Table 21
Tools Needed
9U-7330 or Equivalent Multimeter
7X-1710 Multimeter Probe
Locate the suspect sensor. Identify the sensor wires
and connector contacts. DO NOT DISCONNECT
ANY HARNESS CONNECTORS AT THIS TIME.
Turn the key start switch to the ON position. Shut off
the engine, unless it is necessary for the engine to
be running. The truck can be empty or the truck can
be loaded.
148
Troubleshooting Section
Test Step 1. CHECK THE SENSOR
SUPPLY VOLTAGE.
A. At the sensor connector, identify the +V and
Ground circuits.
B. Insert the 7X-1710 Multimeter Probe leads into
the back of the sensor's connector along side of
+V and ground circuit wires.
C. Measure the system voltage.
Expected Result:
The voltage is between 22.0 DCV and 29.5 DCV.
Results:
YES The voltage is between 22.0 DCV and 29.5
DCV. The system voltage is present. proceed to
Test Step 2.
NO The voltage is less than 22.0 DCV. The
circuit is not correct.
Repair: Trace the +V and Ground circuits in the
machine harness. Repair the machine harness
or replace the machine harness. If the machine
harness has not failed the sensor is the cause of
the failure. Replace the sensor. A failed sensor is
unlikely.
STOP.
Test Step 2. CHECK THE SENSOR
SIGNAL VOLTAGE.
A. At the sensor connector, identify the signal and
ground circuits.
B. Insert the 7X-1710 Multimeter Probe leads into
the back of the sensor's connector along side of
the signal and ground circuit wires.
C. Measure the signal voltage.
Expected Result:
The signal voltage is between approximately 1.0
DCV and 9.0 DCV.
Results:
The voltage is greater than 9.0 DCV The signal
voltage is not correct. Proceed to Test Step 3.
The voltage is less than 1.0 DCV. The signal
voltage is not correct. Proceed to Test Step 4.
The voltage is between 1.0 DCV and 9.0 DCV
The signal circuit is correct. Proceed to Test Step 5.
KENR9023-01
Test Step 3. CHECK THE SIGNAL
CIRCUIT FOR A SHORT TO +BATTERY.
A. Disconnect the sensor from the machine harness.
B. At the machine harness connector for the sensor,
measure the voltage between the signal contact
and the ground contact.
Expected Result:
The voltage is above 9.0 DCV.
Results:
YES The voltage is above 9.0 DCV.
Repair: The signal circuit is shorted to the +battery
or the VIMS ECM has failed. Trace the Signal
circuit and the Ground circuits in the harness.
Repair the harness or replace the harness. If the
harness is correct, the VIMS electronic control
module has failed. Replace the VIMS ECM.
STOP.
NO The voltage is between 1.0 and 9.0 DCV.
The voltage is correct.
Repair: The sensor has failed. Replace the sensor.
STOP.
Test Step 4. CHECK THE SIGNAL
CIRCUIT FOR A SHORT TO GROUND.
A. Disconnect the sensor from the machine harness.
B. At the machine harness connector for the sensor,
measure the voltage between the signal contact
and the ground contact.
Expected Result:
The voltage is less than 1.0 DCV.
Results:
YES The voltage is less than 1.0 DCV.
Repair: Possible causes
The incorrect VIMS onboard software is installed.
The Signal circuit is shorted to ground in the
machine harness.
The VIMS electronic control module has failed.
Verify the possible causes in the order that is listed
below:
KENR9023-01
1. Verify that the correct VIMS onboard software
is installed. Install the correct VIMS onboard
software.
2. If the software is correct, trace the signal circuit
and the ground circuit in the harness. Repair
the harness or replace the harness.
3. If the harness is correct, the VIMS electronic
control module has failed. Replace the VIMS
electronic control module.
STOP.
NO The voltage is between 1.0 and 9.0 DCV.
The voltage is correct.
Repair: The sensor has failed. Replace the sensor.
STOP.
Test Step 5. CHECK THE FREQUENCY
OF THE SENSOR SIGNAL.
A. Remove the SENSOR from the suspension
cylinder. This is done so the sensor can not
sense the pressure within the suspension
cylinder. DO NOT DISCONNECT THE HARNESS
CONNECTOR.
B. At the machine harness connector of the
sensor, identify the signal and ground circuits.
DO NOT DISCONNECT THE HARNESS
CONNECTOR OR RECONNECT THE HARNESS
CONNECTOR.
C. Insert the 7X-1710 Multimeter Probe leads into
the back of the sensor's connector along side of
the signal and ground circuit wires.
D. Measure the frequency between the signal and
the ground contacts.
Expected Result:
The frequency is between 186 Hz and 214 Hz.
Results:
YES The frequency is between 186 Hz and
214 Hz when ambient temperature is between
10 C (50 F) and 40 C (104 F). The sensor is
generating a valid frequency. If the problem of
incorrect payload measurement persists proceed
to Test Step 6.
NO The frequency is NOT between 186 Hz and
214 Hz. The sensor is generating an incorrect
frequency.
Repair: The sensor has failed. Replace the sensor.
STOP.
149
Troubleshooting Section
Test Step 6. MOVE THE SENSOR.
A. substitute the suspect sensor with a sensor that
is functioning correctly. For example, substitute
a good left rear suspension cylinder pressure
sensor with the suspect right rear suspension
cylinder pressure sensor.
B. Verify that the problem followed the suspect
sensor to the other suspension cylinder. The
service technician can verify that the problem
followed the suspect sensor by riding in the
truck during the loading operation. The service
technician can observe the performance of the
four suspension cylinder pressure sensors by
using the VIMSpc View Real Time option. The
service technician can also activate a data logger.
Compare the signal outputs of the four sensors.
Verify that the suspect sensor does not respond
to the loading of the truck in the same manner as
the other sensors.
Expected Result:
The problem followed the sensor to the other
suspension cylinder.
Results:
YES The problem followed the sensor to the
other suspension cylinder. The sensor has failed.
Repair: Replace the sensor.
STOP.
NO The problem did not follow the sensor to the
other suspension cylinder. The suspension cylinder
is causing the failure. Proceed to Test Step 7.
Test Step 7. CHECK THE SUSPENSION
CYLINDERS.
Verify that the conditions that are listed below are
not present.
The suspension cylinders are NOT sticking when
the truck is empty.
The suspension cylinders are NOT bottoming out
when the truck is loaded.
The service technician can verify that the conditions
that are listed above are present by riding in the truck
during the loading operation. The service technician
can observe the operation of the four suspension
cylinder pressure sensors with the VIMSpc View
Real Time option. The service technician may
also activate a data logger in order to observe the
performance of the suspension cylinder. Compare
the signal outputs of the four sensors. Verify that the
sensor responds to the loading of the truck in the
same manner as the other sensors.
150
Troubleshooting Section
Expected Result:
The conditions that are listed above are not present.
Results:
YES The conditions that are listed above are not
present.
Repair: Perform the Troubleshooting, Payload
System procedure that is located in this manual.
STOP.
NO The conditions that are listed above are
present.
Repair: Service the suspension cylinder
in accordance with the Special Instruction,
SEHS9411, Charging Procedure for Front and
Rear Suspension Cylinders.
STOP.
i03481724
MID 162 - CID 0839 - FMI 03
SMCS Code: 1439-038-CD; 7201-038-PXS
Conditions Which Generate This Code:
g01873494
Illustration 111
Schematic of the suspension cylinder pressure sensor
CID 0839 identifies the Right Front Strut Pressure
sensor. The output frequency of the sensor changes
as the pressure in the suspension cylinder changes.
The sensor is powered by the machine electrical
system.
Note: In addition to the Suspension Cylinder
Pressure Sensor troubleshooting procedure, the
VIMS diagnostics are helpful in troubleshooting
sensors.
KENR9023-01
Use this procedure to troubleshoot the suspect
performance of suspension cylinder pressure sensors
or any failure that is associated with the suspension
cylinder pressure sensors.
Note: This test checks for sensor voltages at the
sensor when all the circuits are connected. Unless
you are directed otherwise, do not disconnect any
components. Troubleshoot the circuit as is before
disconnecting any circuits. Disconnecting the sensor
from the harness before measuring the voltage may
alter a poor connection. This will make the proof of
cause difficult or impossible.
Table 22
Tools Needed
9U-7330 or Equivalent Multimeter
7X-1710 Multimeter Probe
Locate the suspect sensor. Identify the sensor wires
and connector contacts. DO NOT DISCONNECT
ANY HARNESS CONNECTORS AT THIS TIME.
Turn the key start switch to the ON position. Shut off
the engine, unless it is necessary for the engine to
be running. The truck can be empty or the truck can
be loaded.
Test Step 1. CHECK THE SENSOR
SUPPLY VOLTAGE.
A. At the sensor connector, identify the +V and
Ground circuits.
B. Insert the 7X-1710 Multimeter Probe leads into
the back of the sensor's connector along side of
+V and ground circuit wires.
C. Measure the system voltage.
Expected Result:
The voltage is between 22.0 DCV and 29.5 DCV.
Results:
YES The voltage is between 22.0 DCV and 29.5
DCV. The system voltage is present. proceed to
Test Step 2.
NO The voltage is less than 22.0 DCV. The
circuit is not correct.
Repair: Trace the +V and Ground circuits in the
machine harness. Repair the machine harness
or replace the machine harness. If the machine
harness has not failed the sensor is the cause of
the failure. Replace the sensor. A failed sensor is
unlikely.
STOP.
KENR9023-01
Test Step 2. CHECK THE SENSOR
SIGNAL VOLTAGE.
A. At the sensor connector, identify the signal and
ground circuits.
B. Insert the 7X-1710 Multimeter Probe leads into
the back of the sensor's connector along side of
the signal and ground circuit wires.
C. Measure the signal voltage.
Expected Result:
The signal voltage is between approximately 1.0
DCV and 9.0 DCV.
Results:
The voltage is greater than 9.0 DCV The signal
voltage is not correct. Proceed to Test Step 3.
The voltage is less than 1.0 DCV. The signal
voltage is not correct. Proceed to Test Step 4.
The voltage is between 1.0 DCV and 9.0 DCV
The signal circuit is correct. Proceed to Test Step 5.
Test Step 3. CHECK THE SIGNAL
CIRCUIT FOR A SHORT TO +BATTERY.
A. Disconnect the sensor from the machine harness.
B. At the machine harness connector for the sensor,
measure the voltage between the signal contact
and the ground contact.
Expected Result:
The voltage is above 9.0 DCV.
Results:
YES The voltage is above 9.0 DCV.
Repair: The signal circuit is shorted to the +battery
or the VIMS ECM has failed. Trace the Signal
circuit and the Ground circuits in the harness.
Repair the harness or replace the harness. If the
harness is correct, the VIMS electronic control
module has failed. Replace the VIMS ECM.
STOP.
NO The voltage is between 1.0 and 9.0 DCV.
The voltage is correct.
Repair: The sensor has failed. Replace the sensor.
STOP.
151
Troubleshooting Section
Test Step 4. CHECK THE SIGNAL
CIRCUIT FOR A SHORT TO GROUND.
A. Disconnect the sensor from the machine harness.
B. At the machine harness connector for the sensor,
measure the voltage between the signal contact
and the ground contact.
Expected Result:
The voltage is less than 1.0 DCV.
Results:
YES The voltage is less than 1.0 DCV.
Repair: Possible causes
The incorrect VIMS onboard software is installed.
The Signal circuit is shorted to ground in the
machine harness.
The VIMS electronic control module has failed.
Verify the possible causes in the order that is listed
below:
1. Verify that the correct VIMS onboard software
is installed. Install the correct VIMS onboard
software.
2. If the software is correct, trace the signal circuit
and the ground circuit in the harness. Repair
the harness or replace the harness.
3. If the harness is correct, the VIMS electronic
control module has failed. Replace the VIMS
electronic control module.
STOP.
NO The voltage is between 1.0 and 9.0 DCV.
The voltage is correct.
Repair: The sensor has failed. Replace the sensor.
STOP.
Test Step 5. CHECK THE FREQUENCY
OF THE SENSOR SIGNAL.
A. Remove the SENSOR from the suspension
cylinder. This is done so the sensor can not
sense the pressure within the suspension
cylinder. DO NOT DISCONNECT THE HARNESS
CONNECTOR.
152
Troubleshooting Section
B. At the machine harness connector of the
sensor, identify the signal and ground circuits.
DO NOT DISCONNECT THE HARNESS
CONNECTOR OR RECONNECT THE HARNESS
CONNECTOR.
C. Insert the 7X-1710 Multimeter Probe leads into
the back of the sensor's connector along side of
the signal and ground circuit wires.
D. Measure the frequency between the signal and
the ground contacts.
Expected Result:
The frequency is between 186 Hz and 214 Hz.
Results:
YES The frequency is between 186 Hz and
214 Hz when ambient temperature is between
10 C (50 F) and 40 C (104 F). The sensor is
generating a valid frequency. If the problem of
incorrect payload measurement persists proceed
to Test Step 6.
NO The frequency is NOT between 186 Hz and
214 Hz. The sensor is generating an incorrect
frequency.
Repair: The sensor has failed. Replace the sensor.
STOP.
Test Step 6. MOVE THE SENSOR.
A. substitute the suspect sensor with a sensor that
is functioning correctly. For example, substitute
a good left rear suspension cylinder pressure
sensor with the suspect right rear suspension
cylinder pressure sensor.
B. Verify that the problem followed the suspect
sensor to the other suspension cylinder. The
service technician can verify that the problem
followed the suspect sensor by riding in the
truck during the loading operation. The service
technician can observe the performance of the
four suspension cylinder pressure sensors by
using the VIMSpc View Real Time option. The
service technician can also activate a data logger.
Compare the signal outputs of the four sensors.
Verify that the suspect sensor does not respond
to the loading of the truck in the same manner as
the other sensors.
Expected Result:
The problem followed the sensor to the other
suspension cylinder.
KENR9023-01
Results:
YES The problem followed the sensor to the
other suspension cylinder. The sensor has failed.
Repair: Replace the sensor.
STOP.
NO The problem did not follow the sensor to the
other suspension cylinder. The suspension cylinder
is causing the failure. Proceed to Test Step 7.
Test Step 7. CHECK THE SUSPENSION
CYLINDERS.
Verify that the conditions that are listed below are
not present.
The suspension cylinders are NOT sticking when
the truck is empty.
The suspension cylinders are NOT bottoming out
when the truck is loaded.
The service technician can verify that the conditions
that are listed above are present by riding in the truck
during the loading operation. The service technician
can observe the operation of the four suspension
cylinder pressure sensors with the VIMSpc View
Real Time option. The service technician may
also activate a data logger in order to observe the
performance of the suspension cylinder. Compare
the signal outputs of the four sensors. Verify that the
sensor responds to the loading of the truck in the
same manner as the other sensors.
Expected Result:
The conditions that are listed above are not present.
Results:
YES The conditions that are listed above are not
present.
Repair: Perform the Troubleshooting, Payload
System procedure that is located in this manual.
STOP.
NO The conditions that are listed above are
present.
Repair: Service the suspension cylinder
in accordance with the Special Instruction,
SEHS9411, Charging Procedure for Front and
Rear Suspension Cylinders.
STOP.
KENR9023-01
i03481726
MID 162 - CID 0839 - FMI 04
SMCS Code: 1439-038-CD; 7201-038-PXS
Conditions Which Generate This Code:
g01873494
Illustration 112
Schematic of the suspension cylinder pressure sensor
CID 0839 identifies the Right Front Strut Pressure
sensor. The output frequency of the sensor changes
as the pressure in the suspension cylinder changes.
The sensor is powered by the machine electrical
system.
Note: In addition to the Suspension Cylinder
Pressure Sensor troubleshooting procedure, the
VIMS diagnostics are helpful in troubleshooting
sensors.
Use this procedure to troubleshoot the suspect
performance of suspension cylinder pressure sensors
or any failure that is associated with the suspension
cylinder pressure sensors.
Note: This test checks for sensor voltages at the
sensor when all the circuits are connected. Unless
you are directed otherwise, do not disconnect any
components. Troubleshoot the circuit as is before
disconnecting any circuits. Disconnecting the sensor
from the harness before measuring the voltage may
alter a poor connection. This will make the proof of
cause difficult or impossible.
Table 23
Tools Needed
9U-7330 or Equivalent Multimeter
7X-1710 Multimeter Probe
Locate the suspect sensor. Identify the sensor wires
and connector contacts. DO NOT DISCONNECT
ANY HARNESS CONNECTORS AT THIS TIME.
Turn the key start switch to the ON position. Shut off
the engine, unless it is necessary for the engine to
be running. The truck can be empty or the truck can
be loaded.
153
Troubleshooting Section
Test Step 1. CHECK THE SENSOR
SUPPLY VOLTAGE.
A. At the sensor connector, identify the +V and
Ground circuits.
B. Insert the 7X-1710 Multimeter Probe leads into
the back of the sensor's connector along side of
+V and ground circuit wires.
C. Measure the system voltage.
Expected Result:
The voltage is between 22.0 DCV and 29.5 DCV.
Results:
YES The voltage is between 22.0 DCV and 29.5
DCV. The system voltage is present. proceed to
Test Step 2.
NO The voltage is less than 22.0 DCV. The
circuit is not correct.
Repair: Trace the +V and Ground circuits in the
machine harness. Repair the machine harness
or replace the machine harness. If the machine
harness has not failed the sensor is the cause of
the failure. Replace the sensor. A failed sensor is
unlikely.
STOP.
Test Step 2. CHECK THE SENSOR
SIGNAL VOLTAGE.
A. At the sensor connector, identify the signal and
ground circuits.
B. Insert the 7X-1710 Multimeter Probe leads into
the back of the sensor's connector along side of
the signal and ground circuit wires.
C. Measure the signal voltage.
Expected Result:
The signal voltage is between approximately 1.0
DCV and 9.0 DCV.
Results:
The voltage is greater than 9.0 DCV The signal
voltage is not correct. Proceed to Test Step 3.
The voltage is less than 1.0 DCV. The signal
voltage is not correct. Proceed to Test Step 4.
The voltage is between 1.0 DCV and 9.0 DCV
The signal circuit is correct. Proceed to Test Step 5.
154
Troubleshooting Section
Test Step 3. CHECK THE SIGNAL
CIRCUIT FOR A SHORT TO +BATTERY.
A. Disconnect the sensor from the machine harness.
B. At the machine harness connector for the sensor,
measure the voltage between the signal contact
and the ground contact.
Expected Result:
The voltage is above 9.0 DCV.
Results:
YES The voltage is above 9.0 DCV.
Repair: The signal circuit is shorted to the +battery
or the VIMS ECM has failed. Trace the Signal
circuit and the Ground circuits in the harness.
Repair the harness or replace the harness. If the
harness is correct, the VIMS electronic control
module has failed. Replace the VIMS ECM.
STOP.
NO The voltage is between 1.0 and 9.0 DCV.
The voltage is correct.
Repair: The sensor has failed. Replace the sensor.
STOP.
Test Step 4. CHECK THE SIGNAL
CIRCUIT FOR A SHORT TO GROUND.
A. Disconnect the sensor from the machine harness.
B. At the machine harness connector for the sensor,
measure the voltage between the signal contact
and the ground contact.
Expected Result:
The voltage is less than 1.0 DCV.
Results:
YES The voltage is less than 1.0 DCV.
Repair: Possible causes
The incorrect VIMS onboard software is installed.
The Signal circuit is shorted to ground in the
machine harness.
The VIMS electronic control module has failed.
Verify the possible causes in the order that is listed
below:
KENR9023-01
1. Verify that the correct VIMS onboard software
is installed. Install the correct VIMS onboard
software.
2. If the software is correct, trace the signal circuit
and the ground circuit in the harness. Repair
the harness or replace the harness.
3. If the harness is correct, the VIMS electronic
control module has failed. Replace the VIMS
electronic control module.
STOP.
NO The voltage is between 1.0 and 9.0 DCV.
The voltage is correct.
Repair: The sensor has failed. Replace the sensor.
STOP.
Test Step 5. CHECK THE FREQUENCY
OF THE SENSOR SIGNAL.
A. Remove the SENSOR from the suspension
cylinder. This is done so the sensor can not
sense the pressure within the suspension
cylinder. DO NOT DISCONNECT THE HARNESS
CONNECTOR.
B. At the machine harness connector of the
sensor, identify the signal and ground circuits.
DO NOT DISCONNECT THE HARNESS
CONNECTOR OR RECONNECT THE HARNESS
CONNECTOR.
C. Insert the 7X-1710 Multimeter Probe leads into
the back of the sensor's connector along side of
the signal and ground circuit wires.
D. Measure the frequency between the signal and
the ground contacts.
Expected Result:
The frequency is between 186 Hz and 214 Hz.
Results:
YES The frequency is between 186 Hz and
214 Hz when ambient temperature is between
10 C (50 F) and 40 C (104 F). The sensor is
generating a valid frequency. If the problem of
incorrect payload measurement persists proceed
to Test Step 6.
NO The frequency is NOT between 186 Hz and
214 Hz. The sensor is generating an incorrect
frequency.
Repair: The sensor has failed. Replace the sensor.
STOP.
KENR9023-01 155
Troubleshooting Section

Test Step 6. MOVE THE SENSOR. Expected Result:

A. substitute the suspect sensor with a sensor that
is functioning correctly. For example, substitute
a good left rear suspension cylinder pressure
sensor with the suspect right rear suspension
cylinder pressure sensor.
B. Verify that the problem followed the suspect
sensor to the other suspension cylinder. The
service technician can verify that the problem
followed the suspect sensor by riding in the
truck during the loading operation. The service
technician can observe the performance of the
four suspension cylinder pressure sensors by
using the VIMSpc View Real Time option. The
service technician can also activate a data logger.
Compare the signal outputs of the four sensors.
Verify that the suspect sensor does not respond
to the loading of the truck in the same manner as
the other sensors.
The conditions that are listed above are not present.
Results:
YES The conditions that are listed above are not
present.
Repair: Perform the Troubleshooting, Payload
System procedure that is located in this manual.
STOP.
NO The conditions that are listed above are
present.
Repair: Service the suspension cylinder
in accordance with the Special Instruction,
SEHS9411, Charging Procedure for Front and
Rear Suspension Cylinders.

Expected Result: STOP.

The problem followed the sensor to the other

i03481727
suspension cylinder.

Results:
MID 162 - CID 0839 - FMI 08
SMCS Code: 1439-038-CD; 7201-038-PXS
YES The problem followed the sensor to the
other suspension cylinder. The sensor has failed. Conditions Which Generate This Code:
Repair: Replace the sensor.

STOP.

NO The problem did not follow the sensor to the

other suspension cylinder. The suspension cylinder
is causing the failure. Proceed to Test Step 7.

Test Step 7. CHECK THE SUSPENSION

CYLINDERS.
Verify that the conditions that are listed below are
not present.

The suspension cylinders are NOT sticking when Illustration 113

g01873494

the truck is empty. Schematic of the suspension cylinder pressure sensor

The suspension cylinders are NOT bottoming out
when the truck is loaded.
The service technician can verify that the conditions
that are listed above are present by riding in the truck
during the loading operation. The service technician
can observe the operation of the four suspension
cylinder pressure sensors with the VIMSpc View
Real Time option. The service technician may
also activate a data logger in order to observe the
performance of the suspension cylinder. Compare
the signal outputs of the four sensors. Verify that the
sensor responds to the loading of the truck in the
same manner as the other sensors.
CID 0839 identifies the Right Front Strut Pressure
sensor. The output frequency of the sensor changes
as the pressure in the suspension cylinder changes.
The sensor is powered by the machine electrical
system.
Note: In addition to the Suspension Cylinder
Pressure Sensor troubleshooting procedure, the
VIMS diagnostics are helpful in troubleshooting
sensors.
156
Troubleshooting Section
Use this procedure to troubleshoot the suspect
performance of suspension cylinder pressure sensors
or any failure that is associated with the suspension
cylinder pressure sensors.
Note: This test checks for sensor voltages at the
sensor when all the circuits are connected. Unless
you are directed otherwise, do not disconnect any
components. Troubleshoot the circuit as is before
disconnecting any circuits. Disconnecting the sensor
from the harness before measuring the voltage may
alter a poor connection. This will make the proof of
cause difficult or impossible.
Table 24
Tools Needed
9U-7330 or Equivalent Multimeter
7X-1710 Multimeter Probe
Locate the suspect sensor. Identify the sensor wires
and connector contacts. DO NOT DISCONNECT
ANY HARNESS CONNECTORS AT THIS TIME.
Turn the key start switch to the ON position. Shut off
the engine, unless it is necessary for the engine to
be running. The truck can be empty or the truck can
be loaded.
Test Step 1. CHECK THE SENSOR
SUPPLY VOLTAGE.
A. At the sensor connector, identify the +V and
Ground circuits.
B. Insert the 7X-1710 Multimeter Probe leads into
the back of the sensor's connector along side of
+V and ground circuit wires.
C. Measure the system voltage.
Expected Result:
The voltage is between 22.0 DCV and 29.5 DCV.
Results:
YES The voltage is between 22.0 DCV and 29.5
DCV. The system voltage is present. proceed to
Test Step 2.
NO The voltage is less than 22.0 DCV. The
circuit is not correct.
Repair: Trace the +V and Ground circuits in the
machine harness. Repair the machine harness
or replace the machine harness. If the machine
harness has not failed the sensor is the cause of
the failure. Replace the sensor. A failed sensor is
unlikely.
STOP.
KENR9023-01
Test Step 2. CHECK THE SENSOR
SIGNAL VOLTAGE.
A. At the sensor connector, identify the signal and
ground circuits.
B. Insert the 7X-1710 Multimeter Probe leads into
the back of the sensor's connector along side of
the signal and ground circuit wires.
C. Measure the signal voltage.
Expected Result:
The signal voltage is between approximately 1.0
DCV and 9.0 DCV.
Results:
The voltage is greater than 9.0 DCV The signal
voltage is not correct. Proceed to Test Step 3.
The voltage is less than 1.0 DCV. The signal
voltage is not correct. Proceed to Test Step 4.
The voltage is between 1.0 DCV and 9.0 DCV
The signal circuit is correct. Proceed to Test Step 5.
Test Step 3. CHECK THE SIGNAL
CIRCUIT FOR A SHORT TO +BATTERY.
A. Disconnect the sensor from the machine harness.
B. At the machine harness connector for the sensor,
measure the voltage between the signal contact
and the ground contact.
Expected Result:
The voltage is above 9.0 DCV.
Results:
YES The voltage is above 9.0 DCV.
Repair: The signal circuit is shorted to the +battery
or the VIMS ECM has failed. Trace the Signal
circuit and the Ground circuits in the harness.
Repair the harness or replace the harness. If the
harness is correct, the VIMS electronic control
module has failed. Replace the VIMS ECM.
STOP.
NO The voltage is between 1.0 and 9.0 DCV.
The voltage is correct.
Repair: The sensor has failed. Replace the sensor.
STOP.
KENR9023-01
Test Step 4. CHECK THE SIGNAL
CIRCUIT FOR A SHORT TO GROUND.
A. Disconnect the sensor from the machine harness.
B. At the machine harness connector for the sensor,
measure the voltage between the signal contact
and the ground contact.
Expected Result:
The voltage is less than 1.0 DCV.
Results:
YES The voltage is less than 1.0 DCV.
Repair: Possible causes
The incorrect VIMS onboard software is installed.
The Signal circuit is shorted to ground in the
machine harness.
The VIMS electronic control module has failed.
Verify the possible causes in the order that is listed
below:
1. Verify that the correct VIMS onboard software
is installed. Install the correct VIMS onboard
software.
2. If the software is correct, trace the signal circuit
and the ground circuit in the harness. Repair
the harness or replace the harness.
3. If the harness is correct, the VIMS electronic
control module has failed. Replace the VIMS
electronic control module.
STOP.
NO The voltage is between 1.0 and 9.0 DCV.
The voltage is correct.
Repair: The sensor has failed. Replace the sensor.
STOP.
Test Step 5. CHECK THE FREQUENCY
OF THE SENSOR SIGNAL.
A. Remove the SENSOR from the suspension
cylinder. This is done so the sensor can not
sense the pressure within the suspension
cylinder. DO NOT DISCONNECT THE HARNESS
CONNECTOR.
157
Troubleshooting Section
B. At the machine harness connector of the
sensor, identify the signal and ground circuits.
DO NOT DISCONNECT THE HARNESS
CONNECTOR OR RECONNECT THE HARNESS
CONNECTOR.
C. Insert the 7X-1710 Multimeter Probe leads into
the back of the sensor's connector along side of
the signal and ground circuit wires.
D. Measure the frequency between the signal and
the ground contacts.
Expected Result:
The frequency is between 186 Hz and 214 Hz.
Results:
YES The frequency is between 186 Hz and
214 Hz when ambient temperature is between
10 C (50 F) and 40 C (104 F). The sensor is
generating a valid frequency. If the problem of
incorrect payload measurement persists proceed
to Test Step 6.
NO The frequency is NOT between 186 Hz and
214 Hz. The sensor is generating an incorrect
frequency.
Repair: The sensor has failed. Replace the sensor.
STOP.
Test Step 6. MOVE THE SENSOR.
A. substitute the suspect sensor with a sensor that
is functioning correctly. For example, substitute
a good left rear suspension cylinder pressure
sensor with the suspect right rear suspension
cylinder pressure sensor.
B. Verify that the problem followed the suspect
sensor to the other suspension cylinder. The
service technician can verify that the problem
followed the suspect sensor by riding in the
truck during the loading operation. The service
technician can observe the performance of the
four suspension cylinder pressure sensors by
using the VIMSpc View Real Time option. The
service technician can also activate a data logger.
Compare the signal outputs of the four sensors.
Verify that the suspect sensor does not respond
to the loading of the truck in the same manner as
the other sensors.
Expected Result:
The problem followed the sensor to the other
suspension cylinder.
158
Troubleshooting Section
Results:
YES The problem followed the sensor to the
other suspension cylinder. The sensor has failed.
Repair: Replace the sensor.
STOP.
NO The problem did not follow the sensor to the
other suspension cylinder. The suspension cylinder
is causing the failure. Proceed to Test Step 7.
Test Step 7. CHECK THE SUSPENSION
CYLINDERS.
Verify that the conditions that are listed below are
not present.
The suspension cylinders are NOT sticking when
the truck is empty.
The suspension cylinders are NOT bottoming out
when the truck is loaded.
The service technician can verify that the conditions
that are listed above are present by riding in the truck
during the loading operation. The service technician
can observe the operation of the four suspension
cylinder pressure sensors with the VIMSpc View
Real Time option. The service technician may
also activate a data logger in order to observe the
performance of the suspension cylinder. Compare
the signal outputs of the four sensors. Verify that the
sensor responds to the loading of the truck in the
same manner as the other sensors.
Expected Result:
The conditions that are listed above are not present.
Results:
YES The conditions that are listed above are not
present.
Repair: Perform the Troubleshooting, Payload
System procedure that is located in this manual.
STOP.
NO The conditions that are listed above are
present.
Repair: Service the suspension cylinder
in accordance with the Special Instruction,
SEHS9411, Charging Procedure for Front and
Rear Suspension Cylinders.
STOP.
KENR9023-01
i03481728
MID 162 - CID 0840 - FMI 03
SMCS Code: 1439-038-CD; 7201-038-PXS
Conditions Which Generate This Code:
g01873813
Illustration 114
Schematic of the suspension cylinder pressure sensor
CID 0840 identifies the Left Rear Strut Pressure
sensor. The output frequency of the sensor changes
as the pressure in the suspension cylinder changes.
The sensor is powered by the machine electrical
system.
Note: In addition to the Suspension Cylinder
Pressure Sensor troubleshooting procedure, the
VIMS diagnostics are helpful in troubleshooting
sensors.
Use this procedure to troubleshoot the suspect
performance of suspension cylinder pressure sensors
or any failure that is associated with the suspension
cylinder pressure sensors.
Note: This test checks for sensor voltages at the
sensor when all the circuits are connected. Unless
you are directed otherwise, do not disconnect any
components. Troubleshoot the circuit as is before
disconnecting any circuits. Disconnecting the sensor
from the harness before measuring the voltage may
alter a poor connection. This will make the proof of
cause difficult or impossible.
Table 25
Tools Needed
9U-7330 or Equivalent Multimeter
7X-1710 Multimeter Probe
Locate the suspect sensor. Identify the sensor wires
and connector contacts. DO NOT DISCONNECT
ANY HARNESS CONNECTORS AT THIS TIME.
Turn the key start switch to the ON position. Shut off
the engine, unless it is necessary for the engine to
be running. The truck can be empty or the truck can
be loaded.
KENR9023-01
Test Step 1. CHECK THE SENSOR
SUPPLY VOLTAGE.
A. At the sensor connector, identify the +V and
Ground circuits.
B. Insert the 7X-1710 Multimeter Probe leads into
the back of the sensor's connector along side of
+V and ground circuit wires.
C. Measure the system voltage.
Expected Result:
The voltage is between 22.0 DCV and 29.5 DCV.
Results:
YES The voltage is between 22.0 DCV and 29.5
DCV. The system voltage is present. proceed to
Test Step 2.
NO The voltage is less than 22.0 DCV. The
circuit is not correct.
Repair: Trace the +V and Ground circuits in the
machine harness. Repair the machine harness
or replace the machine harness. If the machine
harness has not failed the sensor is the cause of
the failure. Replace the sensor. A failed sensor is
unlikely.
STOP.
Test Step 2. CHECK THE SENSOR
SIGNAL VOLTAGE.
A. At the sensor connector, identify the signal and
ground circuits.
B. Insert the 7X-1710 Multimeter Probe leads into
the back of the sensor's connector along side of
the signal and ground circuit wires.
C. Measure the signal voltage.
Expected Result:
The signal voltage is between approximately 1.0
DCV and 9.0 DCV.
Results:
The voltage is greater than 9.0 DCV The signal
voltage is not correct. Proceed to Test Step 3.
The voltage is less than 1.0 DCV. The signal
voltage is not correct. Proceed to Test Step 4.
The voltage is between 1.0 DCV and 9.0 DCV
The signal circuit is correct. Proceed to Test Step 5.
159
Troubleshooting Section
Test Step 3. CHECK THE SIGNAL
CIRCUIT FOR A SHORT TO +BATTERY.
A. Disconnect the sensor from the machine harness.
B. At the machine harness connector for the sensor,
measure the voltage between the signal contact
and the ground contact.
Expected Result:
The voltage is above 9.0 DCV.
Results:
YES The voltage is above 9.0 DCV.
Repair: The signal circuit is shorted to the +battery
or the VIMS ECM has failed. Trace the Signal
circuit and the Ground circuits in the harness.
Repair the harness or replace the harness. If the
harness is correct, the VIMS electronic control
module has failed. Replace the VIMS ECM.
STOP.
NO The voltage is between 1.0 and 9.0 DCV.
The voltage is correct.
Repair: The sensor has failed. Replace the sensor.
STOP.
Test Step 4. CHECK THE SIGNAL
CIRCUIT FOR A SHORT TO GROUND.
A. Disconnect the sensor from the machine harness.
B. At the machine harness connector for the sensor,
measure the voltage between the signal contact
and the ground contact.
Expected Result:
The voltage is less than 1.0 DCV.
Results:
YES The voltage is less than 1.0 DCV.
Repair: Possible causes
The incorrect VIMS onboard software is installed.
The Signal circuit is shorted to ground in the
machine harness.
The VIMS electronic control module has failed.
Verify the possible causes in the order that is listed
below:
160
Troubleshooting Section
1. Verify that the correct VIMS onboard software
is installed. Install the correct VIMS onboard
software.
2. If the software is correct, trace the signal circuit
and the ground circuit in the harness. Repair
the harness or replace the harness.
3. If the harness is correct, the VIMS electronic
control module has failed. Replace the VIMS
electronic control module.
STOP.
NO The voltage is between 1.0 and 9.0 DCV.
The voltage is correct.
Repair: The sensor has failed. Replace the sensor.
STOP.
Test Step 5. CHECK THE FREQUENCY
OF THE SENSOR SIGNAL.
A. Remove the SENSOR from the suspension
cylinder. This is done so the sensor can not
sense the pressure within the suspension
cylinder. DO NOT DISCONNECT THE HARNESS
CONNECTOR.
B. At the machine harness connector of the
sensor, identify the signal and ground circuits.
DO NOT DISCONNECT THE HARNESS
CONNECTOR OR RECONNECT THE HARNESS
CONNECTOR.
C. Insert the 7X-1710 Multimeter Probe leads into
the back of the sensor's connector along side of
the signal and ground circuit wires.
D. Measure the frequency between the signal and
the ground contacts.
Expected Result:
The frequency is between 186 Hz and 214 Hz.
Results:
YES The frequency is between 186 Hz and
214 Hz when ambient temperature is between
10 C (50 F) and 40 C (104 F). The sensor is
generating a valid frequency. If the problem of
incorrect payload measurement persists proceed
to Test Step 6.
NO The frequency is NOT between 186 Hz and
214 Hz. The sensor is generating an incorrect
frequency.
Repair: The sensor has failed. Replace the sensor.
STOP.
KENR9023-01
Test Step 6. MOVE THE SENSOR.
A. Substitute the suspect sensor with a sensor that
is functioning correctly. For example, substitute
a good right rear suspension cylinder pressure
sensor with the suspect left rear suspension
cylinder pressure sensor.
B. Verify that the problem followed the suspect
sensor to the other suspension cylinder. The
service technician can verify that the problem
followed the suspect sensor by riding in the
truck during the loading operation. The service
technician can observe the performance of the
four suspension cylinder pressure sensors by
using the VIMSpc View Real Time option. The
service technician can also activate a data logger.
Compare the signal outputs of the four sensors.
Verify that the suspect sensor does not respond
to the loading of the truck in the same manner as
the other sensors.
Expected Result:
The problem followed the sensor to the other
suspension cylinder.
Results:
YES The problem followed the sensor to the
other suspension cylinder. The sensor has failed.
Repair: Replace the sensor.
STOP.
NO The problem did not follow the sensor to the
other suspension cylinder. The suspension cylinder
is causing the failure. Proceed to Test Step 7.
Test Step 7. CHECK THE SUSPENSION
CYLINDERS.
Verify that the conditions that are listed below are
not present.
The suspension cylinders are NOT sticking when
the truck is empty.
The suspension cylinders are NOT bottoming out
when the truck is loaded.
The service technician can verify that the conditions
that are listed above are present by riding in the truck
during the loading operation. The service technician
can observe the operation of the four suspension
cylinder pressure sensors with the VIMSpc View
Real Time option. The service technician may
also activate a data logger in order to observe the
performance of the suspension cylinder. Compare
the signal outputs of the four sensors. Verify that the
sensor responds to the loading of the truck in the
same manner as the other sensors.
KENR9023-01
Expected Result:
The conditions that are listed above are not present.
Results:
YES The conditions that are listed above are not
present.
Repair: Perform the Troubleshooting, Payload
System procedure that is located in this manual.
STOP.
NO The conditions that are listed above are
present.
Repair: Service the suspension cylinder
in accordance with the Special Instruction,
SEHS9411, Charging Procedure for Front and
Rear Suspension Cylinders.
STOP.
i03481729
MID 162 - CID 0840 - FMI 04
SMCS Code: 1439-038-CD; 7201-038-PXS
Conditions Which Generate This Code:
g01873813
Illustration 115
Schematic of the suspension cylinder pressure sensor
CID 0840 identifies the Left Rear Strut Pressure
sensor. The output frequency of the sensor changes
as the pressure in the suspension cylinder changes.
The sensor is powered by the machine electrical
system.
Note: In addition to the Suspension Cylinder
Pressure Sensor troubleshooting procedure, the
VIMS diagnostics are helpful in troubleshooting
sensors.
161
Troubleshooting Section
Use this procedure to troubleshoot the suspect
performance of suspension cylinder pressure sensors
or any failure that is associated with the suspension
cylinder pressure sensors.
Note: This test checks for sensor voltages at the
sensor when all the circuits are connected. Unless
you are directed otherwise, do not disconnect any
components. Troubleshoot the circuit as is before
disconnecting any circuits. Disconnecting the sensor
from the harness before measuring the voltage may
alter a poor connection. This will make the proof of
cause difficult or impossible.
Table 26
Tools Needed
9U-7330 or Equivalent Multimeter
7X-1710 Multimeter Probe
Locate the suspect sensor. Identify the sensor wires
and connector contacts. DO NOT DISCONNECT
ANY HARNESS CONNECTORS AT THIS TIME.
Turn the key start switch to the ON position. Shut off
the engine, unless it is necessary for the engine to
be running. The truck can be empty or the truck can
be loaded.
Test Step 1. CHECK THE SENSOR
SUPPLY VOLTAGE.
A. At the sensor connector, identify the +V and
Ground circuits.
B. Insert the 7X-1710 Multimeter Probe leads into
the back of the sensor's connector along side of
+V and ground circuit wires.
C. Measure the system voltage.
Expected Result:
The voltage is between 22.0 DCV and 29.5 DCV.
Results:
YES The voltage is between 22.0 DCV and 29.5
DCV. The system voltage is present. proceed to
Test Step 2.
NO The voltage is less than 22.0 DCV. The
circuit is not correct.
Repair: Trace the +V and Ground circuits in the
machine harness. Repair the machine harness
or replace the machine harness. If the machine
harness has not failed the sensor is the cause of
the failure. Replace the sensor. A failed sensor is
unlikely.
STOP.
162
Troubleshooting Section
Test Step 2. CHECK THE SENSOR
SIGNAL VOLTAGE.
A. At the sensor connector, identify the signal and
ground circuits.
B. Insert the 7X-1710 Multimeter Probe leads into
the back of the sensor's connector along side of
the signal and ground circuit wires.
C. Measure the signal voltage.
Expected Result:
The signal voltage is between approximately 1.0
DCV and 9.0 DCV.
Results:
The voltage is greater than 9.0 DCV The signal
voltage is not correct. Proceed to Test Step 3.
The voltage is less than 1.0 DCV. The signal
voltage is not correct. Proceed to Test Step 4.
The voltage is between 1.0 DCV and 9.0 DCV
The signal circuit is correct. Proceed to Test Step 5.
Test Step 3. CHECK THE SIGNAL
CIRCUIT FOR A SHORT TO +BATTERY.
A. Disconnect the sensor from the machine harness.
B. At the machine harness connector for the sensor,
measure the voltage between the signal contact
and the ground contact.
Expected Result:
The voltage is above 9.0 DCV.
Results:
YES The voltage is above 9.0 DCV.
Repair: The signal circuit is shorted to the +battery
or the VIMS ECM has failed. Trace the Signal
circuit and the Ground circuits in the harness.
Repair the harness or replace the harness. If the
harness is correct, the VIMS electronic control
module has failed. Replace the VIMS ECM.
STOP.
NO The voltage is between 1.0 and 9.0 DCV.
The voltage is correct.
Repair: The sensor has failed. Replace the sensor.
STOP.
KENR9023-01
Test Step 4. CHECK THE SIGNAL
CIRCUIT FOR A SHORT TO GROUND.
A. Disconnect the sensor from the machine harness.
B. At the machine harness connector for the sensor,
measure the voltage between the signal contact
and the ground contact.
Expected Result:
The voltage is less than 1.0 DCV.
Results:
YES The voltage is less than 1.0 DCV.
Repair: Possible causes
The incorrect VIMS onboard software is installed.
The Signal circuit is shorted to ground in the
machine harness.
The VIMS electronic control module has failed.
Verify the possible causes in the order that is listed
below:
1. Verify that the correct VIMS onboard software
is installed. Install the correct VIMS onboard
software.
2. If the software is correct, trace the signal circuit
and the ground circuit in the harness. Repair
the harness or replace the harness.
3. If the harness is correct, the VIMS electronic
control module has failed. Replace the VIMS
electronic control module.
STOP.
NO The voltage is between 1.0 and 9.0 DCV.
The voltage is correct.
Repair: The sensor has failed. Replace the sensor.
STOP.
Test Step 5. CHECK THE FREQUENCY
OF THE SENSOR SIGNAL.
A. Remove the SENSOR from the suspension
cylinder. This is done so the sensor can not
sense the pressure within the suspension
cylinder. DO NOT DISCONNECT THE HARNESS
CONNECTOR.
KENR9023-01
B. At the machine harness connector of the
sensor, identify the signal and ground circuits.
DO NOT DISCONNECT THE HARNESS
CONNECTOR OR RECONNECT THE HARNESS
CONNECTOR.
C. Insert the 7X-1710 Multimeter Probe leads into
the back of the sensor's connector along side of
the signal and ground circuit wires.
D. Measure the frequency between the signal and
the ground contacts.
Expected Result:
The frequency is between 186 Hz and 214 Hz.
Results:
YES The frequency is between 186 Hz and
214 Hz when ambient temperature is between
10 C (50 F) and 40 C (104 F). The sensor is
generating a valid frequency. If the problem of
incorrect payload measurement persists proceed
to Test Step 6.
NO The frequency is NOT between 186 Hz and
214 Hz. The sensor is generating an incorrect
frequency.
Repair: The sensor has failed. Replace the sensor.
STOP.
Test Step 6. MOVE THE SENSOR.
A. Substitute the suspect sensor with a sensor that
is functioning correctly. For example, substitute
a good right rear suspension cylinder pressure
sensor with the suspect left rear suspension
cylinder pressure sensor.
B. Verify that the problem followed the suspect
sensor to the other suspension cylinder. The
service technician can verify that the problem
followed the suspect sensor by riding in the
truck during the loading operation. The service
technician can observe the performance of the
four suspension cylinder pressure sensors by
using the VIMSpc View Real Time option. The
service technician can also activate a data logger.
Compare the signal outputs of the four sensors.
Verify that the suspect sensor does not respond
to the loading of the truck in the same manner as
the other sensors.
Expected Result:
The problem followed the sensor to the other
suspension cylinder.
163
Troubleshooting Section
Results:
YES The problem followed the sensor to the
other suspension cylinder. The sensor has failed.
Repair: Replace the sensor.
STOP.
NO The problem did not follow the sensor to the
other suspension cylinder. The suspension cylinder
is causing the failure. Proceed to Test Step 7.
Test Step 7. CHECK THE SUSPENSION
CYLINDERS.
Verify that the conditions that are listed below are
not present.
The suspension cylinders are NOT sticking when
the truck is empty.
The suspension cylinders are NOT bottoming out
when the truck is loaded.
The service technician can verify that the conditions
that are listed above are present by riding in the truck
during the loading operation. The service technician
can observe the operation of the four suspension
cylinder pressure sensors with the VIMSpc View
Real Time option. The service technician may
also activate a data logger in order to observe the
performance of the suspension cylinder. Compare
the signal outputs of the four sensors. Verify that the
sensor responds to the loading of the truck in the
same manner as the other sensors.
Expected Result:
The conditions that are listed above are not present.
Results:
YES The conditions that are listed above are not
present.
Repair: Perform the Troubleshooting, Payload
System procedure that is located in this manual.
STOP.
NO The conditions that are listed above are
present.
Repair: Service the suspension cylinder
in accordance with the Special Instruction,
SEHS9411, Charging Procedure for Front and
Rear Suspension Cylinders.
STOP.
164
Troubleshooting Section
i03481731
MID 162 - CID 0840 - FMI 08
SMCS Code: 1439-038-CD; 7201-038-PXS
Conditions Which Generate This Code:
g01873813
Illustration 116
Schematic of the suspension cylinder pressure sensor
CID 0840 identifies the Left Rear Strut Pressure
sensor. The output frequency of the sensor changes
as the pressure in the suspension cylinder changes.
The sensor is powered by the machine electrical
system.
Note: In addition to the Suspension Cylinder
Pressure Sensor troubleshooting procedure, the
VIMS diagnostics are helpful in troubleshooting
sensors.
Use this procedure to troubleshoot the suspect
performance of suspension cylinder pressure sensors
or any failure that is associated with the suspension
cylinder pressure sensors.
Note: This test checks for sensor voltages at the
sensor when all the circuits are connected. Unless
you are directed otherwise, do not disconnect any
components. Troubleshoot the circuit as is before
disconnecting any circuits. Disconnecting the sensor
from the harness before measuring the voltage may
alter a poor connection. This will make the proof of
cause difficult or impossible.
Table 27
Tools Needed
9U-7330 or Equivalent Multimeter
7X-1710 Multimeter Probe
Locate the suspect sensor. Identify the sensor wires
and connector contacts. DO NOT DISCONNECT
ANY HARNESS CONNECTORS AT THIS TIME.
Turn the key start switch to the ON position. Shut off
the engine, unless it is necessary for the engine to
be running. The truck can be empty or the truck can
be loaded.
KENR9023-01
Test Step 1. CHECK THE SENSOR
SUPPLY VOLTAGE.
A. At the sensor connector, identify the +V and
Ground circuits.
B. Insert the 7X-1710 Multimeter Probe leads into
the back of the sensor's connector along side of
+V and ground circuit wires.
C. Measure the system voltage.
Expected Result:
The voltage is between 22.0 DCV and 29.5 DCV.
Results:
YES The voltage is between 22.0 DCV and 29.5
DCV. The system voltage is present. proceed to
Test Step 2.
NO The voltage is less than 22.0 DCV. The
circuit is not correct.
Repair: Trace the +V and Ground circuits in the
machine harness. Repair the machine harness
or replace the machine harness. If the machine
harness has not failed the sensor is the cause of
the failure. Replace the sensor. A failed sensor is
unlikely.
STOP.
Test Step 2. CHECK THE SENSOR
SIGNAL VOLTAGE.
A. At the sensor connector, identify the signal and
ground circuits.
B. Insert the 7X-1710 Multimeter Probe leads into
the back of the sensor's connector along side of
the signal and ground circuit wires.
C. Measure the signal voltage.
Expected Result:
The signal voltage is between approximately 1.0
DCV and 9.0 DCV.
Results:
The voltage is greater than 9.0 DCV The signal
voltage is not correct. Proceed to Test Step 3.
The voltage is less than 1.0 DCV. The signal
voltage is not correct. Proceed to Test Step 4.
The voltage is between 1.0 DCV and 9.0 DCV
The signal circuit is correct. Proceed to Test Step 5.
KENR9023-01
Test Step 3. CHECK THE SIGNAL
CIRCUIT FOR A SHORT TO +BATTERY.
A. Disconnect the sensor from the machine harness.
B. At the machine harness connector for the sensor,
measure the voltage between the signal contact
and the ground contact.
Expected Result:
The voltage is above 9.0 DCV.
Results:
YES The voltage is above 9.0 DCV.
Repair: The signal circuit is shorted to the +battery
or the VIMS ECM has failed. Trace the Signal
circuit and the Ground circuits in the harness.
Repair the harness or replace the harness. If the
harness is correct, the VIMS electronic control
module has failed. Replace the VIMS ECM.
STOP.
NO The voltage is between 1.0 and 9.0 DCV.
The voltage is correct.
Repair: The sensor has failed. Replace the sensor.
STOP.
Test Step 4. CHECK THE SIGNAL
CIRCUIT FOR A SHORT TO GROUND.
A. Disconnect the sensor from the machine harness.
B. At the machine harness connector for the sensor,
measure the voltage between the signal contact
and the ground contact.
Expected Result:
The voltage is less than 1.0 DCV.
Results:
YES The voltage is less than 1.0 DCV.
Repair: Possible causes
The incorrect VIMS onboard software is installed.
The Signal circuit is shorted to ground in the
machine harness.
The VIMS electronic control module has failed.
Verify the possible causes in the order that is listed
below:
165
Troubleshooting Section
1. Verify that the correct VIMS onboard software
is installed. Install the correct VIMS onboard
software.
2. If the software is correct, trace the signal circuit
and the ground circuit in the harness. Repair
the harness or replace the harness.
3. If the harness is correct, the VIMS electronic
control module has failed. Replace the VIMS
electronic control module.
STOP.
NO The voltage is between 1.0 and 9.0 DCV.
The voltage is correct.
Repair: The sensor has failed. Replace the sensor.
STOP.
Test Step 5. CHECK THE FREQUENCY
OF THE SENSOR SIGNAL.
A. Remove the SENSOR from the suspension
cylinder. This is done so the sensor can not
sense the pressure within the suspension
cylinder. DO NOT DISCONNECT THE HARNESS
CONNECTOR.
B. At the machine harness connector of the
sensor, identify the signal and ground circuits.
DO NOT DISCONNECT THE HARNESS
CONNECTOR OR RECONNECT THE HARNESS
CONNECTOR.
C. Insert the 7X-1710 Multimeter Probe leads into
the back of the sensor's connector along side of
the signal and ground circuit wires.
D. Measure the frequency between the signal and
the ground contacts.
Expected Result:
The frequency is between 186 Hz and 214 Hz.
Results:
YES The frequency is between 186 Hz and
214 Hz when ambient temperature is between
10 C (50 F) and 40 C (104 F). The sensor is
generating a valid frequency. If the problem of
incorrect payload measurement persists proceed
to Test Step 6.
NO The frequency is NOT between 186 Hz and
214 Hz. The sensor is generating an incorrect
frequency.
Repair: The sensor has failed. Replace the sensor.
STOP.
166 KENR9023-01
Troubleshooting Section

Test Step 6. MOVE THE SENSOR. Expected Result:

A. Substitute the suspect sensor with a sensor that
is functioning correctly. For example, substitute
a good right rear suspension cylinder pressure
sensor with the suspect left rear suspension
cylinder pressure sensor.
B. Verify that the problem followed the suspect
sensor to the other suspension cylinder. The
service technician can verify that the problem
followed the suspect sensor by riding in the
truck during the loading operation. The service
technician can observe the performance of the
four suspension cylinder pressure sensors by
using the VIMSpc View Real Time option. The
service technician can also activate a data logger.
Compare the signal outputs of the four sensors.
Verify that the suspect sensor does not respond
to the loading of the truck in the same manner as
the other sensors.
The conditions that are listed above are not present.
Results:
YES The conditions that are listed above are not
present.
Repair: Perform the Troubleshooting, Payload
System procedure that is located in this manual.
STOP.
NO The conditions that are listed above are
present.
Repair: Service the suspension cylinder
in accordance with the Special Instruction,
SEHS9411, Charging Procedure for Front and
Rear Suspension Cylinders.

Expected Result: STOP.

The problem followed the sensor to the other

i03481732
suspension cylinder.

Results:
MID 162 - CID 0841 - FMI 03
SMCS Code: 1439-038-CD; 7201-038-PXS
YES The problem followed the sensor to the
other suspension cylinder. The sensor has failed. Conditions Which Generate This Code:
Repair: Replace the sensor.

STOP.

NO The problem did not follow the sensor to the

other suspension cylinder. The suspension cylinder
is causing the failure. Proceed to Test Step 7.

Test Step 7. CHECK THE SUSPENSION

CYLINDERS.
Verify that the conditions that are listed below are
not present.

The suspension cylinders are NOT sticking when Illustration 117

g01874113

the truck is empty. Schematic of the suspension cylinder pressure sensor

The suspension cylinders are NOT bottoming out
when the truck is loaded.
The service technician can verify that the conditions
that are listed above are present by riding in the truck
during the loading operation. The service technician
can observe the operation of the four suspension
cylinder pressure sensors with the VIMSpc View
Real Time option. The service technician may
also activate a data logger in order to observe the
performance of the suspension cylinder. Compare
the signal outputs of the four sensors. Verify that the
sensor responds to the loading of the truck in the
same manner as the other sensors.
CID 0841 identifies the Right Rear Strut Pressure
sensor. The output frequency of the sensor changes
as the pressure in the suspension cylinder changes.
The sensor is powered by the machine electrical
system.
Note: In addition to the Suspension Cylinder
Pressure Sensor troubleshooting procedure, the
VIMS diagnostics are helpful in troubleshooting
sensors.
KENR9023-01
Use this procedure to troubleshoot the suspect
performance of suspension cylinder pressure sensors
or any failure that is associated with the suspension
cylinder pressure sensors.
Note: This test checks for sensor voltages at the
sensor when all the circuits are connected. Unless
you are directed otherwise, do not disconnect any
components. Troubleshoot the circuit as is before
disconnecting any circuits. Disconnecting the sensor
from the harness before measuring the voltage may
alter a poor connection. This will make the proof of
cause difficult or impossible.
Table 28
Tools Needed
9U-7330 or Equivalent Multimeter
7X-1710 Multimeter Probe
Locate the suspect sensor. Identify the sensor wires
and connector contacts. DO NOT DISCONNECT
ANY HARNESS CONNECTORS AT THIS TIME.
Turn the key start switch to the ON position. Shut off
the engine, unless it is necessary for the engine to
be running. The truck can be empty or the truck can
be loaded.
Test Step 1. CHECK THE SENSOR
SUPPLY VOLTAGE.
A. At the sensor connector, identify the +V and
Ground circuits.
B. Insert the 7X-1710 Multimeter Probe leads into
the back of the sensor's connector along side of
+V and ground circuit wires.
C. Measure the system voltage.
Expected Result:
The voltage is between 22.0 DCV and 29.5 DCV.
Results:
YES The voltage is between 22.0 DCV and 29.5
DCV. The system voltage is present. proceed to
Test Step 2.
NO The voltage is less than 22.0 DCV. The
circuit is not correct.
Repair: Trace the +V and Ground circuits in the
machine harness. Repair the machine harness
or replace the machine harness. If the machine
harness has not failed the sensor is the cause of
the failure. Replace the sensor. A failed sensor is
unlikely.
STOP.
167
Troubleshooting Section
Test Step 2. CHECK THE SENSOR
SIGNAL VOLTAGE.
A. At the sensor connector, identify the signal and
ground circuits.
B. Insert the 7X-1710 Multimeter Probe leads into
the back of the sensor's connector along side of
the signal and ground circuit wires.
C. Measure the signal voltage.
Expected Result:
The signal voltage is between approximately 1.0
DCV and 9.0 DCV.
Results:
The voltage is greater than 9.0 DCV The signal
voltage is not correct. Proceed to Test Step 3.
The voltage is less than 1.0 DCV. The signal
voltage is not correct. Proceed to Test Step 4.
The voltage is between 1.0 DCV and 9.0 DCV
The signal circuit is correct. Proceed to Test Step 5.
Test Step 3. CHECK THE SIGNAL
CIRCUIT FOR A SHORT TO +BATTERY.
A. Disconnect the sensor from the machine harness.
B. At the machine harness connector for the sensor,
measure the voltage between the signal contact
and the ground contact.
Expected Result:
The voltage is above 9.0 DCV.
Results:
YES The voltage is above 9.0 DCV.
Repair: The signal circuit is shorted to the +battery
or the VIMS ECM has failed. Trace the Signal
circuit and the Ground circuits in the harness.
Repair the harness or replace the harness. If the
harness is correct, the VIMS electronic control
module has failed. Replace the VIMS ECM.
STOP.
NO The voltage is between 1.0 and 9.0 DCV.
The voltage is correct.
Repair: The sensor has failed. Replace the sensor.
STOP.
168
Troubleshooting Section
Test Step 4. CHECK THE SIGNAL
CIRCUIT FOR A SHORT TO GROUND.
A. Disconnect the sensor from the machine harness.
B. At the machine harness connector for the sensor,
measure the voltage between the signal contact
and the ground contact.
Expected Result:
The voltage is less than 1.0 DCV.
Results:
YES The voltage is less than 1.0 DCV.
Repair: Possible causes
The incorrect VIMS onboard software is installed.
The Signal circuit is shorted to ground in the
machine harness.
The VIMS electronic control module has failed.
Verify the possible causes in the order that is listed
below:
1. Verify that the correct VIMS onboard software
is installed. Install the correct VIMS onboard
software.
2. If the software is correct, trace the signal circuit
and the ground circuit in the harness. Repair
the harness or replace the harness.
3. If the harness is correct, the VIMS electronic
control module has failed. Replace the VIMS
electronic control module.
STOP.
NO The voltage is between 1.0 and 9.0 DCV.
The voltage is correct.
Repair: The sensor has failed. Replace the sensor.
STOP.
Test Step 5. CHECK THE FREQUENCY
OF THE SENSOR SIGNAL.
A. Remove the SENSOR from the suspension
cylinder. This is done so the sensor can not
sense the pressure within the suspension
cylinder. DO NOT DISCONNECT THE HARNESS
CONNECTOR.
KENR9023-01
B. At the machine harness connector of the
sensor, identify the signal and ground circuits.
DO NOT DISCONNECT THE HARNESS
CONNECTOR OR RECONNECT THE HARNESS
CONNECTOR.
C. Insert the 7X-1710 Multimeter Probe leads into
the back of the sensor's connector along side of
the signal and ground circuit wires.
D. Measure the frequency between the signal and
the ground contacts.
Expected Result:
The frequency is between 186 Hz and 214 Hz.
Results:
YES The frequency is between 186 Hz and
214 Hz when ambient temperature is between
10 C (50 F) and 40 C (104 F). The sensor is
generating a valid frequency. If the problem of
incorrect payload measurement persists proceed
to Test Step 6.
NO The frequency is NOT between 186 Hz and
214 Hz. The sensor is generating an incorrect
frequency.
Repair: The sensor has failed. Replace the sensor.
STOP.
Test Step 6. MOVE THE SENSOR.
A. Substitute the suspect sensor with a sensor that
is functioning correctly. For example, substitute
a good right rear suspension cylinder pressure
sensor with the suspect left rear suspension
cylinder pressure sensor.
B. Verify that the problem followed the suspect
sensor to the other suspension cylinder. The
service technician can verify that the problem
followed the suspect sensor by riding in the
truck during the loading operation. The service
technician can observe the performance of the
four suspension cylinder pressure sensors by
using the VIMSpc View Real Time option. The
service technician can also activate a data logger.
Compare the signal outputs of the four sensors.
Verify that the suspect sensor does not respond
to the loading of the truck in the same manner as
the other sensors.
Expected Result:
The problem followed the sensor to the other
suspension cylinder.
KENR9023-01
Results:
YES The problem followed the sensor to the
other suspension cylinder. The sensor has failed.
Repair: Replace the sensor.
STOP.
NO The problem did not follow the sensor to the
other suspension cylinder. The suspension cylinder
is causing the failure. Proceed to Test Step 7.
Test Step 7. CHECK THE SUSPENSION
CYLINDERS.
Verify that the conditions that are listed below are
not present.
The suspension cylinders are NOT sticking when
the truck is empty.
The suspension cylinders are NOT bottoming out
when the truck is loaded.
The service technician can verify that the conditions
that are listed above are present by riding in the truck
during the loading operation. The service technician
can observe the operation of the four suspension
cylinder pressure sensors with the VIMSpc View
Real Time option. The service technician may
also activate a data logger in order to observe the
performance of the suspension cylinder. Compare
the signal outputs of the four sensors. Verify that the
sensor responds to the loading of the truck in the
same manner as the other sensors.
Expected Result:
The conditions that are listed above are not present.
Results:
YES The conditions that are listed above are not
present.
Repair: Perform the Troubleshooting, Payload
System procedure that is located in this manual.
STOP.
NO The conditions that are listed above are
present.
Repair: Service the suspension cylinder
in accordance with the Special Instruction,
SEHS9411, Charging Procedure for Front and
Rear Suspension Cylinders.
STOP.
169
Troubleshooting Section
i03481733
MID 162 - CID 0841 - FMI 04
SMCS Code: 1439-038-CD; 7201-038-PXS
Conditions Which Generate This Code:
g01874113
Illustration 118
Schematic of the suspension cylinder pressure sensor
CID 0840 identifies the Right Rear Strut Pressure
sensor. The output frequency of the sensor changes
as the pressure in the suspension cylinder changes.
The sensor is powered by the machine electrical
system.
Note: In addition to the Suspension Cylinder
Pressure Sensor troubleshooting procedure, the
VIMS diagnostics are helpful in troubleshooting
sensors.
Use this procedure to troubleshoot the suspect
performance of suspension cylinder pressure sensors
or any failure that is associated with the suspension
cylinder pressure sensors.
Note: This test checks for sensor voltages at the
sensor when all the circuits are connected. Unless
you are directed otherwise, do not disconnect any
components. Troubleshoot the circuit as is before
disconnecting any circuits. Disconnecting the sensor
from the harness before measuring the voltage may
alter a poor connection. This will make the proof of
cause difficult or impossible.
Table 29
Tools Needed
9U-7330 or Equivalent Multimeter
7X-1710 Multimeter Probe
Locate the suspect sensor. Identify the sensor wires
and connector contacts. DO NOT DISCONNECT
ANY HARNESS CONNECTORS AT THIS TIME.
Turn the key start switch to the ON position. Shut off
the engine, unless it is necessary for the engine to
be running. The truck can be empty or the truck can
be loaded.
170
Troubleshooting Section
Test Step 1. CHECK THE SENSOR
SUPPLY VOLTAGE.
A. At the sensor connector, identify the +V and
Ground circuits.
B. Insert the 7X-1710 Multimeter Probe leads into
the back of the sensor's connector along side of
+V and ground circuit wires.
C. Measure the system voltage.
Expected Result:
The voltage is between 22.0 DCV and 29.5 DCV.
Results:
YES The voltage is between 22.0 DCV and 29.5
DCV. The system voltage is present. proceed to
Test Step 2.
NO The voltage is less than 22.0 DCV. The
circuit is not correct.
Repair: Trace the +V and Ground circuits in the
machine harness. Repair the machine harness
or replace the machine harness. If the machine
harness has not failed the sensor is the cause of
the failure. Replace the sensor. A failed sensor is
unlikely.
STOP.
Test Step 2. CHECK THE SENSOR
SIGNAL VOLTAGE.
A. At the sensor connector, identify the signal and
ground circuits.
B. Insert the 7X-1710 Multimeter Probe leads into
the back of the sensor's connector along side of
the signal and ground circuit wires.
C. Measure the signal voltage.
Expected Result:
The signal voltage is between approximately 1.0
DCV and 9.0 DCV.
Results:
The voltage is greater than 9.0 DCV The signal
voltage is not correct. Proceed to Test Step 3.
The voltage is less than 1.0 DCV. The signal
voltage is not correct. Proceed to Test Step 4.
The voltage is between 1.0 DCV and 9.0 DCV
The signal circuit is correct. Proceed to Test Step 5.
KENR9023-01
Test Step 3. CHECK THE SIGNAL
CIRCUIT FOR A SHORT TO +BATTERY.
A. Disconnect the sensor from the machine harness.
B. At the machine harness connector for the sensor,
measure the voltage between the signal contact
and the ground contact.
Expected Result:
The voltage is above 9.0 DCV.
Results:
YES The voltage is above 9.0 DCV.
Repair: The signal circuit is shorted to the +battery
or the VIMS ECM has failed. Trace the Signal
circuit and the Ground circuits in the harness.
Repair the harness or replace the harness. If the
harness is correct, the VIMS electronic control
module has failed. Replace the VIMS ECM.
STOP.
NO The voltage is between 1.0 and 9.0 DCV.
The voltage is correct.
Repair: The sensor has failed. Replace the sensor.
STOP.
Test Step 4. CHECK THE SIGNAL
CIRCUIT FOR A SHORT TO GROUND.
A. Disconnect the sensor from the machine harness.
B. At the machine harness connector for the sensor,
measure the voltage between the signal contact
and the ground contact.
Expected Result:
The voltage is less than 1.0 DCV.
Results:
YES The voltage is less than 1.0 DCV.
Repair: Possible causes
The incorrect VIMS onboard software is installed.
The Signal circuit is shorted to ground in the
machine harness.
The VIMS electronic control module has failed.
Verify the possible causes in the order that is listed
below:
KENR9023-01
1. Verify that the correct VIMS onboard software
is installed. Install the correct VIMS onboard
software.
2. If the software is correct, trace the signal circuit
and the ground circuit in the harness. Repair
the harness or replace the harness.
3. If the harness is correct, the VIMS electronic
control module has failed. Replace the VIMS
electronic control module.
STOP.
NO The voltage is between 1.0 and 9.0 DCV.
The voltage is correct.
Repair: The sensor has failed. Replace the sensor.
STOP.
Test Step 5. CHECK THE FREQUENCY
OF THE SENSOR SIGNAL.
A. Remove the SENSOR from the suspension
cylinder. This is done so the sensor can not
sense the pressure within the suspension
cylinder. DO NOT DISCONNECT THE HARNESS
CONNECTOR.
B. At the machine harness connector of the
sensor, identify the signal and ground circuits.
DO NOT DISCONNECT THE HARNESS
CONNECTOR OR RECONNECT THE HARNESS
CONNECTOR.
C. Insert the 7X-1710 Multimeter Probe leads into
the back of the sensor's connector along side of
the signal and ground circuit wires.
D. Measure the frequency between the signal and
the ground contacts.
Expected Result:
The frequency is between 186 Hz and 214 Hz.
Results:
YES The frequency is between 186 Hz and
214 Hz when ambient temperature is between
10 C (50 F) and 40 C (104 F). The sensor is
generating a valid frequency. If the problem of
incorrect payload measurement persists proceed
to Test Step 6.
NO The frequency is NOT between 186 Hz and
214 Hz. The sensor is generating an incorrect
frequency.
Repair: The sensor has failed. Replace the sensor.
STOP.
171
Troubleshooting Section
Test Step 6. MOVE THE SENSOR.
A. Substitute the suspect sensor with a sensor that
is functioning correctly. For example, substitute
a good right rear suspension cylinder pressure
sensor with the suspect left rear suspension
cylinder pressure sensor.
B. Verify that the problem followed the suspect
sensor to the other suspension cylinder. The
service technician can verify that the problem
followed the suspect sensor by riding in the
truck during the loading operation. The service
technician can observe the performance of the
four suspension cylinder pressure sensors by
using the VIMSpc View Real Time option. The
service technician can also activate a data logger.
Compare the signal outputs of the four sensors.
Verify that the suspect sensor does not respond
to the loading of the truck in the same manner as
the other sensors.
Expected Result:
The problem followed the sensor to the other
suspension cylinder.
Results:
YES The problem followed the sensor to the
other suspension cylinder. The sensor has failed.
Repair: Replace the sensor.
STOP.
NO The problem did not follow the sensor to the
other suspension cylinder. The suspension cylinder
is causing the failure. Proceed to Test Step 7.
Test Step 7. CHECK THE SUSPENSION
CYLINDERS.
Verify that the conditions that are listed below are
not present.
The suspension cylinders are NOT sticking when
the truck is empty.
The suspension cylinders are NOT bottoming out
when the truck is loaded.
The service technician can verify that the conditions
that are listed above are present by riding in the truck
during the loading operation. The service technician
can observe the operation of the four suspension
cylinder pressure sensors with the VIMSpc View
Real Time option. The service technician may
also activate a data logger in order to observe the
performance of the suspension cylinder. Compare
the signal outputs of the four sensors. Verify that the
sensor responds to the loading of the truck in the
same manner as the other sensors.
172
Troubleshooting Section
Expected Result:
The conditions that are listed above are not present.
Results:
YES The conditions that are listed above are not
present.
Repair: Perform the Troubleshooting, Payload
System procedure that is located in this manual.
STOP.
NO The conditions that are listed above are
present.
Repair: Service the suspension cylinder
in accordance with the Special Instruction,
SEHS9411, Charging Procedure for Front and
Rear Suspension Cylinders.
STOP.
i03481734
MID 162 - CID 0841 - FMI 08
SMCS Code: 1439-038-CD; 7201-038-PXS
Conditions Which Generate This Code:
g01874113
Illustration 119
Schematic of the suspension cylinder pressure sensor
CID 0840 identifies the Right Rear Strut Pressure
sensor. The output frequency of the sensor changes
as the pressure in the suspension cylinder changes.
The sensor is powered by the machine electrical
system.
Note: In addition to the Suspension Cylinder
Pressure Sensor troubleshooting procedure, the
VIMS diagnostics are helpful in troubleshooting
sensors.
KENR9023-01
Use this procedure to troubleshoot the suspect
performance of suspension cylinder pressure sensors
or any failure that is associated with the suspension
cylinder pressure sensors.
Note: This test checks for sensor voltages at the
sensor when all the circuits are connected. Unless
you are directed otherwise, do not disconnect any
components. Troubleshoot the circuit as is before
disconnecting any circuits. Disconnecting the sensor
from the harness before measuring the voltage may
alter a poor connection. This will make the proof of
cause difficult or impossible.
Table 30
Tools Needed
9U-7330 or Equivalent Multimeter
7X-1710 Multimeter Probe
Locate the suspect sensor. Identify the sensor wires
and connector contacts. DO NOT DISCONNECT
ANY HARNESS CONNECTORS AT THIS TIME.
Turn the key start switch to the ON position. Shut off
the engine, unless it is necessary for the engine to
be running. The truck can be empty or the truck can
be loaded.
Test Step 1. CHECK THE SENSOR
SUPPLY VOLTAGE.
A. At the sensor connector, identify the +V and
Ground circuits.
B. Insert the 7X-1710 Multimeter Probe leads into
the back of the sensor's connector along side of
+V and ground circuit wires.
C. Measure the system voltage.
Expected Result:
The voltage is between 22.0 DCV and 29.5 DCV.
Results:
YES The voltage is between 22.0 DCV and 29.5
DCV. The system voltage is present. proceed to
Test Step 2.
NO The voltage is less than 22.0 DCV. The
circuit is not correct.
Repair: Trace the +V and Ground circuits in the
machine harness. Repair the machine harness
or replace the machine harness. If the machine
harness has not failed the sensor is the cause of
the failure. Replace the sensor. A failed sensor is
unlikely.
STOP.
KENR9023-01
Test Step 2. CHECK THE SENSOR
SIGNAL VOLTAGE.
A. At the sensor connector, identify the signal and
ground circuits.
B. Insert the 7X-1710 Multimeter Probe leads into
the back of the sensor's connector along side of
the signal and ground circuit wires.
C. Measure the signal voltage.
Expected Result:
The signal voltage is between approximately 1.0
DCV and 9.0 DCV.
Results:
The voltage is greater than 9.0 DCV The signal
voltage is not correct. Proceed to Test Step 3.
The voltage is less than 1.0 DCV. The signal
voltage is not correct. Proceed to Test Step 4.
The voltage is between 1.0 DCV and 9.0 DCV
The signal circuit is correct. Proceed to Test Step 5.
Test Step 3. CHECK THE SIGNAL
CIRCUIT FOR A SHORT TO +BATTERY.
A. Disconnect the sensor from the machine harness.
B. At the machine harness connector for the sensor,
measure the voltage between the signal contact
and the ground contact.
Expected Result:
The voltage is above 9.0 DCV.
Results:
YES The voltage is above 9.0 DCV.
Repair: The signal circuit is shorted to the +battery
or the VIMS ECM has failed. Trace the Signal
circuit and the Ground circuits in the harness.
Repair the harness or replace the harness. If the
harness is correct, the VIMS electronic control
module has failed. Replace the VIMS ECM.
STOP.
NO The voltage is between 1.0 and 9.0 DCV.
The voltage is correct.
Repair: The sensor has failed. Replace the sensor.
STOP.
173
Troubleshooting Section
Test Step 4. CHECK THE SIGNAL
CIRCUIT FOR A SHORT TO GROUND.
A. Disconnect the sensor from the machine harness.
B. At the machine harness connector for the sensor,
measure the voltage between the signal contact
and the ground contact.
Expected Result:
The voltage is less than 1.0 DCV.
Results:
YES The voltage is less than 1.0 DCV.
Repair: Possible causes
The incorrect VIMS onboard software is installed.
The Signal circuit is shorted to ground in the
machine harness.
The VIMS electronic control module has failed.
Verify the possible causes in the order that is listed
below:
1. Verify that the correct VIMS onboard software
is installed. Install the correct VIMS onboard
software.
2. If the software is correct, trace the signal circuit
and the ground circuit in the harness. Repair
the harness or replace the harness.
3. If the harness is correct, the VIMS electronic
control module has failed. Replace the VIMS
electronic control module.
STOP.
NO The voltage is between 1.0 and 9.0 DCV.
The voltage is correct.
Repair: The sensor has failed. Replace the sensor.
STOP.
Test Step 5. CHECK THE FREQUENCY
OF THE SENSOR SIGNAL.
A. Remove the SENSOR from the suspension
cylinder. This is done so the sensor can not
sense the pressure within the suspension
cylinder. DO NOT DISCONNECT THE HARNESS
CONNECTOR.
174
Troubleshooting Section
B. At the machine harness connector of the
sensor, identify the signal and ground circuits.
DO NOT DISCONNECT THE HARNESS
CONNECTOR OR RECONNECT THE HARNESS
CONNECTOR.
C. Insert the 7X-1710 Multimeter Probe leads into
the back of the sensor's connector along side of
the signal and ground circuit wires.
D. Measure the frequency between the signal and
the ground contacts.
Expected Result:
The frequency is between 186 Hz and 214 Hz.
Results:
YES The frequency is between 186 Hz and
214 Hz when ambient temperature is between
10 C (50 F) and 40 C (104 F). The sensor is
generating a valid frequency. If the problem of
incorrect payload measurement persists proceed
to Test Step 6.
NO The frequency is NOT between 186 Hz and
214 Hz. The sensor is generating an incorrect
frequency.
Repair: The sensor has failed. Replace the sensor.
STOP.
Test Step 6. MOVE THE SENSOR.
A. Substitute the suspect sensor with a sensor that
is functioning correctly. For example, substitute
a good right rear suspension cylinder pressure
sensor with the suspect left rear suspension
cylinder pressure sensor.
B. Verify that the problem followed the suspect
sensor to the other suspension cylinder. The
service technician can verify that the problem
followed the suspect sensor by riding in the
truck during the loading operation. The service
technician can observe the performance of the
four suspension cylinder pressure sensors by
using the VIMSpc View Real Time option. The
service technician can also activate a data logger.
Compare the signal outputs of the four sensors.
Verify that the suspect sensor does not respond
to the loading of the truck in the same manner as
the other sensors.
Expected Result:
The problem followed the sensor to the other
suspension cylinder.
KENR9023-01
Results:
YES The problem followed the sensor to the
other suspension cylinder. The sensor has failed.
Repair: Replace the sensor.
STOP.
NO The problem did not follow the sensor to the
other suspension cylinder. The suspension cylinder
is causing the failure. Proceed to Test Step 7.
Test Step 7. CHECK THE SUSPENSION
CYLINDERS.
Verify that the conditions that are listed below are
not present.
The suspension cylinders are NOT sticking when
the truck is empty.
The suspension cylinders are NOT bottoming out
when the truck is loaded.
The service technician can verify that the conditions
that are listed above are present by riding in the truck
during the loading operation. The service technician
can observe the operation of the four suspension
cylinder pressure sensors with the VIMSpc View
Real Time option. The service technician may
also activate a data logger in order to observe the
performance of the suspension cylinder. Compare
the signal outputs of the four sensors. Verify that the
sensor responds to the loading of the truck in the
same manner as the other sensors.
Expected Result:
The conditions that are listed above are not present.
Results:
YES The conditions that are listed above are not
present.
Repair: Perform the Troubleshooting, Payload
System procedure that is located in this manual.
STOP.
NO The conditions that are listed above are
present.
Repair: Service the suspension cylinder
in accordance with the Special Instruction,
SEHS9411, Charging Procedure for Front and
Rear Suspension Cylinders.
STOP.
KENR9023-01 175
Troubleshooting Section

i03665043 The part number of the VIMS 3G Application

ECM onboard software
MID 162 - CID 1089 - FMI 08
The part number of the VIMS 3G Application
SMCS Code: 7601-038 ECM
Conditions Which Generate This Code: Note: Consult the Business Unit that produces
the product for the correct part numbers of the
configuration software.

Expected Result:

All part numbers are correct.

Results:

OK All part numbers are correct. Proceed to

Test Step 2.

NOT OK All part numbers are NOT correct.

Repair: The installed VIMS 3G Application ECM
has the wrong part number or the incorrect
configuration software is installed. Replace the
incorrect VIMS 3G Application ECM with an
ECM that has the correct part number. Refer to
Service Manual, KENR9023, Electronic Control
Module (ECM) - Replace. Flash the correct
configuration software. Refer to Service Manual,
KENR9023, Electronic Control Module (ECM) -
Flash Program.

STOP.

Test Step 2. INSPECT THE HARNESS

CONNECTIONS.
A. Turn the disconnect switch to the OFF position.

B. Inspect all harness connections that are related to

the Cat Data Link. Make sure that the connectors
are clean and tight.

C. Check the connectors for proper mating. Ensure

that all the seals are present and in place.

D. Check the harness for signs of damage or

g01969413
abrasion.
Illustration 120
Schematic of the data link E. Check the wires at the connector. Ensure that the
wires are secured tightly into the connector. Take
System Response: care not to pull the wire out of the connector.

This diagnostic code is recorded when the VIMS 3G
Application ECM has an abnormal frequency, pulse
width, or pulse period.
Test Step 1. VERIFY THE HARDWARE
AND THE SOFTWARE PART NUMBERS.
A. Verify that the following information is correct:
F. Check the exposed wires at the connectors for
nicks or signs of abrasion.
G. Check for moisture inside the connector.
H. Check the connectors for dirty contacts or
corroded contacts.
176
Troubleshooting Section
I. Check each pin and each socket of the machine
harness connectors. Ensure that the contacts
are properly installed. The contacts should mate
correctly when the two pieces of the connector
are placed together.
Expected Result:
The machine harness connectors are tight and free
of corrosion.
Results:
OK The machine harness connectors are tight
and free of corrosion. Proceed to Test Step 3.
NOT OK The machine harness connectors are
in need of repair.
Repair: Repair the machine harness or replace the
machine harness.
STOP.
Test Step 3. CHECK FOR SHORTS TO
GROUND
A. The disconnect switch remains in the OFF
position.
B. Disconnect all ECM from the Cat Data Link.
C. At the machine harness for the VIMS 3G
Application ECM, measure the resistance
between frame ground and connector contacts
8 (wire 893-GN) and 9 (wire 892-BR) of the Cat
Data Link circuit.
Expected Result:
The resistance is greater than 5000 ohms.
Results:
OK The resistance is greater than 5000 ohms.
The harness circuit resistance is correct. Proceed
to Test Step 4.
NOT OK The resistance is less than 5000 ohms.
The machine harness has failed.
Repair: There is a short between frame ground
and the Cat Data Link circuit in the machine
harness. Repair the machine harness or replace
the machine harness.
STOP.
Test Step 4. CHECK FOR SHORT TO
+BATTERY
A. The disconnect switch remains in the OFF
position.
KENR9023-01
B. All of the related ECM remain disconnected from
the machine harness.
C. At the machine harness connector for the VIMS
3G Application ECM, perform the checks that are
listed here:
Measure the resistance between the +Battery
connector contact 52 (wire 170-RD) and
connector contact 8 (wire 893-GN).
Measure the resistance between connector
contact 52 (wire 170-RD) and connector contact
9 (wire 892-BR).
Expected Result:
The resistance is greater than 5000 ohms.
Results:
OK The harness circuit resistance is correct.
Proceed to Test Step 5.
NOT OK The resistance is less than 5000 ohms.
The machine harness has failed.
Repair: There is a short between the +battery
and the Cat Data Link circuit in the machine
harness. Repair the machine harness or replace
the machine harness.
STOP.
Test Step 5. CHECK FOR OPEN HARNESS
A. The disconnect switch remains in the OFF
position.
B. Ensure that all of the ECM are disconnected from
the machine harness.
C. Check the continuity of the Cat Data Link circuit
in the machine harness:
Measure the resistance between connector
contact 8 (wire 893-GN) of the VIMS 3G
Application ECM and connector contact 8 (wire
893-GN) of the VIMS 3G Main ECM.
Measure the resistance between connector
contact 9 (wire 892-BR) of the VIMS 3G
Application ECM and connector contact 9 (wire
892-BR) of the VIMS 3G Main ECM.
Expected Result:
The resistance measures less than 5 ohms.
KENR9023-01 177
Troubleshooting Section

Results: i03665182

OK The resistance is less than 5 ohms. The Cat MID 162 - CID 1089 - FMI 11
Data Link circuit in the machine harness is correct.
Proceed to Test Step 6. SMCS Code: 7601-038

NOT OK The resistance is greater than 5 Ohms.
The machine harness has failed.
Repair: The Cat Data Link circuit is open in the
machine harness. Repair the machine harness or
replace the machine harness.
STOP.
Test Step 6. CHECK FOR ADDITIONAL
DIAGNOSTIC CODES FOR THE OTHER
ECM.
A. Reconnect all of the ECM that use the Cat Data
Link.
B. Turn the disconnect switch and the key start
switch to the ON position.
Conditions Which Generate This Code:
This diagnostic code is recorded when the Electronic
Control Module (ECM) has not been flashed with the
correct configuration file.
System Response:
This failure results in events that are logged to the
VIMS 3G Application ECM when the ECM is not
configured correctly.
Refer to this Service Manual, KENR9023, Electronic
Control Module (ECM) - Flash Program and follow
the instructions in order to Flash the correct software
to the ECM.
Results:

C. Check the Event List for diagnostic codes that are STOP.
logged against the other ECM.

Expected Result:

Diagnostic codes are not present for the other ECM

in the event list.

Results:

OK Diagnostic codes are not present for the

other ECM in the event list.

Repair: The VIMS 3G Application ECM has failed.

It is unlikely that the ECM has failed. Exit this
procedure. Perform this procedure again. If the
failure is not found, replace the ECM. Refer to
Service Manual, KENR9023, Electronic Control
Module (ECM) - Replace.

STOP.

NOT OK Diagnostic codes are present for the

other ECM in the event list.

Repair: Follow the procedure for the other

diagnostic codes that are present.

STOP.
178 KENR9023-01
Troubleshooting Section

i03481735 Test Step 1. VERIFY THE HARDWARE

AND THE SOFTWARE PART NUMBERS.
MID 162 - CID 1273 - FMI 02
A. Verify that the following information is correct:
SMCS Code: 7610-038-CS
The part number of the VIMS 3G Application
Conditions Which Generate This Code: ECM onboard software

The part number of the flash software for the

Chassis ECM

The part number of the VIMS 3G Application

ECM

The part number of the Chassis ECM

Note: Consult the Business Unit that produces
the product for the correct part numbers of the
configuration software.

Expected Result:

All part numbers are correct.

Results:

OK All part numbers are correct. Proceed to

Test Step 2.

NOT OK All part numbers are NOT correct.

Repair: The installed VIMS 3G Application ECM
or the Chassis ECM has the wrong part number
or the incorrect configuration software is installed.
Replace the incorrect VIMS 3G Application ECM or
the Chassis ECM with an ECM that has the correct
part number. Refer to Service Manual, KENR9023,
Electronic Control Module (ECM) - Replace.
Flash the correct configuration software. Refer to
Service Manual, KENR9023, Electronic Control
Module (ECM) - Flash Program.

STOP.

Test Step 2. INSPECT THE HARNESS

CONNECTIONS.

g01969413
A. Turn the disconnect switch to the OFF position.
Illustration 121
Schematic of the data link B. Inspect all harness connections that are related to
the Cat Data Link. Make sure that the connectors
This diagnostic code is recorded when the VIMS are clean and tight.
3G Application ECM receives data that is erratic or
incorrect from the chassis ECM through the Cat data C. Check the connectors for proper mating. Ensure
link. that all the seals are present and in place.

System Response: D. Check the harness for signs of damage or

This failure results in events that are logged against
the Chassis ECM that can not be explained directly.
The VIMS 3G Application ECM cannot communicate
with the Chassis ECM or the Chassis ECM appears
to communicate intermittently.
abrasion.
E. Check the wires at the connector. Ensure that the
wires are secured tightly into the connector. Take
care not to pull the wire out of the connector.
KENR9023-01
F. Check the exposed wires at the connectors for
nicks or signs of abrasion.
G. Check for moisture inside the connector.
H. Check the connectors for dirty contacts or
corroded contacts.
I. Check each pin and each socket of the machine
harness connectors. Ensure that the contacts
are properly installed. The contacts should mate
correctly when the two pieces of the connector
are placed together.
Expected Result:
The machine harness connectors are tight and free
of corrosion.
Results:
OK The machine harness connectors are tight
and free of corrosion. Proceed to Test Step 3.
NOT OK The machine harness connectors are
in need of repair.
Repair: Repair the machine harness or replace the
machine harness.
STOP.
Test Step 3. CHECK FOR SHORTS TO
GROUND
A. The disconnect switch remains in the OFF
position.
B. Disconnect all ECM from the Cat Data Link.
C. At the machine harness for the VIMS 3G
Application ECM, measure the resistance
between frame ground and connector contacts
8 (wire 893-GN) and 9 (wire 892-BR) of the Cat
Data Link circuit.
Expected Result:
The resistance is greater than 5000 ohms.
Results:
OK The resistance is greater than 5000 ohms.
The harness circuit resistance is correct. Proceed
to Test Step 4.
NOT OK The resistance is less than 5000 ohms.
The machine harness has failed.
179
Troubleshooting Section
Repair: There is a short between frame ground
and the Cat Data Link circuit in the machine
harness. Repair the machine harness or replace
the machine harness.
STOP.
Test Step 4. CHECK FOR SHORT TO
+BATTERY
A. The disconnect switch remains in the OFF
position.
B. All of the related ECM remain disconnected from
the machine harness.
C. At the machine harness connector for the Chassis
ECM, perform the checks that are listed here:
Measure the resistance between the +Battery
connector contact J1-31 (wire 173-RD) and
connector contact J1-10 (wire 893-GN).
Measure the resistance between connector
contact J1-31 (wire 173-RD) and connector
contact J1-20 (wire 892-BR).
Expected Result:
The resistance is greater than 5000 ohms.
Results:
OK The harness circuit resistance is correct.
Proceed to Test Step 5.
NOT OK The resistance is less than 5000 ohms.
The machine harness has failed.
Repair: There is a short between the +battery
and the Cat Data Link circuit in the machine
harness. Repair the machine harness or replace
the machine harness.
STOP.
Test Step 5. CHECK FOR OPEN HARNESS
A. The disconnect switch remains in the OFF
position.
B. Ensure that all of the ECM are disconnected from
the machine harness.
C. Check the continuity of the Cat Data Link circuit
in the machine harness:
Measure the resistance between connector
contact 8 (wire 893-GN) of the VIMS 3G
Application ECM and connector contact J1-10
(wire 893-GN) of the Chassis ECM.
180 KENR9023-01
Troubleshooting Section

Measure the resistance between connector i03481736

contact 9 (wire 892-BR) of the VIMS 3G
Application ECM and connector contact J1-20 MID 162 - CID 1273 - FMI 09
(wire 892-BR) of the Chassis ECM.
SMCS Code: 7610-038-CS
Expected Result:
Conditions Which Generate This Code:
The resistance measures less than 5 ohms.

Results:

OK The resistance is less than 5 ohms. The Cat

Data Link circuit in the machine harness is correct.
Proceed to Test Step 6.

NOT OK The resistance is greater than 5 Ohms.

The machine harness has failed.

Repair: The Cat Data Link circuit is open in the

machine harness. Repair the machine harness or
replace the machine harness.

STOP.

Test Step 6. CHECK FOR ADDITIONAL

DIAGNOSTIC CODES FOR THE OTHER
ECM.
A. Reconnect all of the ECM that use the Cat Data
Link.

B. Turn the disconnect switch and the key start

switch to the ON position.

C. Check the Event List for diagnostic codes that are

logged against the other ECM.

Expected Result:

Diagnostic codes are not present for the other ECM

in the event list.

Results:

OK Diagnostic codes are not present for the

other ECM in the event list.

Repair: The Chassis ECM has failed. It is g01969413

unlikely that the Chassis ECM has failed. Exit this
procedure. Perform this procedure again. If the
failure is not found, replace the Chassis ECM.
STOP.
NOT OK Diagnostic codes are present for the
other ECM in the event list.
Repair: Perform the troubleshooting procedure for
the other diagnostic codes.
STOP.
Illustration 122
Schematic of the data link
This diagnostic code is recorded when the VIMS 3G
Application ECM receives data with an abnormal
update rate from the Chassis ECM through the Cat
data link.
System Response:
This failure results in events that are logged against
the Chassis ECM that can not be explained directly.
The VIMS 3G Application ECM cannot communicate
with the Chassis ECM or the Chassis ECM appears
to communicate intermittently.
KENR9023-01
Test Step 1. VERIFY THE HARDWARE
AND THE SOFTWARE PART NUMBERS.
A. Verify that the following information is correct:
The part number of the VIMS 3G Application
ECM onboard software
The part number of the flash software for the
Chassis ECM
The part number of the VIMS 3G Application
ECM
The part number of the Chassis ECM
Note: Consult the Business Unit that produces
the product for the correct part numbers of the
configuration software.
Expected Result:
All part numbers are correct.
Results:
OK All part numbers are correct. Proceed to
Test Step 2.
NOT OK All part numbers are NOT correct.
Repair: The installed VIMS 3G Application ECM
or the Chassis ECM has the wrong part number
or the incorrect configuration software is installed.
Replace the incorrect VIMS 3G Application ECM or
the Chassis ECM with an ECM that has the correct
part number. Refer to Service Manual, KENR9023,
Electronic Control Module (ECM) - Replace.
Flash the correct configuration software. Refer to
Service Manual, KENR9023, Electronic Control
Module (ECM) - Flash Program.
STOP.
Test Step 2. INSPECT THE HARNESS
CONNECTIONS.
A. Turn the disconnect switch to the OFF position.
B. Inspect all harness connections that are related to
the Cat Data Link. Make sure that the connectors
are clean and tight.
C. Check the connectors for proper mating. Ensure
that all the seals are present and in place.
D. Check the harness for signs of damage or
abrasion.
E. Check the wires at the connector. Ensure that the
wires are secured tightly into the connector. Take
care not to pull the wire out of the connector.
181
Troubleshooting Section
F. Check the exposed wires at the connectors for
nicks or signs of abrasion.
G. Check for moisture inside the connector.
H. Check the connectors for dirty contacts or
corroded contacts.
I. Check each pin and each socket of the machine
harness connectors. Ensure that the contacts
are properly installed. The contacts should mate
correctly when the two pieces of the connector
are placed together.
Expected Result:
The machine harness connectors are tight and free
of corrosion.
Results:
OK The machine harness connectors are tight
and free of corrosion. Proceed to Test Step 3.
NOT OK The machine harness connectors are
in need of repair.
Repair: Repair the machine harness or replace the
machine harness.
STOP.
Test Step 3. CHECK FOR SHORTS TO
GROUND
A. The disconnect switch remains in the OFF
position.
B. Disconnect all ECM from the Cat Data Link.
C. At the machine harness for the VIMS 3G
Application ECM, measure the resistance
between frame ground and connector contacts
8 (wire 893-GN) and 9 (wire 892-BR) of the Cat
Data Link circuit.
Expected Result:
The resistance is greater than 5000 ohms.
Results:
OK The resistance is greater than 5000 ohms.
The harness circuit resistance is correct. Proceed
to Test Step 4.
NOT OK The resistance is less than 5000 ohms.
The machine harness has failed.
182
Troubleshooting Section
Repair: There is a short between frame ground
and the Cat Data Link circuit in the machine
harness. Repair the machine harness or replace
the machine harness.
STOP.
Test Step 4. CHECK FOR SHORT TO
+BATTERY
A. The disconnect switch remains in the OFF
position.
B. All of the related ECM remain disconnected from
the machine harness.
C. At the machine harness connector for the Chassis
ECM, perform the checks that are listed here:
Measure the resistance between the +Battery
connector contact J1-31 (wire 173-RD) and
connector contact J1-10 (wire 893-GN).
Measure the resistance between connector
contact J1-31 (wire 173-RD) and connector
contact J1-20 (wire 892-BR).
Expected Result:
The resistance is greater than 5000 ohms.
Results:
OK The harness circuit resistance is correct.
Proceed to Test Step 5.
NOT OK The resistance is less than 5000 ohms.
The machine harness has failed.
Repair: There is a short between the +battery
and the Cat Data Link circuit in the machine
harness. Repair the machine harness or replace
the machine harness.
STOP.
Test Step 5. CHECK FOR OPEN HARNESS
A. The disconnect switch remains in the OFF
position.
B. Ensure that all of the ECM are disconnected from
the machine harness.
C. Check the continuity of the Cat Data Link circuit
in the machine harness:
Measure the resistance between connector
contact 8 (wire 893-GN) of the VIMS 3G
Application ECM and connector contact J1-10
(wire 893-GN) of the Chassis ECM.
KENR9023-01
Measure the resistance between connector
contact 9 (wire 892-BR) of the VIMS 3G
Application ECM and connector contact J1-20
(wire 892-BR) of the Chassis ECM.
Expected Result:
The resistance measures less than 5 ohms.
Results:
OK The resistance is less than 5 ohms. The Cat
Data Link circuit in the machine harness is correct.
Proceed to Test Step 6.
NOT OK The resistance is greater than 5 Ohms.
The machine harness has failed.
Repair: The Cat Data Link circuit is open in the
machine harness. Repair the machine harness or
replace the machine harness.
STOP.
Test Step 6. CHECK FOR ADDITIONAL
DIAGNOSTIC CODES FOR THE OTHER
ECM.
A. Reconnect all of the ECM that use the Cat Data
Link.
B. Turn the disconnect switch and the key start
switch to the ON position.
C. Check the Event List for diagnostic codes that are
logged against the other ECM.
Expected Result:
Diagnostic codes are not present for the other ECM
in the event list.
Results:
OK Diagnostic codes are not present for the
other ECM in the event list.
Repair: The Chassis ECM has failed. It is
unlikely that the Chassis ECM has failed. Exit this
procedure. Perform this procedure again. If the
failure is not found, replace the Chassis ECM.
STOP.
NOT OK Diagnostic codes are present for the
other ECM in the event list.
Repair: Perform the troubleshooting procedure for
the other diagnostic codes.
STOP.
KENR9023-01 183
Troubleshooting Section

i03481740 i03481742

MID 162 - CID 1273 - FMI 14 MID 162 - CID 2448 - FMI 02
SMCS Code: 7610-038-CS SMCS Code: 7490-038

Conditions Which Generate This Code: Conditions Which Generate This Code:

This diagnostic code is recorded when the software is

not matched between two Electronic Control Modules
(ECM). This may happen when the software for one
ECM has been updated, but the software for another
ECM must be updated in order to match the first
ECM.

System Response:

This failure results in events that are logged to the

VIMS 3G Application ECM that can not be explained
directly. The VIMS 3G Application ECM cannot
communicate correctly with the Chassis ECM.

Refer to Service Manual, KENR9023, Electronic

Control Module (ECM) - Flash Program and follow
the instructions in order to Flash the correct software
to both of the ECM.

Results:

STOP.

g01969413
Illustration 123
Schematic of the data link

This diagnostic code is recorded when the VIMS

3G Application ECM receives data through the Cat
data link from the Advisor module that is erratic or
incorrect.

System Response:

This failure results in events that are logged against

the Advisor module that can not be explained directly.
The VIMS 3G Application ECM cannot communicate
with the Advisor module or the Advisor module
appears to communicate intermittently.
184
Troubleshooting Section
Test Step 1. VERIFY THE HARDWARE
AND THE SOFTWARE PART NUMBERS.
A. Verify that the following information is correct:
The part number of the VIMS 3G Application
ECM onboard software
The part number of the flash software for the
Advisor module
The part number of the VIMS 3G Application
ECM
The part number of the Advisor module
Note: Consult the Business Unit that produces
the product for the correct part numbers of the
configuration software.
Expected Result:
All part numbers are correct.
Results:
OK All part numbers are correct. Proceed to
Test Step 2.
NOT OK All part numbers are NOT correct.
Repair: The installed VIMS 3G Application ECM
or the Advisor module has the wrong part number
or the incorrect configuration software is installed.
Replace the incorrect VIMS 3G Application
ECM or the Advisor module with an ECM that
has the correct part number. Refer to Service
Manual, KENR9023, Electronic Control Module
(ECM) - Replace. Flash the correct configuration
software. Refer to the Service Manual, KENR9023,
Electronic Control Module (ECM) - Flash
Program.
STOP.
Test Step 2. INSPECT THE HARNESS
CONNECTIONS.
A. Turn the disconnect switch to the OFF position.
B. Inspect all harness connections that are related to
the Cat Data Link. Make sure that the connectors
are clean and tight.
C. Check the connectors for proper mating. Ensure
that all the seals are present and in place.
D. Check the harness for signs of damage or
abrasion.
E. Check the wires at the connector. Ensure that the
wires are secured tightly into the connector. Take
care not to pull the wire out of the connector.
KENR9023-01
F. Check the exposed wires at the connectors for
nicks or signs of abrasion.
G. Check for moisture inside the connector.
H. Check the connectors for dirty contacts or
corroded contacts.
I. Check each pin and each socket of the machine
harness connectors. Ensure that the contacts
are properly installed. The contacts should mate
correctly when the two pieces of the connector
are placed together.
Expected Result:
The machine harness connectors are tight and free
of corrosion.
Results:
OK The machine harness connectors are tight
and free of corrosion. Proceed to Test Step 3.
NOT OK The machine harness connectors are
in need of repair.
Repair: Repair the machine harness or replace the
machine harness.
STOP.
Test Step 3. CHECK FOR SHORTS TO
GROUND
A. The disconnect switch remains in the OFF
position.
B. Disconnect all ECM from the Cat Data Link.
C. At the machine harness for the VIMS 3G
Application ECM, measure the resistance
between frame ground and connector contacts
8 (wire 893-GN) and 9 (wire 892-BR) of the Cat
Data Link circuit.
Expected Result:
The resistance is greater than 5000 ohms.
Results:
OK The resistance is greater than 5000 ohms.
The harness circuit resistance is correct. Proceed
to Test Step 4.
NOT OK The resistance is less than 5000 ohms.
The machine harness has failed.
KENR9023-01
Repair: There is a short between frame ground
and the Cat Data Link circuit in the machine
harness. Repair the machine harness or replace
the machine harness.
STOP.
Test Step 4. CHECK FOR SHORT TO
+BATTERY
A. The disconnect switch remains in the OFF
position.
B. All of the related ECM remain disconnected from
the machine harness.
C. At the machine harness connector for the Advisor
module, perform the checks that are listed here:
Measure the resistance between the +Battery
connector contact 1 (wire 108-RD) and
connector contact 8 (wire 893-GN).
Measure the resistance between the +Battery
connector contact 1 (wire 108-RD) and
connector contact 9 (wire 892-BR).
Expected Result:
The resistance is greater than 5000 ohms.
Results:
OK The harness circuit resistance is correct.
Proceed to Test Step 5.
NOT OK The resistance is less than 5000 ohms.
The machine harness has failed.
Repair: There is a short between the +battery
and the Cat Data Link circuit in the machine
harness. Repair the machine harness or replace
the machine harness.
STOP.
Test Step 5. CHECK FOR OPEN HARNESS
A. The disconnect switch remains in the OFF
position.
B. Ensure that all of the ECM are disconnected from
the machine harness.
C. Check the continuity of the Cat Data Link circuit
in the machine harness:
Measure the resistance between connector
contact 8 (wire 893-GN) of the VIMS 3G
Application ECM and connector contact 8 (wire
893-GN) of the Advisor module.
185
Troubleshooting Section
Measure the resistance between connector
contact 9 (wire 892-BR) of the VIMS 3G
Application ECM and connector contact 9 (wire
892-BR) of the Advisor module.
Expected Result:
The resistance measures less than 5 ohms.
Results:
OK The resistance is less than 5 ohms. The Cat
Data Link circuit in the machine harness is correct.
Proceed to Test Step 6.
NOT OK The resistance is greater than 5 Ohms.
The machine harness has failed.
Repair: The Cat Data Link circuit is open in the
machine harness. Repair the machine harness or
replace the machine harness.
STOP.
Test Step 6. CHECK FOR ADDITIONAL
DIAGNOSTIC CODES FOR THE OTHER
ECM.
A. Reconnect all of the ECM that use the Cat Data
Link.
B. Turn the disconnect switch and the key start
switch to the ON position.
C. Check the Event List for diagnostic codes that are
logged against the other ECM.
Expected Result:
Diagnostic codes are not present for the other ECM
in the event list.
Results:
OK Diagnostic codes are not present for the
other ECM in the event list.
Repair: The Advisor module has failed. It is
unlikely that the Advisor module has failed. Exit
this procedure. Perform this procedure again. If the
failure is not found, replace the Advisor module.
STOP.
NOT OK Diagnostic codes are present for the
other ECM in the event list.
Repair: Perform the troubleshooting procedure for
the other diagnostic codes.
STOP.
186 KENR9023-01
Troubleshooting Section

i03661404 Test Step 1. VERIFY THE HARDWARE

AND THE SOFTWARE PART NUMBERS.
MID 162 - CID 2448 - FMI 09
A. Verify that the following information is correct:
SMCS Code: 7490-038
The part number of the VIMS 3G Application
Conditions Which Generate This Code: ECM onboard software

The part number of the flash software for the

Advisor module

The part number of the VIMS 3G Application

ECM

The part number of the Advisor module

Note: Consult the Business Unit that produces
the product for the correct part numbers of the
configuration software.

Expected Result:

All part numbers are correct.

Results:

OK All part numbers are correct. Proceed to

Test Step 2.

NOT OK All part numbers are NOT correct.

Repair: The installed VIMS 3G Application ECM
or the Advisor module has the wrong part number
or the incorrect configuration software is installed.
Replace the incorrect VIMS 3G Application
ECM or the Advisor module with an ECM that
has the correct part number. Refer to Service
Manual, KENR9023, Electronic Control Module
(ECM) - Replace. Flash the correct configuration
software. Refer to the Service Manual, KENR9023,
Electronic Control Module (ECM) - Flash
Program.

STOP.

Test Step 2. INSPECT THE HARNESS

g01969413
Illustration 124
Schematic of the data link
This diagnostic code is recorded when the VIMS 3G
Application ECM receives data through the Cat data
link from the Advisor module at an abnormal update
rate.
System Response:
This failure results in events that are logged against
the Advisor module that can not be explained directly.
The VIMS 3G Application ECM cannot communicate
with the Advisor module or the Advisor module
appears to communicate intermittently.
CONNECTIONS.
A. Turn the disconnect switch to the OFF position.
B. Inspect all harness connections that are related to
the Cat Data Link. Make sure that the connectors
are clean and tight.
C. Check the connectors for proper mating. Ensure
that all the seals are present and in place.
D. Check the harness for signs of damage or
abrasion.
E. Check the wires at the connector. Ensure that the
wires are secured tightly into the connector. Take
care not to pull the wire out of the connector.
KENR9023-01
F. Check the exposed wires at the connectors for
nicks or signs of abrasion.
G. Check for moisture inside the connector.
H. Check the connectors for dirty contacts or
corroded contacts.
I. Check each pin and each socket of the machine
harness connectors. Ensure that the contacts
are properly installed. The contacts should mate
correctly when the two pieces of the connector
are placed together.
Expected Result:
The machine harness connectors are tight and free
of corrosion.
Results:
OK The machine harness connectors are tight
and free of corrosion. Proceed to Test Step 3.
NOT OK The machine harness connectors are
in need of repair.
Repair: Repair the machine harness or replace the
machine harness.
STOP.
Test Step 3. CHECK FOR SHORTS TO
GROUND
A. The disconnect switch remains in the OFF
position.
B. Disconnect all ECM from the Cat Data Link.
C. At the machine harness for the VIMS 3G
Application ECM, measure the resistance
between frame ground and connector contacts
8 (wire 893-GN) and 9 (wire 892-BR) of the Cat
Data Link circuit.
Expected Result:
The resistance is greater than 5000 ohms.
Results:
OK The resistance is greater than 5000 ohms.
The harness circuit resistance is correct. Proceed
to Test Step 4.
NOT OK The resistance is less than 5000 ohms.
The machine harness has failed.
187
Troubleshooting Section
Repair: There is a short between frame ground
and the Cat Data Link circuit in the machine
harness. Repair the machine harness or replace
the machine harness.
STOP.
Test Step 4. CHECK FOR SHORT TO
+BATTERY
A. The disconnect switch remains in the OFF
position.
B. All of the related ECM remain disconnected from
the machine harness.
C. At the machine harness connector for the Advisor
module, perform the checks that are listed here:
Measure the resistance between the +Battery
connector contact 1 (wire 108-RD) and
connector contact 8 (wire 893-GN).
Measure the resistance between the +Battery
connector contact 1 (wire 108-RD) and
connector contact 9 (wire 892-BR).
Expected Result:
The resistance is greater than 5000 ohms.
Results:
OK The harness circuit resistance is correct.
Proceed to Test Step 5.
NOT OK The resistance is less than 5000 ohms.
The machine harness has failed.
Repair: There is a short between the +battery
and the Cat Data Link circuit in the machine
harness. Repair the machine harness or replace
the machine harness.
STOP.
Test Step 5. CHECK FOR OPEN HARNESS
A. The disconnect switch remains in the OFF
position.
B. Ensure that all of the ECM are disconnected from
the machine harness.
C. Check the continuity of the Cat Data Link circuit
in the machine harness:
Measure the resistance between connector
contact 8 (wire 893-GN) of the VIMS 3G
Application ECM and connector contact 8 (wire
893-GN) of the Advisor module.
188 KENR9023-01
Troubleshooting Section

Measure the resistance between connector i03481744

contact 9 (wire 892-BR) of the VIMS 3G
Application ECM and connector contact 9 (wire
892-BR) of the Advisor module.
Expected Result:
The resistance measures less than 5 ohms.
Results:
OK The resistance is less than 5 ohms. The Cat
Data Link circuit in the machine harness is correct.
Proceed to Test Step 6.
MID 162 - CID 2448 - FMI 14
SMCS Code: 7610-038
Conditions Which Generate This Code:
This diagnostic code is recorded when the software is
not matched between two Electronic Control Modules
(ECM). This may happen when the software for one
ECM has been updated, but the software for another
ECM must be updated in order to match the first
ECM.

NOT OK The resistance is greater than 5 Ohms. System Response:

The machine harness has failed.
Repair: The Cat Data Link circuit is open in the
machine harness. Repair the machine harness or
replace the machine harness.
This failure results in events that are logged to the
VIMS 3G Application ECM that can not be explained
directly. The VIMS 3G Application ECM cannot
communicate correctly with the Advisor display.

STOP. Refer to Service Manual, KENR9023, Electronic

Control Module (ECM) - Flash Program and follow
Test Step 6. CHECK FOR ADDITIONAL the instructions in order to Flash the correct software
DIAGNOSTIC CODES FOR THE OTHER to both of the ECM.
ECM.
Results:
A. Reconnect all of the ECM that use the Cat Data
Link. STOP.

B. Turn the disconnect switch and the key start

switch to the ON position.

C. Check the Event List for diagnostic codes that are

logged against the other ECM.

Expected Result:

Diagnostic codes are not present for the other ECM

in the event list.

Results:

OK Diagnostic codes are not present for the

other ECM in the event list.

Repair: The Advisor module has failed. It is

unlikely that the Advisor module has failed. Exit
this procedure. Perform this procedure again. If the
failure is not found, replace the Advisor module.

STOP.

NOT OK Diagnostic codes are present for the

other ECM in the event list.

Repair: Perform the troubleshooting procedure for

the other diagnostic codes.

STOP.
KENR9023-01 189
Troubleshooting Section

Diagnostic System Repair: Replace the blown fuse or reset the circuit
breaker. Observe the machine for a recurrence of
Procedures the problem. If the problem persists, the reason for
the blown fuse must be isolated and corrected.
i03551163 STOP.
Power Supply Circuit of Test Step 3. CHECK THE POWER WIRE
Electronic Control Module TO THE ECM.
SMCS Code: 7601; 7610 A. Turn the key start switch and the disconnect
switch to the OFF position.
System Operation Description:
B. Measure the resistance between wire 170-RD at
Power to the ECM can fail due to an open circuit in the fuse for the VIMs and contact 52 at the VIMS
the wire, or a blown fuse. A fuse can be blown as Main ECM connector.
the result of an overloaded circuit. For example, the
+battery connection is shorted to ground. Expected Result:

Test Step 1. CHECK THE ECM FOR The resistance is less than 5.0 ohms.
POWER AND GROUND.
Results:
Measure the voltage from contact 52 to contact 65 on
the VIMS 3G Main ECM . OK The resistance is less than 5 ohms. The
wiring circuit is correct. Proceed to Test Step 4.
Expected Result:
NOT OK The resistance measurement to one or
The measured voltage is the same as the system more of the contacts is greater than 5.0 ohms. The
voltage. wiring has an open circuit.

Results: Repair: Repair the wiring harness or replace the

wiring harness.
OK The measured voltage is the same as the
system voltage. The power supply circuit is correct. STOP.
STOP.
Test Step 4. CHECK THE ECM GROUND
NOT OK The measured voltage is not the same CONNECTIONS.
as the system voltage. Proceed to Test Step 2.
A. The key start switch and the disconnect switch
Test Step 2. CHECK THE FUSE remain in the OFF position.

Check the fuse for the power supply circuit for the B. Measure the resistance between contact 65 at the
ECM. VIMS Main ECM connector and frame ground.

A. (NEED FUSE NUMBER FOR VIMS) Check the Expected Result:

fuse for the ECM. The wire to the fuse for the
electronic control is 170-RD. The resistance is less than 5.0 ohms.

Expected Result: Results:

The fuse is correct. OK The resistance is less than 5 ohms. The

ground circuit is correct. The ECM may have failed.
Results: This is unlikely. Perform this entire procedure
again. If the problem remains, the ECM may need
YES The fuse is correct. Proceed to Test Step 3. to be replaced. Contact your dealership for possible
consultation with Caterpillar. This consultation may
NO The fuse is not correct. greatly reduce repair time. STOP.

NOT OK The resistance is greater than 5.0

ohms. The ground circuit has failed.
190 KENR9023-01
Troubleshooting Section

Repair: The ground circuit has failed. Repair the

wiring harness or replace the wiring harness.

STOP.
KENR9023-01 191
Testing and Adjusting Section

Testing and Adjusting

Section

Testing and Adjusting

i03550864

Payload System - Calibrate

SMCS Code: 7494-524

The Truck Payload Measurement System (TPMS)

must also be calibrated after the replacement of the
VIMS Application ECM, the suspension cylinders, the
suspension cylinder pressure sensors, etc.

The following information describes the service

operation of the calibration for the truck payload. The
service operation uses the following procedure in
order to calibrate the VIMS TPMS:

Note: The VIMS TPMS will not operate until a

successful payload calibration has been completed.

Note: For security, this service program code will

only function while Cat ET is connected or the service
mode in the Advisor is enabled.

Procedure

1. Ensure that the truck body is empty. Carryback

weight will affect the payload measurement.

2. The payload system can be calibrated with the

Advisor or with Cat ET. Follow Step 2.a in order to
calibrate with the Advisor. Follow Step 2.b in order
to calibrate with Cat ET.

a. Highlight the Payload Calibration function

that is located in the Servicemenu under
Calibrations. Press the OK button.

b. From the Cat ET menu, select Service then

select Calibrations. Select Truck Payload
and follow the instructions shown in Cat ET.

3. Operate the empty truck to a minimum ground

speed of four MPH on hard level ground.

4. Move the transmission gear selector to the neutral

position and allow the truck to coast to a stop. Do
not use the service brakes or the retarder.
192
Testing and Adjusting Section
i03550868
Payload System - Configure
SMCS Code: 7494-025
Illustration 125
Structure of the Settings menu
The following information describes the settings for
the Settings: Payload Config menu on the truck.
The Settings: Payload Config menu is located in the
Settings menu under VIMS. Refer to this Service
Manual , KENR9023, Settings Menu in order to
view the structure of the Settings menu.
Note: In order to configure the settings for the
payload, the Advisor must have the Service Mode
enabled. Refer to Service Manual , KENR9023,
Service Mode Menu for instructions in order to
enable the Service Mode.
g01962469
Illustration 126
Settings: Payload Config menu
Payload Target Weight
1. Navigate to the Payload menu From the
Settings menu. Press the OK key in order to
continue.
2. Press the down button in order to select the
Payload Target Weight.
KENR9023-01
g01962688
3. Press the OK button in order to change the value
for the Payload Target Weight.
4. Enter the desired value for the Payload Target
Weight field by pressing the up arrow or the down
arrow in order to change the value.
5. Press the OK button in order to accept the value
that is displayed and to return to the parameter
configuration selection.
Payload Overload Limit
1. Navigate to the Payload menu From the
Settings menu. Press the OK key in order to
continue.
2. Press the down button in order to select the
Payload Overload Limit.
3. Press the OK button in order to change the value
for the Payload Overload Limit.
4. Enter the desired value for the Payload Overload
Limit field by pressing the up arrow or the down
arrow in order to change the value.
Note: Refer to Service Manual, KENR9023,
Maximum Payload Speed Manager for information
on selecting a setting for the overload limit.
5. Press the OK button in order to accept the value
that is displayed and to return to the parameter
configuration selection.
KENR9023-01
Payload Last Pass Status
1. Navigate to the Payload menu From the
Settings menu. Press the OK key in order to
continue.
2. Press the down button in order to select the
Payload Last Pass Status.
3. Press the OK button in order to change the value
for the Payload Last Pass Status.
4. Enter the desired value for the Payload Last Pass
Status field by pressing the up arrow or the down
arrow in order to change the value.
5. Press the OK button in order to accept the value
that is displayed and to return to the parameter
configuration selection.
i03668741
Electrical Connector - Inspect
SMCS Code: 7553-040-WW
Reference: Special Instruction, SEHS9615,
Servicing DT Connectors.
Reference: Special Instruction, REHS0148, Listing
Of Deutsch Connector Components
Reference: Special Instruction, SEHS9065, Use Of
CE Connector Tools.
Reference: Service Magazine, SEPD0342, 27
January 97, Field Repair Of Single Wire Breaks In
Harnesses (Sealed Splice).
Reference: Service Magazine, SEPD0371, 28 July
97, Protection Of Unsealed Electrical Terminations
For Machines In Corrosive Applications.
Reference: Service Magazine, SEPD0473, 24 May
99, New DT Connector Plugs With Improved Seal
Retention.
Reference: Service Magazine, SEPD0545, 09
October 00, Dielectric Grease Should Not Be Used
In Electrical Connectors.
Reference: Pocket Guide, SEBD0402, Guidelines
For Routing And Installing Wire Harness Assemblies.
This information will assist in detecting problems with
connectors and with wiring. If a problem is found,
correct the condition and verify that the problem is
resolved.
193
Testing and Adjusting Section
Disconnecting and reconnecting connectors
sometimes resolve intermittent electrical problems.
It is very important to check for diagnostic codes
immediately before disconnecting a connector.
Also check for diagnostic codes after reconnecting
the connector. If the status of a diagnostic code is
changed due to disconnecting and reconnecting a
connector, there are several possible reasons. The
likely reasons are loose terminals, improperly crimped
terminals, moisture, corrosion, and inadequate
mating of a connection.
Important Safety Information
Work safely. Most accidents that involve product
operation, maintenance, and repair are caused by
failure to observe basic safety rules or precautions.
An accident can often be avoided by recognizing
potentially hazardous situations before an accident
occurs.
A person must be alert to potential hazards. This
person should also have the necessary training,
skills, and tools in order to perform these functions
properly.
Safety precautions and warnings are provided in
this instruction and on the product. If these hazard
warnings are not heeded, bodily injury or death could
occur to you or to other persons. Caterpillar cannot
anticipate every possible circumstance that might
involve a potential hazard.
Therefore, the warnings in this publication and the
warnings that are on the product are not all inclusive.
If a tool, a procedure, a work method or operating
technique that is not specifically recommended by
Caterpillar is used, you must ensure that it is safe for
you and for other people to use.
You should ensure that the product will not be
damaged or the product will be made unsafe by the
operation, lubrication, maintenance or the repair
procedures that are used.
Guidelines
Always use a 1U-5804 Crimp Tool (12-GA TO
18-GA) to service Deutsch HD and DT connectors.
Never solder the terminals onto the wires. Refer
to Tool Operating Manual, SEHS9615, Servicing
Deutsch HD and DT Style Connectors.
Always use a 147-6456 Wedge Removal Tool
in order to remove wedges from DT connectors.
Never use a screwdriver to pry a wedge from a
connector.
Always use a breakout harness for a voltmeter
probe or a test light. Never break the insulation
of a wire in order to access to a circuit for
measurements.
194 KENR9023-01
Testing and Adjusting Section

If a wire is cut, always install a new terminal for
the repair.
Tests
Check Connectors for Moisture and
Corrosion
Inspect all wiring harnesses. Ensure that the routing
of the wiring harness allows the wires to enter the
face of each connector at a perpendicular angle.
Otherwise, the wire will deform the seal bore. This
will create a path for the entrance of moisture. Verify
that the seals for the wires are sealing correctly.
The plug end of the DT connector has a seal at
the mating end of the connector. This seal has
been improved on black connectors in order to help
prevent slipping. Additionally, this seal is replaceable.
This improvement will help keep moisture and dirt
from entering the connector.
The current seal design (2) is not interchangeable
with the former design (1). The receptacle has also
changed to the new colors.
1. Inspect all wiring harnesses. Ensure that the
routing of the wiring harness allows the wires to
enter the face of each connector at a perpendicular
angle. Otherwise, the wire will deform the seal
bore. This will create a path for the entrance of
moisture. Verify that the seals for the wires are
sealing correctly.

2. Disconnect the suspect connector and inspect the

connector seal. Ensure that the seals are in good
condition. If necessary, replace the connector.

3. Thoroughly inspect the connectors for evidence

of moisture entry.

It is normal to see some minor seal abrasion on

connector seals. Minor seal abrasion will not allow
the entry of moisture. If moisture or corrosion
is evident in the connector, the source of the
moisture entry must be found and the source of
the moisture entry must be repaired. If the source
of the moisture entry is not repaired, the problem
will recur. Simply drying the connector will not fix
the problem. Check the following items for the
possible moisture entry path:
g01960167
Illustration 127
Missing seals
(1) Former Seal Design
(2) Current Seal Design
Improperly installed seals
Nicks in exposed insulation
Improperly mated connectors
Moisture can also travel to a connector through the
inside of a wire. If moisture is found in a connector,
thoroughly check the connector's harness for
damage. Also check other connectors that share the
harness for moisture.

Expected Result

The harness wiring, connectors, and seals are in

Illustration 128
g01960176 good condition. There is no evidence of moisture in
the connectors.
(3) Seal for a three-pin connector (typical example)

Results

OK The harness wiring, connectors, and seals are

in good condition. Proceed to Check the Wires for
Damage to the Insulation.
KENR9023-01
Not OK A problem has been found with the
harness or the connectors.
Repair
Repair the connectors or the wiring, as required.
Ensure that all of the seals are properly in place.
Ensure that the connectors have been reattached.
If corrosion is evident on the pins, sockets or the
connector, use only denatured alcohol to remove
the corrosion. Use a cotton swab or a soft brush to
remove the corrosion. If moisture was found in the
connectors, run the engine for several minutes and
check again for moisture. If moisture reappears, the
moisture is wicking into the connector. Even if the
moisture entry path is repaired, it may be necessary
to replace the wires. Verify that the repair eliminates
the problem.
STOP
Check the Wires for Damage to the
Insulation
1. Carefully inspect each wire for signs of abrasion,
of nicks, and of cuts. Inspect the wires for the
following conditions:
Exposed insulation
Rubbing of a wire against the chassis
Rubbing of a wire against a sharp point
2. Check all of the wiring harness fasteners in order
to verify that the harness is properly secured. Also
check all of the fasteners in order to verify that the
harness is not compressed. Pull back the harness
sleeves in order to check for a flattened portion of
wire. A fastener that has been overtightened will
flatten the harness. This damages the wires that
are inside the harness.
Expected Result
The wires are free of abrasion, of nicks, and of cuts
and the harness is properly clamped.
Results
OK The harness is OK. Proceed to Inspect the
Connector Terminals.
Not OK There is damage to the harness.
Repair
Repair the wires or replace the wires, as required.
Verify that the repair eliminates the problem.
STOP
195
Testing and Adjusting Section
Inspect the Connector Terminals
A. Visually inspect each terminal in the connector.
Verify that the terminals are not damaged. Verify that
the terminals are properly aligned in the connector
and verify that the terminals are properly located in
the connector.
Expected Result
The terminals are properly aligned and the terminals
appear undamaged.
Results
OK The terminals are OK. Proceed to Perform a
Pull Test on Each Wire Terminal Connection.
Not OK The terminals of the connector are
damaged.
Repair
Repair the terminals and/or replace the terminals, as
required. Verify that the repair eliminates the problem.
STOP
Perform a Pull Test on Each Wire
Terminal Connection
g01625756
Illustration 129
1. Ensure that the locking wedge for the connector
is installed properly. Terminals cannot be retained
inside the connector if the locking wedge is not
installed properly. Refer to Illustration 128.
2. Perform the 45 N (10 lb) pull test on each wire.
Each terminal and each connector should easily
withstand 45 N (10 lb) of tension and each wire
should remain in the connector body. This test
checks whether the wire was properly crimped
in the terminal and whether the terminal was
properly inserted into the connector.
196
Testing and Adjusting Section
Expected Result
Each terminal and each connector easily withstands
45 N (10 lb) of pull and each wire remains in the
connector body.
Results
OK All terminals pass the pull test. Proceed to
Check Individual Pin Retention into the Socket.
Not OK A wire has been pulled from a terminal or
a terminal has been pulled from the connector.
Repair
Use the 1U-5804 Crimp Tool (12-GA TO 18-GA) to
replace the terminal. Replace damaged connectors,
as required. Verify that the repair eliminates the
problem.
STOP
Check Individual Pin Retention into the
Socket
A. Verify that the sockets provide good retention for
the pins. Disconnect the harness and insert a new
pin into each socket of the mating plug one at a time
in order to check for a good grip on the pin by the
socket.
Expected Result
The sockets provide good retention for the new pin.
Results
OK The terminals are OK. Proceed to Check the
Locking Mechanism of the Connectors.
Not OK Terminals are damaged.
Repair
Use the 1U-5804 Crimp Tool (12-GA TO 18-GA) to
replace the damaged terminals. Verify that the repair
eliminates the problem.
STOP
Check the Locking Mechanism of the
Connectors
1. Ensure that the connectors lock properly. After
locking the connectors, ensure that the two halves
cannot be pulled apart.
2. Verify that the latch tab of the connector is
properly latched. Also verify that the latch tab of
the connector returns to the locked position.
KENR9023-01
Expected Result
The connector will securely lock. The connector and
the locking mechanism are without cracks or breaks.
Results
OK The connectors are in good repair. Proceed to
Perform the Wiggle Test on the Caterpillar Electronic
Technician (ET).
Not OK The connector's locking mechanism is
damaged or missing.
Repair
Repair the connector or replace the connector, as
required. Verify that the repair eliminates the problem.
STOP
Perform the Wiggle Test on the Caterpillar
Electronic Technician (ET)
1. Select the Wiggle Test from the diagnostic tests
on Cat ET.
2. Choose the appropriate group of parameters to
monitor.
3. Press the Start button. Wiggle the wiring harness
in order to reproduce intermittent problems.
If an intermittent problem exists, the status will be
highlighted and an audible beep will be heard.
Expected Result
No intermittent problems were indicated during the
Wiggle Test.
Results
OK No intermittent problems were found. The
harness and connectors appear to be OK. If another
procedure recommended this test, return to that
procedure and continue testing. If the problem has
been resolved, return the machine to service.
STOP
Not OK At least one intermittent problem was
indicated.
Repair
Repair the harness or the connector. Verify that the
repair eliminates the problem.
STOP
KENR9023-01
i03422904
Wiring Harness (Open Circuit)
- Test
SMCS Code: 1408-081
An open circuit is the failure of an electrical circuit that
results in no flow of electrical current. An open circuit
is usually caused by failed electrical wires or a poor
connection of electrical connectors. If an electrical
wire or a connection is broken, the flow of electrical
current through the circuit is interrupted. A normal
circuit will have less than 5 ohms of resistance. The
following procedure explains the test for an open
circuit:
Reference: For a complete electrical schematic,
refer to the Electrical System Schematic for the
machine that is being serviced.
TEST FOR AN OPEN CIRCUIT.
1. Identify the connectors and the wire numbers of
the suspect circuits. Use the Electrical System
Schematic of the machine in order to identify the
circuits.
2. Turn the key start switch and the disconnect
switch to the OFF position.
3. Disconnect the component and the Electronic
Control Module (ECM) from the wiring harness.
4. At one of the disconnected harness connections,
place a jumper wire from the contact of the
suspect wire to frame ground.
5. At the other connector of the machine harness,
use the multimeter probes to measure the
resistance from the contact of the suspect wire to
frame ground.
Expected Result: The resistance is less than 5
ohms.
OK The resistance is less than 5 ohms. The
harness circuit is correct.
Stop.
NOT OK The resistance is greater than 5000
ohms. There is an open in the machine harness.
Repair: Repair the machine harness or replace
the machine harness.
Stop.
197
Testing and Adjusting Section
i03553922
Wiring Harness (Short Circuit)
- Test
SMCS Code: 1408-081
A short circuit is a failure of an electrical circuit that
results in undesired electrical current. Usually, a
short circuit is a bypass of the circuit across a load.
For example, a short across the wires in a circuit for
a lamp produces too much current in the wires but
no current is felt at the lamp. The lamp is shorted
out. The resistance in a normal circuit is greater than
5000 ohms. The following procedure explains the
test for a short circuit:
Reference: For a complete electrical schematic,
refer to the Electrical System Schematic for the
machine that is being serviced.
TEST FOR A SHORT CIRCUIT.
1. Identify the connectors and the wire numbers of
the suspect circuits. Use the Electrical System
Schematic of the machine to identify the circuits.
2. Turn the key start switch and the disconnect
switch to the OFF position.
3. Disconnect the component and the ECM from the
wiring harness.
4. At the machine harness connector for the ECM,
place one of the multimeter probes on the contact
of the suspect wire.
5. Use the other multimeter probe to check the
resistance across all other contacts in the
connector(s) of the ECM and frame ground.
Expected Result: The resistance is greater than
5000 ohms for all the measurements.
OK The resistance is greater than 5000 ohms
for all the measurements. The harness circuits are
correct.
Stop.
NOT OK The resistance is less than 5 ohms.
There is a short in the machine harness. The short
is between the suspected wire and the wire with
the lowest resistance measurement.
Repair: Repair the machine harness or replace
the machine harness.
Stop.
198 KENR9023-01
Testing and Adjusting Section

i03422642 2. Turn the disconnect switch and the key start

switch to the OFF position.
Electronic Control Module
(ECM) - Flash Program 3. Disconnect the machine harness connectors from
the ECM.
SMCS Code: 7601-591-EK2
4. Verify that the part number of the replacement
Table 31 ECM is correct.
Required Tools
5. Install the replacement ECM.
WinFlash Software
6. Connect the machine harness to the ECM.
Perform the following procedures to flash program
7. Turn the disconnect switch and the key start
an Electronic Control Module (ECM). The ECM is
switches to the ON position.
flashed in order to upgrade software. The ECM is
flashed in order to load software into an ECM. Flash
8. Verify that the ECM is correctly configured for
programming of an ECM must also be done if the
the application. If necessary, use Cat ET to flash
ECM has been replaced. The Caterpillar Electronic
the ECM with the correct software. Refer to the
Technician (Cat ET) contains the program WinFlash.
Testing and Adjusting, Electronic Control Module
WinFlash is used to load software into the ECM. The
(ECM) - Flash Program section of this manual.
following procedure is used in order to flash software
into an ECM.
9. Clear any diagnostic codes that were caused by
the previous procedures.
1. Connect the 7x-1425 Data Link Cable between
the 7x-1700 Communication Adapter and Cat ET.
10. Verify that the ECM operates correctly.
2. Connect the 139-4166 Data Link Cable between
the 7x-1700 Communication Adapter and the i03423042
diagnostic connector of the machine.
Electronic Control Module
3. Use WinFlash to load the new software.
(ECM) - Configure
Note: Winflash will indicate that the ECM is BLANK
SMCS Code: 7601-587; 7610-587
if the ECM is blank or if the flash was unsuccessful.

Machine Configuration
i03422604

Electronic Control Module Table 32

Required Tools
(ECM) - Replace
Part Number Description Quantity
SMCS Code: 7601-510; 7610-510 JEBD3003 Caterpillar Electronic 1
Technician (Cat ET)
Prior to the replacement of the Electronic Control
Module (ECM), ensure that replacement is necessary. 171-4401 Communications 1
Adapter II
The ECM is seldom the cause of a failure. Always
check that power is available to all of the contacts of 207-6845 Adapter Cable As 1
the ECM that are marked with + Battery.
160-0141 Adapter Cable As 1
Note: Corrupted configuration software or the wrong
software may cause an ECM to incorrectly report The Cat ET service tool is used to access the
diagnostic codes. Prior to replacing the ECM, flash configuration screen . A message on the Cat ET
the ECM with the correct configuration software screen will give instructions that guide the user
in order to verify that the failure is not related to through the procedure. Refer to the Manual that
corrupted software. Refer to Testing and Adjusting, is provided with the Cat ET software for more
Electronic Control Module (ECM) - Flash Program. information about Cat ET.

Procedure

1. Connect the Caterpillar Electronic Technician (Cat

ET). Note all of the configurations for the ECM.
KENR9023-01 199
Testing and Adjusting Section

i03552682

Off-Board Service Tool

SMCS Code: 0785

g01783157
Illustration 130
VIMS 3G and Data Link connectors

The Electronic Control Module (ECM) must be

configured when the ECM has been replaced. The
configuration screen is only for machines with an
ECM. The ECM needs to be configured before a
calibration can be started.

A check of the configuration screen could resolve

a problem with the machine. A problem with a
component could be identified as one of the following Illustration 131
g01965055
items: A schematic of the VIMS 3G service cable 305-5528 Cable As.

The component is not installed.

The component is installed but a change to the
installation is needed in order to correct a problem.

Follow these instructions to get to the configuration

screen:

1. Connect the communications adapter and the

computer to the diagnostic service tool connector.

2. Start Cat ET.

3. Select File. Go to Select ECM. Choose the

VIMS ECM. g01962314
Illustration 132
VIMS 3G service cable 305-5528 Cable As.
4. Go to the Service Menu. Select Configuration.
Click OK. Certain operations or characteristics
can be changed for attachments or preferences.

i03506046

Battery - Replace
SMCS Code: 1401-510-UB

VIMS 3G Electronic Control Modules (ECM) do not

contain replaceable backup batteries.

g01962324
Illustration 133
Ground level service port
200 KENR9023-01
Testing and Adjusting Section

VIMS 3G has extensive off-board capabilities. The Microsoft Windows 95

information that is stored in the onboard memory
can be downloaded. The service tool is used by RS-232 port with 16550AF UART
the service technician to download the onboard
information. The service technician can choose from An additional RS-232 port
two locations to connect the service tool to a machine.
A service port is available in the machine cab and at The software that is required for the service tool is
ground level on the bumper. If the ground level port listed here:
is used it is necessary for the service technician to
turn the master disconnect switch to the ON position. Software
The master disconnect switch is located next to the
ground level port. The onboard information may be Caterpillar Vital Information Management System ,
downloaded in order to help the service technician to FERV0066
identify a problem that needs to be repaired.

The information can be used to create reports as

Related Material and Support
graphs and in the tabular form. The reports supply A Product Support Hotline is available in order to
information on a variety of topics. The following topics
assist dealers with questions about VIMS. The
are included: repair management, repair intervals,
Product Support Hotline is open Monday through
modification to the application of the site, operator Friday. The hours of operation are from 8:00 AM
training, evaluation of the site, and evaluating
to 4:30 PM Central Standard Time (CST). Call
productivity.
1-800-290-1808 within the US and parts of Canada
and 309-675-6229 for all other locations.
The Caterpillar Vital Information Management
System (VIMSpc), FERV0066 interfaces with the
onboard system. VIMSpc User Manual , FEBJ0047 (Only available
on the VIMSpc CD-ROM)
The Caterpillar Vital Information Management
System (VIMSpc), FERV0066 allows the user to VIMSpc CD-ROM, FERV0066
perform the functions that are listed below:
Technical Information Manual (TIM) , SEGV2597,
VIMS Introduction
Allow the user to set up machines in the database.
Technical Information Manual (TIM) , SEGV2610,
Allow the user to view data and download data by VIMS Off Highway Trucks
communicating with the onboard system.
VIMS CD, SERV7041, VIMS Interactive Training
Allow the user to view reports. The user may create CD 2007
reports in the form of graphs or in a tabular form
from downloaded data and historical data.
i03423007
Allow the user to view reports. The user may create
reports in the form of graphs or in a tabular form Connector Contact Description
from downloaded data and historical data.
SMCS Code: 7553-WW
Allow the user to incorporate downloaded data into
historical data. Table 33 shows the pin numbers of the connector for
the Instrument Cluster display. The signal on each
The minimum computer requirements that are pin is also shown.
required to successfully run the VIMS PC software
are listed here:

Laptop Computer

IBM-COMPATIBLE 166 MHz processor or better

1 Gbyte hard drive.
CD-ROM
3.5 inch 1.44 Mbyte disk drive.
Mouse
KENR9023-01 201
Testing and Adjusting Section

Table 33
Pins of the Instrument Cluster
793F and 797F
Pin Number Description of Signal
1 B+
2 B-
3 Chassis Ground
4 STB L13
5 Not Used
6 Not Used
7 Not Used
8 Not Used
9 Not Used
10 STB - LH Turn Signal
11 STB - RH Turn Signal
g00901469
Illustration 134
12 STB - Input #1
Rear view of Instrument Cluster
13 Not Used
(1) Instrument Cluster connector 14 Not Used
15 STB - High Beam
16 STB - Park/Dimming
17 STB - Input #3
18 Not Used
19 CAN+
20 CAN-
21 CAN Shield
22 Input #2
23 Horn Driver
24 Key Switch Input

Table 34 shows the pin numbers of the connector for

the Advisor display. The signal on each pin is also
shown.

Table 34
Pins of the Advisor Display
793F and 797F
Pin Number Description of Signal
1 B+
2 Ground
3 Key Switch
4 Dimming
5 Not Used
6 Not Used
7 Not Used
(continued)
202 KENR9023-01
Testing and Adjusting Section

(Table 34, contd) (Table 34, contd)

Pins of the Advisor Display Pins of the Advisor Display
793F and 797F 793F and 797F
Pin Number Description of Signal Pin Number Description of Signal
8 Cat Data Link + 46 Not Used
9 Cat Data Link - 47 Not Used
10 Not Used 48 Not Used
11 Not Used 49 Not Used
12 Not Used 50 CAN E+
13 Not Used 51 Not Used
14 Not Used 52 Not Used
15 Not Used 53 Not Used
16 Not Used 54 Not Used
17 Not Used 55 Not Used
18 Not Used 56 Not Used
19 Not Used 57 Not Used
20 Not Used 58 Not Used
21 Not Used 59 Not Used
22 Not Used 60 Not Used
23 Not Used 61 Not Used
24 Not Used 62 Not Used
25 Not Used 63 Not Used
26 Not Used 64 Not Used
27 Not Used 65 Not Used
28 Not Used 66 Not Used
29 Not Used 67 Not Used
30 Not Used 68 Not Used
31 Not Used 69 Not Used
32 Not Used 70 Not Used
33 Not Used
34 CAN E- i03558422

35 CAN B+ Glossary of Terms

36 CAN B
SMCS Code: 7601
37 Not Used
38 Not Used Battery Backed Up RAM This is the Random
Access Memory (RAM) that is contained in an
39 Not Used electronic control that is protected by an internal
40 Not Used battery. The data that is held in the Random
Access Memory will be lost if the external power is
41 Not Used disconnected without the internal battery.
42 Not Used
43 Not Used
44 Not Used
45 Not Used
(continued)
KENR9023-01
Broadcast This is a process that transfers data
from a mobile unit (machine or vehicle) to a stationary
location. This is usually wireless transfer. Refer to the
Radio Telemetry System. This term also describes
the data link communication between electronic
controls. One control automatically sends a message
to other controls on the data link.
Cat Data Link (CDL) The Cat Data Link is
an electrical connection for communication with
onboard devices that use the data link (ECM, CMS,
VIMS, electronic power train, electronic dashboards
and service tools such as Caterpillar Electronic
Technician). The Cat Data Link is also the medium
that is used for programming with Caterpillar service
tools and for troubleshooting with Caterpillar service
tools.
Category 1 Warning This is a red alert indicator
that flashes in order to warn the operator that a
Category 1 Warning condition exists. The indicator
also indicates the failed machine system. A Category
1 condition needs attention by the end of the shift.
Category 2 Warning This is a red alert indicator
that flashes in order to warn the operator that a
Category 2 condition exists. The indicator also
indicates the failed machine system. The action lamp
also flashes in order to indicate Category 2 warning.
The presence of this category usually indicates
that the operator must alter the operation of the
machine or that the service technician must perform
maintenance. This warning most often relates to a
system temperature that is too high.
Category 2S Warning This is a special version
of the standard Category 2 warning that includes
a CONTINUOUS action alarm. The action alarm
is used in order to get the operator's attention in
situations that may be normally overlooked.
Category 3 Warning This is a red alert indicator
that flashes in order to warn the operator that a
Category 3 condition exists. The indicator also
indicates the failed machine system. The action lamp
also flashes in order to indicate a Category 3 warning.
The action alarm sounds on and off. This warns the
operator to safely shut down the machine. There is
an exception to this warning. When the parking brake
is turned ONand the transmission is in gear.
Caterpillar Electronic Technician (ET) This is
a Windows based program, that is used to service
Caterpillar products. The software operates on a
service tool (personal computer).
CDL See the Cat Data Link.
CD-ROM See the Compact Disc-Read Only
Memory.
203
Testing and Adjusting Section
Channel This describes an input to an electronic
control. This may also be a frequency that is used for
a voice transmission and/or the transmission of data.
Clear This is the removal of diagnostic information
that is stored in the memory of an electronic control.
Before clearing a failure, the failure must be on hold
and the failure must not be present. Reset can be
used in place of Clear. Clear is the preferred term.
Communication Adapter This is a device that
allows the service tool to communicate with an
electronic control over the Cat Data Link and the ATA
data link. The communication adapter converts the
information on the Cat data link and the ATA data link
to the RS-232 format. The communication adapter
converts the RS-232 information to a format that can
be used by the Cat Data Link and the ATA data link.
Configuration Software This is the information
that is provided for use by the on board system. This
information contains specific characteristics of the
machine.
Connector This is a device that is usually
constructed of two pieces that mate. A connector
provides a way to easily disconnect circuits or
separate circuits. Connectors are also used for
hydraulic circuits or pneumatic circuits.
Cycle Time This is the elapsed time that is
required for one load cycle.
Data Link This is a circuit that is used for
digital communications. The communications occur
between electronic controls or the communications
occur between electronic controls and a service tool.
Default This is the initial value of a parameter prior
to programming by the customer. This is also the
value of the parameter after the system has been
reset.
Dialog box A window that allows the user to review
information needed by the application or A window
that allows the user to maintain the information
needed by the application.
Disk Operating System (MS-DOS) This is
the software that contains the internal operating
instructions for the computer. This software also
allows the computer operator to make manual
commands. All computer systems have some type of
operating system in order to function.
Display Any gauge, indicator, or digital
readout that is used to display machine data.
Download The process of moving or transferring
stored information from an electronic control to
an off-board system such as a service tool. See
Upload.
204
Testing and Adjusting Section
Electronic Control Module (ECM) This is an
electronic control. The control monitors machine
systems. The control also outputs commands to
drive components. The term was formerly used to
specifically describe an electronic engine control.
ET See the Caterpillar Electronic Technician.
Fill Factor The fill factor is determined by dividing
the actual volume of the load by the maximum volume
of the load. This is expressed as a percentage.
Flash Files These Software programs contain
instructions on the operation of electronic controls.
The programs are transferred from the off-board
service tool to any on board electronic control. See
Flash Programming.
Flash Memory This is solid state memory that
is used in electronic controls. The memory can be
reprogrammed with an off-board service tool through
a data link without being removed from the control.
Other types of memory can only be programmed
outside of the control.
Flash Programming Flash programming is a
means of programming an electronic control. Flash
programming is also used to update the software
of a control. This is done with an off-board service
tool instead of replacing the control or a personality
module. This process involves the transfer of
configuration software from the service tool to the
electronic control. Communication is done over a
data link. See Flash Memory and Uploading.
Gage See Gauge.
Gauge This is a type of display device. The gauge
is usually a circular shape with a indicator needle.
The gauge can be a mechanical device or a solid
state device.
Hardware (H/W) This is the electrical components
and electronic components that make up an electrical
system.
Icon This is a symbol that is used instead of words
in order to convey a message in any language.
Input/Output (I/O) This term describes the
electronic circuits within an electronic control. These
circuits are used as inputs. Input components are
sensors and switches. These circuits are used as
outputs from the control to the external circuits.
Output components are horns, lamps and solenoids.
kPa See Kilopascal.
Keypad The keypad is a panel of keys that is
similar to the number pad that is used on a telephone.
The keypad is used as an interface to the onboard
electrical system.
KENR9023-01
Key Start Switch The key start switch is a
automotive start switch. The switch includes the
functions that are listed here: ON (relay), CRANK,
and ACCESSORY
Kilopascal (kPa) This is a Metric unit of measure.
A NEWTON is equal to the force that is applied to
one square meter. (6.89 kPa = 1 psi).
List box This is a rectangular box with scroll bars
that contains a scrollable list of items. Some list
boxes permit the user to select a single item. This is
accomplished by clicking on the desired entry. Other
list boxes permit the user to select multiple items.
This is accomplished by clicking on each of the
desired selections. The user can unselect an entry
on a list box with multiple selections. This is done by
clicking on the undesired selection. Some list boxes
do not permit the user to select an item. These list
boxes are used to display information only.
Load Cycle The load cycle is equivalent to a
pass.
Load Factor The load factor is determined by
dividing the actual mass of the load by the maximum
mass of the load. This is expressed as a percentage.
Loading Software This is the process of
transferring a program and/or configuration into an
electronic control from an off-board service tool. See
Flash Programming and Download.
Message Center Module This is a VIMS
module that contains the main display for the
operator warning system. This module also displays
information for the service technician.
Module This is a shortened term that is used
in place of the electronic control module. See
Electronic Control Module.
Non-Volatile Memory (NVM) Non-volatile memory
is a type of data storage that is unaffected by an
interruption of power. See Volatile Memory.
Off-Board This refers to hardware and software
that is located off the machine. The hardware
and software can be temporarily connected to the
electrical system.
Off Highway Truck (OHT) The off-highway truck
is used to haul material. These trucks are used by off
road mining applications.
Onboard This refers to hardware and software
that is located on the machine as part of the electrical
system.
KENR9023-01
Parameter This is a value or a limit that
is sometimes programmable. The parameter
determines the characteristics or behavior of the
engine and/or machine electrical system. See
Protected Parameter. A parameter can also refer to
the gauge functions and/or the monitored channels of
information (Vital Information Management System).
Pass A pass is the normal loading cycle of the
loading tool. The pass is composed of the operations
that are listed here: dig, lift, and dump
Password This is a group of numeric characters
or alpha-numeric characters that restrict the access
to information in a control system.
Percent Slope A one percent slope is a 1 m
(3.28 ft) change in elevation in 100 m (328 ft). This is
equal to 0.57 degree slope.
Polled Data This is data that is requested by
an electronic control. The data is not brought in
automatically.
Pounds per square inch (psi) This is an English
unit of pressure measurement. The measurement
represents the force that is applied to one square
inch. The value is measured in pounds. 6.89 kPa
(1 psi)
Pressure Sensor This is a device that generates
a signal that is proportional to the pressure that is
sensed.
Pulse Width Modulation (PWM) This is a signal
that is made up of a string of pulses that vary in
width. The frequency of the signal (repetition rate) of
the pulses and the height of the signal (amplitude)
remain constant.
Push Button The push button has the shape of a
rectangle. This is used by computer programs. The
push button is labelled with a text message. The text
describes the action that will be performed.
Quad Gauge Module This is an display module
that contains four analog gauges.
Random Access Memory (RAM) This is a type
of computer memory that is usually volatile. This
memory is used for the temporary storage of data.
Read Only Memory (ROM) This is a type of
computer memory that is programmed during the
manufacturing process. The memory cannot be
reprogrammed later. See Erasable Programmable
Read Only Memory.
Real Time This term is used to describe the
relationship of information (events) that is based on
a true clock.
205
Testing and Adjusting Section
Real Time Clock (RTC) This is the method that
is used by electronic controls to measure time. The
time is based upon true clock hours. See Diagnostic
Clock, Service Meter Hours and Service Meter
Units.
Reset This is a command that restores memory
to a default state. The default state is usually zero.
This means that all of the data has been removed or
erased. See Clear.
RS-232 Data Link This is a serial data link that
transfers data between electronic devices such as a
personal computer and a printer. See Serial data
link.
Scroll This is the process of showing all available
sets of event information within a digital display area.
The information is shown one set at a time. A set
of event information is shown briefly. The display
will automatically advance to the next set. After all
the sets are shown the process is repeated. Some
controls will show the message END before the
control repeats the process.
Sensor This is a device that monitors the physical
condition of a machine system. The sensors can
monitor the conditions that are listed here: pressure,
temperature, flow, and mechanical movement. The
sensors convert the condition into an electrical signal
that can be understood by an electronic control.
Serial Data Link This is a type of data link that
transfers one bit of data at a time. The data link
is used to transfer information. The information is
transferred between computerized controls.
Service Hour Meter (SHM) This is a meter on the
machine that totals the running hours of the engine.
Service Meter Hours (SMH) This meter
increments time only when the engine is running.
This meter is most often used in order to determine
the intervals for servicing the machine. This meter
is also used to identify the time of occurrence of an
event. This is used as part of the diagnostic process.
Also see Service Meter Units.
Service Program Code (SPC) These codes
are entered into the electrical system by the user
through the keypad. The codes initiate the requested
operation.
Service Tool This is a tool that is used in order to
service Caterpillar machines. This term most often
refers to the service equipment that is listed here:
Electronic Control Analyzer Programmer (ECAP),
Caterpillar Electronic Technician (ET), a digital
multimeter, and laptop computer This may also refer
to any other dedicated service equipment.
206 KENR9023-01
Testing and Adjusting Section

Signal This is the changing voltage that is used i03462544

to carry information. A signal is typically sent from a
sensor to an electronic control. For example, a signal System Schematic
is sent from the transmission output speed sensor
(TOS) to the transmission control. SMCS Code: 7566

Signal Wire This is the harness wire that carries
the signal voltage to the electronic control. The signal
is sent by any of the components that are listed here:
a sensor, a switch, and any other similar components.
Software (S/W) This is a step-by-step instruction
that defines the operation of a computer system. This
is often called a program.
The following schematics do not show all possible
harness connectors. The schematic does not show
all related electrical systems on the machine. Refer
toElectrical System Schematic, KENR8728 for a
complete electrical system schematic.
The schematic in Illustration 135 shows the
connections of the VIMS Main ECM.

Source Software This is software that contains

detailed operating instruction for the on board system.
This is software that is similar to the operating system
that is used with a personal computer.

Speedometer/Tachometer Module This is a

display module that contains the components that
are listed here: speedometer for machine ground
speed, a tachometer for engine speed, and a display
for actual gear.

Store This is the process that is used to record the

event information in an electronic control.

Subsystem This is a system that is part of a larger

system.

Telemetry This is a wireless method of

broadcasting data between two points. This method
most often uses a radio. The mobile unit transfers the
data to the data collection area.

VIMSpc This is a Windows based off-board

software product. The software is used with a service
tool. The service tool communicates with the VIMS
through the RS-232 data link.

VIMS Supervisor This is a Windows based

off-board software product. The software enhances
VIMSpc by providing analysis of Fleets and single
machines with advanced capabilities of data filtering.

Vital Information Management System (VIMS)

This is a system that is designed to monitor all on
board systems for abnormal conditions. The VIMS
controls the operator's electronic instrument panel
via a special data link.

Volatile Memory (VM) This is a type of data

storage that is lost with a interruption of power.

Warning Category This describes the severity of

an operator warning. This is based on one of three
categories.
KENR9023-01 207
Testing and Adjusting Section

g01839855
Illustration 135
Schematic that shows the connection of the VIMS Main ECM
208 KENR9023-01
Testing and Adjusting Section

The schematic in Illustration 136 shows the

connection of the VIMS Application ECM.
KENR9023-01 209
Testing and Adjusting Section

g01805398
Illustration 136
Schematic that shows the VIMS Application ECM
210 KENR9023-01
Testing and Adjusting Section

The schematic in Illustration 137 shows the

connections of CAT and CAN data link.
KENR9023-01 211
Testing and Adjusting Section

g01805413
Illustration 137
Schematic that shows data link connections of CAT and CAN
212
Index Section
Index
B M
Battery - Replace................................................. 199
C Operation of the Maximum Payload Speed
Connector Contact Description............................ 200
D Reweighing in Second Gear .............................. 20
Diagnostic Capabilities .......................................... 60
Caterpillar Electronic Technician (Cat ET) ......... 60
Diagnostic Code List.............................................. 69
Failure Mode Identifier ....................................... 71
Module Identifier (MID) ...................................... 70
Diagnostic Code Procedures................................. 69
Diagnostic System Procedures ........................... 189
Display................................................................... 27
Display Modules .................................................... 27
Advisor Display Module ..................................... 27
E MID 161 - CID 0768 - FMI 14 ................................ 97
Electrical Component and Connector Locations ... 59
Electrical Connector - Inspect.............................. 193
Guidelines ........................................................ 193
Important Safety Information............................ 193
Tests................................................................. 194
Electronic Control Module ....................................... 8
Characteristics of the VIMS 3G Electronic Control
Module (ECM) .................................................... 8
Electronic Control Module (ECM) - Configure ..... 198
Machine Configuration ..................................... 198
Electronic Control Module (ECM) - Flash
Program ............................................................. 198
Electronic Control Module (ECM) - Replace........ 198
Event Code List ..................................................... 65
Indications and System Response..................... 65
Power Train Event Code List ............................. 66
Troubleshooting ................................................. 66
Warning Levels .................................................. 65
G MID 162 - CID 0768 - FMI 09 .............................. 135
General Information........................................... 5, 58
Feature Variations................................................ 6
Related Support Material ..................................... 8
Types of Recorded Data ...................................... 6
Glossary of Terms................................................ 202
I MID 162 - CID 0839 - FMI 08 .............................. 155
Important Safety Information ................................... 2
Introduction........................................................ 5, 58
KENR9023-01
Maximum Payload Speed Manager ...................... 23
Configuring the Maximum Payload Speed
Manager ........................................................... 25
Manager ........................................................... 23
Measurement Accuracy......................................... 19
Distance Measurements .................................... 23
Payload Weight Measurement........................... 19
Time Measurements .......................................... 23
Troubleshoot the TPMS ..................................... 20
MID 161 - CID 0248 - FMI 09 ................................ 76
MID 161 - CID 0296 - FMI 02 ................................ 81
MID 161 - CID 0296 - FMI 09 ................................ 79
MID 161 - CID 0296 - FMI 14 ................................ 84
MID 161 - CID 0533 - FMI 02 ................................ 84
MID 161 - CID 0533 - FMI 09 ................................ 87
MID 161 - CID 0533 - FMI 14 ................................ 89
MID 161 - CID 0590 - FMI 02 ................................ 90
MID 161 - CID 0590 - FMI 09 ................................ 92
MID 161 - CID 0590 - FMI 14 ................................ 95
MID 161 - CID 0768 - FMI 09 ................................ 95
MID 161 - CID 0800 - FMI 08 ................................ 98
MID 161 - CID 0800 - FMI 11 .............................. 101
MID 161 - CID 0890 - FMI 09 .............................. 101
MID 161 - CID 1089 - FMI 09 .............................. 103
MID 161 - CID 1089 - FMI 14 .............................. 105
MID 161 - CID 1273 - FMI 02 .............................. 106
MID 161 - CID 1273 - FMI 09 .............................. 108
MID 161 - CID 1273 - FMI 14 ............................... 111
MID 161 - CID 2448 - FMI 02 ............................... 111
MID 161 - CID 2448 - FMI 09 ............................... 114
MID 161 - CID 2448 - FMI 14 ............................... 116
MID 162 - CID 0248 - FMI 09 ............................... 117
MID 162 - CID 0296 - FMI 02 ............................... 119
MID 162 - CID 0296 - FMI 09 .............................. 122
MID 162 - CID 0296 - FMI 14 .............................. 124
MID 162 - CID 0533 - FMI 02 .............................. 125
MID 162 - CID 0533 - FMI 09 .............................. 127
MID 162 - CID 0533 - FMI 14 .............................. 130
MID 162 - CID 0590 - FMI 02 .............................. 130
MID 162 - CID 0590 - FMI 09 .............................. 133
MID 162 - CID 0590 - FMI 14 .............................. 135
MID 162 - CID 0768 - FMI 14 .............................. 138
MID 162 - CID 0800 - FMI 09 .............................. 139
MID 162 - CID 0800 - FMI 14 .............................. 141
MID 162 - CID 0838 - FMI 03 .............................. 141
MID 162 - CID 0838 - FMI 04 .............................. 144
MID 162 - CID 0838 - FMI 08 .............................. 147
MID 162 - CID 0839 - FMI 03 .............................. 150
MID 162 - CID 0839 - FMI 04 .............................. 153
MID 162 - CID 0840 - FMI 03 .............................. 158
MID 162 - CID 0840 - FMI 04 .............................. 161
MID 162 - CID 0840 - FMI 08 .............................. 164
MID 162 - CID 0841 - FMI 03 .............................. 166
KENR9023-01
MID 162 - CID 0841 - FMI 04 .............................. 169
MID 162 - CID 0841 - FMI 08 .............................. 172
MID 162 - CID 1089 - FMI 08 .............................. 175
MID 162 - CID 1089 - FMI 11 .............................. 177
MID 162 - CID 1273 - FMI 02 .............................. 178
MID 162 - CID 1273 - FMI 09 .............................. 180
MID 162 - CID 1273 - FMI 14 .............................. 183
MID 162 - CID 2448 - FMI 02 .............................. 183
MID 162 - CID 2448 - FMI 09 .............................. 186
MID 162 - CID 2448 - FMI 14 .............................. 188
Monitor Menu......................................................... 28
Monitoring System.................................................. 11
O Table of Contents..................................................... 3
Off-Board Service Tool ........................................ 199
Related Material and Support .......................... 200
Operator Menu ...................................................... 29
Create a Profile .................................................. 30
Delete a Profile .................................................. 30
Edit/Save Current............................................... 30
Factory Set......................................................... 30
Select a Profile................................................... 30
P
Payload Management Guidelines.......................... 16
Overloading........................................................ 16
Payload Bias ...................................................... 19
Placement Of The Payload ................................ 19
Road Analysis Control ....................................... 16
The Loading Floor.............................................. 19
Payload Memory Capacity..................................... 27
Payload Memory Full Message ....................... 27
Payload Memory Low ....................................... 27
Payload Menu........................................................ 30
Payload System..................................................... 13
Off-Board Features of the TPMS ....................... 16
Onboard Features of the TPMS......................... 14
Payload System - Calibrate ................................. 191
Payload System - Configure................................ 192
Payload Last Pass Status.............................. 193
Payload Overload Limit ................................. 192
Payload Target Weight .................................. 192
Power Supply Circuit of Electronic Control
Module ............................................................... 189
S
Service Menu.........................................................
Calibrations ........................................................
Diagnostics ........................................................
Service Parameters .........................................
System Information..........................................
System Tests......................................................
Tattletale.............................................................
Service Mode Menu...............................................
Configuration of the Password in Cat ET...........
Service Tool Software............................................
Service Tools .........................................................
213
Index Section
Settings Menu........................................................ 31
Brake ............................................................... 33
Chassis............................................................ 33
Display Setup .................................................. 32
Machine ........................................................... 33
Transmission ................................................... 33
VIMS................................................................ 33
Software ................................................................ 41
System Schematic............................................... 206
Systems Operation Section ..................................... 5
T
Testing and Adjusting .......................................... 191
Testing and Adjusting Section ............................. 191
Troubleshooting Section........................................ 58
U
Using Advisor to Determine Diagnostic Codes...... 75
Using Caterpillar Electronic Technician to Determine
Diagnostic Codes................................................. 73
V
VIMS 3G Connect.................................................. 41
Communicate With a Machine ........................... 41
Download Recommendations ............................ 41
Downloading Data From The Machine .............. 45
Install Configuration Software ............................ 42
VIMSpc Payload Reports ...................................... 50
Truck Payload Analysis Criteria....................... 50
Truck Payload Reports ...................................... 51
VIMSpc Software................................................... 46
Application Window of VIMSpc .......................... 48
Recommendation for the System....................... 46
VIMSpc Features ............................................... 46
VIMSpc Software and the Truck Payload
System ............................................................. 48
W
Warning Operation ................................................ 12
Wiring Harness (Open Circuit) - Test................... 197
Wiring Harness (Short Circuit) - Test ................... 197
34
36
35
37
36
37
36
37
38
41
58
214 KENR9023-01
Index Section
KENR9023-01 215
Index Section
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