KENR9938-14 (en-us)

July 2019

Systems Operation
Troubleshooting
Testing and Adjusting
770G, 772G, 773E, 777E, 777G Off-
Highway Trucks and , 773G, 775G
Quarry Trucks
Monitoring System
KDH 1-UP (Machine) TWB 1-UP (Machine)
KD2 1-UP (Machine) T5T 1-1999 (Machine)
KEX 1-UP (Machine) T5S 1-1999 (Machine)
KE3 1-UP (Machine) T5F 1-1999 (Machine)
JWS 1-1999 (Machine) T5W 1-1999 (Machine)
MJS 1-1999 (Machine) T5A 1-1999 (Machine)
RDR 1-1999 (Machine) T4Y 1-1999 (Machine)
ECX 1-UP (Machine) PRB 1-UP (Machine)
ECM 1-UP (Machine) DJS 1-UP (Machine)
LTX 1-UP (Machine) KDP 1-UP (Machine)
LTS 1-UP (Machine) KDZ 1-UP (Machine)
MWH 1-1999 (Machine) RJZ 1-UP (Machine)
RFM 1-1999 (Machine)
TNM 1-1999 (Machine)
GT7 1-UP (Machine)
RMA 1-UP (Machine)
RMD 1-UP (Machine)
TWA 1-UP (Machine)
RME 1-UP (Machine)
RMH 1-UP (Machine)

PUBLICATIONS.CAT.COM
 i06558969

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, including human factors
that can affect safety. 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 verify
that you are authorized to perform this work, and 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 you are authorized to perform this work, and 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. Cat dealers have the most current information available.

When replacement parts are required for this

product Caterpillar recommends using Cat re-
placement parts.
Failure to follow this warning may lead to pre-
mature failures, product damage, personal in-
jury 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.
KENR9938-14 3
Table of Contents

Table of Contents Electrical Connector - Inspect............................. 134

Wiring Harness (Open Circuit) - Test................... 138
Wiring Harness (Short Circuit) - Test ................... 139
Systems Operation Section Module - Replace .............................................. 139
Module - Flash Program .................................... 140
General Information ..............................................4 Connector Contact Description........................... 140
Monitoring System ................................................7 System Schematic ............................................ 143
Display Module .....................................................8
Input Components...............................................16 Index Section
Output Components ............................................20
Warning Operation ..............................................21 Index................................................................ 147
Diagnostic Operation...........................................22
Menus (Advisor)..................................................23
Menus (Messenger) ............................................36

Troubleshooting Section

Introduction
General Information ............................................49
Service Tools ......................................................49
Connector Locations ...........................................51
Diagnostic Capabilities ........................................52
Event Code List...................................................55

Diagnostic Code Procedures

Diagnostic Code List ...........................................57
Using the Operator Monitor to Determine Diagnostic
Codes...............................................................58
Using Caterpillar Electronic Technician to Determine
Diagnostic Codes ..............................................58
MID 053 - CID 0168 - FMI 03................................61
MID 053 - CID 0168 - FMI 04................................62
MID 053 - CID 0268 - FMI 02................................63
MID 053 - CID 0271 - FMI 03................................63
MID 053 - CID 0271 - FMI 05................................64
MID 053 - CID 0271 - FMI 06................................66
MID 053 - CID 0533 - FMI 02................................67
MID 053 - CID 0533 - FMI 09................................71
MID 053 - CID 0533 - FMI 14................................75
MID 053 - CID 0590 - FMI 02................................77
MID 053 - CID 0590 - FMI 09................................81
MID 053 - CID 0590 - FMI 14................................84
MID 053 - CID 0800 - FMI 02................................86
MID 053 - CID 0800 - FMI 09................................90
MID 053 - CID 0800 - FMI 14................................93
MID 053 - CID 0811 - FMI 09................................95
MID 053 - CID 1089 - FMI 02................................99
MID 053 - CID 1089 - FMI 09.............................. 103
MID 053 - CID 1089 - FMI 14.............................. 107
MID 053 - CID 1273 - FMI 02.............................. 111
MID 053 - CID 1273 - FMI 09.............................. 114
MID 053 - CID 1273 - FMI 14.............................. 118
MID 053 - CID 4255 - FMI 09.............................. 120

Diagnostic System Procedures

Charging System .............................................. 124
Power Supply Circuit ......................................... 132

Testing and Adjusting Section

Testing and Adjusting

Self Test ........................................................... 134
4 KENR9938-14
Systems Operation Section

Systems Operation Section

i06753603

General Information
SMCS Code: 7490

Illustration 1 g02711693
Typical Dash for 773, 775, and 777G
KENR9938-14 5
Systems Operation Section

Illustration 2 g03870431
Typical Dash for 777E and 773E Off- Highway Trucks

Illustration 3 g02711691
Typical Instrument Cluster for 773, 775, and 777G
6 KENR9938-14
Systems Operation Section

Illustration 4 g03870405
Instrument Cluster for 777E and 773E
(1) Left turn signal (9) Transmission reverse (17) Engine Fault
(2) High beam (10) Body up (18) Action light
(3) Coolant temperature (11) LCD display (19) Primary steering system
(4) Parking brake (12) Transmission fault (20) Brake System Pressure
(5) Fuel level (13) Charging System (21) Tachometer
(6) Right turn signal (14) Retarder (22) Torque converter oil temperature
(7) Brake system fault (15) Lockout mode (23) Brake oil temperature
(8) Throttle lock (16) Traction Control System (TCS)

This manual discusses the monitoring system that is

used on the 773G/775G Off Highway Truck.
Details on the hardware components and the
software that make up the monitoring system will be
identified. This manual will also discuss the means of
navigating through the various screens of the
monitoring system.
The monitoring system continuously monitors all
machine systems. The monitoring system consists of
both software and hardware components. The
monitoring system communicates with the ECM of
other systems via the Cat Data Link.
KENR9938-14 7
Systems Operation Section

Monitoring System i04527373

Monitoring System
SMCS Code: 7490

Illustration 5 g02711719
Typical Advisor

The hardware components of the standard

monitoring system consist of the following: Illustration 6 g02711740

• Instrument Cluster display Display of the Advisor

• Advisor display The Advisor monitoring system monitors the

operation of the machine.
The standard monitoring system can indicate
warnings that have occurred in the ECM of other The Advisor provides the operator with the following
systems. These systems include the following: information:

• Brake ECM • Operating Characteristics of the Machine

• Chassis ECM • Diagnostics

• Product Link Radio ECM • Service Intervals

• Engine ECM • Warning Events

See System Operation, Troubleshooting, and Test/ • Modes of Operation

Adjust, RENR8284-00 and System Operation,
KENR5955-00 for more information on the VIMS and Instantaneous information and lifetime totals about
the Advisor. the machine condition and performance is constantly
gathered by Advisor.
The Advisor will display information on a display. The
display is located at the front of the right side
console.
The operator is able to adjust many of the settings in
order to match the machine to the desired
application. Advisor is used for the following:

• View the preferences of the operator.

• Change the preferences of the operator.

• Change the parameters.

The operator can provide input to the Advisor by
using the following buttons. The buttons are located
on the right-hand side of the display.

• Left/Up Arrow Button

• Right/Down Arrow Button
8 KENR9938-14
Systems Operation Section

• Back Arrow Button

• Home Button

• “OK” Button (Enter/Select)

Advisor allows the technician to perform the
following:
• View logged events and diagnostic codes.

• View the status of the system components.

• View the parameters of the system.

• Calibrate the payload system.

If a warning event occurs, a message will appear on
the Advisor display. The corresponding action lamp
will illuminate on the dash. An audible alarm will
sound for level III warning.
When the engine key start switch is turned to the ON
position, the Advisor continuously monitors all
machine systems. The following machine systems
are monitored:

• Sensors
• Electronic control modules
• Monitoring system components

i06753608

Display Module
SMCS Code: 7490

Instrument Cluster
The Monitoring System is designed to alert the
operator to an immediate problem with any of the
machine systems that are monitored. The Monitoring
System is also designed to alert the operator to an
impending problem with any of the machine systems
that are monitored.
KENR9938-14 9
Systems Operation Section

Illustration 7 g02710741
Instrument Cluster for a 773G, 775G, and 777G
10 KENR9938-14
Systems Operation Section

Illustration 8 g02710418
Instrument Cluster for a 770G and 772G prefixes ECM and LTS
KENR9938-14 11
Systems Operation Section

Illustration 9 g02710480
Instrument Cluster for 770G and 772G prefixes KDH and KEX
(1) Throttle lock (9) Charging System (17) Brake oil temperature
(2) Primary steering system (10) Body up (18) Coolant temperature
(3) Secondary steering system (11) Lockout mode (19) Parking brake
(4) Engine Fault (12) High beam (20) LCD display
(5) Brake system fault (13) Retarder (21) Transmission reverse
(6) Transmission fault (14) Traction Control System (TCS) (22) Torque converter oil temperature
(7) Action light (15) Fasten Seat Belt (23) Fuel level
(8) Tachometer (16) Left turn signal (24) Right turn signal

Throttle Lock (1) – This indicator is Secondary Steering System (3) – When
illuminated when the throttle lock is this indicator is illuminated, the
activated. secondary steering system is active.
The secondary steering system becomes active
Throttle Lock (1) – This indicator is when the primary steering system has failed.
illuminated when the throttle lock is
activated. Engine Fault (4) – When this indicator is
illuminated, there is a general fault in the
Primary Steering System (2) – When this engine.
indicator is illuminated, the primary
steering system pressure is low. Stop Brake System Fault (5) – When this
the machine immediately. Stop the engine and indicator is illuminated, there is a
investigate the cause. Do not operate the general fault in the brake system.
machine until the primary steering system
pressure is normal.
12 KENR9938-14
Systems Operation Section

Transmission Fault (6) – When this Fasten Seat Belt (15) – This indicator
indicator is illuminated, there is a illuminates when the seat belt is not
general fault in the transmission fastened.
system.
Left Turn Signal (16) – This indicator
Action Light (7) – When this indicator is illuminates when the left turn signal light
illuminated, there is a malfunction in a is operating.
machine system. This indicator is used
with the system indicators to convey the severity Brake Oil Temperature (17) – When the
of the situation. Refer to Systems Operation, brake oil temperature is above the
“Warning Operation” for more information about normal operating value, the brake oil
the severity of various warnings. temperature gauge will be in the red zone.

Tachometer (8) – The tachometer will Coolant Temperature (18) – When the
indicate the engine RPM. This also coolant temperature is above the normal
indicates engine overspeed. Engine operating value, the coolant
overspeed is represented by the yellow zone and temperature gauge will be in the red zone.
the red zone.
Parking Brake (19) – When this indicator
Charging System (9) – When this is illuminated, the parking brake is
indicator is illuminated, there is a fault in engaged.
the charging system.
LCD Display (20) – This display is used
Body Up (10) – When this indicator is to display the following information:
illuminated, the truck body is in the service hour meter, machine ground
raised position. speed, actual gear and direction.

Lockout Mode (11) – This indicator will Transmission Reverse (21) – The
be illuminated when the engine lockout transmission lever is in the REVERSE
has been activated. The indicator will position. This also indicates the
also be illuminated when the machine lockout is possibility that the machine will shift into reverse
activated. Refer to the following topics for more when forward ground speed drops.
information:
Torque Converter Oil Temperature (22) –
• Operation and Maintenance Manual, “Engine When the oil for the torque converter is
Lockout Control” above normal operating temperature,
the torque converter oil temperature gauge will
• Operation and Maintenance Manual, “Machine be in the red zone.
Lockout Control”
Fuel Level (23) – When the level of fuel
High Beam (12) – When this indicator is in the fuel tank is low, the fuel level
illuminated, the high beam headlights gauge will be in the red zone.
are on.
Right Turn Signal (24) – This indicator
Retarder (13) – This indicator will illuminates when the right turn signal
illuminate when the Automatic Retarder light is operating.
Control (ARC) is engaged or when the
manual retarder control is engaged. Refer to The Instrument Cluster display is located in the upper
Operation and Maintenance Manual, “Retarding”. center of the dash panel. The Instrument Cluster has
the following types of display:
Traction Control System (14) – This
indicator is illuminated when the • Status indicator
Traction Control System (TCS) applies
• Warning indicator
the rear brakes of a wheel that is losing traction.
This also flashes during the TCS test. • Gauges
Traction Control System (14) – This • LCD display
indicator is illuminated when the
Traction Control System (TCS) applies
the rear brakes of a wheel that is losing traction.
This also flashes during the TCS test.
KENR9938-14 13
Systems Operation Section

Illustration 10 g03870405
Instrument Cluster for 777E prefixes KDP and 773E prefixes PRB
(1) Left turn signal (9) Transmission reverse (17) Engine Fault
(2) High beam (10) Body up (18) Action light
(3) Coolant temperature (11) LCD display (19) Primary steering system
(4) Parking brake (12) Transmission fault (20) Brake System Pressure
(5) Fuel level (13) Charging System (21) Tachometer
(6) Right turn signal (14) Retarder (22) Torque converter oil temperature
(7) Brake system fault (15) Lockout mode (23) Brake oil temperature
(8) Throttle lock (16) Traction Control System (TCS)

Left Turn Signal (1) – This indicator Fuel Level (5) – When the level of fuel in
illuminates when the left turn signal light the fuel tank is low, the fuel level gauge
is operating. will be in the red zone.

High Beam (2) – When this indicator is Right Turn Signal (6) – This indicator
illuminated, the high beam headlights illuminates when the right turn signal
are on. light is operating.
Coolant Temperature (3) – When the Brake System Fault (7) – When this
coolant temperature is above the normal indicator is illuminated, there is a
operating value, the coolant general fault in the brake system.
temperature gauge will be in the red zone.
Throttle Lock (8) – This indicator is
Parking Brake (4) – When this indicator illuminated when the throttle lock is
is illuminated, the parking brake is activated.
engaged.
14 KENR9938-14
Systems Operation Section

Throttle Lock (8) – This indicator is Action Light (18) – When this indicator is
illuminated when the throttle lock is illuminated, there is a malfunction in a
activated. machine system. This indicator is used
with the system indicators to convey the severity
Transmission Reverse (9) – The of the situation. Refer to Systems Operation,
transmission lever is in the REVERSE “Warning Operation” for more information about
position. This also indicates the the severity of various warnings.
possibility that the machine will shift into reverse
when forward ground speed drops. Primary Steering System (19) – When
this indicator is illuminated, the primary
Body Up (10) – When this indicator is steering system pressure is low. Stop
illuminated, the truck body is in the the machine immediately. Stop the engine and
raised position. investigate the cause. Do not operate the
machine until the primary steering system
LCD Display (11) – This display is used pressure is normal.
to display the following information:
service hour meter, machine ground Brake System - Pressure (20) – This
speed, actual gear, and direction. gauge displays the pressure on brake
system.
Transmission Fault (12) – When this
indicator is illuminated, there is a Tachometer (21) – The tachometer will
general fault in the transmission indicate the engine RPM. This also
system. indicates engine overspeed. Engine
overspeed is represented by the yellow zone and
Charging System (13) – When this the red zone.
indicator is illuminated, there is a fault in
the charging system. Torque Converter Oil Temperature (22) –
When the oil for the torque converter is
Retarder (14) – This indicator will above normal operating temperature,
illuminate when the Automatic Retarder the torque converter oil temperature gauge will
Control (ARC) is engaged or when the be in the red zone.
manual retarder control is engaged. Refer to
Operation and Maintenance Manual, “Retarding”. Brake Oil Temperature (23) – When the
brake oil temperature is above the
Lockout Mode (15) – This indicator will normal operating value, the brake oil
be illuminated when the engine lockout temperature gauge will be in the red zone.
has been activated. The indicator will
also be illuminated when the machine lockout is The Instrument Cluster display is located in the upper
activated. Refer to the following topics for more center of the dash panel. The Instrument Cluster has
information: the following types of display:
• Operation and Maintenance Manual, “Engine • Status indicator
Lockout Control”
• Warning indicator
• Operation and Maintenance Manual, “Machine
Lockout Control” • Gauges

Traction Control System (16) – This • LCD display

indicator is illuminated when the
Traction Control System (TCS) applies Advisor Display Module
the rear brakes of a wheel that is losing traction.
This also flashes during the TCS test. The Advisor display module is on the operator
console. The Advisor display module interfaces with
Traction Control System (16) – This the monitoring system.
indicator is illuminated when the
Traction Control System (TCS) applies
the rear brakes of a wheel that is losing traction.
This also flashes during the TCS test.
Engine Fault (17) – When this indicator
is illuminated, there is a general fault in
the engine.
KENR9938-14 15
Systems Operation Section

The Advisor display module contains an LCD screen profile.

and ten buttons for accessing information through the
menu. The display will allow viewing of diagnostic Display Menu (11) – The “Home Menu” screen lists
codes. The display will also allow viewing of event the menus that are used to navigate to other menus.
codes. The display provides an interface to perform The “Home Menu” screen also lists the menus that
calibrations. In addition, the Advisor display module are used to navigate to submenus.
is used to allow programming of configurable More Options (12) – Additional information is
parameters. The display is used to perform the available on the subject that is highlighted on the
calculation of the performance characteristics of the display screen. Use the appropriate arrow button to
machine. The Advisor display module will display view the information.
readings on the machine and readings on the engine
operating parameters. The software will be flashed
by using the Caterpillar Electronic Technician service Use the arrow buttons to highlight the desired
tool. selection to navigate through the menus and
submenus. Then press the “OK” button. Also, use the
The Advisor display module, combined with the arrow buttons to highlight a mode or parameter
monitoring system, allows additional means for the setting. Then, press the “OK” button to select that
operator to increase machine efficiency. Refer to the option.
Illustration .
Gauge Cluster
After the start-up cycle has been completed, the next
screen display is the gauge cluster. The gauge
cluster is a collection of machine parameters which
are referenced by the operator during the operation
of the machine. The operator can access the menu
by pressing the home button, on the right side of the
display.
“ Check Engine”” – The “ Check Engine””
light activates when the Engine ECM
emits system warnings of Level 2 or
higher.

“ Operator Alert”” – The “ Operator Alert””

Illustration 11 g02709796
indicator activates by the Machine ECM.
The functions of the buttons on the Advisor display
are described below. Begin with the buttons on the
upper left corner of the display. Messenger
“ Preset buttons”” (1-5) – The “Advisor” system
allows you to program the locations of five menu
items. To store a menu item into the memory, go to
the desired screen display in the menu. Then,
choose a preset button and hold the preset button for
2 seconds. Use the preset button to access the
corresponding screen display from any location in the
menu.
“ Left/Up”” (6) – This button is used for the following
purposes: “menu” navigation button, data
information, and decreasing a setting value.
“ Right/Down”” (7) – This button is used for the
following purposes: “menu” navigation button, data
information, and increasing a setting value.
Illustration 12 g02710738
“ Back”” (8) – This button is used to return to the
previous screen. Digital display area (1) – This Messenger system
shows information on the digital display area.
“ Home”” (9) – This button is used to return to the
“Home Menu” from any screen. Previous button (2) – Use this button to return to
information that was previously shown on digital
“ OK”” (10) – This button is used to make selections on display area.
the screen . Also, use this button to confirm a
password entry or use the button to save an operator
16 KENR9938-14
Systems Operation Section

Scroll up/left button (3) – This button is used to Hydraulic Oil Temperature Sender
scroll up through information that is shown on the
display area. The button can also be used to scroll to
the left through information that is shown on the
display area.
Scroll down/right button (4) – This button is used to
scroll down through information that is shown on the
display area. The button can also be used to scroll to
the right through information that is shown on the
display area.
OK button (5) – After highlighting a selection with the
scroll up/left button and with the scroll down/right
button, use this button to confirm the selection.

i05733544

Illustration 14 g01304277
Input Components Temperature Sender
SMCS Code: 7490 (32) Schematic symbol
(33) Sender
The input components of the monitoring system
follow. The temperature sender (33) senses the temperature
of fluids. A resistive signal which corresponds to the
Senders temperature of the fluid that is being monitored is
sent from the sender to the main display module. The
typical resistance of the sender is 70 to 800 ohms.
Engine Coolant Temperature Sender The main display module measures the value of the
resistance in order to determine the temperature of
the fluid.

Sensors
Sensors provide information to the main display
module about changing conditions. Two of the
changing conditions are speed and temperature. The
sensor signal changes in a proportional manner in
order to reflect the condition. The main display
Illustration 13 g00496856 module shows the sensor information on the gauges.
Engine Coolant Temperature Sender

The engine coolant temperature sender is used to

operate the water temperature gauge on the face of
the front panel. The sender uses variable resistance.
The resistance of the sender is proportional to the
temperature of the coolant. As temperature
increases, the resistance of the sender decreases.
The increasing resistance and the decreasing
resistance controls the flow of the electrical current in
the gauge. The electrical current in the circuit of the
sender is also controlled by the increasing resistance
and the decreasing resistance. The value that is
showing on the gauge reflects the amount of current
flowing in the circuit. The sender and the gauge are
matched to work together as a unit.
KENR9938-14 17
Systems Operation Section

Fuel Level Sensor Speed Sensor

Illustration 16 g01304275
Speed sensor
(34) Sensor
(35) Connector

Speed sensor (34) is a frequency sensor. Speed

sensors are used to measure engine rpm. The
Illustration 15 g03350145 sensor generates an AC signal from passing gear
Fuel Level Sensor teeth, which is sent to the main display module. The
main display module measures the frequency of the
The fuel level sensor is an active analog sensor. The sender at a rate of one pulse per gear tooth. The
electronics of the sensor measures the change in main display module then determines the engine
capacitance of the tube wall as the fluid height on the speed. Next, the main display module shows the
tube changes. This measurement is then converted engine speed.
by the sensor into an analog voltage signal for the
Chassis ECM to read. The engine speed sensor is located on the flywheel
Table 1 housing.
Fuel Level Sensor Output

Percent of Fuel in Tank Sensor Output Voltage

0% (Empty) 0.5 V

25% 1.5 V

50% 2.5 V
75% 3.5 V

100% (Full) 4.5 V

18 KENR9938-14
Systems Operation Section

Pulse Width Modulated Sensors Engine Speed Sensor

Illustration 19 g00311291
Magnetic Speed Pickup (MPU)

The magnetic speed pickup (MPU) sends a signal

that represents the speed of the engine to the control
board and to the tachometer. The MPU is located on
the engine flywheel housing. The MPU is a single-
pole permanent magnetic generator that is made of
wire coils around a permanent magnet pole piece. As
the teeth of the flywheel ring gear go through the
magnetic lines of flux around the pickup, an AC
voltage is generated. A positive voltage is generated
when each tooth goes by the pole piece. A negative
voltage is generated when each space between the
Illustration 17 g00288430 teeth goes by the pole piece. The control board
Pulse Width Modulated Signal counts the frequency of this speed signal. The control
board determines the speed of the engine.

Air Inlet Pressure Sensor

The air inlet pressure sensor is an input of the
monitoring system. This sensor gives the monitoring
system a value for the air inlet pressure. A gauge
displays the status of the pressure. This pressure
sensor senses the outlet pressure. The air inlet
pressure sensor is a pulse width modulated sensor.
This sensor continuously generates a PWM signal.
The duty cycle of the PWM signal varies from 10 to
90% in proportion to the air inlet pressure. The base
frequency of the sensor is constant at 500 ± 150 Hz.

Illustration 18 g00497140
Typical PWM Sensor

Pulse width modulated sensors produce a digital

signal. The duty cycle of the digital signal varies as
the condition changes. The frequency remains
constant.
KENR9938-14 19
Systems Operation Section

Temperature Sensor

Illustration 21 g00927534

Illustration 20 g01304274
Engine Coolant Temperature Switch
Temperature Sensor
(36) Sensor
(37) Connector

Temperature sensor (37) reacts to the temperature of

fluids such as engine oil or engine coolant. The
sensor receives operating power from the main
display module (+8 DCV) or from the battery (+12
DCV). The temperature sensor sends a signal to the
monitoring system which changes as the
temperature of the fluid changes. The main display
module measures the duty cycle of the sensor signal
in order to determine the fluid temperature.

Switches
Switches provide information (input) to the main
display module. Switches are two state devices. The Illustration 22 g00496872
two states are described below. Engine Coolant Temperature Switch
Closed – The switch connects the control input to the
ground. The engine coolant temperature switch sends a B−
signal to the control board when the coolant
Open – The switch does not connect the control temperature exceeds the trip point of the switch. This
input. The input is floating. signal causes the control board to perform an engine
shutdown for a high water temperature fault. The
switch is mounted in the water jacket usually near the
During normal operation, all switches are closed to front of the engine. The exact location depends on
the ground terminal. When a condition exceeds the the engine model.
trip point of the switch, the switch opens. This action
tells the main display module of the abnormal The switch has normally open contacts and normally
condition. The main display module goes into closed contacts. Only the normally open contacts “A”
warning operation. The main display notifies the and “B” are used. Contact “A” connects to the control
operator of the abnormal condition (problem). board. Contact “B” connects to the negative battery
terminal.
Note: See Engine Service Manual, “Electrical
System Schematic” for specifications for switches.

Key Start Switch

When the key start switch is in the ON position,
electrical power from the batteries is supplied to the
electronic control modules.
When the key start switch is in the START position
and the conditions for starting the engine are
satisfied, the start relay is energized.
20 KENR9938-14
Systems Operation Section

Engine Oil Pressure Switch Hydraulic Oil Filter Switch

Illustration 23 g00496875
Engine Oil Pressure Switch

The engine oil pressure switch sends a B− signal to

the control board when the oil pressure drops below
the trip point of the switch. The B− signal causes the
control board to perform an engine shutdown for a
low oil pressure fault. The switch is mounted on the Illustration 24 g01304276
outside of an oil gallery of the engine. The exact Hydraulic Oil Filter Switch
location depends on the engine model. (38) Switch
(39) Schematic Symbol
The switch has normally open contacts and normally
closed contacts. Only the normally closed contact “A” Switch (38) is open during normal operation. This
and contact “C” are used. Contact “C” connects to the switch closes to ground when the pressure for the
control board. Contact “A” connects to B−. hydraulic oil filter is greater than the specified value
The specifications for the 3E-6455 Pressure Switch for the switch. The closed switch tells the monitoring
are listed below. system that the hydraulic oil filter is restricted. The
switch is open when the switch is off the machine.
• Pressure for actuation is 90 ± 21 kPa (13 ± 3 psi).
i04527401
• Pressure for deactuation is 70 ± 21 kPa
(10 ± 3 psi). Output Components
SMCS Code: 7490
The Advisor monitoring system has two primary
outputs. The outputs are used to alert the operator to
abnormal operating conditions with the machine. The
Advisor monitoring system sends a signal to the
cluster to light the action lamp or the action alarm in
order to alert the operator. With the alert, the Advisor
display screen will be overridden with a popup
message.
KENR9938-14 21
Systems Operation Section

The main display module analyzes the problem

signals. To notify the operator of a warning, the
display components of the main display module
activate the appropriate warning indication on the
Instrument Cluster. The following warning indications
will notify the operator:

• The status indicator illuminates.

• The action lamp flashes. The lamp is ON for one
second and the lamp is OFF for 2 seconds.

• The action alarm sounds. The alarm is ON for one

second and the alarm is OFF for 2 seconds.

• The action alarm sounds. During a Level 2-S

Illustration 25 g02175827 warning, the alarm sounds continuously.
When an abnormal machine condition exists, the Note: In order to activate warning indications, more
Advisor monitoring system will send a signal in order than one input is required. The main display module
to energize the following components: decides when the warning indications are activated.
• Action Lamp
Warning Categories
• Action Alarm
Problems from the machine system are classified into
• Both lamp and alarm four warning categories. The categories are based on
the severity of the problem. The categories also
For more information, see System Operation, dictate the required response of the operator.
“Warning Operation”. Warning category 1 represents the least severe
problem and warning category 3 represents the most
i04527438 severe problem. The warning categories are
identified for the operator according to the
combination of warning indications that are active.
Warning Operation See the Table 2 for Warning Operation.
SMCS Code: 7490 Note: See the Operation and Maintenance Manual
The Caterpillar Monitoring and Display system for complete information on the Warning Operation.
notifies the operator of an immediate problem with a
machine system or an impending problem with a
machine system. Warning operation begins when the
main display module receives a problem signal. The
problem signal reflects an abnormal condition of the
machine. Warning operation also begins when the
main display module detects a problem with the
control system. Switches, sensors, and other
electronic control modules on the machine provide
signals to the main display module. The problem
signals are the following conditions:
Open switch – When a condition exceeds the trip
point of the switch, the switch opens.

Sensor signal exceeds the limits – The main

display module determines the limits.

Abnormal condition that is detected by another

electronic control module – The abnormal
condition is then communicated over the Cat Data
Link to the main display module.
22 KENR9938-14
Systems Operation Section

Table 2
WARNING OPERATION
Warning Indications (1)

Status In- Action Action

Warning dicator Lamp Alarm
Category Flashes (3) Flashes Sounds Required Operator Action Possible Result (2)
1 X No immediate action is required. The sys- No harmful or damaging effects.
tem needs attention soon.
2 X X Change machine operation and perform Severe damage to components.
maintenance to the system.

2-S X X X (4) Immediately change operation Severe damage to machine components.

3 X X X (5) Immediately perform a safe engine Operator injury or severe damage to

shutdown. components.
(1) The active warning indications are marked with an “X” .
(2) This is the possible result if no operator action is taken.
(3) Based on the problem detected, the specific status indicator will illuminate.
(4) The alarm is on continuously.
(5) Pulsating alarm.

Warning Messages Action Alarm

During the normal operation mode and the menu If a level 3 warning is active, the action alarm will
mode, the Messenger display may be interrupted by sound a pulsing tone. A level 3 warning requires an
a warning message. Warning messages are immediate safe machine shutdown. The action alarm
displayed when important instructions or information will sound this tone in order to alert the machine
need to be displayed. operator that immediate action is required.

If the warning is a Level 1 or a Level 2, the message i03938311

may be acknowledged by pressing the “OK” button.
The “OK” button is pressed the message will Diagnostic Operation
disappear from the screen. Cycle the power in order
to view the Level 1 or a Level 2 warning message SMCS Code: 7490
after the message has been acknowledged.
A diagnostic code indicates that the ECM has
If the severity of the warning is Level 3, the message detected one or more of the following conditions:
will not be removable with the “OK” button. The
message will only disappear when the problem no • an invalid signal from an input
longer exists or when the machine is shut down.
• an improper feedback from an output

• an internal error
One method of displaying diagnostic information is
provided:

• Diagnostic codes with descriptive text can be

viewed with the Caterpillar Electronic Technician
(ET).
Display the diagnostic code with the Caterpillar
Electronic Technician.
This method of displaying the diagnostic codes uses
the service tool to display the codes. The Component
Illustration 26 g02175827
Identifier (CID) identifies the specific component for a
specific diagnostic. The Failure Mode Identifier (FMI)
Typical screen of the Advisor Display identifies the type of diagnostic that was detected.
The diagnostic codes allow consistent identification
The warning message gives indications of the of the problem. The service tool is used to display the
problem. A Troubleshooting Code and an instruction CID-FMI with descriptive text for each combination.
for the operator are displayed. The descriptive text will help to avoid mistakes in
interpreting the codes.
KENR9938-14 23
Systems Operation Section

Active Diagnostics Home Menu

If the Cat service tool is available, the service tool
can be used to display all active diagnostic codes.
The service tool will also display codes that have
been logged.

Logged Diagnostics
Logged diagnostics eliminate the need to duplicate
problems that are intermittent. Logged diagnostics
will increase the accuracy of diagnosis. The time that
is required to troubleshoot a problem is reduced with
the use of Diagnostics. Logged diagnostics eliminate
the need for trip recorders that are used to capture
intermittent diagnostic information.
The control modules memory is used to store
diagnostic information. When a diagnostic is Illustration 27 g02710811
detected, the following information is logged:
The “Home Menu” screen is the default screen for
• The CID will identify the component that has Advisor. This screen allows the operator to access
failed. different function screens by highlighting the
appropriate title with the “up” and “down” buttons and
• The FMI will describe the problem. pressing the “OK” button. Refer to figure 27 for
menus accessible from the “home menu” .
• Number of occurrences of the diagnostic code

• The time of the first occurrence that the diagnostic

was detected.
• Last occurrence time, when the diagnostic was
last detected (stored with both machine hours and
RTC stamp)
The problems which can be logged are listed in
Troubleshooting, “Diagnostic Code List”. Refer to the
Troubleshooting manual for your machine
The ECM logs the number of times that the machine
is started with the methods that are listed below:

• Starting using an unauthorized method

i05928721

Menus (Advisor)
SMCS Code: 7490
The Advisor is equipped on all 773G, 775G, and
777G. The advisor is an option on 770G and 772G.
24 KENR9938-14
Systems Operation Section

Operator Menu • Delete a profile.

• Set to Factory Defaults.
The profile of an operator is a saved set of
preferences that are identified by a name. Once the
profile is created, the operator may associate various
display settings and settings for the power train to
that profile. After all of the parameters have been
adjusted to the preference of the operator, you may
then save the parameters for future usage.

Illustration 29 g02175827
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 29 .
Note: The Home menu can be displayed from any
screen by pressing the Home button.
The following screen will now be displayed.

Illustration 28 g02709891
The selection menu for the operator

The “Operator” menu allows the user to perform the Illustration 30 g02710001
following: The “Operator” screen
• Input your Operator ID. The “Operator” menu contains the following options:
• Select a profile. • “Operator ID”
• Edit/Save a current profile. • “Select Profile”
• Create a profile. • “Edit/Save Current”
KENR9938-14 25
Systems Operation Section

• “Create Profile” The operator may exit this display without saving by
pressing the back button. The operator may save the
• “Delete Profile” settings to memory by selecting “SAVE” and then
pressing the “OK” button. The settings will not
• “Factory Set” change unless you successfully save the settings.
To access the “Operator” menu option, press the up
arrow button or the down arrow button until the Factory Set
desired category is highlighted. Then press the “OK”
button. The following explains the usage of each From the “Operator” menu, use the appropriate arrow
menu option. button to highlight the “Factory Set” option. Then
press the “OK” button in order to make the default
settings active.
Select a Profile
This procedure recalls the default settings. The
From the “Operator” menu, use the appropriate arrow default settings are then the active settings and the
button to highlight the “Select Profile” option. Then Advisor display and the instrument cluster will reflect
press the “OK” button in order to display a list of the default settings. Once the default settings have
existing profiles. Again, use the appropriate arrow been activated, the settings may be viewed without
button to highlight the desired profile. Then press the saving using the “Edit/Save Current” option.
“OK” button in order to select that profile.
The default settings will not be saved with the current
Note: A maximum of ten profiles may be used. profile unless the operator saves the default settings
to a profile by using the “Edit/Save Current” option.
Create a Profile
Monitor Menu
From the “Operator” menu, use the appropriate arrow
button to highlight the “Create Profile” option. Then
press the “OK” button in order to display the “Create
Profile” screen. Follow the screen instructions to
create and give a name to a new profile. 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 ten profiles may be used.

Delete a Profile
From the “Operator” menu, use the appropriate arrow
Illustration 31 g02175790
button to highlight the “Delete Profile” option. Then
press the “OK” button in order to display a list of Select “Monitor” from the menu.
existing profiles. Use the appropriate arrow button to
highlight the profile for deleting. Then press the “OK” The “Monitor” menu option is entered by selecting
button in order to delete that profile. This procedure “Monitor” from the Home menu. The Home menu can
deletes the selected profile from the list of stored be displayed from any screen by pressing the Home
profiles. 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
Edit/Save Current the “Monitor” menu.
From the “Operator” menu, use the appropriate arrow
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.
26 KENR9938-14
Systems Operation Section

Illustration 32 g02709991 Illustration 34 g02710008

The “Monitor Parameter Screen 1” screen The “Payload” screen
The “Monitor” menu option allows the user to view The “Payload” menu option allows the operator to
four parameters. Use the navigation buttons in order view the information for the payload in the form of an
to select the parameter. Also, use the navigation analog gauge. The operator can view the menu in
buttons to view a different parameter. Press the “OK” order to monitor the loading of the payload.
button in order to attain a list of available parameters.
Refer to Systems Operation, KENR9023, “Menu Note: The Home menu can be displayed from any
Contents” in this manual in order to view the screen by pressing the Home button.
complete list of available parameters. The list of
parameters is under the “Monitor” heading.

Payload Menu

Illustration 33 g02175800
Select “Payload” on the menu.

The “Payload” menu option is entered by selecting

“Payload” from the Home menu. Press the up button
or the down button until the “Payload” is highlighted
in order to select the menu. Then, press the “OK”
button in order to select the “Payload” menu.
The following screen will now be displayed.
KENR9938-14 27
Systems Operation Section

Service Menu
28 KENR9938-14
Systems Operation Section

Illustration 35 g02709932
KENR9938-14 29
Systems Operation Section

The “Service” menu is entered by selecting “Service” Diagnostics

from the “Home Menu” . Press the up arrow button or
the down arrow button until “Service” is highlighted to From the “Service” menu, use the appropriate arrow
select the “Service” menu. Press the “OK” button. button to highlight the “Diagnostics” menu. Press the
Refer to Illustration 36 . “OK” button to access the “Diagnostics” menu. The
“Diagnostics” menu will display the following:
Note: The “Home Menu” can be displayed from any
screen by pressing the “Home” button. • Active Events
• Chronological Events

• Logged Events
• Event Configuration

• Snapshot configuration
• Clear snapshot configuration

• “Trigger Snapshot”
• “Data Logger”

Active Events
Illustration 36 g02175801 The “Active Events” menu shows the ECM and the
Select the “Service” menu. service hours for each event. Press the “OK” button
to view the information for the active event. The
The following screen will now be displayed. following is a list of information that is displayed for
the active event:
• Electronic Control Module

• Event Code
• Date of occurrence

• Time of occurrence
• Warning Level

• Number of occurrences

Logged Events
Illustration 37 g02710018 The “Data Logger Start” menu allows the user to
The “Service” menu initiate the data logger. The total logging time for the
data logger is 30 minutes. The operator can start and
The “Service” menu contains seven sub menus. stop the data logger until 30 minutes of time is
logged. The status of the data logger is shown in the
• “Diagnostics” right portion of the screen on the Advisor. “Data
Logger Stop” will change to “Data Logger Start” when
• “Calibrations” the data logger is no longer recording data. The
remaining storage time of the data logger is shown
• “System Information” on the message area when the user highlights “Data
Logger Reset” on the Advisor display. The format of
• “Tattletale” the time is shown in “minutes:seconds” .

• “System Tests” Note: If information from the data logger is being

downloaded from the machine, the data logger
• “Service Parameters” cannot be started.
The following explains the usage of each sub menu.
30 KENR9938-14
Systems Operation Section

“ Data Logger Reset”” Tattletale

The “Data Logger Reset” menu allows the user to From the “Service” menu, use the appropriate arrow
reset the data logger. This option clears all of the button to highlight the “Tattle Tale” menu. Press the
logged information. Select the “Data Logger Reset” “OK” button to access the Tattletale menu. The
menu item. The Advisor shows the time that is following options are available under Tattletale:
available for the data logger on the right side of the
screen. 30 minutes will be available after the data • Active
logger has been reset.
• Brake Oil Temperature
Note: The Data Logger is the only onboard file that
can be reset through the Advisor display. The Advisor • Engine Coolant Temperature
must be in the Service Mode or Cat ET must be
connected to the data link to reset the data logger. • Engine Speed
The VIMSpc software is not needed in order to reset • Torque Converter Temperature
the data logger.
• Fuel Level
Calibrations
• DEF Level (for prefixes KDH and KEX only)
Press the “OK” button to enter the “Calibration”
menu. Use the appropriate arrow button to highlight Any option from the prior list can be selected. The
the desired calibration from the list. Press the “OK” “Active” option will display the tattletale value for
button. Follow the directions that are displayed on the each gauge. The five specific options will display that
screen to perform the calibration. tattletale value for the gauge that is specified.

“ System Information”” Note: Tattletale is password protected. The value for

each gauge is protected from being cleared.
The “System Information” menu allows the user to
view the information for ECM that are on machine. System Tests
When the “System Information” menu is selected, a
submenu is displayed. The submenu displays the From the “Service” menu, use the appropriate arrow
ECM on the data link. The following is a typical list of button to highlight the “System Tests” menu. Press
ECM for a VIMS 3G QCT: the “OK” button in order to access the “System Tests”
menu.
• Advisor

• Engine “ Service Parameters””

• Chassis From the “Service” menu, use the appropriate arrow

button to highlight the “Service Parameters” menu.
• Brake Press the “OK” button in order to access the “Service
Parameters” menu. The following options will be
• VIMS Main displayed:

• VIMS Application • “Sort By ECM”

• Object Detect System • “Sort By Type”

Use the appropriate up arrow button or the down • All Parameters

arrow button in order to highlight the desired ECM.
Press the “OK” button to access the information for “ Sort By ECM””
the ECM. ECM information contains the following:
The “Sort By ECM” menu allows the user to view the
• Serial number of the ECM parameters that are associated with each ECM. Use
the appropriate up arrow button or the down arrow
• Part number of the software button to highlight “Sort By ECM” . Press the “OK”
button. All of the parameters for the specific ECM are
• Release date of the software listed.
• Description of the software
KENR9938-14 31
Systems Operation Section

“ Sort By Type””
The “Sort By Type” menu allows the user to view the
parameters that are associated with different
components. Use the appropriate up arrow button or
the down arrow button to highlight the “Sort By Type”
menu. Press the “OK” button. A list of the types of
parameters is displayed. Use the up arrow button
and the down arrow button and press the “OK” button
to select the desired type. The following types of
parameters can be chosen:
• Fluid Levels
• Fuel Monitoring

• Machine Status
• Operator Inputs

• Pressures
• Speeds

• Temperatures
• Tire Monitoring

• Totals - Lifetime
• Totals - Reset

• Installation
32 KENR9938-14
Systems Operation Section

Settings Menu
KENR9938-14 33
Systems Operation Section

Illustration 38 g02709905
34 KENR9938-14
Systems Operation Section

“Settings” menu

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 Illustration 40 g02710013
the need to adjust the parameters. Parameters that
are displayed are determined by the configuration The “Settings” screen
and the options on the machine. The options on the
machine can determine the software versions that The “Settings” menu organizes the parameters into
are contained in the Electronic Control Modules six categories. These categories have adjustable
(ECM). The Advisor menu display may change parameters. The menu options are displayed on the
according to the software versions that are used for left half of the screen, and the information is
the ECM on the machine. displayed on the right half of the screen.

Note: Caterpillar Electronic Technician (Cat ET) may To adjust the associated parameters, the Advisor
also be used in order to change settings. 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 adjust the
parameter.

“ Display Setup””
From the “Display Setup” menu, use the appropriate
up arrow button or the down arrow button to highlight
the desired parameter. Then press the “OK” button to
have access to the parameter on the 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
Illustration 39 g02175803 the Advisor display. The following parameters may be
Select “Settings” from the screen. adjusted:

The “Settings” menu option is entered by selecting • “Language”

“Settings” from the Home menu. Press the up arrow
button or the down arrow button until “Settings” is • “Units”
highlighted in order to select the “Settings” menu.
Then press the “OK” button. Refer to Illustration 39 . • “Contrast”

Note: The Home menu can be displayed from any • “Lights ON”
screen by pressing the Home button.
• “Lights OFF”
The following screen will now be displayed.
• “Date Format”

• “Time Format”
KENR9938-14 35
Systems Operation Section

Engine • Tire Monitoring

From the “Engine” menu, use the appropriate “Up” or Note: “Forced Fuel Economy Mode Configuration”
“Down” arrow the highlight the desired information has the following five options:
and press the “OK” button. The following information
is accessible: • Automatic - This overrides cab switch and
leaves the machine in the Adaptive Mode.
“ Machine”” • Not Forced - This overrides cab switch and
leaves the machine in the Power Mode.
From the “Machine” menu, use the appropriate up
arrow button or the down arrow button in order to • Manual - This overrides cab switch and leaves
highlight the desired parameter. Then press the “OK”
button to have access to the parameter on the the machine in standard economy.
screen. The following information may be viewed:
• On
• “Top Gear Limit”
• Off - This option allows switch in cab to control
• “Machine Overload Speed Limit” the fuel economy mode.

• “Machine Loaded Speed Limit” “ Brake””

• “Machine Overload Speed Limit” From the “Brake” menu, press the “OK” button in
order to view, and have access to the desired
• “Machine Speed Limit” information. All of the information in this category
relates to the Retarder. The following information
• “Fuel Economy Mode” may be viewed:
• “Product ID” • “Desired Engine Retard Speed”
• “Equipment ID”
“ VIMS””
“ Chassis”” From the “VIMS” menu, use the appropriate up arrow
button or the down arrow button to view the desired
From the “Chassis” menu, use the appropriate up information. Then press the “OK” button to have
arrow button or the down arrow button to view the access to the information on the screen. The
desired information. Then press the “OK” button to following information may be viewed:
have access to the information displayed on the
screen. The following information may be viewed: VIMS “ Payload””
• Autolube Duration
• “Payload Target Weight”
• Autolube Interval
• “Payload Ovrld Limit”
• Economy Mode Percent
• “Payload Last Pass Status”
• Forced Fuel Economy Mode Configuration (see
Note) VIMS “ Conditional Logger””
• Load Count Body • “Conditional Logger”
• Machine Body Up Speed Limit

• Machine Overload Speed Limit Enable Status

• Maximum Forward Ground Speed

• Maximum Reverse Ground Speed

• Transmission Second Forward Gear Start Feature
Enable Status
• Send Red Engine Speed
• Send Red Test Mode

• Top Gear Limit

36 KENR9938-14
Systems Operation Section

Service Mode Menu Home Menu

Illustration 41 g02175804 Illustration 42 g02711260

The “Service Mode” menu option is accessed from The “Home Menu” screen is the default screen for
the “Home” menu. Press the up arrow button or the Messenger. This screen allows the operator to
down arrow button until “Service Mode” is access different function screens by highlighting the
highlighted. Then press the “OK” button. appropriate title with the “up” and “down” buttons and
pressing the “OK” button. Refer to figure 42 for
The “Service Mode” menu is used in order to access menus accessible from the “home menu” .
the password protected menu options. The “Service
Mode” protects certain features from access by the
operator. Features that are protected from the
operator can be “enabled” or “disabled” with a
password.
Note: A password may, or may not, be required
dependent on the settings that were made in Cat ET.
A Service Tool must be used to program the
password into the display. The password cannot be
changed within the Advisor.

i04529054

Menus (Messenger)
SMCS Code: 7490
The Messenger is an option on all 770G and 772G.
KENR9938-14 37
Systems Operation Section

Operator Menu • Set to Factory Defaults.

The profile of an operator is a saved set of
preferences that are identified by a name. Once the
profile is created, the operator may associate various
display settings and settings for the power train to
that profile. After all of the parameters have been
adjusted to the preference of the operator, you may
then save the parameters for future usage.

Illustration 44 g02711584

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” appears. Then press the “OK” button.
Refer to Illustration 44 .

Note: The Home menu can be displayed from any

screen by pressing the Home button.
The “Operator” menu contains the following options:
• “Operator ID”
• “Select Profile”

• “Edit/Save Current”
• “Create Profile”

• “Delete Profile”
• “Factory Set”
To access the “Operator” menu option, press the up
arrow button or the down arrow button until the
desired category appears. Then press the “OK”
button. The following explains the usage of each
Illustration 43 g02711256 menu option.
The selection menu for the operator

The “Operator” menu allows the user to perform the

Select a Profile
following: From the “Operator” menu, use the appropriate arrow
button to highlight the “Select Profile” option. Then
• Select a profile. press the “OK” button in order to display a list of
existing profiles. Again, use the appropriate arrow
• Edit/Save a current profile.
button to highlight the desired profile. Then press the
• Create a profile. “OK” button in order to select that profile.

• Delete a profile. Note: A maximum of ten profiles may be used.

38 KENR9938-14
Systems Operation Section

Create a Profile Monitor Menu

From the “Operator” menu, use the appropriate arrow
button to highlight the “Create Profile” option. Then
press the “OK” button in order to display the “Create
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 ten profiles may be used.

Delete a Profile
From the “Operator” menu, use the appropriate arrow Illustration 45 g02711588
button to highlight the “Delete Profile” option. Then
press the “OK” button in order to display a list of The “Monitor” menu option is entered by selecting
existing profiles. Use the appropriate arrow button to “Monitor” from the Home menu. The Home menu can
highlight the profile for deleting. Then press the “OK” be displayed from any screen by pressing the Home
button in order to delete that profile. This procedure button. Press the up button or the down button until
deletes the selected profile from the list of stored the “Monitor” appears in order to select the menu.
profiles. Then, press the “OK” button in order to select the
“Monitor” menu.
Edit/Save Current The “Monitor” menu option allows the user to view
From the “Operator” menu, use the appropriate arrow machine parameters. Use the navigation buttons in
button to highlight the “Edit/Save Current” option. order to select the parameter. Also, use the
Then, press the “OK” button in order to view the navigation buttons to view a different parameter.
settings that are associated with the current profile. Press the “OK” button in order to attain a list of
available parameters.
This procedure will cause the current settings of the
selected profile to be displayed on the screen. The Payload Menu
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
From the “Operator” menu, use the appropriate arrow
button to highlight the “Factory Set” option. Then
press the “OK” button in order to make the default
settings active.
This procedure recalls the default settings. The
default settings are then the active settings and the Illustration 46 g02711592
Messenger display and the instrument cluster will
reflect the default settings. Once the default settings The “Payload” menu option is entered by selecting
have been activated, the settings may be viewed “Payload” from the Home menu. Press the up button
without saving using the “Edit/Save Current” option. or the down button until the “Payload” appears in
order to select the menu. Then, press the “OK” button
The default settings will not be saved with the current in order to select the “Payload” menu.
profile unless the operator saves the default settings
to a profile by using the “Edit/Save Current” option. 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.
KENR9938-14 39
Systems Operation Section

Note: The Home menu can be displayed from any

screen by pressing the Home button.
40 KENR9938-14
Systems Operation Section

Settings Menu
KENR9938-14 41
Systems Operation Section

Illustration 47 g02711252
42 KENR9938-14
Systems Operation Section

“Settings” menu

The “Settings” menu allows the user to view and to To adjust the associated parameters, the Messenger
adjust parameters for the following: must be placed in the Service mode. Refer to the
Systems Operation, KENR9023, “Service Mode”
• “Display Setup” section of this manual for more information. Press the
up arrow button or the down arrow button until the
• “Engine” desired parameter appears. Then press the “OK”
button in order to access the parameter. Follow the
• “Machine” instructions on the screen in order to adjust the
parameter.
• “Chassis”

• “Brake” “ Display Setup””

• “VIMS” From the “Display Setup” menu, use the appropriate

up arrow button or the down arrow button in order to
Operating conditions, preferences of the operator highlight the desired parameter. Then press the “OK”
and requirements for operating efficiency determine button. This will allow access to that parameters
the need to adjust the parameters. Parameters that screen. Then follow the instructions on the screen in
are displayed are determined by the configuration order to adjust the parameter. All of the parameters in
and the options on the machine. The options on the this category relate to the preferences of the operator
machine can determine the software versions that in regard to the Messenger display. The following
are contained in the Electronic Control Modules parameters may be adjusted:
(ECM). The Messenger menu display may change
according to the software versions that are used for • “Language”
the ECM on the machine.
• “Units”
Note: Caterpillar Electronic Technician (Cat ET) may
also be used in order to change settings. • “Contrast”

• “Lights ON”
• “Lights OFF”

“ 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:
• “Top Gear Limit”

• “Machine Overload Speed Limit”

Illustration 48 g02711596 • “Machine Loaded Speed Limit”

The “Settings” menu option is entered by selecting • “Machine Ovrld Speed Limit”
“Settings” from the Home menu. Press the up arrow
button or the down arrow button until “Settings” • “Machine Speed Limit”
appears in order to select the “Settings” menu. Then
press the “OK” button. Refer to Illustration 48 . • “Fuel Economy Mode”

Note: The Home menu can be displayed from any • “Product ID”
screen by pressing the Home button.
• “Equipment ID”
The “Settings” menu organizes the parameters into
six categories. These categories have adjustable “ Chassis””
parameters. The menu options are displayed on the
left half of the screen, and the information is From the “Chassis” menu, use the appropriate up
displayed on the right half of the screen. 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:
KENR9938-14 43
Systems Operation Section

• Top Gear Select

• Body Up Speed Limit

• Max Forward Speed Limit

• Max Reverse Speed Limit

• Economy %
• Sound Reduction Test Mode

• Second Gear Shift

• Load Count Body

• Machine Overspeed Speed Limit

• Auto Lube Duration

• Tire Monitoring

“ Brake””
From the “Brake” menu, press the “OK” button in
order to view the desired information. This will allow
access to that screen. All of the information in this
category relates to the retarder. The following
information may be viewed:
• “Desired Engine Retard Speed”

“ VIMS””
From the “VIMS” 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:

VIMS “ Payload””
• “Payload Target Weight”
• “Payload Ovrld Limit”

• “Payload Last Pass Status”

Engine
From the “Engine” menu, use the appropriate “Up” or
“Down” arrow the highlight the desired information
and press the “OK” button. The following information
is accessable:
• EIS Delay Time

• EIS Enable Start

• EIS Max Air Temp

• EIS Min Air Temp

• Ether Solenoid
44 KENR9938-14
Systems Operation Section

Service Menu
KENR9938-14 45
Systems Operation Section

Illustration 49 g02711257
46 KENR9938-14
Systems Operation Section

The “Service” menu is entered by selecting “Service” Active Events

from the “Home Menu” . Press the up arrow button or
the down arrow button until “Service” appears to The “Active Events” menu shows the ECM and the
select the “Service” menu. Press the “OK” button. service hours for each event. Press the “OK” button
Refer to Illustration 50 . to view the information for the active event. The
following is a list of information that is displayed for
Note: The “Home Menu” can be displayed from any the active event:
screen by pressing the “Home” button.
• Electronic Control Module
• Event Code

• Date of occurrence
• Time of occurrence
• Warning Level

• Number of occurrences

Logged Events
The “Data Logger Start” menu allows the user to
initiate the data logger. The total logging time for the
data logger is 30 minutes. The operator can start and
Illustration 50 g02711599 stop the data logger until 30 minutes of time is
logged. The status of the data logger is shown in the
The “Service” menu contains seven sub menus. right portion of the screen on the Messenger. “Data
Logger Stop” will change to “Data Logger Start” when
• “Diagnostics” the data logger is no longer recording data. The
remaining storage time of the data logger is shown
• “Service Parameters” on the message area when the user highlights “Data
Logger Reset” on the Messenger display. The format
• “Calibrations” of the time is shown in “minutes:seconds” .
• “System Tests” Note: If information from the data logger is being
downloaded from the machine, the data logger
• “System Information” cannot be started.
• “Service Lamp”
“ Data Logger Reset””
• “Tattletale”
The “Data Logger Reset” menu allows the user to
The following explains the usage of each sub menu. reset the data logger. This option clears all of the
logged information. Select the “Data Logger Reset”
Diagnostics menu item. The Messenger shows the time that is
available for the data logger on the right side of the
From the “Service” menu, use the appropriate arrow screen. 30 minutes will be available after the data
button to highlight the “Diagnostics” menu. Press the logger has been reset.
“OK” button to access the “Diagnostics” menu. The
“Diagnostics” menu will display the following: Note: The Data Logger is the only onboard file that
can be reset through the Messenger display. The
• “Active Events” Messenger must be in the Service Mode or Cat ET
must be connected to the data link to reset the data
• “Logged Events” logger. The VIMSpc software is not needed in order
to reset the data logger.
• “Trigger Snapshot”
• “Data Logger” “ Service Parameters””
From the “Service” menu, use the appropriate arrow
button to highlight the “Service Parameters” menu.
Press the “OK” button in order to access the “Service
Parameters” menu. The following options will be
displayed:

• “Sort By ECM”
KENR9938-14 47
Systems Operation Section

• “Sort By Type” “ System Information””

“ Sort By ECM”” The “System Information” menu allows the user to

view the information for ECM that are on machine.
When the “System Information” menu is selected, a
The “Sort By ECM” menu allows the user to view the submenu is displayed. The submenu displays the
parameters that are associated with each ECM. Use ECM on the data link. The following is a typical list of
the appropriate up arrow button or the down arrow ECM for a VIMS 3G QCT:
button to highlight “Sort By ECM” . Press the “OK”
button. All of the parameters for the specific ECM are • Messenger
listed.
• Engine
“ Sort By Type””
• Chassis
The “Sort By Type” menu allows the user to view the
parameters that are associated with different • Brake
components. Use the appropriate up arrow button or
the down arrow button to highlight the “Sort By Type” • VIMS Main
menu. Press the “OK” button. A list of the types of
parameters is displayed. Use the up arrow button • VIMS Application
and the down arrow button and press the “OK” button Use the appropriate up arrow button or the down
to select the desired type. The following types of arrow button in order to highlight the desired ECM.
parameters can be chosen: Press the “OK” button to access the information for
the ECM. ECM information contains the following:
• Fluid Levels
• Serial number of the ECM
• Fuel Monitoring
• Part number of the software
• Machine Status
• Release date of the software
• Operator Inputs
• Description of the software
• Pressures
• Speeds Tattletale
• Temperatures From the “Service” menu, use the appropriate arrow
button to highlight the “Tattle Tale” menu. Press the
• Tire Monitoring “OK” button to access the Tattletale menu. The
following options are available under Tattletale:
• Totals - Lifetime
• Active
• Totals - Reset
• Brake Oil Temperature
• Installation
• Engine Coolant Temperature
Calibrations • Engine Speed
Press the “OK” button to enter the “Calibration” • Torque Converter Temperature
menu. Use the appropriate arrow button to highlight
the desired calibration from the list. Press the “OK” • Fuel Level
button. Follow the directions that are displayed on the
screen to perform the calibration. • DEF Level (for prefixes KDH and KEX only)

System Tests Any option from the prior list can be selected. The
“Active” option will display the tattletale value for
From the “Service” menu, use the appropriate arrow each gauge. The five specific options will display that
button to highlight the “System Tests” menu. Press tattletale value for the gauge that is specified.
the “OK” button in order to access the “System Tests”
menu. Note: Tattletale is password protected. The value for
each gauge is protected from being cleared.
48 KENR9938-14
Systems Operation Section

Service Mode Menu

Illustration 51 g02711616

The “Service Mode” menu option is accessed from

the “Home” menu. Press the up arrow button or the
down arrow button until “Service Mode” appears.
Then press the “OK” button.
The “Service Mode” menu is used in order to access
the password protected menu options. The “Service
Mode” protects certain features from access by the
operator. Features that are protected from the
operator can be “enabled” or “disabled” with a
password.
Note: A password may be required or a password
may not be required. This depends on the settings
that have been made in Cat ET.
A Service Tool must be used to program the
password into the display. The password cannot be
changed within the Messenger.
KENR9938-14 49
Introduction

Troubleshooting Section Failure of an electrical component can cause the

failure of other components. Also, failure of an
electrical component can be caused by the failure of
other components. Always attempt to correct the
Introduction cause of an electrical system failure before you
replace a component.

i06694175

i03938282 Service Tools

General Information SMCS Code: 0785

SMCS Code: 7000 The following service tools should be used to aid in
troubleshooting the electrical system.
The diagnostics for the electronic control module Table 3
(ECM) can be accessed through one of the following
tools: the Vital Information Management System Service Tools
(VIMS) and Caterpillar Electronic Technician (Cat Part Number Part
ET). Troubleshooting the transmission system
requires additional information from the Service Caterpillar Electronic Technician (ET)
Manual of the machine. The following list contains
237-5130 Digital Multimeter
some of the required support materials: Service
Manual, KENR9960, “773G/775G Chassis Electronic 257-9140 Digital Multimeter
Control”, the Electrical System Schematic, the Parts
Manual and the Operation and Maintenance Manual. 8T-3224 Needle Tip Group

As a guide, a typical system schematic is included in 7X-1710 Multimeter Probe Group

this manual. For an accurate representation of the
8T-8726 Adapter Cable Assembly
machine that is being diagnosed, refer to Electrical
System Schematic in the Service Manual for the 9U-7246 Connector Repair Kit
machine that is being serviced. DT (less crimp tool)

When the troubleshooting procedure instructs you to 1U-5804 Crimp Tool

“REPAIR THE HARNESS OR REPLACE THE
HARNESS”, use the Electrical System Schematic for 4C-3406 Connector Repair Kit
the machine that is being serviced to trace the circuit.
4C-8195 Control Service Tool (Switch Box)
Perform continuity checks at the harness connectors
in order to locate harness failures. At the connectors 276-7273 Sensor Test Box (1)
of the components, always check the ground circuit.
Less than 5 ohms of resistance is required between (1) An instrument that is used to monitor the sensors of the
the ground contacts of the connector and the frame cylinder
ground. The power circuits of the ECM should have
less than 2 ohms of resistance between the contacts
of the ground connector and the frame ground. Less
than 5 ohms of resistance is required for signal
circuits for normal operation. Excessive ground
resistance that is greater than 5 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.
50 KENR9938-14
Introduction

Illustration 52 g06079957
Connections for the Communication Adapter II and the Caterpillar Electronic Technician (ET)
The components that are needed to use the Communication Adapter II and the Caterpillar Electronic Technician (
ET) to determine diagnostic codes are listed:
(1) 14 Pin Connector ( Only for 777E and (3) “Service Diagnostic Cable” (5) Current version of Cat ET software and
773E Off-Highway trucks) (4) 171-4400 Communication Adapter II an IBM COMPATIBLE personal
(2) 9 Pin Connector computer

Reference: See Special Publication, NEHS0758, To use Cat ET, order the following materials: Special
“Communications Adapter II User's Manual Contains Publication, JERD2129, “ET Single Use Program
Software”. License”, Special Publication, JEHP1026,
“Information and Requirements Sheet”, 7X-1425
Note: Caterpillar Electronic Technician (ET) is a Data Link Cable and the Data Subscription and
software program that can be used on an IBM Special Publication, JERD2142, “Data Subscription”.
compatible personal computer. The Special Publication, JEHP1026, “Information and
Requirements Sheet” lists the required hardware and
the features of Cat ET.
KENR9938-14 51
Introduction

Cat ET is not required to determine the diagnostic • The “Harness Connector Location” table uses
codes and Cat ET is not required to clear the white circles to mark the locations in the general
diagnostic codes. However, the process of view and in the area views. Alphabetical letters in
determining the diagnostic codes is easier and faster the “Machine Location” column indicate a general
by using Cat ET. Cat ET can also display information area of the vehicle. Refer to the corresponding
on the history of a diagnostic code and the parameter footnote at the end of the table for a description of
status of diagnostic codes. These features allow Cat the location.
ET to be a useful tool for troubleshooting.
Cat ET is used to communicate to the electronic Connector Contact Numbers
control module over the data link by connecting to the
machine diagnostic connector. For more information
and the locations of the connectors, see
Troubleshooting, “Electrical Components and
Connector Locations” and the Electrical System
Schematic in your machine's Service Manual.
For instructions on servicing Sure Seal connectors,
see Special Instruction, SMHS7531. For instructions
on servicing Deutsch connectors, see Special
Instruction, SEHS9615.
Use the digital multimeter for measuring resistance or
for measuring voltage. For instructions about the use
of the 257-9140 Digital Multimeter, see Special
Instruction, SEHS7734. The 7X-1710 Multimeter
Probe measures the voltage at the connectors
without disconnecting the connectors. The probe
cables are pushed into the back of the connector
along the wire. The 8T-8726 Adapter Cable has a
breakout with three pins. The adapter cable is used
for measurements in the sensor circuits.

Note: Except for harness tests, using continuity

testers such as the 8T-0500 Continuity Tester or Illustration 53 g01030469
voltage testers such as the 5P-7277 Voltage Tester Rear View of the Instrument Cluster
is not recommended for today's Caterpillar electrical
circuits.

i06245273

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.
• 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. Illustration 54 g03870432
Rear View of the Instrument Cluster for 777ESeries 2
for Off-Highway Truck/Tractors
52 KENR9938-14
Introduction

Illustration 55 g01324753
Instrument Cluster 24 pin Connector

Illustration 56 g02161093
(1) “CAT ET” connector

i06753614

Diagnostic Capabilities
SMCS Code: 1400
KENR9938-14 53
Introduction

Caterpillar Electronic Technician (Cat

ET)

Illustration 57 g03892241

(1) 14-pin connector (777E and 773E Off- (2) 9-pin connector
Highway Trucks

Cat ET is a software program that is used to access • Flash the Electronic Control Module (ECM). This
data. The service technician can use Cat ET to is done with the WINflash program. Refer to
perform maintenance on the machine. Some of the Service Manual, KENR9938, “Electronic Control
options that are available with Cat ET are listed Module (ECM) - Flash Program”.
below:
• Print reports.
• View diagnostic codes. Refer to Service Manual,
KENR9938, “Using the Caterpillar Electronic The following list contains some of the diagnostic
Technician to Determine Diagnostic Codes”. functions and programming functions that are
performed by the service tools.
• View the active event codes and logged event
codes. • The failures of the ECM system are displayed.
• View the status of parameters. • The status of most of the inputs and the outputs
are displayed.
• Clear the active diagnostic codes and clear logged
diagnostic codes. • The settings for the ECM are displayed.
• Perform the calibration of machine systems. • Display the status of the input and output
parameters in real time.
54 KENR9938-14
Introduction

• Display the clock hour of the internal diagnostic

clock.

• 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, KENR9938, “Diagnostic
Code List” for the list of diagnostic codes for the
ECM.
• Active diagnostic codes

• Logged diagnostic codes

Event Codes
Logged Event Codes

Illustration 58 g01961184
Typical Cat ET screen for logged events

An indicator for logged events is provided. The • The number of occurrences of the problem
indicator allows the service technician to track event
codes that are intermittent. The data for the logged • A time stamp will display the first occurrence of the
event will include the following information: problem.
• An Event Identifier (EID) • A time stamp will display the last occurrence of the
problem.
• A text description of the problem
KENR9938-14 55
Introduction

Status Groups For Cat ET

The Status groups are lists of machine parameters.
The status of the parameters is shown in real time.

Illustration 59 g01961185
Typical Cat ET Status Screen

i04536497 Level 2 – This warning level will indicate that the

operation of the machine should be changed or
Event Code List maintenance should be performed to the machine.
Possible damage to components on the machine
SMCS Code: 1400 may occur.

Table 4 Level 3 – This warning level will indicate that the

machine needs to have an immediate, safe
WARNING OPERATION emergency engine shutdown. Possible injury to the
Warning Level Action Alarm Action Advisor Dis-
operator or severe damage to components may
occur.
Indicator play Pop Up
Message
If an action alarm, alert indicator, or a warning occurs,
Level 1 OFF OFF ON
a pop-up message will override any screen that was
Level 2 OFF Flash ON and ON displayed on the Advisor display module.
OFF
Level 3 Pulse ON and Flash ON and ON
OFF OFF

Recommended actions to be taken by the machine

operator in response to the different warning levels.
Level 1 – This warning level will cause the involved
alert indicator to illuminate. A level 1 warning will
indicate that the operator should be aware of a
condition of one or more of the machine systems.
56 KENR9938-14
Introduction

Table 5
Event Codes for the Advisor
EID Warning Description
Level Activation
642 1 Display Button Stuck Display Button Stuck

861 1 Clock manual alignment required Display SHM is different from sync clock master
by more than 50 hours

1132 2 Inconsistent configuration detected Wrong instrument cluster

KENR9938-14 57
Diagnostic Code Procedures

Diagnostic Code (Table 6, contd)

Diagnostic Codes for the Caterpillar Advisor or Mes-
Procedures senger ECM (MID No. 053)(1)

For troubleshooting, see the procedure with the same

CID FMI.

CID / FMI Description

i04536543
CID 0800 - VIMS Main Module
Diagnostic Code List FMI 02 Incorrect signal.
SMCS Code: 7569 FMI 09 Abnormal update.

Use the Caterpillar Electronic Technician (ET) or the FMI 12 Failed component or device.
Caterpillar Advisor in order to determine the
diagnostic codes. After the diagnostic codes are CID 0811 - Gauge Cluster
determined, refer to the corresponding test FMI 09 Abnormal update.
procedure for more information. Perform the
procedure that corresponds to the diagnostic code CID 1089- VIMS Analysis Module
(CID and FMI). The following table is a list of possible
diagnostic codes for the power train, implement, and FMI 02 Data erratic, intermittent, or incorrect.
Caterpillar Advisor electronic control modules. FMI 09 Abnormal update.
The following table is a list of possible diagnostic FMI 14 Special Instruction.
codes for the Caterpillar Advisor.
Table 6 CID 1273- Chassis Control Module

Diagnostic Codes for the Caterpillar Advisor or Mes- FMI 02 Data erratic, intermittent, or incorrect.
senger ECM (MID No. 053)(1) FMI 09 Abnormal update.
For troubleshooting, see the procedure with the same FMI 14 Special Instruction.
CID FMI.
(1) For the Caterpillar Advisor ECM, the MID is 053. This table per-
CID / FMI Description tains only to a diagnostic code with a MID of 053.

CID 0168 - Electrical System Voltage

FMI 03 Voltage above normal or shorted high.

FMI 04 Voltage below normal or shorted low.

CID 0271 - Action Alarm

FMI 03 Voltage above normal or shorted high.

FMI 04 Voltage below normal or shorted low.

FMI 05 Current low

CID 0268 - Programmed Parameter Fault

FMI 02 Data erratic, intermittent, or incorrect.

CID 0533 - Brake Control Module

FMI 02 Data erratic, intermittent, or incorrect.

FMI 09 Abnormal update.

FMI 14 Special Instruction.

CID 0590 - Engine Electronic Control Module

FMI 02 Incorrect signal.

FMI 09 Abnormal update.

FMI 12 Failed component or device.

(continued)
58 KENR9938-14
Diagnostic Code Procedures

i04527947 The detailed view will display a text message. The

text message will include the following:
Using the Operator Monitor to • The reporting ECM (MID)
Determine Diagnostic Codes
• Identity of the component that has failed (CID)
SMCS Code: 7490; 7569
• An explanation of the failure
Note: The codes and the events that are displayed in
the Diagnostics option may be viewed at any time.
Logged codes cannot be cleared until the technician
has successfully entered the Four Digit Machine
Password. See Service Manual, KENR9022 for
additional information.

i05897609

Using Caterpillar Electronic

Technician to Determine
Diagnostic Codes
Illustration 60 g02710018 SMCS Code: 0785-UE; 7569
Advisor Diagnostic Screen
Perform the following steps to use Cat ® Electronic
Technician (Cat ET) Service Tool to determine
Perform the following to access the Diagnotics
diagnostic codes:
screen from the Service Menu:
1. Connect Cat ET to the machine.
1. Use the appropriate Arrow button to highlight the
Diagnostics option if using Advisor or make the 2. Turn the keyswitch on.
“Diagnostics” menu appear is using Messenger.
3. Start Cat ET.
2. Press the “OK” button to access the Diagnostics
Cat ET will initiate communication with the
screen.
Electronic Control Modules (ECMs) on the
The Diagnostics screen shows a complete list of all machine. After communication has been
active diagnostic codes and logged diagnostic codes. established, Cat ET will list the ECMs.
Each line on the list shows the following:
4. Select the desired ECM.
• MID
5. After the diagnostic codes have been determined
• CID with Cat ET, see the test procedure for the desired
diagnostic code.
• FMI
Reference: Troubleshooting, “Service Tools”
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 to access the codes and events
from the Diagnostics screen:
1. Use the appropriate Arrow button to highlight a
specific code (line on the list).
2. Press the “OK” button to display the line detailed
view.
KENR9938-14 59
Diagnostic Code Procedures

Active Diagnostic Codes

Illustration 61 g02355999
Typical Cat ® Electronic Technician (Cat ET) Service Tool screen for active diagnostic codes.

Cat ET has an active diagnostic code screen. The

screen shows component identifier (CID), failure
mode identifier (FMI) and text description of the
problem.
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 and perform the desired
procedure. Clear any diagnostic codes caused by the
procedure.

Note: Before performing a procedure, always check

all the circuit breakers. Repair the cause of any circuit
breaker that has been tripped.
60 KENR9938-14
Diagnostic Code Procedures

Logged Diagnostic Codes

Illustration 62 g02356001
Typical Cat ET screen for logged diagnostic codes.

Cat ET has a logged diagnostic code screen. Cat ET

will log diagnostic codes that are intermittent. The
logged diagnostic data includes component identifier
(CID), failure mode identifier (FMI), and a text
description of the problem. Also, the logged
diagnostic data includes the number of occurrences
of the problem and two time stamps. The time
stamps display the first occurrence and the most
recent occurrence of the problem.
KENR9938-14 61
Diagnostic Code Procedures

Diagnostics are logged in non-volatile memory. On B. Place CID 0168 FMI 03 on hold.
powerup, the ECM will clear any diagnostic codes
that have not been detected or active within the last C. View the status of the diagnostic code.
1000 hours of machine operation.
Expected Result:
i04526858
The diagnostic code is NO longer active.
MID 053 - CID 0168 - FMI 03 Results:
SMCS Code: 1406-038
• YES – The diagnostic code is NO longer active
Conditions Which Generate This Code: watch for a recurrence.

STOP.

• NO – The diagnostic code is active. The charging

system is charging at an excessive voltage.

Repair: Check the charging system. See

Special Instruction, REHS0354, “Charging
Illustration 63 g02709037
System Troubleshooting” for more information.
Schematic of the System Voltage STOP.
This diagnostic code is recorded when the ECM
reads the system voltage as being greater than 32 Test Step 3. CHECK THE BATTERY
DCV. VOLTAGE.
The possible causes of this diagnostic code are A. The engine should not be running.
listed:
B. At the battery, measure the voltage of the battery.
• A charging system component has failed.
Expected Result:
• The wiring of the machine harness has failed.
The voltage should measure less than 32 DCV.
• The ECM has failed. An ECM failure is unlikely.
Results:

Test Step 1. CHECK THE CHARGING • YES – The voltage measures less than 32 DCV.
SYSTEM. The ECM must be recording this diagnostic code
incorrectly. The ECM may have failed.
A. Turn the disconnect switch and the key start
switch to the ON position. Repair: An ECM failure is unlikely. Exit this
procedure and perform this procedure again. If
B. Place CID 0168 FMI 03 on hold. the cause of the diagnostic code is NOT found,
C. View the status of the diagnostic code. replace the ECM. See Troubleshooting,
“Electronic Control Module (ECM) - Replace”.
Expected Result:
STOP.
The diagnostic code is NO longer active.
• NO – The voltage measurement is greater than 32
Results: DCV. The charging system is charging at an
excessive voltage.
• YES – The diagnostic code is NO longer active.
Proceed to test step 2. Repair: Check the charging system.

• NO – The diagnostic code remains active.Proceed STOP.

to test step 3.

Test Step 2. CHECK THE CHARGING

SYSTEM AGAIN.
A. Start the engine.
62 KENR9938-14
Diagnostic Code Procedures

i04526860 Test Step 2. CHECK THE BATTERY

VOLTAGE.
MID 053 - CID 0168 - FMI 04
A. Measure the system voltage at the battery posts.
SMCS Code: 1406-038
Expected Result:
Conditions Which Generate This Code:
The voltage is greater than 24V.

Results:

• YES – The voltage is greater than 24 DCV.

Proceed to Test Step 3.

• NO – The voltage is less than 24 DCV.

Illustration 64 g02709037
Schematic of the System Voltage Repair: The charging system is not correct.
Check the charging system. See Special
This diagnostic code is recorded when the control Instruction, REHS0354, “Charging System
reads the electrical system voltage that is at contact 1 Troubleshooting”.
as being below normal range (less than 24V for 2
seconds). STOP.

The possible causes of this diagnostic code are Test Step 3. CHECK THE SYSTEM
listed:
VOLTAGE AT THE ECM
• A charging system component has failed.
A. Turn the disconnect switch and the key start
• The wire harness has failed. switch to the OFF position.

• The ECM has failed. An ECM failure is unlikely. B. Disconnect the machine harness connector from
the control.
System Response:
C. Turn the disconnect switch and the key start
The outputs of the control may operate incorrectly. switch to the ON position.

Note: Make sure that the 10 Amp fuse is not open. D. Run the engine at high idle.
E. At the machine harness connector for the ECM,
measure the voltage between contact 1 and
Test Step 1. CHECK FOR AN ACTIVE contact 2.
DIAGNOSTIC CODE
Expected Result:
A. Start the engine.
The voltage is greater than 24 DCV.
B. Run the engine at high idle.
C. View the status of the diagnostic code. Results:

Expected Result: • YES – The voltage is greater 24 VDC. A voltage

greater than 24VDC should not cause the
The diagnostic code is NOT active. diagnostic code.

Results: Repair: Inspect the connector. Connect the

machine harness to the ECM. Check all
• YES – The diagnostic code is NOT active. The connectors in the wire harness. If the CID 0168
problem does not exist at this time. Watch for a FMI F04 remains active, replace the control.
recurrence. See Troubleshooting, “Electronic Control
Module (ECM) - Replace”.
STOP.
STOP.
• NO – The diagnostic code is active.Proceed to
Test Step 2. • NO – The voltage is less than 24 VDC. The
machine harness has failed.
KENR9938-14 63
Diagnostic Code Procedures

Repair: Check the +battery circuit and the i03938372

ground circuit in the machine harness. Repair
the machine harness or replace the machine MID 053 - CID 0271 - FMI 03
harness.
SMCS Code: 7407-038
STOP.
Conditions Which Generate This Code:
i04526837

MID 053 - CID 0268 - FMI 02

SMCS Code: 7490-038

Conditions Which Generate This Code:

The electronic control module (ECM) detects that one
or more of the programmable parameters have not
been programmed. The data that is being received is
erratic, intermittent, or incorrect.

System Response:
A Level 2 warning will be generated when this CID
0268 FMI 02 diagnostic code is generated. Machine Illustration 65 g01942765
operation will be inhibited.
Schematic of the action alarm
Any unprogrammed parameters are set to the default
value. If the default setting of the configuration is not This diagnostic code is associated with the action
changed to the appropriate sales model, a diagnostic alarm. The FMI 03 means that the ECM has
determined that the voltage of the alarm circuit is
code is generated. The CID 0268 FMI 02 diagnostic
above normal.
code is generated in order to warn the service
personnel that the module must be configured. The possible causes of the diagnostic code are listed
below:
SYSTEM CONFIGURATION
• The alarm has failed.
A. Use the Caterpillar Electronic Technician (Cat ET)
in order to verify that the ECM is configured to the • The energize circuit of the alarm is shorted to the
default setting configuration. +battery circuit.

B. Reset the configuration to the appropriate sales • The ECM has failed. This is unlikely.
model for your machine.
Note: The following test procedure may create other
Note: Programming this parameter to the incorrect diagnostic codes. Ignore these created diagnostic
value will disable the machine until the parameter is codes and clear these diagnostic codes when the
corrected. Consult your dealer with any questions original diagnostic code has been corrected. Ensure
concerning this parameter. that the diagnostic code of CID 0271 FMI 03 is
active before performing this procedure.
Expected Result:
Note: Use the 146-4080 Digital Multimeter for the
The control module is configured correctly for the measurements in this procedure.
machine type. The CID 0268 FMI 02 diagnostic code
is not active.
Test Step 1. CHECK THE ENERGIZE
Results: CIRCUIT OF THE ALARM FOR A SHORT
• OK – The control module is configured correctly TO THE +BATTERY CIRCUIT.
for the machine type. The CID 0268 FMI 02 A. Turn the key start switch and the disconnect
diagnostic code is not active. switch to the OFF position.
STOP. B. Disconnect the machine harness connectors from
the alarm and the ECM.
64 KENR9938-14
Diagnostic Code Procedures

C. At the machine harness connector for the ECM, Repair: The initial diagnostic code was
measure the resistance from contact IC-23 (wire probably caused by a poor electrical connection
410-WH(White)) to all contacts that are used in the or a short at one of the harness connectors that
machine harness connectors for the ECM. was disconnected and reconnected. Resume
normal machine operation.
Expected Result:
STOP.
Each resistance measurement is greater than 5000
ohms. i03938369

Results: MID 053 - CID 0271 - FMI 05

SMCS Code: 7407-038
• OK – Each resistance measurement is greater
than 5000 ohms. The machine harness is correct. Conditions Which Generate This Code:
Proceed to Test Step 2.

• NOT OK – Each resistance measurement is not

greater than 5000 ohms. There is a short in the
machine harness. The short is between IC-23 (
410-WH(White)) and the circuit that has a low
resistance measurement.

Repair: Repair the machine harness or replace

the machine harness.

STOP.

Test Step 2. CHECK IF THE DIAGNOSTIC

CODE IS STILL ACTIVE.
Illustration 66 g01943113
A. Inspect the contacts of the harness connectors. Schematic of the action alarm
Clean the contacts of the harness connectors.
This diagnostic code is associated with the action
B. Reconnect all harness connectors. alarm. The FMI 05 means that the ECM has
determined that the current of the alarm circuit is
C. Turn the disconnect switch and the key start below normal.
switch to the ON position.
The possible causes of this diagnostic code are listed
D. Operate the machine. below:
E. Determine if the CID 0271 FMI 03 is active. • The energize circuit of the alarm is open.

Expected Result: • The return circuit of the alarm is open.

The CID 0271 FMI 03 is active. • The alarm has failed.

Results: • The ECM has failed. This is unlikely.

• YES – The CID 0271 FMI 03 is active. The Note: The following test procedure may create other
problem has not been corrected. The ECM may diagnostic codes. Ignore these created diagnostic
have failed. codes and clear these diagnostic codes when the
original diagnostic code has been corrected. Ensure
Repair: It is unlikely that the ECM has failed. that the diagnostic code of CID 0271 FMI 05 is
Exit this procedure and perform this procedure active before performing this procedure.
again. If the cause of the diagnostic code is not
Note: Use the 146-4080 Digital Multimeter for the
found, replace the ECM. See Troubleshooting,
measurements in this procedure.
“Electronic Control Module (ECM) - Replace”.

STOP.
Test Step 1. CHECK THE ALARM.
• NO – The CID 0271 FMI 03 is not active. The A. Turn the disconnect switch and the key start
problem does not exist at this time.
switch to the ON position. Do not start the engine.
KENR9938-14 65
Diagnostic Code Procedures

B. Disconnect the alarm with the active diagnostic Repair: The open is in wire 410-WH(White) or
code from the machine harness. in wire 208-BK(Black) of the machine harness.
Repair the machine harness or replace the
C. At the machine harness connector for the alarm, machine harness.
place a jumper wire from the positive contact (wire
410-WH(White)) to the negative contact (wire STOP.
201-BK(Black)).
D. Observe the status of the CID 0271 FMI 05. Test Step 3. CHECK IF THE DIAGNOSTIC
CODE REMAINS.
Expected Result:
A. Inspect the contacts of the harness connectors
The CID 0271 FMI 05 diagnostic code remains and clean the harness connectors.
active.
B. Reconnect all harness connectors.
Results: C. Turn the disconnect switch and the key start
switch to the ON position.
• YES – The diagnostic code remains active. The
jumper wire does not affect the diagnostic code. D. Operate the machine.
Proceed to Test Step 2.
E. Check the status of the CID 0271 FMI 05
• NO – The diagnostic is no longer active. The alarm diagnostic code.
has failed.
Expected Result:
Repair: The alarm has failed. Repeat this Test
The CID 0271 FMI 05 diagnostic code is active.
Step “CHECK THE ALARM” in order to verify
the failure of the alarm. Replace the alarm.
Results:
Verify that the new alarm corrects the problem.
• YES – The CID 0271 FMI 05 diagnostic code is
STOP.
active. The diagnostic code has not been
corrected. The ECM may have failed.
Test Step 2. CHECK THE HARNESS FOR
AN OPEN. Repair: It is unlikely that the ECM has failed.
Exit this procedure and perform this procedure
A. Turn the key start switch and the disconnect again. If the cause of the diagnostic code is not
switch to the OFF position. found, replace the ECM. See Troubleshooting,
“Electronic Control Module (ECM) - Replace”.
B. Disconnect the machine harness connector(s)
from the ECM. STOP.
C. The jumper wire that was installed in the previous
test remains in place. • NO – The CID 0271 FMI 05 is not active. The
diagnostic code does not exist at this time.
D. At the machine harness connector, measure the
resistance from signal contact IC-23 (wire Repair: The initial diagnostic code was
410-WH(White)) to contact IC-2 (wire probably caused by a poor electrical connection
201-BK(Black)). at one of the harness connectors that was
disconnected and reconnected. Resume
Expected Result: normal machine operation.

The resistance is less than 5.0 ohms. STOP.

Results:

• OK – The resistance is less than 5.0 ohms. The

machine harness is correct.Proceed to Test Step
3.

• NOT OK – The resistance is greater than 5 ohms.

The resistance measurement is not correct. There
is an open circuit in the machine harness.
66 KENR9938-14
Diagnostic Code Procedures

i03938370 The CID 0271 FMI 06 diagnostic code changes to a

CID 0271 FMI 05 diagnostic code when the alarm is
MID 053 - CID 0271 - FMI 06 disconnected.
SMCS Code: 7407-038 Results:
Conditions Which Generate This Code: • YES – The CID 0271 FMI 06 diagnostic code
changes to a CID 0271 FMI 05 diagnostic code
when the alarm is disconnected. The circuit is
correct.

Repair: The alarm has failed. Repeat this test

“CHECK THE ALARM” in order to verify the
failure of the alarm. Replace the alarm.

STOP.

• NO – The CID 0271 FMI 06 diagnostic code

remains active.Proceed to Test Step 2.

Test Step 2. CHECK THE ENERGIZE

Illustration 67 g01943597 CIRCUIT OF THE ALARM FOR A SHORT
Schematic of the action alarm TO GROUND.
This diagnostic code is associated with the action A. Turn the key start switch and the disconnect
alarm. The FMI 06 means that the ECM has switch to the OFF position.
determined that the current of the alarm circuit is
above normal or grounded to the circuit. B. The alarm remains disconnected from the
machine harness.
The possible causes of this diagnostic code are listed
below: C. Disconnect the machine harness connector(s)
from the ECM.
• The energize circuit of the alarm is shorted to
ground. D. At the machine harness connector, measure the
resistance from the signal contact IC-23 (wire
• The alarm has failed. 410-WH(White)) to all contacts that are used in the
• The ECM has failed. This is unlikely. machine harness connectors for the ECM.

Note: The following test procedure may create other Expected Result:
diagnostic codes. Ignore these created diagnostic
codes and clear these diagnostic codes when the Each resistance measurement is greater than 5000
ohms.
original diagnostic code has been corrected. Ensure
that the diagnostic code of CID 0271 FMI 06 is
Results:
active before performing this procedure.
Note: Use the 146-4080 Digital Multimeter for the • OK – Each resistance measurement is greater
measurements in this procedure. than 5000 ohms. The machine harness is correct.
Proceed to Test Step 3.

• NOT OK – Each resistance measurement is not

Test Step 1. CHECK THE ALARM. greater than 5000 ohms. There is a short in the
A. Turn the disconnect switch and the key start machine harness. The short is between IC-23
switch to the ON position. Do not start the engine. (wire 410-WH(White)) and the circuit with the low
resistance measurement.
B. Observe the status of the diagnostic code.
Repair: Repair the machine harness or replace
C. Disconnect the alarm with the active diagnostic
the machine harness.
code from the machine harness.
STOP.
Expected Result:
KENR9938-14 67
Diagnostic Code Procedures

Test Step 3. CHECK IF THE DIAGNOSTIC i06753627

CODE REMAINS.
MID 053 - CID 0533 - FMI 02
A. Inspect the harness connectors and clean the
contacts of the harness connectors. SMCS Code: 7610-038-BRK

B. Reconnect all harness connectors. Conditions Which Generate This Code:

C. Turn the disconnect switch and the key start
switch to the ON position.
D. Operate the machine.
E. Check the status of the CID 0271 FMI 06
diagnostic code.

Expected Result:
The CID 0271 FMI 06 diagnostic code is active.

Results:

• YES – The CID 0271 FMI 06 diagnostic code is

active. The diagnostic code has not been
corrected. The ECM may have failed.

Repair: It is unlikely that the ECM has failed.

Exit this procedure and perform this procedure
again. If the cause of the diagnostic code is not
found, replace the ECM. See Troubleshooting,
“Electronic Control Module (ECM) - Replace”.

STOP.

• NO – The CID 0271 FMI 06 diagnostic code is not

active. The diagnostic code does not exist at this
time.

Repair: The initial diagnostic code was

probably caused by a poor electrical connection
or a short at one of the harness connectors that
was disconnected and reconnected. Resume
normal machine operation.
Illustration 68 g02714481

STOP. Schematic of the Cat Data Link for770G, 772G and

777G Off-Highway Trucks, 773G and 775G Quarry
Trucks
68 KENR9938-14
Diagnostic Code Procedures

Illustration 69 g03859095
Schematic of the Cat Data Link for 777E and 773E Off-Highway Trucks

This diagnostic code is recorded when the Brake Expected Result:

ECM dropped off the Cat Data Link 10 times within a
ten minute period for more than five seconds. The All part numbers are correct.
diagnostic code is active until communication is
reliable for more than ten minutes. Results:

System Response: • OK – All part numbers are correct.Proceed to test

step 2.
This failure results in events that are logged against
an ECM that cannot be explained. The power train • NOT OK – All part numbers are NOT correct.
ECM cannot communicate with this ECM or the ECM
appears to work intermittently.
Repair: It is unlikely that the ECM has failed.
Exit this procedure and perform this procedure
Test Step 1. VERIFY THE HARDWARE again. If the cause of the diagnostic code is not
AND THE SOFTWARE PART NUMBERS. found, replace the ECM. See Troubleshooting,
“Electronic Control Module (ECM) - Replace”.
A. Verify that the following information is correct:
STOP.
• The part number of the “power train onboard
flash software”
Test Step 2. INSPECT THE HARNESS
• The part number of the “advisor ECM flash CONNECTIONS.
software”
A. Turn the disconnect switch to the OFF position.
• The part number of the “power train ECM” B. Inspect all harness connections that are related to
the Cat Data Link. Make sure that the connectors
• The part number of the “advisor ECM”
are clean and tight.
Note: Consult the Business Unit that produces the C. Check the connectors for proper mating. Ensure
product for the correct part numbers of the that all the seals are present and in place.
configuration software.
KENR9938-14 69
Diagnostic Code Procedures

D. Check the harness for signs of damage or • OK – The resistance is greater than 5000 ohms.
abrasion. The harness circuit resistance is correct.Proceed
to test step 4.
E. Check the wires at the connector. Ensure that the
wires are secured tightly into the connector. Take • NOT OK – The resistance is less than 5000 ohms.
care not to pull the wire out of the connector. The machine harness has failed.
F. Check the exposed wires at the connectors for
Repair: There is a short between frame ground
nicks or signs of abrasion. and the Cat Data Link circuit in the machine
G. Check for moisture inside the connector. harness. Repair the machine harness or
replace the machine harness.
H. Check the connectors for dirty contacts or
corroded contacts. STOP.
I. Check each pin and each socket of the machine
harness connectors. Ensure that the contacts are Test Step 4. CHECK FOR SHORT TO
properly installed. The contacts should mate +BATTERY
correctly when the two pieces of the connector are A. The disconnect switch remains in the OFF
placed together. position.
Expected Result: B. All related electronic control modules remain
disconnected from the machine harness.
The machine harness connectors are tight and free
of corrosion. C. At the machine harness connector for the advisor
ECM, perform the checks that are listed here:
Results:
• Measure the resistance between the connector
• OK – The machine harness connectors are tight contact 1 (wire 145-RD(Red)) and connector
and free of corrosion.Proceed to test step 3. contact 8 (wire 893-GN(Green)).
• NOT OK – The machine harness connectors are in • Measure the resistance between connector
need of repair. contact 1 (wire 145-RD(Red)) and connector
contact 9 (wire 892-BR(Brown)).
Repair: Repair the machine harness or replace
the machine harness. Expected Result:
STOP. The resistance is greater than 5000 ohms.

Test Step 3. CHECK FOR SHORTS TO Results:

GROUND • OK – The harness circuit resistance is correct.
A. The disconnect switch remains in the OFF Proceed to test step 5.
position.
• NOT OK – The resistance is less than 5000 ohms.
B. Disconnect the machine harness from all The machine harness has failed.
electronic control modules that use the Cat Data
Link. Repair: There is a short between +battery and
the Cat Data Link circuit in the machine
C. At the machine harness for the advisor ECM, harness. Repair the machine harness or
measure the resistance between frame ground replace the machine harness.
and connector contacts 8 (wire 893-GN(Green))
and 9 (wire 892-BR(Brown)) of the Cat Data Link STOP.
circuit.
Test Step 5. CHECK FOR OPEN
Expected Result:
HARNESS
The resistance is greater than 5000 ohms. A. The disconnect switch remains in the OFF
position.
Results:
B. All related electronic control modules remain
disconnected from the machine harness.
70 KENR9938-14
Diagnostic Code Procedures

C. Check the continuity of the Cat Data Link circuit in Repair: The advisor ECM has failed. It is
the machine harness: unlikely that the ECM has failed. Exit this
procedure. Perform this procedure again. If the
• Measure the resistance between connector failure is not found, check the +battery contacts
contact J1-20 (wire 892-BR(Brown)) of the and ground contacts of the ECM. If these
power train ECM and connector contact 8 (wire contacts are correct, replace the ECM.
893-GN(Green)) of the advisor ECM.
STOP.
• Measure the resistance between connector
contact J1-10 (wire 893-GN(Green)) of the • NOT OK – Diagnostic codes are present for the
power train ECM and connector contact 9 (wire other electronic control modules (ECM).
892-BR(Brown)) of the advisor ECM.
Repair: The power train ECM has failed. It is
unlikely that the ECM has failed. Exit this
Expected Result:
procedure. Perform this procedure again. If the
The resistance measures less than 5 ohms. failure is not found, replace the ECM. See the
Troubleshooting, “Electronic Control Module
Results: (ECM) - Replace” section of this manual.

• OK – The resistance is less than 5 ohms. The Cat STOP.

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
ELECTRONIC CONTROL MODULES.
A. Turn the key start switch and the disconnect
switch to the OFF position.
B. One at a time, reconnect the electronic control
modules that use the Cat Data Link.
C. Turn the disconnect switch and the key start
switch to the ON position.
D. After each of the electronic control modules has
been reconnected, check the Event List for
diagnostic codes that are logged against the
electronic control module.

Expected Result:
Diagnostic codes are not present for the other
electronic control modules.

Results:

• OK – Diagnostic codes are not present for the

other electronic control modules.
KENR9938-14 71
Diagnostic Code Procedures

i06753639

MID 053 - CID 0533 - FMI 09

SMCS Code: 7610-038-BRK

Conditions Which Generate This Code:

Illustration 70 g02714481
Schematic of the Cat Data Link for770G, 772G and
777G Off-Highway Trucks, 773G and 775G Quarry
Trucks
72 KENR9938-14
Diagnostic Code Procedures

Illustration 71 g03859095
Schematic of the Cat Data Link for 777E and 773E Off-Highway Trucks

This diagnostic code is recorded when the Advisor Expected Result:

ECM does not receive expected information from the
Brake ECM through the Cat Data Link for a period of All part numbers are correct.
more than five seconds.
Results:
System Response:
• OK – All part numbers are correct.Proceed to test
This failure results in events that are logged against step 2.
an ECM that cannot be explained directly. The
Advisor ECM cannot communicate with this ECM or • NOT OK – All part numbers are NOT correct.
the ECM appears to communicate intermittently.
Repair: The installed Advisor ECM or the Brake
Test Step 1. VERIFY THE HARDWARE ECM has the wrong part number or the
AND THE SOFTWARE PART NUMBERS. incorrect configuration software is installed.
Replace the incorrect Advisor ECM or the
A. Verify that the following information is correct: Brake ECM with a module that has the correct
part number. Flash the correct configuration
• The part number of the “Advisor ECM onboard software. See the Testing and Adjusting,
software” “Electronic Control Module (ECM) - Flash
Program” section of this manual.
• The part number of the Brake ECM flash
software. STOP.
• The part number of the Advisor ECM
Test Step 2. INSPECT THE HARNESS
• The part number of the Brake ECM CONNECTIONS.
Note: Consult the Business Unit that produces the A. Turn the disconnect switch to the OFF position.
product for the correct part numbers of the
configuration software.
KENR9938-14 73
Diagnostic Code Procedures

B. Inspect all harness connections that are related to The resistance is greater than 5000 ohms.
the Cat Data Link. Make sure that the connectors
are clean and tight. Results:
C. Check the connectors for proper mating. Ensure • OK – The resistance is greater than 5000 ohms.
that all the seals are present and in place. The harness circuit resistance is correct.Proceed
to test step 4.
D. Check the harness for signs of damage or
abrasion. • NOT OK – The resistance is less than 5000 ohms.
E. Check the wires at the connector. Ensure that the The machine harness has failed.
wires are secured tightly into the connector. Take
care not to pull the wire out of the connector. Repair: There is a short between frame ground
and the Cat Data Link circuit in the machine
F. Check the exposed wires at the connectors for harness. Repair the machine harness or
nicks or signs of abrasion. replace the machine harness.

G. Check for moisture inside the connector. STOP.

H. Check the connectors for dirty contacts or
corroded contacts. Test Step 4. CHECK FOR SHORT TO
+BATTERY
I. Check each pin and each socket of the machine
harness connectors. Ensure that the contacts are A. The disconnect switch remains in the OFF
properly installed. The contacts should mate position.
correctly when the two pieces of the connector are
B. All related electronic control modules remain
placed together.
disconnected from the machine harness.
Expected Result: C. At the machine harness connector for the Advisor
ECM, perform the checks that are listed here:
The machine harness connectors are tight and free
of corrosion.
• Measure the resistance between the +Battery
Results: connector contact 1 (wire 113-OR(Orange))
and connector contact 8 (wire 893-GN(Green)).
• OK – The machine harness connectors are tight
and free of corrosion.Proceed to test step 3. • Measure the resistance between connector
contact 1 (wire 113-OR(Orange)) and
• NOT OK – The machine harness connectors are in connector contact 9 (wire 892-BR(Brown)).
need of repair.
Expected Result:
Repair: Repair the machine harness or replace
The resistance is greater than 5000 ohms.
the machine harness.
Results:
STOP.
• OK – The harness circuit resistance is correct.
Test Step 3. CHECK FOR SHORTS TO Proceed to test step 5.
GROUND
• NOT OK – The resistance is less than 5000 ohms.
A. The disconnect switch remains in the OFF The machine harness has failed.
position.
Repair: There is a short between the +battery
B. Disconnect the machine harness from all
and the Cat Data Link circuit in the machine
electronic control modules that use the Cat Data harness. Repair the machine harness or
Link. replace the machine harness.
C. At the machine harness for the Advisor ECM,
measure the resistance between frame ground STOP.
and connector contacts 8 (wire 893-GN(Green))
and connector contact 9 (wire 892-BR(Brown)) of Test Step 5. CHECK FOR OPEN
the Cat Data Link circuit. HARNESS
Expected Result:
74 KENR9938-14
Diagnostic Code Procedures

A. The disconnect switch remains in the OFF Repair: The Brake ECM has failed. It is unlikely
position. that the ECM has failed. Exit this procedure.
Perform this procedure again. If the failure is
B. All related electronic control modules remain not found, replace the ECM. See the Testing
disconnected from the machine harness. and Adjusting, “Electronic Control Module
(ECM) - Replace” section of this manual.
C. Check the continuity of the Cat Data Link circuit in
the machine harness:
STOP.
• Measure the resistance between connector
• NOT OK – Diagnostic codes are present for the
contact 8 (wire 893-GN(Green)) of the Advisor other electronic control modules in the event list.
ECM and connector contact J1-10 (wire
893-GN(Green)) of the Brake ECM. Repair: The Advisor ECM has failed. It is
unlikely that the ECM has failed. Exit this
• Measure the resistance between connector procedure. Perform this procedure again. If the
contact 9 (wire 892-BR(Brown)) of the Advisor failure is not found, replace the ECM. See the
ECM and connector contact J1-20 (wire Testing and Adjusting, “Electronic Control
892-BR(Brown)) of the Brake ECM. Module (ECM) - Replace” section of this
manual.
Expected Result:
STOP.
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
ELECTRONIC CONTROL MODULES.
A. Reconnect all the electronic control modules 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 electronic control
modules.

Expected Result:
Diagnostic codes are not present for the other
electronic control modules in the event list.

Results:

• OK – Diagnostic codes are not present for the

other electronic control modules (ECM) in the
event list.
KENR9938-14 75
Diagnostic Code Procedures

i06753655

MID 053 - CID 0533 - FMI 14

SMCS Code: 7610-038-BRK

Conditions Which Generate This Code:

Illustration 72 g02714481
Schematic of the Cat Data Link for770G, 772G and
777G Off-Highway Trucks, 773G and 775G Quarry
Trucks
76 KENR9938-14
Diagnostic Code Procedures

Illustration 73 g03859095
Schematic of the Cat Data Link for 777E and 773E Off-Highway Trucks

This diagnostic code is recorded when the Brake The proper versions of software are installed on the
ECM is not sending the necessary parameters to the Advisor ECM and the Brake ECM.
Advisor ECM at the proper rate. The update rate for
parameters that are generated by the Brake ECM is Results:
not correct. The communication failure may be due to
disconnected connectors or a faulty wiring harness. • YES – The versions of software are compatible.
Proceed to Test Step 2.
The possible causes of this diagnostic code are
listed:
• NO – The proper software is not installed.
• The Brake ECM has the incorrect software
installed. Repair: Flash the proper software to the
appropriate ECM. Cycle the key switch to
• The Advisor ECM has the incorrect software initialize the new software. Ensure that the
installed. diagnostic code is no longer active.

• Incompatible software may be installed. STOP.

• The fuse for the Brake ECM may have failed.
Test Step 2. RECHECK FOR DIAGNOSTIC
CODES.
Test Step 1. CHECK THE BRAKE ECM A. Ensure that diagnostic code is active.
AND THE ADVISOR ECM FOR PROPER
SOFTWARE VERSIONS. Expected Result:

A. Use Caterpillar Electronic Technician (ET) to verify The diagnostic code is inactive. The diagnostic code
that the versions of software are compatible. indicator is inactive.

Expected Result: Results:

KENR9938-14 77
Diagnostic Code Procedures

• YES – The diagnostic code indicator and the i06283972

diagnostic code are inactive.
MID 053 - CID 0590 - FMI 02
Repair: Clear the diagnostic code.
SMCS Code: 1901-038
STOP.
Conditions Which Generate This Code:
• NO – The diagnostic code is active.

Repair: Ensure that the proper software is

installed before replacing the ECM. If the
software is correct, replace the Advisor ECM.
See Testing and Adjusting, “Electronic Control
Module (ECM) - Replace”. If the Advisor ECM
was just replaced , install a new Brake ECM.
See Testing and Adjusting, “Electronic Control
Module (ECM) - Replace” for the machine that
is being serviced.

STOP.

Illustration 74 g02714481
Schematic of the Cat Data Link for 770G, 772G and
777G Off-Highway Trucks, 773G and 775G Quarry
Trucks
78 KENR9938-14
Diagnostic Code Procedures

Illustration 75 g03859095
Schematic of the Cat Data Link for 777E Series 2 and 773E Series 2Off-Highway Trucks

This failure results in codes that are logged against Results:

an ECM that is not communicating some expected
information to the Main Display Module. The Main • OK – All part numbers are correct.Proceed to test
Display Module cannot communicate with the Engine step 2.
ECM or the ECM appears to work intermittently.
• NOT OK – All part numbers are NOT correct. The
System Response: part number of the Main Display Module may be
Certain features may not function properly. incorrect. The part number of the Engine ECM
may be incorrect. The incorrect software for the
ECM may also be installed.
Test Step 1. VERIFY THE HARDWARE
AND THE SOFTWARE PART NUMBERS. Repair: Replace the incorrect ECM with an
ECM that has the correct part number. Flash
A. Verify that the following information is correct: the most current software. See
Troubleshooting, “Electronic Control Module
• The part number of the software for the Main (ECM) - Flash Program”.
Display Module
STOP.
• The part number of the “engine ECM software”

• The part number of the Main Display Module Test Step 2. INSPECT THE HARNESS
CONNECTIONS.
• The part number of the engine ECM
A. Turn the disconnect switch to the OFF position.
Note: Consult the Business Unit that produces the
product for the correct part numbers of the B. Inspect all harness connections that are related to
configuration software. the Cat Data Link. Make sure that the connectors
are clean and tight.
Expected Result: C. Check the connectors for proper mating.
All part numbers are correct. D. Check the wires at the connector.
KENR9938-14 79
Diagnostic Code Procedures

E. Check each wire for nicks or signs of abrasion in Repair: There is a short between frame ground
the insulation. and the Cat Data Link circuit in the machine
harness. Repair the machine harness or
F. Check for moisture at the connector. replace the machine harness.
G. Check the connectors for dirty contacts or
STOP.
corroded contacts.
H. Check each pin and each socket of the machine Test Step 4. CHECK FOR A SHORT TO
harness connectors. THE +BATTERY CIRCUIT.
Expected Result: A. The disconnect switch remains in the OFF
position.
The machine harness connectors are tight and free
of corrosion. B. All related electronic control modules remain
disconnected from the machine harness.
Results:
C. At the machine harness connector for the Main
• OK – The machine harness connectors are tight Display Module, perform the checks that are listed
and free of corrosion.Proceed to test step 3. here:

• NOT OK – The machine harness connectors are in • Measure the resistance between the connector
need of repair. contact 8 (wire 944-OR(Orange)) and all
sources of +battery.
Repair: Repair the machine harness or replace
the machine harness. • Measure the resistance between connector
contact 9 (wire 945-BR(Brown)) and all sources
STOP. of +battery.

Test Step 3. CHECK FOR SHORTS TO Expected Result:

GROUND. The resistance is greater than 5.0 ohms.
A. The disconnect switch remains in the OFF
position. Results:

B. Disconnect the machine harness from all • OK – The harness circuit resistance is correct.
electronic control modules that use the Cat Data Proceed to test step 5.
Link.
• NOT OK – The resistance is less than 5.0 ohms.
C. At the machine harness for the Main Display The machine harness has failed.
Module, measure the resistance between frame
ground and connector contact 8 (wire Repair: There is a short between the +battery
944-OR(Orange)) of the Cat Data Link circuit . circuit and the Cat Data Link circuit in the
machine harness. Repair the machine harness
D. At the machine harness for the Main Display or replace the machine harness.
Module, measure the resistance between frame
ground and connector contact 9 (wire STOP.
945-BR(Brown)) of the Cat Data Link circuit .
Test Step 5. CHECK FOR A OPEN
Expected Result:
HARNESS.
The resistances are greater than 5 ohms.
A. The disconnect switch remains in the OFF
Results: position.
B. All related electronic control modules remain
• OK – The resistances are greater than 5000 disconnected from the machine harness.
ohms. The harness circuit resistance is correct.
Proceed to test step 4. C. Check the continuity of the Cat Data Link circuit in
the machine harness:
• NOT OK – Any resistance is less than 5000 ohms.
The machine harness has failed.
80 KENR9938-14
Diagnostic Code Procedures

• Measure the resistance between connector Caterpillar. This consultation may greatly
contact 8 (wire 944-OR(Orange)) of the Main reduce repair time. If the failure is not found,
Display Module and connector contact 23 (wire replace the ECM.
944-OR(Orange)) of the Engine ECM.
STOP.
• Measure the resistance between connector
contact 9 (wire 945-BR(Brown)) of the Main • NOT OK – Diagnostic codes are present for the
Display Module and connector contact 24 (wire other electronic control modules (ECM).
945-BR(Brown)) of the Engine ECM.
Repair: Exit this procedure and perform the
diagnostic code procedure again. If the problem
Expected Result:
persists, the ECM may have failed. Prior to
The resistance measures less than 5 ohms. replacing an ECM, always contact your
dealership for possible consultation with
Results: Caterpillar. This consultation may greatly
reduce repair time. See the Troubleshooting,
• OK – The resistance is less than 5 ohms. The Cat “Electronic Control Module (ECM) - Replace”.
Data Link circuit in the machine harness is correct.
Proceed to test step 6. STOP.

• 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
ELECTRONIC CONTROL MODULES.
A. Reconnect all the electronic control modules that
use the Cat Data Link.
B. Turn the disconnect switch and the key start
switch to the ON position.
C. After each of the electronic control modules has
been reconnected, check the Event List for
diagnostic codes that are logged against the
electronic control module.

Expected Result:
Diagnostic codes are not present for the other
electronic control modules (ECM) in the event list.

Results:

• OK – Diagnostic codes are NOT present for the

other electronic control modules (ECM).

Repair: The engine ECM may have failed. It is

unlikely that the ECM has failed. Exit this
procedure. Perform this procedure again. Prior
to replacing an ECM, always contact your
dealership for possible consultation with
KENR9938-14 81
Diagnostic Code Procedures

i06753659

MID 053 - CID 0590 - FMI 09

SMCS Code: 1901-038

Conditions Which Generate This Code:

Illustration 76 g02714481
Schematic of the Cat Data Link for770G, 772G and
777G Off-Highway Trucks, 773G and 775G Quarry
Trucks
82 KENR9938-14
Diagnostic Code Procedures

Illustration 77 g03859095
Schematic of the Cat Data Link for 777E and 773E Off-Highway Trucks

This diagnostic code is recorded when the advisor All of the part numbers are correct.
does not receive expected information from the
engine ECM. The possible causes of this diagnostic Results:
code are listed:
• OK – All of the part numbers are correct.Proceed
• The wires for the Cat Data Link to the engine to Test Step 2.
ECM are open or the wires are shorted.

• The wrong software is installed on an ECM. • NOT OK – All of the part numbers are not correct.

Repair: The installed engine ECM or the

advisor have the wrong part number or the
Test Step 1. VERIFY THE HARDWARE incorrect flash software is installed. Replace the
AND THE SOFTWARE PART NUMBERS. engine ECM or replace the advisor that is
incorrect. Replace the ECM with a module that
A. Verify that the following information is correct: has the correct part number. Flash the correct
software. See Testing and Adjusting, “Electronic
• The part number of the flash software for the
Control Module (ECM) - Flash Program” for
engine ECM additional information.
• The part number of the flash software for the
STOP.
advisor

• The part number of the engine ECM Test Step 2. INSPECT THE HARNESS
CONNECTIONS.
• The part number of the advisor
A. Turn the disconnect switch to the OFF position.
Note: Consult your Caterpillar Dealer for the correct
part numbers of the flash software. B. Inspect all harness connections that are related to
the Cat Data Link. Make sure that the connectors
Expected Result: are clean and tight.
KENR9938-14 83
Diagnostic Code Procedures

C. Check the connectors for proper mating. Ensure • OK – Each of the resistance measurements is
that all the seals are present and in place. greater than 5000 ohms. The harness circuit
resistance is correct.Proceed to Test Step 4.
D. Check the harness for signs of damage or
abrasion. • NOT OK – One of the resistance measurements is
E. Check the wires at the connector. Ensure that the less than 5000 ohms. The machine harness has
failed.
wires are secured tightly into the connector. Take
care not to pull the wire out of the connector. Repair: There is a short between contacts 8
F. Check the exposed wires at the connectors for (wire 893-GN(Green)) or 9 (wire
nicks or signs of abrasion. 892-BR(Brown)) of the Cat Data Link and the
circuit with the low resistance measurement.
G. Check for moisture inside the connector. Repair the machine harness or replace the
machine harness.
H. Check the connectors for dirty contacts or
corroded contacts. STOP.
I. Check each pin and each socket of the machine
harness connectors. Ensure that the contacts are Test Step 4. CHECK FOR OPEN
properly installed. The contacts should mate HARNESS
correctly when the two pieces of the connector are
A. The disconnect switch remains in the OFF
placed together.
position.
Expected Result: B. All related electronic control modules remain
The machine harness connectors are tight and free disconnected from the machine harness.
of corrosion. C. Check the resistance of the Cat Data Link circuit in
the machine harness:
Results:
• Measure the resistance between connector
• OK – The machine harness connectors are tight contact J1-8 (wire 893-GN(Green)) of the
and free of corrosion.Proceed to Test Step 3.
engine ECM and connector contact 8 (wire
• NOT OK – The machine harness connectors are in 893-GN(Green)) of the advisor.
need of repair.
• Measure the resistance between connector
Repair: Repair the machine harness or replace contact J1-9 (wire 892-BR(Brown)) of the
the machine harness. engine ECM and connector contact 9 (wire
892-BR(Brown)) of the advisor.
STOP.
Expected Result:
Test Step 3. CHECK FOR SHORTS The resistance measures less than 5 ohms.
A. The disconnect switch remains in the OFF
Results:
position.
B. Disconnect the machine harness connectors from • OK – The resistance is less than 5 ohms. The Cat
all electronic control modules that use the Cat Data Link circuit in the machine harness is correct.
Data Link. Proceed to Test Step 5.

C. At the harness connector for the advisor, measure • NOT OK – The resistance is greater than 5 ohms.
the resistance between connector contact 8 (wire The machine harness has failed.
893-GN(Green)) and all of the contacts that are
used in the machine harness connector for the Repair: The Cat Data Link circuit is open in the
advisor. Perform the same measurements for machine harness. Repair the machine harness
or replace the machine harness.
connector contact 9 (wire 892-BR(Brown)).
STOP.
Expected Result:
Each resistance measurement is greater than 5000 Test Step 5. CHECK IF THE DIAGNOSTIC
ohms.
CODE REMAINS
Results:
84 KENR9938-14
Diagnostic Code Procedures

A. Inspect the contacts of the harness connectors i06753662

and clean the contacts.
B. Reconnect all harness connectors.
MID 053 - CID 0590 - FMI 14
SMCS Code: 1901-038
C. Turn the disconnect switch and the key start
switch to the ON position. Conditions Which Generate This Code:
D. Operate the machine.
E. Check the status of the CID 0590 FMI 09.

Expected Result:
The CID 0590 FMI 09 is active.

Results:

• YES – The CID 0590 FMI 09 is active. The

diagnostic code has not been corrected. The ECM
may have failed.

Repair: It is unlikely that the ECM has failed.

Exit this procedure and perform this procedure
again. If the cause of the diagnostic code is not
found, replace the ECM. See Testing and
Adjusting, “Electronic Control Module (ECM) -
Replace”.

STOP.

• NO – The CID 0590 FMI 09 is not active. The

diagnostic code does not exist at this time.

Repair: The initial diagnostic code was

probably caused by a poor electrical connection
or a short at one of the harness connectors that
was disconnected and reconnected. Resume
normal machine operation.

STOP.

Illustration 78 g01816865
Schematic of the Cat Data Link for770G, 772G and
777G Off-Highway Trucks, 773G and 775G Quarry
Trucks
KENR9938-14 85
Diagnostic Code Procedures

Illustration 79 g03859095
Schematic of the Cat Data Link for 777E and 773E Off-Highway Trucks

This diagnostic code is recorded when the Engine The proper versions of software are installed on
ECM is not sending the necessary parameters to the theAdvisorECM and the Engine ECM.
Advisor at the proper rate. The update rate for
parameters that are generated by the Engine ECM is Results:
not correct. The communication failure may be due to
disconnected connectors or a faulty wiring harness. • YES – The versions of software are compatible.
Proceed to Test Step 2.
The possible causes of this diagnostic code are
listed:
• NO – The proper software is not installed.
• The Engine ECM has the incorrect software
installed. Repair: Flash the proper software to the
appropriate ECM. Cycle the key switch to
• The Advisor ECM has the incorrect software initialize the new software. Ensure that the
installed. diagnostic code is no longer active.

• Incompatible software may be installed. STOP.

• The fuse for the Engine ECM may have failed.
Test Step 2. RECHECK FOR DIAGNOSTIC
CODES.
Test Step 1. CHECK THE ENGINE ECM A. Ensure that the diagnostic code is active.
AND THE ADVISOR ECM FOR PROPER
SOFTWARE VERSIONS. Expected Result:

A. Use Caterpillar Electronic Technician (ET) to verify The diagnostic code is inactive. The diagnostic code
that the versions of software are compatible. indicator is inactive.

Expected Result: Results:

86 KENR9938-14
Diagnostic Code Procedures

• YES – The diagnostic code indicator and the i06753665

diagnostic code are inactive.
MID 053 - CID 0800 - FMI 02
Repair: Clear the diagnostic code.
SMCS Code: 7601-038-EK2; 7610-038
STOP.
Conditions Which Generate This Code:
• NO – The diagnostic code is active.

Repair: Ensure that the proper software is

installed before replacing the ECM. If the
software is correct, replace the Advisor ECM.
See Testing and Adjusting, “Electronic Control
Module (ECM) - Replace”. If the Advisor ECM
was just replaced , install a new Engine ECM.
See Testing and Adjusting, “Electronic Control
Module (ECM) - Replace” for the machine that
is being serviced.

STOP.

Illustration 80 g02714481
Schematic of the Cat Data Link for770G, 772G and
777G Off-Highway Trucks, 773G and 775G Quarry
Trucks
KENR9938-14 87
Diagnostic Code Procedures

Illustration 81 g03859095
Schematic of the Cat Data Link for 777E and 773E Off-Highway Trucks

This diagnostic code is recorded when the VIMS Expected Result:

ECM has dropped off the Cat Data Link 10 times
within a ten minute period for more than five seconds. All part numbers are correct.
The diagnostic code is active until communication is
reliable for more than ten minutes. Results:

System Response: • OK – All part numbers are correct.Proceed to test

step 2.
This failure results in events that are logged against
an ECM that cannot be explained. The power train • NOT OK – All part numbers are NOT correct.
ECM cannot communicate with this ECM or the ECM
appears to work intermittently.
Repair: It is unlikely that the ECM has failed.
Exit this procedure and perform this procedure
Test Step 1. VERIFY THE HARDWARE again. If the cause of the diagnostic code is not
AND THE SOFTWARE PART NUMBERS. found, replace the ECM. See Troubleshooting,
“Electronic Control Module (ECM) - Replace”.
A. Verify that the following information is correct:
STOP.
• The part number of the “power train onboard
flash software”
Test Step 2. INSPECT THE HARNESS
• The part number of the “advisor ECM flash CONNECTIONS.
software”
A. Turn the disconnect switch to the OFF position.
• The part number of the “power train ECM” B. Inspect all harness connections that are related to
the Cat Data Link. Make sure that the connectors
• The part number of the “advisor ECM”
are clean and tight.
Note: Consult the Business Unit that produces the C. Check the connectors for proper mating. Ensure
product for the correct part numbers of the that all the seals are present and in place.
configuration software.
88 KENR9938-14
Diagnostic Code Procedures

D. Check the harness for signs of damage or • OK – The resistance is greater than 5000 ohms.
abrasion. The harness circuit resistance is correct.Proceed
to test step 4.
E. Check the wires at the connector. Ensure that the
wires are secured tightly into the connector. Take • NOT OK – The resistance is less than 5000 ohms.
care not to pull the wire out of the connector. The machine harness has failed.
F. Check the exposed wires at the connectors for
Repair: There is a short between frame ground
nicks or signs of abrasion. and the Cat Data Link circuit in the machine
G. Check for moisture inside the connector. harness. Repair the machine harness or
replace the machine harness.
H. Check the connectors for dirty contacts or
corroded contacts. STOP.
I. Check each pin and each socket of the machine
harness connectors. Ensure that the contacts are Test Step 4. CHECK FOR SHORT TO
properly installed. The contacts should mate +BATTERY
correctly when the two pieces of the connector are A. The disconnect switch remains in the OFF
placed together. position.
Expected Result: B. All related electronic control modules remain
disconnected from the machine harness.
The machine harness connectors are tight and free
of corrosion. C. At the machine harness connector for the advisor
ECM, perform the checks that are listed here:
Results:
• Measure the resistance between the connector
• OK – The machine harness connectors are tight contact 1 (wire 145-RD(Red)) and connector
and free of corrosion.Proceed to test step 3. contact 8 (wire 893-GN(Green)).
• NOT OK – The machine harness connectors are in • Measure the resistance between connector
need of repair. contact 1 (wire 145-RD(Red)) and connector
contact 9 (wire 892-BR(Brown)).
Repair: Repair the machine harness or replace
the machine harness. Expected Result:
STOP. The resistance is greater than 5000 ohms.

Test Step 3. CHECK FOR SHORTS TO Results:

GROUND • OK – The harness circuit resistance is correct.
A. The disconnect switch remains in the OFF Proceed to test step 5.
position.
• NOT OK – The resistance is less than 5000 ohms.
B. Disconnect the machine harness from all The machine harness has failed.
electronic control modules that use the Cat Data
Link. Repair: There is a short between +battery and
the Cat Data Link circuit in the machine
C. At the machine harness for the advisor ECM, harness. Repair the machine harness or
measure the resistance between frame ground replace the machine harness.
and connector contacts 8 (wire 893-GN(Green))
and 9 (wire 892-BR(Brown)) of the Cat Data Link STOP.
circuit.
Test Step 5. CHECK FOR OPEN
Expected Result:
HARNESS
The resistance is greater than 5000 ohms. A. The disconnect switch remains in the OFF
position.
Results:
B. All related electronic control modules remain
disconnected from the machine harness.
KENR9938-14 89
Diagnostic Code Procedures

C. Check the continuity of the Cat Data Link circuit in Repair: The advisor ECM has failed. It is
the machine harness: unlikely that the ECM has failed. Exit this
procedure. Perform this procedure again. If the
• Measure the resistance between connector failure is not found, check the +battery contacts
contact J1-20 (wire 892-BR(Brown)) of the and ground contacts of the ECM. If these
power train ECM and connector contact 8 (wire contacts are correct, replace the ECM.
893-GN(Green)) of the advisor ECM.
STOP.
• Measure the resistance between connector
contact J1-10 (wire 893-GN(Green)) of the • NOT OK – Diagnostic codes are present for the
power train ECM and connector contact 9 (wire other electronic control modules (ECM).
892-BR(Brown)) of the advisor ECM.
Repair: The power train ECM has failed. It is
unlikely that the ECM has failed. Exit this
Expected Result:
procedure. Perform this procedure again. If the
The resistance measures less than 5 ohms. failure is not found, replace the ECM. See the
Troubleshooting, “Electronic Control Module
Results: (ECM) - Replace” section of this manual.

• OK – The resistance is less than 5 ohms. The Cat STOP.

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
ELECTRONIC CONTROL MODULES.
A. Turn the key start switch and the disconnect
switch to the OFF position.
B. One at a time, reconnect the electronic control
modules that use the Cat Data Link.
C. Turn the disconnect switch and the key start
switch to the ON position.
D. After each of the electronic control modules has
been reconnected, check the Event List for
diagnostic codes that are logged against the
electronic control module.

Expected Result:
Diagnostic codes are not present for the other
electronic control modules.

Results:

• OK – Diagnostic codes are not present for the

other electronic control modules.
90 KENR9938-14
Diagnostic Code Procedures

i06753666

MID 053 - CID 0800 - FMI 09

SMCS Code: 7601-038-EK2; 7610-038

Conditions Which Generate This Code:

Illustration 82 g02714481
Schematic of the Cat Data Link for770G, 772G and
777G Off-Highway Trucks, 773G and 775G Quarry
Trucks
KENR9938-14 91
Diagnostic Code Procedures

Illustration 83 g03859095
Schematic of the Cat Data Link for 777E and 773EOff-Highway Trucks

This diagnostic code is recorded when the advisor All of the part numbers are correct.
does not receive expected information from the VIMS
ECM. The possible causes of this diagnostic code Results:
are listed:
• OK – All of the part numbers are correct.Proceed
• The wires for the Cat Data Link to the VIMS ECM to Test Step 2.
are open or the wires are shorted.

• The wrong software is installed on an ECM. • NOT OK – All of the part numbers are not correct.

Repair: The installed VIMS ECM or the advisor

have the wrong part number or the incorrect
Test Step 1. VERIFY THE HARDWARE flash software is installed. Replace the VIMS
AND THE SOFTWARE PART NUMBERS. ECM or replace the advisor that is incorrect.
Replace the ECM with a module that has the
A. Verify that the following information is correct: correct part number. Flash the correct software.
See Testing and Adjusting, “Electronic Control
• The part number of the flash software for the
Module (ECM) - Flash Program” for additional
VIMS ECM information.
• The part number of the flash software for the
STOP.
advisor

• The part number of the VIMS ECM Test Step 2. INSPECT THE HARNESS
CONNECTIONS.
• The part number of the advisor
A. Turn the disconnect switch to the OFF position.
Note: Consult your Caterpillar Dealer for the correct
part numbers of the flash software. B. Inspect all harness connections that are related to
the Cat Data Link. Make sure that the connectors
Expected Result: are clean and tight.
92 KENR9938-14
Diagnostic Code Procedures

C. Check the connectors for proper mating. Ensure • OK – Each of the resistance measurements is
that all the seals are present and in place. greater than 5000 ohms. The harness circuit
resistance is correct.Proceed to Test Step 4.
D. Check the harness for signs of damage or
abrasion. • NOT OK – One of the resistance measurements is
E. Check the wires at the connector. Ensure that the less than 5000 ohms. The machine harness has
failed.
wires are secured tightly into the connector. Take
care not to pull the wire out of the connector. Repair: There is a short between contacts 8
F. Check the exposed wires at the connectors for (wire 893-GN(Green)) or 9 (wire
nicks or signs of abrasion. 892-BR(Brown)) of the Cat Data Link and the
circuit with the low resistance measurement.
G. Check for moisture inside the connector. Repair the machine harness or replace the
machine harness.
H. Check the connectors for dirty contacts or
corroded contacts. STOP.
I. Check each pin and each socket of the machine
harness connectors. Ensure that the contacts are Test Step 4. CHECK FOR OPEN
properly installed. The contacts should mate HARNESS
correctly when the two pieces of the connector are
A. The disconnect switch remains in the OFF
placed together.
position.
Expected Result: B. All related electronic control modules remain
The machine harness connectors are tight and free disconnected from the machine harness.
of corrosion. C. Check the resistance of the Cat Data Link circuit in
the machine harness:
Results:
• Measure the resistance between connector
• OK – The machine harness connectors are tight contact J1-7 (wire 893-GN(Green)) of the VIMS
and free of corrosion.Proceed to Test Step 3.
ECM and connector contact 8 (wire
• NOT OK – The machine harness connectors are in 893-GN(Green)) of the advisor.
need of repair.
• Measure the resistance between connector
Repair: Repair the machine harness or replace contact J1-6 (wire 892-BR(Brown)) of the VIMS
the machine harness. ECM and connector contact 9 (wire
892-BR(Brown)) of the advisor.
STOP.
Expected Result:
Test Step 3. CHECK FOR SHORTS The resistance measures less than 5 ohms.
A. The disconnect switch remains in the OFF
Results:
position.
B. Disconnect the machine harness connectors from • OK – The resistance is less than 5 ohms. The Cat
all electronic control modules that use the Cat Data Link circuit in the machine harness is correct.
Data Link. Proceed to Test Step 5.

C. At the harness connector for the advisor, measure • NOT OK – The resistance is greater than 5 ohms.
the resistance between connector contact 8 (wire The machine harness has failed.
893-GN(Green)) and all of the contacts that are
used in the machine harness connector for the Repair: The Cat Data Link circuit is open in the
advisor. Perform the same measurements for machine harness. Repair the machine harness
or replace the machine harness.
connector contact 9 (wire 892-BR(Brown)).
STOP.
Expected Result:
Each resistance measurement is greater than 5000 Test Step 5. CHECK IF THE DIAGNOSTIC
ohms.
CODE REMAINS
Results:
KENR9938-14 93
Diagnostic Code Procedures

A. Inspect the contacts of the harness connectors i06753675

and clean the contacts.
B. Reconnect all harness connectors.
MID 053 - CID 0800 - FMI 14
SMCS Code: 7601-038-EK2; 7610-038
C. Turn the disconnect switch and the key start
switch to the ON position. Conditions Which Generate This Code:
D. Operate the machine.
E. Check the status of the CID 0800 FMI 09.

Expected Result:
The CID 0800 FMI 09 is active.

Results:

• YES – The CID 0800 FMI 09 is active. The

diagnostic code has not been corrected. The ECM
may have failed.

Repair: It is unlikely that the ECM has failed.

Exit this procedure and perform this procedure
again. If the cause of the diagnostic code is not
found, replace the ECM. See Testing and
Adjusting, “Electronic Control Module (ECM) -
Replace”.

STOP.

• NO – The CID 0800 FMI 09 is not active. The

diagnostic code does not exist at this time.

Repair: The initial diagnostic code was

probably caused by a poor electrical connection
or a short at one of the harness connectors that
was disconnected and reconnected. Resume
normal machine operation.

STOP.

Illustration 84 g02714481
Schematic of the Cat Data Link for770G, 772G and
777G Off-Highway Trucks, 773G and 775G Quarry
Trucks
94 KENR9938-14
Diagnostic Code Procedures

Illustration 85 g03859095
Schematic of the Cat Data Link for 777E and 773E Off-Highway Trucks

This diagnostic code is recorded when the VIMS The proper versions of software are installed on the
ECM is not sending the necessary parameters to the Advisor ECM and the VIMS ECM.
Advisor ECM at the proper rate. The update rate for
parameters that are generated by the VIMS ECM is Results:
not correct. The communication failure may be due to
disconnected connectors or a faulty wiring harness. • YES – The versions of software are compatible.
Proceed to Test Step 2.
The possible causes of this diagnostic code are
listed:
• NO – The proper software is not installed.
• The VIMS ECM has the incorrect software
installed. Repair: Flash the proper software to the
appropriate ECM. Cycle the key switch to
• The Advisor ECM has the incorrect software initialize the new software. Ensure that the
installed. diagnostic code is no longer active.

• Incompatible software may be installed. STOP.

• The fuse for the VIMS ECM may have failed.
Test Step 2. RECHECK FOR DIAGNOSTIC
CODES.
Test Step 1. CHECK THE VIMS ECM AND A. Ensure that diagnostic code is active.
THE ADVISOR ECM FOR PROPER
SOFTWARE VERSIONS. Expected Result:

A. Use Caterpillar Electronic Technician (ET) to verify The diagnostic code is inactive. The diagnostic code
that the versions of software are compatible. indicator is inactive.

Expected Result: Results:

KENR9938-14 95
Diagnostic Code Procedures

• YES – The diagnostic code indicator and the i06753679

diagnostic code are inactive.
MID 053 - CID 0811 - FMI 09
Repair: Clear the diagnostic code.
SMCS Code: 7490-038
STOP.
Conditions Which Generate This Code:
• NO – The diagnostic code is active.

Repair: Ensure that the proper software is

installed before replacing the ECM. If the
software is correct, replace the Advisor ECM.
See Testing and Adjusting, “Electronic Control
Module (ECM) - Replace”. If the Advisor ECM
was just replaced , install a new VIMS ECM.
See Testing and Adjusting, “Electronic Control
Module (ECM) - Replace” for the machine that
is being serviced.

STOP.

Illustration 86 g02714481
Schematic of the Cat Data Link for770G, 772G and
777G Off-Highway Trucks, 773G and 775G Quarry
Trucks
96 KENR9938-14
Diagnostic Code Procedures

Illustration 87 g03859095
Schematic of the Cat Data Link for 777E and 773E Off-Highway Trucks

This diagnostic code is recorded when the Advisor Results:

ECM does not receive expected information from the
instrument cluster through the CAN Data Link for a • OK – All part numbers are correct.Proceed to test
period of more than five seconds. step 2.
System Response: • NOT OK – All part numbers are NOT correct.
This failure results in events that are logged against
an ECM that can not be explained directly. The Repair: The installed Advisor ECM has the
Advisor ECM cannot communicate with the wrong part number or the incorrect
instrument cluster or the instrument cluster appears configuration software is installed. Replace the
to communicate intermittently. incorrect Advisor ECM with a module that has
the correct part number. Flash the correct
configuration software. See the Testing and
Test Step 1. VERIFY THE HARDWARE Adjusting, “Electronic Control Module (ECM) -
AND THE SOFTWARE PART NUMBERS. Flash Program” section of this manual.
A. Verify that the following information is correct:
STOP.
• The part number of the “Advisor ECM onboard
software” Test Step 2. INSPECT THE HARNESS
CONNECTIONS.
• The part number of the Advisor ECM
A. Turn the disconnect switch to the OFF position.
Note: Consult the Business Unit that produces the
product for the correct part numbers of the B. Inspect all harness connections that are related to
configuration software. the CAN Data Link. Make sure that the connectors
are clean and tight.
Expected Result:
C. Check the connectors for proper mating. Ensure
All part numbers are correct. that all the seals are present and in place.
KENR9938-14 97
Diagnostic Code Procedures

D. Check the harness for signs of damage or • OK – Each resistance measurement is greater
abrasion. than 5000 ohms. The harness circuit resistance is
correct.Proceed to test step 4.
E. Check the wires at the connector. Ensure that the
wires are secured tightly into the connector. Take • NOT OK – One resistance measurement is less
care not to pull the wire out of the connector. than 5000 ohms. The machine harness has failed.
F. Check the exposed wires at the connectors for
Repair: There is a short between frame ground
nicks or signs of abrasion. and the circuit for the CAN Data Link in the
G. Check for moisture inside the connector. machine harness. Repair the machine harness
or replace the machine harness.
H. Check the connectors for dirty contacts or
corroded contacts. STOP.
I. Check each pin and each socket of the machine
harness connectors. Ensure that the contacts are Test Step 4. CHECK FOR SHORT TO
properly installed. The contacts should mate +BATTERY
correctly when the two pieces of the connector are A. The disconnect switch remains in the OFF
placed together. position.
Expected Result: B. All related electronic control modules remain
disconnected from the machine harness.
The machine harness connectors are tight and free
of corrosion. C. At the machine harness connector for the Advisor
ECM, perform the checks that are listed here:
Results:
• Measure the resistance between the +Battery
• OK – The machine harness connectors are tight connector contact 1 (wire 133-RD(Red)) and
and free of corrosion.Proceed to test step 3. connector contact 34 (wire F712-GY(Grey)).
• NOT OK – The machine harness connectors are in • Measure the resistance between the +Battery
need of repair. connector contact 53 (wire 133-RD(Red)) and
connector contact 34 (wire F712-GY(Grey)).
Repair: Repair the machine harness or replace
the machine harness. • Measure the resistance between the +Battery
connector contact 68 (wire 133-RD(Red)) and
STOP. connector contact 34 (wire F712-GY(Grey)).

Test Step 3. CHECK FOR SHORTS TO • Measure the resistance between connector
GROUND contact 1 (wire 133-RD(Red)) and connector
contact 50 (wire F711-GN(Green)).
A. The disconnect switch remains in the OFF
position. • Measure the resistance between connector
contact 53 (wire 133-RD(Red)) and connector
B. Disconnect the machine harness from all
contact 50 (wire F711-GN(Green)).
electronic control modules that use the CAN Data
Link. • Measure the resistance between connector
C. At the machine harness for the Advisor ECM, contact 68 (wire 133-RD(Red)) and connector
measure the resistance between frame ground contact 50 (wire F711-GN(Green)).
and connector contacts 34 (wire F712-GY(Grey))
and connector contact 50 (wire F711-GN(Green)) Expected Result:
at the instrument cluster for the CAN Data Link. Each resistance measurement is greater than 5000
ohms.
Expected Result:
Results:
Each resistance measurement is greater than 5000
ohms.
• OK – The harness circuit resistance is correct.
Proceed to test step 5.
Results:
• NOT OK – One resistance measurement is less
than 5000 ohms. The machine harness has failed.
98 KENR9938-14
Diagnostic Code Procedures

Repair: There is a short between the +battery C. Check the Event List for diagnostic codes that are
and the circuit for the CAN Data Link in the logged against the other electronic control
machine harness. Repair the machine harness modules.
or replace the machine harness.
Expected Result:
STOP.
Diagnostic codes are not present for the other
Test Step 5. CHECK FOR AN OPEN electronic control modules in the event list.
HARNESS Results:
A. The disconnect switch remains in the OFF
• OK – Diagnostic codes are not present for the
position.
other electronic control modules (ECM) in the
B. All related electronic control modules remain event list.
disconnected from the machine harness.
Repair: The instrument cluster has failed. It is
C. Check the continuity of the circuit for the CAN unlikely that the instrument cluster has failed.
Data Link in the machine harness: Exit this procedure. Perform this procedure
again. If the failure is not found, replace the
• Measure the resistance between connector instrument cluster.
contact 34 (wire F712-GY(Grey)) of the Advisor
ECM and connector contact 20 (wire STOP.
F712-GY(Grey)) of the instrument cluster.
• NOT OK – Diagnostic codes are present for the
• Measure the resistance between connector other electronic control modules in the event list.
contact 50 (wire F711-GN(Green)) of the
Advisor ECM and connector contact 19 (wire Repair: The Advisor ECM has failed. It is
F711-GN(Green)) of the instrument cluster. unlikely that the ECM has failed. Exit this
procedure. Perform this procedure again. If the
Expected Result: failure is not found, replace the ECM. See the
Testing and Adjusting, “Electronic Control
Each resistance measurement is less than 5 ohms. Module (ECM) - Replace” section of this
manual.
Results:
STOP.
• OK – Each resistance measurement is less than 5
ohms. The circuit for the CAN Data Link in the
machine harness is correct.Proceed to test step
6.

• NOT OK – One resistance measurement is

greater than 5 Ohms. The machine harness has
failed.

Repair: The circuit for the CAN Data Link 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
ELECTRONIC CONTROL MODULES.
A. Reconnect all the electronic control modules that
use the CAN Data Link.
B. Turn the disconnect switch and the key start
switch to the ON position.
KENR9938-14 99
Diagnostic Code Procedures

i06753682

MID 053 - CID 1089 - FMI 02

SMCS Code: 7601-038

Conditions Which Generate This Code:

Illustration 88 g02714481
Schematic of the Cat Data Link for770G, 772G and
777G Off-Highway Trucks, 773G and 775G Quarry
Trucks
100 KENR9938-14
Diagnostic Code Procedures

Illustration 89 g03859095
Schematic of the Cat Data Link for 777E and 773E Off-Highway Trucks

This diagnostic code is recorded when the Advisor • The part number of the VIMS 3G Application
ECM has an abnormal update rate with the VIMS 3G ECM
Application ECM through the Cat data link.
Note: Consult the Business Unit that produces the
Note: Cat ET will report a CID 1089 code as a VIMS product for the correct part numbers of the
Analysis control module fault. In a VIMS 3G system configuration software.
the VIMS 3G Application ECM is the ECM that has
created the fault. Expected Result:
System Response: All part numbers are correct.
This failure results in events that are logged against Results:
the VIMS 3G Application ECM that cannot be
explained directly. The Advisor ECM cannot • OK – All part numbers are correct.Proceed to Test
communicate with the VIMS 3G Application ECM or
Step 2.
the VIMS 3G Application ECM appears to
communicate intermittently.
• NOT OK – All part numbers are NOT correct.
Test Step 1. VERIFY THE HARDWARE Repair: The installed Advisor ECM or the VIMS
AND THE SOFTWARE PART NUMBERS. 3G Application ECM has the wrong part number
or the incorrect configuration software is
A. Verify that the following information is correct: installed. Replace the incorrect Advisor ECM or
the VIMS 3G Application ECM with an ECM that
• The part number of the Advisor ECM onboard has the correct part number. Refer to Service
software Manual, “Electronic Control Module (ECM) -
Replace”. Flash the correct configuration
• The part number of the flash software for the software. Refer to Service Manual, “Electronic
VIMS 3G Application ECM Control Module (ECM) - Flash Program”.
• The part number of the Advisor ECM STOP.
KENR9938-14 101
Diagnostic Code Procedures

Test Step 2. INSPECT THE HARNESS Expected Result:

CONNECTIONS. The resistance is greater than 5000 ohms.
A. Turn the disconnect switch to the OFF position.
Results:
B. Inspect all harness connections that are related to
the Cat Data Link. Make sure that the connectors • OK – The resistance is greater than 5000 ohms.
are clean and tight. The harness circuit resistance is correct.Proceed
to Test Step 4.
C. Check the connectors for proper mating. Ensure
that all the seals are present and in place. • NOT OK – The resistance is less than 5000 ohms.
D. Check the harness for signs of damage or The machine harness has failed.
abrasion.
Repair: There is a short between frame ground
E. Check the wires at the connector. Ensure that the and the Cat Data Link circuit in the machine
wires are secured tightly into the connector. Take harness. Repair the machine harness or
care not to pull the wire out of the connector. replace the machine harness.

F. Check the exposed wires at the connectors for STOP.

nicks or signs of abrasion.
G. Check for moisture inside the connector. Test Step 4. CHECK FOR SHORT TO
+BATTERY
H. Check the connectors for dirty contacts or
corroded contacts. A. The disconnect switch remains in the OFF
position.
I. Check each pin and each socket of the machine
harness connectors. Ensure that the contacts are B. All of the related ECM remain disconnected from
properly installed. The contacts should mate the machine harness.
correctly when the two pieces of the connector are C. At the machine harness connector for the VIMS
placed together. 3G Application ECM, perform the checks that are
listed here:
Expected Result:
The machine harness connectors are tight and free • Measure the resistance between the +battery
of corrosion. connector contact 52 (wire 170-RD(Red)) and
connector contact 8 (wire 893-GN(Green)).
Results:
• Measure the resistance between connector
• OK – The machine harness connectors are tight contact 52 (wire 170-RD(Red)) and connector
and free of corrosion.Proceed to Test Step 3. contact 9 (wire 892-BR(Brown)).

• NOT OK – The machine harness connectors are in Expected Result:

need of repair.
The resistance is greater than 5000 ohms.
Repair: Repair the machine harness or replace
the machine harness. Results:

STOP. • OK – The harness circuit resistance is correct.

Proceed to Test Step 5.
Test Step 3. CHECK FOR SHORTS TO • NOT OK – The resistance is less than 5000 ohms.
GROUND The machine harness has failed.
A. The disconnect switch remains in the OFF
Repair: There is a short between the +battery
position. and the Cat Data Link circuit in the machine
B. Disconnect all ECM from the Cat Data Link. harness. Repair the machine harness or
replace the machine harness.
C. At the machine harness for the Advisor ECM,
measure the resistance between frame ground STOP.
and connector contacts 8 (wire 893-GN(Green))
and 9 (wire 892-BR(Brown)) of the Cat Data Link
circuit.
102 KENR9938-14
Diagnostic Code Procedures

Test Step 5. CHECK FOR OPEN • OK – Diagnostic codes are not present for the
HARNESS other ECM in the event list.

A. The disconnect switch remains in the OFF Repair: The VIMS 3G Application ECM has
position. failed. It is unlikely that the VIMS 3G Application
ECM has failed. Exit this procedure. Perform
B. Ensure that all of the ECM are disconnected from this procedure again. If the failure is not found,
the machine harness. replace the VIMS 3G Application ECM.
C. Check the continuity of the Cat Data Link circuit in
STOP.
the machine harness:

• Measure the resistance between connector • NOT OK – Diagnostic codes are present for the
other ECM in the event list.
contact 8 (wire 893-GN(Green)) of the Advisor
ECM and connector contact 8 (wire Repair: Perform the troubleshooting procedure
893-GN(Green)) of the VIMS 3G Application for the other diagnostic codes.
ECM.
STOP.
• Measure the resistance between connector
contact 9 (wire 892-BR(Brown)) of the Advisor
ECM and connector contact 9 (wire
892-BR(Brown)) 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.

• 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:
KENR9938-14 103
Diagnostic Code Procedures

i06753683

MID 053 - CID 1089 - FMI 09

SMCS Code: 7601-038

Conditions Which Generate This Code:

Illustration 90 g02714481
Schematic of the Cat Data Link for770G, 772G and
777G Off-Highway Trucks, 773G and 775G Quarry
Trucks
104 KENR9938-14
Diagnostic Code Procedures

Illustration 91 g03859095
Schematic of the Cat Data Link for 777E and 773E Off-Highway Trucks

This diagnostic code is recorded when the Advisor • The part number of the VIMS 3G Application
ECM has an abnormal update rate with the VIMS 3G ECM
Application ECM through the Cat data link.
Note: Consult the Business Unit that produces the
Note: Cat ET will report a CID 1089 code as a VIMS product for the correct part numbers of the
Analysis control module fault. In a VIMS 3G system configuration software.
the VIMS 3G Application ECM is the ECM that has
created the fault. Expected Result:
System Response: All part numbers are correct.
This failure results in events that are logged against Results:
the VIMS 3G Application ECM that cannot be
explained directly. The Advisor ECM cannot • OK – All part numbers are correct.Proceed to Test
communicate with the VIMS 3G Application ECM or
Step 2.
the VIMS 3G Application ECM appears to
communicate intermittently.
• NOT OK – All part numbers are NOT correct.
Test Step 1. VERIFY THE HARDWARE Repair: The installed Advisor ECM or the VIMS
AND THE SOFTWARE PART NUMBERS. 3G Application ECM has the wrong part number
or the incorrect configuration software is
A. Verify that the following information is correct: installed. Replace the incorrect Advisor ECM or
the VIMS 3G Application ECM with an ECM that
• The part number of the Advisor ECM onboard has the correct part number. Refer to Service
software Manual, “Electronic Control Module (ECM) -
Replace”. Flash the correct configuration
• The part number of the flash software for the software. Refer to Service Manual, “Electronic
VIMS 3G Application ECM Control Module (ECM) - Flash Program”.
• The part number of the Advisor ECM STOP.
KENR9938-14 105
Diagnostic Code Procedures

Test Step 2. INSPECT THE HARNESS Expected Result:

CONNECTIONS. The resistance is greater than 5000 ohms.
A. Turn the disconnect switch to the OFF position.
Results:
B. Inspect all harness connections that are related to
the Cat Data Link. Make sure that the connectors • OK – The resistance is greater than 5000 ohms.
are clean and tight. The harness circuit resistance is correct.Proceed
to Test Step 4.
C. Check the connectors for proper mating. Ensure
that all the seals are present and in place. • NOT OK – The resistance is less than 5000 ohms.
D. Check the harness for signs of damage or The machine harness has failed.
abrasion.
Repair: There is a short between frame ground
E. Check the wires at the connector. Ensure that the and the Cat Data Link circuit in the machine
wires are secured tightly into the connector. Take harness. Repair the machine harness or
care not to pull the wire out of the connector. replace the machine harness.

F. Check the exposed wires at the connectors for STOP.

nicks or signs of abrasion.
G. Check for moisture inside the connector. Test Step 4. CHECK FOR SHORT TO
+BATTERY
H. Check the connectors for dirty contacts or
corroded contacts. A. The disconnect switch remains in the OFF
position.
I. Check each pin and each socket of the machine
harness connectors. Ensure that the contacts are B. All of the related ECM remain disconnected from
properly installed. The contacts should mate the machine harness.
correctly when the two pieces of the connector are C. At the machine harness connector for the VIMS
placed together. 3G Application ECM, perform the checks that are
listed here:
Expected Result:
The machine harness connectors are tight and free • Measure the resistance between the +battery
of corrosion. connector contact 52 (wire 170-RD(Red)) and
connector contact 8 (wire 893-GN(Green)).
Results:
• Measure the resistance between connector
• OK – The machine harness connectors are tight contact 52 (wire 170-RD(Red)) and connector
and free of corrosion.Proceed to Test Step 3. contact 9 (wire 892-BR(Brown)).

• NOT OK – The machine harness connectors are in Expected Result:

need of repair.
The resistance is greater than 5000 ohms.
Repair: Repair the machine harness or replace
the machine harness. Results:

STOP. • OK – The harness circuit resistance is correct.

Proceed to Test Step 5.
Test Step 3. CHECK FOR SHORTS TO • NOT OK – The resistance is less than 5000 ohms.
GROUND The machine harness has failed.
A. The disconnect switch remains in the OFF
Repair: There is a short between the +battery
position. and the Cat Data Link circuit in the machine
B. Disconnect all ECM from the Cat Data Link. harness. Repair the machine harness or
replace the machine harness.
C. At the machine harness for the Advisor ECM,
measure the resistance between frame ground STOP.
and connector contacts 8 (wire 893-GN(Green))
and 9 (wire 892-BR(Brown)) of the Cat Data Link
circuit.
106 KENR9938-14
Diagnostic Code Procedures

Test Step 5. CHECK FOR OPEN • OK – Diagnostic codes are not present for the
HARNESS other ECM in the event list.

A. The disconnect switch remains in the OFF Repair: The VIMS 3G Application ECM has
position. failed. It is unlikely that the VIMS 3G Application
ECM has failed. Exit this procedure. Perform
B. Ensure that all of the ECM are disconnected from this procedure again. If the failure is not found,
the machine harness. replace the VIMS 3G Application ECM.
C. Check the continuity of the Cat Data Link circuit in
STOP.
the machine harness:

• Measure the resistance between connector • NOT OK – Diagnostic codes are present for the
other ECM in the event list.
contact 8 (wire 893-GN(Green)) of the Advisor
ECM and connector contact 8 (wire Repair: Perform the troubleshooting procedure
893-GN(Green)) of the VIMS 3G Application for the other diagnostic codes.
ECM.
STOP.
• Measure the resistance between connector
contact 9 (wire 892-BR(Brown)) of the Advisor
ECM and connector contact 9 (wire
892-BR(Brown)) 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.

• 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:
KENR9938-14 107
Diagnostic Code Procedures

i06753690

MID 053 - CID 1089 - FMI 14

SMCS Code: 7601-038

Conditions Which Generate This Code:

Illustration 92 g02714481
Schematic of the Cat Data Link for770G, 772G and
777G Off-Highway Trucks, 773G and 775G Quarry
Trucks
108 KENR9938-14
Diagnostic Code Procedures

Illustration 93 g03859095
Schematic of the Cat Data Link for 777E and 773E Off-Highway Trucks

This diagnostic code is recorded when the Advisor • The part number of the VIMS 3G Application
ECM has an abnormal update rate with the VIMS 3G ECM
Application ECM through the Cat data link.
Note: Consult the Business Unit that produces the
Note: Cat ET will report a CID 1089 code as a VIMS product for the correct part numbers of the
Analysis control module fault. In a VIMS 3G system configuration software.
the VIMS 3G Application ECM is the ECM that has
created the fault. Expected Result:
System Response: All part numbers are correct.
This failure results in events that are logged against Results:
the VIMS 3G Application ECM that cannot be
explained directly. The Advisor ECM cannot • OK – All part numbers are correct.Proceed to Test
communicate with the VIMS 3G Application ECM or
Step 2.
the VIMS 3G Application ECM appears to
communicate intermittently.
• NOT OK – All part numbers are NOT correct.
Test Step 1. VERIFY THE HARDWARE Repair: The installed Advisor ECM or the VIMS
AND THE SOFTWARE PART NUMBERS. 3G Application ECM has the wrong part number
or the incorrect configuration software is
A. Verify that the following information is correct: installed. Replace the incorrect Advisor ECM or
the VIMS 3G Application ECM with an ECM that
• The part number of the Advisor ECM onboard has the correct part number. Refer to Service
software Manual, “Electronic Control Module (ECM) -
Replace”. Flash the correct configuration
• The part number of the flash software for the software. Refer to Service Manual, “Electronic
VIMS 3G Application ECM Control Module (ECM) - Flash Program”.
• The part number of the Advisor ECM STOP.
KENR9938-14 109
Diagnostic Code Procedures

Test Step 2. INSPECT THE HARNESS Expected Result:

CONNECTIONS. The resistance is greater than 5000 ohms.
A. Turn the disconnect switch to the OFF position.
Results:
B. Inspect all harness connections that are related to
the Cat Data Link. Make sure that the connectors • OK – The resistance is greater than 5000 ohms.
are clean and tight. The harness circuit resistance is correct.Proceed
to Test Step 4.
C. Check the connectors for proper mating. Ensure
that all the seals are present and in place. • NOT OK – The resistance is less than 5000 ohms.
D. Check the harness for signs of damage or The machine harness has failed.
abrasion.
Repair: There is a short between frame ground
E. Check the wires at the connector. Ensure that the and the Cat Data Link circuit in the machine
wires are secured tightly into the connector. Take harness. Repair the machine harness or
care not to pull the wire out of the connector. replace the machine harness.

F. Check the exposed wires at the connectors for STOP.

nicks or signs of abrasion.
G. Check for moisture inside the connector. Test Step 4. CHECK FOR SHORT TO
+BATTERY
H. Check the connectors for dirty contacts or
corroded contacts. A. The disconnect switch remains in the OFF
position.
I. Check each pin and each socket of the machine
harness connectors. Ensure that the contacts are B. All of the related ECM remain disconnected from
properly installed. The contacts should mate the machine harness.
correctly when the two pieces of the connector are C. At the machine harness connector for the VIMS
placed together. 3G Application ECM, perform the checks that are
listed here:
Expected Result:
The machine harness connectors are tight and free • Measure the resistance between the +battery
of corrosion. connector contact 52 (wire 170-RD(Red)) and
connector contact 8 (wire 893-GN(Green)).
Results:
• Measure the resistance between connector
• OK – The machine harness connectors are tight contact 52 (wire 170-RD(Red)) and connector
and free of corrosion.Proceed to Test Step 3. contact 9 (wire 892-BR(Brown)).

• NOT OK – The machine harness connectors are in Expected Result:

need of repair.
The resistance is greater than 5000 ohms.
Repair: Repair the machine harness or replace
the machine harness. Results:

STOP. • OK – The harness circuit resistance is correct.

Proceed to Test Step 5.
Test Step 3. CHECK FOR SHORTS TO • NOT OK – The resistance is less than 5000 ohms.
GROUND The machine harness has failed.
A. The disconnect switch remains in the OFF
Repair: There is a short between the +battery
position. and the Cat Data Link circuit in the machine
B. Disconnect all ECM from the Cat Data Link. harness. Repair the machine harness or
replace the machine harness.
C. At the machine harness for the Advisor ECM,
measure the resistance between frame ground STOP.
and connector contacts 8 (wire 893-GN(Green))
and 9 (wire 892-BR(Brown)) of the Cat Data Link
circuit.
110 KENR9938-14
Diagnostic Code Procedures

Test Step 5. CHECK FOR OPEN • OK – Diagnostic codes are not present for the
HARNESS other ECM in the event list.

A. The disconnect switch remains in the OFF Repair: The VIMS 3G Application ECM has
position. failed. It is unlikely that the VIMS 3G Application
ECM has failed. Exit this procedure. Perform
B. Ensure that all of the ECM are disconnected from this procedure again. If the failure is not found,
the machine harness. replace the VIMS 3G Application ECM.
C. Check the continuity of the Cat Data Link circuit in
STOP.
the machine harness:

• Measure the resistance between connector • NOT OK – Diagnostic codes are present for the
other ECM in the event list.
contact 8 (wire 893-GN(Green)) of the Advisor
ECM and connector contact 8 (wire Repair: Perform the troubleshooting procedure
893-GN(Green)) of the VIMS 3G Application for the other diagnostic codes.
ECM.
STOP.
• Measure the resistance between connector
contact 9 (wire 892-BR(Brown)) of the Advisor
ECM and connector contact 9 (wire
892-BR(Brown)) 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.

• 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:
KENR9938-14 111
Diagnostic Code Procedures

i06753701

MID 053 - CID 1273 - FMI 02

SMCS Code: 7610-038-CS

Conditions Which Generate This Code:

Illustration 94 g02714481
Schematic of the Cat Data Link for770G, 772G and
777G Off-Highway Trucks, 773G and 775G Quarry
Trucks
112 KENR9938-14
Diagnostic Code Procedures

Illustration 95 g03859095
Schematic of the Cat Data Link for 777E and 773E Off-Highway Trucks

This diagnostic code is associated with the Chassis • OK – All part numbers are correct.Proceed to test
ECM. This failure results in codes that are logged step 2.
against an ECM that cannot be explained. The
Advisor ECM cannot communicate with the Chassis • NOT OK – All part numbers are NOT correct. The
ECM or the ECM appears to work intermittently. part number of the Advisor ECM may be incorrect.
The part number of the Chassis ECM may be
Test Step 1. VERIFY THE HARDWARE incorrect. The incorrect software for the ECM may
AND THE SOFTWARE PART NUMBERS. also be installed.

A. Verify that the following information is correct: Repair: Replace the incorrect ECM with an
ECM that has the correct part number. Flash
• The part number of the software for the Advisor the correct, most current software. See Testing
ECM and Adjusting, “Electronic Control Module
(ECM) - Flash Program”.
• The part number of the “Chassis ECM
software” STOP.

• The part number of the Advisor ECM Test Step 2. INSPECT THE HARNESS
• The part number of the Chassis ECM CONNECTIONS.
Note: Consult the business unit that produces the A. Turn the disconnect switch to the OFF position.
product for the correct part numbers of the B. Inspect all harness connections that are related to
configuration software. the Cat Data Link. Make sure that the connectors
are clean and tight.
Expected Result:
C. Check the connectors for proper mating.
All part numbers are correct.
D. Check the wires at the connector.
Results:
KENR9938-14 113
Diagnostic Code Procedures

E. Check each wire for nicks or signs of abrasion in STOP.

the insulation.
F. Check for moisture at the connector. Test Step 4. CHECK FOR A SHORT TO
THE +BATTERY CIRCUIT.
G. Check the connectors for dirty contacts or
corroded contacts. A. The disconnect switch remains in the OFF
position.
H. Check each pin and each socket of the machine
harness connectors. B. All related electronic control modules remain
disconnected from the machine harness.
Expected Result:
C. At the machine harness connector for the Advisor
The machine harness connectors are tight and free ECM, perform the checks that are listed here:
of corrosion.
• Measure the resistance between the connector
Results: contact 1 (wire 113-OR(Orange)) and
connector contact 8 (wire 893-GN(Green)).
• OK – The machine harness connectors are tight
and free of corrosion.Proceed to test step 3. • Measure the resistance between connector
contact 1 (wire 113-OR(Orange)) and
• NOT OK – The machine harness connectors are in connector contact 9 (wire 892-BR(Brown)).
need of repair.
Expected Result:
Repair: Repair the machine harness or replace
the machine harness. The resistance is greater than 5.0 ohms.

STOP. Results:

• OK – The harness circuit resistance is correct.

Test Step 3. CHECK FOR SHORTS TO Proceed to test step 5.
GROUND.
A. The disconnect switch remains in the OFF • NOT OK – The resistance is less than 5.0 ohms.
The machine harness has failed.
position.
B. Disconnect the machine harness from all Repair: There is a short between the +battery
electronic control modules that use the Cat Data circuit and the Cat Data Link circuit in the
Link. machine harness. Repair the machine harness
or replace the machine harness.
C. At the machine harness for the Advisor ECM,
measure the resistance between frame ground STOP.
and connector contact 8 (wire 893-GN(Green))
and connector contact 9 (wire 892-BR(Brown)) of Test Step 5. CHECK FOR A OPEN
the Cat Data Link circuit . HARNESS.
Expected Result: A. The disconnect switch remains in the OFF
position.
The resistance is greater than 5 ohms.
B. All related electronic control modules remain
Results: disconnected from the machine harness.

• OK – The resistance is greater than 5000 ohms. C. Check the continuity of the Cat Data Link circuit in
The harness circuit resistance is correct.Proceed the machine harness:
to test step 4.
• Measure the resistance between connector
• NOT OK – The resistance is less than 5000 ohms. contact 8 (wire 893-GN(Green)) of the Advisor
The machine harness has failed. ECM and connector contact J1-8 (wire
893-GN(Green)) of the Chassis ECM.
Repair: There is a short between frame ground
and the Cat Data Link circuit in the machine • Measure the resistance between connector
harness. Repair the machine harness or contact 9 (wire 892-BR(Brown)) of the Advisor
replace the machine harness. ECM and connector contact J1-9 (wire
892-BR(Brown)) of the Chassis ECM.
114 KENR9938-14
Diagnostic Code Procedures

Expected Result: i06753704

The resistance measures less than 5 ohms. MID 053 - CID 1273 - FMI 09
Results: SMCS Code: 7610-038-CS

• 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 five

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
ELECTRONIC CONTROL MODULES.
A. Reconnect all the electronic control modules that
use the Cat Data Link.
B. Turn the disconnect switch and the key start
switch to the ON position.
C. After each of the electronic control modules has
been reconnected, check the event list for
diagnostic codes that are logged against the ECM.

Expected Result:
Diagnostic codes are not present for the other
electronic control modules in the event list.

Results:

• OK – Diagnostic codes are NOT present for the

other electronic control modules (ECM).
Illustration 96 g02714481

Repair: The Chassis ECM has failed. It is Schematic of the Cat Data Link for770G, 772G and
unlikely that the ECM has failed. Exit this 777G Off-Highway Trucks, 773G and 775G Quarry
Trucks
procedure. Perform this procedure again. If the
failure is not found, replace the ECM.

STOP.

• NOT OK – Diagnostic codes are present for the

other electronic control modules (ECM).

Repair: The Advisor 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
Testing and Adjusting, “Electronic Control
Module (ECM) - Replace”.

STOP.
KENR9938-14 115
Diagnostic Code Procedures

Illustration 97 g03859095
Schematic of the Cat Data Link for 777E and 773E Off-Highway Trucks

This diagnostic code is recorded when the Advisor Expected Result:

ECM does not receive expected information from the
Chassis ECM through the Cat Data Link for a period All part numbers are correct.
of more than five seconds.
Results:
System Response:
• OK – All part numbers are correct.Proceed to test
This failure results in events that are logged against step 2.
an ECM that can not be explained directly. The
Advisor ECM cannot communicate with this ECM or • NOT OK – All part numbers are NOT correct.
the ECM appears to communicate intermittently.
Repair: The installed Advisor ECM or the
Test Step 1. VERIFY THE HARDWARE Chassis ECM has the wrong part number or the
AND THE SOFTWARE PART NUMBERS. incorrect configuration software is installed.
Replace the incorrect Advisor ECM or the
A. Verify that the following information is correct: Chassis ECM with a module that has the
correct part number. Flash the correct
• The part number of the “Advisor ECM onboard configuration software. See the Testing and
software” Adjusting, “Electronic Control Module (ECM) -
Flash Program” section of this manual.
• The part number of the “Chassis ECM flash
software” STOP.
• The part number of the Advisor ECM
Test Step 2. INSPECT THE HARNESS
• The part number of the Chassis ECM CONNECTIONS.
Note: Consult the Business Unit that produces the A. Turn the disconnect switch to the OFF position.
product for the correct part numbers of the
configuration software.
116 KENR9938-14
Diagnostic Code Procedures

B. Inspect all harness connections that are related to The resistance is greater than 5000 ohms.
the Cat Data Link. Make sure that the connectors
are clean and tight. Results:
C. Check the connectors for proper mating. Ensure • OK – The resistance is greater than 5000 ohms.
that all the seals are present and in place. The harness circuit resistance is correct.Proceed
to test step 4.
D. Check the harness for signs of damage or
abrasion. • NOT OK – The resistance is less than 5000 ohms.
E. Check the wires at the connector. Ensure that the The machine harness has failed.
wires are secured tightly into the connector. Take
care not to pull the wire out of the connector. Repair: There is a short between frame ground
and the Cat Data Link circuit in the machine
F. Check the exposed wires at the connectors for harness. Repair the machine harness or
nicks or signs of abrasion. replace the machine harness.

G. Check for moisture inside the connector. STOP.

H. Check the connectors for dirty contacts or
corroded contacts. Test Step 4. CHECK FOR SHORT TO
+BATTERY
I. Check each pin and each socket of the machine
harness connectors. Ensure that the contacts are A. The disconnect switch remains in the OFF
properly installed. The contacts should mate position.
correctly when the two pieces of the connector are
B. All related electronic control modules remain
placed together.
disconnected from the machine harness.
Expected Result: C. At the machine harness connector for the Advisor
ECM, perform the checks that are listed here:
The machine harness connectors are tight and free
of corrosion.
• Measure the resistance between the +Battery
Results: connector contact 1 (wire 113-OR(Orange))
and connector contact 8 (wire 893-GN(Green)).
• OK – The machine harness connectors are tight
and free of corrosion.Proceed to test step 3. • Measure the resistance between connector
contact 1 (wire 113-OR(Orange)) and
• NOT OK – The machine harness connectors are in connector contact 9 (wire 892-BR(Brown)).
need of repair.
Expected Result:
Repair: Repair the machine harness or replace
The resistance is greater than 5000 ohms.
the machine harness.
Results:
STOP.
• OK – The harness circuit resistance is correct.
Test Step 3. CHECK FOR SHORTS TO Proceed to test step 5.
GROUND
• NOT OK – The resistance is less than 5000 ohms.
A. The disconnect switch remains in the OFF The machine harness has failed.
position.
Repair: There is a short between the +battery
B. Disconnect the machine harness from all
and the Cat Data Link circuit in the machine
electronic control modules that use the Cat Data harness. Repair the machine harness or
Link. replace the machine harness.
C. At the machine harness for the Advisor ECM,
measure the resistance between frame ground STOP.
and connector contacts 8 (wire 893-GN(Green))
and connector contact 9 (wire 892-BR(Brown)) of Test Step 5. CHECK FOR OPEN
the Cat Data Link circuit. HARNESS
Expected Result:
KENR9938-14 117
Diagnostic Code Procedures

A. The disconnect switch remains in the OFF Repair: The Chassis ECM has failed. It is
position. unlikely that the ECM has failed. Exit this
procedure. Perform this procedure again. If the
B. All related electronic control modules remain failure is not found, replace the ECM. See the
disconnected from the machine harness. Testing and Adjusting, “Electronic Control
Module (ECM) - Replace” section of this
C. Check the continuity of the Cat Data Link circuit in
manual.
the machine harness:
STOP.
• Measure the resistance between connector
contact 8 (wire 893-GN(Green)) of the Advisor
• NOT OK – Diagnostic codes are present for the
ECM and connector contact J1-8 (wire other electronic control modules in the event list.
893-GN(Green)) of the Chassis ECM.
Repair: The Advisor ECM has failed. It is
• Measure the resistance between connector unlikely that the ECM has failed. Exit this
contact 9 (wire 892-BR(Brown)) of the Advisor procedure. Perform this procedure again. If the
ECM and connector contact J1-9 (wire failure is not found, replace the ECM. See the
892-BR(Brown)) of the Chassis ECM. Testing and Adjusting, “Electronic Control
Module (ECM) - Replace” section of this
Expected Result: manual.
The resistance measures less than 5 ohms. STOP.
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
ELECTRONIC CONTROL MODULES.
A. Reconnect all the electronic control modules 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 electronic control
modules.

Expected Result:
Diagnostic codes are not present for the other
electronic control modules in the event list.

Results:

• OK – Diagnostic codes are not present for the

other electronic control modules (ECM) in the
event list.
118 KENR9938-14
Diagnostic Code Procedures

i06753878

MID 053 - CID 1273 - FMI 14

SMCS Code: 7610-038-CS

Conditions Which Generate This Code:

Illustration 98 g02714481
Schematic of the Cat Data Link for770G, 772G and
777G Off-Highway Trucks, 773G and 775G Quarry
Trucks
KENR9938-14 119
Diagnostic Code Procedures

Illustration 99 g03859095
Schematic of the Cat Data Link for 777E and 773E Off-Highway Trucks

This diagnostic code is recorded when the Chassis The proper versions of software are installed on the
ECM is not sending the necessary parameters to Advisor ECM and the Chassis ECM.
theAdvisor ECM at the proper rate. The update rate
for parameters that are generated by the Chassis Results:
ECM is not correct. The communication failure may
be due to disconnected connectors or a faulty wiring • YES – The versions of software are compatible.
harness. Proceed to Test Step 2.
The possible causes of this diagnostic code are
listed: • NO – The proper software is not installed.

• The Chassis ECM has the incorrect software Repair: Flash the proper software to the
installed. appropriate ECM. Cycle the key switch to
initialize the new software. Ensure that the
• The Advisor ECM has the incorrect software diagnostic code is no longer active.
installed.
STOP.
• Incompatible software may be installed.
• The fuse for the Chassis ECM may have failed. Test Step 2. RECHECK FOR DIAGNOSTIC
CODES.
A. Ensure that the diagnostic code is active.
Test Step 1. CHECK THE CHASSIS ECM
AND THE ADVISOR ECM FOR PROPER Expected Result:
SOFTWARE VERSIONS.
The diagnostic code is inactive. The diagnostic code
A. Use Caterpillar Electronic Technician (ET) to verify indicator is inactive.
that the versions of software are compatible.
Results:
Expected Result:
120 KENR9938-14
Diagnostic Code Procedures

• YES – The diagnostic code indicator and the i07814365

diagnostic code are inactive.
MID 053 - CID 4255 - FMI 09
Repair: Clear the diagnostic code.
SMCS Code: 7490
STOP.
Conditions Which Generate This Code:
• NO – The diagnostic code is active.

Repair: Ensure that the proper software is

installed before replacing the ECM. If the
software is correct, replace the Advisor ECM.
See Testing and Adjusting, “Electronic Control
Module (ECM) - Replace”. If the Advisor ECM
was just replaced , install a new Chassis ECM.
See Testing and Adjusting, “Electronic Control
Module (ECM) - Replace” for the machine that
is being serviced.

STOP.

Illustration 100 g02714481

Schematic of the Cat Data Link for770G, 772G and
777G Off-Highway Trucks, 773G and 775G Quarry
Trucks
KENR9938-14 121
Diagnostic Code Procedures

Illustration 101 g03859095

Schematic of the Cat Data Link for 777E and 773E Off-Highway Trucks

This diagnostic code is recorded when the Advisor • Ensure that there are no active diagnostic code.
ECM does not receive expected information from the
instrument cluster through the CAN Data Link for System Response:
more than five seconds. The diagnostic code MID
053 - CID 4255 - FMI09 corresponds to Telemetry This failure results in events that are logged against
Data Link #2 abnormal update rate. an ECM that cannot be explained directly. The
Advisor ECM cannot communicate with the
instrument cluster or the instrument cluster appears
Troubleshooting MID 053 - CID 4255 - FMI09 to communicate intermittently.
MID 053 - CID 4255 - FMI09 (Telemetry Data Link #2
abnormal update rate) has been appearing in the Test Step 1. VERIFY THE HARDWARE
active codes on the machine dashboard on certain
Off-Highway Trucks. The information being displayed AND THE SOFTWARE PART NUMBERS.
is sent from the Product Link Electronic Control A. Verify that the following information is correct:
Module (ECM).
Troubleshoot the code using the following • The part number of the “Advisor ECM onboard
procedures: software”

• Check if the truck is fitted with Scoreboard as • The part number of the Advisor ECM
factory fitment
Note: Consult the Business Unit that produces the
• If Scoreboard is not installed from factory, Connect product for the correct part numbers of the
CAT ET to the product link ECM configuration software.

• Check for the configuration: External Payload Expected Result:

Indicator Configuration
All part numbers are correct.
• If configuration found to be installed, disable
“External Payload Indicator Configuration” Results:
• Do ignition Key OFF and Key ON
122 KENR9938-14
Diagnostic Code Procedures

• OK – All part numbers are correct.Proceed to test Repair: Repair the machine harness or replace
step 2. the machine harness.

• NOT OK – All part numbers are NOT correct. STOP.

Repair: The installed Advisor ECM has the Test Step 3. CHECK FOR SHORTS TO
wrong part number or the incorrect
configuration software is installed. Replace the GROUND
incorrect Advisor ECM with a module that has A. The disconnect switch remains in the OFF
the correct part number. Flash the correct position.
configuration software. See the Testing and
Adjusting, “Electronic Control Module (ECM) - B. Disconnect the machine harness from all
Flash Program” section of this manual. electronic control modules that use the CAN Data
Link.
STOP.
C. At the machine harness for the Advisor ECM,
Test Step 2. INSPECT THE HARNESS measure the resistance between frame ground
and connector contacts 34 (wire F712-GY(Grey))
CONNECTIONS. and connector contact 50 (wire F711-GN(Green))
A. Turn the disconnect switch to the OFF position. at the instrument cluster for the CAN Data Link.
B. Inspect all harness connections that are related to Expected Result:
the CAN Data Link. Make sure that the connectors
are clean and tight. Each resistance measurement is greater than 5000
ohms.
C. Check the connectors for proper mating. Ensure
that all the seals are present and in place. Results:
D. Check the harness for signs of damage or • OK – Each resistance measurement is greater
abrasion. than 5000 ohms. The harness circuit resistance is
E. Check the wires at the connector. Ensure that the correct.Proceed to test step 4.
wires are secured tightly into the connector. Take
• NOT OK – One resistance measurement is less
care not to pull the wire out of the connector.
than 5000 ohms. The machine harness has failed.
F. Check the exposed wires at the connectors for
nicks or signs of abrasion. Repair: There is a short between frame ground
and the circuit for the CAN Data Link in the
G. Check for moisture inside the connector. machine harness. Repair the machine harness
or replace the machine harness.
H. Check the connectors for dirty contacts or
corroded contacts. STOP.
I. Check each pin and each socket of the machine
harness connectors. Ensure that the contacts are Test Step 4. CHECK FOR SHORT TO
properly installed. The contacts should mate +BATTERY
correctly when the two pieces of the connector are
placed together. A. The disconnect switch remains in the OFF
position.
Expected Result: B. All related electronic control modules remain
The machine harness connectors are tight and free disconnected from the machine harness.
of corrosion. C. At the machine harness connector for the Advisor
ECM, perform the checks that are listed here:
Results:
• Measure the resistance between the +Battery
• OK – The machine harness connectors are tight
connector contact 1 (wire 133-RD(Red)) and
and free of corrosion.Proceed to test step 3.
connector contact 34 (wire F712-GY(Grey)).
• NOT OK – The machine harness connectors are in
• Measure the resistance between the +Battery
need of repair.
connector contact 53 (wire 133-RD(Red)) and
connector contact 34 (wire F712-GY(Grey)).
KENR9938-14 123
Diagnostic Code Procedures

• Measure the resistance between the +Battery Results:

connector contact 68 (wire 133-RD(Red)) and
connector contact 34 (wire F712-GY(Grey)). • OK – Each resistance measurement is less than 5
ohms. The circuit for the CAN Data Link in the
• Measure the resistance between connector machine harness is correct.Proceed to test step
contact 1 (wire 133-RD(Red)) and connector 6.
contact 50 (wire F711-GN(Green)).
• NOT OK – One resistance measurement is
• Measure the resistance between connector greater than 5 Ohms. The machine harness has
contact 53 (wire 133-RD(Red)) and connector failed.
contact 50 (wire F711-GN(Green)).
Repair: The circuit for the CAN Data Link is
• Measure the resistance between connector open in the machine harness. Repair the
contact 68 (wire 133-RD(Red)) and connector machine harness or replace the machine
harness.
contact 50 (wire F711-GN(Green)).
STOP.
Expected Result:
Each resistance measurement is greater than 5000 Test Step 6. CHECK FOR ADDITIONAL
ohms.
DIAGNOSTIC CODES FOR THE OTHER
Results: ELECTRONIC CONTROL MODULES.
A. Reconnect all the electronic control modules that
• OK – The harness circuit resistance is correct.
use the CAN Data Link.
Proceed to test step 5.
B. Turn the disconnect switch and the key start
• NOT OK – One resistance measurement is less switch to the ON position.
than 5000 ohms. The machine harness has failed.
C. Check the Event List for diagnostic codes that are
Repair: There is a short between the +battery logged against the other electronic control
and the circuit for the CAN Data Link in the modules.
machine harness. Repair the machine harness
or replace the machine harness. Expected Result:

STOP. Diagnostic codes are not present for the other

electronic control modules in the event list.
Test Step 5. CHECK FOR AN OPEN Results:
HARNESS
• OK – Diagnostic codes are not present for the
A. The disconnect switch remains in the OFF
other electronic control modules (ECM) in the
position. event list.
B. All related electronic control modules remain
disconnected from the machine harness. Repair: The instrument cluster has failed.
Failure of the instrument cluster is unlikely. Exit
C. Check the continuity of the circuit for the CAN this procedure. Perform this procedure again. If
Data Link in the machine harness: the failure is not found, replace the instrument
cluster.
• Measure the resistance between connector
contact 34 (wire F712-GY(Grey)) of the Advisor STOP.
ECM and connector contact 20 (wire
F712-GY(Grey)) of the instrument cluster. • NOT OK – Diagnostic codes are present for the
other electronic control modules in the event list.
• Measure the resistance between connector
contact 50 (wire F711-GN(Green)) of the Repair: The Advisor ECM has failed. Failure of
Advisor ECM and connector contact 19 (wire the ECM is unlikely. Exit this procedure.
F711-GN(Green)) of the instrument cluster. Perform this procedure again. If the failure is
not found, replace the ECM. See the Testing
Expected Result: and Adjusting, “Electronic Control Module
(ECM) - Replace” section of this manual.
Each resistance measurement is less than 5 ohms.
STOP.
124 KENR9938-14
Diagnostic System Procedures

Diagnostic System (Table 7, contd)

Specifications of the Alternators
Procedures Peak Am- Minimum
perage Peak Am-
Rating perage
Rating
i04831772
2Y-8310 21 19

Charging System 6T-1395, 7T-2095, OR-3653 33 30

SMCS Code: 1406-038 6N-9294, OR-5217, OR-3482 35 32

5N-5692, OR-2698 45 41
System Operation Description:
Table 7 5S-9088, 100-5047, 50 45
112-5041, 3E-7578, OR-5206,
Specifications of the Alternators OR-3667, OR-3668

Peak Am- Minimum 109-2362, 9W-3043 55 50

perage Peak Am- , OR-3652( “D+” ), 112-8032
Rating perage
Rating 3E-7772( “IG” ), OR-9437( “IG” 60 54
), 105-3132( “IG” ), 4N-3986,
12 V Alternators OR-5203
8C-5535 32 28 155-7434, 132-2156( “I” ), 70 63
107-7977( “I” ), OR-8279( “I” )
7N-4784, OR-5201 40 36
169-4319, 167-7812 75 67.5
6T-1396, 7T-2096, 8C-5908, 51 46
OR-3654 107-7976, 114-2401, 75 68
OR-8997, 3E-7577, OR-3615
9W-2648, 9W-2949, 8T-9700, 55 49
105-2811( “IG” ), OR-4327( “IG” 165-5140 100 90
), 105-2812( “IG” ), OR-9273(
“IG” ), 34-3268, 68-4139, 9X-7803, OR-3749 100 90
3E-7295( “D+” ), 7T-2876( “D+”
12 VDC Alternators That Are Discontinued (Parts Only)
), 100-8223
6T-1193 18 16
7G-7889 60 54
7N-6118, 6N-5460, 4N-4540 40 36
8C-5510( “I” ), OR-5200 61 55
6T-1195 42 38
8N-2268 75 68
7X-1340 45 41
3E-7892, OR-3616 85 77
9G-6079, 6T-1194 63 57
105-2813( “IG” ), OR-9274( “IG” 90 81
), 105-2814( “IG” ), OR-4328( 24 VDC Alternators That Are Discontinued (Parts Only)
“IG” ), 149-2064( “REG” ),
OR-9410( “REG” ), 9X-0341( “D 9G-6081, 6T-1196 40 36
+” )
“D+” Diode trio output
8C-6163, OR-1699, 107-2519 105 95 The alternator requires excitation from an external source.

167-7816 110 99 “ REG”” - Terminal (Regulator)

The alternator requires excitation from an external source.
9X-6796, 9X-9096, 121-4134, 115 104
121-4136, OR-3527 I - Ignition Terminal
The alternator can be excited from an external source through
3E-8827, 121-4135, 130 117 this terminal.
117-1379(I)
IG - “Ignition Terminal” .
152-8746 135 122 System voltage must be supplied to this terminal in order to turn
125-9597, OR-8332 145 131 on the alternator. Some of these alternators use the IG terminal
as a sense terminal.
24 V Alternators
2P-1204, 3Y-8200 19 17

(continued)
KENR9938-14 125
Diagnostic System Procedures

Often when problems with the charging system are • YES – The voltage reads .2 volts or more. The
being investigated, the alternator is not the problem. excitation circuit is correct.Proceed to test step 4.
If a low battery condition is present test the batteries
first. See Special Instruction, SEHS7633, “Battery • NO – The voltage is less than .2 volts. There is a
Test Procedure” for more information. If the engine problem in the wiring harness to the alternator or
cranks slowly, then test the starting system. See there is a poor electrical connection. Correct the
Service Magazine, SEPD0020, “Testing The Starter problem and operate the machine. Watch for a
On The Engine” for more information. If a warning recurrence of the problem.
indicator for the charging system is ON, see Service
Magazine, SEBD1751, “Difference Between
Alternator Indicator In Electronic Monitoring System STOP.
(EMS) And Low Voltage Indicator In Operating
Monitoring System (OMS)”. Test Step 3. CHECK THE RESISTANCE IN
Note: Severely discharged batteries can cause low
THE EXCITATION CIRCUIT
system voltage. Low system voltage can occur even Note: This step is only for alternators with external
while the engine is running above idle, and the excitation when the terminal for excitation is Labeled:
alternator is working properly. Proper low engine idle “IG” .
is also important.
A. Turn the key start switch to the ON position.

Test Step 1. DETERMINE THE METHOD B. Verify voltage at the excitation terminal. Connect
the red lead from a multimeter to the excitation
OF EXCITATION FOR THE ALTERNATOR. terminal. Connect the black test lead to a ground
A. Check the rear of your alternator in order to source (alternator case ground).
determine the method of excitation. See table 7 in
order to verify the proper alternator excitation. Note: For G3B, K3A, and L3A alternators, Insert a
7X-1710 Multimeter Probe Group into the rear of
Expected Result: the middle wire in the connector. See figure 102
below. Insert the probes spoon lead between the seal
Test method 1. These alternators have a “1” , “REG” , and the wire that surrounds the wire and the outer
or “D+” terminal. Test method 2. These alternators shell of the connector. Do not insert the probe
are self-excited. Test method 3. These alternators between the wire insulation and the black seal. This
have a “IG” terminal. terminal (IG) is the terminal for excitation.
Results:

• Method 1 – The alternator has a “1” , “REG” , or “D

+” terminal.Proceed to test step 2.

• Method 2 – The alternator is self-excited.Proceed

to test step 4.

• Method 3 – The alternator has an “IG” terminal.

Proceed to test step 3.

Test Step 2. CHECK THE RESISTANCE IN

THE EXCITATION CIRCUIT.
A. Turn the key start switch to the ON position.
B. Verify voltage at the excitation terminal. Connect
the red lead from a multimeter to the excitation
terminal. Connect the black lead to a ground
source (alternator case ground).
C. Read the voltage that is shown on the multimeter.
Illustration 102 g00496660
Expected Result: Special technique for alternators: G3B, Y3A and L3A.
The voltage reads at least .2 volts.
C. Read the voltage that is shown on the multimeter.
Results:
126 KENR9938-14
Diagnostic System Procedures

Expected Result: the previous test step “Check The System

Voltage” . The voltage is also less than the
The voltage measurement is within .5 volts of the maximum voltage that is listed in the specifications
battery voltage. for the alternator. The alternator is partially
charging the battery.Proceed to test step 6.
Results:
• VOLTAGE TOO HIGH – The voltage
• YES – The voltage reads battery voltage. The measurement is greater than the voltage that was
excitation circuit is correct.Proceed to test step 4. observed in the previous test step “Check The
System Voltage” . The voltage is also greater than
• NO – The voltage is less than .5 volts of the the maximum voltage that is listed in the
battery. There is a problem in the wiring harness to specifications for the alternator. The alternator is
the alternator or there is a poor electrical over charging.Proceed to test step 19.
connection. Correct the problem and operate the
machine. Watch for a recurrence of the problem. • VOLTAGE LOWER – The voltage is not higher
than the voltage that was observed in the previous
STOP. test step.Proceed to test step 7.

Test Step 4. CHECK THE SYSTEM Test Step 6. TEST THE ALTERNATOR
VOLTAGE. OUTPUT.
A. Before you start the machine, connect a voltmeter
Note: For the proper output current, refer to table 7 .
between the “B+” terminal and the case of the
alternator. Turn OFF all electrical loads. A. Ensure that the batteries are NOT fully charged.
B. Turn the key to the ON position but do not start the Note: A fully charged battery may have open circuit
engine. Read the voltage on the voltmeter. Make a voltage above 12.5 V on 12 V systems. 24 V systems
note of the voltage that was measured. may be as high as 25 V.
Expected Result: B. If the batteries are fully charged, then crank the
engine for 30 seconds. This action reduces the
This voltage should be approximately system
voltage. battery voltage. Operate the lights for 10 minutes
while the engine is off as an alternative.
Results: C. Connect the 9U-5795 Current Probe to a DMM
(digital multimeter) or use a 225-8266 Ammeter
• YES – The voltage is approximately system
voltage. Proceed to test step 5. Tool Gp. The multimeter must have a peak hold
feature. Clamp the probe around the alternator
• NO – The voltage is less than system voltage. output wire “B+” . Before you clamp the probe
Proceed to test step 7. around the wire, ensure that the probe is “zeroed”.
D. Set the digital multimeter to “peak hold” or “max
Test Step 5. CHECK THE OPERATION OF mode” on the “mV” scale.
THE ALTERNATOR.
E. Turn on all electrical accessories: lights, air
A. The voltmeter remains connected between the “B conditioning and radio.
+” terminal and the case of the alternator.
F. Start the machine, and immediately set the throttle
B. Start the machine. Set the throttle to at least 75 to at least 75 percent. The peak current will appear
percent. Read the voltage on the voltmeter. Make on the voltmeter in “peak hold” or “max” mode.
a note of the voltage that was measured.
Expected Result:
Expected Result:
The current reading should be at least 90 percent of
The voltage measurement is greater than the voltage the specified peak output.
that was recorded in the previous test step “Check
The System Voltage” . Results:

Results: • YES – The current is at least 90 percent of the

specified peak output. Proceed to test step 13.
• VOLTAGE HIGHER – The voltage measurement
is greater than the voltage that was observed in
KENR9938-14 127
Diagnostic System Procedures

• NO – The current is less than 90 percent of the E. Measure the voltage across the battery. Put the
specified peak output.Proceed to test step 7. red lead on the battery positive terminal, and put
the black lead on the battery negative terminal.
Test Step 7. CHECK THE DRIVE SYSTEM Make a note of the voltage that was measured.
OF THE ALTERNATOR.
Expected Result:
A. Check the condition of the alternator drive belt.
Clean the pulley and replace the drive belt if the The voltage at the battery should be less than the
voltage at the alternator. The difference in voltages
drive belt is oily. Dry the drive belt if the belt is wet.
should not be more than 1 V on 12 V systems. The
Replace the drive belt, if the belt is worn. difference should not be more than 2 V on 24 V
systems.
B. Check the tension of the alternator drive belt.
Adjust the drive belt to the correct tension. Results:
C. Check the nut on the alternator pulley. Tighten the
nut if the nut is loose. • YES – The voltage at the battery is less than the
voltage at the alternator. Also, the difference in
Expected Result: voltages is less than 1 V for 12 V systems and the
difference is less than 2 V for 24 V systems. The
The drive system of the alternator is functioning wiring that is related to the alternator is correct at
correctly. No corrections to the drive system were this time.
necessary.
Repair: There is an internal problem with the
Results: alternator. Repair the alternator or replace the
alternator.
• YES – The drive system of the alternator is
functioning correctly. No corrections were STOP.
necessary.Proceed to test step 8.
• NO – The voltage at the battery is less than the
• NO – The drive system of the alternator was not voltage at the alternator. However, the difference
functioning correctly. Corrections were necessary. in voltages is greater than 1 V for 12 V systems
and the difference is greater than 2 V for 24 V
Repair: Ensure that the problems have been systems.Proceed to test step 9.
corrected. Exit this procedure and retest the
alternator charging system.
Test Step 9. TEST THE POSITIVE SIDE OF
STOP. THE CHARGING CIRCUIT.
A. Measure the voltage between the frame ground
Test Step 8. TEST THE CHARGING and the “B+” alternator terminal. Make a note of
CIRCUIT. the voltage that was measured. Perform the next
measurement immediately.
A. Verify that the nut on the “B+” alternator terminal is
tight. Also, verify that the wire has a good B. Measure the voltage between the frame ground
connection to the “B+” terminal. and the + battery post. Make a note of the voltage
that was measured.
B. Many Caterpillar machines are equipped with a
connector for the 6V-2150 Starting/Charging Expected Result:
Analyzer. Use of this tester replaces the remainder
of this test step. To operate the analyzer, refer to The voltage difference does not exceed 1 V on 24 V
Tool Operating Manual, SEHS7768, “Using the systems or 0.5 V on 12 V systems.
6V-2150”.
Results:
C. Start the engine and set the throttle to at least 75
percent. Turn ON all electrical accessories for the • YES – The voltage difference does not exceed the
remainder of this test step. Allow the engine to run tolerance. The positive circuit is good.Proceed to
for at least 3 minutes before continuing. test step 10.

D. Measure the voltage between the “B+” alternator • NO – The voltage difference exceeds the
terminal and the alternator case ground. Make a tolerance.
note of the measured voltage. Perform the next
measurement immediately.
128 KENR9938-14
Diagnostic System Procedures

Repair: There is high resistance in the positive C. Disconnect the wire from the “R” terminal. Select
side of the charging circuit that is caused by “YES” if the “R” terminal is not used on the
one of the following conditions: machine.
• An electrical connection has loosened. Expected Result:
• An electrical connection has corroded. The voltage does not change.
• The main relay has failed.
Results:
• A circuit breaker has failed.
• YES – The voltage does not change.Proceed to
Repair the problem or replace any component test step 12.
that has failed. Exit this procedure and retest
the alternator charging system. • NO – The voltage rises and the alternator begins
charging.
STOP.
Repair: The wire to the “R” terminal is shorted.
Test Step 10. TEST THE NEGATIVE SIDE Repair the wiring or replace the wiring. Exit this
procedure and retest the alternator charging
OF THE CHARGING CIRCUIT. system.
A. Check the voltage between the negative battery
post and the alternator case ground. STOP.

Expected Result: Test Step 12. RESTORE THE RESIDUAL

The voltage does not exceed 1 V on 24 V systems or MAGNETISM OF THE ROTOR.
0.5 V on 12 V systems. A. Connect one end of a jumper wire to the “B+”
terminal ( “D+” terminal for K1, N1, and N3) of the
Results:
alternator.
• YES – The voltage difference does not exceed the B. Connect the other end of the jumper wire to the
tolerance. The negative circuit is good. Proceed to “R” terminal of the alternator for 2 seconds.
test step 11.
Expected Result:
• NO – The voltage difference exceeds the
tolerance. The voltage output rises on the “B+” terminal. The
residual magnetism of the rotor has been restored.
Repair: There is high resistance in the negative
side of the charging circuit that is caused by Results:
one of the following conditions:
• YES – The voltage output rises. The residual
• An electrical connection has loosened. magnetism of the rotor has been restored. The
alternator is now charging.
• The alternator ground has loosened.
Repair: Exit this procedure and retest the
• The engine ground has opened.
alternator charging system.
Repair the problem or replace any component
that has failed. Exit this procedure and retest STOP.
the alternator charging system.
• NO – The voltage output does not rise.
STOP.
Repair: There is an internal problem with the
Test Step 11. TEST THE CIRCUIT OF THE alternator. Repair the alternator or replace the
alternator.
“ R”” TERMINAL.
A. Start the engine and set the throttle to at least 75 STOP.
percent.
Test Step 13. TEST FOR UNDESIRABLE
B. Connect a voltmeter between the “B+” terminal
CURRENT FLOW IN THE ALTERNATOR
and the alternator case ground.
CHARGING SYSTEM.
KENR9938-14 129
Diagnostic System Procedures

A. Turn off all of the accessories. Turn the keyswitch failure is possibly an intermittent draw in the
to the OFF position. system. The batteries may have failed. Ensure
that NO accessories were ON during the test. Exit
B. Clamp a 9U-5795 Current Probe or 225-8266 this procedure and retest the alternator charging
Ammeter Tool Gp around the main ground cable. system.
Clamp the tool with the positive side away from the
battery. Reset the probe (zero) before you clamp STOP.
the probe around the wire. Read the current on the
meter. Make a note of the current that was • NO – The current is above 0.050 A. There is a
measured. draw in the system.Proceed to test step 16.

Expected Result: Test Step 15. MEASURE THE CURRENT

The current is below 2 A. The “YES” selection is OF THE SYSTEM BY REMOVING THE
dependent on the presence of a main disconnect NEGATIVE BATTERY CABLE.
switch on the machine that is being tested.
A. Disconnect the ground cable from the negative
Results: battery post. There may be more than one battery
that is connected to ground. Disconnect all of the
• YES - WITH DISCONNECT SWITCH – The batteries that are connected to ground. Do not
current is below 2 A.For machines with a main disconnect cables that are between batteries that
disconnect switch, proceed to test step 14. are connected in series.
• YES - WITHOUT DISCONNECT SWITCH – The B. Connect a multimeter between the disconnected
current is below 2 A.For machines without a main battery ground cable and one of the negative
disconnect switch, proceed to test step 15. battery terminals. Connect the red positive lead of
the multimeter to the cable. The negative lead
• NO – The current is above 2 A. There is a current should be connected to the battery terminal. Use
draw in the system.Proceed to test step 16. the 10A connections in order to avoid damage.

Test Step 14. MEASURE THE CURRENT Note: The standard acceptable current draw is 50
OF THE SYSTEM BY USING THE MAIN mA. A current draw above 50 mA usually indicates a
problem. However, some large machines with
DISCONNECT SWITCH. multiple electronic control modules have a higher
A. Turn the disconnect switch to the ON position. acceptable limit. For more information, contact a
Caterpillar dealer or contact the business unit that
B. Connect a multimeter across the disconnect produces the machine.
switch terminals. Connect the red lead to the
terminal on the frame side. Connect the black lead Expected Result:
to the terminal on the battery side. Use the 10A The current is below .050 A (50 mA).
connections in order to avoid damage.
C. Turn the disconnect switch to the OFF position Results:
and read the current. Make a note of the
• YES – The current is below 0.050 A. The charging
measured current.
system is currently good. The problem is a
Note: The standard acceptable current draw is 50 possible intermittent current draw in the system.
mA. A current draw above 50 mA usually indicates a The batteries may have failed. Check that NO
problem. However, some large machines with accessories were ON during the test.
multiple electronic control modules have a higher
acceptable limit. For more information, contact a STOP.
Caterpillar dealer or contact the business unit that
produces the machine. • NO – The current is above 0.050 A. There is
excessive current flow in the system.Proceed to
Expected Result: test step 16.

The current is below 0.050 A (50 mA). Test Step 16. TEST THE CURRENT OF
Results: THE ALTERNATOR OUTPUT BELOW 2
AMPERES.
• YES – The current is below 0.050 A. The charging
A. Turn the keyswitch to the OFF position.
system is functioning properly at this time. The
130 KENR9938-14
Diagnostic System Procedures

B. Connect the 9U-5795 Current Probe to a DMM A. Make sure that every electrical component is
(digital multimeter) or use a 225-8266 Ammeter turned OFF. Make sure that the keyswitch is
Tool Gp. Clamp the probe around the “B+” wire of turned OFF. Make sure that the dome lights are
the alternator. Before you clamp the probe around OFF.
the wire, ensure that the probe is “zeroed”.
B. Clamp a 9U-5795 Current Probe or 225-8266
C. Read the current on the meter. Make a note of the Ammeter Tool Gp around the main ground cable.
current that was measured. Clamp the tool with the positive side away from the
battery. Reset the probe (zero) before clamping
Expected Result: the probe around the wire. Use the current probe if
the draw is above approximately 2 A. Use the
The current is under 2 A.
Ammeter if the draw is below approximately 2 A.
Results: C. Remove the fuses or open the circuit breakers one
at a time. Check the current after each fuse has
• YES – The current is under 2 A.Proceed to test been removed or each circuit breaker has been
step 17.
opened. After observing the current, reinstall the
• NO – The current is over 2 A. fuse or close the circuit breaker. Start with the
main circuits first, and proceed to smaller circuits.
Repair: There is an internal problem with the D. Check if any components on the circuit are ON.
alternator. Repair the alternator or Replace the
alternator. E. If everything is OFF, then disconnect electrical
components on the circuit one at a time. Monitor
STOP. the current after each component is disconnected.
F. All of the components in the circuit should be
Test Step 17. TEST THE OUTPUT
disconnected. If the problem still exists, then
CURRENT OF THE ALTERNATOR check the wiring in the circuit. There may be circuit
BELOW 0.015 AMPERES. leakage through corrosion or circuit leakage
A. Disconnect the wire from the “B+” terminal of the through a short.
alternator. Set the multimeter on the 10 amp scale. Note: The standard acceptable current draw is 50
Connect the red lead of the multimeter to the wire mA. A current draw above 50 mA usually indicates a
that was disconnected. Connect the black lead of problem. However, some large machines with
the multimeter to the “B+” terminal of the multiple electronic control modules have a higher
alternator. Make a note of the current that was acceptable limit. For more information, contact a
measured. Caterpillar dealer or contact the business unit that
produces the machine.
Expected Result:
Expected Result:
The current is less than 0.015 A.
The source of the excessive current draw was
Results: determined.

• YES – The current is under 0.015 A. The Results:

alternator is operating correctly. There may be a
current draw on the machine.Proceed to test step • YES – The source of the excessive current draw
18. was determined.

• NO – The current is over 0.015 A. Repair: Repair the problem or replace any
component that has failed. Exit this procedure
Repair: There is an internal problem with the and retest the alternator charging system.
alternator. Repair the alternator or replace the
alternator. STOP.

STOP. • NO – The source of the excessive current draw

was not determined.
Test Step 18. IDENTIFY THE SOURCE OF Repair: Exit this procedure and retest the
EXCESSIVE CURRENT DRAW. alternator charging system.
KENR9938-14 131
Diagnostic System Procedures

STOP. Test Step 20. TEST THE POSITIVE SIDE

OF THE CHARGING CIRCUIT.
Test Step 19. TEST FOR AN
A. Measure the voltage between the frame of the
OVERCHARGING CONDITION FROM machine and the “B+” terminal of the alternator.
THE ALTERNATOR. Make a note of the voltage that was measured.
A. Verify that the nut on the “B+” alternator terminal is Perform the next measurement immediately.
tight. Also, verify that the wire has a good B. Measure the voltage between the frame of the
connection to the “B+” terminal. machine and the positive terminal of the battery.
B. Many Caterpillar machines are equipped with a Make a note of the voltage that was measured.
connector for the 6V-2150 Starting/Charging
Expected Result:
Analyzer. Use of this tester replaces the remainder
of this test step. To operate the analyzer, refer to The voltage difference does not exceed 1 V on 24 V
Tool Operating Manual, SEHS7768, “Using the systems or 0.5 V on 12 V systems.
6V-2150”.
Results:
C. Start the engine and set the throttle to at least 75
percent. Turn ON all electrical accessories for the • VOLTAGE OK - ALT. WITHOUT IG/S TERM. –
remainder of this test step. Allow the engine to run The voltage difference does not exceed the
for at least 3 minutes before continuing. tolerance. The positive circuit is good.
D. Measure the voltage between the “B+” terminal of Repair: There is an internal problem with the
the alternator and the case of the alternator. Make alternator. Repair the alternator or Replace the
a note of the voltage that was measured. Perform alternator.
the next measurement immediately.
STOP.
E. Measure the voltage across the battery. Put the
red lead on the positive terminal of the battery, and • VOLTAGE EXCESSIVE - ALL ALT. – The voltage
put the black lead on the negative terminal of the difference exceeds the tolerance.
battery. Make a note of the voltage that was
measured. Repair: There is high resistance in the positive
side of the charging circuit that is caused by
Expected Result: one of the following conditions:
The voltage at the battery should be less than the • An electrical connection has loosened.
voltage at the alternator. On systems that are 12 V,
the difference in voltages should not be more than 1 • An electrical connection has corroded.
V. On systems that are 24 V, the difference should
not be more than 2 V. • The main relay has failed.

Results: • A circuit breaker has failed.

Correct the problem. Exit this procedure and
• YES – The voltage at the battery is less than the retest the alternator charging system.
voltage at the alternator. Also, the difference in
voltages is less than 1 V for 12 V systems and the STOP.
difference is less than 2 V for 24 V systems. The
wiring that is related to the alternator is correct at • VOLTAGE OK - ALT. WITH IG/S TERM. – The
this time. voltage difference does not exceed the tolerance.
The positive circuit is good.Proceed to test step
Repair: There is an internal problem with the 21.
alternator. Repair the alternator or Replace the
alternator.
Test Step 21. TEST FOR
STOP. OVERCHARGING
• NO – The voltage at the battery is less than the A. Start the engine and set the throttle to at least 75
voltage at the alternator. However, the difference percent.
in voltages is greater than 1 V for 12 V systems B. Measure the voltage between the sense terminal
and the difference is greater than 2 V for 24 V
(S) and/or the “IG” terminal to the case of the
systems.Proceed to test step 20.
alternator.
132 KENR9938-14
Diagnostic System Procedures

Expected Result: Expected Result:

The voltage at the “S” terminal and/or “IG” terminal is The fuse is correct.
above the specification.
Results:
Results:
• YES – The fuse is correct. Proceed to Test Step 3.
• YES – The measured voltage exceeds the
specification. There is an internal malfunction in • NO – The fuse is not correct.
the alternator. See the appropriate service manual
for the alternator in order to test the internal Repair: Replace the blown fuse or reset the
components and connections. circuit breaker. Observe the machine for a
recurrence of the problem. If the problem
STOP. persists, the reason for the blown fuse must be
isolated and corrected.
• NO – The voltage from the “B+” terminal to the
case of the alternator is below the measurement STOP.
that was taken in the initial tests. The sense circuit
in the generator set has high resistance. Correct Test Step 3. CHECK THE POWER WIRE
the problem. Exit this procedure and retest the
alternator charging system. TO THE ECM.
A. Turn the key start switch and the disconnect
STOP. switch to the OFF position.
i03938332
B. At the fuse, connect the lead from the multimeter
to wire 133-RD(Red).
Power Supply Circuit
C. At the ECM, connect the other lead from the
SMCS Code: 1408-038
multimeter to connector contact 1 and measure
System Operation Description: the resistance.

Power to the ECM can fail due to an open circuit in Expected Result:
the wire, or a blown fuse. A fuse is blown as a result
of an overloaded circuit. For example, the +battery The resistance is less than 5 ohms.
connection is shorted to ground.
Results:
Test Step 1. CHECK THE ECM FOR
• OK – The resistance is less than 5 ohms. The
POWER AND GROUND. wiring circuit is correct. Proceed to Test Step 4.
At the ECM, measure the voltage from contact 1 to
contact 2. • NOT OK – The resistance measurement is greater
than 5000 ohms. The wiring has an open circuit.
Expected Result:
Repair: Repair the wiring harness or replace
The voltage is system voltage. the wiring harness.

Results: STOP.

• OK – The voltage is system voltage. The power Test Step 4. CHECK THE ECM GROUND
supply circuit to the ECM is correct.
CONNECTIONS.
STOP. A. The keyswitch and the disconnect switch remain
in the OFF position.
• NOT OK – The voltage is not system voltage.
Proceed to Test Step 2. B. At the ECM, measure the resistance from
connector contact 2 to frame ground.
Test Step 2. CHECK THE FUSE
Expected Result:
Whenever the machine electronic components fail to
function, check the appropriate fuse for the ECM. The resistance is less than 5 ohms.
A. Check the fuse for the ECM. Results:
KENR9938-14 133
Diagnostic System Procedures

• OK – The resistance is less than 5 ohms. The

ground circuit is correct. The ECM may have
failed. This is unlikely. Perform this entire
procedure again. If the problem remains, the ECM
may need replaced. Contact your dealerships for
possible consultation with Caterpillar . This
consultation may greatly reduce repair time.

STOP.

• NOT OK – The resistance is greater than 5000

ohms. The ground circuit has failed.

Repair: The ground circuit has failed. Repair

the wiring harness or replace the wiring
harness.

STOP.
134 KENR9938-14
Testing and Adjusting

Testing And Adjusting After completion of the self test, the Dash Panel
Cluster goes to normal mode operation. This could
Section include subsequent machine tests.

i03938292

Testing and Adjusting Electrical Connector - Inspect

SMCS Code: 7553-040-WW

Reference: Special Instruction, SEHS9615,

i03938285 “Servicing DT Connectors”.

Self Test Reference: Special Instruction, REHS0148, “Listing

Of Deutsch Connector Components”
SMCS Code: 7490-038
Reference: Special Instruction, SEHS9065, “Use Of
CE Connector Tools”.
Self Test
The Dash Panel Cluster will initiate a self test when Reference: Service Magazine, SEPD0342,27
the engine key start switch is moved to the START January 97, “Field Repair Of Single Wire Breaks In
position. The gauge needles will move to the Harnesses (Sealed Splice)”.
maximum right position. The needles will remain
there for 0.5 seconds. The gauge needles will then Reference: Service Magazine, SEPD0371,28 July
be returned to minimum left, preventing the gauge 97, “Protection Of Unsealed Electrical Terminations
needles from circling to the bottom side of the gauge. For Machines In Corrosive Applications”.
Which would happen if the display is inverted. A self
test begins after the hardware is tested. Reference: Service Magazine, SEPD0473,24 May
99, “New DT Connector Plugs With Improved Seal
The ECM controlled test of the Dash Panel Cluster Retention”.
will begin after the hardware is tested. The test will
proceed while the engine key start switch remains in Reference: Service Magazine, SEPD0545,09
the RUN position. The test is initiated. This would October 00, “Dielectric Grease Should Not Be Used
happen because the Dash Panel Cluster is not In Electrical Connectors”.
required to operate through engine cranking.
Reference: Pocket Guide, SEBD0402, “Guidelines
The duration of the ECM controlled test is 3seconds. For Routing And Installing Wire Harness
During this time, the following functions will be
performed: Assemblies”.
This information will assist in detecting problems with
• The gauge needles are set to the minimum connectors and with wiring. If a problem is found,
position. The needles move smoothly from the correct the condition and verify that the problem is
minimum value to the maximum value during the resolved.
test.
Disconnecting and reconnecting connectors
• The icons and the segments are illuminated. The sometimes resolve intermittent electrical problems. It
illumination continues for the duration of the self is important to check for diagnostic codes
test. immediately before disconnecting a connector. Also
check for diagnostic codes after reconnecting the
• All LED indicators are illuminated for testing. connector. If the status of a diagnostic code is
changed due to disconnecting and reconnecting a
• The alarm mode activates at the beginning of the connector, there are several possible reasons. The
self test mode. The alarm state remains on for one likely reasons are loose terminals, improperly
second. 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.
KENR9938-14 135
Testing and Adjusting

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 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.
Illustration 103 g01960167
Guidelines (1) Former Seal Design
(2) Current Seal Design
• 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.
• If a wire is cut, always install a new terminal for the
repair. Illustration 104 g01960176
(3) Seal for a three-pin connector (typical example)
Tests
The plug end of the DT connector has a seal at the
mating end of the connector. This seal has been
Check Connectors for Moisture and improved on black connectors in order to help
Corrosion prevent slipping. Additionally, this seal is replaceable.
This improvement will help keep moisture and dirt
Inspect all wiring harnesses. Ensure that the routing from entering the connector.
of the wiring harness allows the wires to enter the
face of each connector at a perpendicular angle. The current seal design (2) is not interchangeable
Otherwise, the wire will deform the seal bore. This with the former design (1). The receptacle has also
will create a path for the entrance of moisture. Verify changed to the new colors.
that the seals for the wires are sealing correctly. 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.
136 KENR9938-14
Testing and Adjusting

2. Disconnect the suspect connector and inspect the STOP

connector seal. Ensure that the seals are in good
condition. If necessary, replace the connector. Check the Wires for Damage to the
3. Thoroughly inspect the connectors for evidence of Insulation
moisture entry.
1. Carefully inspect each wire for signs of abrasion, of
It is normal to see some minor seal abrasion on nicks, and of cuts. Inspect the wires for the
connector seals. Minor seal abrasion will not allow following conditions:
the entry of moisture. If moisture or corrosion is
evident in the connector, the source of the • Exposed insulation
moisture entry must be found and the source of
the moisture entry must be repaired. If the source • Rubbing of a wire against the chassis
of the moisture entry is not repaired, the problem
• Rubbing of a wire against a sharp point
will recur. Simply drying the connector will not fix
the problem. Check the following items for the 2. Check all of the wiring harness fasteners in order
possible moisture entry path: to verify that the harness is properly secured. Also
check all of the fasteners in order to verify that the
• Missing seals
harness is not compressed. Pull back the harness
• Improperly installed seals sleeves in order to check for a flattened portion of
wire. A fastener that has been overtightened will
• Nicks in exposed insulation flatten the harness. This damages the wires that
are inside the harness.
• Improperly mated connectors
Moisture can also travel to a connector through the Expected Result
inside of a wire. If moisture is found in a connector,
thoroughly check the connector's harness for The wires are free of abrasion, of nicks, and of cuts
damage. Also check other connectors that share the and the harness is properly clamped.
harness for moisture.
Results
Expected Result
OK – The harness is OK. Proceed to “Inspect the
The harness wiring, connectors, and seals are in Connector Terminals”.
good condition. There is no evidence of moisture in Not OK – There is damage to the harness.
the connectors.

Results Repair
OK – The harness wiring, connectors, and seals are
Repair the wires or replace the wires, as required.
in good condition. Proceed to “Check the Wires for Verify that the repair eliminates the problem.
Damage to the Insulation”.
Not OK – A problem has been found with the STOP
harness or the connectors.
Inspect the Connector Terminals
Repair A. Visually inspect each terminal in the connector.
Verify that the terminals are not damaged. Verify that
Repair the connectors or the wiring, as required. the terminals are properly aligned in the connector
Ensure that all of the seals are properly in place. and verify that the terminals are properly located in
Ensure that the connectors have been reattached. If the connector.
corrosion is evident on the pins, sockets or the
connector, use only denatured alcohol to remove the Expected Result
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 The terminals are properly aligned and the terminals
check again for moisture. If moisture reappears, the appear undamaged.
moisture is wicking into the connector. Even if the
moisture entry path is repaired, it may be necessary Results
to replace the wires. Verify that the repair eliminates
the problem. OK – The terminals are OK. Proceed to “Expected
Result”.
KENR9938-14 137
Testing and Adjusting

Repair
Not OK – The terminals of the connector are
damaged. 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
Repair problem.

Repair the terminals and/or replace the terminals, as STOP

required. Verify that the repair eliminates the
problem. Check Individual Pin Retention into the
STOP Socket
A. Verify that the sockets provide good retention for
Perform a Pull Test on Each Wire the pins. Disconnect the harness and insert a new pin
Terminal Connection 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
Illustration 105 g01625756
Use the 1U-5804 Crimp Tool (12-GA TO 18-GA) to
replace the damaged terminals. Verify that the repair
1. Ensure that the locking wedge for the connector is eliminates the problem.
installed properly. Terminals cannot be retained
inside the connector if the locking wedge is not STOP
installed properly. Refer to Illustration 104 .
2. Perform the 45 N (10 lb) pull test on each wire. Check the Locking Mechanism of the
Connectors
Each terminal and each connector should easily
withstand 45 N (10 lb) of tension and each wire 1. Ensure that the connectors lock properly. After
should remain in the connector body. This test locking the connectors, ensure that the two halves
checks whether the wire was properly crimped in cannot be pulled apart.
the terminal and whether the terminal was properly
inserted into the connector. 2. Verify that the latch tab of the connector is properly
latched. Also verify that the latch tab of the
Expected Result connector returns to the locked position.

Each terminal and each connector easily withstands Expected Result

45 N (10 lb) of pull and each wire remains in the
connector body. The connector will securely lock. The connector and
the locking mechanism are without cracks or breaks.
Results
Results
OK – All terminals pass the pull test. Proceed to
“Expected Result”. OK – The connectors are in good repair. Proceed to
“Perform the Wiggle Test on the Caterpillar Electronic
Not OK – A wire has been pulled from a terminal or a Technician (ET), and Caterpillar Electronic
terminal has been pulled from the connector. Technician (ET)”.
138 KENR9938-14
Testing and Adjusting

Not OK – The connector's locking mechanism is STOP

damaged or missing.
i07493451

Repair Wiring Harness (Open Circuit)

Repair the connector or replace the connector, as - Test
required. Verify that the repair eliminates the
problem. SMCS Code: 1408-081

STOP An open circuit is a failure of an electrical circuit that

results in no flow of electrical current. An open circuit
can be caused by several issues within the circuit. An
Perform the Wiggle Test on the open circuit is caused by a poor connection, broken
Caterpillar Electronic Technician (ET) wire, or a failed connection in one of the electrical
connectors used in a circuit. A normally closed circuit
will have less than 5 of resistance.
1. Select the Wiggle Test from the diagnostic tests on
Cat ET. Reference: For a complete electrical schematic,
refer to the Electrical System Schematic for the
2. Choose the appropriate group of parameters to machine that is being serviced.
monitor.
The following procedure is a way to check for an
3. Press the “Start” button. Wiggle the wiring harness open or a poor connection in a circuit.
in order to reproduce intermittent problems.
TEST FOR AN OPEN CIRCUIT.
If an intermittent problem exists, the status will be
highlighted and an audible beep will be heard. 1. Identify the connectors and the wire numbers of
the suspect circuits. Use the Electrical System
Expected Result Schematic of the machine to identify the circuits.
2. Turn the key start switch and the disconnect switch
No intermittent problems were indicated during the to the OFF position.
Wiggle Test.
3. Disconnect the component and the ECM or ECU
Results from the wiring harness.

OK – No intermittent problems were found. The 4. At one of the disconnected harness connections,
harness and connectors appear to be OK. If another place a jumper wire from the contact of the
procedure recommended this test, return to that suspect wire to frame ground.
procedure and continue testing. If the problem has
been resolved, return the machine to service. 5. At the other connector of the machine harness,
use the multimeter probes to measure the
STOP resistance from the contact of the suspect wire to
frame ground.
Not OK – At least one intermittent problem was
indicated. Expected Result: The resistance is less than 5
ohms.
OK – The resistance is less than 5 ohms. The
Repair harness circuit is correct.
Repair the harness or the connector. Verify that the
repair eliminates the problem. 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.
KENR9938-14 139
Testing and Adjusting

Stop. Stop.

i07493450 i03938288

Wiring Harness (Short Circuit) Module - Replace

- Test SMCS Code: 7490-510
SMCS Code: 1408-081 Prior to replacement of a module, ensure that
replacement is absolutely necessary. A diagnostic
A short circuit is a failure of an electrical circuit that code is seldom caused by the module. Always
results in undesired electrical current. Usually, a short ensure that the machine code is correct for the
circuit is a bypass of the circuit across a load. For machine. Also ensure that the power is available to
example, a short across the wires in a circuit for a the main display module. The system voltage is
lamp produces too much current in the wires but no required between the contacts 1 and 2 of the
current is measured at the lamp. The lamp is shorted connector for the main display module.
out. The resistance in a normal circuit can vary, but
the resistance between a particular circuit and other
unrelated circuits is always greater than 5000 ohms.
Procedure
The following procedure explains the test for a short 1. Replace the module.
circuit:
a. Turn the key start switch to the OFF position.
Reference: For a complete electrical schematic,
refer to Electrical System Schematic for the machine b. Disconnect the machine harness from the
that is being serviced. module.

TEST FOR A SHORT CIRCUIT. c. Ensure that the module that is replacing the old
module has the correct part number.
1. Identify the connectors and the wire numbers of
the suspect circuits. Use the Electrical System d. Install the new module.
Schematic of the machine to identify the circuits. Note: If the main display module that is replacing
2. Turn the key start switch and the disconnect switch the old module was previously removed from
to the OFF position. service, see Testing and Adjusting, “Main Display
Module Initialization - Adjust”.
3. Disconnect the component and the ECM or ECU
from the wiring harness. e. Connect the machine harness to the module.
On so equipped machines, make sure that the
4. At the machine harness connector for the ECM or harness code plug is installed.
ECU, place one of the multimeter probes on the
contact of the suspect wire. f. Turn the disconnect switch and the key start
switches to the ON position. Make sure that the
5. Use the other multimeter probe to check the module successfully completes the self test:
resistance across all other contacts in the see the Testing and Adjusting, “Self Test”
connectors of the ECM or ECU and frame ground. Section of this manual.
Expected Result: The resistance is greater than Expected Result
5000 ohms for all the measurements.
The module has been successfully replaced
OK – The resistance is greater than 5000 ohms for and the module has completed the self test.
all the measurements. The harness circuits are
correct. Results
Yes – The replacement of the module was
Stop. successful. The self test has been successfully
NOT OK – The resistance is less than 5 ohms. There completed. Proceed to Step 2.
is a short in the machine harness. The short is
between the suspected wire and the wire with the
No – The module has been successfully replaced.
lowest resistance measurement.
The self test was not successfully completed.
Ensure that the module is correct. Ensure that the
Repair: Repair the machine harness or replace installation is correct and ensure that no related
diagnostic codes are present.
the machine harness.

STOP –
140 KENR9938-14
Testing and Adjusting

2. Setup
a. Set up the optional display modules. See
Systems Operation, “Settings Menu” of this
manual.
Note: Once the module has been replaced
successfully, see Testing and Adjusting, RENR8284,
“Electronic Control Module (ECM) - Flash Program”.

i03938286

Module - Flash Program

SMCS Code: 7490-591
Perform the following procedure in order to flash
program the ECM. The ECM is flashed in order to
upgrade the software. Flash programming of the
ECM must also be done if the ECM has been
replaced. The Caterpillar Electronic Technician (ET)
contains the program WinFlash. WinFlash is used in
order to load software into the ECM. The following Illustration 106 g00901469
procedure is used in order to FLASH software into
the ECM for the Caterpillar Monitoring System. Rear view of Instrument Cluster
(1) Instrument Cluster connector
1. Procedure
a. Connect the 7X-1425 Data Link Cable
between the 7x-1700 Communication Adapter
and the Electronic Technician.
b. Connect the 139-4166 Data Link Cable
between the 7x-1700 Communication Adapter
and the diagnostic connector of the machine.
c. Turn the key to the ON position.
d. Use WinFlash in order to load the software.
Note: Flash programming is not allowed if the
engine is running, or the machine is moving.

i06285257

Connector Contact
Description
SMCS Code: 7490-546-CY
Illustration 107 g03870469
Table 8 shows the pin numbers of the connector for
the Instrument Cluster display. The signal on each (2)Instrument Cluster connector for 777E 2 and 773E
pin is also shown. 2 Off-Highway Trucks
KENR9938-14 141
Testing and Adjusting

Table 8
Pins of the Instrument Cluster (Table 9, contd)
773G , 775G
, and 777G Pins of the Advisor Display
773G, 775G
Pin Number Description of Signal , and 777G

1 B+ Pin Number Description of Signal

2 B- 5 Not Used
3 Chassis Ground 6 Not Used
4 STB L13 7 Not Used
5 Not Used 8 Cat Data Link +
6 Not Used 9 Cat Data Link -
7 Not Used 10 Not Used
8 Not Used 11 Not Used
9 Not Used 12 Not Used
10 STB - LH Turn Signal 13 Not Used
11 STB - RH Turn Signal 14 Not Used

12 STB - Input #1 15 Not Used

13 Not Used 16 Not Used

14 Not Used 17 Not Used

15 STB - High Beam 18 Not Used

19 Not Used
16 STB - Park/Dimming
20 Not Used
17 STB - Input #3
21 Not Used
18 Not Used
22 Not Used
19 CAN+
23 Not Used
20 CAN-
24 Not Used
21 CAN Shield
25 Not Used
22 Input #2
26 Not Used
23 Horn Driver
27 Not Used
24 Key Switch Input
28 Not Used
29 Not Used
Table 9 shows the pin numbers of the connector for
the Advisor display. The signal on each pin is also 30 Not Used
shown.
31 Not Used
Table 9
32 Not Used
Pins of the Advisor Display
773G, 775G 33 Not Used
, and 777G
34 CAN E-
Pin Number Description of Signal
35 CAN B+
1 B+ 36 CAN B
2 Ground 37 Not Used
3 Key Switch 38 Not Used
4 Dimming 39 Not Used

(continued) (continued)
142 KENR9938-14
Testing and Adjusting

(Table 9, contd)
Pins of the Advisor Display
773G, 775G
, and 777G

Pin Number Description of Signal

40 Not Used
41 Not Used
42 Not Used
43 Not Used
44 Not Used
45 Not Used
46 Not Used
47 Not Used
48 Not Used
49 Not Used
50 CAN E+
51 Not Used
52 Not Used
53 Not Used
54 Not Used
55 Not Used
56 Not Used
57 Not Used
58 Not Used
59 Not Used
60 Not Used
61 Not Used
62 Not Used
63 Not Used
64 Not Used
65 Not Used
66 Not Used
67 Not Used
68 Not Used
69 Not Used
70 Not Used
KENR9938-14 143
Testing and Adjusting

i06753879

System Schematic
SMCS Code: 7566

Illustration 108 g03859084

Connections for the monitoring system for 770G ,772G, and 777GOff-Highway Trucks, 773G, and 775G Quarry
Trucks
144 KENR9938-14
Testing and Adjusting

Illustration 109 g03859087

Connections for the monitoring system for 777E and 773E Off-Highway Trucks
KENR9938-14 145
Testing and Adjusting

Illustration 110 g02715025

146 KENR9938-14
Testing and Adjusting

Data Link Connections for 770G ,772G, and 777G Off-Highway Trucks, 773G, and 775G Quarry Trucks

Illustration 111 g03859088

Data Link Connections for 777E and 773E Off-Highway Truck/Tractors
KENR9938-14 147
Index Section

Index
C Settings Menu .................................................40
MID 053 - CID 0168 - FMI 03................................61
Charging System .............................................. 124 MID 053 - CID 0168 - FMI 04................................62
Connector Contact Description........................... 140 MID 053 - CID 0268 - FMI 02................................63
Connector Locations ...........................................51 MID 053 - CID 0271 - FMI 03................................63
Connector Contact Numbers ............................51 MID 053 - CID 0271 - FMI 05................................64
MID 053 - CID 0271 - FMI 06................................66
D MID 053 - CID 0533 - FMI 02................................67
MID 053 - CID 0533 - FMI 09................................71
Diagnostic Capabilities ........................................52 MID 053 - CID 0533 - FMI 14................................75
Caterpillar Electronic Technician (Cat ET) .........53 MID 053 - CID 0590 - FMI 02................................77
Diagnostic Code List ...........................................57 MID 053 - CID 0590 - FMI 09................................81
Diagnostic Code Procedures................................57 MID 053 - CID 0590 - FMI 14................................84
Diagnostic Operation...........................................22 MID 053 - CID 0800 - FMI 02................................86
Active Diagnostics ...........................................23 MID 053 - CID 0800 - FMI 09................................90
Logged Diagnostics .........................................23 MID 053 - CID 0800 - FMI 14................................93
Diagnostic System Procedures .......................... 124 MID 053 - CID 0811 - FMI 09................................95
Display Module .....................................................8 MID 053 - CID 1089 - FMI 02................................99
Advisor Display Module ....................................14 MID 053 - CID 1089 - FMI 09.............................. 103
Gauge Cluster .................................................15 MID 053 - CID 1089 - FMI 14.............................. 107
Instrument Cluster .............................................8 MID 053 - CID 1273 - FMI 02.............................. 111
Messenger ......................................................15 MID 053 - CID 1273 - FMI 09.............................. 114
MID 053 - CID 1273 - FMI 14.............................. 118
MID 053 - CID 4255 - FMI 09.............................. 120
E Module - Flash Program .................................... 140
Electrical Connector - Inspect............................. 134 Module - Replace .............................................. 139
Guidelines..................................................... 135 Procedure ..................................................... 139
Important Safety Information........................... 134 Monitoring System ................................................7
Tests............................................................. 135
Event Code List...................................................55 O
Output Components ............................................20
G
General Information ........................................ 4, 49 P
Monitoring System .............................................7
Power Supply Circuit ......................................... 132
I
S
Important Safety Information ..................................2
Input Components...............................................16 Self Test ........................................................... 134
Senders ..........................................................16 Self Test........................................................ 134
Sensors ..........................................................16 Service Tools ......................................................49
Switches .........................................................19 System Schematic ............................................ 143
Introduction ........................................................49 Systems Operation Section....................................4

M T
Menus (Advisor)..................................................23 Table of Contents ..................................................3
Home Menu ....................................................23 Testing and Adjusting ........................................ 134
Monitor Menu ..................................................25 Testing and Adjusting Section ............................ 134
Operator Menu ................................................24 Troubleshooting Section ......................................49
Payload Menu .................................................26
Service Menu ..................................................27
Service Mode Menu .........................................36 U
Settings Menu .................................................32 Using Caterpillar Electronic Technician to
Menus (Messenger) ............................................36 Determine Diagnostic Codes ..............................58
Home Menu ....................................................36 Active Diagnostic Codes...................................59
Monitor Menu ..................................................38 Logged Diagnostic Codes.................................60
Operator Menu ................................................37 Using the Operator Monitor to Determine
Payload Menu .................................................38 Diagnostic Codes ..............................................58
Service Menu ..................................................44
Service Mode Menu .........................................48
148 KENR9938-14
Index Section

W
Warning Operation ..............................................21
Action Alarm....................................................22
Warning Categories .........................................21
Warning Messages ..........................................22
Wiring Harness (Open Circuit) - Test................... 138
Wiring Harness (Short Circuit) - Test ................... 139
KENR9938 CAT, CATERPILLAR, LET’S DO THE WORK, their respective logos, “Caterpillar Yellow”, the
©2019 Caterpillar “Power Edge” and Cat “Modern Hex” trade dress as well as corporate and product identity used
All Rights Reserved herein, are trademarks of Caterpillar and may not be used without permission.

150 July 2019