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RENR2692 November 2000

Schematic
797 Truck Electrical Schematic Tables and Symbol Definitions
5YW1-UP

Important Safety Information


Most accidents that involve product operation, maintenance and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skills and tools to perform these function properly. Improper operation, lubrication, maintenance or repair of this product can be dangerous and could result in injury or death. Do not operate or perform any lubrication, maintenance or repair on this product until you have read and understood the operation, lubrication, maintenance and repair information. Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or other persons. The hazards are identified by the Safety Alert Symbol and followed by a Signal Word such as WARNING as 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. 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. If a tool, procedure, work method or operating technique that is not specifically recommended by Caterpillar is used, you must satisfy yourself that it is safe for you and for others. You should also ensure that the product will not be damaged or made unsafe by the operation, lubrication, maintenance or repair procedures you choose. The information, specifications, and illustrations in this publication are on the basis of information available at the time it was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time. These changes can affect the service given to the product. Obtain the complete and most current information before you start any job. Caterpillar dealers have the most current information available. For a list of the most current publication form numbers available, see the Service Manual Contents Microfiche, REG1139F.

3 Table of Contents

Table of Contents
Machine View......................................................................... 4 Cab View............................................................................. 5 Engine Views......................................................................... 6-8 Component Location Charts............................................................ 9-11 Connector Location Charts............................................................ 12 Wire Description Chart............................................................... 13-16 Switch Specification Chart........................................................... 17 Resistor and Solenoid Specifications Chart........................................... 18 Component Identifier Charts.......................................................... 19-20 VIMS Component Identifier Chart...................................................... 21-22 Failure Mode Identifier Chart........................................................ 23 Related Electrical Manuals........................................................... 24 Harness and Wire Symbols............................................................. 25 Symbols and Definitions.............................................................. 26 Note: Use the Hand Tool to select the desired page.

4 Machine View

52

28 4 41 40 7 11 55 51 38 27 36 33 43 9 78 20 39 79 12 14 35 48 34 46 21 24 44 23 10 32 47 18 37 15 8 26 5 25 22 17 42 45 2 29 50 31 16 30

13

77

49 54

6 3 19

53

52 11 12 54 53 55 77 13 4 46 35 28 24 1 21 50 16 48 36 43 30 34 39 44 33 31 78 23 20 79 9 47 22 10 17 18 8 15 37 27 26 32 42 45 2 25 29 3 6 5

41

14 51 7 40 49

38 19

Machine Harness Connector And Component Locations

5 Cab View

71

71

B
68 69 69

B
68

D E
57 58 72 59 76 75

E A
67

A
66 60 76 74 65 58 72

67 59 56

D F C
57 60 75

F
56 74

66

73

70

64

62

63 61

62 61 70

64 63

73 65 3

Side View

Rear View

75

68 3

71 60 57

73

C B D
67 56

F
66 64

65

58

63

E
72 70 59

A
62 74 76 69 61

Top View

Cab Harness Connector And Component Locations

85

152

130 94 90 91 92 87 97 95 98 99 101 100 103 86 96 106 89 129 107 108 150 148 151 83 102 82 104 84 105 88 131 132 133 135 134

149

93

Left Side View


6 Engine Views

113

111

112

147

146

145

144

143

142

141

140

139

138

137

136

110

109

Right Side View


7 Engine Views

117

116 118

115

119 81

114 120 122 124 126 80

123

127

128

125 121

Top View
8 Engine Views

9 Component Location Charts Chassis Component Location


Component Air Dryer - System Air Dryer - System Alarm - Backup Assembly - Stud Batteries Breaker - Alternator Buffer - PWM Buffer - PWM Ground - Chassis Ground - Chassis Ground - Rear Frame Ground - Rear Frame Motor - Brake Retract Sender - Tire Monitor Sensor - Aftercooler Level Sensor - Ambient Air Temp Sensor - Autolube Press Sensor - Brake Oil Cool Pump Shaft Sensor - Diff Oil Temp Sensor - Final Drive Press Sensor - Fuel Level Sensor - Hoist Position Sensor - Intermidiate Speed Sensor - Jacket Water Coolant Level Sensor - LH Front Brake Temp Sensor - LH Front Strut Press Sensor - LH Rear Bk Oil Temp Sensor - LH Rear Park Brake Rel Sensor - LH Rear Strut Press Sensor - LH Whl Speed Sensor - Radiator Shaft Speed Sensor - RH Front Brake Temp Sensor - RH Front Strut Press Sensor - RH Rear Bk Oil Temp Sensor - RH Rear Park Brake Rel Sensor - RH Rear Strut Press Sensor - RH Whl Speed Sensor - Steering Oil Level Sensor - Steering Oil Temp Sensor - System Air Press Sensor - XMSN Latching Press Sensor - XMSN Speed 1 Sensor - XMSN Speed 2 Solenoid - AETA 4 Way Solenoid - AETA Prop Solenoid - Air Start Solenoid - Autolube A = Located in Steering Column. B = Located in Overhead Panel. C = Located in Center Console. D = Located in Instrument Panel. E = Located in Switch Panel. F = Located in Relay Panel. Schematic RENR2680 RENR2680 RENR2684 RENR2680 RENR2680 RENR2680 RENR2687 RENR2683 RENR2680 RENR2680 RENR2680 RENR2680 RENR2684 RENR2683 RENR2683 RENR2683 RENR2683 RENR2682 RENR2682 RENR2682 RENR2683 RENR2687 RENR2688 RENR2683 RENR2682 RENR2683 RENR2682 RENR2682 RENR2683 RENR2682 RENR2682 RENR2682 RENR2683 RENR2682 RENR2682 RENR2683 RENR2682 RENR2683 RENR2683 RENR2683 RENR2688 RENR2688 RENR2688 RENR2682 RENR2682 RENR2681 RENR2683 Machine Location 1 1 2 3 4 4 5 30 6 7 8 9 9 10 11 13 14 16 15 15 19 5 78 12 21 24 22 23 25 26 77 50 28 22 23 29 27 30 31 1 78 32 32 23 23 1 1 Component Solenoid - Bk Oil Cool Pump Drive Solenoid - Brake Accum Bleed Solenoid - Brake Oil Diverter Solenoid - Final Drive Oil Bypass Solenoid - Front Eng Start Aid 1 Solenoid - Front Eng Start Aid 2 Solenoid - Hoist Head End CT Solenoid - Hoist Head End PC Solenoid - Hoist Pilot Sys Solenoid - Hoist Pump Bypass 1 Solenoid - Hoist Pump Bypass 2 Solenoid - Hoist Rod End CT Solenoid - Hoist Rod End PC Solenoid - Horn Solenoid - Radiator Pump Drive Solenoid - RAX Drive Pump Oil Div Solenoid - Rear Eng Start Aid 1 Solenoid - Rear Eng Start Aid 2 Solenoid - Steering Bleed Solenoid - Wastegate Air Shutoff Solenoid - XMSN 2 Stage Relief Valve Solenoid - XMSN Clutch Pack 1 Solenoid - XMSN Clutch Pack 2 Solenoid - XMSN Clutch Pack 3 Solenoid - XMSN Clutch Pack 4 Solenoid - XMSN Clutch Pack 5 Solenoid - XMSN Clutch Pack 6 Solenoid - XMSN Clutch Pack 7 Solenoid - XMSN Latch Valve Switch - Brake Oil Accum Press Switch - Brake Oil Filter Switch - Diff Lube Filt Bypass Switch - Diff Lube Press Switch - Disconnect Switch - Eng Flood Lamp Switch - Fan Drive Filter Switch - Final Drive Filt Bypass Switch - Front Brake Cooling Filter Switch - Ground Level Shutdown Switch - Hoist Screen 1 Switch - Hoist Screen 2 Switch - Ladder Lamp 2 Switch - Rear Brake Cool Filt Bypass Switch - Steering High Press Switch - Steering Low Press Switch - VIMS Service Key Switch - XMSN Charge Filter Schematic RENR2682 RENR2684 RENR2682 RENR2682 RENR2681 RENR2681 RENR2687 RENR2687 RENR2687 RENR2687 RENR2687 RENR2687 RENR2687 RENR2684 RENR2682 RENR2682 RENR2681 RENR2681 RENR2684 RENR2680 RENR2688 RENR2688 RENR2688 RENR2688 RENR2688 RENR2688 RENR2688 RENR2688 RENR2688 RENR2682 RENR2682 RENR2682 RENR2682 RENR2680 RENR2684 RENR2682 RENR2682 RENR2682 RENR2689 RENR2687 RENR2687 RENR2684 RENR2682 RENR2683 RENR2683 RENR2683 RENR2688 Machine Location 33 34 34 37 35 35 20 20 20 20 20 20 20 1 36 16 35 35 38 1 78 78 78 78 78 78 78 78 78 34 39 42 42 40 40 41 15 43 40 43 43 40 44 38 38 40 79

Locations are repeated for components located close together.

Note: Use the Hand Tool to select the desired schematic or machine location.

10 Component Location Charts Cab Component Location


Component Alarm - VIMS Action Assembly - Stud Breaker - 12V ACC Lighter Breaker - 24V Accessories Breaker - AC Breaker - AC Condenser Breaker - ACC Lamp Breaker - ADEM Master Breaker - ADEM Front Engine Breaker - ADEM Rear Engine Breaker - Air Dryer Breaker - Alternator Breaker - Alternator Breaker - Backup Alarm Breaker - Brake Retract Breaker - Chassis Control Breaker - Converter Breaker - Floodlamp Breaker - Headlamp Breaker - IBC Control Breaker - Key Breaker - Power Window Breaker - Start Aid Breaker - Start Aid Breaker - Stop/Turn/Dome Breaker - VIMS Breaker - Wiper Breaker - XMSN Control Cluster - Four Gauge Cluster - Speed Tach Cluster - VIMS Message Center Condensor Group Conditioner Group Control - Chassis Control - IBC Control - VIMS Control - VIMS Main Module Control - XMSN Converter - 5A 24 to 12 Volt Converter - 15A 24 to 12 Volt Flasher Ground Boss 1 - Rear Cab Ground Boss 2 - Rear Cab Junction Block (6) Lamp - Cane Lever Module - Int Wiper Module - VIMS Keypad Motor - Blower Motor - Condensor Motor - Front Wiper Motor - Washer Radio A = Located in Steering Column. B = Located in Overhead Panel. C = Located in Center Console. D = Located in Instrument Panel. E = Located in Switch Panel. F = Located in Relay Panel. Schematic RENR2683 RENR2680 RENR2684 RENR2680 RENR2680 RENR2680 RENR2680 RENR2680 RENR2680 RENR2680 RENR2680 RENR2680 RENR2680 RENR2680 RENR2680 RENR2680 RENR2680 RENR2680 RENR2680 RENR2680 RENR2680 RENR2680 RENR2680 RENR2680 RENR2680 RENR2680 RENR2680 RENR2680 RENR2683 RENR2683 RENR2683 RENR2686 RENR2686 RENR2687 RENR2682 RENR2683 RENR2683 RENR2688 RENR2680 RENR2680 RENR2685 RENR2680 RENR2680 ALL RENR2683 RENR2685 RENR2683 RENR2686 RENR2686 RENR2685 RENR2685 RENR2684 Machine Location B 3 56 56 56 56 56 56 56 56 56 56 56 56 56 56 56 56 56 56 56 56 56 56 56 56 56 56 D 59 D 71 72 62 61 63 65 64 67 67 60 66 66 64 C 60 D 72 71 58 57 B Component Relay - Backup Alarm Light Relay - Condensor Relay - Foglamp Relay - Headlamp Relay - Main Relay - Prelube Relay - Start Aid Hold Relay - Start Aid Hold Relay - Start Aid Pull In Relay - Start Aid Pull In Relay - Steering Brake Bleed Relay - Stoplamp Relay - Wiper Motor Resistor - Blower Motor Resistor - Start Aid (4) Sensor - Hoist Lever Pos Sensor - Throttle Position Sensor - XMSN Cane Pos Solenoid - Park Brake Switch - AC On Switch - ARC Press Switch - Auto Retarder Switch - Blower Switch - Brake Retract Switch - Brake System Press Switch - Dimmer Switch - Fog Lamp Switch - Foot Brake Press Switch - Hazard Switch - Horn Switch - Key Start Switch - Ladder Lamp Switch - LH Door Switch - LH Power Window Switch - Park Brake On/Off Switch - Rear Backup Lamp Switch - Retarder Switch - RH Door Switch - RH Power Window Switch - Running Lamp Switch - Start Aid Switch - Strobe Lamp Switch - TCS Test Switch - Thermostat Switch - Throttle Backup Switch - Wiper/Washer Turn Terminal Stud Terminal Stud #2 Valve - ARC Control Valve - ARC Supply Window - LH Electric Window - RH Electric Schematic RENR2687 RENR2686 RENR2684 RENR2684 RENR2680 RENR2691 RENR2681 RENR2681 RENR2681 RENR2681 RENR2687 RENR2682 RENR2685 RENR2686 RENR2681 RENR2687 RENR2691 RENR2687 RENR2682 RENR2686 RENR2682 RENR2682 RENR2686 RENR2684 RENR2682 RENR2683 RENR2684 RENR2682 RENR2685 RENR2684 RENR2681 RENR2684 RENR2684 RENR2684 RENR2682 RENR2684 RENR2682 RENR2684 RENR2684 RENR2684 RENR2681 RENR2684 RENR2682 RENR2686 RENR2691 RENR2685 RENR2680 RENR2680 RENR2682 RENR2682 RENR2684 RENR2684 Machine Location F 71 F F 56 F F F F F F F F 72 F C 70 C 73 E 73 E E E 73 E B 73 B A E B 69 C C B A 68 C B E B E 72 E A 56 56 73 73 75 76

Locations are repeated for components located close together.

Note: Use the Hand Tool to select the desired schematic or machine location.

11 Component Location Charts Engine Component Location


Component Alternator 1 Alternator 2 ECM - Eng Front ECM - Eng Master ECM - Eng Rear Motor - Prelube Relay - Prelube Main Power Sensor - Eng Speed Sensor - Front Eng Aftercooler Temp Sensor - Front Eng Atmospheric Press Sensor - Front Eng Coolant Temp Sensor - Front Eng Crankcase Press Sensor - Front Eng Filtered Oil Press Sensor - Front Eng LH Turbo Exh Temp Sensor - Front Eng Master Speed Sensor - Front Eng RH Turbo Exh Temp Sensor - Front Eng RH Turbo Inlet Press Sensor - Front Eng Speed Timing Sensor - Front Eng Turbo Outlet Press Sensor - Front Eng Unfiltered Oil Press Sensor - Rear Eng Aftercooler Temp Sensor - Rear Eng Atmospheric Press Sensor - Rear Eng Coolant Temp Sensor - Rear Eng Crankcase Press Sensor - Rear Eng Filtered Oil Press Sensor - Rear Eng LH Turbo Exh Temp Sensor - Rear Eng Master Speed Sensor - Rear Eng RH Turbo Exh Temp Sensor - Rear Eng RH Turbo Inlet Press Sensor - Rear Eng Speed Timing Sensor - Rear Eng Turbo Outlet Press Sensor - Rear Eng Unfiltered Oil Press Sensor - TC Oil Temp Sensor - XMSN Input Speed Solenoid - A/C Clutch Solenoid - Front Eng Cont Oil Burn Solenoid - Front Eng Cyl Head 1 A = Located in Steering Column. B = Located in Overhead Panel. C = Located in Center Console. D = Located in Instrument Panel. E = Located in Switch Panel. F = Located in Relay Panel. Schematic RENR2680 RENR2680 RENR2689 RENR2691 RENR2690 RENR2684 RENR2684 RENR2688 RENR2689 RENR2689 RENR2689 RENR2689 RENR2689 RENR2689 RENR2691 RENR2689 RENR2689 RENR2689 RENR2689 RENR2689 RENR2690 RENR2690 RENR2690 RENR2690 RENR2690 RENR2690 RENR2691 RENR2690 RENR2690 RENR2690 RENR2690 RENR2690 RENR2688 RENR2688 RENR2686 RENR2689 RENR2689 Machine Location 80 81 83 82 84 117 117 114 126 102 85 95 86 119 100 127 111 103 128 96 122 104 152 105 106 115 107 123 113 108 124 89 129 120 90 118 92 Component Solenoid - Front Eng Cyl Head 2 Solenoid - Front Eng Cyl Head 3 Solenoid - Front Eng Cyl Head 4 Solenoid - Front Eng Cyl Head 5 Solenoid - Front Eng Cyl Head 6 Solenoid - Front Eng Cyl Head 7 Solenoid - Front Eng Cyl Head 8 Solenoid - Front Eng Cyl Head 9 Solenoid - Front Eng Cyl Head 10 Solenoid - Front Eng Cyl Head 11 Solenoid - Front Eng Cyl Head 12 Solenoid - Front Eng Wastegate Prop Solenoid - Rear Eng Cont Oil Burn Solenoid - Rear Eng Cyl Head 1 Solenoid - Rear Eng Cyl Head 2 Solenoid - Rear Eng Cyl Head 3 Solenoid - Rear Eng Cyl Head 4 Solenoid - Rear Eng Cyl Head 5 Solenoid - Rear Eng Cyl Head 6 Solenoid - Rear Eng Cyl Head 7 Solenoid - Rear Eng Cyl Head 8 Solenoid - Rear Eng Cyl Head 9 Solenoid - Rear Eng Cyl Head 10 Solenoid - Rear Eng Cyl Head 11 Solenoid - Rear Eng Cyl Head 12 Solenoid - Rear Eng Wastegate Prop Solenoid - TC Lockup Switch - A/C Hi/Low Press Switch - Front Eng Fuel Filter Diff Switch - Front Eng Oil Very Low Switch - Rear Eng Fuel Filter Diff Switch - Rear Eng Oil Very Low Switch - Eng Coolant Flow Switch - PT Oil Level Switch - TC Inlet Filter Switch - TC Screen Schematic RENR2689 RENR2689 RENR2689 RENR2689 RENR2689 RENR2689 RENR2689 RENR2689 RENR2689 RENR2689 RENR2689 RENR2689 RENR2690 RENR2690 RENR2690 RENR2690 RENR2690 RENR2690 RENR2690 RENR2690 RENR2690 RENR2690 RENR2690 RENR2690 RENR2690 RENR2690 RENR2688 RENR2686 RENR2689 RENR2689 RENR2690 RENR2690 RENR2691 RENR2688 RENR2688 RENR2688 Machine Location 136 94 137 97 138 98 139 99 140 101 141 125 116 130 142 131 143 132 144 133 145 134 146 135 147 121 148 91 87 93 88 109 110 149 150 151

Locations are repeated for components located close together.

Note: Use the Hand Tool to select the desired schematic or machine location.

12 Connector Location Charts Chassis Connector Location


Connector Number
CONN 1 CONN 2 CONN 3 CONN 4 CONN 5 CONN 6 CONN 7 CONN 8 CONN 48 CONN 49 CONN 50 CONN 51 CONN 52 CONN 53 CONN 54 CONN 55 CONN 56 CONN 57 CONN 58 CONN 59 CONN 66 CONN 67 CONN 68 CONN 71 CONN 72 CONN 73 CONN 74 CONN 75 CONN 76 VIMS Ground Level Service CONN 77 CONN 78 CONN 79 CONN 80 CONN 81 CONN 82

Cab Connector Location


Connector Number
CONN 1 CONN 2 CONN 3 CONN 4 CONN 5 CONN 6 CONN 7 CONN 8 CONN 9 XMSN Lockout CONN 10 CONN 11 CONN 12 CONN 13 CONN 14 CONN 15 CONN 16 CONN 17 CONN 18 Telemetry Download CONN 19 Cab Serial Download CONN 20 Diagnostic CONN 21 Power Port CONN 22 CONN 23 CONN 24 CONN 25 CONN 26 CONN 27 CONN 28 User Defined Shutdown CONN 29 CONN 30 CONN 31 CONN 32 CONN 33 CONN 34 CONN 35 CONN 36 CONN 37 CONN 38 CONN 39 CONN 40 CONN 41 CONN 42 CONN 43 CONN 44 CONN 45 CONN 46 CONN 47 CAN Link

Engine Connector Location


Connector Number
CONN 1 CONN 2 CONN 3 CONN 4 CONN 5 CONN 6 CONN 7 CONN 8 CONN 60 CONN 61 CONN 62 Timing Cal (Rear Eng) CONN 63 CONN 64 CONN 65 CONN 69 CONN 70 Timing Cal (Front Eng)

Machine Location
3 3 3 3 3 3 3 3 45 46 47 47 78 39 39 48 78 48 48 48 37 49 49 55 52 51 13 49 40 40 53 54 1 1 39

Machine Location
3 3 3 3 3 3 3 3 64 64 64 63 63 64 64 65 56 56 56 56 56 75 56 71 71 71 56 3 F 76 75 C C C E E E 72 74 74 74 74 D D D 56 56

Machine Location
3 3 3 3 3 3 3 3 116 118 84 84 82 84 83 110

Note: The connectors shown in these charts are for harness to harness connectors. Connectors that join a harness to a component are generally located at or near the component. See the Component Location Charts.

13 Wire Description Chart Wire Description


Wire Number 101 102 103 105 109 110 112 113 115 119 120 121 122 123 124 125 126 127 128 135 139 149 150 151 170 173 176 185 200 201 229 A234 A251 A252 A253 A274 301 307 308 321 322 326 327 393 R317 T317 X337 403 410 411 417 Wire Color RD RD RD RD RD RD PU OR PK PK YL YL BU WH GN OR RD RD RD BU OR PU RD GN RD RD RD YL BK BK BK BK BK BK BK BK BU OR YL BR GY PU PK BR YL YL WH GN WH PK GY Bat (+) Hd Lmp Aux Ckt Key Sw Alt Output (+) Term. Aux Ckt Main Power Rly Output VIMS B+ Switched Aux Ckt Aux Ckt Aux Ckt Back Alarm To Lamp Aux Ckt Aux Ckt A/C Aux Ckt Xmsn Ctrl Aux Ckt Aux Ckt Aux Ckt Aux Ckt Aux Ckt Bat (+) Aux Ckt Aux Ckt Aux Ckt Aux Ckt Aux Ckt Ground Circuits Main Chassis Operator Monitor Return Bat (-) J1939 Shield Gnd VIMS Ser Mod #1 VIMS Ser Mod #2 VIMS Ser Mod #3 Power Neg Basic Machine Circuits Starter No. 1 Sol Key SW To VIMS Sensor Module Main Power Relay Coil Backup Alarm Lamp Travel Alarm Warning Horn (Forward) Key SW "C" Term. Shutdown Solenoid Dimmer Relay Coil Start Aid Relay to Start Aid Sol Front Eng. Start Aid Relay to Start Aid Sol Rear Eng. Prelube Signal from ECM to Relay Monitoring Circuits Alternator (R) Term. Opr Mon Action Alarm Opr Mon Master Primary Ster SW Description Power Distribution Circuits R709 R710 R711 R712 R718 R719 R723 R724 R725 R726 R727 R728 R729 R730 R731 R746 R747 R751 R795 R796 R797 R798 R799 T701 T702 T703 T704 T705 T706 T707 T708 T709 T710 T711 T712 T718 T719 T723 T724 T725 T726 T727 T728 T729 T730 T731 T746 T747 T751 T795 T796 T797 T798 T799 OR GY PU BR BU BR PK PU WH PU YL BR GN GY OR PK GY YL YL GN WH PK BR GY PU BR GN YL GY PU BR OR GY PU BR BU BR PK PU WH YL GN BR GN GY OR PK GY YL YL GN WH PK BR Wire Number Wire Color Injector 9 Sol Injector 10 Sol Injector 11 Sol Injector 12 Sol Eng Oil Low Sw Eng Oil Very Low Sw Timing Cal + Timing Cal Fuel Filter Sw Injector 1 & 3 Sol Return Injector 2 & 4 Sol Return Injector 5 & 7 Sol Return Injector 6 & 8 Sol Return Injector 9 & 11 Sol Return Injector 10 & 12 Sol Return Turbo Outlet Press Sensor Atmospheric Press Sensor Aftercooler Temp Sensor Crankcase Press Sensor Oil Press Sensor Unfiltered Wastegate Return Wastegate Solenoid PWM Return 1&2 Injector 1 Sol Injector 2 Sol Injector 3 Sol Injector 4 Sol Injector 5 Sol Injector 6 Sol Injector 7 Sol Injector 8 Sol Injector 9 Sol Injector 10 Sol Injector 11 Sol Injector 12 Sol Eng Oil Low Sw Eng Oil Very Low Sw Timing Cal + Timing Cal Fuel Filter Sw Injector 1 & 3 Sol Return Injector 2 & 4 Sol Return Injector 5 & 7 Sol Return Injector 6 & 8 Sol Return Injector 9 & 11 Sol Return Injector 10 & 12 Sol Return Turbo Outlet Press Sensor Atmospheric Press Sensor Aftercooler Temp Sensor Crankcase Press Sensor Oil Press Sensor Unfiltered Wastegate Return Wastegate Solenoid PWM Return 1&2 Description Control Circuits Continued

14 Wire Description Chart Wire Description


Wire Number 425 426 428 429 432 447 450 451 454 481 A451 A491 A492 A493 A495 C413 C414 C415 C428 C429 C453 C466 C467 C473 C484 E456 F418 F419 F433 F447 G427 G428 G439 H428 H429 H430 X412 500 501 502 506 508 509 511 512 513 515 516 517 518 520 521 522 526 Wire Color PK BR OR YL PK PK YL BR GN GN WH WH OR YL GY YL BU WH GN GY YL YL BU GN YL WH GN YL PU PU BU BU YL GY BU BU BU BR GN OR PU PU WH BR GN OR GY GN BU OR WH YL WH YL Description Opr Mon Power Train Oil Level Opr Mon Power Train Oil Filter Opr Mon Xmsn Oil Temp Opr Mon Brake Oil Temp Opr Mon Brake Press. (Oil) Fuel Level Gage Tach Sender (+) Tach Sender (-) Retarder Indicator Lamp Converter Temp SW To Brake Oil Temp SW Opr Mon Steering Oil Temp Trans Supply SW To T/C Inlet Filter SW Hoist Filter SW To Hoist Filter SW Hoist Filter SW To T.C. SW Alternator (R) Terminal #2 VIMS Display Data VIMS Display Load VIMS Display Keydata Brake Cooling Filter SW Differential Oil Temp Ambient Temp LF Brake Oil Temp LR Brake Oil Temp Rear Pump Press Rear Differential Filter Press SW Autolube Pressure VIMS RS232 Port 2 Trans VIMS RS232 Port 2 Receive Brake Temp Steering HI Press SW To LO Press SW T/C Inlet Filter SW To Hoist Screen SW Transmission Oil Press Steering Oil Tank Level SW (VIMS) Left Rear Brake Oil Pressure Right Rear Brake Oil Pressure Body Up Indicator Coolant Flow Switch Accessory Circuits Wiper - Front (Park) Wiper - Front (Low) Wiper - Front (HI) Washer - Front Radio Speaker - Left Radio Speaker - Left (Commom) Radio Speaker - Right Radio Speaker - Right (Common) A/C Compressor/Refrigerant Pressure SW Blower Motor (HI) Blower Motor (Medium) Blower Motor (Low) Hazard Flasher To SW Opr A/C SW To Thermostat/Fuse A/C SW To Refrigerant SW A/C Clutch To Thermostat SW Wiper - Right (Park) Wire Number X717 X720 X721 801 858 859 860 861 875 876 892 893 H801 H802 H803 H807 H809 H863 H864 H865 H867 J800 J802 J803 J804 J805 J806 J810 J811 J812 J813 J814 J815 J816 J817 J818 J819 J820 J821 J822 J823 J824 J825 J826 J827 J828 J829 J830 J831 J832 J840 J841 J842 J845 J846 Wire Color YL GN BR PK GY YL PK PU BU OR BR GN PU GY BU YL YL BU GN BR YL OR OR BR WH YL GY PU BK PK BK BK BK GN WH OR BR OR BR WH YL GY PU PK GN BU OR BR GY YL WH YL BK PU BR Throttle Bypass Start Aid Switch User Defined Shutdown Auto Lube Sol Or Motor Payload Mon Right Front Sensor Payload Mon Left Front Sensor Payload Mon Right Rear Sensor Payload Mon Left Rear Sensor VIMS RS 232 Port Trans VIMS RS 232 Port Receive VIMS Strt Mod Right (-) Port/CAT Data Link (-) VIMS Strt Mod Right (+) Port/CAT Data Link (+) Proportional Driver Return (1-4) Proportional Driver Return (5-8) Proportional Driver Return (9-12) On/Off Driver Return (1-8) Timer Output / Shutdown Timer Output Proportional Driver Return (Rear Eng ECM) Proportional Driver Return (Rear Eng ECM) Proportional Driver Return (Rear Eng ECM) On/Off Driver Return (Rear Eng ECM) ABL (IBC) +12 Volts Differential Pump Pressure Switch Radiator Fan Shaft Speed + Radiator Fan Shaft Speed Brake Filter Switch Rear Differential Filter Switch Brake Cooling Filter On/Off Return Fan Drive Oil Filter Bypass Switch Proportional Return Proportional Return Proportional Return Radiator Pump Drive Brake Cooling Pump Drive Brake Cooling Mtr Speed (+) Brake Cooling Mtr Speed (-) Hoist Pressure Sensor 2 Hoist Pressure Sensor 1 Hoist Position Sensor XMSN Latching Press Sensor Hoist CT Head Prop Sol (Body Up) Hoist PC Head Prop Sol (Body Up) Hoist Pilot System On/Off Sol Hoist CT Rod Prop Sol (Body Down) Hoist PC Rod Prop Sol (Body Down) Hoist Pump Bypass 1 Sol Hoist Pump Bypass 2 Sol XMSN 2 Stage Relief Valve XMSN Latch Sol Lamp HS Return Lamp HS Return Digital Return Rear Differential Bypass Sol Lamp HS Return Description

15 Wire Description Chart Wire Description


Wire Number 527 539 540 575 590 591 592 593 A513 A524 A589 A590 C569 C597 C598 E501 602 603 604 605 606 607 608 610 611 612 614 619 620 622 623 626 627 630 631 635 636 700 705 706 711 712 713 714 715 716 751 752 754 755 769 770 773 Wire Color GN BU WH YL GY WH BU GN PK BR OR BU YL BU OR BU WH PK OR YL GY PK GN OR PU GY PU GN WH PU BU BU YL GY GY BU GN PK PK BR BR WH OR YL GN BU GN YL BU OR BU GN GY Description Wiper - Right (Low) Turn Signal Indicator Basic/Right Turn Signal Indicator Left Wiper - Aux (Park) Wiper SW To Intermittent Module Intermittent Module To Wiper Motor DC/DC Converter Power Output Condensor Fan Relay To Motors DC/DC Converter Memory Output Temp Potentiometer Pos 2 Power Window Up Power Window Down Second DC/DC Converter Power Output Right Power Window Up Right Power Window Down Floating Blade Relay #2 to Blade Relay Lighting Circuits Dome Lamp Rotary Beacon Stop Lamp Turn Lamp - Left Turn Lamp - Right Flood Lamp - Front Flood Lamp - Rear Head Lamp Basic Head Lamp Hi Backup Lamp Park/Tail/Dash/Lamp Head Lamp Lo Flood Lamp - Front (Eng. Flood Lamp) Flood Lamp 3-Way SW Jumper Flood Lamp 3-Way SW Jumper Dash Lamp Dimmer Fog Lamp Flood Lamp Rear Fog Lamp - Right Payload Mon Red Lamp Payload Mon Green Lamp Control Circuits AETA Test SW XMSN Lockup Clutch Sol Basic XMSN Retarder SW XMSN Lever Code 1 XMSN Lever Code 2 XMSN Lever Code 3 XMSN Lever Code 4 XMSN Lever Code 5 XMSN Lever Code 6 XMSN Shift Sol No. 1 Or 3 XMSN Shift Sol No. 2 XMSN Shift Sol No. 3 Or 1 XMSN Shift Sol No. 4 Or 5 Wheel Speed Pickup Left Wheel Speed Pickup Right AETA Servovalve Wire Number J847 J848 J849 J878 J879 J881 J882 J883 R800 R803 R804 R807 R810 R814 T800 T803 T804 T807 T810 T814 X800 X809 X815 X816 900 901 902 958 987 A958 C976 C985 C989 E900 E901 E902 E903 E906 E907 E908 E909 E972 K983 K985 K986 K988 K989 K991 K992 M901 M914 M966 M967 M996 R914 Wire Color GN BU WH YL GN YL BR BU OR GY GY WH BR PK OR GY OR WH BR OR OR BU PU WH PU WH BR YL WH WH YL BU PU WH GN PU YL OR GY BR WH BU BU BR PK WH BU OR PU YL WH GY OR PK OR Description VIMS Action Alarm Return VIMS Service Lamp Return VIMS ABL PWM Return Switch/Sensor Return #5 Switch/Sensor Return #6 Xmsn Control State Cab Control State Gear Select State +8v Digital Sensor Power LH Turbo Exh Temp Sensor RH Turbo Exh Temp Sensor Start Aid Hold Relay Start Aid Pull In Relay RH Turbo Exh Press Sensor +8v Digital Sensor Power LH Turbo Exh Temp Sensor RH Turbo Exh Temp Sensor Start Aid Hold Relay Start Aid Pull In Relay RH Turbo Exh Press Sensor +8v Sensor Power Prelube Relay Ground Level Shutdown N/O Ground Level Shutdown N/C XMSN Shift Sol No. 5 or 4 XMSN Shift Sol No. 6 XMSN Shift Sol No. 7 Relay Logic Diverter Sol Park Brake Sol Parking Brake Switch +8V Oil Level ECPC Trans Output SPD + ECPC Trans Output SPD ECPC Trans Intermediate SPD + ECPC Trans Intermediate SPD ECPC Trans Output SPD Q+ ECPC Trans Output SPD QECPC Trans Input SPD + ECPC Trans Input SPD SPI Datalink End VIMS Sensor Module 1 - +8V Supply Auto Retard On SW Auto Regard Off SW Auto Retard Air Cont Valve Auto Retard AIr Supply Valve Auto Retard Press SW Auto Retard Manual Retard SW Aux Lamp Driver 1 VIMS System Air Pressure Sensor VIMS Aftercooler Coolant Level VIMS Jacket Coolant Level Hoist Lever Position Throttle Signal

16 Wire Description Chart Wire Description


Wire Number 774 775 777 799 E707 E708 E709 E710 E793 E794 F708 F711 F712 F780 F790 G736 J764 J765 J766 J767 R701 R702 R703 R704 R705 R706 R707 R708 Wire Color YL BR PU WH GN PK WH BU BU YL YL GN GY PK BR PK BR BU PU GY GY PU BR GN YL GY PU BR AETA Sol - Left AETA Sol - Right Brake Release Motor Sensor Power VIMS Display +V VIMS Display Clock VIMS Service Lamp VIMS LCD Lamp Driver ATA Data Link ATA Data Link + Dout 3 CAN Link + CAN Link Parking Brake SW Service Brake Pedal Oil Cooler Motor Switch/Sensor Return #1 Switch/Sensor Return #2 Switch/Sensor Return #3 Switch/Sensor Return #4 Injector 1 Sol Injector 2 Sol Injector 3 Sol Injector 4 Sol Injector 5 Sol Injector 6 Sol Injector 7 Sol Injector 8 Sol Description Wire Number R915 R982 R984 R988 R989 R993 R994 R995 R996 R997 R998 R999 T914 T915 T984 T993 T994 T995 T996 T997 T998 T999 X900 X912 X996 X998 X999 Wire Color YL YL GY PK PU BR GY BU GN OR BR WH GN YL GY BR GY BU GN OR BR WH YL GN GN BR GN Oil Renewal Sol Dash Lamp Driver (-) E/P Controller to Aux/Hyd Controller (RS485 -) Transmision Lockdown Sw Park Brake Lockdown Sw Analog Sensor Return Eng Oil Press Sensor Unfiltered Coolant Temp Sensor +V TIMING +5v Analog Sensor Power Digital Sensor Return Engine Speed / Timing Sensor Throttle Signal Oil Renewal Sol Start Aid Timer Output Rear Eng. Analog Sensor Return Eng Oil Press Sensor Unfiltered Coolant Temp Sensor +V TIMING +5v Analog Sensor Power Digital Sensor Return Engine Speed / Timing Sensor Master Engine Speed Sensor Throttle Position Sensor +V TIMING Digital Sensor Return Master Engine Speed Sensor Description

17 Switch Specification Chart Off Machine Switch Specification


Part No.
3E-7809 9X-6855 9X-7781 114-5333 128-5091 130-7459 138-3672 144-5661 156-1382 173-2679

Function
Steering Low Press Brake Oil Accum Pressure Diff Lube Filter Bypass Fan Drive Filter Final Drive Filter Bypass Refrigerant Pressure (AC) ARC Pressure Brake System Pressure Foot Brake Pressure Diff Lube Pressure Coolant Flow Fuel Filter Diff Brake Oil Filter Steering High Press

Actuate
1900 kPa MAX (275 psi MAX) 13800 kPa MAX (2001.5 psi) 210 70 kpa (30 10 psi) 275 to 1750 kpa (40 to 255 psi) 551 kPa (36.3 psi) 93 20 kpa (13.5 2.9 psi) 362 29 mN (1.3 0.1 oz) at point X 137.9 13.8 kpa (20.0 2.0 psi) 276 28 kpa (40 4 psi) 14350 kPa MAX (2081.28 psi MAX)

Deactuate
1400 140 kpa (205 20 psi) 12300 345 kpa (1784 50 psi) ----344 20 kpa (49.9 2.9 psi) 70 20 kpa (10.2 2.9 psi) 303 mN MIN (1.1 oz MIN) at point X 82.7 kPa MIN (12.0 psi) 79 kPa MIN (26 psi) 12350 350 kpa (1791.20 50.76 psi)

Contact Position
B-A Normally Open B-C Normally Closed 1-2 Normally Open 1-3 Normally Closed Normally Open Normally Open B-A Normally Open A-C Normally Closed Normally Open Normally Open Normally Closed Normally Closed B-A Normally Open B-C Normally Closed

A hysteresis band exists: with increasing pressure the closed condition can be maintained up to 2800 kpa (405 psi), with decreasing pressure the closed condition can be maintained down to 170 kpa (25 psi). Contact position at the contacts of the harness connector.

18 Resistor and Solenoid Specifications Chart

Resistor and Solenoid Specifications


Part No.
3T-0062 5T-4434 7T-9074 9G-9988 109-4591

Component Description
Solenoid: Solenoid: Solenoid: Solenoid: Solenoid: AETA Proportional Air Start Auto Lube Horn Wastegate Air Shutoff AETA Four way Wastegate Proportional Arc Supply Valve Brake Accum Bleed Diff Oil Bypass RAX Drive Pump Oil Div Blower Motor XMSN Latch Valve Torque Converter Lockup Transmission Clutch Pack (7) Hoist Head End: CT Hoist Head End: PC Hoist Pump Bypass (2) Hoist Rod End: CT Hoist Rod End: PC Brake Oil Diverter Park Brake Final Drive Oil Bypass Steering Bleed

Resistance (Ohms)
16 42.0 4.0 55.17 5.77 24.9 7.75

122-1134 125-9740 142-7324 145-1144

Solenoid: Resistor: Solenoid: Solenoid:

41.9 Overall 2.6 0.12 32.6 1.6 8.5 0.4

148-2350

Solenoid:

5.5 0.2

152-8340 156-1113 156-5542 At room temperature unless otherwise noted.

Solenoid: Solenoid: Solenoid:

32.6 1.6 32.6 1.6 32.6 1.6

19 Component Identifier Charts Component Identifiers (CID) for the Engine Controls (MID 033,034, and 036)
CID
0001 0002 0003 0004 0005 0006 0007 0008 0009 0010 0011 0012 0091 0100 0101 0110 0168 0190 0248 0253 0254 0261 0262 0263 0267 0268 0273 0274 0275 0276 0291 0296 0338 0526 0542 0543 0544 0545 0546 0562 0569 0800 0827 0828 0829

Component Identifiers (CID) for the Brake Control (MID 116)


CID
0041 0070 0168 0190 0248 0269 0291 0296 0544 0607 0608 0627 0681 0689 0690 0704 0710 0711 0712 0713 0714 0719 0742 0796 0835 0852 0853 0854 0855 0966 0967 1225 1226 1227 1229 1230 1231 1232 1269 1271 1422

Component Cylinder 1 Cylinder 2 Cylinder 3 Cylinder 4 Cylinder 5 Cylinder 6 Cylinder 7 Cylinder 8 Cylinder 9 Cylinder 10 Cylinder 11 Cylinder 12 Throttle Sensor Output Filtered Oil Pressure Crankcase Pressure Signal Coolant Temperature Battery Voltage Engine RPM Signal CAT Data Link Personality Module ECM Timing Calibration Analog Sensor Supply Digital Sensor Supply Shutdown Inputs System Parameters Turbocharger Outlet Pressure Atmospheric Pressure Right Turbocharger Inlet Pressure Left Turbocharger Inlet Pressure Engine Cooling Fan Solenoid Communicate w/Trans Prelube Pump Relay Wastegate Solenoid Unfiltered Oil Pressure Signal Filtered Oil Pressure Engine Fan Speed Sensor Signal Start Aid Relay Start Aid Hold Relay Caterpillar Monitoring System Communications Oil Renewal Solenoid CAT Data Link Communication Left Exhaust Temp Signal Right Exhaust Temp Signal Rear Aftercooler Coolant Temperature Signal

1437 The CID is a diagnostic code that indicates which component is faulty.

Component +8 Volt Sensor Supply Operator Park Brake On/Off Switch System Voltage Engine Output Speed(EOS) Signal CAT Data Link Sensor Supply Voltage Engine Cooling Fan Solenoid Transmission Control Engine Cooling Fan Speed Left Wheel Speed Sensor Right Wheel Speed Sensor Parking Brake Switch Parking Brake Solenoid TCS Left Brake Solenoid TCS Right Brake Solenoid Brake System Pressure Switch ARC Supply Solenoid ARC Control Solenoid ARC Lamp Operator ARC On/Off Switch ARC Pressure Switch TCS Proportional Solenoid Service Brake Lamp Relay Differential High Speed Fan Solenoid Rear Differential Temperature Sensor Right Front Brake Temperature Sensor Left Front Brake Temperature Sensor Right Rear Brake Temperature Sensor Left Rear Brake Temperature Sensor TCS Lamp Machine Application Left Rear Park Brake Pressure Sensor Right Rear Park Brake Pressure Sensor Retarder Lever Brake Cooling Pump Speed Brake Cooling Pump Drive Solenoid Brake Oil Diverter Solenoid Rear Differential Lube Bypass Solenoid Operator Service Brake Pressure Switch Final Drive Lube Pressure Switch Front Engine Electronic Control Module Rear Axle Pump Diverter Solenoid Valve

The MID is a diagnostic code that indicates which electronic control module diagnosed the fault.

20 Component Identifier Charts Component Identifiers (CID) for the Transmission Control (MID 081)
CID
0041 0127 0168 0177 0190 0248 0268 0533 0585 0672 0673 0674 0709 0826 0967 1233 1235 1244 1273 1401 1402 1403 1404 1405 1406 1407 1427 1428

Component Identifiers (CID) for the Chassis Control (MID 087)


CID
0144 0168 0248 0296 0444 0533 0702 0733 0967 1175 1236 1237 1238 1239 1240 1241 1242 1243 1245 1274

Component +8 Volt Sensor Supply Transmission Oil Pressure Sensor System Voltage Transmission Oil Temperature Sensor Engine Output Speed(EOS) Signal CAT Data Link Programmable Parameters Brake Control Transmission Output Speed I Converter Output Speed(COS) Transmission Output Speed II Transmission Intermediate Speed 1 Lockup Solenoid Torque Converter Oil Temperature Sensor Machine Application Transmission Latching Pressure Sensor 1 Transmission Latching Solenoid Transmission Second Stage Relief Solenoid Chassis Electronic Control Module Transmission Solenoid 1 Transmission Solenoid 2 Transmission Solenoid 3 Transmission Solenoid 4 Transmission Solenoid 5 Transmission Solenoid 6 Transmission Solenoid 7 Machine Lockout Indicator Lamp Requested Gear Command Signal

Component Backup Alarm Relay System Voltage CAT Data Link Transmission Electronic Control Module Start Relay Brake Control Gear Selector Lever Hoist Lever Machine Application Body Position Sensor Body Up Lamp Hoist Pump Bypass 1 Solenoid Hoist Pump Bypass 2 Solenoid Hoist Control To Tank Head Solenoid Hoist Control To Tank Rod Solenoid Hoist Pump To Control Head Solenoid Hoist Pump To Control Rod Solenoid Hoist Pilot System Enable Solenoid Accumulator Bleed Relay Machine Operation State

The CID is a diagnostic code that indicates which component is faulty. The MID is a diagnostic code that indicates which electronic control module diagnosed the fault.

21 VIMS Component Identifier Chart Component Identifiers (CID) and Module Identifiers (MID) For VIMS (MID NO's. 49, 57, 58, 59, 60, 65, 66, 67, and 68)
CID
0041 0075 0091 0096 0098 0100 0101 0102 0110 0127 0168 0171 0177 0190 0248 0253 0245 0261 0262 0263 0267 0268 0269 0271 0272 0273 0274 0275 0276 0277 0278 0279 0280 0291 0292 0295 0296 0298 0324 0341 0350 0351 0352 0353 0354 0355 0356 0357 0358 0359 0360 0361 0363 0364 0365 0367 0370

Component 8 Volt Sensor Power Supply Steering Oil Temperature Sensor Throttle Position Sensor Fuel Level Sensor Engine Oil Level Sensor Engine Oil Pressure Sensor Crankcase Air Pressure Sensor Boost Pressure Sensor Engine Coolant Temperature Sensor Transmission Oil Pressure Sensor Electrical System Voltage Ambient Air Temperature Sensor Transmission Oil Temperature Sensor Engine Speed Sensor CAT Data Link Personality Module (Engine Control) Electronic Control Module (ECM) Engine Timing Calibration 5 Volt Sensor Power Supply 8V (or 12V) Sensor Pwr Supply Engine Shutdown Switch (Remote) Programmable Parameters (Eng Ctrl) Sensor Power Supply Action Alarm Turbo Outlet High Press Sensor Turbocharger Outlet Pressure Sensor Atmospheric Pressure Sensor Right Turbo Inlet Press Sensor Left Turbo Inlet Press Sensor Timing Calibration Sensor AESC Enable Lamp Aftercooler Coolant Temp Sensor Gear Box Temperature Sensor Engine Coolant Cooling Fan Solenoid Hydraulic Oil Cooling Fan Solenoid Electronic Control Module (ECM) Transmission ECM Service Brake Pedal Switch Action (Warning) Lamp Hyd Ctrl Valve Warm Up Sol #4 Lift Linkage Position Sensor Tilt Linkage Position Sensor Lift Lever (Cab) Sensor Tilt Lever (Cab) Sensor Lift Raise Solenoid #1 Lift Lower Solenoid #1 Tilt Dump Solenoid #1 Tilt Rackback Solenoid #1 Pilot Pressure Solenoid (Supply) Lift Raise Kickout Solenoid Lift Lower Kickout Solenoid Tilt Kickout Solenoid Machine Ride Control Actuator Lift Cylinder Head Pressure Sensor Kickout Set Switch Ride Control Switch Boom Float Solenoid

CID
0558 0559 0562 0569 0580 0581 0590 0592 0593 0594 0595 0596 0600 0621 0623 0626 0627 0628 0641 0642 0643 0644 0645 0646 0650 0654 0655 0656 0657 0658 0659 0670 0671 0672 0678 0679 0700 0701 0702 0703 0704 0705 0706 0707 0708 0709 0710 0711 0712 0713 0714 0715 0800 0801 0802 0803 0804

Component Autolube Relay Boom Float Relay Caterpillar Monitoring System Oil Injection Solenoid Power Shift Pressure Sensor Power Shift Solenoid Engine Electronic Control Module Lift Raise Solenoid #2 Lift Lower Solenoid #2 Tilt Rackback Solenoid #2 Tilt Dump Solenoid #2 Implement Electronic Control Module Hydraulic Oil Temperature Sensor Downshift Switch Directional Switch Steering/Transmission Lock Switch Parking Brake Pressure Switch Quickshift Switch Transmission Solenoid #1 Transmission Solenoid #2 Transmission Solenoid #3 Transmission Solenoid #4 Transmission Solenoid #5 Transmission Solenoid #6 Harness Code Trailer Right Brake Oil Temp Sensor Trailer Left Brake Oil Temp Sensor Trailer Brake Oil Cooler Inlet Temp Sen Trailer Brake Oil Cooler Temp Sensor Trailer Rt Suspension Cyl Press Sensor Trailer Lt Suspension Cyl Press Sensor Torque Converter Pedal Pos Sensor Transmission Output Speed Sensor Torque Converter Output Spd Sensor Torque Converter Impeller Clutch Sol Torque Converter Lockup Clutch Sol Transmission Gear Actuator Sensor Transmission Output Speed Sensor Transmission Gear Selector Switch Trailer Door Position Sensor Service Brake Pressure Switch Body Raise Switch Body Up Sensor Transmission Upshift Solenoid Transmission Downshift Solenoid Trans Lockup Clutch Sol ARC Supply Valve ARC Control Valve ARC Lamp ARC ON/OFF Switch ARC Pressure Switch Retarder Pressure Switch VIMS Main Module VIMS Interface Module #1 VIMS Interface Module #2 VIMS Interface Module #3 VIMS Interface Module #4

22 VIMS Component Identifier Chart Component Identifiers (CID) and Module Identifiers (MID) For VIMS (MID NO's. 49, 57, 58, 59, 60, 65, 66, 67, and 68)
CID
0371 0372 0373 0374 0376 0377 0378 0379 0423 0424 0425 0426 0427 0428 0429 0430 0431 0432 0433 0434 0436 0438 0439 0440 0444 0457 0458 0459 0489 0490 0499 0526 0533 0541 0542 0544 0545 0546 0548

Component Horn Solenoid (Forward) Bucket/Shovel Open Solenoid Bucket/Shovel Close Solenoid Swing Brake Solenoid Travel Alarm (Solenoid/Switch) Travel Brake Solenoid Machine Autolube Solenoid Machine Autolube Pressure Sensor Front Brake Accumulator Press Sw Rear Brake Accumulator Press Sw Front Brake Oil Pressure Sensor Rear Brake Oil Pressure Sensor Front Axle Oil Temperature Sensor Rear Axle Oil Temperature Sensor Steering Pump Oil Pressure Sensor Steering Pilot Pressure Sensor Steering Oil Level Switch Steering Filter By-Pass Switch Implement Filter Switch Hyd Pilot Oil Press Sensor Torque Converter Oil Pressure Sensor Hyd Ctrl Valve Warm Up Sol #1 Hyd Ctrl Valve Warm Up Sol #2 Hyd Ctrl Valve Warm Up Sol #3 Start Relay Brake Oil Temperature Sensor Tilt Cylinder Rod Pressure Sensor Impeller Clutch System Switch Implement Select Switch Implement Lockout Switch Implement Variable Hyd Oil Pump Sol Turbocharger Wastegate Valve Auto Retarder Control (ARC) Differential (Axle) Oil Pressure Sensor Engine Oil Pressure/uh/Unfiltered Sensor Engine Fan Speed Sensor Start Aid Relay Start Aid Hold Relay Throttle Lock Lamp

CID
0805 0806 0807 0808 0809 0810 0811 0812 0813 0814 0815 0816 0817 0819 0820 0821 0822 0823 0824 0825 0856 0827 0828 0829 0830 0833 0835 0838 0839 0840 0841 0849 0851 0852 0853 0854 0855 0890

Component VIMS Interface Module #5 VIMS Interface Module #6 VIMS Interface Module #7 VIMS Interface Module #8 Speedometer/Tachometer #1 Speedometer/Tachometer #2 Gauge (Quad) Cluster #1 Gauge (Quad) Cluster #2 Gauge (Quad) Cluster #3 Gauge (Quad) Cluster #4 Message Center #1 Message Center #2 ECM Internal Backup Battery Display Data Link Keypad Data Link Display Power Supply (9 Volt) Display Lighting Power Supply VIMS Service Lamp Truck Payload Lamp #1 (Green) Truck Payload Lamp #2 (Red) Torque Converter Oil Temp Sensor Left Exhaust Temp Sensor Right Exhaust Temp Rear Aftercooler Cool Temp Sensor Front Brake Oil Temperature Sensor Rear Brake Oil Temperature Sensor Differential (Axle) Oil Temp Sensor Lt Front Suspension Cyl Press Sensor Rt Front Suspension Cyl Press Sensor Lt Rear Suspension Cyl Press Sensor Rt Rear Suspension Cyl Press Sensor System Air Pressure Sensor Gear Box Pressure Sensor Brake Oil Temp Sensor (Rt Front) Brake Oil Temp Sensor (Lt Front) Brake Oil Temp Sensor (Rt Rear) Brake Oil Temp Sensor (Lt Rear) Broadcast Port (Data Link)

The CID is a diagnostic code that indicates which component is faulty. The MID is a diagnostic code that indicates which electronic control module diagnosed the fault.

23 Failure Mode Identifier Chart

Failure Mode Identifiers (FMI)


0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Data valid but above normal operational range. Data valid but below normal operational range. Data erratic, intermittent, or incorrect. Voltage above normal or shorted high. Voltage below normal or shorted low. Current below normal or open circuit. Current above normal or grounded circuit. Mechanical system not responding properly. Abnormal frequency, pulse width, or period. Abnormal update. Abnormal rate of change. Failure mode not identifiable. Bad device or component. Out of calibration. Parameter failures. Parameter failures. Parameter not available. Module not responding. Sensor supply fault. Condition not met. Parameter failures.

The FMI is a diagnostic code that indicates what type of failure has occurred.

24 Related Electrical Manuals Related Electrical Service Manuals


Title
3524B Troubleshooting Brake/Cooling ECM for 797 Truck Chassis ECM for 797 Truck Transmission ECM for 797 Truck Vital Information Management System (VIMS) System Operation Vital Information Management System (VIMS) Testing and Adjusting / Troubleshooting

Form Number
RENR2275 RENR2677 RENR2676 RENR2678 RENR2630 RENR2631

25 Harness and Wire Symbols

Harness And Wire Electrical Schematic Symbols


Part Numbers For Connector Assembly AG-C4 * 111-7898 1 Plug 2 Pin or Socket Number * * C-C4 AG-C3 130-6795 130-6795 325-A135 PK-14 Pin Socket Wire, Cable, or Harness Assembly Identification Receptacle L-C12 * 3E-5179 1 2 Typical representation of a Deutsch connector. The plug contains all sockets and the receptacle contains all pins. 1 2 Typical representation of a Sure-Seal connector. The plug and receptacle contain both pins and sockets. Component Part Number

9X-1123

* AG-C4 111-7898 1

* L-C12 3E-5179

325-L25 PK-14

Harness identification code This example indicates wire 32 in harness "L'.

Single Wire Connector * Harness identification letter(s) and a serializing code. The "C" stands for connector and the number indicates which connector in the harness. 2 Circuit Number Identification 200-L32 BK-14 Wire Color Wire Gauge

Electrical Schematic Symbols And Definitions


FUSE - A component in an electrical circuit that will open the circuit if too much current flows through it. REED SWITCH - A switch whose contacts are controlled by a magnet. A magnet closes the contacts of a normally open reed switch; it opens the contacts of a normally closed reed switch. SENDER - A component that is used with a temperature or pressure gauge. The sender measures the temperature or pressure. Its resistance changes to give an indication to the gauge of the temperature or pressure. RELAY (Magnetic Switch) - A relay is an electrical component that is activated by electricity. It has a coil that makes an electromagnet when current flows through it. The electromagnet can open or close the switch part of the relay. CIRCUIT BREAKER (C/B) - A component in an electrical circuit that will open the circuit if too much current flows through it. This does not destroy the circuit breaker and it can be reset to become part of the circuit again. SOLENOID - A solenoid is an electrical component that is activated by electricity. It has a coil that makes an electromagnet when current flows through it. The electromagnet can open or close a valve or move a piece of metal that can do work.

26 Symbols and Definitions

Electrical Schematic Symbols And Definitions

Pressure Symbol

Temperature Symbol

Level Symbol

Flow Symbol

Normally open switch that will close with an increase of a specific condition (temp-press-etc.).

Normally open switch that is closed due to an applied condition, and will open again with a specific decrease in that condition.

Normally closed switch that will open with an increase of a specific condition.

Normally closed switch that is open due to an applied condition, and will close again with a specific decrease in that condition.

The circle indicates that the component has screw terminals and a wire can be disconnected from it.

No circle indicates that the wire cannot be disconnected from the component.

This indicates that the component has a wire connected to it that is connected to ground.

This indicates that the component does not have a wire connected to ground. It is grounded by being fastened to the machine.

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