Sounds like the the Cat manuals are woefully short on info. Many times just a continuity check on a wiring harness and across the connectors will find many troubles. Crusty,rusty loose chassis return connections are regulars. On cards, modules etc, a check of the cards power supply/filter then checking for traffic data on the buss will often find the trouble. Corrupted data from electrical noise is common. A $1500 card will also show a false fault due to a $49.99 sensor failure/mis-adjustment. The function of a sensor,card, wiring harness and computer can be checked. Just by either injecting a test voltage,current or frequency and look for the appearance or absence of the data on the system. The good old dunking a sensor in hot water, applying pressure or waving it past metal will verify most faults. A half decent ohmmeter and a $100 surplus oscilloscope will find most of the faults. Most of the time the faults trace back to rodents, big clumsy feet, panels doors left off/not properly installed let moisture,heat,dirt or oil enter.And damaged incurred during assembly, maintenance or service.
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