Installation Instructions to Retrofit VIMS Hardware Version 2.0/3.0 to VIMS Hardware Version 4.0 {7601} Caterpillar

Off-Highway Truck/Tractor

776D (S/N: 5ER1-UP)

784C (S/N: 2PZ1-UP)

785B (S/N: 6HK1-UP)

789B (S/N: 7EK1-UP)

793B (S/N: 1HL1-UP)

793C (S/N: 4AR1-UP; 4GZ1-UP)

Wheel Loader

994D (S/N: 3TZ1-UP)

Introduction

This Special Instruction provides directions on the physical replacement of VIMS Main Module hardware version 2.0 ( 3E-3666 Electronic Control Gp, 115-0648 Electronic Control Gp, 118-9636 Electronic Control Gp, and 124-6134 VIDS/VIMS Main Module) and VIMS Main Module hardware version 3.0 ( 130-5131 Electronic Control Module and 165-8682 Electronic Control Module) with a 327-3520 Electronic Control Module (VIMS) main module hardware version 4.0.

Note: Prior to the retrofit installation process, the "Before Flashing" portion of the VIMS Software Update Checklist will need to be filled out. The checklist is at the end of this document. The technician will also need to confirm that the appropriate software is available to complete the retrofit procedure.

Do not perform any procedure in this Special Instruction until you have read the information and you understand the information.

Safety Section

Do not perform any procedure in this Special Instruction until you have read this Special Instruction and you understand this information. Use only proper tools and observe all precautions that pertain to the use of those tools. Failure to follow these procedures can result in personal injury. The following procedures also should be observed.

Work safely. Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs.

A person must be alert to potential hazards. This person should also have the necessary training, skills, and tools 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. Ensure that any tool, procedure, work method, or operating technique you use that is not recommended by Caterpillar is safe.

Ensure that the product will not be damaged or the product will not be made unsafe by the operation, lubrication, maintenance, or repair procedures used.

Ground the equipment. Improper grounding will result in electrical current paths that are uncontrolled and unreliable. Uncontrolled electrical circuit paths can result in damage to the equipment. Uncontrolled electrical circuit paths can also cause electrical activity that may degrade the electronics and communications. Ensure that all grounds are secure and free of corrosion.

Note: Caterpillar recommends that each customer conducts a risk assessment for remote control operation and establish layers of protection in and around the area of the remote controlled machine and establish safe job site procedures. Examples may include personnel training, warning signs, and barricades.

Note: Prior to operation of the machine read the Operation and Maintenance Manual.

• Only mount the machine and dismount the machine at locations that have steps and/or handholds.

• Inspect the steps and the handholds before mounting and dismounting. Clean the steps and the handholds, if necessary. Repair the steps and the handholds, if necessary.

Illustration 1	g00037367

• Face the machine when you are mounting and dismounting.

• Maintain a three-point contact with the steps and the handholds. Three-point contact is maintained when two feet and one hand are in contact or one foot and two hands are in contact.

• Never get on a moving machine or off a moving machine.

• Never jump off the machine.

• Do not try to climb on the machine or climb off the machine when you are carrying tools or supplies. Use a hand line to pull equipment up to the operator platform.

• Do not use any of the controls as handholds as you are climbing into the machine or exiting the machine .

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Improper operation of an access platform could result in injury or death. Operators must carry out their duties properly and follow all instructions and guidelines given for the machine and access platform.

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Be sure all personnel are clear of the equipment while the equipment is being lowered. Failure to stay clear of the equipment while the equipment is being lowered may result in personal injury.

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Do not operate or work on this machine unless you have read and understand the instructions and warnings in the Operation and Maintenance Manual. Failure to follow the instructions or heed the warnings could result in injury or death. Contact any Caterpillar dealer for replacement manuals. Proper care is your responsibility.

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Personal injury or death can result from sudden machine movement. Sudden movement of the machine can cause injury to persons on or near the machine. Prevent possible injury by performing the procedure that follows before working on the machine. Move the machine to a smooth and level location that is away from working machines and personnel. Ground all implements. Engage the parking brake. Stop the engine. Move the hydraulic control levers to all positions to release the pressure in the hydraulic system. To avoid accidental engine starting, turn the battery disconnect switch to the OFF position. Remove the key for the battery disconnect switch. Use a secure padlock in order to lock the battery compartment access door. Place a "Do Not Operate" tag at the Start/Stop switch location to inform personnel that the equipment is being worked on.

541-4828 Communication-Kit (INSTALLATION, VIMS)

Required Parts

Remove the Existing VIMS Main Module

Perform the following procedure to remove the existing VIMS main module:

1. Complete the "Before Flashing" portion of the VIMS Software Update Checklist (at the end of this instruction). Refer to "VIMS Software Update Check List".

2. Shut off and lockout the main power disconnect switch.

3. Install the truck body retaining cable in accordance with the Disassembly and Assembly, SENR1463, "793C Off-Highway Truck Machine Systems", "Truck Body Retaining Cable - Remove and Install" procedure.
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   Illustration 2	g00734886
   (1) Truck body retaining cable

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   The space between the body and the frame becomes a zero clearance area when the body is lowered. Failure to install the retaining cable can result in injury or death to personnel working in this area.

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   Illustration 3	g01063864
   (2) Auto retarder (3) VIMS main module

4. Remove the rear access cab panel. Located from left to right will be an Auto Retarder (2) and the VIMS main module (3).
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   Illustration 4	g01063914

5. Disconnect the existing VIMS main module from the chassis harness.
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   Illustration 5	g01063915

6. Remove the four bolts (4) that secure the VIMS main module and the mounting plate to the cab floor. These bolts will need to be used later to complete the retrofit procedure.
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   Illustration 6	g01067696

7. Remove the VIMS main module and the mounting plate.

Install the New VIMS Main Module

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Illustration 7	g01067709

1. Attach the new 548-7591 Monitor Harness As to the bulkhead elbow on the 235-8155 Plate As.

   Note: In some machines there may not be enough space to mount the ECM along with the mounting plate on the dash. Under such circumstances, an additional mounting bracket/plate would have to be fabricated for placing VIMS kit without any interference with any existing components or harness. Caterpillar recommends ensuring that this mounting bracket/plate is bolted and shall have a thickness of 3 mm (0.12 inch) to 6 mm (0.24 inch).

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   Illustration 8	g01067713

2. Connect the new 548-7591 Monitor Harness As to the existing 37-pin chassis harness.
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   Illustration 9	g01067711

3. Install the new mounting plate and harness to the cab floor with the original mounting plate bolts. Ensure that the harness clips (5) are reattached at this step.
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   Illustration 10	g01067708
   DETAIL A identifies the mounting hardware used (in two locations) with the 133-3489 Plate AS (17). DETAIL B identifies the mounting hardware used in the remaining two locations. (6) 8T-6870 Bolt (7) 9N-0869 Washer (8) 8T-9655 Mount (9) 145-0487 Spacer (10) 9S-8413 Washer (11) 6D-4244 Clip (12) 8T-4177 Bolt (13) 130-5300 Clip (14) 8T-4224 Washer (15) 6V-8801 Nut (16) 8T-4896 Washer (17) 133-3489 Plate AS (18) 8M-2773 Clip (19) 8L-5449 Spacer

4. The hardware included in the 541-4828 Communication-Kit (INSTALLATION, VIMS) will be used to install the new VIMS main module.
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   Illustration 11	g01067721
   (8) 8T-9655 Mount (9) 145-0487 Spacer

5. In all four mounting locations insert the 8T-9655 Mount (8) and 145-0487 Spacer (9) as shown.

6. Attach the 327-3520 Electronic Control Module (VIMS) to the mounting plate. The mounting hardware should be assembled as shown in Illustration 10.
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   Illustration 12	g01067728

7. Secure the new 548-7591 Monitor Harness As in two locations with 6D-4244 Clips (11) and tighten all four mounting bolts.
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   Illustration 13	g01068411
   (13) 130-5300 Clips

8. Two 130-5300 Clips (13) are provided to secure a 12-pin breakout connector and a 3-pin breakout connector.
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   Illustration 14	g01067730

9. Attach the 12-pin breakout connector to the 130-5300 Clip provided. If the truck is equipped with a RAC Module, connect the 12-pin breakout connector to the RAC harness. If the machine is not equipped with a RAC Module, a connector plug will need to be attached as shown in Illustration 14.
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   Illustration 15	g01067740

10. Attach the 3-pin breakout connector to the second 130-5300 Clip as shown in Illustration 15.
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    Illustration 16	g01067741
    (17) 8M-2773 Clips

11. Connect the two 70-pin connectors "J1" and "J2" to the 327-3520 Electronic Control Module (VIMS). Secure the harness in the remaining locations with 8M-2773 Clips (17).

12. After all connections are made, turn on main power disconnect switch.

VIMS ABL Software

Refer to Table 2 for software information.

VIMS Software Update Check List

Illustration 17	g01052974

Illustration 18	g01068704

Perform the following procedure:

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Illustration 19	g01068548

1. Connect Cat^® Electronic Technician (Cat ET) and the comm adapter.

2. Ensure that the "Before Flashing" portion of the checklist has been filled out. If you have completed the installation of the 327-3520 Electronic Control Module (VIMS), proceed to Step 4.

3. Refer to Table 2 for the software for cross referencing the appropriate prefix. Once the retrofit procedure is performed, you will have a production updated machine. Additional ECM software may be necessary to obtain all the new features.

4. Flash new file to new 327-3520 Electronic Control Module (VIMS). If you do not know the correct software part number, contact VIMS Product Support for the correct software part number. For VIMS / DSN Support, contact your local technical communicator.

5. After flash is complete, turn off main power again for at least 40 seconds.

6. Turn on main power and keyswitch power. Then proceed through the parameters on the message center and VIMS Software Update Check List.

   Note: Machines with different Interface Modules may experience a Data Link Error upon initial key cycle after the retrofit procedure has been completed. To allow time for the modules to reinitialize, cycle the Main power and leave off for a minimum of 40 seconds. Full response from the gages and the parameters may take up to 3 minutes. If the problem persists, contact VIMS Product Support. For VIMS / DSN Support, contact your local technical communicator.

Illustration 20	g06244964
VIMS Schematic 1

Illustration 21	g06245145
VIMS Schematic 2

235-8155 Plate As Modifications for Machines (S/N:2BW, ; S/N:4GZ, and ; S/N:5AZ Only)

Perform the following procedure to update the 235-8155 Plate As:

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Illustration 22	g06234261
(1) 235-8155 Plate As (2) 8R-6927 Bosses

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Illustration 23	g06227799
235-8155 Plate As

1. Remove the welded 8R-6927 Bosses from the 235-8155 Plate As.
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   Illustration 24	g06227805
   Modified 235-8155 Plate As

2. Cut the side edges of the 235-8155 Plate As up to 35 mm (1.38 inch) maximum.
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   Illustration 25	g06227808
   ECM set-up

3. Place the ECM set up over the modified 235-8155 Plate As.
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   Illustration 26	g06244514
   (3) 174-1377 Plate As (4) Connectors from main harness carrying engine RPM (when present) (5) Interface Module Connectors

4. Assemble the ECM and the 235-8155 Plate As with the 174-1377 Plate As. Refer to Illustration 26.

   Note: If VIMS interface module is not available, tie back both the connectors (5) and engine harness (4).

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   Illustration 27	g06244875
   (6) General location of the ECM and the 235-8155 Plate As with the 174-1377 Plate As

5. Refer to Illustration 27 for the modified setup to be mounted on the ECM tower.