Systems Operation Testing and Adjusting

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Systems Operation

Testing and Adjusting

Vital Information Management

System (VIMS)

9YF1-Up (Machine) 7TJ1-Up (Machine) 5RK1-Up (Machine) 6HK1-Up (Machine) 7EK1-Up (Machine) 1HL1-Up (Machine) 5ZL1-Up (Machine) 7LL1-Up (Machine) 4AR1-Up (Machine) 7HR1-Up (Machine) 4CS1-Up (Machine) 1HW1-Up (Machine) 2BW1-302 (Machine) 3TZ1-Up (Machine) 4GZ1-Up (Machine)

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Most accidents that involve product operation, maintenance and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skills and tools to perform these functions properly.

Improper operation, lubrication, maintenance or repair of this product can be dangerous and could result in injury or death.

Do not operate or perform any lubrication, maintenance or repair on this product, until you have read and understood the operation, lubrication, maintenance and repair information.

Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons.

The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as “DANGER”, “WARNING” or “CAUTION”. The Safety Alert “WARNING” label is shown below.

The meaning of this safety alert symbol is as follows:

Attention! Become Alert! Your Safety is Involved.

The message that appears under the warning explains the hazard and can be either written or pictorially presented.

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 be made unsafe by the operation, lubrication, maintenance or repair procedures that you choose.

The information, specifications, and illustrations in this publication are on the basis of information that was available at the time that the publication was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time. These changes can affect the service that is given to the product. Obtain the complete and most current information before you start any job. Caterpillar dealers have the most current information available. For a list of the most current publication form numbers available, see the Service Manual Contents Microfiche, REG1139F.

When replacement parts are required for this product Caterpillar recommends using Caterpil-lar replacement parts or parts with equivalent specifications including, but not limited to, phys-ical dimensions, type, strength and material. Failure to heed this warning can lead to prema-ture failures, product damage, personal injury or death.

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Systems Operation Section

General Information ... 9

VIMS History ... 16

Normal Operation ... 18

Service Operations ... 19

Attachment Code - Configure ... 20

Calibration Mode - Enter ... 21

Data Logger - Reset ... 21

Data Logger - Start/Stop ... 22

Display Backlighting - Set ... 22

Display Contrast - Set ... 23

Display Language - Set ... 23

Display Units - Set ... 23

Event - Configure ... 23

Event Acknowledged - Show ... 25

Event List - Show ... 25

Event Recorder - Start ... 26

Event Statistics - Show ... 27

Lubrication Interval - Set ... 27

Lubrication Manual - Start ... 28

Machine Status - Show ... 28

Odometer - Set ... 29

Resettable Totals - Reset ... 30

Resettable Totals - Show ... 30

Service Lamp - Reset ... 31

Service Lamp - Set ... 31

Snapshot Trigger - Configure ... 34

System Self Test ... 36

Truck Payload - Calibrate ... 38

Truck Payload - Configure ... 38

Warning Operation ... 39

Loader Payload System (LPS) General Information ... 41

LPS Menu Functions Summary ... 42

LPS Calibration ... 43

Truck Payload System (TPS) General Information ... 53 TPS Component Function ... 54 TPS On-Board Features ... 55 TPS Off-Board Features ... 57 TPS Normal Operation ... 57 TPS Service Operation ... 60

TPS Maximum Payload Speed Manager ... 62

TPS Accuracy ... 67

Component Descriptions ... 68

Main Module ... 69

Interface Module ... 74

Display Modules ... 76

Quad Gauge Module ... 77

Speedometer/Tachometer Module ... 78

Message Center Module ... 79

Keypad ... 85 Switches ... 89 Sensors ... 92 Data Connectors ... 96 Action Lamp ... 97 Action Alarm ... 97 Payload Lamps ... 98 Service Lamp ... 98 Related Components ... 99 Parameters ... 100

Testing and Adjusting Section

Testing and Adjusting General Information ... 155

Service Tools ... 156

Troubleshooting Diagnostic Codes ... 157

Troubleshooting Diagnostic Codes Using Abbreviated Procedure ... 164

CID 0041 FMI 03 Sensor Power Supply (8 DCV) Voltage Above Normal - Test ... 209

CID 0041 FMI 04 Sensor Power Supply (8 DCV) Voltage Below Normal - Test ... 210

CID 0041 FMI 06 Sensor Power Supply (8 DCV) Current Above Normal - Test ... 211

CID 0075 FMI 03 Temperature Sensor (Steering Oil) Voltage Above Normal - Test ... 212

CID 0075 FMI 04 Temperature Sensor (Steering Oil) Voltage Below Normal - Test ... 214

CID 0075 FMI 06 Temperature Sensor (Steering Oil) Current Above Normal - Test ... 215

CID 0096 FMI 03 Level Sensor (Fuel) Voltage Above Normal - Test ... 217

CID 0096 FMI 04 Level Sensor (Fuel) Voltage Below Normal - Test ... 218

CID 0096 FMI 06 Level Sensor (Fuel) Current Above Normal - Test ... 220

CID 0100 FMI 03 Pressure Sensor (Engine Oil) Voltage Above Normal - Test ... 221

CID 0100 FMI 04 Pressure Sensor (Engine Oil) Voltage Below Normal - Test ... 223

CID 0100 FMI 06 Pressure Sensor (Engine Oil) Current Above Normal - Test ... 224

CID 0110 FMI 03 Temperature Sensor (Engine Coolant) Voltage Above Normal - Test ... 225

CID 0110 FMI 04 Temperature Sensor (Engine Coolant) Voltage Below Normal - Test ... 227

CID 0110 FMI 06 Temperature Sensor (Engine Coolant) Current Above Normal - Test ... 228

CID 0127 FMI 03 Pressure Sensor (Transmission Oil) Voltage Above Normal - Test ... 229

CID 0127 FMI 04 Pressure Sensor (Transmission Oil) Voltage Below Normal - Test ... 231

CID 0127 FMI 06 Pressure Sensor (Transmission Oil) Current Above Normal - Test ... 232

CID 0171 FMI 03 Temperature Sensor (Ambient Air) Voltage Above Normal - Test ... 233

CID 0171 FMI 04 Temperature Sensor (Ambient Air) Voltage Below Normal - Test ... 235

CID 0171 FMI 06 Temperature Sensor (Ambient Air) Current Above Normal - Test ... 237

CID 0177 FMI 03 Temperature Sensor (Transmission Oil) Voltage Above Normal - Test ... 238

CID 0177 FMI 04 Temperature Sensor (Transmission Oil) Voltage Below Normal - Test ... 240

CID 0177 FMI 06 Temperature Sensor (Transmission Oil) Current Above Normal - Test ... 241

CID 0190 FMI 02 Speed Sensor (Engine) Incorrect Signal - Test ... 242

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CID 0190 FMI 03 Speed Sensor (Engine) Voltage Above Normal - Test ... 244 CID 0190 FMI 04 Speed Sensor (Engine) Voltage

Below Normal - Test ... 245 CID 0190 FMI 08 Speed Sensor (Engine) Abnormal

Signal - Test ... 246 CID 0248 FMI 09 CAT Data Link Abnormal Update

-Test ... 247 CID 0262 FMI 03 Sensor Power Supply (5 DCV)

Voltage Above Normal - Test ... 249 CID 0262 FMI 04 Sensor Power Supply (5 DCV)

Voltage Below Normal - Test ... 250 CID 0262 FMI 06 Sensor Power Supply (5 DCV)

Current Above Normal - Test ... 251 CID 0263 FMI 03 Sensor Power Supply (8 or 12

DCV) Voltage Above Normal - Test ... 251 CID 0263 FMI 04 Sensor Power Supply (8 or 12

DCV) Voltage Below Normal - Test ... 252 CID 0263 FMI 06 Sensor Power Supply (8 or 12

DCV) Current Above Normal - Test ... 253 CID 0271 FMI 03 Alarm (Action) Voltage Above

Normal - Test ... 254 CID 0271 FMI 05 Alarm (Action) Current Below

Normal - Test ... 255 CID 0271 FMI 06 Alarm (Action) Current Above

Normal - Test ... 256 CID 0279 FMI 03 Temperature Sensor (Front

Aftercooler Coolant) Voltage Above Normal -Test ... 257 CID 0279 FMI 04 Temperature Sensor (Front

Aftercooler Coolant) Voltage Below Normal -Test ... 259 CID 0279 FMI 06 Temperature Sensor (Front

Aftercooler Coolant) Current Above Normal -Test ... 261 CID 0280 FMI 03 Temperature Sensor (Pump Drive)

Voltage Above Normal - Test ... 262 CID 0280 FMI 04 Temperature Sensor (Pump Drive)

Voltage Below Normal - Test ... 264 CID 0280 FMI 06 Temperature Sensor (Pump Drive)

Current Above Normal - Test ... 265 CID 0295 FMI 02 Electronic Control Module

(Machine) Incorrect Signal - Test ... 266 CID 0295 FMI 09 Electronic Control Module

(Machine) Abnormal Update - Test ... 268 CID 0295 FMI 12 Electronic Control Module

(Machine) Failed - Test ... 270 CID 0296 FMI 02 Power Train Electronic Control

Module (Electronic Clutch Pressure Control) Incorrect Signal - Test ... 272 CID 0296 FMI 09 Power Train Electronic Control

Module (Electronic Clutch Pressure Control) Abnormal Update) - Test ... 274 CID 0296 FMI 12 Power Train Electronic Control

Module (Electronic Clutch Pressure Control) Failed -Test ... 276 CID 0324 FMI 03 Lamp (Action) Voltage Above

Normal - Test ... 278 CID 0324 FMI 05 Lamp (Action) Current Below

Normal - Test ... 278

CID 0324 FMI 06 Lamp (Action) Current Above Normal - Test ... 279 CID 0341 FMI 03 Solenoid Valve (No. 4) (Warm Up)

Voltage Above Normal - Test ... 281 CID 0341 FMI 05 Solenoid Valve (No. 4) (Warm Up)

Current Below Normal - Test ... 281 CID 0341 FMI 06 Solenoid Valve (No. 4) (Warm Up)

Current Above Normal - Test ... 282 CID 0341 FMI 11 Solenoid Valve (No. 4) (Warm Up)

Failure Mode Not Identifiable - Test ... 282 CID 0350 FMI 00 Position Sensor (Lift Linkage)

Above Normal Range - Test ... 283 CID 0350 FMI 01 Position Sensor (Lift Linkage)

Below Normal Range - Test ... 283 CID 0350 FMI 02 Position Sensor (Lift Linkage)

Incorrect Signal - Test ... 284 CID 0350 FMI 03 Position Sensor (Lift Linkage)

Voltage Above Normal - Test ... 284 CID 0350 FMI 04 Position Sensor (Lift Linkage)

Voltage Below Normal - Test ... 285 CID 0350 FMI 06 Position Sensor (Lift Linkage)

Current Above Normal - Test ... 285 CID 0350 FMI 08 Position Sensor (Lift Linkage)

Abnormal Signal - Test ... 286 CID 0350 FMI 11 Position Sensor (Lift Linkage)

Failure Mode Not Identifiable - Test ... 286 CID 0350 FMI 13 Position Sensor (Lift Linkage) Out

of Calibration - Test ... 287 CID 0364 FMI 03 Pressure Sensor (Lift Cylinder

Head End) Voltage Below Normal - Test ... 287 CID 0364 FMI 04 Pressure Sensor (Lift Cylinder

Head End) Voltage Below Normal - Test ... 287 CID 0364 FMI 06 Pressure Sensor (Lift Cylinder

Head End) Current Above Normal - Test ... 287 CID 0371 FMI 03 Solenoid Valve (Air Horn) Voltage

Above Normal - Test ... 287 CID 0371 FMI 05 Solenoid Valve (Air Horn) Current

Below Normal - Test ... 288 CID 0371 FMI 06 Solenoid Valve (Air Horn) Current

Above Normal - Test ... 289 CID 0371 FMI 11 Solenoid Valve (Air Horn) Failure

Mode Not Identifiable - Test ... 289 CID 0378 FMI 03 Solenoid Valve (Automatic

Lubrication) Voltage Above Normal - Test ... 290 CID 0378 FMI 05 Solenoid Valve (Automatic

Lubrication) Current Below Normal - Test ... 291 CID 0378 FMI 06 Solenoid Valve (Automatic

Lubrication) Current Above Normal - Test ... 292 CID 0378 FMI 11 Solenoid Valve (Automatic

Lubrication) Failure Mode Not Identifiable

-Test ... 293 CID 0379 FMI 03 Pressure Sensor (Automatic

Lubrication) Voltage Above Normal - Test ... 293 CID 0379 FMI 04 Pressure Sensor (Automatic

Lubrication) Voltage Below Normal - Test ... 295 CID 0379 FMI 06 Pressure Sensor (Automatic

Lubrication) Current Above Normal - Test ... 297 CID 0425 FMI 03 Pressure Sensor (Front Brake Oil)

Voltage Above Normal - Test ... 298 CID 0425 FMI 04 Pressure Sensor (Front Brake Oil)

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CID 0425 FMI 06 Pressure Sensor (Front Brake Oil) Current Above Normal - Test ... 301 CID 0426 FMI 03 Pressure Sensor (Rear Brake Oil)

Voltage Above Normal - Test ... 302 CID 0426 FMI 04 Pressure Sensor (Rear Brake Oil)

Voltage Below Normal - Test ... 304 CID 0426 FMI 06 Pressure Sensor (Rear Brake Oil)

Current Above Normal - Test ... 305 CID 0427 FMI 03 Temperature Sensor (Front Axle

Oil) Voltage Above Normal - Test ... 306 CID 0427 FMI 04 Temperature Sensor (Front Axle

Oil) Voltage Below Normal - Test ... 308 CID 0427 FMI 06 Temperature Sensor (Front Axle

Oil) Current Above Normal - Test ... 309 CID 0428 FMI 03 Temperature Sensor (Rear Axle

Oil) Voltage Above Normal - Test ... 310 CID 0428 FMI 04 Temperature Sensor (Rear Axle

Oil) Voltage Below Normal - Test ... 312 CID 0428 FMI 06 Temperature Sensor (Rear Axle

Oil) Current Above Normal - Test ... 313 CID 0429 FMI 03 Pressure Sensor (Steering Oil)

Voltage Above Normal - Test ... 314 CID 0429 FMI 04 Pressure Sensor (Steering Oil)

Voltage Below Normal - Test ... 316 CID 0429 FMI 06 Pressure Sensor (Steering Oil)

Current Above Normal - Test ... 317 CID 0430 FMI 03 Pressure Sensor (Steering Pilot

Oil) Voltage Above Normal - Test ... 318 CID 0430 FMI 04 Pressure Sensor (Steering Pilot

Oil) Voltage Below Normal - Test ... 320 CID 0430 FMI 06 Pressure Sensor (Steering Pilot

Oil) Current Above Normal - Test ... 321 CID 0434 FMI 03 Pressure Sensor (Hydraulic Pilot

Oil) Voltage Above Normal - Test ... 322 CID 0434 FMI 04 Pressure Sensor (Hydraulic Pilot

Oil) Voltage Below Normal - Test ... 324 CID 0434 FMI 06 Pressure Sensor (Hydraulic Pilot

Oil) Current Above Normal - Test ... 325 CID 0436 FMI 03 Pressure Sensor (Torque Converter Oil) Voltage Above Normal - Test ... 326 CID 0436 FMI 04 Pressure Sensor (Torque Converter Oil) Voltage Below Normal - Test ... 328 CID 0436 FMI 06 Pressure Sensor (Torque Converter Oil) Current Above Normal - Test ... 329 CID 0438 FMI 03 Solenoid Valve (No. 1) (Warm Up)

Failure Mode Not Identifiable - Test ... 332 CID 0439 FMI 03 Solenoid Valve (No. 2) (Warm Up)

Failure Mode Not Identifiable - Test ... 334 CID 0440 FMI 03 Solenoid Valve (No. 3) (Warm Up)

Voltage Above Normal - Test ... 335

CID 0440 FMI 05 Solenoid Valve (No. 3) (Warm Up) Current Below Normal - Test ... 336 CID 0440 FMI 06 Solenoid Valve (No. 3) (Warm Up)

Failure Mode Not Identifiable - Test ... 337 CID 0457 FMI 03 Temperature Sensor (Brake Oil)

Voltage Above Normal - Test ... 338 CID 0457 FMI 04 Temperature Sensor (Brake Oil)

Voltage Below Normal - Test ... 339 CID 0457 FMI 06 Temperature Sensor (Brake Oil)

Current Above Normal - Test ... 340 CID 0458 FMI 03 Pressure Sensor (Tilt Cylinder Rod) Voltage Above Normal - Test ... 342 CID 0458 FMI 04 Pressure Sensor (Tilt Cylinder Rod) Voltage Below Normal - Test ... 342 CID 0458 FMI 06 Pressure Sensor (Tilt Cylinder Rod) Current Above Normal - Test ... 342 CID 0533 FMI 02 Machine Electronic Control Module (Integrated Brake) Incorrect Signal - Test ... 342 CID 0533 FMI 09 Machine Electronic Control Module (Integrated Brake) Abnormal Update - Test ... 344 CID 0533 FMI 12 Machine Electronic Control Module (Integrated Brake) Failed - Test ... 346 CID 0541 FMI 03 Pressure Sensor (Differential Oil)

Voltage Above Normal - Test ... 348 CID 0541 FMI 04 Pressure Sensor (Differential Oil)

Voltage Below Normal - Test ... 350 CID 0541 FMI 06 Pressure Sensor (Differential Oil)

Current Above Normal - Test ... 351 CID 0562 FMI 02 Caterpillar Monitoring System

Incorrect Signal - Test ... 352 CID 0562 FMI 09 Caterpillar Monitoring System

Abnormal Update - Test ... 354 CID 0562 FMI 12 Caterpillar Monitoring System

Failed - Test ... 356 CID 0590 FMI 02 Electronic Control Module (Engine) Incorrect Signal - Test ... 358 CID 0590 FMI 09 Electronic Control Module (Engine) Abnormal Update - Test ... 360 CID 0590 FMI 12 Electronic Control Module (Engine) Failed - Test ... 362 CID 0596 FMI 02 Electronic Control Module

(Implement) Incorrect Signal - Test ... 364 CID 0596 FMI 09 Electronic Control Module

(Implement) Abnormal Update - Test ... 366 CID 0596 FMI 12 Electronic Control Module

(Implement) Failed - Test ... 368 CID 0600 FMI 03 Temperature Sensor (Hydraulic Oil) Voltage Above Normal - Test ... 370 CID 0600 FMI 04 Temperature Sensor (Hydraulic Oil) Voltage Below Normal - Test ... 372 CID 0600 FMI 06 Temperature Sensor (Hydraulic Oil) Current Above Normal - Test ... 374 CID 0650 FMI 02 Harness Code Incorrect

-Test ... 375 CID 0654 FMI 03 Temperature Sensor (Trailer Right

Brake Oil) Voltage Above Normal - Test ... 376 CID 0654 FMI 04 Temperature Sensor (Trailer Right

Brake Oil) Voltage Below Normal - Test ... 378 CID 0654 FMI 06 Temperature Sensor (Trailer Right

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CID 0655 FMI 03 Temperature Sensor (Trailer Left Brake Oil) Voltage Above Normal - Test ... 380 CID 0655 FMI 04 Temperature Sensor (Trailer Left

Brake Oil) Voltage Below Normal - Test ... 381 CID 0655 FMI 06 Temperature Sensor (Trailer Left

Brake Oil) Current Above Normal - Test ... 382 CID 0656 FMI 03 Temperature Sensor (Trailer Brake

Oil Cooler Inlet) Voltage Above Normal - Test ... 383 CID 0656 FMI 04 Temperature Sensor (Trailer Brake

Oil Cooler Inlet) Voltage Below Normal - Test ... 385 CID 0656 FMI 06 Temperature Sensor (Trailer Brake

Oil Cooler Inlet) Current Above Normal - Test ... 386 CID 0657 FMI 03 Temperature Sensor (Trailer

Brake Oil Cooler Outlet) Voltage Above Normal -Test ... 387 CID 0657 FMI 04 Temperature Sensor (Trailer

Brake Oil Cooler Outlet) Voltage Below Normal -Test ... 388 CID 0657 FMI 06 Temperature Sensor (Trailer

Brake Oil Cooler Outlet) Current Above Normal -Test ... 389 CID 0658 FMI 02 Pressure Sensor (Trailer Right

Suspension Cylinder) Incorrect Signal - Test .... 390 CID 0658 FMI 03 Pressure Sensor (Trailer Right

Suspension Cylinder) Voltage Above Normal -Test ... 391 CID 0658 FMI 04 Pressure Sensor (Trailer Right

Suspension Cylinder) Voltage Below Normal -Test ... 391 CID 0658 FMI 06 Pressure Sensor (Trailer Right

Suspension Cylinder) Current Above Normal -Test ... 391 CID 0659 FMI 02 Pressure Sensor (Trailer Left

Suspension Cylinder) Incorrect Signal - Test .... 391 CID 0659 FMI 03 Pressure Sensor (Trailer Left

Suspension Cylinder) Voltage Above Normal -Test ... 391 CID 0659 FMI 04 Pressure Sensor (Trailer Left

Suspension Cylinder) Voltage Below Normal -Test ... 391 CID 0659 FMI 06 Pressure Sensor (Trailer Left

Suspension Cylinder) Current Above Normal -Test ... 392 CID 0672 FMI 01 Speed Sensor (Torque Converter

Output) Below Normal Range - Test ... 392 CID 0672 FMI 02 Speed Sensor (Torque Converter

Output) Incorrect Signal - Test ... 392 CID 0672 FMI 03 Speed Sensor (Torque Converter

Output) Voltage Above Normal - Test ... 394 CID 0672 FMI 04 Speed Sensor (Torque Converter

Output) Voltage Below Normal - Test ... 395 CID 0672 FMI 08 Speed Sensor (Torque Converter

Output) Abnormal Signal - Test ... 396 CID 0767 FMI 03 Pressure Sensor (Fixed

Displacement Pump Oil) Voltage Above Normal -Test ... 397 CID 0767 FMI 04 Pressure Sensor (Fixed

Displacement Pump Oil) Voltage Below Normal -Test ... 399

CID 0767 FMI 06 Pressure Sensor (Fixed Displacement Pump Oil) Current Above Normal -Test ... 400 CID 0801 FMI 09 Interface Module (No. 1) Abnormal

Update - Test ... 401 CID 0802 FMI 09 Interface Module (No. 2) Abnormal

Update - Test ... 402 CID 0809 FMI 02 Speedometer/Tachometer Module

(No. 1) Incorrect Signal - Test ... 403 CID 0809 FMI 12 Speedometer/Tachometer Module

(No. 1) Failed - Test ... 403 CID 0810 FMI 02 Speedometer/Tachometer Module

(No. 2) Incorrect Signal - Test ... 403 CID 0810 FMI 12 Speedometer/Tachometer Module

(No. 2) Failed - Test ... 403 CID 0811 FMI 02 Quad Gauge Module (No. 1)

Incorrect Signal - Test ... 403 CID 0811 FMI 12 Quad Gauge Module (No. 1) Failed - Test ... 403 CID 0812 FMI 02 Quad Gauge Module (No. 2)

Incorrect Signal - Test ... 404 CID 0814 FMI 12 Quad Gauge Module (No. 4) Failed - Test ... 404 CID 0815 FMI 02 Message Center Module (No. 1)

Incorrect Signal - Test ... 404 CID 0815 FMI 12 Message Center Module (No. 1)

Failed - Test ... 404 CID 0816 FMI 02 Message Center Module (No. 2)

Incorrect Signal - Test ... 404 CID 0816 FMI 12 Message Center Module (No. 2)

Failed - Test ... 404 CID 0817 FMI 02 Battery (Internal Backup) Incorrect

- Test ... 405 CID 0817 FMI 12 Battery (Internal Backup) Failed

-Test ... 405 CID 0819 FMI 02 Display Data Link Incorrect

-Test ... 405 CID 0819 FMI 03 Display Data Link Voltage Above

Normal - Test ... 405 CID 0819 FMI 06 Display Data Link Current Above

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CID 0819 FMI 12 Display Data Link Failed

-Test ... 406 CID 0820 FMI 02 Keypad Data Link Incorrect

-Test ... 406 CID 0820 FMI 03 Keypad Data Link Voltage Above

Normal - Test ... 407 CID 0820 FMI 06 Keypad Data Link Current Above

Normal - Test ... 407 CID 0820 FMI 12 Keypad Data Link Failed

-Test ... 408 CID 0821 FMI 03 Display Power Supply Voltage

Above Normal - Test ... 408 CID 0821 FMI 06 Display Power Supply Current

Above Normal - Test ... 409 CID 0822 FMI 03 Display Backlighting Voltage Above Normal - Test ... 409 CID 0822 FMI 05 Display Backlighting Current Below Normal - Test ... 410 CID 0822 FMI 06 Display Backlighting Current Above Normal - Test ... 410 CID 0823 FMI 03 Lamp (Service) Voltage Above

Normal - Test ... 411 CID 0823 FMI 05 Lamp (Service) Current Below

Normal - Test ... 412 CID 0823 FMI 06 Lamp (Service) Current Above

Normal - Test ... 413 CID 0824 FMI 03 Lamp (Green Payload) Voltage

Above Normal - Test ... 414 CID 0824 FMI 05 Lamp (Green Payload) Current

Below Normal - Test ... 414 CID 0824 FMI 06 Lamp (Green Payload) Current

Above Normal - Test ... 415 CID 0825 FMI 03 Lamp (Red Payload) Voltage Above Normal - Test ... 416 CID 0825 FMI 05 Lamp (Red Payload) Current Below Normal - Test ... 417 CID 0825 FMI 06 Lamp (Red Payload) Current Above Normal - Test ... 418 CID 0826 FMI 03 Temperature Sensor (Torque

Converter Oil) Voltage Above Normal - Test ... 419 CID 0826 FMI 04 Temperature Sensor (Torque

Converter Oil) Voltage Below Normal - Test ... 421 CID 0826 FMI 06 Temperature Sensor (Torque

Converter Oil) Current Above Normal - Test ... 422 CID 0826 FMI 11 Temperature Sensor (Torque

Converter Oil) Failure Mode Not Identifiable -Test ... 424 CID 0827 FMI 03 Temperature Sensor (Left Exhaust) Voltage Above Normal - Test ... 424 CID 0827 FMI 04 Temperature Sensor (Left Exhaust) Voltage Below Normal - Test ... 426 CID 0827 FMI 06 Temperature Sensor (Left Exhaust) Current Above Normal - Test ... 427 CID 0827 FMI 08 Temperature Sensor (Left Exhaust) Abnormal Signal - Test ... 428 CID 0828 FMI 03 Temperature Sensor (Right

Exhaust) Voltage Above Normal - Test ... 429 CID 0828 FMI 04 Temperature Sensor (Right

Exhaust) Voltage Below Normal - Test ... 431 CID 0828 FMI 06 Temperature Sensor (Right

Exhaust) Current Above Normal - Test ... 432 CID 0828 FMI 08 Temperature Sensor (Right

Exhaust) - Test ... 434

CID 0829 FMI 03 Temperature Sensor (Rear Aftercooler Coolant) Voltage Above Normal -Test ... 435 CID 0829 FMI 04 Temperature Sensor (Rear

Aftercooler Coolant) Voltage Below Normal -Test ... 436 CID 0829 FMI 06 Temperature Sensor (Rear

Aftercooler Coolant) Current Above Normal -Test ... 437 CID 0830 FMI 03 Temperature Sensor (Front Brake

Oil) Voltage Above Normal - Test ... 439 CID 0830 FMI 04 Temperature Sensor (Front Brake

Oil) Voltage Below Normal - Test ... 440 CID 0830 FMI 06 Temperature Sensor (Front Brake

Oil) Current Above Normal - Test ... 441 CID 0833 FMI 03 Temperature Sensor (Rear Brake

Oil) Voltage Above Normal - Test ... 442 CID 0833 FMI 04 Temperature Sensor (Rear Brake

Oil) Voltage Below Normal - Test ... 444 CID 0833 FMI 06 Temperature Sensor (Rear Brake

Oil) Current Above Normal - Test ... 445 CID 0835 FMI 03 Temperature Sensor (Differential

Oil) Voltage Above Normal - Test ... 446 CID 0835 FMI 04 Temperature Sensor (Differential

Oil) Voltage Below Normal - Test ... 447 CID 0835 FMI 06 Temperature Sensor (Differential

Oil) Current Above Normal - Test ... 449 CID 0838 FMI 02 Pressure Sensor (Left Front

Suspension Cylinder) Incorrect Signal - Test .... 450 CID 0838 FMI 03 Pressure Sensor (Left Front

Suspension Cylinder) Voltage Above Normal -Test ... 450 CID 0838 FMI 04 Pressure Sensor (Left Front

Suspension Cylinder) Voltage Below Normal -Test ... 450 CID 0838 FMI 06 Pressure Sensor (Left Front

Suspension Cylinder) Current Above Normal -Test ... 450 CID 0838 FMI 08 Pressure Sensor (Left Front

Suspension Cylinder) Abnormal Signal - Test ... 450 CID 0839 FMI 02 Pressure Sensor (Right Front

Suspension Cylinder) Incorrect Signal - Test .... 451 CID 0839 FMI 03 Pressure Sensor (Right Front

Suspension Cylinder) Voltage Above Normal -Test ... 451 CID 0839 FMI 04 Pressure Sensor (Right Front

Suspension Cylinder) Voltage Below Normal -Test ... 451 CID 0839 FMI 06 Pressure Sensor (Right Front

Suspension Cylinder) Current Above Normal -Test ... 451 CID 0839 FMI 08 Pressure Sensor (Right Front

Suspension Cylinder) Abnormal Signal - Test ... 451 CID 0840 FMI 02 Pressure Sensor (Left Rear

Suspension Cylinder) Voltage Above Normal -Test ... 451 CID 0840 FMI 03 Pressure Sensor (Left Rear

Suspension Cylinder) Voltage Above Normal -Test ... 452 CID 0840 FMI 04 Pressure Sensor (Left Rear

Suspension Cylinder) Voltage Below Normal -Test ... 452

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CID 0840 FMI 06 Pressure Sensor (Left Rear Suspension Cylinder) Current Above Normal

-Test ... 452

CID 0840 FMI 08 Pressure Sensor (Left Rear Suspension Cylinder) Abnormal Signal - Test ... 452

CID 0841 FMI 02 Pressure Sensor (Right Rear Suspension Cylinder) Incorrect Signal - Test .... 452

CID 0841 FMI 03 Pressure Sensor (Right Rear Suspension Cylinder) Voltage Above Normal -Test ... 452

CID 0841 FMI 04 Pressure Sensor (Right Rear Suspension Cylinder) Voltage Below Normal -Test ... 453

CID 0841 FMI 06 Pressure Sensor (Right Rear Suspension Cylinder) Current Above Normal -Test ... 453

CID 0841 FMI 08 Pressure Sensor (Right Rear Suspension Cylinder) Abnormal Signal - Test ... 453

CID 0849 FMI 03 Pressure Sensor (Air System) Voltage Above Normal - Test ... 453

CID 0849 FMI 04 Pressure Sensor (Air System) Voltage Below Normal - Test ... 455

CID 0849 FMI 06 Pressure Sensor (Air System) Current Above Normal - Test ... 457

CID 0851 FMI 03 Pressure Sensor (Pump Drive) Voltage Above Normal - Test ... 458

CID 0851 FMI 04 Pressure Sensor (Pump Drive) Voltage Below Normal - Test ... 460

CID 0851 FMI 06 Pressure Sensor (Pump Drive) Current Above Normal - Test ... 462

CID 0852 FMI 03 Temperature Sensor (Right Front Brake Oil) Voltage Above Normal - Test ... 463

CID 0852 FMI 04 Temperature Sensor (Right Front Brake Oil) Voltage Below Normal - Test ... 465

CID 0852 FMI 06 Temperature Sensor (Right Front Brake Oil) Current Above Normal - Test ... 466

CID 0853 FMI 03 Temperature Sensor (Left Front Brake Oil) Voltage Above Normal - Test ... 467

CID 0853 FMI 04 Temperature Sensor (Left Front Brake Oil) Voltage Below Normal - Test ... 469

CID 0853 FMI 06 Temperature Sensor (Left Front Brake Oil) Current Above Normal - Test ... 470

CID 0854 FMI 03 Temperature Sensor (Right Rear Brake Oil) Voltage Above Normal - Test ... 472

CID 0854 FMI 04 Temperature Sensor (Right Rear Brake Oil) Voltage Below Normal - Test ... 473

CID 0854 FMI 06 Temperature Sensor (Right Rear Brake Oil) Current Above Normal - Test ... 474

CID 0855 FMI 03 Temperature Sensor (Left Rear Brake Oil) Voltage Above Normal - Test ... 476

CID 0855 FMI 04 Temperature Sensor (Left Rear Brake Oil) Voltage Below Normal - Test ... 477

CID 0855 FMI 06 Temperature Sensor (Left Rear Brake Oil) Current Above Normal - Test ... 478

CID 0890 FMI 09 Telemetry Data Link Abnormal Update - Test ... 480

CID 1089 FMI 02 Analysis Control Module Incorrect Signal - Test ... 481

CID 1089 FMI 09 Analysis Control Module Abnormal Update - Test ... 483

CID 1089 FMI 12 Analysis Control Module Failed -Test ... 484

Alert Indicator - Troubleshoot ... 487

Chip Detector - Test ... 490

Lift or Tilt Cylinder Sensor - Troubleshoot ... 491

Suspension Cylinder Sensor - Troubleshoot ... 495

Troubleshooting Electrical System Using Abbreviated Procedures ... 502

Charging System - Test ... 503

Pulse Width Modulated (PWM) Sensor - Test .... 512

Sensor Signal Voltage - Test ... 513

Sensor Dynamic Test ... 516

Diode Assembly - Test ... 519

Position Sensor (Lift Arm) - Adjust ... 520

Speed Sensor (Engine) - Adjust ... 520

Module - Replace ... 521

Battery - Replace ... 521

Cable Connections ... 522

Off-Board Service Tool ... 524

Glossary of Terms ... 535

System Schematic ... 546

Index Section

Index ... 573

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Systems Operation Section

i01306165

General Information

SMCS Code:7601 g00480385 Illustration 1

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g00511864

Illustration 2

VIMS display components. (1) Gauge cluster module

(2) Speedometer/tachometer module (3) Message center module (4) Alert indicator

(5) Data logging indicator (6) Gauges

(7) Tachometer

(8) Ground speed readout (9) Actual gear indicator (10) Message area (11) Universal gauge (12) Gauge warning area

g00511863

Illustration 3

The VIMS keypad module that is used on the Off-Highway Trucks and the Large Hydraulic Excavators

(13) “Gauge” Key (14) Key pressed indicator (15) Backward arrow key (16) Forward arrow key

g00480392

Illustration 4

The VIMS keypad module that is used on the Large Wheel Loaders (13) “Gauge” Key

(14) Key pressed indicator (15) Backward arrow key (16) Forward arrow Key

The Vital Information Management System (VIMS) is a state-of-the-art onboard system with the following features:

•

Machine systems are monitored for the operator.

•

Payload productivity information is measured by the system and stored in onboard memory. This information can be downloaded later for analysis.

•

Abnormal machine conditions and/or incorrect

operation of the machine are identified. The diagnosis of these abnormal conditions will allow the operator to modify the operation of the machine in order to correct the problem. The service technician is able to schedule maintenance for the machine if the condition is not related to the operation of the machine.

•

Prognostic information that can help predict

potential problems before failures can occur. This allows the maintenance of the machine to be scheduled during the preventive maintenance servicing interval.

The components of the typical VIMS are listed here:

•

Up to eight interface modules

•

The main module

•

VIMS keypad

•

Display components

•

Switches

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•

Solenoids

•

Warning lamps

•

Warning alarms

Data Links

All VIMS modules communicate with each other, with other electronic controls on the machine and with systems off the machine through data links. The five VIMS data links are listed here:

CAT Data Link –This two wire serial data link allows communication between the VIMS modules and other machine control systems.

Display Data Link –This four wire data link allows communication between the VIMS main module and all display components except the keypad.

Keypad Data Link –This two wire data link allows communication between the VIMS main module and the keypad.

RS-232 Data Link (Service Tool) –This three wire serial data link allows communication between the VIMS main module and the service tool (laptop computer).

RS-232 Data Link (Broadcast) –This three-wire serial data link allows communication between the VIMS main module and other off-board systems (non service tool). Onboard data can be passed from the machine hands free if a user supplied system such as radio telemetry is connected to this port. This port can be configured by the configuration software on the large wheel loaders as a payload printer port instead.

Data

The Vital Information Management System uses four types of data. The four types of data are listed here:

Sensed –Data is read from the sensors and the switches. The sensors and the switches communicate with the interface modules.

Internal –The data is generated within the VIMS main module. The date and time are examples of internal data.

Communicated –The data is received through the CAT data link from other machine systems. For example, the engine speed is received through the CAT data link from the electronic engine control.

Calculated –Data mathematically determined by the VIMS main module. For example, the event duration is calculated and stored in the event list.

Events

Table 1

VIMS EVENTS

Data Event(1) _{Maintenance Event}(2) Filters Open Sensor Circuits, etc. Temperature Calibration

Possible Machine Damage Performance (Payload) Location (GPS)

(1) _{This term was formerly referred to as a machine event.} (2) _{This term was formerly referred to as a system event.}

The operator is alerted to the existence of all abnormal machine conditions by VIMS. All abnormal machine conditions are called data (machine)

events. A high engine coolant temperature is an example of a data event. The operator is alerted to problems in the VIMS modules and other electronic modules on the machine. The electronic system failures are called a diagnostic type ofmaintenance (system) events. The signal voltage of the coolant temperature sensor that is above normal is an example of a maintenance event. Stored VIMS event (data and maintenance) information is used to assist service personnel with machine maintenance and troubleshooting.

DATA (MACHINE) events are related to a machine system. The operator needs to RESPOND to this event in most cases. For example, the operator needs to modify operation in order to cool the converter oil temperature when the temperature is too high. When such an event is present, pressing the “F1” key will show more information. The operator is shown additional information on the second line of the message center. During temperature warnings, the “F1” key will cause the display to show the actual temperature of the machine system.

MAINTENANCE (SYSTEM) events are related to an electrical system problem that requires a service technician to PERFORM SERVICE or MAKE A REPAIR. When a diagnostic code is present , pressing the “F1” key will display the diagnostic codes for the MID, the CID and the FMI. When a MID for a different system is displayed in place of a MID for VIMS, refer to the applicable Service Manual for that electronic control.

Note:Multiple events (data and maintenance) for a single machine condition may occur. The Vital Information Management System can determine if the actual cause of a stored event is due to a faulty component or a true abnormal condition.

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The same VIMS operates on a variety of different machines. All the possible VIMS functions are not performed on every machine. Configuration software is used in order to identify the type of VIMS machine. The configuration software also identifies the available VIMS functions. The number of VIMS modules and the type of VIMS modules may vary in different applications.

The quantity of VIMS display components and the type of available indications are listed here:

•

Quad gauge modules (1) are used in order

to show changing machine conditions.

Speedometer/tachometer modules (2) are used to show changing machine conditions. Tachometer gauge (7) shows engine speed (RPM) information. Gauges (6) are used to display information such as temperature, pressure, and level.

•

One two-digit gear readout (9) per speedometer/tachometer module shows the actual transmission gear and the direction information.

•

One three-digit speed readout (8) per speedometer/tachometer module shows the ground speed information (“[MPH (km/h)]”).

•

One alert indicator (4) per message center

module shows that an event has been detected and the event is present.

•

One data logging indicator (5) per message center module shows that the data logging function is active. The data logging indicator indicates that the data logger was activated via the keypad.

•

One universal gauge (11) per message center module (3). The value of the parameter that is displayed on message area (10) will be indicated by the universal gauge.

•

One message area (10) per message center module. The parameter name, status and operator instructions are information that is displayed on the message area.

The type of indications and the quantity of indications that are used in the VIMS display area will vary according to the application. All the indications that are used in the VIMS display area may not be used on every machine. A machine may use one or two of the message center modules. In addition to the above indications, the action lamp and the action alarm indicate the severity (warning category) of a problem. The service indicator lamp alerts the service technician of an event that has occurred. The service indicator lamp indicates that the event is present.

Diagnostic information is stored for all maintenance (system) events even if the event is not present at the time of troubleshooting. A lap top personal computer (PC) is used as the VIMS service tool. Refer to the Testing and Adjusting, “Off-Board Service Tool” section for more information.

Stored Data

The occurrence of certain VIMS events and real time machine conditions are recorded in on board VIMS memory. The information is organized into seven categories. This information is used to analyze machine problems and forecast machine problems. The information is typically used at a later date by service technicians or management. The seven categories of information are listed here:

Event List/Summary List –The event list is a record of stored events (what happened and when) that have occurred on the machine. Not all events are stored. The record contains the last 500 events (data or maintenance) that are listed in chronological order. This means that the events are listed in the order of occurrence. The newest events appear at the top of the list. The event list transfers the oldest data into the event summary list when the event list exceeds 500 records. The event summary list is composed of the first five occurrences, the last five occurrences and the worst five occurrences that are recorded for any of the data events. The event summary list is limited to storing only 500 records. Maintenance events can be identified by the diagnostic codes (MID, CID and FMI).

All other events are data events. The event list is accessible from the message center or with the service tool.

Note:All events that contain the MID, the CID and the FMI information are the diagnostic type of maintenance event. Not all events without the MID, the CID and the FMI information are data events. An example of a maintenance event without diagnostic codes is an open wire in the “hydraulic oil level circuit”. Remember that a “2-wire” switch circuit (open switch) can report a true condition that relates to a parameter. This same “2-wire” switch circuit can indicate a system failure (open wire) but the failure is reported as low hydraulic oil level.

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Snapshot (Event Recorder) –The Snapshot (event recorder) stores a segment of history in real time for all parameters (channels) at a one second interval. The snapshot relates to a set of “predefined events”. A snapshot is triggered automatically for a severe event. The snapshot is then stored in memory. The configuration software designates the events that are considered to be severe events. The keypad can be used to initiate a snapshot manually. A snapshot consists of a “flight recording” of all parameters that describe system conditions that happened from five minutes before the event to one minute after the event. This strategy is applied to snapshots that are triggered immediately after key ON. However, a portion of the five minutes of data that occurred prior to the event that triggered this snapshot was actually captured prior to turning the key start switch OFF. This data may have been stored hours or days before the event that triggered the snapshot.

The VIMS has the capability of storing two sets of snapshot information. If a snapshot is in the process of being recorded and a second snapshot is triggered the second snapshot is ignored. The snapshot is accessible only with the service tool.

Data Logger –The data logger captures all the machine parameters (channels) that are monitored by “VIMS”. The data logger is recorded in real time at “one second intervals”. The operation of the data logger is similar to the snapshot (event recorder). However, the data logger can not be triggered automatically. The manual triggering of the data logger can only be done by the service tool or the keypad. The logger can be started and stopped with a total recording time of 30 minutes.

The data logger is accessible only with the service tool. The data logger can be reset by the service tool or the keypad.

Note:Truck payload cycle data (time and date) can be used as data logger basic information in place of this data logger.

Trends –Trend information consists of the minimums, maximums and averages of parameter data over time. Trend information is viewed with VIMS-PC software. The trend information is displayed as a graph or the trend information is tabulated as columns of data. An example of trend information is the average brake temperature per hour. Trend information is recorded for predefined parameters for each machine. Trend information is recorded under the specified guidelines that are listed here:

•

All one hour continuous trends begin when the key start switch is turned to the ON position.

•

Trend data that is collected during a period less than one hour when the key start switch is turned to the OFF position is discarded.

•

Trend points are the average of each trend that was captured during the past hour. Each trend must meet the conditions that are set for that trend. For example, a boost trend is captured each time that the coolant temperature and the engine load have exceeded the “trap ”conditions. A single trend point for the designated hour is calculated and stored when the measured trends are averaged over one hour.

The trend data point or the responsible failure mode identifier are stored according to the guidelines that are listed below:

1. At least one Trend condition was met during at least one continuous hour.

2. FMI 19 conditions not met is stored or the actual FMI that was responsible for the conditions that were not met for the entire store.

Trends are accessible only with the service tool.

Note:Refer to table 2 for the recommended download information for trends and the recommended reset information for trends. This should help prevent the loss of data or the corruption of data. Machines that were built after June 1996 use the 9.X class of onboard configurations. The 9.X class of onboard configurations will not damage the data. The configuration simply drops off oldest data.

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Table 2

Recommended Service Meter Hour Download and Reset Times for Trends

On Board Software “OHT” “LWL” “LHEX”

6.8X Reset before 500 hours(1) _N/A _{Reset before 500 hours}(1)

7.0X Reset before 500 hours(1) _N/A _N/A

9.0X Reset before 1000 hours(2) _{Reset before 500 hours}(2) _N/A

9.3X Reset before 1000 hours(2) _{Reset before 500 hours}(2) _{Reset before 3500 hours}(2) 9.4X Reset before 1000 hours(2) _{Reset before 500 hours}(2) _N/A

(1) _{The Trends are not correctly time stamped. The “Trend data” will be incorrect if the data is not downloaded and then reset in less than 500}

hours. The roll over point is determined by the configuration software.

(2) _{The trends are time stamped while being collected onboard. This ensures that the trend is correct any time that the trends are downloaded.}

Roll over is determined by the configuration software. At roll over, the oldest Trends are covered up with new trend data.

Cumulative –Cumulative information is the number of occurrences (counts) of specific events. An example of cumulative information is total engine revolutions or total fuel consumption over the life of the machine or component. Cumulative information is recorded for a standard set of parameters. The parameters are defined in the configuration software for each machine. The “9.5X” class of source software uses the “configuration type” in order to determine that a new machine’s software has been flashed into memory. Stored cumulative information is retained during flashing of 9.5X or later classes of source and configuration software. The on board system collects life-time cumulatives with no need to reset. The situations that will cause an automatic resetting of the cumulatives are listed here:

•

A new “configuration type” is flashed into the onboard memory. A VIDS 992G configuration that is replaced by a VIMS 992G configuration is a typical example of changing the configuration type.

Note:The term configuration type describes the system (VIMS or VIDS) and the model of the machine.

•

A configuration is loaded with any changes to the methods of calculating and storing cumulative data. The change indicates that a correction has actually been made to the configuration or the VIMS main module has just been installed from a different VIMS application. The new VIMS main module may not recognize the methods of calculating and storing cumulative data that is used by the configuration.

•

The VIMS internal backup battery is removed while the disconnect switch is in the OPEN position.

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

Cumulatives are accessible only with the service tool.

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Table 3

Recommended Service Meter Hour Download and Reset Times for Cumulatives

On board Software “OHT” “LWL” “LHEX”

6.8X Reset before 750 hours(1) _N/A _{Reset before 750 hours.}(1)

7.0X Reset before 750 hours.(1) _N/A _N/A

9.0X Reset before 750 hours.(1) _{Reset before 750 hours.}(1) _N/A

9.3X Reset before 750 hours.(1) _{Reset before 750 hours.}(1) _{Reset before 750 hours.}(1) 9.4X Reset before 750 hours.(1) _{Reset before 750 hours.}(1) _N/A

9.5X No reset is necessary.(2) _{No reset is necessary.}(2) _{No reset is necessary.}(2) 9.6X No reset is necessary.(2) _{No reset is necessary.}(2) _N/A

(1) _{Cumulative data will begin to saturate at approximately 1000 hours. This means that a maximum number will be reached and then}

increase no further.

(2) _{The 9.5X or later on board software allows for the collection of lifetime cumulative records.}

Histograms - Histogram information records the history of a parameter since last reset. For example, a histogram of the engine speed would indicate the percentage of time that the engine operated within a defined speed limit (example 0-699, 700-1299, 1300-1699, 1700-2199, 2200-up) and the time interval (example 25 to 475 SMH or 1 January 1996 to 2 February 1996) of the data gathered. Histograms can be used to evaluate the range of operation for a parameter.

Histograms are accessible only with the service tool.

Table 4

Recommended Service Meter Hour Download and Reset Times for Histograms

On Board Software “OHT” “LWL” “HEX”

6.8X DO NOT RESET.(1) _N/A _{DO NOT RESET}(1)_.

7.0X Reset before 750 hours(2) _N/A _N/A

9.0X Reset before 750 hours(2) _{Reset before 750 hours}(2) _N/A

(1) _{Never Reset, the data will be permanently corrupted.}

(2) _{Saturation could occur, meaning a maximum number will be reached and increase no further, between 1000 and 2000 hours for some}

parameters.

Payload- Payload information is recorded for the off-highway trucks and large wheel loaders, as required.

Total payload data is accessible only with the service tool. Basic data is available through the message center by accessing resettable cumulatives.

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i01306231

VIMS History

SMCS Code:7601

Hardware

This manual describes the V2.0 and V3.0 versions of VIMS hardware. The original V2.0 VIMS hardware (main and interface modules) went into production in the third quarter of 1994. In the third quarter of 1996, V3.0 hardware began production. The interface modules have the same physical appearance. Part numbers are the only way to tell the difference. V2.0 main modules have the backup battery holder for stored data on the side of the module. In order to access the battery, a black “knob” needs to be unscrewed. V3.0 main modules have an “egg shaped” cover on the top of the module. In order to gain access to the battery, two screws must be removed. The battery is flat with four pin type contacts on the bottom. An L-shaped tool is required to pry the battery out.

VIMS onboard features are based on the hardware and the source software. This chart lists the combinations of the production hardware and the software classes.

Table 5

VIMS Hardwareand Software Class History Software Class Model Usage Hardware

Version 6.X LHEX/OHT 2.0 7.X OHT 2.0 8.X(1) _LWL _3.0 9.X LHEX/LWL 3.0 9.3X LHEX/LWL/OHT 3.0 9.4X LWL 3.0 9.5X OHT/LHEX/LWL 3.0 9.6X LWL/OHT 3.0 9.62X LWL/OHT 3.0

(1) _{8.X was used in a limited field test.}

Table 6

VIMS Hardware Part Numbers

Version Main Interface Battery

2.0 3E-3666 115-0648 118-9636 124-6134 3E-3667 118-9634 123-8164 9X-5402 3.0 130-5131 165-8682 138-1756 144-7172 101-1785

All modules are backward compatible. However, the modules are not usually forward compatible. Refer to the product support group of the business unit for more information. However, 9.X software must be used with V3.0 modules to gain full benefits and features. As an example, a V3.0 main module can be used on a machine that was built with the V2.0 module. This combination of hardware will work. However, not all of the features that are available with the V3.0 hardware will not work.

Software

The VIMS main module is a dedicated computer. The computer is dedicated to the task that is described in this manual. The main module must be loaded with two basic sets of software:

•

An operating system (similar to MS-DOS on a PC).

•

An application program (similar to a word

processing program on a PC)

The operating system software that is required by the main module is called source or source software. This software file may be identified on a PC with the file extension of “src”. Features are determined by the on board class. The version of source software is considered to be generic because the same version of source software will eventually be used for most applications of VIMS. The application program is called a configuration. Configuration software provides the main module with the specific parameters that are used by the machine. Some examples of the information that is provided in the configuration software are listed here: the engine speed which is considered as an overspeed, the system voltage that is considered too low, and the basic guidelines for operator warnings.

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VIMS on board features are based upon hardware and source software. A complete history of the VIMS source software classes (“change levels”) that have been used are listed in Table 7. The 9.X class of software is the focus of this document. The 9.X class of software is also called later software (9.3X, 9.4X, ect.). The source software that was used prior to the 9.X class of source software is called earlier. THE CONFIGURATION SOFTWARE IS DESIGNED TO BE USED WITH A PARTICULAR PART NUMBER OF THE SOURCE SOFTWARE (CLASS) AND THE CONFIGURATION MUST BE USED WITH ONLY THAT PART NUMBER.

VIMS Hardware, Software, and Service Tool History

Total VIMS features are based upon onboard hardware, onboard software and the VIMS-PC software in the service tool. Table 7 lists the serviceable combinations of the hardware and software. Table 7 VIMS Source Software Class Approx. Production Software Pt. No.

Model Usage Hardware Version VIMS-PC Version ISB Version 6.X 7/93 9/94 122-4810 LHEX OHT 2.0/3.0 1.2/2.0/2.1/2.2/2.3/2.4 1.0/1.1 7.X 11/95 130-1345 OHT 2.0/3.0 1.2/2.0/2.1/2.2/2.3/2.4 1.0/1.1 8.X(1) _6/95 132-1968 _LWL _3.0 _{2.0/2.1/2.2/2.3/2.4} _1.0/1.1 9.X 7/96 3/96 133-4304 LHEX LWL 2.0/3.0 2.0/2.1/2.2/2.3/2.4 1.0/1.1 9.3X 12/96 140-9474 LHEX OHT LWL 2.0/3.0 2.1/2.2/2.3/2.4 1.0/1.1 9.4X 5/97 147-2046 LWL 2.0/3.0 2.3 or later 1.1 9.5X 3/98 151-1293 OHT LHEX LWL 2.0/3.0 2.3 or later 1.2 9.6X 3/99 157-2892 LWL OHT 2.0/3.0 VIMSpc99 N/A(4) 9.62X 12/00 199-6528 LWL OHT 2.0/3.0 VIMSpc99 (V2.0.3) N/A(4) (1) _{This version of software was used in limited field test only.}

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i01351829

Normal Operation

SMCS Code:7601

g00302063

Illustration 5

Gauge Cluster Module (1) Gauge warning area (2) Pictograph symbol g00485026 Illustration 6 Speedometer/Tachometer Module (3) Tachometer (4) Pictograph symbol (5) Ground speed readout

(6) Transmission actual gear readout

g00483761

Illustration 7

Message Center Module (9) Alert indicator (10) Data logging indicator (11) Message area (12) Universal gauge (13) Gauge warning area

During normal operation, the VIMS display components provide the operator and the service technician with the information that is listed here:

•

The display components indicate whether

the Vital Information Management System is operating properly. Whenever the key start switch is turned to the ON position, some of the VIMS outputs (gauges and message center module) briefly operate. This is a system self-test of the display components. See the Systems Operation, “System Self Test” topic for the complete test of the VIMS outputs.

•

The measured value of present system conditions are shown on the display components. The machine systems are continuously monitored. The normal range value of the gauges in the quad gauge module are shown in the central region.

•

The display components will indicate whether an

abnormal machine system condition (data event) exists. The machine systems are continuously monitored. When an abnormal condition (problem) exists, alert indicator (9) FLASHES. Message area (11) shows the system parameter with the abnormal condition and the value of the parameter. Universal gauge (12) also shows the relative value of the abnormal parameter. The service indicator lamp is turned ON and the event may be stored in the memory of the main module. A problem that is more severe requires the action lamp to FLASH and the action alarm is required to SOUND. See the Systems Operation, “Warning Operation” section.

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•

The display components will indicate when a VIMS failure (maintenance event) exists. Continuous checks are made for the existence of electrical failures in the VIMS modules and in the other electronic control modules (engine, transmission, etc) installed on the machine. When the Vital Information Management System detects a diagnostic type of maintenance event (system event), the service indicator lamp is activated. The event is shown on the message area. The event is also stored in the main module memory. See the Systems Operation, “Service Operations” section.

The Vital Information Management System enters the normal mode when the key start switch is turned to the ON position. This is the mode of “normal” operation. The system will enter the normal mode after the installation of valid source software and configuration software. Refer to the Systems Operation, “Main Module” section of this manual for additional information on the modes of operation.

i01382740

Service Operations

SMCS Code:7601

Numerous VIMS service operations can be initiated by the operator or a service technician. A unique service program code (SPC) is assigned to each of the service operations. The service program codes are entered through the VIMS keypad module. Entering the service program code starts the corresponding service operation. The service operations are listed in Table 8.

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Table 8

VIMS Service Operations

Service Operation Service Program Code Service Program Code No.

Attachment Code - Configure “ATTACH” 288224

Calibration Modes - Enter “SERV” 7378

Data Logger - Reset “DLRES” 35737

Data Logger - Start/Stop “DLOG” 3564

Display Backlighting - Set “BLT” 258

Display Contrast - Set “CON” 266

Display Language - Set “LA” 52

Display Units - Set UN 86

Event - Configure (9.6X or later) “ESET”(1) ₃₇₃₈

Events Acknowledged - Show “EACK” 3225

Event List - Show “ELIST” 35478

Event Recorder - Start “EREC” 3732

Events Statistics - Show “ESTAT” 37828

Lubrication Cycle Times - Set “LUBSET” 582738

Lubrication Manual - Start “LUBMAN” 582626

Machine Status - Show “MSTAT” 67828

Odometer - Set “ODO”(1) ₆₃₆

Resettable Totals - Reset (LHEX/OHT) “RESET” 73738

Resettable Totals - Show (LHEX/OHT) “TOT” 868

Service Lamp - Reset “SVCLIT” 782548

Service Lamp - Set (9.5X or later) “SVCSET”(1) ₇₈₂₇₃₈ Snapshot Trigger- Configure (9.5X or later) “ERSET”(1) ₃₇₇₃₈

System Self Test “TEST” 8378

Truck Payload - Calibrate “PAYCAL”(1) ₇₂₉₂₂₅

Truck Payload - Configure “PAYCONF”(1) _7292663

(1) _{The service tool is required to be connected and communicating with the machine before this SPC is active.}

Each service program code is a unique number of one to ten digits that abbreviates this operation. The service program codes have a letter equivalent that describes the service operation. This letter equivalent makes remembering the service program code for each operation easier. The English letter equivalent for each service program code is shown in parentheses. The same service program codes are used regardless of the onboard language.

After entering the service program code on the keypad, this request will begin after the “OK” key is pressed. This command must be activated within five seconds of entering the last SPC character. The maximum delay that is allowed between the entry of the SPC characters is five seconds.

i01351847

Attachment Code - Configure

SMCS Code:7601

The following information describes the service program code: 288224 (ATTACH)

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This service program allows the operator to configure the attachment code for large wheel loaders and the 5230 (S/N: 7LL99-Up) Large Hydraulic Excavators. The Attachment Code is the software version of the Harness Code. The harness code is a hard wired configuration of jumper wires that ground certain circuits in a harness code plug. The VIMS broadcasts the attachment code via the CAT data link to other electronic control modules on the machine that need this code.

Note:Applicable attachment codes are listed on the back of machine Electrical Schematic and in the Operations and Maintenance Manual.

After “ATTACH” is entered from the keypad, the operator presses the “OK” key. The message center will show:

g00485847

Illustration 8

The desired attachment code can then be entered from the keypad by entering the desired attachment code. Then press the “OK” key. If a valid attachment code has been entered, the message center will prompt the operator to re-enter the attachment code. The message center will show:

g00485848

Illustration 9

If the same code is entered again, this code will be accepted as the new attachment code. If the same code is not entered at the second prompt, the new attachment code will not be accepted. The old attachment code remains valid. A new attachment code will not be accepted, if an invalid code is entered at either prompt. The old attachment code remains valid. If the “OK” key was pressed at either prompt prior to entering a number, the old attachment code remains valid.

Note:The Machine Status (MSTAT) (67828) code can be used to view the present, active attachment code.

i00952599

Calibration Mode - Enter

SMCS Code:7601

The following information describes the service program code: 7378 (SERV)

The service program code (SERV) is used to enter the calibration modes and the calibration procedures. The Vital Information Management System’s configuration software defines the calibration modes and the calibration procedures. The arrow keys can be used to scroll through the various calibration modes. The message center will show:

g00485849

Illustration 10

Other calibration display messages are listed here:

•

LIFT ARM SNSR - CAL

•

IMPL RLF - VARIABLE PUMP

•

LINKAGE SENSORS - SET

•

TC PDL POS SENSORS - CAL

•

TC IMPLR SOL - CAL

•

TILT ARM SNSR - CAL

•

IMPL VALVE SOL - CAL

•

IMPL RLF - FIX PUMP

•

LEFT PEDAL - CAL

•

IC HOLD PRES - CAL

•

REDUCED RIMPULL - CAL

Note:If the “[OK]” key is pressed, the message stays on the display for 15 seconds. The message will stay even if the “[OK]” key is pressed again.

i00952586

Data Logger - Reset

SMCS Code:7601

The following information describes the service program code: 35737 (DLRES)

(22)

This service program code resets the available data logger storage time to 30 minutes. Use the keypad to enter the service code 35737 (DLRES) and press the “OK” key in order to reset the data logger. Resetting the data logger erases any presently stored information. The message area will show:

g00485813

Illustration 11

Note:The Data Logger is the only “downloadable on board file” that can be reset through the keypad (“VIMS-PC software is not needed”).

i00952585

Data Logger - Start/Stop

SMCS Code:7601

The following information describes the service program code: 3564 (DLOG)

This service program code starts or stops data logging (storage of data) until 30 minutes of information is stored. (If the data logger data is being downloaded from the machine, the data logger can not be started.) The data logger can be started and the data logger can stopped any number of times over any period of time (minutes, hours or days) until the “data logging” time totals 30 minutes and eight seconds. The dots of the data logger indicator are in the upper right hand corner of the universal gauge. The dots of the data logger indicator will stop scrolling when the data logger is no longer recording data. The dots of the data logger do not scroll when the service tool starts the data logger. The remaining storage time of the data logger is shown on the message area for five seconds after entering this SPC on the keypad. The format of the time is shown in “minutes:seconds”. An example is shown here:

g00529116

Illustration 12

The information that is shown in illustration 12 is displayed in the message area. The message area will display the remaining storage time prior to starting the data logger. When data logging is in operation a series of dots scroll in the upper right hand corner of the universal gauge.

Note:The dots in the upper right corner of the universal gauge scroll only if data logging is started from the keypad.

i00952589

Display Backlighting - Set

SMCS Code:7601

The following information describes the service program code: 258 (BLT)

This service program code allows the backlight intensity of the message area to be changed. After the service program code is entered, the actions that are listed here will occur in the following order:

•

The intensity will automatically decrease from the

original setting to 0%.

•

The setting will automatically jump from 0% to 100%. The intensity will then decrease to the original value.

•

Pressing the arrow keys will manually scroll through the intensity settings.

As the message area scrolls in intensity, the corresponding percentage of backlight intensity is displayed in the message area. The arrow keys are used in the scrolling procedure in order to select a new backlight intensity setting. Press the “OK” key in order to accept the new setting. Backlight Intensity adjustment requires the use of VIMS V3.0 hardware and 9.X class or later on board software.

g00485814

(23)

i00952590

Display Contrast - Set

SMCS Code:7601

The following information describes the Service Program Code: 266 (CON)

This service program code allows the contrast of the message center to be changed. After the service program code is entered, the actions that are listed here will occur in the following order:

•

The contrast will automatically decrease from the original setting to 0%.

•

The setting will automatically jump from 0% to 100%. The contrast will then decrease to the original value.

•

Pressing the arrow keys will manually scroll through the intensity settings.

As the message area scrolls in contrast, the corresponding percentage of contrast is displayed in the message area. The arrow keys are used in the scrolling procedure in order to select a new contrast setting. Press the“OK”key in order to accept the new selection.

Message center contrast adjustment requires the use of VIMS: V3.0 hardware, 9.X class or later on board software, and the133-1840 or later VIMS Message Center Module.

g00485815

Illustration 14

i00952588

Display Language - Set

SMCS Code:7601

The following information describes the service program code: 52 (LA)

This service program code toggles the information that is shown on the message area. The information is toggled between the two available languages. Information is shown in the selected language until the other language is selected. This setting may be performed when the key start switch is in the OFF position.

The primary language for a given VIMS configuration is the language that will be active after a new upload. English will always be one of the two available onboard languages.

i00952587

Display Units - Set

SMCS Code:7601

The following information describes the service program code: 86 (UN)

The service program code toggles the data that is shown on the display. The data is toggled between the “English” or “Metric” units of measurement. Data is shown in the selected unit until the other unit is selected. The new setting will remain until the setting is changed by repeating this procedure. The setting will not be changed when the key start switch is in the OFF position.

i01306332

Event - Configure

SMCS Code:7601

The following information describes the service program code: 3738 (“ESET”)

This service program code is available with the 9.6X class of source software or later.

The event - configure (ESET) command allows the service technician to modify a configuration with the Information System Builder software program in order to turn off the functions that are listed here:

•

Event Storage

•

Event Display

•

Service Lamp

•

Broadcast (Radio Telemetry System)

Note:The “Event - Configure” command is not available for all events. The parameter must be designated as user configured in the configuration software.

Security

1. The service program code only functions while the service tool (VIMS-PC) is connected.

2. After the service tool (VIMS-PC) is disconnected for 30 seconds, this service program code will no longer be active.

Systems Operation Testing and Adjusting