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Product: TRUCK
Model: 789C TRUCK 2BW
Configuration: 789C Off-Highway Truck 2BW00001-UP (MACHINE)
POWERED BY 3516 Engine

Special Instruction
Road Analysis Control (RAC) Installation on Large Off-Highway Trucks Equipped with
VIMS {7632}
Media Number -REHS0875-01 Publication Date -01/06/2005 Date Updated -15/06/2005

i02061880

Road Analysis Control (RAC) Installation on Large Off-


Highway Trucks Equipped with VIMS {7632}
SMCS - 7632-012

Off-Highway Truck:
793B (S/N: 1HL1-UP)
793C (S/N: 4AR1-UP)
Off-Highway Truck:
785B (S/N: 6HK1-UP)
785C (S/N: 1HW1-UP; APX1-UP; 5AZ1-UP)
789B (S/N: 7EK1-UP)
789C (S/N: 2BW1-UP)
793C (S/N: ATY1-UP; 4GZ1-UP)

Introduction
This procedure is for installing the Road Analysis Control (RAC) on Large Off-Highway Trucks.
The trucks must be equipped with VIMS 3.0 (S/N:1HL1-UP and ; S/N:4AR1-UP) or 4.0 version of
hardware. The trucks must use VIMS onboard software that is version 9.6X or a later version. Earlier
versions of VIMS hardware are not compatible.

Table 1

Required Publications
Special Instruction, SEHS9411, "Suspension Cylinder Servicing"
Systems Operation, RENR2636, "Road Analysis Control (RAC)"
Systems Operation, RENR2630, "Off-Highway Truck/Tractors Vital Information Management
System (VIMS)"
Service Manual, SENR6059, "Vital Information Management System (VIMS)"
Special Instruction, REHS2142, "Installation Instructions to Retrofit VIMS Hardware Version
2.0/3.0 to VIMS Hardware Version 4.0"

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Service Magazine, SEPD0757 1 November, "An Updated Replacement Cab Is Available for
Certain Off-Highway Trucks"
Service Magazine, SEPD0699 8 September, "New VIMS 10.4 Class of Onboard Software"

Table 2

Tools Needed
Part
Description Quantity
Number
1U-8071 9/16 inch Wrench 1
6V-0006 Electrical Connector Pliers 2
Service Tool (laptop computer) (1) 1
127-9797 Download Cable (VIMS ) 1
1U-7563 4 mm Hex Wrench 1
(1) The VIMSpc and the Electronic Technician software are required for the service tool.

Procedure to Install RAC on Machines That Have Been


Retrofitted to 4.0 ABL
Note: S/N:6HK1-UP, ; S/N:1HW1-UP, ; S/N:7EK1-UP, ; S/N:2BW1-302, and ; S/N:5AZ1-263
must retrofit to VIMS 4.0 in order to have the RAC feature.

Note: If the cab has been replaced with an ABL retrofitted cab or the machine has been retrofitted
from 68K VIMS to ABL, refer to 239-4254 Electronic Control and Mounting Gp (Illustration 1).

Procedure and Parts List

Table 3

239-4254 Electronic Control and Mounting Gp for Installing RAC into Trucks that Have
Been Upgraded to VIMS 4.0 Hardware
Part Number Part Name Quantity
133-3489 Plate Assembly 1
143-0008 Spacer 2
145-0487 Spacer 4
192-7413 Harness Assembly 1
101-9759 Spacer 2
4D-7794 Clip 1

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6V-8801 Nut (3/8-16) 2


7K-1181 Strap 2
8L-5449 Spacer 2
8M-2772 Clip 1
8T-4896 Washer - Hard 4
8T-9655 Mount 8
9N-0869 Washer - Hard 9
9X-6000 Bolt (M8x1.25) 2
9X-6628 Bolt (M8x1.25) 2
231-1365 Service Group Electronic Control Module 1

1. Recharge all four of the suspension cylinders per Special Instruction, SEHS9411. This ensures
the mechanical condition of all cylinders.

2. Ensure that the suspension cylinder pressure sensors are operating in accordance with the
Service Manual, SENR6059, "Vital Information Management System (VIMS)", "Suspension
Cylinder Pressure Sensors Troubleshoot" procedure.

3. Verify that the switch (body position) is adjusted properly and that the switch (body position)
is working correctly. The switch (body position) determines when the Road Analysis Control
Module starts and stops taking data.

4. Check the body of the truck in order to ensure that the body does not contain a significant
amount of carryback.

5. Calibrate the Truck Payload System. Use the PAYCAL command on the keypad to calibrate
the payload system. Successful calibration ensures that the Truck Payload System is working
correctly.

Note: The 9.5X version of VIMS and later versions of onboard software requires the Service
Tool to be connected. The Service Tool must also be communicating with the main module of
the VIMS. The VIMS service port must be used in order to perform the payload calibration
with the PAYCAL command.

6. Put the truck back into production for a minimum of eight hours.

7. After the eight hour shift, stop the truck and then connect VIMSpc (service tool) via the VIMS
service port.

8. Establish communications with the VIMS.

9. Use the "Tab" key to access the "VIMS Status" screen. Observe the amount of onboard
memory that is available for the "Event List". Approximately 95 percent of the onboard
memory must be available. The "Event List" has the capacity to store up to 500 Data events
and Maintenance events. With less than 95 percent of onboard memory for the "Event List"
remaining, the limit of the memory may be exhausted before the next download. If there is less

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than 95 percent of the available memory remaining for the "Event List", raise the RAC Event
Category from Group One to Group Two or even Group Three. Refer to Systems Operation,
RENR2636, "Events" for additional information. Fewer events will occur if the previous
procedure is used. Therefore, less onboard memory will be required.

10. Perform a complete download of onboard data from the VIMS main module.

Note: The RAC ECM is to be mounted on top of the existing ABL (VIMS 4.0) ECM.

11. Remove the four 5M-3062 Bolts and four 8T-4896 Hard Washers that secure the VIMS ECM
in place.

12. Install the RAC components on top of the VIMS ECM as shown in the 239-4254 Electronic
Control and Mounting Gp (Illustration 1).

13. Connect the two connectors from the 192-7413 Control Harness As to the RAC ECM and
install the 12-pin DT plug into the 12-pin receptacle of the standard cab harness.

14. Secure the 192-7413 Control Harness As to the VIMS breakout of the main harness using two
7K-1181 Cable Straps .

15. Flash the new VIMS software (available on CATMINER.cat.com).

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Illustration 1 g

239-4254 Control Group

(1) 133-3489 Plate As

(2) 143-0008 Spacer

(3) 145-0487 Spacer

(4) 160-4891 Electronic Control Module

(5) 192-7413 Control Harness As

(6) 101-9759 Spacer

(7) 4D-7794 Clip

(8) 6V-8801 Nut

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(9) 7K-1181 Cable Strap

(10) 8L-5449 Spacer

(11) 8M-2772 Clip

(12) 8T-4896 Hard Washer

(13) 8T-9655 Isolation Mount

(14) 9N-0869 Hard Washer

(15) 9X-6000 Bolt M8X1.25

(16) 9X-6628 Bolt M8X1.25

Illustration 2 g
Completed RAC installation

Procedure and Parts List for (S/N: 1HL1-UP)


Note: The machine must be equipped with VIMS hardware version 3.0. If the machine is not

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equipped with VIMS hardware version 3.0, update the hardware before proceeding.

Note: For information on how to install RAC, refer to the "Procedure to Install RAC" section that
appears earlier in this Special Instruction.

Table 4

196-1875 Control Mounting Group used for Off-Highway Trucks with VIMS 3.0 hardware
(S/N:1HL1-UP)
Part Part
Quantity
Number Name
1 4D-7794 Clip
8 5M-3062 Bolt
2 6V-8801 Nut
15 7K-1181 Cable Strap
2 8L-5449 Spacer
1 8M-2770 Clip
2 8T-4177 Bolt
2 8T-4224 Washer
10 8T-4896 Washer
2 8T-6869 Bolt
8 8T-9655 Mount
4 8X-4549 Boss
4 9N-0869 Washer
1 133-3489 Plate Assembly
4 145-0487 Spacer
1 194-7583 Plate Assembly
1 196-1878 Harness Assembly
1 231-1365 Monitor Electronic Control Module

1. Recharge all four of the suspension cylinders per Special Instruction, SEHS9411. This ensures
the mechanical condition of all cylinders.

2. Ensure that the suspension cylinder pressure sensors are operating in accordance with the
Service Manual, SENR6059, "Vital Information Management System (VIMS)", "Suspension
Cylinder Pressure Sensors Troubleshoot" procedure.

3. Verify that the switch (body position) is adjusted properly and that the switch (body position)

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is working correctly. The switch (body position) determines when the Road Analysis Control
Module starts and stops taking data.

4. Check the body of the truck in order to ensure that the body does not contain a significant
amount of carryback.

5. Calibrate the Truck Payload System. Use the PAYCAL command on the keypad to calibrate
the payload system. Successful calibration ensures that the Truck Payload System is working
correctly.

Note: The 9.5X version of VIMS and later versions of onboard software requires the Service
Tool to be connected. The Service Tool must also be communicating with the main module of
the VIMS. The VIMS service port must be used in order to perform the payload calibration
with the PAYCAL command.

6. Put the truck back into production for a minimum of eight hours.

7. After the eight hour shift, stop the truck and then connect VIMSpc (service tool) via the VIMS
service port.

8. Establish communications with the VIMS.

9. Use the "Tab" key to access the "VIMS Status" screen. Observe the amount of onboard
memory that is available for the "Event List". Approximately 95 percent of the onboard
memory must be available. The "Event List" has the capacity to store up to 500 Data events
and Maintenance events. With less than 95 percent of onboard memory for the "Event List"
remaining, the limit of the memory may be exhausted before the next download. If there is less
than 95 percent of the available memory remaining for the "Event List", raise the RAC Event
Category from Group One to Group Two or even Group Three. Refer to Systems Operation,
RENR2636, "Events" for additional information. Fewer events will occur if the previous
procedure is used. Therefore, less onboard memory will be required.

10. Perform a complete download of onboard data from the VIMS main module.

11. Install the Truck Body Retaining Cable (1) in accordance with the Disassembly and Assembly,
SENR1463, "Truck Body Retaining Cable - Remove and Install" procedure.

Illustration 3 g00734886

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(1) Truck Body Retaining Cable

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.

12. Remove the rear access panel that is located behind the CAB in order to gain access to the
VIMS main module.

Illustration 4 g00734894
(2) Bolts

(3) Cover Assembly

a. Remove six bolts (2) and the six washers.

b. Remove cover assembly (3). The cover assembly weighs approximately 35 kg (77 lb).

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Illustration 5 g00734898
(4) Harness connector (37 pin)

(5) VIMS main module

(6) Bolt (Mounting)

(7) 8X-3706 Plate

13. Disconnect harness connector (4) from VIMS main module (5) .

14. Remove the four bolts (6) and washers that secure the mounting plate (7) to the cab.

15. Remove the VIMS main module (5) and the mounting plate (7) from the cab.

Illustration 6 g00734720
(8) 8X-4549 Boss

16. Install the four 8X-4549 Bosses (8). Use four 5M-3062 Bolts (14) and four 8T-4896 Washers

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to secure the four 8X-4549 Bosses to the 8X-3706 Plate (7) .

Illustration 7 g00734755
196-1878 Tee Harness Assembly

17. Connect the 196-1878 Tee Harness Assembly to the VIMS Main Module Connector
(disconnected in Step 13). Refer to Illustration 8.

Illustration 8 g00734772
The 196-1878 Tee Harness Assembly connected to the VIMS main module

18. Position the VIMS main module back into the rear cab.

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Illustration 9 g00734779
(9) Bolts

(10) Mounting Plate

(11) Machine Harness Connector

(12) Harness Connector for 196-1878 Harness

19. Reinstall four bolts (9) and the washers that secure the mounting plate of the VIMS main
module to the cab.

20. Connect machine harness connector (11) for the VIMS main module to harness connector (12)
of the 196-1878 Tee Harness Assembly .

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Illustration 10 g00734798
(13) 194-7583 Plate assembly

(14) 5M-3062 Bolt

(15) VIMS main module

21. Install the 194-7583 Plate (13). Use four 5M-3062 Bolts (14) and the 8T-4896 Hard Washers
to secure the plate to the four 8X-4549 Bosses (8) .

Illustration 11

(16) 231-1365 Monitor Service Electronic Control Module (RAC)

(17) 9N-0869 Washer

(18) 8T-6869 Bolt

(19) 8T-4177 Bolt

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(20) 8T-9655 Mount

(21) 8L-5449 Spacer

(22) J1 Connector

(23) J2 Connector

(24) 4D-7794 Clip

(25) 6V-8801 Nut

(26) 133-3489 Plate Assembly

(27) 8M-2770 Clip

(28) 8T-4224 Washer

22. Install eight 8T-9655 Mounts (20, F) and four 145-0487 Spacers (H) in the four mounting
holes of the module for the Road Analysis Control. Refer to Illustration 12.

Illustration 12 g01084912

Shock Mount Assemblies

(A) 8T-4177 Bolt

(B) 8T-4224 Washer

(C) 133-3489 Plate Assembly

(D) 8L-5449 Spacer

(E) 9N-0869 Washer

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(F) 8T-9655 Mounts

(G) Mounting holes of the Road Analysis Control Module

(H) 145-0487 Spacer

(J) 9S-8413 Washer

23. Mount the 231-1365 Monitor Service Electronic Control Module (RAC) (16) on the 194-7583
Plate Assembly (13). Use two 8T-6869 Bolts (18) and the 9N-0869 Washers (17) to attach the
rear end of the RAC module to the plate. Use two 8T-4177 Bolts (19, A) and the 8T-4224
Washers (28, B) to attach the front end of the RAC module, the 133-3489 Plate Assembly (26,
C), two 8L-5449 Spacers (21, D) and two 9N-0869 Washers (17, E) to the plate.

24. Connect the two 70-contact connectors (of the tee harness) to the connectors J1 (22) and J2
(23) on the RAC module.

25. Install the 7K-1181 Cable Straps in order to secure the machine harness.

26. Upload the new VIMS software for source and configuration. Refer to the Service Magazine
announcement for information regarding the 9.62X version of VIMS onboard software for the
part numbers of the software.

Note: Use VIMSpc to upload version 3.0 of the VIMS software.

27. Enter the Attachment Code for the RAC.

a. With the message center in the background mode, enter the service program code
"ATTACH" and then press the "OK" key. This will cause the following message to
display in the message area of the message center.

Table 5

ENTER ATTACH CODE


_

b. Enter the attachment code of "4" and then press the "OK" key. The VIMS will then
prompt you to validate the previous entry.

Table 6

ENTER CODE AGAIN


_

c. Enter the attachment code of "4" again and press the "OK" key. The attachment code is
now set.

Note: Use the Machine Status ("MSTAT") command in order to view the active
attachment code.

28. Replace the rear access panel that is located behind the CAB.

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a. Replace the cover assembly (3). The cover assembly weighs approximately 35 kg (77
lb).

b. Install six bolts (2) and the six washers.

29. Remove the truck body retaining cable in accordance with the Disassembly and Assembly,
SENR1463, "Truck Body Retaining Cable - Remove and Install" procedure.

Procedure and Parts List for (S/N: 4AR1-UP)


Note: For information on how to install RAC, refer to the "Procedure to Install RAC" section that
appears earlier in this Special Instruction.

Table 7

The 196-1874 Control Mounting Group used for Off-Highway Trucks with VIMS 3.0
hardware (S/N:4AR1-UP)
Part Part
Quantity
Number Name
1 4D-7794 Clip
8 5M-3062 Bolt
2 6V-8801 Nut
10 7K-1181 Cable Strap
2 8L-5449 Spacer
1 8M-2770 Clip
2 8T-4177 Bolt
2 8T-4224 Washer
10 8T-4896 Washer
2 8T-6869 Bolt
8 8T-9655 Mount
4 8X-4549 Boss
4 9N-0869 Washer
1 133-3489 Plate Assembly
4 145-0487 Spacer
1 194-7583 Plate Assembly
1 192-7413 Harness Assembly
1 231-1365 Monitor Electronic Control Module

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1. Recharge all four of the suspension cylinders in accordance with the Special Instruction,
SEHS9411. This ensures the mechanical condition of all cylinders.

2. Ensure that the suspension cylinder pressure sensors are operating in accordance with the
Service Manual, SENR6059, "Vital Information Management System (VIMS)", "Suspension
Cylinder Pressure Sensor Troubleshoot" procedure.

3. Verify that the switch (body position) is adjusted properly and that the switch (body position)
is working correctly. The switch (body position) determines when the Road Analysis Control
Module starts and stops taking data.

4. Check the body of the truck in order to ensure that the body does not contain a significant
amount of carryback.

5. Calibrate the Truck Payload System. Use the (PAYCAL) keypad command. Successful
calibration ensures that the Truck Payload System is working correctly.

Note: VIMS version 9.5X and later classes of onboard software requires the Service Tool to
be connected and communicating with the VIMS main module via the VIMS service port in
order to perform the payload calibration with the PAYCAL command.

6. Put the truck back into production for a minimum of eight hours.

7. After the eight hour shift, stop the truck and then connect VIMSpc (service tool) via the VIMS
service port.

8. Establish communications with the VIMS.

9. Use the "Tab" key to access the "VIMS Status" screen. Observe the amount of onboard
memory that is available for the "Event List". Approximately 95 percent of the onboard
memory must be available. The "Event List" is able to store in memory up to 500 Data events
and Maintenance events. With less than 95 percent of onboard memory for the "Event List"
remaining, the memory capacity may be exhausted before the next download. If there is less
than 95 percent of the memory capacity remaining for the "Event List", raise the RAC Event
Category from Group One to Group Two or even Group Three. (Refer to Systems Operation,
RENR2636, "Events" for additional information.) This action will cause fewer events to occur.
This will require less onboard memory.

10. Perform a complete download of onboard data from the VIMS main module.

11. Install the Truck Body Retaining Cable (1) in accordance with the Disassembly and Assembly,
SENR1463, "Truck Body Retaining Cable - Remove and Install" procedure.

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Illustration 13 g00734886
(1) Truck Body Retaining Cable

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.

12. Remove the rear access panel that is located behind the CAB in order to gain access to the
VIMS main module.

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Illustration 14 g00734894
(2) Bolts

(3) Cover

a. Remove six bolts (2) and the six washers.

b. Remove cover assembly (3). The cover assembly weighs approximately 35 kg (77 lb).

Illustration 15 g00734898
(4) Harness connector (37 pin)

(5) VIMS main module

(6) Bolt (Mounting)

(7) 8X-3706 Plate

13. Disconnect Harness Connector (4) from VIMS main module (5) .

14. Remove four bolts (6) and the washers that secure the mounting plate (7) to the cab.

15. Remove the VIMS main module and the mounting plate from the cab.

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Illustration 16 g00734720
(8) 8X-4549 Boss

16. Install the four 8X-4549 Bosses (8). Use four of the 5M-3062 Bolts and the 8T-4896 Washers
to secure the four 8X-4549 Bosses to the 8X-3706 Plate Assembly (7) .

17. Position the VIMS main module back into the rear cab.

Illustration 17 g00737606
(9) Bolt

(10) Mounting Plate

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18. Reinstall four bolts (9) and the washers that secure the mounting plate (10) of the VIMS main
module to the cab.

19. Reconnect the Harness Connector (4) that was disconnected in Step 13.

Illustration 18 g00737610
(11) 194-7583 Plate

(12) 5M-3062 Bolt

(13) VIMS main module

20. Install the 194-7583 Plate Assembly (11). Use four 5M-3062 Bolts (12) and the 8T-4896
Washers to secure the plate to the four 8X-4549 Bosses (8) .

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Illustration 19

(14) 231-1365 Monitor Service Electronic Control Module (RAC)

(15) 9N-0869 Washer

(16) 8T-6869 Bolt

(17) 8T-4177 Bolt

(18) 8T-9655 Mount

(19) 8L-5449 Spacer

(20) J1 Connector

(21) J2 Connector

(22) 4D-7794 Clip

(23) 6V-8801 Nut

(24) 133-3489 Plate Assembly

(25) 8M-2770 Clip

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(26) 8T-4224 Washer

21. Install eight 8T-9655 Mounts (18, F) and four 145-0487 Spacers (H) in the four mounting
holes of the RAC module. Refer to Illustration 23.

22. Mount the 231-1365 Monitor Service Electronic Control Module (RAC) (14) on the 194-7583
Plate Assembly (11). Use two 8T-6869 Bolts (16) and the 9N-0869 Washers (15) to attach the
front end of the RAC module to the plate. Use two 8T-4177 Bolts (17, A) and four 8T-4224
Washers (26, B) to attach the rear end of the RAC module, the 133-3489 Plate Assembly (24,
C), two 8L-5449 Spacers (19, D) and two 9N-0869 Washer (15, E) to the plate.

Illustration 20 g01087723
(27) 164-5393 Wire Assembly

Illustration 21 g01087724
(28) Main Harness connector

(29) Connector of the 192-7413 Harness Assembly

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Illustration 22 g01087725
(30) Harness connectors

(31) 192-7413 Harness Assembly

(32) Harness connector

Illustration 23 g01084912
Shock Mount Assemblies

(A) 8T-4177 Bolt

(B) 8T-4224 Washer

(C) 133-3489 Plate Assembly

(D) 8L-5449 Spacer

(E) 9N-0869 Washer

(F) 8T-9655 Mounts

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(G) Mounting holes of the Road Analysis Control Module

(H) 145-0487 Spacer

(J) 9S-8413 Washer

23. Remove the 164-5393 Wire assembly (27) from the main harness connector (28). Connect the
harness assembly connector (29) of the 192-7413 Harness Assembly (31) to the main harness
connector (28) .

24. Connect the two 70-contact connectors (30) of the tee harness to connectors J1 (20) and J2
(21) on the RAC Module.

25. Install the 7K-1181 Cable Straps to secure the machine harness.

26. Upload the new VIMS source and configuration software.

Note: Use VIMSpc to upload the VIMS version 3.0 software. Refer to the Service Magazine
announcement for the version 9.62X class of VIMS onboard software for the part numbers of
the software.

27. Enter the Attachment Code For RAC.

a. With the message center in the background mode, enter the service program code
"ATTACH" and then press the "OK" key. This will cause the following message to
display in the message area of the message center.

Table 8

ENTER ATTACH CODE


_

b. Enter the attachment code of "4" and then press the "OK" key. The VIMS will then
prompt you to validate the previous entry.

Table 9

ENTER CODE AGAIN


_

c. Enter the attachment code of "4" again and press the "OK" key. The attachment code is
now set.

Note: The Machine Status ("MSTAT") command can be used to view the active
attachment code.

28. Replace the rear access panel that is located in the CAB.

a. Replace the cover assembly (3). The cover assembly weighs approximately 35 kg (77

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lb).

b. Install six bolts (2) and the six washers.

29. Remove the truck body retaining cable. Refer to Disassembly and Assembly, SENR1463,
"Truck Body Retaining Cable - Remove and Install" for the correct procedure.

Procedure and Parts List for (S/N: 4GZ1-UP)


Table 10

196-1873 Control Mounting Group used for Off-Highway Trucks (S/N:4GZ1-UP


Part Part
Quantity
Number Name
1 4D-7794 Clip
2 6V-8801 Nut
4 7K-1181 Cable Strap
2 8L-5449 Spacer
1 8M-2770 Clip
2 8T-4177 Bolt
2 8T-4224 Washer
2 8T-4896 Washer
2 8T-6870 Bolt
8 8T-9655 Mount
4 9N-0869 Washer
4 9S-8413 Washer
1 133-3489 Plate Assembly
4 145-0487 Spacer
2 174-1377 Plate Assembly
1 192-7413 Harness Assembly
1 231-1365 Monitor Electronic Control Module

1. Recharge all four of the suspension cylinders in accordance with the Special Instruction,
SEHS9411. This ensures the mechanical condition of all cylinders.

2. Ensure that the suspension cylinder pressure sensors are operating in accordance with the
Service Manual, SENR6059, "Vital Information Management System (VIMS)", "Suspension
Cylinder Pressure Sensor Troubleshoot" procedure.

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3. Verify that the switch (body position) is adjusted properly and that the switch (body position)
is working correctly. The switch (body position) determines when the Road Analysis Control
Module starts and stops taking data.

4. Check the body of the truck in order to ensure that the body does not contain a significant
amount of carryback.

5. Calibrate the Truck Payload System. Use the (PAYCAL) keypad command. Successful
calibration ensures that the Truck Payload System is working correctly.

Note: In order to perform the payload calibration with the PAYCAL command, the Service
Tool must be connected to the machine via the VIMS service port and communications must
be established between VIMSpc and the VIMS main module.

6. Put the truck back into production for a minimum of eight hours.

7. After the eight hour shift, stop the truck and then connect VIMSpc (service tool) via the VIMS
service port.

8. Establish communications with the VIMS.

9. Use the "Tab" key to access the "VIMS Status" screen. Observe the amount of onboard
memory that is available for the "Event List". Approximately 95 percent of the onboard
memory must be available. The "Event List" has the capacity to store in memory up to 500
Data events and Maintenance events. With less than 95 percent of onboard memory for the
"Event List" remaining, the memory capacity may be exhausted before the next download. If
there is less than 95 percent of the memory capacity remaining for the "Event List", raise the
RAC Event Category from Group One to Group Two or even Group Three. (Refer to Systems
Operation, RENR2636, "Events" for additional information.) This action will cause fewer
events to occur. This will require less onboard memory.

10. Perform a complete download of onboard data from the VIMS main module.

11. Install the Truck Body Retaining Cable (1) in accordance with the Disassembly and Assembly,
RENR2535, "Truck Body Retaining Cable - Remove and Install" procedure.

Illustration 24 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.

12. Remove the rear access panel that is located behind the Cab in order to gain access to the
VIMS main module.

Illustration 25 g00734894
(2) Bolts

(3) cover assembly

a. Remove six bolts (2) and the six washers.

b. Remove cover assembly (3). The cover assembly weighs approximately 41 kg (91 lb).

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Illustration 26 g01087727
(4) VIMS interface module

(5) VIMS main module

(6) Bolt (Mounting)

(7) Harness connector (37 pin)

(8) VIMS interface module

Illustration 27 g01087728
(9) Plate assembly

(10) Brake ECM

(11) Bolts

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Illustration 28 g01087729
(12) Rear Bolts

13. Remove two bolts (12) from brake electronic control module (10) .

14. Loosen two bolts (11) from the slots in the side panels.

15. Slide the Brake ECM (10) toward the rear of the cab.

Illustration 29 g01087730
(13) grounding strap

(14) bolt

(15) Brake ECM

(16) plate assemblies

16. Remove bolt (14) and the washer in order to disconnect grounding strap (13) .

17. Remove the three remaining bolts (14), the washers, the mounts, and the spacers in order to
remove brake electronic control module (15) from plate assemblies (16) .

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Illustration 30 g01087731
(17) 174-1377 Plate assemblies

(18) bolts

(19) Brake ECM

18. Use three bolts (18), the washers, the mounts and the spacers in order to install brake
electronic control module (19) onto 174-1377 plate assemblies (17). Tighten three bolts (18) to
a torque of 25 ± 3 N·m (18.4 ± 2.2 lb ft).

19. Use the remaining bolt (18) and the washer in order to connect ground strap (13). Tighten bolt
(18) to a torque of 25 ± 3 N·m (18.4 ± 2.2 lb ft).

Illustration 31 g01087732
(20) 164-5393 Wire Assembly

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Illustration 32 g01087733
(21) 198-5697 Road Analysis Control Module

(22) Main Harness Connector

(23) Harness Assembly Connector

Illustration 33 g01087876
(24) Harness connectors

(25) 192-7413 Harness Assembly

(26) Harness connector

20. Remove the 164-5393 Wire Assembly (20) from main harness connector (22). Connect
harness assembly connector (23) of the 192-7413 Harness Assembly (25) to Harness assembly
connector (22) .

21. Connect harness connectors to the J1 and J2 (32) connectors of the Road Analysis Control
Module (16)

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Illustration 34
Typical installation of the Road Analysis Control Module

(27) 231-1365 Monitor Service Electronic Control Module (RAC)

(28) 9N-0869 Washer

(29) 8T-4177 Bolt

(30) 8T-9655 Mounts

(31) 8L-5449 Spacer

(32) Connector J2

(33) 133-3489 Plate Assembly

(34) 8T-4224 Washer

(35) 8T-6870 Bolt

22. Install eight 8T-9655 Mounts (30, F), four 145-0487 Spacers (H) and four 9S-8413 Washers
(J) into the four mounting holes of the Road Analysis Control Module. Refer to Illustration 36.

23. Mount the 231-1365 Monitor Service Electronic Control Module (RAC) (27) on the two 174-
1377 Plates . Use two 8T-6870 Bolts (35) and the 9N-0869 Washer (28) to attach the right side
of the Road Analysis Control Module to the plate. Use two 8T-4177 Bolts (29), the 8T-4224
Washer (34), 9N-0869 Washer (28), the 133-3489 Plate Assembly (33) and the two 8L-5449
Spacers (31) to attach the left side of the Road Analysis Control Module to the plate.

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24. Connect the two 70-contact connectors of the tee harness to the connectors J1 and J2 (32) on
the Road Analysis Control Module.

Illustration 35 g01087893
(36) Front Bolts

Illustration 36 g01084912

Shock Mount Assemblies

(A) 8T-4177 Bolt

(B) 8T-4224 Washer

(C) 133-3489 Plate Assembly

(D) 8L-5449 Spacer

(E) 9N-0869 Washer

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(F) 8T-9655 Mounts

(G) Mounting holes of Road Analysis Control Module

(H) 145-0487 Spacer

(J) 9S-8413 Washer

25. Install the brake electronic control and the Road Analysis Control Module in the slots of the
two side panels. Tighten the two rear bolts (12). Tighten the two front bolts (36) .

26. Install the 7K-1181 Cable Straps in order to secure the machine harness.

27. Upload the new VIMS source and configuration software. Refer to the Service Magazine
announcement for the version 9.62X class of VIMS onboard software for the part numbers of
the software.

Note: Use VIMSpc to upload the VIMS (version 3.0) software.

28. Enter the Attachment Code For RAC.

a. With the message center in the background mode, enter the service program code
"ATTACH" and then press the "OK" key. This will cause the following message to
display in the message area of the message center.

Table 11

ENTER ATTACH CODE


_

b. Enter the attachment code of "4" and then press the "OK" key. The VIMS will then
prompt you to validate the previous entry.

Table 12

ENTER CODE AGAIN


_

c. Enter the attachment code of "4" again and press the "OK" key. The attachment code is
now set.

Note: The Machine Status ("MSTAT") command can be used to view the active
attachment code.

29. Replace the rear access panel that is located behind the CAB.

a. Replace the cover assembly (3). The cover assembly weighs approximately 41 kg (91
lb).

b. Install six bolts (2) and the six washers.

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30. Remove the truck body retaining cable in accordance with the Disassembly and Assembly,
SENR1463, "Truck Body Retaining Cable - Remove and Install" procedure.

Procedure and Parts List for (S/N: ATY1-UP; APX1-UP;


2BW303-UP)
Table 13

192-7419 Control Mounting Group (Nonserviceable) (1) for Off-Highway Trucks.


(S/N:ATY1-UP, ; S/N:APX1-UP, ; S/N:2BW303-UP)
Part Part
Quantity
Number Name
1 4D-7794 Clip
1 5P-7854 Clip
2 6V-8801 Nut
2 7K-1181 Cable Strap
1 8M-2770 Clip
2 8T-4896 Washer
Harness
1 192-7413
Assembly
(1) The parts that are listed in this table must be ordered separately.

Table 14

192-7420
Control Mounting Group
Part Part
Quantity
Number Name
8 8T-9655 Mounts
4 145-0487 Spacer
4 9N-0869 Washer
2 8L-5449 Spacer
2 8T-4224 Washer
2 8T-4177 Bolt
Plate
1 133-3489
Assembly
4 4L-9337 Bolt

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4 8T-4896 Washer
Plate
1 192-1519
Assembly
2 8T-6869 Bolt
1 231-1380 Monitor Electronic Control Module

1. Recharge all four of the suspension cylinders in accordance with the Special Instruction,
SEHS9411. This ensures the mechanical condition of all cylinders.

2. Ensure that the suspension cylinder pressure sensors are operating in accordance with the
Service Manual, RENR2631, "Off-Highway Truck Vital Information Management System
(VIMS)", "Suspension Cylinders Pressure Sensor" procedure.

3. Verify that the switch (body position) is adjusted properly and that the switch (body position)
is working correctly. The switch (body position) determines when the Road Analysis Control
Module starts and stops taking data.

4. Check the body of the truck in order to ensure that the body does not contain a significant
amount of carryback.

5. Calibrate the Truck Payload System. Use the (PAYCAL) keypad command. Successful
calibration ensures that the Truck Payload System is working correctly.

Note: In order to perform the payload calibration with the PAYCAL command, the Service
Tool must be connected to the machine via the VIMS service port and communications must
be established between VIMSpc and the VIMS ECM.

6. Put the truck back into production for a minimum of eight hours.

7. After the eight hour shift, stop the truck and then connect VIMSpc (service tool) via the VIMS
service port.

8. Establish communications with the VIMS.

9. Use the "Tab" key to access the "VIMS Status" screen. Observe the amount of onboard
memory that is available for the "Event List". Approximately 95 percent of the onboard
memory must be available. The "Event List" has the capacity to store in memory up to 500
Data events and Maintenance events. With less than 95 percent of onboard memory for the
"Event List" remaining, the memory capacity may be exhausted before the next download. If
there is less than 95 percent of the memory capacity remaining for the "Event List", raise the
RAC Event Category from Group One to Group Two or even Group Three. (Refer to Systems
Operation, RENR2636, "Events" for additional information.) This action will cause fewer
events to occur. This will require less onboard memory.

10. Perform a complete download of onboard data from the VIMS ECM.

11. Install the Truck Body Retaining Cable in accordance with the Disassembly and Assembly,
SENR1463, "Truck Body Retaining Cable - Remove and Install" procedure.

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Illustration 37 g00734886
(1) Truck Body Retaining Cable

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.

12. Remove the rear access panel that is located behind the CAB in order to gain access to the
VIMS ECM.

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Illustration 38 g00734894
(2) Bolts

(3) Cover Assembly

a. Remove six bolts (2) and the six washers.

b. Remove cover assembly (3). The cover assembly weighs approximately 41 kg (91 lb).

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Illustration 39 g01088224
(4) Machine harness

(5) Bolt and spacer

13. Remove the bolt and spacer (5) that is holding machine harness (4) in place.

14. Carefully adjust the machine harness (4) to allow enough room in order to install the Road
Analysis Control Module.

Illustration 40 g01088244

(6) 192-1519 Plate

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(7) 4L-9337 Bolt

(8) 8T-4896 Hard Washers

15. Install the 192-1519 Plate (6). Use four 4L-9337 Bolts (7) and the 8T-4896 Hard Washers (8)
to secure the plate to the ECM rack.

Illustration 41
(9) 231-1380 Monitor Service Electronic Control Module (RAC)

(10) 9N-0869 Washer

(11) 8T-6869 Bolts

(12) 8T-4177 Bolts

(13) 8T-9655 Mount

(14) 8L-5449 Spacer

(15) 133-3489 plate

(16) 8T-4224 Washer

16. Install the 231-1380 Monitor Service Electronic Control Module (RAC) (9). Use the 8T-6869
Bolts (11), 9N-0869 Washer (10), 8T-9655 Mount (13), and the 145-0487 Spacer (H) to
mount the top of the Road Analysis Control Module to plate. Use the 8T-4177 Bolts (12, A),
8T-4224 Washer (16, B), the 8L-5449 Spacer (14, D), 133-3489 Mount (15, C), 9N-0869

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Washer (E), 8T-9655 Mount (13, F), and the 145-0487 Spacer (H) to mount the bottom of the
Road Analysis Control Module to plate. Refer to Illustration 42.

Illustration 42 g01084912
Shock Mount Assemblies

(A) 8T-4177 Bolt

(B) 8T-4224 Washer

(C) 133-3489 Mounts

(D) 8L-5449 Spacer

(E) 9N-0869 Washer

(F) 8T-9655 Mounts

(G) Mounting holes of the Road Analysis Control Module

(H) 145-0487 Spacer

(I) 9S-8413 Washer

(J) 8T-6870 Bolt

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Illustration 43 g01088270
(17) Harness Connectors

(18) 192-7413 Harness Assembly

(19) Harness Connector

Illustration 44 g01088271
(20) 164-5393 Wire assembly

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Illustration 45 g01088276
(21) Main Harness Connector

(22) Harness connector from 192-7413 Harness Assembly

17. Remove the 164-5393 Wire assembly (20) from the main harness connector (21). Connect the
Harness Assembly Connector (22) of the 192-7413 Harness Assembly to the main harness
connector (21) .

18. Join the harness connectors to the J1 and J2 connectors of the Road Analysis Control Module.

Illustration 46 g01088470
(23) 4D-7794 Clip

(24) 8T-4896 Hard Washer

(25) 6V-8801 Nut

(26) 5P-7854 Clip

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Illustration 47 g01088471
(27) 7K-1181 Cable Strap

(28) VIMS ECM

(29) RAC ECM

19. Install the brackets and clips as shown in Illustration 47.

20. Flash the new VIMS software. Refer to Service Magazine, SEPD0699 8 September, "New
VIMS 10.4 Class of Onboard Software" for the version 10.4 class of VIMS onboard software
for the part numbers of the software.

Note: Use the WinFlash program of the Electronic Technician program to flash the VIMS
version 4.0 hardware.

21. Enter the Attachment Code.

a. With the message center in the background mode, enter the service program code
"ATTACH" and then press the "OK" key. This will cause the following message to
display in the message area of the message center.

Table 15

"ENTER ATTACH CODE"


_

b. Enter the attachment code of "4" and then press the "OK" key. The VIMS will then
prompt you to validate the previous entry.

Table 16

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"ENTER CODE AGAIN"


_

c. Enter the attachment code of "4" again and press the "OK" key. The attachment code is
now set.

Note: The active attachment code can be viewed by using the command that is called
machine status which is represented by the abbreviation "MSTAT".

22. Replace the rear access panel that is located behind the CAB.

a. Replace the cover assembly (3). The cover assembly weighs approximately 41 kg (91
lb).

b. Install six bolts (2) and the six washers.

23. Remove the truck body retaining cable. Refer to Disassembly and Assembly, SENR1463,
"Truck Body Retaining Cable - Remove and Install" for the correct procedure.

Technical Assistance
The support staff for VIMS is available Monday through Friday from 7:30 AM to 5:30 PM Central
Standard Time in the United States.

US and Canada: 1-800-290-1808Elsewhere: (309) 494-4151

The support staff can also be contacted via e-mail by using the internet.

E-mail Address: metsmining@cat.com

Copyright 1993 - 2006 Caterpillar Inc. Tue Aug 8 19:42:56 UTC-0400 2006
All Rights Reserved.
Private Network For SIS Licensees.

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