Service Training

Instructor Module SEGV2597

April 1994

TECHNICAL INSTRUCTION MODULE

VI
M
S
VITAL INFORMATION MANAGEMENT
SYSTEM
INTRODUCTION
SEGV2597 Table of Contents
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TABLE OF CONTENTS

MODULE DESCRIPTION

PREPARATION CHECKLIST

MODULE PREREQUISITES

MODULE LESSON PLAN

MODULE OBJECTIVES

SLIDE/TEXT REFERENCE
Introduction
System Operation
Message Center and Keypad
Onboard Applications
Electronic Control Inputs and Outputs
Offboard Applications
Conclusion

LABORATORY EXERCISES

CASE STUDY

POSTTEST

STUDENT MATERIALS
Acronyms and Glossary
SEGV2597 Module Description
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MODULE DESCRIPTION

CONTENT This Technical Instruction Module is designed to introduce students to the

Vital Information Management System (VIMS). It covers the System
Operation as well as the Onboard and Offboard Applications.

AUDIENCE This module prepares the students for the product specific applications of
VIMS that will be taught in future modules. This module provides
general information about VIMS for technicians who will be continuing
on to the product specific application courses. Also included in this
module is a section on general diagnostic information. The information is
located in the student materials section and can be used as a handout or be
presented during classroom discussions.

Level II - Field service personnel, resident mechanics, Technical

Communicators and shop technicians. All students should have a
working knowledge of basic electrical and electronic controls on
Caterpillar products.

REFERENCES Service Manual Module Form No.

Vital Information Management System (VIMS) SENR6059

Miscellaneous

Interactive Video Course "Fundamentals of Electrical

Systems" TEVR9002

Programmed Instruction Course "Basic Electricity" SEBV0534

793B Truck Operation and Maintenance Manual SEBU6710

5130 Excavator Operation and Maintenance Manual SEBU6551

Training Book "Easy Windows, 3.1 Edition"

by Shelly O'Hara
Available from:
Prentice Hall Computer Publishing
0-88022-985-3
Attn: Order Dept
201 W. 103rd St.
Indianapolis, IN 46290
SEGV2597 Preparation Checklist
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PREPARATION CHECKLIST

MODULE Gather the following materials before the training session:

PREPARATION
_____ Slide/Text Reference "Vital Information Management System"
(Form SEBV2597) included in this module.

_____ A copy of the appropriate Service Manual Modules for the

specific machine available.

CLASSROOM Prior to delivering the classroom training session, perform the following
PREPARATION
steps:

_____ Review the Slide/Text Reference to become familiar with the

topic.

_____ Duplicate enough Student Materials (Form SEEV2597) at the end

of this module for each participant in the training session.

_____ Review the questions and answers in the Posttest.

_____ Check all Service Magazine articles, Service Letters and Technical
Information Bulletins related to the topic.

LABORATORY
PREPARATION
Prior to conducting the lab exercises, perform the following steps:

_____ Determine the type of machine or training aid to be used for the
lab exercises.

_____ Gather all necessary tools and diagnostic tooling need to perform
the lab exercises.
SEGV2597 Module Prerequisites
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MODULE PREREQUISITES

PREREQUISITE TEST Prerequisite tests should be administered at least one or two weeks before
the participant takes the course.

Participants should pass the following pretest with a score of 90% or

better:

Machine Electrical Pretest SEBV0558

If a participant does not accomplish 90% or better, identify the area of

deficiency and then recommend materials for the student to review. After
ample review time, the student should re-take the test.

PREREQUISITE The following prerequisite course should be completed prior to

COURSE participating in this course:

Interactive Video Course "Fundamentals

of Electrical Systems" TEVR9002
SEGV2597 Lesson Plan
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LESSON PLAN

INSTRUCTOR TIPS Introduction Time Estimates

•Provide each student Welcome and Course Description 15 min.

with a printed copy of
the course objectives
Discuss Objectives and Class Agenda 15 min.

•Slides: 1 - 9 Slide Presentation

•Hand out Lab A
Worksheet Introduction 20 min.
System Operation 20 min.

•Conduct Lab A Lab Exercise A: VIMS Component Functions 20 min.

•Slides: 10 - 16 Slide Presentation

Message Center and Keypad 20 min.

•Conduct Lab B Lab Exercise B: Perform Message Center and

Keypad Operations 20 min.

•Slides: 17 - 27 Slide Presentation

Electronic Control Inputs and Outputs 20 min.

•Conduct Lab C Lab Exercise C: Identify Input/Output Components 20 min.

•Slides: 28 - 37 Slide Presentation

Offboard Applications 20 min.

•Conduct Lab D Lab Exercise D: Perform Offboard Service Tool 20 min.

Operations

•Hand out Case Study Case Study 30 min.

•Hand out Posttest Posttest

Administer Posttest 35 min.

Review and Discuss Posttest Results 25 min.

Total Estimated Time 5 hrs.

SEGV2597 Module Objectives
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MODULE OBJECTIVES

After completing this module, the student will be able to:

•Slides: 1 - 9 1. Without using any notes, identify and explain the function of the
•Lab A instrumentation modules, interface modules, and main module on a
lab worksheet.

•Slide: 3 2. Without using any notes, identify the machine and system events, and
•Posttest explain their differences on a posttest.

•Slide: 10 3. Given a machine or training aid, the appropriate service literature, and
•Lab B using the keypad and message center, enter the following service
•Posttest operation codes: (1) start manual lube, (2) view event statistics and
(3) start/stop Data Logger.

•Slide: 10 4. Given a lab worksheet and a machine or training aid, scroll through a
•Lab B
list of selected parameters. Record the parameter value and units on
the worksheet.

•Slides: 10 - 15 5. Given a machine or training aid, the appropriate service literature,

•Lab B and using the keypad and message center, identify all machine events
stored in the VIMS memory. Record the parameter and value on a lab
worksheet.

•Slide: 16 6. Given a machine or training aid, the appropriate service literature, and
•Lab B using the keypad and message center, display the diagnostic
information for all stored system events. Record the diagnostic codes
on a lab worksheet.

•Slides: 17 - 27 7. Without using any notes, identify and explain the function of the
•Lab C input and output devices related to the VIMS and other major
•Posttest
components on a lab worksheet.
•Slides: 28 - 37 8. Given a machine or training aid, the appropriate VIMS
•Lab D documentation, and an offboard service tool (PC), display the VIMS
Communicate main dialog group box.

•Slides: 28 - 37 9. Given a machine or training aid, the appropriate VIMS

•Lab D documentation, and an offboard service tool (PC), display the
Machine Status Dialog. On a worksheet, record the following
information from the Machine Status dialog:
a. Source Code
b. Service Meter Units
c. Number of Category 3 events since last reset
SEGV2597 Slide/Text
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SLIDE/TEXT REFERENCE

INSTRUCTOR NOTE The following text for this module explains the basic operation of the
Vital Information Management System used on Caterpillar machines.
The information is generic in nature and is intended to be used with
machine specific materials to be developed at a later date.

The text is accompanied by instructor tips. These tips provide helpful

information for conducting training classes.

The Slide/Text information assumes that the user of this material

understands basic electrical principles, can read electrical schematics and
has a fundamental knowledge of machines and their components.

For your convenience, additional copies (text only, slides not included) of
the "Slide/Text Reference" may be ordered separately as:

Vital Information Management System--Introduction

Slide/Text Reference SEBV2597

NOTE: Insert "Vital Information Management System--Introduction"

Slide/Text Reference (Form SEBV2597) behind this page.
SEGV2597 Laboratory Exercises
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LABORATORY EXERCISES
INSTRUCTOR NOTE The following section provides directions to set up, facilitate and assist
during the student lab exercises

Some lab exercises are the written type with worksheets, while other labs
are the traditional "on the iron" labs. Answers are provided for the
worksheet exercises.

The actual student lab sheets along with accompanying materials are
located in the Student Materials section (Form SEEV2597).

At the beginning of each lab, review the lab description.

NOTE: Discuss safety procedures with the students for each shop lab
(i.e. safety glasses, clothing).
SEGV2597 -2- Laboratory Exercises
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Lab A: VIMS Component Functions

INSTRUCTOR NOTE
Classroom Lab Exercise

INDIVIDUAL EXERCISE Procedure:

Distribute the Lab A Worksheet at the beginning of the slide presentation.

Explain to the class how to complete the worksheet.

As slides No. 1 through 9 are presented, have each student write a brief
description of the function of each module within the VIMS.

After presenting slide No. 9, review the function of each component with
the class.

MATERIALS NEEDED Lab A Worksheet

SEGV2597 -3- Laboratory Exercises
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Lab A Worksheet

VIMS Component Functions

Directions: Briefly describe the function of the following components.

Instrumentation Modules:

Gauge Cluster Module--Four gauge cluster with each of the four gauges dedicated to a
parameter within a machine system. Graphic symbols are used to identify the
parameter.

Speedometer/Tachometer Module--Speed readout consists of three digits and displays

speed in mph (km/h). The VIMS calculates speed based on a frequency input.
Tachometer section displays engine rpm received from the electronic engine control and
the gear readout section consists of two digits displaying actual gear position.

Message Center Module--Contains an alert indicator, a Data Logger indicator, a

universal gauge, and a text message area. The alert indicator notifies the operator of an
abnormal condition. The Data Logger indicator is a series of dots (four) that scroll in
the top right corner when the Data Logger is turned on. The universal gauge shows the
value of the parameter that is being shown in the message area. The text (two lines)
identifies the abnormal parameter; the first line shows the condition, and the second line
prompts the operator for a reaction. The second line is also used to display other types
of information, such as diagnostic, etc.

Keypad--Allows the operator or serviceman to communicate with the main VIMS

module. The keypad contains ten numeric keys (0 - 9) for data entry. Six other keys are
also available for selecting or accessing information.

Interface Module(s)

The VIMS can support up to eight interface modules, depending on the specific machine
application. All modules contain the same capabilities. Each module is supplied with a
40 pin connector. Four of the inputs supply harness code information and four of the
pins are dedicated to the CAT Data Link (which can be both input and output
connections).
SEGV2597 -4- Laboratory Exercises
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Each interface module will also support eight PWM sensor inputs, eight
uncommitted switch inputs, one key start switch input, and three frequency inputs. The
module supports two regulated voltage outputs and two solenoid outputs (in addition to
the CAT Data Link outputs explained earlier).

Each interface module installed on a machine will have its own specific module identifier
(MID) assigned. The MID uses the harness code inputs to identify each module.

Main VIMS Module

The main VIMS module makes decisions based upon inputs from the interface module(s),
the keypad, and other electronic controls (such as engine and transmission controls).
The outputs of the main VIMS module notify the operator or serviceman of the machine
status. This information is provided through the display modules (such as the gauge
cluster and speedometer/tachometer). The main VIMS outputs also operate the warning
system (alert indicator, action lamp and alarm).

The main VIMS module also supports two RS-232 data links for communicating with an
offboard service tool, such as a personal computer.
SEGV2597 -6- Laboratory Exercises
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Lab B: VIMS Keypad and Message Center Operation

INSTRUCTOR NOTE
Classroom and/or machine Lab Exercise

GROUP EXERCISE Procedure:

Explain to the class how to complete the worksheet.

Have each student list the service operation program code for the
requested service operations.

Have each student enter the service operation program code into the
VIMS and record the message center information on the worksheet (if a
machine is available).

MATERIALS NEEDED Appropriate VIMS Service Manual

Lab B Worksheet

VIMS training aid or machine equipped with VIMS

SEGV2597 -7- Laboratory Exercises
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Lab B Worksheet

VIMS Keypad and Message Center Operation

Directions: In the space provided, list the numerical service identifier and the letter (alpha) equivalent
for the following operations. Enter the code using the keypad. Write a brief description explaining the
steps required to enter the operations.

1. 3564 (DLOG) Start/stop Data Logger

Enter the above code and press the OK key on the keypad. The four data dots will begin
scrolling above the universal gauge and the Data Logger remaining time will be displayed in the
message area for five seconds after turning the Data Logger on.

2. 582738 (LUBSET) Set lube cycle times

Enter the above code on the keypad. The display will show AUTO LUBE DURATION on the
first line of text and the time in seconds on the second line. Use the arrow keys on the keypad to
adjust the duration time. Press the OK key to set new time.

3. 37828 (ELIST) View Event statistics

Enter the above code and press the OK key on the keypad. The message area will show the
number of system events stored in memory on line one, and line two will display the number of
machine events stored. The numbers represent events stored in memory since the last time the
memory was cleared.

Directions: Scroll to the following sensor parameters. Record the parameter value and units in the
space provided.

4. 100 (Show the Engine rpm)

131 (Show Oil Pressure in psi)
121 (Show % rated Fuel)

Directions: Using the message center and keypad, record all machine and system events. (List all the
events stored in memory. For machine events, list the parameter value and units. For system events, list
the diagnostic information available.)

5. (Example of Machine event)-----85 DEG F

(Example of System event)-------MID049 CID801 FMI12

Directions: Using the above example of a system event, briefly describe the types of information
contained in the diagnostic codes.

6. MID049 identified the fault being diagnosed by the main VIMS module. The CID801 code
identified the component with the problem as VIMS interface module No. 1, and the FMI
identified a communication problem in the interface module.
SEGV2597 Laboratory Exercises
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Lab C: Identifying Input/Output Components

INSTRUCTOR NOTE
Classroom Lab Exercise

INDIVIDUAL EXERCISE Procedure:

Explain to the class how to complete the worksheet.

Have each student identify the input/output components of the VIMS.

MATERIALS NEEDED
Lab C Worksheet
SEGV2597 -8- Laboratory Exercises
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Lab C Worksheet

Identify Input/Output Components

Directions: Identify the following devices by placing an "I" for input or an "O" for output next to the
component name, and briefly describe the function of each.

I Key Start Switch

Input to interface module. With key switch ON, +Battery is supplied to pin 32.

I Left Rear Strut Sensor

Sends Payload Measurement System frequency signal to the interface module
from an off-highway truck equipped with TPMS.

O Auto Lube Solenoid

Output voltage from interface module pin 31 energizes auto lube solenoid.

O Action Lamp
Main VIMS module output. Lamp flashes whenever a Category 2 or Category 3
warning exists.

O Service Light
Main VIMS module output. Lamp comes on steady whenever an active fault is
present. If event is diagnosed as machine abuse, the lamp will flash.

I/O CAT Data Link

A bi-directional input/output circuit that permits all electronic controls to
communicate with each other.

O Sensor Voltage 8 DCV

Interface module regulated +8 DC output that supplies voltage to all sensors
requiring +8 DC input.

I Harness Code Inputs 0, 1, 2, 3, 4

Interface module input that provides a specific MID code that identifies which
interface module is sending information to the main VIMS module.

I Frequency Sensor
Input sensor that supplies a frequency signal to the interface module.

I Keypad
Allows communication between operator and main VIMS module.
SEGV2597 -8- Laboratory Exercises
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Lab D: VIMS Offboard Service Tool Operation

INSTRUCTOR NOTE
Machine Lab Exercise

GROUP EXERCISE Procedure:

Explain to the class how to complete the worksheet.

Have each student connect an offboard service tool to a machine equipped

with VIMS or a training aid.

Using the VIMS software, have each student select the Communicate
option from the VIMS software, pull down the machine status dialog box
and complete the worksheet.

MATERIALS NEEDED An offboard service tool (PC) and applicable cable

Appropriate VIMS Service Manual

Lab C Worksheet

VIMS training aid or machine equipped with VIMS

SEGV2597 -9- Laboratory Exercises
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Lab D Worksheet

VIMS Offboard Service Tool Operation

Directions: Connect an offboard service tool (PC) to a machine or training aid. Select the
Communicate icon from the VIMS group box displayed on the Windows Program Manager dialog. Pull
down the Machine Status dialog box. Fill in the following information:

Machine Status

Model # Equipment #
Serial # Service Meter Units:

Event Data Remaining Space for Onboard Information

Number of Events since Reset % Available
Events:
Level 0: Level 1:
Event Recorder % Available
Level 2: Level 3:
Data Logger Min. Available
Last Event Download:
Payload % Available
Last Reset of Onboard
Event Data:

Version Numbers:
Current Onboard
Machine Setup:
Date: Source Code:
Time: Hardware:

Data Logger Onboard Languages

Current Status Primary:

Secondary:
Close

Display of current machine status

SEGV2597 Case Study
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CASE STUDY

INSTRUCTOR NOTE The following section provides a case study and a possible solution. You
may want to work through the case study and make your own notes. The
actual case study without solutions is located in the Student Materials
Section (Form SEEV2597).

DIRECTIONS The case study presented in this section reflects an actual field reported
problem. A recommended procedure for presenting this information is as
follows:

A. Present students with the operator complaint and then ask for a
written response, or use an open classroom discussion to solve
(Instructor decision).

B. Students may complete the study in small groups, discuss the

solution within their group and then present the results to the class
(Instructor decision).

Students may use their class notes and any other reference material.

NOTE: The VIMS is installed in several product models. This module,

being generic, did not present model specific information. The case study
reflects information from an Off-highway Truck field report.
SEGV2597 -2- Case Study
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VIMS CASE STUDY

DIRECTIONS Students may use service manual modules and their class notes to
complete the case study.

SITUATION The following case study is based on an actual field report.

The operator of a VIMS equipped 793B Truck reported that he received

several "Low Voltage" events on his message center module.

The maintenance supervisor advised the operator to turn the Data Logger
ON during his next pass. The operator followed instructions and reported
that the VIMS again detected a "Low Voltage" event while the Data
Logger was running.

Maintenance personnel were called to the machine to investigate the

problem.

The maintenance mechanic operated the machine at high idle for several
minutes with no electrical warnings or symptoms present.

ADDITIONAL What additional steps should the mechanic take to solve the reported
INFORMATION problem?

1. More information is needed from the operator, such as:

• When the events occurred. Was the situation repeatable?

• Was the speed of the machine constant, or did the event

come ON at one specific speed? Did the event come
ON during acceleration or deceleration?

2. Is any additional information available from the VIMS?

3. If so, examine all the facts and analyze the key parameters
associated with the "event."

4. Inspect and correct.

POSSIBLE SOLUTIONS The additional information from the operator indicated that the "event"
came ON when the machine was accelerating and it appeared to be
repeatable.

A visual check of the electrical system showed no external damage or

loose connectors.
SEGV2597 -3- Case Study
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OBSERVATIONS The mechanic started the engine again and ran the engine at high idle. A
voltage measurement at the alternator indicated the system voltage to be
within specification.

From the information gathered during his discussion with the operator, the
mechanic knew the Data Logger was recording when the "event" occurred
and that he could download the information using a service tool (PC) and
view the Event List.

The Event List indicated that the Data Logger was operating during the
time of the "event" and additional information would be available by
viewing the Data Logger information.

Using the service tool (PC) and offboard software, the mechanic was able
use the downloaded Data Logger information to produce a graph of the
machine engine speed and the system voltage. He discovered that as
engine speed decreased, the system voltage decreased (as expected). But
when the operator increased the engine speed, the system voltage
continued to decrease. This condition was not what the mechanic
expected to see.

ACTUAL SOLUTION After analyzing all the data, the mechanic decided that the most likely
cause was a slipping alternator belt. The mechanic changed the
serpentine belt and performed an operational check of the system. No
additional operator complaints were reported.
SEGV2597 Posttest
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POSTTEST

INSTRUCTOR NOTE The following posttest is intended to measure a student's knowledge after
the slide presentation and lab exercises have been completed. Two copies
of the posttest are included. The copy in this section contains the answers
and the other copy without answers is contained in the Student Materials
section.

The lab exercises measure the student's ability to satisfy the performance
objectives, and the posttest will measure the knowledge objectives.
SEGV2597 -2- Posttest
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VIMS POSTTEST

Directions: Circle the correct response.

1. Sensors receive their regulated input voltage from:

a. the battery
b. the main VIMS module
c. the interface module
d. the key start switch

2. All abnormal machine conditions are called:

a. system events
b. system faults
c. machine faults
d. machine events

3. The instrumentation display components are controlled by the:

a. interface module
b. main VIMS module
c. CAT Data Link
d. keypad

4. Each interface module installed on a machine will have a different module identification code
(MID) assigned to it.

a. true
b. false

5. A machine may have up to eight individual interface modules.

a. true
b. false

6. The VIMS has three types of input devices.

a. true
b. false

7. The service light:

a. is turned ON for active events, and FLASHES if the event is related to abuse
b. FLASHES for active events, and is ON steady if the event is related to abuse
c. is ON any time the key switch is in the ON position
d. none of the above
SEGV2597 -3- Posttest
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8. The gauge cluster module contains:

a. one gauge
b. two gauges
c. three gauges
d. four gauges

9. The universal gauge shows only switch-type parameters values.

a. true
b. false

10. Service operations are initiated through the keypad.

a. true
b. false

11. Each service operation program code has a unique number of one to:

a. five digits
b. six digits
c. seven digits
d. eight digits

12. Both machine and system events are classified into multiple warning categories, of which three
are shown to the operator.

a. true
b. false

13. Category one, two and three events may be acknowledged by pressing the OK key on the
keypad.

a. true
b. false

14. The action lamp and action alarm are outputs of:

a. the instrumentation module

b. the interface module
c. the main VIMS module
d. the CAT Data Link

15. The RS-232 data link allows the various electronic control modules to communicate with the
main VIMS module.

a. true
b. false
SEGV2597 Student Materials
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STUDENT MATERIALS
INSTRUCTOR NOTE The following section contains all lab exercises, troubleshooting aids,
case studies (if available), and the posttest for students. You may want to
add additional information to this section before duplicating. Materials
may be distributed to the students at the beginning of class or at a time
when they need them during class activities.

For your convenience, additional copies of the "Student Materials" may

be ordered separately as:

Vital Information Management System--Introduction

Student Materials SEEV2597

NOTE: Insert "Vital Information Management System--Introduction"

Student Materials (Form SEEV2597) behind this page.