Installation of VIMS Guardian on Underground Mining Machines{7601} Caterpillar


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Installation of VIMS Guardian on Underground Mining Machines{7601} [REHS4879]
OPERATOR STATION
MONITOR GP
1.1. Introduction
2.1. Important Safety Information
3.1. Access to Guardian Information
4.2. Manual Downloads
5.2. Ordering VIMS Software
6.2. Wireless Access to Data
7.1. Installation of VIMS on the AD30 Underground Articulated Dump Truck (UAD Truck)
8.1. Installation on AD45B Trucks, AD55B Trucks, and AD30 Trucks with a <B>S/N:</B>DXR Serial Number Prefix
9.1. Installation on the R1600G Load Haul Dump
10.1. Installation on the R1700G Load Haul Dump
11.1. Installation on the R2900G Load Haul Dump
12.1. Appendix A: UGM Guardian Switch Inputs
13.1. Appendix B: Activating Guardian Software
14.2. Permanent Installation
15.2. Temporary Installation
16.2. After Installation
17.2. Obtaining Factory Passwords for the SEA
18.2. Flashing Guardian
19.2. Technical Assistance
Load Haul Dump:
R1600G (S/N: 9PP1-UP; 9YZ1-UP)
R1700G (S/N: SBR1-UP; 8XZ351-UP)
R2900G (S/N: GLK1-UP; JLK1-UP)
Underground Articulated Truck:
AD30 (S/N: CXR1-UP; DXR1-UP)
AD45B (S/N: CXM1-UP)
AD55B (S/N: JNW1-UP)

Introduction

The procedure in this manual is for installing VIMS Guardian Monitoring System on the Underground Articulated Trucks with the serial number prefixes that are shown above.

Guardian will use the same hardware as the Equipment Access Module (EAM). The EAM is an option from the factory. Guardian provides additional information in the form of cumulatives, histograms, and trends. Guardian also has an optional switch to ground inputs for activating machine speed limit events, snapshots, the datalogger, or other user-defined events. The switch inputs are detailed in ""Appendix A: UGM Guardian Switch Inputs" ".

Required parts are listed by the machine model. Kits are available that provide a new ECM with the correct software and the correct mounting hardware. The kit will provide common parts. Depending on the machine, additional harnesses and other components may be required.

Note: The software will require activation with the Software Enabled Attachment (SEA). This activation is an additional cost. The reference part number for cost information is 279-9019 Premium Configuration . This software does not need to be ordered, and the billing is handled automatically via the factory password system after activating the SEA. Refer to Special Instruction, REHS1238, "Obtaining Factory Passwords and Software Enabled Attachments" for more information.

Reason code 111 authorization is required to obtain Guardian passwords.

Important Safety Information

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

A person must be alert to potential hazards. This person should also have the necessary training, skills, and tools in order to perform these functions properly.

Safety precautions and warnings are provided in this instruction and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons. AVSpare cannot anticipate every possible circumstance that might involve a potential hazard.

Therefore, the warnings in this publication and the warnings that are on the product are not all inclusive. If a tool, a procedure, a work method, or operating technique that is not recommended by AVSpare is used, you must ensure that it is safe for you and for other people to use.

You should ensure that the product will not be damaged or the product will be made unsafe by the operation, lubrication, maintenance, or the repair procedures that are used.

Access to Guardian Information

Guardian information is accessed by downloading files from the ECM. The file download can be done at the machine manually. Another option is wireless file download at the telemetry port. Guardian interfaces are identical to full VIMS and EAM machines.

Manual Downloads

Manual downloads require the installation of a service port on the machine. VIMSpc is the software that is used for downloading. VIMSpc is also used for storing and for viewing downloads. More information on VIMS usage is found on the following web site:

http://www.catminer.com

Once you are on the site, click the following tabs in order to find the necessary information:

  1. Select "Product Support".

  1. Select "Equipment Management".

  1. Select "Condition Monitoring".

  1. Select "Electronic Machine Data".

  1. Select VIMS.

  1. Select "Application Material".

A 127-9797 Cable As is also needed to connect a PC to the download port. Use the 327-0375 Adapter Kit to adapt a USB port to a serial port if a serial port is not available. This adapter is also compatible with Windows VISTA. Other brands may not function properly.

Note: An updated VIMSpc database is needed for UGM Guardian machines. This updated file is available under the VIMS section. The minimum version for the database that is needed is 9.0.6 in order for Guardian to function properly.

Ordering VIMS Software

In order to purchase information about VIMSpc, use the following procedure:

  1. Select "Product Support".

  1. Select "Equipment Management".

  1. Select "Condition Monitoring".

  1. Select "Electronic Machine Data".

  1. Select VIMS.

  1. Select "VIMS Software and Current Releases".

  1. Select "See Related Links".

  1. Select "VIMS Software Ordering Instructions".

    The user manual for the VIMSpc is also found in this section.

Wireless Access to Data

Wireless access is also available by using the same interfaces that are available with VIMStm. An interface module is used to provide high speed automatic wireless downloads. The VIMS Communicator Module, or the Health Interface Module (HIM) are recommended. Various third-party radios are available for use with these interfaces.

Information on the Communicator Module and the Health Interface Module (HIM) is found in Information Release Memo, PELJ1025, "AVSpare Offers VIMS Communicator or Health Interface Module for Remote Download".

Installation of VIMS on the AD30 Underground Articulated Dump Truck (UAD Truck)

Table 1
EAM is Already Installed    
Quantity     Part Number     Description    
1     347-3677     Wiring Harness    
4     6B-4540     Nut    
4     6D-3033     Socket Head Screw    
4     6V-9497     Hard Washer    
1     8D-9537     Dust Cap    
3     8T-8730     Connector Socket    
5     5W-2226     Straps    
1     3S-8665     Clip    
1     347-3675     Monitor Software Gp    

Table 2
EAM is Not Installed    
Quantity     Part Number     Description    
1     347-3678     Monitor Kit    
1     347-3677     Wiring Harness    
1     235-8234     Control Harness As    
3     130-5300     Clip    
7     4K-8864     Clip    
1     6K-8178     Clip    
5     5W-2226     Straps    
4     5P-2955     Bolt    
3     8T-8730     Connector Socket    
1     3S-8665     Clip    

Table 3
Contents of the 347-3678 Monitor Kit    
Quantity     Part Number     Description    
8     8T-9655     Isolation Mount    
4     145-0487     Spacer    
8     9N-0869     Hard Washer    
4     6B-4540     Nut    
4     6D-3033     Socket Head Screw    
4     6V-9497     Hard Washer    
1     8D-9537     Dust Cap    
2     8T-4224     Hard Washer    
1     347-3676     Monitor Service Electronic Control Module    



Illustration 1g02022921

(A) J1 Plug

(B) J2 Plug

(1) 5P-2955 Bolt

(2) 8T-4224 Hard Washer

(3) 9N-0869 Hard Washer

(4) 145-0487 Spacer

(5) 8T-9655 Isolation Mount

(6) 347-3676 Monitor Service Electronic Control Module




Illustration 2g01923075

This illustration is showing that the ECM is mounted under the seat.

If the EAM is already installed, proceed to Step 3.

  1. Install the Guardian ECM under the seat per Illustration 2.



    Illustration 3g01923193

    (1) 235-8233 Power Harness As

    (2) 235-8234 Control Harness As

    (3) 130-5300 Clip

    (4) 4K-8864 Clip

    (5) 6K-8178 Clip

    (6) 5W-2226 Strap

  1. Install the EAM harness that is shown in Illustration 3. Do not install J1 connector or the J2 connector at this time.



    Illustration 4g01960490



    Illustration 5g01960492

  1. Refer to Illustration 4 and Illustration 5. The 892-BR wire and the 893-GN wire are from the Cat ET service port and must be removed and connected to the blank two wire Deutsch connector on the EAM harness. The two wires (892-BR(a)) and (892-GN(a)) in the EAM harness are then placed in the Cat ET service port replacing the wires that were removed. This action provides a data link connection to the ECM.



    Illustration 6g01960500



    Illustration 7g01960501

  1. The remaining EAM harness receptacle attaches to a connector for the telemetry port "CN32". Refer to Illustration 6 and Illustration 7. The "CN32" is part of the 235-8233 Power Harness As that is already installed on the machine.



    Illustration 8g01960509



    Illustration 9g02023125

  1. Install the 347-3677 Wiring Harness and the connector for the VIMS service port. The harness must be cut to the desired length after the routing is determined. The connector should be placed in a convenient location. One example would be on the dash next to the other download ports that are shown in Illustration 8. Another option is to use a 3S-8665 Clip and mount the port on a mounting bolt for the ECM as shown in Illustration 9.

    1. To mount the service port on the dash, drill a 15/16 inch hole.

    1. Secure the connector by using the 6D-3033 Socket Head Screws , 6V-9497 Hard Washers , and 6B-4540 Nuts .

  1. Add the 8T-8730 Connector Socket to the 347-3677 Wiring Harness after cutting to proper length.



    Illustration 10g01917294

  1. Insert the 347-3677 Wiring Harness sockets into the unused sockets of the J2 connector of the 251-1356 Control Harness As . Refer to Illustration 10.

  1. Install any jumpers and other switch inputs into the J1 connector. Refer to ""Appendix A: UGM Guardian Switch Inputs" ".

  1. Install the J2 connector into the ECM.

  1. Secure the download harness with straps and clips.

  1. Activate the Guardian software with either the temporary installation or the permanent installation with factory passwords. Refer to ""Appendix B: Activating Guardian Software" ". Set the hours in Guardian to match the service meter hours for the machine.

Installation on AD45B Trucks, AD55B Trucks, and AD30 Trucks with a S/N:DXR Serial Number Prefix

Table 4
EAM is Already Installed    
Quantity     Part Number     Description    
1     347-3677     Wiring Harness    
4     6B-4540     Nut    
4     6D-3033     Socket Head Screw    
4     6V-9497     Hard Washer    
1     8D-9537     Dust Cap    
9     8T-8730     Connector Socket    
5     5W-2226     Straps    
1     3S-8665     Clip    
1     347-3675     Monitor Software Gp    

Table 5
EAM is Not Installed    
Quantity     Part Number     Description    
1     347-3678     Monitor Kit    
1     347-3677     Wiring Harness    
1     267-6269     Control Harness As    
3     130-5300     Clip    
5     4K-8864     Clip    
1     6K-8178     Clip    
5     5W-2226     Straps    
1     8T-4185     Bolt    
1     1K-4649     Spacer    
1     6V-5839     Washer    
4     5P-2955     Bolt    
3     8T-8730     Connector Socket    
1     3S-8665     Clip    

Table 6
Contents of the 347-3678 Monitor Kit    
Quantity     Part Number     Description    
8     8T-9655     Isolation Mount    
4     145-0487     Spacer    
8     9N-0869     Hard Washer    
4     6B-4540     Nut    
4     6D-3033     Socket Head Screw    
4     6V-9497     Hard Washer    
1     8D-9537     Dust Cap    
2     8T-4224     Hard Washer    
1     347-3676     Monitor Service Electronic Control Module    



Illustration 11g01960617

(A) J1 Plug

(B) J2 Plug

(1) 5P-2955 Bolt

(2) 8T-4224 Hard Washer

(3) 9N-0869 Hard Washer

(4) 145-0487 Spacer

(5) 8T-9655 Isolation Mount

(6) 347-3676 Monitor Service Electronic Control Module




Illustration 12g01960618

This illustration is showing that the ECM is mounted under the seat.

If the EAM is already installed, proceed to Step 3.

  1. Install the Guardian ECM under the seat per Illustration 12.



    Illustration 13g01923338

    (1) 267-6269 Control Harness As

    (2) 212-4331 Connector Plug

    (3) 130-5300 Clip

    (4) 4K-8864 Clip

    (5) 6K-8178 Clip

    (6) 5W-2226 Strap

    (7) 8T-4185 Bolt

    (8) 1K-4649 Spacer

    (9) 6V-5839 Washer




    Illustration 14g01960741

  1. Install the EAM harness that is shown in Illustration 13. Do not install the J1 connector or the J2 connector at this time. Care must be taken in order to ensure that the correct breakout connector is installed into the "CN58" harness lead of the EAM for the machine. Refer to Illustration 14.

    Note: The wire colors and codes will match for both harnesses. "CN58" is for the AD45B. Other models will have different connector numbers, but the wiring colors and codes are the same.




    Illustration 15g02023133



    Illustration 16g02023134

  1. Install the 347-3677 Wiring Harness and the connector for the VIMS service port. The harness must be cut to the desired length after the routing is determined. The connector should be placed in a convenient location. This location could be on the dash next to the other download ports. Refer to Illustration 15 for the placement of this connector. Another option is to use a 3S-8665 Clip and mount the port on a mounting bolt for the ECM as shown is Illustration 16.

    1. In order to mount the service port, drill a 15/16 hole on the dash.

    1. Secure the connector by using the 6D-3033 Socket Head Screws , 6V-9497 Hard Washers , and the 6B-4540 Nuts .

  1. Add the 8T-8730 Connector Sockets to the 347-3677 Wiring Harness after cutting to proper length.



    Illustration 17g01960764

  1. Insert the 347-3677 Wiring Harness sockets into the unused sockets of the J2 connector of the 251-1356 Control Harness As . Refer to Illustration 10.

  1. Install any jumpers and other switch inputs in the J1 connector. Refer to ""Appendix A: UGM Guardian Switch Inputs" ".

  1. Install the J2 connector into the ECM.

  1. Secure the download harness with straps and clips.

  1. Activate Guardian software with either temporary installation or permanent installation with factory passwords. Set hours in Guardian to match the service meter hours for the machine. Refer to ""Appendix B: Activating Guardian Software" ".

Installation on the R1600G Load Haul Dump

Table 7
EAM is Already Installed    
Quantity     Part Number     Description    
1     347-3677     Wiring Harness    
4     6B-4540     Nut    
4     6D-3033     Socket Head Screw    
4     6V-9497     Hard Washer    
1     8D-9537     Dust Cap    
9     8T-8730     Connector Socket    
10 foot     Wire     18 gauge Black    
10 foot     Wire     18 gauge Yellow    
10 foot     Wire     18 gauge Green    
10 foot     Sleeve     Varflo 5/16 inch diameter. Black or equivalent (1)    
10     5W-2226     Straps    
5     4P-8134     Clips    
        Bolts and washers that are needed for the clips    
1     3S-8665     Clip    
1     347-3675     Monitor Software Gp    
1     355-6252     Monitor Software Gp    
( 1 ) Varflex Corporation, 512 West Court Street, Rome New York 13440, Phone 315-336-4400 or Toll Free 800-648-4014, Fax 315-336-0005, Email: [email protected], web site: http//www.varflex.com

Table 8
EAM is Not Installed    
Quantity     Part Number     Description    
1     347-3678     Monitor Kit    
1     347-3677     Wiring Harness    
4     5P-2955     Bolt    
1     246-3017     Control Harness As    
1     4K-8864     Clip    
3     130-5300     Clip    
1     246-3009     Mount As    
3     1A-2029     Bolt    
1     7C-8246     Spacer    
1     8T-9377     Bolt    
3     8T-8730     Connector Socket    
10     5W-2226     Straps    
5     4P-8134     Clips    
        Bolts and washers that are needed for the clips    
10 foot     Wire     18 gauge Black    
10 foot     Wire     18 gauge Yellow    
10 foot     Wire     18 gauge Green    
10 foot     Sleeve     Varflo 5/16 inch diameter. Black or equivalent (1)    
1     3S-8665     Clip    
1     355-6252     Monitor Software Gp    
( 1 ) Varflex Corporation, 512 West Court Street, Rome New York 13440, Phone 315-336-4400 or Toll Free 800-648-4014, Fax 315-336-0005, Email: [email protected], web site: http//www.varflex.com

Table 9
Contents of the 347-3678 Monitor Kit    
Quantity     Part Number     Description    
8     8T-9655     Isolation Mount    
4     145-0487     Spacer    
8     9N-0869     Hard Washer    
4     6B-4540     Nut    
4     6D-3033     Socket Head Screw    
4     6V-9497     Hard Washer    
1     8D-9537     Dust Cap    
2     8T-4224     Hard Washer    
1     347-3676     Monitor Service Electronic Control Module    



Illustration 18g01923375

(1) 5P-2955 Bolt

(2) 9N-0869 Hard Washer

(3) 145-0487 Spacer

(4) 4B-4277 Washer

(5) 8T-9655 Isolation Mount

(6) 246-3008 Electronic Control Module

(7) 246-3009 Mount As

(8) 1A-2029 Bolt

If the EAM is already installed, proceed to Step 3.

  1. Install the Guardian ECM on the transmission per Illustration 18.



    Illustration 19g01923413

    (A) Splice plug

    (1) 246-3017 Control Harness As

    (2) 4K-8864 Clip

    (3) 130-5300 Clip

    (4) 7C-8246 Spacer

    (5) 8T-9377 Bolt




    Illustration 20g01959617

  1. Install the 246-3017 Control Harness As that is shown in Illustration 19. Do not install the J1 connector or the J2 connector at this time. Take care to connect the harness to the correct breakout connector on the machine, which will have the same wire colors and codes. The EAM breakout connector and the harness will be strapped to the main harness. The location of the EAM harness may be difficult to find. See the diagram in Illustration 20.



    Illustration 21g02023135

  1. Install the 347-3677 Wiring Harness and the connector for the VIMS service port. The harness must be cut to the desired length after the routing is determined. The connector should be placed on the dash next to the other download ports, that are shown in Illustration 21. The other end is connected to the 24-pin bulkhead connector through the cab wall. Choose three unused pins. Use tie straps to secure the harness to the existing wiring.

    1. To mount the service port permanently, drill a 15/16 inch hole.

    1. Secure the connector by using the 6D-3033 Socket Head Screws , 6V-9497 Hard Washers , and 6B-4540 Nuts .

  1. Add the 8T-8730 Connector Socket to the 347-3677 Wiring Harness after cutting to the proper length.

  1. Insert the 347-3677 Wiring Harness sockets into the three pins that are chosen on the 24-pin bulkhead connector.

  1. Construct the harness that is attached to the other side of the bulkhead connector. Insert the black, yellow, and green wire through the sleeve.

  1. Install the sockets on one end. Insert in 24-pin bulkhead connector to matching colors on other side.

  1. Route the resulting harness along the frame and along the EAM harness to the ECM. Use a clip or a strap to prevent vibration against other components.



    Illustration 22g01923453

  1. After routing, trim the harness and add the 8T-8730 Connector Sockets . Install the wires in the J2 connector of the EAM harness. Use the diagram in Illustration 22 as a guide. Find a suitable place in order to cut the harness and install the 3-pin Deutsch connectors. The Deutsch connectors allow the cab to be removed without removing the pins from the 70-pin connector.

  1. Install any jumpers and other switch inputs into the J1 connector. Refer to ""Appendix A: UGM Guardian Switch Inputs" ".

  1. Install the J2 connector into the ECM.

  1. Download the new 355-6252 Monitor Software Gp and flash into EMS with Cat ET Winflash. The software is the 3556252.fls flash file in SIS. This action is required to allow EMS to provide ground speed and gear information to the Guardian.

  1. Activate the Guardian software with either the temporary installation or the permanent installation with factory passwords. Refer to ""Appendix B: Activating Guardian Software" ". Set the hours in Guardian to match the service meter hours for the machine.

Installation on the R1700G Load Haul Dump

Table 10
EAM is Already Installed    
Quantity     Part Number     Description    
1     347-3677     Wiring Harness    
4     6B-4540     Nut    
4     6D-3033     Socket Head Screw    
4     6V-9497     Hard Washer    
1     8D-9537     Dust Cap    
9     8T-8730     Connector Socket    
15 feet     Wire     18 gauge Black    
15 feet     Wire     18 gauge Yellow    
15 feet     Wire     18 gauge Green    
15 feet     Sleeve     Varflo 5/16 inch diameter or equivalent (1)    
15     5W-2226     Straps    
10     4P-8134     Clips    
1     347-3675     Monitor Software Gp    
1     355-6252     Monitor Software Gp (2)    
( 1 ) Varflex Corporation, 512 West Court Street, Rome New York 13440, Phone 315-336-4400 or Toll Free 800-648-4014, Fax 315-336-0005, Email: [email protected], web site: http//www.varflex.com
( 2 ) S/N:8XZ prefix only

Table 11
EAM is Not Installed    
Quantity     Part Number     Description    
1     347-3678     Monitor Kit    
1     347-3677     Wiring Harness    
4     5P-2955     Bolt    
1     246-3558     Control Harness As    
2     4K-8864     Clip    
3     130-5300     Clip    
2     5S-7379     Bolt    
1     9B-7237     Bolt    
1     9M-4136     Spacer    
3     8T-4896     Hard Washer    
3     8T-8730     Connector Socket    
15     5W-2226     Straps    
15 feet     Wire     18 gauge Black    
15 feet     Wire     18 gauge Yellow    
15 feet     Wire     18 gauge Green    
15 feet     Sleeve     Varflo 5/16 inch diameter or equivalent (1)    
10     4P-8134     Clips    
        Bolts and washers that are needed for the clips    
1     355-6252     Monitor Software Gp (2)    
( 1 ) Varflex Corporation, 512 West Court Street, Rome New York 13440, Phone 315-336-4400 or Toll Free 800-648-4014, Fax 315-336-0005, Email: [email protected], web site: http//www.varflex.com
( 2 ) S/N:8XZ prefix only

Table 12
Contents of the 347-3678 Monitor Kit    
Quantity     Part Number     Description    
8     8T-9655     Isolation Mount    
4     145-0487     Spacer    
8     9N-0869     Hard Washer    
4     6B-4540     Nut    
4     6D-3033     Socket Head Screw    
4     6V-9497     Hard Washer    
1     8D-9537     Dust Cap    
2     8T-4224     Hard Washer    
1     347-3676     Monitor Service Electronic Control Module    



Illustration 23g01923473

(1) 5P-2955 Bolt

(2) 9N-0869 Hard Washer

(3) 145-0487 Spacer

(4) 8T-4224 Hard Washer

(5) 8T-9655 Isolation Mount

(6) 347-3676 Monitor Service Electronic Control Module

If the EAM is already installed, proceed to Step 3.

  1. Install the Guardian ECM by the hydraulic tank per Illustration 23.



    Illustration 24g01953719

    (1) 246-3558 Control Harness As

    (2) 9B-7237 Bolt

    (3) 5S-7379 Bolt

    (4) 4K-8864 Clip

    (5) 130-5300 Clip

    (6) 9M-4136 Spacer

    (7) 8T-4896 Hard Washer




    Illustration 25g01959983

  1. Install the 246-3558 Control Harness As that is shown in Illustration 24. Do not install the J1 connector or the J2 connector at this time. Be sure to connect the harness to the breakout connector for the machine harness with the same wire color and codes. The download harness will be added to the J2 connector in Step 9.



    Illustration 26g02023139

  1. Install the 347-3677 Wiring Harness and the connector for the VIMS service port. The harness must be cut to the desired length after the routing is determined. The connector should be placed on the dash next to the other download ports that are shown in Illustration 25. The other end is connected to the 24-pin bulkhead connector through the cab wall. Choose three unused pins.

    1. To mount the service port permanently, drill a 15/16 inch hole.

    1. Secure the connector by using the 6D-3033 Socket Head Screws , 6V-9497 Hard Washers , and the 6B-4540 Nuts .

  1. Add the 8T-8730 Connector Sockets to the 347-3677 Wiring Harness after cutting the harness to the proper length.

  1. Insert the 347-3677 Wiring Harness sockets into the three pins that were chosen on the 24-pin bulkhead connector.

  1. Construct the harness that is attached to the other side of the bulkhead connector to the ECM. Insert the black, yellow, and green wire through the sleeve.

  1. Install the sockets on one end. Insert the sockets in the 24-pin bulkhead connector so that the colors match on the other side.



    Illustration 27g01954020



    Illustration 28g01954024



    Illustration 29g01954025

  1. Use Illustration 27, Illustration 28, and Illustration 29 as a guide for routing the harness. Secure the harness with clips and straps in order to prevent excessive movement. Be careful not to attach the harness near hot components or lines. Use existing wiring as a guideline. Route the harness from the ECM along the edge of the compartment. Then, route the harness forward on the frame rail to the opening that is used by the remote harness. From the opening, route the harness around the front perimeter of the transmission compartment. Then, route the harness along the opposite side to the 24-pin bulkhead connector for the operator station.



    Illustration 30g01954029

  1. After routing the harness, trim the harness to the desired length and add the 8T-8730 Connector Sockets . Install the wires in the J2 connector of the EAM Harness. Refer to Illustration 30. Find a suitable location in order to cut the harness. Then, install a 3-pin Deutsch connector on the cut harness. This action will allow future removal of the cab without removal of the pins from the 70-pin connector.

  1. Install any jumpers and other switch inputs in the J1 connector. Refer to ""Appendix A: UGM Guardian Switch Inputs" ".

  1. Install the J2 connector into the ECM.

  1. Activate the Guardian software with either temporary installation or permanent installation with factory passwords. Refer to ""Appendix B: Activating Guardian Software" ". Set the hours in Guardian to match the service meter hours of the machine.

  1. For machines that have the S/N:8XZ prefix, flash the new 355-6252 Monitor Software Gp into EMS. This action will be required for Guardian to function properly. The software is available from SIS as the 3556252.fls flash file.

Installation on the R2900G Load Haul Dump

Table 13
EAM is Already Installed    
Quantity     Part Number     Description    
1     347-3677     Wiring Harness    
4     6B-4540     Nut    
4     6D-3033     Socket Head Screw    
4     6V-9497     Hard Washer    
1     8D-9537     Dust Cap    
3     8T-8730     Connector Socket    
1     3S-8665     Clip    
5     5W-2226     Straps    
1     347-3675     Monitor Software Gp    

Table 14
EAM is Not Installed    
Quantity     Part Number     Description    
1     347-3678     Monitor Kit    
1     347-3677     Wiring Harness    
4     251-1863     Special Bolt    
1     251-1356     Control Harness As    
1     130-5300     Clip    
1     4P-8134     Clip    
5     5W-2226     Straps    
4     5M-3062     Bolt    
1     8T-4896     Hard Washer    
3 minimum     8T-8730     Connector Socket    
1     3S-8665     Clip    

Table 15
Contents of the 347-3678 Monitor Kit    
Quantity     Part Number     Description    
8     8T-9655     Isolation Mount    
4     145-0487     Spacer    
8     9N-0869     Hard Washer    
4     6B-4540     Nut    
4     6D-3033     Socket Head Screw    
4     6V-9497     Hard Washer    
1     8D-9537     Dust Cap    
2     8T-4224     Hard Washer    
1     347-3676     Monitor Service Electronic Control Module    



Illustration 31g01926116

(1) 347-3676 Monitor Service Electronic Control Module

(2) 8T-9655 Isolation Mount

(3) 145-0487 Spacer

(4) 9N-0869 Hard Washer

(5) 5M-3062 Bolt

(6) 8T-4224 Hard Washer

(7) 251-1356 Control Harness As

If the EAM is already installed, proceed to Step 3.

  1. Install the Guardian ECM under the seat per Illustration 31. Be sure to connect the harness to the breakout connector for the machine with the same wire colors and codes.

  1. Install the EAM harness that is shown in Illustration 31. Do not install the J1 connector or the J2 connector at this time. The download harness will be added to the J2 connector in Step 5.



    Illustration 32g02023153



    Illustration 33g02023157

  1. Install the 347-3677 Wiring Harness and the connector for the VIMS service port. The harness must be cut to the desired length after the routing is determined. Secure the harness with tie straps to the existing wiring. The connector should be placed in a convenient location. One example is on the dash next to the other download ports. Refer to Illustration 31. Another example of a convenient location is by using a 3S-8665 Clip and mounting the download port on an ECM mounting bolt. Refer to Illustration 33.

    1. To mount the service port on the dash, drill a 15/16 inch hole in the desired location.

    1. Secure the connector by using the 6D-3033 Socket Head Screws , 6V-9497 Hard Washers , and 6B-4540 Nuts .

  1. Add the 8T-8730 Connector Sockets to the 347-3677 Wiring Harness after cutting the harness to the proper length.



    Illustration 34g01926293

  1. Insert the 347-3677 Wiring Harness sockets into the unused sockets of the J2 connector of the 251-1356 Control Harness As . Refer to Illustration 10.

  1. Install any jumpers and other switch inputs in the J1 connector. Refer to ""Appendix A: UGM Guardian Switch Inputs" ".

  1. Install the J2 connector on the ECM.

  1. Secure the download harness with straps and clips.

  1. Activate the Guardian software with either temporary installation or permanent installation with factory passwords. Set the hours in the Guardian to match the service meter hours of the machine. Refer to ""Appendix B: Activating Guardian Software" ".

Appendix A: UGM Guardian Switch Inputs

VIMS Guardian for UGM includes the following switch inputs:

  • Collision detection switches

  • Activating the speed limit events for the machine

  • Snapshot

  • Datalogger

  • Auxiliary events for the user

These switch inputs require grounding to activate. Some switches have additional conditions in order to activate. Grounded pins are on J1 pins 2, 15, and 69 for activating speed limit events. There are other events that are intended to be grounded by a user installed switch. Examples of a user installed switch are an accelerometer or a relay combination for collision detection.

Note: Only two snapshots can be taken in VIMS. Snapshots will provide 5 minutes of data before the event and for 1 minute after the event. Once the snapshots are filled, the snapshots must be reset at the download. Other important machine events also trigger snapshots, such as low oil pressure, so snapshots need to be triggered sparingly.

Note: The datalogger will run up to 30 minutes. The starting and stopping of the datalogger is based on the switch status. This action assumes that the datalogger is not already set to run with VIMSpc, Communicator or HIM. There is only one datalogger.

Note: Additionally, there is a 3.5 amp 24 V driver for a warning lamp in order to indicate that service is needed. The 3.5 amp 24 V driver can also indicate level three active events, such as a plugged air filter, loss of engine coolant, or engine overspeed. The warning lamp is also activated when the two snapshots are full. The pin for the warning lamp is J1-58 and the return is J1-59.




Illustration 35g02023263

Table 16
Pin Identifications    
Pin ID     Parameter Name     Event Name     Speed On     Speed Off     Snapshot     On Delay     Condition    
J1-2     Ground                            
J1-15     Ground                            
J1-69     Ground                            
J1-3     Snapshot Switch     Same             X     1 second     RPM >400    
J1-4     Datalogger     Same                 0 seconds        
J1-5     Left Front Collision Switch     Same             X     1 second     RPM >400    
J1-16     Left Rear Collision Switch     Same             X     1 second     RPM >400    
J1-17     Right Front Collision Switch     Same             X     1 second     RPM >400    
J1-18     Right Rear Collision Switch     Same             X     1 second     RPM >400    
J1-26     Auxiliary Switch to Ground 1     Same                 1 second        
J1-27     Auxiliary Switch to Ground 2     Same                 1 second        
J1-34     Auxiliary Switch to Ground 3     Same                 1 second     RPM >400    
J1-35     Auxiliary Switch to Ground 4     Same                 1 second     RPM >400    
J1-60     Speed Limit Switch 1     Ground Speed     26 kph     23 kph      (1)     2 seconds        
J1-61     Speed Limit Switch 2     Ground Speed     28 kph     25 kph      (1)     2 seconds        
J1-62     Speed Limit Switch 3     Ground Speed     30 kph     27 kph      (1)     2 seconds        
( 1 ) The event is activated for a minimum of 10 seconds once the On speed is reached.

Appendix B: Activating Guardian Software

Permanent Installation




Illustration 36g01960009

  1. Go to the "Data Acquisition Module Configuration" screen in Cat ET. Select the configuration screen under "Service" or use F5.

    1. Select "Configuration Group 1" from "Data Acquisition Module". Then, enter the "Product ID" by double clicking the blank space under "Value". Enter the machine serial number.

    1. Make sure that the "Temporary Installation Status" is "Not Enabled". Change the "Data Acquisition System Installation Status" from "Not Installed" to "Installed". Then, you will get a screen that prompts you to enter factory passwords. Obtain factory passwords and complete the screen. Then press "OK". Refer to ""Obtaining Factory Passwords for the SEA" ".

      Note: This action will cause a charge for the SEA to be billed to the dealer.

    1. Refresh the "Data Acquisition Module Configuration" screen in Cat ET by pressing the F5 key on the laptop computer keyboard.

    1. Change the "Data Acquisition System Customer Enable Status" from "Not Enabled" to "Enabled". This option appears after the "Installation Status" is "Installed".

Temporary Installation

The temporary installation of the "Data Acquisition System" allows you to run Guardian temporarily without activating the SEA. The time that is remaining will show 15000 minutes or 250 hours initially.

  1. Go to the "Data Acquisition Module" configuration screen in Cat ET. Select the "Configuration" screen under "Service" or use F5.

    1. Select "Configuration Group 1" from the "Data Acquisition Module". Then, enter the "Product ID" by double clicking the blank space under "Value". Enter the machine serial number.

    1. Change the "Temporary Installation Status" to "Enabled". Now, you are allowed to connect with VIMSpc until the temporary time runs out. Then Guardian will still be operating, but you will get a connection error message "22017" displayed in VIMSpc, and connection will not occur. Files cannot be downloaded after the time expires until the SEA is activated. Refer to ""Permanent Installation" ".

After Installation

  1. Connect the 127-9797 Cable As to the connector for the VIMS service port. The service port is the 5-pin "cannon" plug that is shown in Illustration 32. Then turn the key to the ON position.

  1. Open VIMSpc in order to assign an equipment number, the date, time, and SMH.

    1. Select "Configure". Then change the equipment number. Reset the date, the time, and the SMH. On some machines, the SMH will automatically update in order to match the machine. If not, then change the date, the time, and the SMH manually.

    1. Get a download at this point. Include a few minutes of the datalogger operation during the download. This action gives a reference point for VIMSpc, which prefers to have at least two downloads for some reports.

Obtaining Factory Passwords for the SEA




Illustration 37g01960158

  1. Add the Product ID (machine serial number), if the information was not added previously.

  1. Bring up the password entry screen in Cat ET, if the password entry screen is not already showing. Under "Information" click "View Passwords". The product identification should appear on the screen. Refer to Illustration 37 for an example.

  1. Copy the screen and obtain factory passwords from the link that is shown in Illustration 37. Reason code 111 authorization is required to obtain Guardian factory passwords.

ReferenceFor further instruction with factory passwords and software enabled attachments, refer to Special Instruction, REHS1238, "Obtaining Factory Passwords and Software Enabled Attachments".

Flashing Guardian

Flashing Guardian is accomplished by using Winflash with Cat ET. This action is necessary for EAM equipped machines or for software updates. The 347-3675 Monitor Software Gp is available from SIS as the 3473675.fls flash file.




Illustration 38g02023236

Note: During the process of flashing Guardian, the message in Illustration 38 will appear. Simply select "OK" in order for the flash to continue successfully.

Note: During the process of flashing over the EAM software, a warning will be given in Cat ET. This warning will indicate that the wrong software is being flashed. This warning is normal. Select "Continue" in order to resume flashing.

Note: When updating Guardian software, the histograms and cumulatives should be reset with VIMSpc before reflashing. The reset option is enabled in the VIMSpc "Setup System Preferences" menu. Normally, the "Setup System Preferences" are not reset in order to maintain data continuity. When flashing Guardian, a reset is needed to show that the data is starting at zero again.

Note: Flashing EAM software over Guardian software is not recommended. If needed, try flashing Guardian again, but unplug the cable during the flash. Then try EAM software. If this action is not successful, contact VIMS Guardian technical assistance.

Technical Assistance

For VIMS / DSN Support contact your local technical communicator.

Information System:

2009/04/27 Preferred Positions for Mechanically Attached Wear Plates (MAWPS) {6100, 6120, 6820}
2009/07/27 A New Fuel Line Is Now Used on D9T Track-Type Tractors {1274}
Relocation of the Rear Disconnect Switch {1411}
3500B and 3500C Marine Engines Alternator and Regulator
2009/04/27 Proper Long Term Storage of Caterpillar Products {0355, 1000, 7000}
C11, C13, C15, and C18 Industrial Engines ECM - Replace
D5R Track-Type Tractor Hydraulic System Oil Contains Air
C9.3 Engine for Wheel Tractor-Scrapers Electrical Connectors
D5R Track-Type Tractor Hydraulic System Has Unusual Noise
C15 and C18 Industrial Engines Temperature Sensor (DPF) - Remove and Install - Clean Emissions Module
980H Wheel Loader Power Train Transmission Planetary - Disassemble - Heavy Duty
D5R Track-Type Tractor MID 039 - CID 2671 - FMI 06
C15 and C18 Industrial Engines Flame Detection Temperature Sensor - Remove and Install - Clean Emissions Module
A New Flange Assembly For the Torque Converter On the D10T Is Now Used{3101}
C13 Tier 4 Final Engines Lubrication System
2009/05/04 A Repair Kit for the Magnet is Now Available for the AccuGrade CD700 Display {7490}
D5R Track-Type Tractor Hydraulic System Steering - Calibrate
C9.3 Engines for Caterpillar Built Machines Electrical Connectors - Inspect
C27 and C32 Engines for Caterpillar Built Machines Valve Mechanism Cover - Remove and Install - C32
C9.3 Engines for Caterpillar Built Machines ECM Software - Install
C13 Tier 4 Final Engines General Information - C13 Engines
C9.3 Engines for Caterpillar Built Machines Injector Trim File - Install
Field Installation of the Payload Monitor Gp Kits{7494}
Relocation Of The Expansion Tanks For The Implement Hydraulic System{1354, 5057, 5505}