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CATERPILLAR ELPHINSTONE PTY. LTD.

      FOR M N O . 9EP162 9EP16222-00 00 FO R U SE IN SE R VIC E TR AIN IN G G U ID E:C EPL R160 R1600 0 - JAN UA RY 1998

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Service Training Module Caterpillar Monitoring System CATERPILLAR ELPHINSTONE PTY. LTD.

List of Contents Caterpillar Elphinstone R1600 LHD List of Contents ................................. ................................................. ................................. ................................. ................................ ............................. ............................ ................................ ............................2 ...........2 Important Safety Notice ................................. .................................................. ................................. ................................ ................................. ........................... .......................... .................................3 .................3 R1600 LHD Caterpillar Monitoring System Overview ...................... .................................. ........................ ....................... ....................... ....................... ............................ ................... 4 Introduction Introduction ................................. .................................................. ................................. ................................ ................................. ................................. .................................. .................................. ............................5 ............5 Caterpillar Electronic Monitoring System Block Diagram Di agram ........................... ........................................ ........................... ............................ ...................... ........................ .................. 6 Caterpillar Caterpillar Monitoring Monitoring System Warning Warning Categories................................ Categories................................................ ................................. ................................. ................................ ...................... ......7 7 Main Display Module ........................... ......................................... ........................... ........................... ............................ ........................... .................................. ..................................... ...............................8 ...............8 Caterpillar Monitoring System Gauge Cluster Module ..................... ............................... .................... .................... ..................... ..................... ..................................10 ........................10 Caterpillar Monitoring System Speedometer/Tachometer Module ...................... ............. ................... ................... .................. ................... ................... .................. ......... 11 Dash Indicators .......................... ....................................... ........................... ............................ ........................... ........................... ............................ ........................................ .......................................... ................... ... 12 Dash Switches ................................. .................................................. ................................. ................................ ................................. ................................ ............................... ................................ ........................ ........13 13 Caterpillar Monitoring System Input Components ................... .............................. ..................... .................... .................... ..................... ........................................ ............................... .. 14 Switch-Type Switch-Type Inputs .......................... ........................................ ........................... ........................... ............................ ........................... ........................... ...................................... ........................................15 ................15 Sender-T Sender-Type ype Inputs Inputs ................................ ................................................ ................................. ................................. ................................. ................................. ................................. .................................17 ................17 Sensor-Type Sensor-Type Inputs .......................... ........................................ ........................... ........................... ............................ ........................... ........................... .......................... ............................ ........................... ...........18 18 Caterpillar Monitoring System Output Components .................... .............................. ..................... ..................... .................... .................... .................................... ............................ .. 20 Caterpillar Monitoring System Main Display Module - Alert Indicators ........................... ........................................ ........................... ............................ ................. ... 21 Caterpillar Monitoring System Main Display Module - N umeric Display Area ....................... ................................... ........................ .......................... .............. 23 Caterpillar Monitoring System Action Lamp and Action Alarm .......................... ....................................... ........................... ............................ ..............................24 ................24 Caterpillar Monitoring System Power Power Suppliers .................... .............................. ..................... ..................... .................... .................... .................... ............ ....................... .......................25 25 Gauge Cluster and Speedometer/Tachometer Speedometer/Tachometer Modules ..................... ............ ................... ................... ................... ................... ................... ................... ................... ............... ..... 26 Caterpillar Monitoring System ....................... .................................. ....................... ........................ ........................ ....................... ....................... ....................................... ...................................... ...........27 27 Input Switches, Sensors and Senders ........................... ......................................... ........................... ........................... ............................ ....................................... .................................... ...........27 27 Modes Of Caterpillar Monitoring System Operation ....................... ................................... ........................ ....................... ....................... .............................. ............................. ...........30 30 Operator Operator Modes ............................... ............................................... ................................. ................................. ................................ ................................. .................................. .................................. ...................... ..... 31 Service Modes ............................... ............................................... ................................. ................................. ................................ ................................. .......................... ......................... ................................32 ................32 Diagnostic Fault Codes ........................... ......................................... ............................ ........................... ........................... ............................ ............................. ................................ ..............................35 .............35 Self Test Operation .......................... ....................................... ........................... ............................ ........................... ........................... ...................................... ......................................... ..............................36 .............36 Diagnostic Troubleshooting Procedure ................... .......... ................... ................... ................... ................... ................... ................... ................... ................... ................... ................... .............. ..... 38 Troubleshooting Tips - FMI 02 ........................... ........................................ ........................... ............................ ........................... ........................... .................................... ....................................40 ..............40 Troubleshooting Tips - FMI 03 ........................... ........................................ ........................... ............................ ........................... ........................... .................................... ....................................42 ..............42 Troubleshooting Tips - FMI 04 ........................... ........................................ ........................... ............................ ........................... ........................... .................................... ....................................43 ..............43 Troubleshooting Tips - FMI 05, FMI 06 & FMI 08 .......................... ........................................ ............................ ........................... ...................................... .................................... ...........44 44 Connect Service S ervice Box to Service Connector(Practical Task) Task) .......................... ........................................ ............................ ........................... ............................... .................... .. 45 Theory Assessment ................................ ................................................ ................................ ................................. ................................. ............................. ........................... ............................... ...................... ..... 46 Theory Assessment Answers ................................ ................................................. ................................. ................................. ................................. ........................ ......................... ......................... ........48 48 Serviceman’s Serviceman’s Handouts ................................ ................................................. ................................. ................................. ................................. ................................ .................................. .................... .. 49 -51 Page 2


List of Contents Caterpillar Elphinstone R1600 LHD List of Contents ................................. ................................................. ................................. ................................. ................................ ............................. ............................ ................................ ............................2 ...........2 Important Safety Notice ................................. .................................................. ................................. ................................ ................................. ........................... .......................... .................................3 .................3 R1600 LHD Caterpillar Monitoring System Overview ...................... .................................. ........................ ....................... ....................... ....................... ............................ ................... 4 Introduction Introduction ................................. .................................................. ................................. ................................ ................................. ................................. .................................. .................................. ............................5 ............5 Caterpillar Electronic Monitoring System Block Diagram Di agram ........................... ........................................ ........................... ............................ ...................... ........................ .................. 6 Caterpillar Caterpillar Monitoring Monitoring System Warning Warning Categories................................ Categories................................................ ................................. ................................. ................................ ...................... ......7 7 Main Display Module ........................... ......................................... ........................... ........................... ............................ ........................... .................................. ..................................... ...............................8 ...............8 Caterpillar Monitoring System Gauge Cluster Module ..................... ............................... .................... .................... ..................... ..................... ..................................10 ........................10 Caterpillar Monitoring System Speedometer/Tachometer Module ...................... ............. ................... ................... .................. ................... ................... .................. ......... 11 Dash Indicators .......................... ....................................... ........................... ............................ ........................... ........................... ............................ ........................................ .......................................... ................... ... 12 Dash Switches ................................. .................................................. ................................. ................................ ................................. ................................ ............................... ................................ ........................ ........13 13 Caterpillar Monitoring System Input Components ................... .............................. ..................... .................... .................... ..................... ........................................ ............................... .. 14 Switch-Type Switch-Type Inputs .......................... ........................................ ........................... ........................... ............................ ........................... ........................... ...................................... ........................................15 ................15 Sender-T Sender-Type ype Inputs Inputs ................................ ................................................ ................................. ................................. ................................. ................................. ................................. .................................17 ................17 Sensor-Type Sensor-Type Inputs .......................... ........................................ ........................... ........................... ............................ ........................... ........................... .......................... ............................ ........................... ...........18 18 Caterpillar Monitoring System Output Components .................... .............................. ..................... ..................... .................... .................... .................................... ............................ .. 20 Caterpillar Monitoring System Main Display Module - Alert Indicators ........................... ........................................ ........................... ............................ ................. ... 21 Caterpillar Monitoring System Main Display Module - N umeric Display Area ....................... ................................... ........................ .......................... .............. 23 Caterpillar Monitoring System Action Lamp and Action Alarm .......................... ....................................... ........................... ............................ ..............................24 ................24 Caterpillar Monitoring System Power Power Suppliers .................... .............................. ..................... ..................... .................... .................... .................... ............ ....................... .......................25 25 Gauge Cluster and Speedometer/Tachometer Speedometer/Tachometer Modules ..................... ............ ................... ................... ................... ................... ................... ................... ................... ............... ..... 26 Caterpillar Monitoring System ....................... .................................. ....................... ........................ ........................ ....................... ....................... ....................................... ...................................... ...........27 27 Input Switches, Sensors and Senders ........................... ......................................... ........................... ........................... ............................ ....................................... .................................... ...........27 27 Modes Of Caterpillar Monitoring System Operation ....................... ................................... ........................ ....................... ....................... .............................. ............................. ...........30 30 Operator Operator Modes ............................... ............................................... ................................. ................................. ................................ ................................. .................................. .................................. ...................... ..... 31 Service Modes ............................... ............................................... ................................. ................................. ................................ ................................. .......................... ......................... ................................32 ................32 Diagnostic Fault Codes ........................... ......................................... ............................ ........................... ........................... ............................ ............................. ................................ ..............................35 .............35 Self Test Operation .......................... ....................................... ........................... ............................ ........................... ........................... ...................................... ......................................... ..............................36 .............36 Diagnostic Troubleshooting Procedure ................... .......... ................... ................... ................... ................... ................... ................... ................... ................... ................... ................... .............. ..... 38 Troubleshooting Tips - FMI 02 ........................... ........................................ ........................... ............................ ........................... ........................... .................................... ....................................40 ..............40 Troubleshooting Tips - FMI 03 ........................... ........................................ ........................... ............................ ........................... ........................... .................................... ....................................42 ..............42 Troubleshooting Tips - FMI 04 ........................... ........................................ ........................... ............................ ........................... ........................... .................................... ....................................43 ..............43 Troubleshooting Tips - FMI 05, FMI 06 & FMI 08 .......................... ........................................ ............................ ........................... ...................................... .................................... ...........44 44 Connect Service S ervice Box to Service Connector(Practical Task) Task) .......................... ........................................ ............................ ........................... ............................... .................... .. 45 Theory Assessment ................................ ................................................ ................................ ................................. ................................. ............................. ........................... ............................... ...................... ..... 46 Theory Assessment Answers ................................ ................................................. ................................. ................................. ................................. ........................ ......................... ......................... ........48 48 Serviceman’s Serviceman’s Handouts ................................ ................................................. ................................. ................................. ................................. ................................ .................................. .................... .. 49 -51 Page 2


IMPORTANT IMPORTANT SAFETY SAFE TY NOTICE The course content and subject matter is current at the time of publication. Specifications, torques, pressure settings, measurements, adjustments, illustrations and other items can change at any time. Always refer to the machine specific service manual, parts book and updates up dates prior to performing repairs and adjustments. Caterpillar Elphinstone Pty Ltd cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in this module are therefore not inclusive. If a procedure, tool, device or work method not specifically recommended by Caterpillar Elphinstone Pty Ltd is to be used, you must satisfy yourself that it is safe for yourself and others. You should also ensure that the machine will not be damaged or made unsafe by the procedures you choose.

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R1600 LHD Caterpillar Caterpill ar Monitoring System OVERVIEW Module Description Aims: T he aim o f th is tr trainin g m o d u le is to to p ro vid e p articip an ts w ith th e kn kno o w led g e and sk ski ills ne n ece cessa ssar ry to u se th e C at aterpi erpillar M o nito rin g S ystem as a d iag no stic to o l.

Nominal Duration: T h e m o d ule is d esig ne ned d so th at m o sto fthe traine nees es w illac acq q uire t th he k kno no w led g e in o ne 4 ho ur sessio n. T he len eng g th o fthe tim e ac act tu ally t tak aken en to co m p let ete e the m o d u le w illvar vary y d ep en d ing o n fac act to rs su ch as th e tea each chi in g m et eth h o d u sed , th e traine e’ s kno w led g e an d sk ski ills a at ten try,and th e in d ivid u altrainee’ sa ab b ility.

Pre-Requisites: M ec echa han n ica cal ltrad es esm m an - sho u ld h ave co m p let eted ed a B asic E lec ect trica cal lTrainin g P ro g ram (p refer err red b u tn o tes esse sent nti ial).

Learning Outcomes: A s a res esu ulto fst stu u d yin g this m o d ule, p articip an ts s sh h o u ld b e ab le to : 1 .D em o ns nst trat ate e an u n d er erst stan and d in g o fth e fun ct cti io n and a nd o p er erat ati io n o fth e C at ater erp p illar M o n ito rin g S yst ystem em an and d its co m p o n en ts. 2 .U se th e C aterpillar M o nito rin g S yst yste em as a d iag no st sti ic t to o o l. 3 .U se the S ervice M an u alan d elect ctr rica cal lsc sch hem at ati ic t to o tro u b le s sh ho o tth e C at aterpi erpillar M o n ito ring S yst yste em elec tricalsys syst tem .

Assessment: Tasks: P ar art a rt A : P rac act tica cal lTest Tests s P ar art t B : Th eor eo ry A ssessm ent (M ultip le C hoi ho ice Q uest uesti ions) on s)

Resource Requirements: •R 160 1600 0 LH LH D • Fu lly eq uip p ed classr assro o om w ith w hite b oa oar rd an and d o ver verhe head ad p ro jec ect to r. • Training M o d ule an and d ha hand nd o ut m at ater eri ial. • D iag no stic scrol scrollb o x. • S ervi ervice M anual an ual. • P ar art ts B oo k. • Too To o ls fo r p pr racticaltasks. sk s.

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3

1

2

1

Introduction • Introd Introduct uction ion::

T h is p re sen se n ta tio n d iscu sc u sse ss e s th th e C a te rp illa r M o n ito rin g S yst yste em inst nstal alled on the R 16 00 LH D .

• The Caterpillar Caterpillar Monitoring Monitoring System consists of:

T h e C ate aterp illar M o n ito rin g S yst ystem em co n sists sts of o f th ree d isp lay m o d u les. es . T h e m ain d isp lay m o d u le (1 ) h as ten ind ivid ualin d icato rs an a nd a d ig ital nu num m er eri ic read o ut ut. . Th e speed spe ed om et eter er/ /tach achom om et eter er m od ule (2) ha has s a tacho ac ho m eter eter, , a d ig ital spee sp eed d read ea d o ut and an d a gea g ear r read ea d o ut. ut. T he g aug au g e clu ste ster m o d u le (3 ) co nsists sts o f fo u r g au g es. es .

(1) Main display module (2) Speedo/tacho module (3) Gauge cluster module

• The Caterp Caterpilla illarr Monitorin Monitoring g System has two functions: • Show machine machine sys system tem status information • Show diagnostic diagnostic information information

T h e C ater aterp p illar M o n ito rin g S yst ystem em h as tw o m ain fu n cti ctio n s. T h e C ater aterp p illar M o n ito rin g S yst ystem em g ives ves th e op o p erat erato o r co n tin u o u s feed b ack ac k o n th th e stat statu u s of o f var vario u s m ach ac h in e syst sys tem s. T h e C aterp erp illar M o n ito rin g S yst ystem em also g ives ves th th e S ervi ervice T ech ec h n ician d iag n o sti stic in fo rm ati atio n to ass ssi ist in tro u b le sho sh o o tin g the C aterp illar M o n ito rin g S yst yste em and the m ach ac h in e el e lect ec trical syst system em .

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VARIOUS SWITCHES

VARIOUS

ACTION

MAIN

SENSORS

LAMP

DISPLAY MODULE

VARIOUS

GAUGE CLUSTER

SENDERS

MODULE DISPLAY AREA

SERVICE

SPEEDO/TACHO

CONNECTOR

MODULE

HARNESS CODE

ACTION

CONNECTOR

ALARM

CAT DATA LINK TO OTHER CONTROLS

2

Caterpillar Electronic Monitoring System Block Diagram • The electronic control for the Caterpillar Monitoring System is the main display module

The electronic control for the C aterpillar M onitoring S ystem is the m ain display m odule. The m ain d isplay m odule has inp uts and outputs. The inputs to the m ain display m odule provide inform ation on the status of various m ach ine system s, diag nostic service inform ation and C aterpillar M onitoring S ystem setup inform ation. The inputs are: the C at D ata Link, sw itch es, sensors, senders, the service connector and the harness code conn ector. T he o utp uts are: the m ain d isp lay m o d ule d isp lay a rea , the speedom eter/tacho m eter m odule, the gauge cluster m odule, the action lam p and the action alarm . The m ain display m odule also outputs inform ation via the C at D ata Link.

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1

2

4 15 10

P

20 AUT

5

IBA

25 X100

0

MPH km/h

30

44

3

3

Caterpillar Monitoring System Warning Categories • Caterpillar Monitoring System Components: (1) Alert indicators (Main display module) (2) Speedo/tacho module (3) Gauge cluster module (4) Action lamp • Three Warning Categories: • Category 1: An alert indicator flashes or a gauge registers in the red area • Category 2: An alert indicator flashes and/or a gauge registers in the red area and the action lamp will flash • Category 3: An alert indicator flashes, the action lamp flashes and the action alarm will sound

The C aterpillar M onitoring S ystem has three w arning categ ories or levels. The first category requires only operator aw areness. The second w arning categ ory req uires o perator resp onse. The third category req uires im m ed iate shutdow n of the m achine. W arning C ateg ory 1 - an alert indicator (1) on the m ain display ategory m odule flashes an d/or the fuel gau ge (3) reg isters in the red area. N o im m ediate action is required by the operator (requires servicing by the end of the sh ift). W arning C ateg ory 2 - an alert indicator (1)flash es and/or a gauge (3) ategory registers in the red area. T he action lam p (4) w illalso flash. M achine operation should be chang ed (to red uce excessive tem perature in on e or m ore system s) or m aintenance p erform ed . W arning C ateg ory 3 - an alert indicator (1) flashes, the action lam p ategory (4) flashes and the action alarm (located behind the d ash panel) w ill soun d. The o perator sho uld p erform an im m ed iate safe engine shutdow n.

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1

P

IBA

2

MILES OR KM

170 4

Main Display Module • The outputs in the main display module are ten alert indicators and a numeric display area • The main display module is the heart of the Caterpillar Monitoring System • The main display module receives information from the switches, sensors and other electronic controls on the machine via the CAT ® data link

The m ain display m odule co ntains the processing functions for the system and m ust be installed for the m onitoring system to operate. The m ain d isplay m odule is located in the d ash and co ntains a section that disp lays ten alert indicators (1)and a b ottom section that disp lays a digital readout (2). The alert indicator section (1) uses inputs from sw itches, sensors, senders and the C A T ® data link to alert the o perator of abnorm al m achine cond itions. The num eric display area (2) provides a six d igit readout that show s: m ac hine o p erational ho urs (service m eter), m ac hine d istan ce (odom eter), tacho m eter and d iag no stic co des. The o perator can select w hat inform ation to show on the display area.

Continued

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• The main display module utilizes two communication links - CAT Data Link and Display Data Link • The CAT Data Link is used to communicate with other electronic controls - the CAT Data Link allows both inputs and outputs to be processed • The Display Data Link communicates information back and forth between the main display module, the gauge cluster module and the speedometer/tachometer module

The m ain disp lay m odule utilizes a pair of co m m unication links to provide a com m unication p ath b etw een o ther electronic controls and to also provide a path for the various d isp lay m odules. The C A T D ata Link is used to co m m un icate w ith o ther electronic controls. The C A T D ata Link is bidirectional, w hich allow s both inputs and outputs to be com m unicated. The other co m m unication p ath is the D isp lay D ata Link. This link co m m un icates inform ation b ack and forth b etw een the m ain d isplay m od ule, the g auge cluster m od ule and the sp eed om eter/tach om eter m od ule.

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2

1

4

3

5

Caterpillar Monitoring System Gauge Cluster Module • The gauge cluster module consists of four gauges: (1) Engine coolant temperature (2) Transmission oil temperature (3) Hydraulic oil temperature (4) Fuel level • The main display module receives inputs from the temperature sensors and the fuel level sender

The gauge cluster m odule consists of four gauges w hich display engine coolant tem perature (1), transm ission oil tem perature (2) hyd raulic oil tem perature (3) and fuel level (4). The gauge cluster is con sidered an outpu t com ponent. The m ain d isplay m odule receives inp uts from the co olant tem perature sensor via the C at D atalink for gau ge (1), the transm ission tem perature sensor for gauge (2), the h ydrau lic tem perature sensor for gau ge (3) and the fuellevelsend er for gauge (4). The m ain display m odule u ses these inputs to calculate the value show n o n the gauges. N orm al operating range values are show n b y the w hite area on the gaug e. A bno rm al range values are show n by the red area on the gauge.

• The main display module sends information to the gauge cluster module to show values on the gauges

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15

3

10

20

5

25 X100

0 1

MPH km/h

30 2 6

Caterpillar Monitoring System Speedometer/Tachometer Module • Speedo/Tacho Module: (1) Speed readout (2) Actual gear readout (3) Tachometer readout • The speed readout shows ground speed in km/h (MPH) • The gear readout shows the transmission actual gear which is engaged • The tachometer shows engine speed in RPM

The sp eedom eter/tacho m eter display m odule consists of a speed readout (1), an actual gear readout (2) an d a tachom eter read out (3). The sp eed readout (1) co nsists of three digits and show s m achine grou nd speed in km /h (M P H ). The m ain d isplay m od ule calculates speed using the inform ation from the C A T data link. The gear readout (2) co nsists o f tw o digits that show the transm ission actual gear w hich is en gag ed . The left digit show s the actual gear; such as “ 1” ,“ 2” ,“ 3” , etc. The right digit show s the direction selected; “ F” ,“ N ”or “ R” . Th e tachom eter (3) show s engine speed in R P M . The en gine sp eed is determ ined using inform ation sen t to the m ain display m odule over the C A T data link.

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1

2

3

AUT

4

5

7

Dash Indicators • Dash Indicators: (1) Action lamp (2) Auto-lubrication (3) Exhaust back pressure (4) Residual brake pressure (5) Ride control

The five indicators to the right of the m ain disp lay m odule are: (1) A ction Lam p - lights w hen a category 2 or 3 w arning is active. (2) A uto-lubrication - Th e indicator illum inates w hen the au tom atic lubrication system is in operation. (3) Exhaust back p ressure - ind icates high exhaust back p ressure. (4) R esidual brake p ressure - The indicator illum inates w hen the service brake is applied or w hen there is residual brake oil pressure in the w heel brakes. (5) R ide co ntrol - The indicator illum inates w hen the ride co ntrol system is in operation

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1

3

2

KG

4

5

6

7

8

8

Dash Switches • Dash Switches: (1) Front lights (2) Rear lights (3) Remote control (4) Bucket positioner (5) Loadrite auto add (6) Ride control (7) Caterpillar Monitoring System Operator mode scroll (8) Torque converter lockup

There are eight sw itches on the dash: (1) Front Lights. (2) R ear Lights. (3) R em ote C ontrol. (4) B ucket P ositioner. (5) Load rite A uto A dd. (6) R ide co ntrol. (7) C aterpillar M onitoring S ystem O perator M ode S croll: This sw itch allow s the operator to scroll through the O perator M od e show n in the m ain d isplay m od ule num eric d isplay area. (8) Torque co nverter lockup.

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Input Components 9

Caterpillar Monitoring System Input Components • The inputs tell the main display module how to operate and the status of the machine systems • Three types of direct inputs: switch-type, sensor-type and sender-type

The C aterp illar M onitoring S ystem m ain d isp lay m odule m ake s decisions based up on the inputs from the various sw itches, sensors and senders installed on the m achine, as w ell as data from the C A T D ata Link. The inputs tellthe m ain d isplay m odule how to operate and the status of the m achine system s. Three typ es o f direct inputs exist: sw itch-typ e, senso r-typ e and sender-type.

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Switch-Type Inputs 10

Switch-Type Inputs • Three different categories of switch-type inputs to the Caterpillar Monitoring System main display module: • Uncommitted • Programming • Service switch inputs • The uncommitted switch inputs are used to operate the ten alert indicators that are part of the main display module

The C aterpillar M onitoring S ystem uses three d ifferent categories of sw itch -type inputs to the m ain disp lay m odule. They are identified as: U ncom m itted , P rog ram m ing and S ervice sw itch inp uts. U ncom nc omm m itted sw itch inp uts: Th e uncom m itted sw itch inp uts are nco used to operate the ten alert indicators that are part of the m ain d isplay m od ule. Th ese inp uts m ay b e prog ram m ed to w ork indep enden tly or in co m bination w ith other types of inputs (sender/ sensor)to p rovide w arning inform ation to the operator. D uring norm al operating co nditions, the sw itch co ntacts are grounded an d the alert indicators are O FF . If a sw itch co ntact opens because of a m achine condition or sw itch m alfunction, the alert indicator corresp onding to that particular sw itch w ill beg in FLA S H IN G to indicate an ab norm al co ndition an d provide the operator w ith the ap propriate w arning categ ory. The un co m m itted sw itches are u sed prim arily for m onitoring pressures (e.g. brake oil pressure sw itch).

Continued

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• The programming switch inputs tell the main display module how to operate • The two service switch inputs control the machine setup, mode of operation and certain diagnostic functions of the main display module

P rogram rog ram m ing sw itch inp uts: The program m ing sw itch inp uts tellthe m ain d isplay m odule how to o perate. These inp uts corresp ond to the op en or grounded cond ition of the m achine harness code connector. A specific harness co de p attern is used to identify the m achine m odel in w hich the C aterpillar Electronic M onitoring S ystem is installed. The m ain d isplay m odule uses specific m achine m odel inform ation (such as engine size, idle sp eed, etc.) to correctly m ake decisions. S ervice sw itch inp uts: The tw o service sw itch inputs co ntrol the m achine setup , m ode o f operation and certain diag nostic functions of the m ain d isplay m odule. The tim ing and state (open /grounded )ofthe service sw itch inputs co ntrolthe above m entioned functions.

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Sender-Type Inputs 11

Sender-Type Inputs • Two different types of senders provide inputs to the main display module: - 0 to 240 ohm senders - 70 to 800 ohm senders • 0 to 240 ohm senders measure a specific system resistance value which corresponds to a specific system condition - a typical system using this type of sender is the fuel level

The C aterpillar M onitoring S ystem uses tw o differen t types of senders to p rovide inputs to the m ain d isp lay m odule. They are identified as: 0 to 2 40 ohm senders,and 70 to 8 00 ohm senders. 0 to 24 0 oh 240 ohmm senders: sen d ers: These send ers m easure a sp ecific system resistan ce value w hich co rresponds to a sp ecific system co ndition. A typ ical system using this typ e o f sender is the fuel level. The output resistance is m easured at the m ain d isplay m odule and the value co rresponds to the dep th of fuelin the tank. The m ain display m odule calcu lates the resistan ce an d disp lays the output on one of the gau ges in the gaug e cluster m od ule. The 0 to 2 40 ohm send er m ay be program m ed to operate a gauge, an alert ind icator, or both a gauge and alert indicator. 70 to 80 8000 ohm senders: sen d ers: (N ot currently used on R 16 00 L H D )

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Sensor-Type Inputs 12

Sensor-Type Inputs • Two different types of sensors provide inputs to the main display module: - pulse width modulation (PWM) sensors - frequency sensors • PWM sensors measure changing machine conditions - the main display module receives and processes a “duty cycle” signal from the sensor and sends the information to one of the gauges in the gauge cluster module

The C aterpillar M onitoring S ystem uses tw o differen t types of sensors to provide inputs to the m ain disp lay m odule. They are identified as: pulse w idth m odulation (P W M ) and freq uency senso rs. P W M se nso rs: Th ese sensors are used in the m onitoring system to senso m easure chang ing m ach ine co nd itions. Th e m ain display m od ule receives and processes a “ duty cycle”signal from the sensor an d send s the inform ation to one o f the g auges in the g auge cluster m odule for disp lay to the o perator. A typicalsystem using this type o f sensor is the hydrau lic tem perature.

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• Frequency sensors measure speed - the main display module receives and processes an AC frequency (Hz) signal from the transmission electronic control module via the sensors and sends the information to the speedometer/tachometer module • Frequency sensors are used to measure engine speed and transmission output speed the signals come via the Cat Data Link

Freq uen cy se senso nso rs: These senso rs are used in the m onitoring system to m easure speed . T he m ain display m od ule receives and processes an A C freq uency (H z) signal from the transm ission electronic control m odule via the senors and sends the inform ation to the speedom eter/ tacho m eter m od ule. Frequency sensors are used on the LH D s to m easure engine sp eed and transm ission output speed .

C ontact 30 is d ed icated to the freq uen cy (H z)input from the alternator “ R ”term inal. The frequency of the alternator is used to determ ine the condition of the m achine electrical charging system . The alternator freq uency is also used in co njunction w ith other inputs to determ ine w hen the engine is running .

N O TE O N C aterp illar M on em IN P U TS : O ther electronic oniitoring S yst ystem controls com m unicate inform ation to the m ain display m odule and that inform ation is d isp layed in the num eric disp lay area of the m ain display m odule. The C aterpillar M onitoring S ystem does not diag nose m alfunctions in other electronic controls, but w ill disp lay fault codes gen erated by other electronic controls. The service technician m ust consu lt the appropriate service literature for the sp ecific electronic control for diagnostic inform ation.

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Output Components 13

Caterpillar Monitoring System Output Components • The Caterpillar Monitoring System outputs notify the operator of the status of machine systems

The C aterpillar M onitoring S ystem outputs are used to notify the operator of the status of the m achine system s. The o utputs are: the m ain disp lay m odule disp lay, the disp lay d ata link, the alert indicators, the action lam p and the action alarm .

• The Caterpillar Monitoring System outputs are: - the main display module display - the display data link - the alert indicators - the action lamp - the action alarm

The categ ories of w arning associated w ith the m onitoring system outputs is d iscussed earlier.

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CMSTG

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