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Global Dealer Learning

320/320GC/323 hydraulic excavator


Electronic Control System and Monitor
Module 1 - Text Reference

SERV2110-01

CAT, CATERPILLAR, their respective logos, ACERT, “Caterpillar Yellow” and the POWER EDGE
trade dress, as well as corporate and product identity used herein, are trademarks of Caterpillar
and may not be used without permission. © 2017 Caterpillar Inc. All Rights Reserved.
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SERV2110-01 - 11/17 -2- Module 1 - Electronic Control System and Monitor

TABLE OF CONTENTS
Safety Briefing��������������������������������������������������������������������������������������������������������������������� 3
Learning outcomes������������������������������������������������������������������������������������������������������������ 4
INTRODUCTION������������������������������������������������������������������������������������������������������������������������� 5
MACHINE COMMUNICATIONS�������������������������������������������������������������������������������������������������� 6
PRIMARY MACHINE ECM INPUTS/OUTPUTS������������������������������������������������������������������������� 8
SECONDARY MACHINE ECM InputS/Outputs����������������������������������������������������������������� 10
body control module (bcm) inputs/outputs���������������������������������������������������������� 12
BCM - MONITOR WAKE UP����������������������������������������������������������������������������������������������������� 14
COMPONENTS BEHIND CAB�������������������������������������������������������������������������������������������������� 15
PRODUCT LINK������������������������������������������������������������������������������������������������������������������������ 16
Engine Speed Control Function���������������������������������������������������������������������������������� 18
Automatic Engine Speed Control (AEC) Function������������������������������������������������� 19
Delayed Engine Shutdown Function������������������������������������������������������������������������� 20
Engine Idle Shutdown Function���������������������������������������������������������������������������������� 21
ELECTRIC FANS (E-FANS) CIRCUIT�������������������������������������������������������������������������������������� 23
KEEP ALIVE CIRCUIT (C4.4 TIER 4 ONLY)����������������������������������������������������������������������������� 24
MONITOR DISPLAY������������������������������������������������������������������������������������������������������������������ 25
POWER MODES����������������������������������������������������������������������������������������������������������������������� 27
EVENT INDICATOR AREA�������������������������������������������������������������������������������������������������������� 28
USB PORT ON MONITOR�������������������������������������������������������������������������������������������������������� 30
RIGHT SWITCH PANEL������������������������������������������������������������������������������������������������������������ 31
MONITOR STARTUP���������������������������������������������������������������������������������������������������������������� 33
MONITOR ACCESS LEVELS��������������������������������������������������������������������������������������������������� 35
APPLICATIONS MENU (MAIN MENU)������������������������������������������������������������������������������������� 36
FUNCTIONS MENU������������������������������������������������������������������������������������������������������������������ 38
SETTING MENU - DISPLAY SETTING������������������������������������������������������������������������������������� 40
SETTING MENU - INFORMATION������������������������������������������������������������������������������������������� 41
SETTING MENU - MACHINE SETTING����������������������������������������������������������������������������������� 42
SETTING MENU - OPERATOR SETTING�������������������������������������������������������������������������������� 44
SETTING MENU - SERVICE���������������������������������������������������������������������������������������������������� 45
Learning Outcomes Review������������������������������������������������������������������������������������������� 46
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SERV2110-01 - 11/17 -3- Module 1 - Electronic Control System and Monitor

Safety Briefing
• Emergency Phone Numbers
• First Aid Responders
• Location of Exits
• Location of Fire Extinguisher
• Room Alerts or Hazards
• Designated Location for Evacuation
• Storm Shelter
• Hazardous Material

Safely Home. Everyone. Every Day.™

3
Safety Briefing

Before beginning this module, the following topics will be reviewed:


• Emergency Phone Numbers
• First Aid Responders
• Location of Exits
• Location of Fire Extinguisher
• Room Alerts or Hazards
• Designated Location for Evacuation
• Storm Shelter
• Hazardous Material

Safely Home. Everyone. Every Day.™

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SERV2110-01 - 11/17 -4- Module 1 - Electronic Control System and Monitor

LEARNING OUTCOMES

Upon completion of this Electronic Control System and


Monitor module, participants will be able to:
• Locate and identify the electronic control system
components and the monitor screens.
• Identify the correct operation of the electronic control
system circuits.
• Access and record machine data using the monitor and
make changes to parameters.

• Learning Outcomes Learning outcomes

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0.0h ISO/JIS 8:48


SMART

1 2

5
INTRODUCTION

• Identify the monitor and jog dial. The electronic control system and the monitor have been updated from the
previous models. This module discusses the electronic control system components
and the functionality of the monitor used in the 320/320GC/323 Next Gen Hydraulic
Excavators.

Additional features have been added to the updated monitor, such as CAT Assist,
Payload, and Grade Control.

The monitor is a touch screen and contains a full color Liquid Crystal Display (LCD)
that provides vital operating and performance information in either metric or English
units. The monitor is capable of multiple language display in an easy-to-navigate
format.

The Application icon (1) and Settings icon (2) allow the operator or service
technician to navigate and scroll through all the available screens, menus and lists,
and to input information. The jog dial (3) on the right side switch panel in the cab
can also be used to navigate the monitor. The dial can be rotated 360°, moved left,
right, up, or down, and can be pushed in to make a selection.

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MACHINE COMMUNICATONS
Monitor (4)
Primary Secondary Body Control 0.0h
SMART
ISO/JIS 8:48

Machine Machine Module (BCM) Four Video


ECM (1) ECM (2) (3) Cameras (5) GNSS
Receivers
EC520 Module (6) (7)

GNSS Radio (8)

PL Heading Sensor (9)


Lightbars
Radio (13)
(24) HVAC
Module (10)
Wiper Control (11)
PL Network Radio Control (12)
Manager (23)
15

Engine Cat ET
MSS (19) Laser
ECM (20) Port (18) Stick/Boom/
DCU (22) Chassis IMUs Catcher (14)
CGC Display (15)
(17)
Emissions System (CGC 3D only) CAN 1 J1939 Data Link (25)
Components (21) CAN 2 Machine CAN Data Link (26)
SCM CAN 3 CGC Data Link (27) (320/323 only)
Module CAN 4 Data Sharing Data Link (28)
(16) CAN C Aftertreatment Data Link (29) (Tier 4 only)
Machine CGC CAN Data Link (30) (CGC 3D only)
GPS Receiver Data Link (31)
Rototilt Data Link (32)
Ethernet (33)
RS-232 (34)

6
MACHINE COMMUNICATIONS

• Identify the electronic This image shows the overall electrical architecture for the Next Gen HEX
components that communicate machines including machine communications over the data links, ethernet, and
over the data links and ethernet. RS-232 serial connections.

The CAN 1 (J1939) Data Link (25) allows communication with the following
components:
• Primary Machine ECM (1)
• Secondary Machine ECM (2)
• Body Control Module (BCM) (3)
• Monitor (4)
• Cat ET port (18)
• Machine Security System (MSS) (19)
• Engine ECM (20)
• Dosing Control Unit (DCU) (22)
• Product Link Network Manager (23)

The CAN 2 Machine CAN Data Link (26) allows communication with the following
components:
• Primary Machine ECM (1)
• BCM (3)
• Monitor (4)

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• HVAC module (10)


• Wiper control (11)
• Radio control (12)
• SCM module (16)

The CAN 3 Cat Grade Control (CGC) Data Link (27), which is installed on 320 and
323 machines only, allows communication with the following components:
• Primary Machine ECM (1)
• Secondary Machine ECM (2)
• EC520 (R2) module (6) (Cat Grade Control Advanced ECM)
• Lightbars (13)
• Laser catcher (14)
• Stick/boom/chassis IMUs (15)

Other components on the machine use the data links for communication as follows:
• CAN 4 Data Sharing Data Link (28): Allows communication between the
primary and secondary ECMs.
• CAN C Aftertreatment Data Link (29) (Tier 4 only): Allows communication
between the Engine ECM, DCU, and the emissions systems components (21)
such as the NOX sensors and soot sensors.
• Machine CGC Data Link (30): If the machine is equipped with the CGC 3D,
allows communication between the EC520 module and the following GPS
components: GNSS receivers (7), GPS radio (8), and heading sensor (9). The
GNSS receivers also communicate with each other over the GNSS Receiver
Data link (31)
• Rototilt Data Link (32): Allows communication between the Secondary
Machine ECM and the EC520 module.
NOTE: For more information on Cat Grade Control, refer to the “Cat Grade
Control Systems” ITTP (SERV1951).

Video signals from the four video cameras (5), are transmitted across two-wire
ethernet cables to the monitor. Ethernet (33) connections exist between the
following components and are used only for software flashing and information
display and do not control machine functions:
• Monitor and Primary Machine ECM
• Primary Machine ECM and Secondary Machine ECM
• Secondary Machine ECM and Product Link Network Manager
• Monitor and Cat ET
• Product Link Network Manager and Product Link Radio (24)
• Product Link Network Manager and EC520 module
• EC520 module and CGC display (17)

The machine is equipped with two-wire and four-wire ethernet. Two-wire ethernet
transmits data at 100 Mb/Sec and four-wire ethernet transmits data at 10 Mb/Sec.
Two-wire ethernet is used for the cameras and four-wire ethernet is used for
all other connections. Ethernet can consist of a serial connection, which is one
component connected to another, or a star connection such as Product Link
Network manager, which has several separate ethernet connections.

The EC520 module also communicates with the optical lightbars through an
RS-232 (34) serial data connection.
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Primary Machine ECM (1) ELECTRONIC CONTROL SYSTEM


B5M5 PRIMARY MACHINE ECM INPUTS/OUTPUTS

INPUT COMPONENTS OUTPUT COMPONENTS


E-Fan Status (2) Hydraulic Lock Solenoid (22)

Swing Angle Sensor (3)


Two Boom Raise Solenoids (23)
Boom Cylinder Head End Pressure Sensor (4)

Boom Cylinder Rod End Pressure Sensor (5) Pump 1 Solenoid (24)

Right Auxilary Pedal Sensor (6) Pump 2 Solenoid (25)

Hydraulic Lockout Switch (7) Boom Lower Solenoid (26)

Pump 1 Pressure Sensor (8)


Stick Out Solenoid (27)
Pump 2 Pressure Sensor (9)

Two Stick In Solenoids (28)


Hydraulic Oil Temperature Sensor (10)

Fuel Level Sensor (11)


Bucket Open Solenoid (29)

Operator Seat Switch (12)


Bucket Close Solenoid (30)
Stick Cylinder Head End Pressure Sensor (13)

Stick Cylinder Rod End Pressure Sensor (14) Swing Priority Solenoid (31)

Return Oil Filter Bypass Switch (15)


Swing Left/Right Solenoids (32)
Engine Push to Start Switch (16)
Travel Left FWD/REV Solenoids (33)
Left Travel Pedal Sensor (17)

Travel Right FWD/REV Solenoids (34)


Right Travel Pedal Sensor (18)

AMR Bucket Position Sensor (19)

Left Joystick (20)

Right Joystick (21)


8
PRIMARY MACHINE ECM INPUTS/OUTPUTS

• Identify the Primary Machine ECM The machine electronic control system controls most of the machine, engine, and
input and output components. aftertreatment functions of the Next Gen HEX. The Primary Machine ECM (1)
monitors and controls a majority of the machine functions.

NOTE: For detailed information on electronic control of the engine


and emissions systems, refer to the “Tier 4 Final Emissions Systems
Diagnostics” ITTP (SERV1981) and either the “C4.4 Tier 4 Final Engine and
Support Systems for Machines” ITTP (SERV2048) or the “C7.1 Tier 4 Final
Engine and Support Systems for Machines” ITTP (SERV2044).

The Primary Machine ECM receives an electronic fan (E-fan) status (2) for
diagnostic purposes. The Primary ECM also receives input signals from the
following components:
• Swing angle sensor (3), two signals (right or left)
• Boom cylinder head end pressure sensor (4)
• Boom cylinder rod end pressure sensor (5)
• Right auxiliary pedal sensor (6)
• Hydraulic lockout switch (7)
• Pump 1 pressure sensor (8)
• Pump 2 pressure sensor (9)
• Hydraulic oil temperature sensor (10)

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• Fuel level sensor (11)


• Operator seat switch (12)
• Stick cylinder head end pressure sensor (13)
• Stick cylinder rod end pressure sensor (14)
• Return oil filter bypass switch (15)
• Engine push to start switch (16)
• Left travel pedal sensor (17)
• Right travel pedal sensor (18)
• Anisotropic Magneto Resistive (AMR) bucket position sensor (19)
• Left joystick (20) includes 4 switches and position sensor
• Right joystick (21) includes 4 switches and position sensor

Based on the input signals, the Primary Machine ECM sends corresponding output
signals to the following components:
• Hydraulic lock solenoid (22) (on/off)
• Two boom raise solenoids (23)
• Pump 1 solenoid (24)
• Pump 2 solenoid (25)
• Boom lower solenoid (26)
• Stick out solenoid (27)
• Two stick in solenoids (28)
• Bucket open solenoid (29)
• Bucket close solenoid (30)
• Swing priority solenoid (31)
• Swing left/right solenoids (32)
• Travel left FWD/REV solenoids (33)
• Travel right FWD/REV solenoids (34)

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Secondary Machine ECM (1) ELECTRONIC CONTROL SYSTEM


B5M5 SECONDARY MACHINE ECM INPUTS/OUTPUTS

INPUT COMPONENTS OUTPUT COMPONENTS

Attachment 1 Extend/Retract Solenoids (11)

Left Joystick Thumbwheel (2)


Attachment 2 Extend/Retract Solenoids (12)
Right Joystick Thumbwheel (3)
Attachment 3 Extend/Retract Solenoids (13)
Left Auxiliary Pedal Sensor (4)
Variable Angle Boom (VAB) Down Solenoid (14)

Foot Switch (5)


VAB Up Solenoid (15)
Bucket Cylinder Rod End Pressure Sensor (6)

Stick Unload Solenoid (16)


Bucket Cylinder Head End Pressure Sensor (7)

Squeeze Head End Pressure Sensor (8) Quick Coupler Lock/Unlock Solenoid 1 (17)

Squeeze Rod End Pressure Sensor (9)


Quick Coupler Lock/Unlock Solenoid 2 (18)

Quick Coupler Switch (10)


Swing Brake ON/OFF Solenoid (19)

Boom Down Electric Check Solenoid (20)

Attachment Variable Relief Solenoid 1 (21)

Attachment Variable Relief Solenoid 2 (22)

10

SECONDARY MACHINE ECM InputS/Outputs

• Identify the Secondary A Secondary Machine ECM is used to handle additional machine functions. The
Machine ECM input and output Secondary Machine ECM receives input signals from the following components:
components. • Left joystick thumb wheel (2)
• Right joystick thumb wheel (3)
• Left auxiliary pedal sensor (4)
• Foot switch (5)
• Bucket cylinder rod end pressure sensor (6)
• Bucket cylinder head end pressure sensor (7)
• Squeeze head end pressure sensor (8)
• Squeeze rod end pressure sensor (9)
• Quick coupler switch (10)

Based on the input signals, the Secondary Machine ECM sends corresponding
output signals to the following components:
• Attachment 1 extend/retract solenoids (11)
• Attachment 2 extend/retract solenoids (12)
• Attachment 3 extend/retract solenoids (13)
• Variable angle boom (VAB) down solenoid (14)

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SERV2110-01 - 11/17 -11- Module 1 - Electronic Control System and Monitor

• VAB up solenoid (15)


• Stick unload solenoid (16)
• Quick coupler lock/unlock solenoid 1 (17)
• Quick coupler lock/unlock solenoid 2 (18)
• Swing brake ON/OFF solenoid (19)
• Boom down electric check solenoid (20)
• Attachment variable relief solenoid 1 (21)
• Attachment variable relief solenoid 2 (22)

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Body Control Module (BCM) (1) ELECTRONIC CONTROL SYSTEM


B5M5 (one connector) BODY CONTROL MODULE INPUTS/OUTPUTS

INPUT COMPONENTS OUTPUT COMPONENTS

Dome Lamp (10)


Door Limit Switch (2)

Main Power Relay (11)


Refueling Switch
(Attachment) (3)
Refuel Pump Relay (12)

Travel Alarm Cancel Switch (4)


Engine Key Switch Relay (13)

Beacon Switch (5)


Boom Lamp Relay (14)

Return Oil Filter Bypass Switch


(Attachment) (6) Chassis Lamp Relay (15)

Caution Lamp Relay (16)

Seat Belt Relay (17)


Engine Start Switch Green LED (7)
Five E-Fan Motors (18)

Engine Start Switch Green LED (8)


Travel Alarm (19)

Monitor Wake Up (9)


Straight Travel Solenoid (20)

Quick Couple Bypass Solenoid (21)

Heavy Lift Solenoid (22)

Travel Speed Solenoid (23)

Fine Swing Solenoid (24)

Boom Up Electrical Check Solenoid (25)


12
body control module (bcm) inputs/outputs

• Identify the BCM input and output The BCM (1) is a non-programmable, non flashable ECM which receives input
components. signals from numerous switches and sensors on the machine and also controls a
number of machine functions. The BCM functions similarly to the Switch Panel
ECM in the F Series machines. Information from other ECMs is shared with the
BCM through the CAN 1 (J1939) Data Link and the CAN 2 Machine CAN Data
Link. The main function of the BCM is to control the machine power status. The
BCM can power off components, without turning the engine start switch (3) off, by
controlling power to the main relay.

The BCM receives input signals from the following components:


• Door limit switch (2)
• Refueling switch (attachment) (3)
• Travel alarm cancel switch (4)
• Beacon switch (5)
• Return oil filter bypass switch (attachment) (6)

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Based on the input signals, the BCM sends corresponding output signals to the
following components:
• Engine start switch green LED (7)
• Engine start switch red LED (8)
• Monitor wake up signal (9)
• Dome lamp (10)
• Main power relay (11)
• Refuel pump relay (12)
• Engine key switch relay (13)
• Boom lamp relay (14)
• Chassis lamp relay (15)
• Caution lamp relay (16)
• Seat belt relay (17)
• Five E-fan motors (18)
• Travel alarm (19)
• Straight travel solenoid (20)
• Quick couple bypass solenoid (21)
• Heavy lift solenoid (22)
• Travel speed solenoid (23)
• Fine swing solenoid (24)
• Boom up electrical check solenoid (25)

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WAKE UP CIRCUIT
BCM (1) Monitor (2)

Low Current Driver (Wake Up) 18 13 Wake Up

Wake Up Input 1 21 29 High Side Driver

Wake Up Input 3 22

Wake Up Input 2 (not used) 40

Door Limit
Switch (3)

14
BCM - MONITOR WAKE UP

• Explain the wake up function. The BCM (1) also controls the ECM Wake Up function by monitoring the door
limit switch (3) in the cab. The BCM will send a signal to activate (wake up) the
monitor (2) when the cab door is opened.

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1
5

3 2

15
COMPONENTS BEHIND CAB

• Identify the components located The Primary Machine ECM (1) and Secondary Machine ECM (2) are located
behind the cab. behind the cab and can be accessed by opening the service door behind the cab
on the left side of the machine. Also located in this compartment are the Product
Link Network Manager (4) and one of the GNSS receivers (5). The GNSS receivers
are only installed on machines with CGC 3D.

The BCM (3) can be accessed from inside the cab by removing a cover from
behind the operator’s seat.

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6
2

3 7

8
4

5 16
PRODUCT LINK

• Identify the Product Link options. Product Link connects directly to the Next Gen HEX machines with the CAN/J1939
Data Link and ethernet. Product Link sends messages via cellular or satellite
communication to the Caterpillar back office and can report into either Vision Link
or Product Link Web. This enables the health and status of the equipment to be
viewed securely in a web-based application.

The Next Gen HEX machines are equipped with one of the following Product Link
options:
• PL631: Consists of the PL631 satellite radio (1) and external antenna (2).
• PL641: Consists of the PL641 cellular radio (3), which can be equipped with
either an internal antenna (not shown) or an external antenna (4). The majority
of PL641 systems use the external antenna. The PL641 with internal antenna
has the cellular and GPS antennas built into the radio, and is not equipped
with coax connectors. The PL641 with the external antenna has the coax
connectors (5) and must be connected to the external antenna for it to transmit
data.
• PLE742: Consists of the PLE702 Network Manager (6), the PL641 cellular
radio (7), and optional external antenna (8). The PLE702 Network Manager is
the Product Link ECM that records input data from the various system sensors
through both the CAN/J1939 Data Link and ethernet. As a system, the PLE742
is the Elite installation which has the data logging capability from the PLE702
Network Manager and uses the PL641 cellular radio only to transmit data.

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The 320 and 323 machines come standard with the PLE742 Elite system. The
320GC machines come standard with the PL641 system. The PLE742 Elite system
is not available on the 320GC.

NOTE: All Next Gen HEX machines are equipped with the PL631 (satellite
system) in regions without cellular certification.

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ENGINE SPEED CONTROL FUNCTION


Engine ECM (2) Primary Machine ECM (1)

0.0h ISO/JIS 8:48


SMART

CAN 1 J1939
Engine Data Link (5)
Speed
Dial (6)

CAN 2 Machine
CAN Data Link (4)

Monitor (3)
2

8
18
Engine Speed Control Function

• Identify and explain the operation The Primary Machine ECM (1) receives the engine speed dial (6) signal from the
of the engine speed control right side control panel via the CAN 2 Machine CAN Data Link (4). The Primary
function components. Machine ECM then transmits the desired engine speed to the Engine ECM (2) over
the CAN 1 J1939 Data Link (5). The throttle switch position can be viewed through
the Service menu on the monitor (3).

The engine speed dial is a 7-position switch. The desired engine speed for each
dial position can be changed through the monitor or Cat ET.

NOTE: The actual engine rpm and torque output will vary, depending on
the setting of the power mode that is selected. The standard mode and
economy mode will change to high hydraulic power mode during travel.

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AUTOMATIC ENGINE SPEED CONTROL (AEC) FUNCTION

Engine ECM (2) Primary Machine ECM (1)

0.0h ISO/JIS 8:48


SMART

CAN 1 J1939
Engine Data Link (5)
Speed
Dial (6)

CAN 2 Machine
CAN Data Link (4)

Pump Pressure
Sensors (7)
Monitor (3)
Joystick Switches
and Sensors (8)
2

Travel Lever/Pedal Sensor (9)

8
One Touch
Low Idle Switch
(10)

19
3

7
1

Automatic Engine Speed Control (AEC) Function


• Identify and explain the operation The Automatic Engine Speed Control (AEC) function automatically reduces engine
of the AEC function components. rpm when no hydraulic demand is detected for five seconds, to reduce fuel
consumption and noise.
When the AEC mode is active, the engine speed dial is set to position 3 through 7
and the manual low idle switch is set to OFF. The AEC system in the electronic
controller will automatically reduce the engine rpm to approximately 1000 rpm after
there has been no hydraulic demand for 5 seconds.
The AEC function is activated when the engine start switch is turned to the ON
position. The AEC function can be turned from ON to OFF from the Monitor (3).
The engine rpm will recover automatically to the setting of the engine speed dial (6)
when any hydraulic function is activated. To determine when a hydraulic function is
activated, the Primary Machine ECM (1) monitors,the pump pressure sensors (7),
joystick switches and sensors (8), and travel lever/pedal sensor (9). The Primary
Machine ECM also monitors the straight travel signal.
Any signal from these input components to the Primary Machine ECM is
communicated to the Engine ECM (2) via the CAN 1 J1939 Data Link (5). The
Engine ECM then responds to those signals by raising engine rpm to the engine
speed dial setting.
The One Touch Low Idle function allows the operator to override the AEC and
manually reduce engine rpm. When the one touch low idle switch (10) (on the right
joystick) is pressed, and there is no hydraulic demand from implement, travel, or
auxiliary tool operation (all levers and pedals in the neutral position), engine rpm is
decreased to engine speed dial setting 1 or the selected low engine speed.
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DELAYED ENGINE SHUTDOWN FUNCTION


Engine ECM (2) Primary Machine ECM (1)

0.0h ISO/JIS 8:48


SMART

CAN 1 J1939
Data Link (5)

Hydraulic Lock Monitor (3)


Engine Start
Solenoid (6)
Switch (4)

20
Delayed Engine Shutdown Function

• Explain the delayed engine The Delayed Engine Shutdown function allows the engine to run at low idle after
shutdown function. the engine start switch (4) is turned OFF. This function provides a cool down period
for the engine and exhaust system, and also allows the engine to burn soot that
has collected in the exhaust system.

The Engine Shutdown Setting function in the monitor (3) is accessible from
the Machine Settings menus and allows the user to view and change the Idle
Shutdown Delay Timer. The Shutdown Delay Timer regulates the length of time the
engine will continue to run after the key start switch is turned to OFF, allowing the
engine, exhaust, and aftertreatment components to cool down after operation.

If the software loaded in the Engine ECM (2) determines the Delayed Engine
Shutdown function is necessary, the strategy will be activated if the engine start
switch is turned to the OFF position and the hydraulic lock solenoid (6) is
de-energized. The hydraulic lock solenoid is controlled by the Primary Machine
ECM (1) and the solenoid status is communicated to the Engine ECM via the CAN
1 J1939 Data Link (5).

NOTE: If the engine requires an immediate shutdown, turn the engine start
ring to the OFF position and push and hold down the engine start switch
approximately two seconds until the engine stops.

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ENGINE IDLE SHUTDOWN FUNCTION

Engine ECM (2) Primary Machine ECM (1)

0.0h ISO/JIS 8:48


SMART

CAN 1 J1939
Data Link (3)

Pump Pressure
Sensors (8)
Monitor (4)
Travel Lever/
Joystick Switches Pedal Sensor (5)
and Sensors (9)
4

Engine Start Switch (6)

One Touch
Low Idle Switch
(10) Hydraulic Lock Solenoid (7)

21
Engine Idle Shutdown Function

• Explain the engine idle shutdown The Engine Idle Shutdown function stops the engine automatically when the
function. machine has been idling for longer than the time programmed delay time in the
monitor (4) and the following conditions are met:
• The control levers are in neutral
• The engine coolant temperature is greater than 70°C (158°F)
• The battery voltage is greater than 24.5V
• The engine speed is less than 2000 rpm
• The ambient temperature range is between 0°C (32°F) and 30°C (86°F)
• The Back Pressure Valve (BPV) is not in operation

Before the engine stops, a warning message will be displayed on the monitor.
The software loaded into the Engine ECM (2) activates the Engine Idle Shutdown
strategy when no hydraulic demand has been requested for the set delay time. To
determine when a hydraulic function is activated, the Primary Machine ECM (1)
monitors the following inputs and communicates with the Engine ECM over the
CAN 1 J1939 Data Link (3):
• Travel levers/pedal sensor (5)
• Engine start switch (6)
• Hydraulic lock solenoid (7)
• Pump pressure sensors (8)
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SERV2110-01 - 11/17 -22- Module 1 - Electronic Control System and Monitor

• Joystick switches and sensors (9)


• One touch low idle switch (10)

The monitor or Cat ET can be used to change the delay time for this function.

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E-FAN ELECTRICAL CIRCUIT


Primary
BCM (1) Machine ECM (3)
CAN 2 Machine
Hydraulic CAN Data Link (5)
Oil Cooler
Hydraulic Oil Temperature Sensor (9)
E-Fan
(12)
CAN 1 J1939
Data Link (4)
Coolant Temperature Sensor (6)
Engine
Hydraulic Intake Air Temperture Sensor (7)
ECM (2)
Oil Cooler
E-Fan Ambient Air Temperature Sensor (8)
(12)

BCM Fuse (10)


15A

Radiator
E-Fan
(13)
E-Fan Fuse (11)
125A

Radiator Pos Neg Pos Neg


E-Fan
(13)

Power Supply
Fan Drive Signal

ATAAC Diagnostic Feedback


E-Fan
(14)

23
ELECTRIC FANS (E-FANS) CIRCUIT

• Explain the operation of the The Next Gen HEX machines are equipped with electronically controlled fans
e-fans. (e-fans) that circulate air though the radiator, hydraulic oil cooler, and Air-to-Air
Aftercooler (ATAAC). The Primary Machine ECM (3) contains the fan control logic
that controls the e-fans. The Primary Machine ECM (3) communicates with the
BCM (1) to control output current to the e-fans.
The BCM contains the fan current drivers, which send current to the hydraulic oil
cooler e-fans (12), radiator e-fans (13), and ATAAC e-fan (14), as shown by the
green wires. Sending current individually to each fan circuit conserves power.
Battery power is provided to the e-fans through a 125 amp e-fan fuse (11) and to
the BCM through a 15 amp BCM fuse (10).
The Primary Machine ECM communicates with the Engine ECM (2) and BCM
over the CAN 1 J1939 Data Link (4) and also over the CAN 2 Machine CAN
Data Link (5) with the BCM. The Primary Machine ECM receives inputs from the
hydraulic oil temperature sensor (9) and from the coolant temperature sensor (6),
intake air temperature sensor (7), and ambient air temperature sensor (8) via the
Engine ECM. The Primary Machine ECM monitors all these temperature inputs.
The highest temperature (relative to the percentage of its temperature map) is the
controlling temperature for fan speed.
The Primary Machine ECM also monitors any fan motor diagnostic signals through
one feedback wire.
A standard cooling package and a high ambient temperature cooling package are
available. The cooling fans can also be reversed to clean the cooling cores.

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KEEP ALIVE ELECTRICAL CIRCUIT

Engine ECM Fuse Engine ECM (3)


J1-84, 85, 86 (ECM Supply)

Battery Disconnect
Switch (1)
J1-81, 82, 83 (ECM Return)

Keep Alive
Relay 2 (5) Keep Alive
Pos Neg
Fuse (6)

J1-05 (DCU Power Relay Supply)


Keep Alive Main J1-15 (DCU Power Relay Return)
Relay 1 (2) Power
Relay

DEF System DEF Tank Header


Fuse Ammonia Sensor
VLPM
DCU
DCU Power DEF Purge Lamp
Relay (4)

24
KEEP ALIVE CIRCUIT (C4.4 TIER 4 ONLY)

• Explain the strategy of the keep This illustration shows the main components in the keep alive electrical circuit,
alive circuit. which maintains power to the Engine ECM when the battery disconnect switch (1)
is off, to ensure completion of the purge cycle.

When the battery disconnect switch is closed, the negative side of the battery
is grounded and machine electrical power is available. The Engine ECM (3)
supplies power to the DCU power relay (4), which closes to provide power to the
aftertreatment components and transfers power to the keep alive No. 1 relay (2).
The keep alive No. 1 relay closes and provides an alternate ground path for the
negative side of the battery through the keep alive No. 2 relay (5) and the keep
alive fuse (6).

When the disconnect switch is opened before the purge cycle is complete, the
alternate ground path provided by the keep alive relays (arrows) maintains power
to the Engine ECM to complete the electrical path to ground, and the DEF purge
cycle continues.

When the purge cycle is complete the DCU sends a signal to the Engine ECM,
which de-energizes the DCU power relay. With the DCU power relay open, the
keep alive circuit opens and power is removed.

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7 4 1
5
3 6

10 11

25
MONITOR DISPLAY

• Identify the monitor gauges and The monitor is the interface between all of the programmable ECMs on the
icons. machine, the electronic input and output components connected to the ECMs, and
the operator and technician. The monitor is located in the right front corner of the
operator compartment. The monitor home screen is shown, which is the default
display when the machine is started.

Action lamps (1) are located at the top of the monitor panel. The left action lamp
will illuminate amber when a Level 2 or Level 3 warning is active, and will flash
when a Level 4 or Level 5 warning is active. The right action lamp will illuminate red
when a Level 5 warning is active.

The status information area (2) displays information such as service hour meter
(3), power mode (4), lever pattern (5), and clock (6). Other information as shown
on the status information inset (7) can also be displayed. When the cursor is in the
status information area, the information can be changed by touching the area or by
rotating the jog dial.

NOTE: Refer to the Next Generation Hydraulic Excavator Monitoring


Systems Operation manual (M0081165) for identification of all status
information.

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The camera view (8) shows the surrounding area of the machine. There may
be three cameras. A rear view camera is mounted on top of the counterweight
and optional side view cameras may be mounted on the left and right side of the
machine. If the machine is equipped with three cameras, the monitor screen can be
toggled to show:
• Rear only
• Side only
• Split vertically
• Split horizontally

The camera view can be toggled when the cursor is on the camera view area and
the area is touched or the jog dial is turned.

The gauge area (9) includes (from left to right) the hydraulic oil temperature gauge,
fuel level gauge, Diesel Exhaust Fluid DEF level gauge (Tier 4 only), and engine
coolant temperature gauge.

The applications icon (10) allows the user to select applications related to operation
and machine settings, and contains air conditioner and radio controls.

The setting icon (11) performs the following two functions:


• When selected from the home screen, the setting icon displays the available
machine functions, which will be discussed later in this module.
• When an application has been selected with the applications icon, the setting
icon allows the user to navigate the settings for the application.

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27
POWER MODES

• Explain the power mode strategy. The following three power modes are available in the Next Gen HEX machines:
• Power Mode (1): Favors maximum engine power and hydraulic torque over
fuel efficiency. (POWER will be displayed on the monitor.)
• Economy Mode (2): Favors fuel efficiency over maximum engine power and
hydraulic torque. (A green leaf and ECO will be displayed on the monitor.)
• Smart Mode (3) : Balances engine power and hydraulic torque with fuel
efficiency. Automatically switches from ECO to Power mode based on machine
operation. (SMART will be displayed on the monitor.)

The power mode can be selected when the machine is first started by pressing the
engine speed dial (4) or by selecting the power mode through the Machine Settings
menu, which will be shown later in this module.

When the operator desires maximum power immediately during operation, the one
touch low idle button (5) can be pressed to select the Power mode.

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2 1 3 4

5 6
8

28
EVENT INDICATOR AREA

• Identify the symbols and icons The event indicator area contains the following information:
shown in the event indicator • Event description (1): This area will display the description of the pop-up
area. message of the impending problem. The information reads, from top to bottom:
-- Line 1: System
-- Line 2: Condition
-- Line 3: Action to be taken
• Event symbol (2): This area will display the symbol of the problem.
• e-OMM key (3): This area will indicate that the e-OMM is available for this
event. If the e-OMM is not available for this even, this area will be blank.
• Close key (4): This key will hide the pop-up message, and the icon list should
be shown.
• Event ID (5): For any event that has an EID or CID ID, the ID will be shown
here.
• Order number/total number (6): The order number of the pop-up message is
shown next to the total number of messages. The messages are ordered from
highest to lowest priority.
• Arrow keys (7): When these areas are selected, the next or previous pop-up
message should be shown. If there is only one even, the arrow keys should be
hidden. If the shown event was the highest or lowest priority, one of the keys
should be hidden.

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The Event Icon List (8) displays all active events. The list orders the higher-level
warnings first, with the red furthest left, and grey furthest right. The current selected
icon will be highlighted with a yellow frame surrounding the icon. Turn the jog dial
left and right to change the highlighted icon and press down on the jog dial to
navigate to the highlighted icon pop-up message.

Arrows will appear at either side of the icon list if there are too many icons to
display on a single bar. The arrow will navigate to the next set of icons instantly
rather than the next icon from the highlighted one.

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30
USB PORT ON MONITOR

• Identify the USB port. A USB storage device (arrow) can be inserted into the port on the left side of the
monitor for flashing software to all programmable ECMs on the machine and for
downloading diagnostic codes, machine configurations, and other data stored in
ECMs. The service technician can also connect a laptop equipped with Cat ET to
perform all the functions the monitor provides, plus allow the technician to load
(flash) new software to all of the ECMs. Cat ET has the same functionality with the
Next Gen HEX machines that has been available in the F Series machines.

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2 3
1

4 5

6 7

31
RIGHT SWITCH PANEL

• Identify the controls on the right The right switch panel is located to the right of the operator’s seat and includes the
switch panel. following components, which can be used to navigate and make selections on the
monitor.
• Jog dial (1): The jog dial can be used to select items displayed on the monitor
screen. The dial can be rotated 360°, moved left, right, up, or down, and can
be pushed in to make a selection.
• Radio mute (2): Press the ratio mute switch to mute the radio. The indicator
light will illuminate when mute is activated. Press the button again to unmute
the radio.
• Operator information (3): Press and hold this button to view the operator
information screen. The indicator light will illuminate when the button is
pressed.
• Radio control (4): Press this button to display the radio controls on the
monitor. The indicator light on the button will illuminate when the radio is turned
on. Use the jog dial to make selections. Using the touch screen display, touch
the icons on the screens to make a selection.
• Air conditioning and heating (5): Press this button to bring up the air
conditioning and heating menu. The indicator light will illuminate when the
heating and cooling system is active. The jog dial can be used to make
selections. Using the touch screen, the selections can be made by touching
the monitor.

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• Home key (6): Press the home key to return to the default display at any time.
• Next menu (7): Press the next menu button to access the next higher menu.
If there is not a menu above the current screen being viewed, pressing the
button will not have any effect.

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3
4

1 2

33
MONITOR STARTUP

• Explain the procedure for starting The monitor display will illuminate when the cab door is opened if the battery
and logging into the monitoring disconnect switch is in the ON position. When the cab door is opened, the door
system. limit switch will send a signal to the BCM, which will send a wakeup signal to the
monitor. The operator must login to use the monitor, but may bypass the login
procedure and login as a guest. As a guest, some menu features will not be
available.

There are three methods of operator login once the engine start ring is turned to
the ON position:
• Passcode
• Caterpillar Bluetooth key® fob
• Cat Equipment mobile application

Passcode allows the operator to enter a passcode using the monitor keypad (1).
If a registered passcode is recognized, the operator information screen (2) will
appear on the display and an “Engine Start Allowed” message will be displayed
across the top of the monitor.

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The Bluetooth key fob (3) contains an electronic chip, which has a unique
identification number (ID). A Bluetooth transceiver module (4) is mounted below
the left side of the operator’s seat in the cab to read the key ID. The transceiver
module translates the information received from the key fob into a J1939 message,
which is sent to the Primary Machine ECM to validate the key fob ID. If the key ID
is recognized, the operator information screen will appear on the display and an
“Engine Start Allowed” message will be displayed across the top of the monitor.

Operators can also log in to a machine using the Cat Equipment mobile application
and a CWS ID user name and password. For the application to be detected by the
system, ensure that the following qualifications are met:
• The MAC address of the mobile application must be registered with the
machine
• The mobile device must be within the cab
• Bluetooth setting must be enabled on the display and the mobile device

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MONITOR ACCESS LEVELS

Access Level Operator Setting


Operator Input Configuration
Guest Response
Change Operator
Operator Input Configuration
Response
Standard
Controls Setup
Change Operator
Operator Input Configuration
Response
Master Controls Setup
Change Operator
Manage Operator

35
MONITOR ACCESS LEVELS

• Identify and explain the monitor There are three levels of operator access recognized by the monitor. The following
access levels. levels are available:
• Guest – If an operator does not have an authenticated key or passcode,
the user is able to bypass log in as a guest. Some menu features will not
be available, such as the options for saving configurations and operator
management. If the Machine Security System (MSS) is enabled, guest
operators cannot start the machine and the monitor is in “Read Only Mode.”
• Standard – A standard operator is a registered user of the machine. Operators
with this access level can start the engine whether or not the MSS is installed.
This user may save a control configuration for future application.
• Master – Master accounts can perform operator management in addition to all
standard level functions. Any “Standard” or “Master” account may be created
or removed by a “Master” level operator.

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36
APPLICATIONS MENU (MAIN MENU)

• Identify the features accessible The Applications menu is the main menu for the monitor and consists of the
through the Applications (main) submenus shown in this image. The main menu is accessed by pressing the
menu. applications icon at the lower left corner of the monitor home screen.

This module will focus on the Setting menu (1), which contains the display,
machine, and operator settings as well as service and diagnostic information.

Additional features accessed through the main menu are (on 320 and 323
machines only):
• Grade: The Grade feature provides several inputs to the operator to grade an
area using only the monitor as a guide. The monitor can guide the operator on
the depth of the cut/fill and angle of slope.
• E-Fence and Assist: Assist provides several functions to the operator for ease
of use and protection against damage to surrounding assets, such as boom,
bucket, grade, and swing assist as well as 2D E-Fence (ceiling, floor, wall),
and cab avoidance.
• Payload: Payload aids in truck loading by weighing the material in the bucket.
The number of buckets and material weight can be tracked, resulting in more
accurate truck loads.

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• Air Conditioner: The heating and cooling menu can be accessed by selecting
the Air Conditioner feature from the main menu or by pressing the heating and
air conditioning button on the right side switch panel as previously discussed.
The heating and air conditioning settings are adjusted using the jog dial on the
right switch panel.
• Audio: The Audio screen allows the user to choose the radio region, enable
Bluetooth, pair devices, and scan for Digital Audio Broadcast (DAB) channels.
The audio menu can be accessed by selecting the Audio feature from the main
menu or by pressing the radio button on the right side switch panel. The audio
settings are adjusted using the jog dial.
• Phone: From the Phone application the user will be able to make a phone call
and pair a phone.
• Bucket/Work Tool Setting: The Bucket/Work Tool Setting screen allows the
operator to choose the appropriate work tool and perform measure-up and
calibrations for the work tools, Cat Grade Control, Grade Assist, and Payload.
NOTE: The Tool Programming menus, accessed from the Setting menu,
allows the operator to configure work tools and will be discussed later in
this module.
• Electronic OMM: The Electronic OMM screen allows the operator to view
the machine Operation and Maintenance Manual (OMM) and watch coaching
videos such as Assist, E-Fence, and Payload.
NOTE: The Grade, Payload, and Audio menus can also be accessed from
the Setting menu.

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38
FUNCTIONS MENU

• Identify the features accessible The functions menu displays the available machine functions, as shown in this
through the Functions menu. image. The Functions menu is accessed from the Home screen by pressing the
functions icon at the lower right corner of the monitor home screen.

The following features can be turned on and off through the Function menu:
• Shovel Crane: The shovel crane option provides a lifting hook that is attached
to the bucket linkage.
• Auto Warm Up: The auto warm up feature ensures the machine component
temperatures are optimum for machine operation.
NOTE: The Auto Warm Up menu, accessed from the Setting menu, allows
the operator to set the Auto Warm Up target temperature and will be
discussed later in this module.
• AEC: When enabled, the Automatic Engine Speed Control (AEC) automatically
reduces engine speed when the machine is inactive. The AEC system is
designed to reduce fuel consumption and noise.
NOTE: The Configurations menu, accessed from the Service menu, allows
the operator to configure the AEC settings.
• Heavy Lift: This work mode increases the relief pressure in the hydraulic
circuit, which increases the hydraulic force that is available for lifting
operations. The cylinder speed is slower when heavy lift is selected.

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• Smart Boom: The smart boom feature provides ease of use features for the
operator during boom lowering and raising.
• Fine Swing: When the fine swing control is enabled, the swing parking brake
is released. Swing control improves during deceleration, since the upper
structure is allowed to drift instead of stopping abruptly.
• Overload Warning Device: In lifting applications, the overload warning device
activates a buzzer when there is an unstable load condition. When the buzzer
sounds, the bucket load should be reduced or the stick should be moved
inward.
• 360 Visibility: If the machine is equipped with side and front cameras, which
gives the capability of 360° visibility, the user can turn ON and OFF this option
in the Function menu.

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40
SETTING MENU - DISPLAY SETTING

• Identify the features accessible The Setting Menu is accessed from the Applications menu and contains access to
through the Setting Menu. the menus most often used by service technicians for machine service, and
consists of the following options:
• Display Setting
• Information
• Machine Setting
• Operator Setting
• Service

The Display Setting option is shown in this image, which allows the user to adjust
the clock, time zone, screen brightness, display units, camera view, and language.

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41
SETTING MENU - INFORMATION

• Identify the features accessible The Information menu is shown in this image and includes the following options:
through the Information menu. • Performance: allows the operator to view common performance information,
such as pump outlet pressure, battery voltage, engine coolant temperature,
engine speed, and hydraulic oil temperature.
• Current Totals: Allows the operator to view total machine operating hours
and components operating hours, such as engine, hydraulic pump, travel and
swing motors, and attachment tools.
• License Information: Allows the user to view the software license agreement.
• ECM Summary: Allows the user to view information for the ECMs such as
hardware part numbers and serial number, and software description, part
number, and release date.
• Diagnostics: Allows the user to view active and logged diagnostic and event
codes
NOTE: The ECM Summary and Diagnostics menus can also be accessed
through the Service menu, which requires a password.

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42
SETTING MENU - MACHINE SETTING

• Identify the features accessible The Machine Setting menu is shown in this image, and includes the following
through the Machine Settings options:
menu. • Engine Shutdown Setting: Allows the user to enable, disable, and adjust the
engine shutdown timer. This feature operates the engine at idle speed for a set
amount of time to cool the engine before shutting down automatically.
• Power Mode Setting: Allows the user to choose the engine power mode:
Economy Mode, Smart Mode, or Power Mode.
• Reverse Fan: Allows the user to activate the reverse fan feature to clean
debris from the cooling group and set the reverse fan duration time.
• Grade: Allows the user to set grade control tolerances, such as alert sound
and on-grade limit, and choose grade enable status and grade unit used.
• Payload: Allows the user to view payload information such as lists and setup
information, and enable or disable the Payload function.
• Audio: Allows the user to choose the radio region, enable Bluetooth, pair
devices, and scan for Digital Audio Broadcast (DAB) channels.
• Lighting Shutdown Timer: Allows the user to set a time up to five minutes
that will automatically turn off the lights after the machine is shut down.
• Auto Warm Up: Allows the user to enable and set the auto warm-up feature.
This feature automatically starts a warm-up period when the engine is started
and the hydraulic oil is below the set temperature.

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• Key Power Setting: Allows the user to set a sleep timer for the engine start
switch. If the start switch is left in the ON position, power will automatically shut
off once the chosen timer interval has elapsed.
• Security: Allows the user to set the operator lockout time. This is the period
after engine shutdown that an operator can start the engine without logging
back in to the monitor.

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44
SETTING MENU - OPERATOR SETTING

• Identify the features accessible The Operator Setting menu is shown in this image, and includes the following
through the Operator Setting options:
menu. • Operator Inputs Configuration: Allows the user to configure the joystick
buttons and lever pattern for operator personal preference and restore the
joysticks to factory settings. The settings will be stored in the preferences for
that login ID.
• Response: Allows the user to adjust the spool settings which will affect how
quick the machine responds when using the joysticks. The settings can be set
to slow, medium, or fast.
• Change Operator: Allows a new operator to log in. After successfully logging
in, the previous operator’s preferences will be overridden with the new
operator’s preferences.
• Manage Operator: Allows the user to add and delete operators. A maximum
of 50 operators can be registered.

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45
SETTING MENU - SERVICE

• Identify the features accessible To access the Service menu, a password is required. The following options are
through the Service menu. available from the Service menu:
• ECM Summary: Allows the user to view information for the ECMs such as
hardware part number and serial number, and software description, part
number, and release date.
• Diagnostics: Allows the user to view active and logged diagnostic and event
codes
• Status: Allows the user to view the status of machine systems and
components.
• Configuration: Allows the user to configure machine features.
• Tool Programming: Allows the user to configure up to 20 work tools.
• Machine Dimensions: Allows the user to view the dimensions of the following
machine components: boom, stick, idler link, power link, and machine body.
• Override Parameters: Allows the user to override system components to help
in the troubleshooting process.
• Calibrations: Allows the user to perform calibrations on certain electronically
controlled machine components.
• WinFlash: Allows the user to flash the latest software to the monitor from a
jump drive using the USB interface. User will also be able to flash the latest
ECM software.

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LEARNING OUTCOMES

Upon completion of this Electronic Control System and


Monitor module, participants are now able to:
• Locate and identify the electronic control system
components and the monitor screens.
• Identify the correct operation of the electronic control
system circuits.
• Access and record machine data using the monitor and
make changes to parameters.

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• Learning outcomes review Learning Outcomes Review

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