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CATERPILLAR MONITORING SYSTEM

The D10R is equipped with the Caterpillar Monitoring System which

• Contains three
individual modules: informs the operator if a problem is present in the machine. The
Caterpillar Monitoring System is an electronic monitoring system that
1. Analog gauge continuously watches machine systems. The system is a flexible, modular
module monitoring system that includes: a main display module, various
2. Tachometer/gear switches and sensors, an action lamp (4) and an action alarm (not shown).
indicator module The system also includes a tachometer module (2) which also displays
3. Main display gear and direction readouts, and an analog gauge module (1). The main
module display module (3) is the “heart” of the system. This module receives
information from the switches, sensors, and other electronic controls on
• Monitors machine
conditions the machine by way of the CAT Data Link. The main display module
processes all this information and activates various outputs. These
4. Action lamp outputs can be in the display portion of the main display module, the ten
alert indicators in the display portion of the main module, the gauge
cluster module, the tachometer/gear indicator module, the action lamp or
the action alarm. The display components show the operator the
condition of machine system diagnostic information.

The same monitoring system operates on a variety of different machines.

All the possible system functions are not performed on every machine.
The main display module recognizes the machine on which it is installed
and performs only the intended functions for that machine. The main
display module is required for the monitoring system to operate.
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THREE LEVELS OF WARNING

• CATEGORY 1
• CATEGORY 2
• CATEGORY 3

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• Three levels of The Caterpillar Monitoring System notifies the operator of an immediate
warning: or impending problem with a machine system. Three levels of warning
can be provided to the operator.

- Category 1 requires Category 1--For the first level of warning, only an alert indicator will
operator attention flash. No immediate action required. This category alerts the operator
that the machine system needs attention soon.
- Category 2 requires
operator to change Category 2--For the second level of warning, the alert indicator and the
method of operation action light flash. This warning category requires the operator to change
the machine operation or perform maintenance to the system. Changing
the machine operation will reduce the excessive temperatures or engine
overspeeds. Failure to change machine operation will result in severe
damage to components.
- Category 3 requires
immediate machine Category 3--For the third level of warning, the alert indicator flashes, the
shutdown action lamp flashes, and the action alarm sounds. This category requires
the operator to perform an immediate safe engine shutdown. This
category could result in possible operator injury or severe damage to

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machine components.
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• System cycles The self test verifies that the main display module, the tachometer
through self test module, and the gauge module are operating correctly. The main display
module performs an automatic self test each time the key start switch is
turned from the OFF to the ON position.

The operator must observe the modules to determine if the system is

operating correctly. The alert indicators and display area are tested for
approximately one second. All alert indicators FLASH, and the display
area shows: all unit indicators (°C, kPa, MILES, KILOMETERS, RPM,
LITERS), the X10 indicator, the service meter symbol, and 888.8.8.8 on
the six-digit readout.

The tachometer and gauge modules are tested for approximately three
seconds. The analog tachometer in the center module and the four analog
gauges in the left module jump to half scale, return to zero, and then
sweep to full scale. After reaching full scale, the tachometer and gauges
return to showing current machine values.

The transmission/direction actual gear readout turns on every segment of

the readout. The readout appears as a "0" with an "x" and a "+" sign laid
on top of the "0." Two of these readouts should appear side by side.

The ground speed display turns on every segment of the readout. It looks
like "188." MPH and km/h are both turned ON.

The action lamp turns ON.

The action alarm SOUNDS once.

The main display module then goes into the normal mode of operation.

INSTRUCTOR NOTE: If the control fails to self test, further

investigation will be needed to determine (1) if the control is defective,
or (2) a harness code problem exists. Always consult the appropriate
service manual before proceeding.

For more complete information on the Caterpillar Monitoring

System, refer to the Service Manual "Caterpillar Monitoring
System" (Form SENR6717) and the Technical Instruction Module
“Caterpillar Monitoring System--Track-type Tractors” (Form
SEGV2619).
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• Engine oil pressure The top left alert indicator (arrow) of the main module is engine oil
indicator (arrow) pressure.

Two pressure sensors are used for the measurement of engine oil pressure
• Two sensors used to (gauge). The two sensors are: the Atmospheric pressure sensor which
calculate engine oil senses the absolute atmospheric pressure, and the engine oil pressure
pressure: sensor which measures the absolute oil pressure.
- Atmospheric The atmospheric pressure sensor is located on the Hydraulic Supply Pump
pressure sensor Group adapter. This sensor is vented to the atmosphere. The engine oil
- Engine oil pressure pressure sensor is located on the front left of the Hydraulic Supply Pump
sensor Group in the vee of the engine.
The engine ECM calculates the difference between the two sensors [oil
pressure (A) - atmospheric (A)] = oil pressure (GP). Engine oil pressure
varies with engine speed. As long as oil pressure maintains a range above
• Calculated absolute
pressure (A) equals the programmed parameters in the ECM at low idle, no warnings are
gauge pressure (GP) activated. If the calculated oil pressure falls below the low range of the
parameter at low idle, an event is logged in the ECM memory, and a
category 3 Warning is activated to alert the operator.
NOTE: A = absolute pressure

GP = gauge pressure
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• System voltage alert The system voltage is sensed directly from the "R" terminal at the
indicator (arrow) alternator. The alternator does not use a switch; instead, the Caterpillar
Monitoring System senses the frequency of the alternator directly from
• System voltage
sensed directly from the "R" terminal. The Caterpillar Monitoring System measures and
"R" terminal determines the system voltage is within specified limits. If the voltage
drops below a certain level, the alert indicator (arrow) will flash,
indicating that a problem exists with the alternator. Since this indication
is a Category 1 Warning, the operator can continue to operate the
machine, but should investigate the cause of the problem when
convenient.
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• Coolant flow alert The coolant flow switch is located on the lower right side of the engine
indicator (arrow) toward the front. If the coolant flow stops, the switch will open, causing
the coolant flow alert indicator (arrow) and the master fault light to flash
and the action alarm to activate notifying the operator of a Category 3
Warning.

The switches on the machine are two-state devices, either open or closed.
• Switches used to
The switches are normally closed while the machine is in operation and
monitor systems
conditions are normal. The Caterpillar Monitoring System identifies an
open switch as an indication of a problem and turns on the appropriate
indicator. In this system, if a wiring harness connection is loose or if a
wire breaks, the Caterpillar Monitoring System identifies it as an open
and turns on the indicator. Switches can be identified in the system by
observing that they have only two wire connections.
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• Air filter restriction Two sensors are used to measure air filter restriction. The turbo inlet
indicator (arrow) pressure sensor, which is mounted between the air filter and turbocharger,
measures the absolute (A) air pressure to the turbo inlet. The atmospheric
• Automatic Filter pressure sensor measures absolute (A) barometric pressure. The engine
Compensation ECM calculates the difference between the two sensors and begins
Automatic Filter Compensation. This compensation protects the engine
against the effects of plugged filters. Derating is automatic as follows:

- Air filter restriction (∆P) exceeds 8.5 kPa (34 in. of water)

- Engine power derating starts at the rate of 2% per 1 kPa of ∆P

• Derating starts above

- Maximum derate is 10%
8.5 kPa (34 in. of
water) - An event is logged when air filter restriction (DP) exceeds
9 kPa (36 in. of water)

Derating is retained at the maximum DP until the key start switch is

cycled OFF and ON.
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• Check engine The alert indicator at the top right of the main display module is the check
indicator (arrow) engine indicator (arrow). This LED indicator indicates that diagnostic
information is present in the engine ECM. This alert does not necessarily
indicate a problem with the engine operation. If this indicator light
activates, the operator should check the engine at the earliest possible
time.
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• Power train electronic The lower five alert indicators on the main display module receive
system alert information from the power train ECM through the CAT Data Link. The
indicators
Caterpillar Monitoring System alerts the operator of the condition by
illuminating the corresponding alert indicator. The left indicator (arrow)
if activated, alerts the operator of a steering electronic system problem.
• Steering system either Steering electronic system problems can be either a Category 1 or a
Category 1 or Category 3 Warning. The Category 1 Warning is activated when the
Category 3 Warning
ECM detects that the steering clutches are not calibrated. This warning
will occur anytime new software has been flashed or the ECM has been
replaced. Scrolling through the Brake Mode will clear the fault code.
Calibrate the steering clutches and brakes if the performance is not
satisfactory. The electrical circuit that can cause this warning is identified
as:
CID 254 ECM failure

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• Category 3 Warning A Category 3 Warning is activated when the ECM detects that a fault is
present in a steering system input or output. The steering system
• Steering system
indicator (arrow) will FLASH, the action lamp will FLASH, and the
indicator (arrow)
action alarm will SOUND. The operator should safely stop the machine
and shut the engine off. A service code will be logged for the fault that is
present. The fault must be corrected before the machine operation is
resumed. The electrical circuits that can cause this warning are identified
as:
CID 698 Left steering clutch solenoid valve
CID 699 Right steering clutch solenoid valve
CID 689 Left brake solenoid valve
CID690 Right brake solenoid valve
CID 676 Left steering lever position sensor
CID 677 Right steering lever position sensor
CID 650 Harness code
CID 254 ECM failure
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• Brake system alert The power train ECM activates warning for the brake system. The
indicator (arrow) warnings categories are:
A Category 1 Warning is activated when the ECM detects that the brakes
are not calibrated. This warning will occur anytime new software has
• Category 1 Warning
been flashed or the ECM has been replaced. Scrolling through the Brake
Mode will clear the fault code. The steering clutches and brakes should
be calibrated when performance is not satisfactory.The brake system alert
indicator (arrow) will FLASH. This alert tells the operator to check or
repair the problem component at the earliest opportunity. The electrical
circuits that can cause this warning are:
CID 070 Parking brake switch - ON/OFF pole
CID 618 Parking brake switch - Brake backup pole
CID 075 Steering system oil temperature sensor
CID 468 Brake pedal position sensor
CID 722 Secondary brake valve solenoid
CID 681 Parking brake solenoid
CID 298 Service brake switch
CID 254 ECM failure
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• Category 3 Warning A Category 3 Warning is activated when the ECM detects that a fault is
present in a brake electronic system input or output. The brake system
alert indicator (arrow) will FLASH, the action lamp will FLASH, and the
action alarm will SOUND. The operator should safely stop the machine
and shut the engine off. A service code will be logged for the fault that is
present. The fault must be corrected before machine operation is
resumed. The electrical circuits that can cause this warning are identified
as:
CID 689 Left brake solenoid valve
CID 690 Right brake solenoid valve
CID 650 Harness code
CID 254 ECM failure
CID 298 Service brake switch
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• Transmission system The power train electronic control system activates a warning for the
alert indicator (arrow) transmission electronic system. The warning categories are:
A Category 1 Warning is activated when the ECM detects that a fault is
• Category 1 Warning present in a transmission electronic system input or output. The
transmission system alert indicator (arrow) will FLASH. This warning
tells the operator to check the transmission system at the earliest
opportunity. A service code will be logged for the fault that is present.
The electrical circuits that can cause this warning are identified as:
CID 621 Downshift switch
CID 622 Upshift switch
CID 623 Reverse switch
CID 177 Transmission oil temperature sensor
CID 695 First gear solenoid valve
CID 694 Second gear solenoid valve
CID 693 Third gear solenoid valve

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• Category 3 Warning A Category 3 Warning is activated when the ECM detects that a fault is
present in a transmission electronic system input or output. The
transmission alert indicator (arrow) will FLASH, the action lamp will
FLASH, and the action alarm will SOUND. The operator should stop the
tractor safely and shut the engine off. A service code will be logged for
the fault that is present. The electrical circuits that could cause this
warning are identified as:
CID 299 Direction selector position sensor
CID 650 Harness code
CID 254 ECM failure
CID 692 Forward gear solenoid
CID 691 Reverse gear solenoid
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• Power train filter The power train filter bypass switch is located in the housing of the power
bypass indicator train hydraulic filter on the left rear of the machine. If the power train
(arrow)
filter becomes restricted, the filter bypass valve will open, permitting oil
to flow past the filter. This condition causes the switch to open. If the
bypass condition occurs at normal machine operating temperature, the
power train filter alert indicator (arrow) and the master fault light will
activate notifying the operator of a Category 2 Warning. A temperature
switch prevents the signal from the bypass switch from alerting the
operator when the oil is cold at start-up.
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• Parking brake system The power train ECM activates a warning for the parking brake. The
alert indicator (arrow) warning category is:

• Category 1 Warning A Category I Warning is activated whenever the parking brake is

engaged. The parking brake alert indicator (arrow) will FLASH. This
warning tells the operator to release the parking brake before placing the
machine in gear.