UENR5484-02 (en-us)

July 2018

Systems Operation
6020B Hydraulic Shovel
Monitoring System
DNY 1-UP (Machine)
DNR 1-UP (Machine)
D4Y 1-UP (Machine)
D4R 1-UP (Machine)
HS2 1-UP (Machine)
HS4 1-UP (Machine)

SAFETY.CAT.COM
 i06558969

Important Safety Information

Most accidents that involve product operation, maintenance and repair are caused by failure to observe
basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous
situations before an accident occurs. A person must be alert to potential hazards, including human factors
that can affect safety. This person should also have the necessary training, skills and tools to perform these
functions properly.
Improper operation, lubrication, maintenance or repair of this product can be dangerous and could
result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you verify
that you are authorized to perform this work, and have read and understood the operation,
lubrication, maintenance and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings
are not heeded, bodily injury or death could occur to you or to other persons.
The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as
“DANGER”, “WARNING” or “CAUTION”. The Safety Alert “WARNING” label is shown below.

The meaning of this safety alert symbol is as follows:

Attention! Become Alert! Your Safety is Involved.
The message that appears under the warning explains the hazard and can be either written or pictorially
presented.
A non-exhaustive list of operations that may cause product damage are identified by “NOTICE” labels on
the product and in this publication.
Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard.
The warnings in this publication and on the product are, therefore, not all inclusive. You must not
use this product in any manner different from that considered by this manual without first
satisfying yourself that you have considered all safety rules and precautions applicable to the
operation of the product in the location of use, including site-specific rules and precautions
applicable to the worksite. If a tool, procedure, work method or operating technique that is not
specifically recommended by Caterpillar is used, you must satisfy yourself that it is safe for you
and for others. You should also ensure that you are authorized to perform this work, and that the
product will not be damaged or become unsafe by the operation, lubrication, maintenance or repair
procedures that you intend to use.
The information, specifications, and illustrations in this publication are on the basis of information that was
available at the time that the publication was written. The specifications, torques, pressures,
measurements, adjustments, illustrations, and other items can change at any time. These changes can
affect the service that is given to the product. Obtain the complete and most current information before you
start any job. Cat dealers have the most current information available.

When replacement parts are required for this

product Caterpillar recommends using Cat re-
placement parts.
Failure to follow this warning may lead to pre-
mature failures, product damage, personal in-
jury or death.

In the United States, the maintenance, replacement, or repair of the emission control devices and
systems may be performed by any repair establishment or individual of the owner's choosing.
UENR5484-02 3
Table of Contents

Table of Contents
Systems Operation Section

Introduction
General Information ..............................................4

Operator Level
Start Screen .........................................................7
System Status Screen .........................................15
Service Screens..................................................24
Documents Screen..............................................27
Event List Screen ................................................31
Setup Login Screen.............................................34
Data Interfaces ...................................................34
Data Interfaces ...................................................35
General Maintenance ..........................................35

Service Level 1
Setup Menu - Service Level 1...............................37
Common Setup Menu..........................................38
Operating Hours Menu ........................................38
Signal Logging Menu...........................................40
Controllers Menu.................................................41
Servo Controller Menu.........................................42
Drive Controller Menu..........................................54

Service Level 2
Setup Menu - Service Level 2...............................62
Copy Files Menu .................................................64
Servo Controller Parameters - Engine Menu .........65
Servo Controller Parameters - Pumps Menu .........66
Servo Controller Parameters - Valves Menu .........67
Servo Controller Parameters - General Menu .......68
Drive Controller Parameters Menu .......................69

Index Section
Index..................................................................71
4 UENR5484-02
Introduction

Systems Operation Section All essential operating data is displayed on the BCS
screen in the form of simulated instruments (dial
gauges). This data is archived and can be called up
when required.
Introduction

i06036113

General Information
SMCS Code: 7490

BCS (Board Control System)

The BCS communicates with other electronic units in
the hydraulic shovel and makes up the CAMP
(Control And Monitoring Platform) system. Illustration 1 g03797132

Controllers actuate and monitor functions such as BCS

motor management, drive and control of the hydraulic
pumps, the pilot control, and others. The controllers The housing, installed on the dashboard inside the
are computers that have been configured for a operator's cab, integrates the computer, monitor,
special application. control elements, and the interfaces.

Other electronic units of the CAMP system that Maintenance

communicate with the BCS can be found in the
locations listed below:
• Cabinets in the module below the operator's cab
• Pump compartment
• Engine compartment
The exchange of data between sensors, controllers,
the BCS, and other involved components takes
places via the CAN bus.
Function of the BCS
The BCS (Board Control System) monitors all of the
essential functions of the hydraulic shovel and the
shovel components.
If any maximum value is exceeded, the BCS releases
an appropriate signal and also sends a report to be
archived in the memory bank.
If a normal operating status can be reached by
temporarily reducing the hydraulic shovel output, the
reduction of the shovel output will be performed by
the CAMP system and monitored by the BCS.
If it is necessary for the operator to take a certain
action (example: stop the engine), a relevant
command is sent to the BCS display screen.
The BCS also displays information on servicing and
troubleshooting.
Sensors installed at various points on the hydraulic
shovel constantly transmit readings to the controllers
of the CAMP system.
If the BCS Display becomes too hot, it can be
damaged. Therefore, do not lay or hang objects
(example: shirts, jackets) over the unit.
The screen of the Display is sensitive to the touch.
Carefully follow all instructions and warnings given in
this manual.
BCS Housing
The BCS screen is designed as a touch screen. By
slightly touching the active areas, the user can
perform activities such as changing to another screen
page.
Active areas are shown on the screen as three-
dimensional graphics. In the basic configuration - not
activated - the buttons seem to project out of the user
interface. When touched, the buttons appear to be
lowered.
NOTICE: Never touch the screen with pointed
objects such as a ball-point pen, screwdriver,
nail, or similar. Sharp or pointed objects could
damage the active surface of the touch-screen.
Do not press on the sensitive areas, just slightly
touch the sensitive areas with your fingertip.
UENR5484-02 5
Introduction

Illustration 2 g03784209

(1) Status Line (5) Brightness Sensor (8) Background Lighting Control - Set
(2) Touch Screen Monitor (6) LED Brighter
(3) Status Line (7) Background Lighting Control - Set (9) Power ON/OFF Button
(4) Touch Screen Buttons Darker (10) Buzzer (Not Used)

Status Line (1) – Indicates activated/deactivated

functions, the number of dumpers loaded, and LED (6) – The LED lights up in green when the
operating hours. Rectangular areas with graphics are electrical system of the machine is switched ON,
touch-sensitive areas. indicating that operating voltage is available.
Touch Screen Monitor (2) – Displays the following
information: The LED flashes during the boot procedure, with
each keypress, and when the background lighting of
the screen is turned OFF.
• Collected operating data graphically and/or
numerically The LED flashes yellow if the temperature inside the
device lies outside the permissible range. The
• Warning messages automatic heating system is then active.

• Fault messages Background Lighting Control - Set Darker (7) –

Used to darken the background lighting.
• Instructions for help Background Lighting Control - Set Brighter (8) –
Status Line (3) – Displays fault messages as a code Used to lighten the background lighting.
number and as plain text. The “Fault” button permits Power ON/OFF Button (9) – Used to turn the BCS
displaying further fault messages stored in the housing ON or OFF.
system.
Buzzer (Not Used ) (10) – The buzzer is not used on
Touch Screen Buttons (4) – Use Touch Screen this machine.
buttons to navigate through screens and open
menus.
Brightness Sensor (5) – The brightness sensor
measures the ambient brightness. The BCS
automatically controls the background illumination of
the screen.
6 UENR5484-02
Introduction

The First Screen After Startup

Illustration 3 g03799917

(11) Confirmation Button

This screen is displayed once after machine startup.

The First Screen after Startup may contain important
messages given from the service personnel to the
operator. In the lower part of the screen, a fault log
may appear. The operator should follow the
messages given.
After pressing the Confirmation button (11), the BCS
Start screen will appear. By pressing the
Confirmation button (11), the operator confirms that
the messages given on the screen have been read.
UENR5484-02 7
Operator Level

Operator Level

i06036129

Start Screen
SMCS Code: 7490

Basic Screen
The BCS screen displays the graphical user interface
of the Board Control System (BCS). The Basic
Screen (Illustration 4 ) appears when all electronic
units of the CAMP (Control And Monitoring Platform)
system have started and when all self-tests have
been completed.

Note: At low outside temperatures, the Basic Screen

may appear a few minutes after switching ON the
electrical system (warming up phase).
Starting from the Basic Screen, the user can access
a number of other screens without an input device
such as a keyboard or mouse.
The BCS Screen is designed as a touchscreen. By
slightly touching the active areas, the user can
perform activities such as navigating to another
screen.
Active areas are shown on the screen as three-
dimensional graphics. In the basic configuration
(active areas not activated), the active areas seem to
project out of the user interface. When touched, the
active areas appear to be lowered.
NOTICE: Never use pointed objects such as a
ball-point pen, screwdriver, nail, or similar. Sharp
or pointed objects could damage the active
surface of the touch-screen.
Do not press the sensitive areas, just slightly
touch the sensitive areas with your fingertip.
8 UENR5484-02
Operator Level

Illustration 4 g03797150
Start Screen

Symbols and Buttons

The touch sensitive buttons shown and described in
Illustration 5 appear on nearly every screen of the
BCS system.
UENR5484-02 9
Operator Level

Illustration 5 g03799948
10 UENR5484-02
Operator Level

Top Section

Illustration 6 g03797187

(1) Operating Hours (5) Track Parking Brakes (9) Hydraulic System Monitoring
(2) Dump Counter (6) Upper Structure Holding Brakes (10) Engine Monitoring
(3) Selected Travel Speed (7) Seat Monitoring (11) Event List
(4) Hydraulic Ladder (8) Central Lubrication System Monitoring (12) Help Screen
UENR5484-02 11
Operator Level

Illustration 7 g03797232
12 UENR5484-02
Operator Level

Middle Section

Illustration 8 g03797559

(13) Temperature Data During Operation: (14) Oil Pressure (bar) (17) Engine (rpm)
Hydraulic Oil (°C), Coolant (°C), and (15) Emergency STOP (18) Fuel Level (Ltr)
Ambient (°C) (16) Battery (VDC)

The Emergency STOP graphic (15) alternates with a

green push-button graphic. The Emergency STOP
graphic indicates that one of the Emergency STOP
switches has been actuated. The Emergency STOP
function is reset by pushing the Emergency STOP
Reset Button.
UENR5484-02 13
Operator Level

Lower Section

Illustration 9 g03797480

(19) System Status Button (21) Event/Fault Banner (Tap on banner to (22) Screen Capture Button
(20) Service Button (Password Needed) display the whole list of stored events.) (23) Date and Clock
14 UENR5484-02
Operator Level

Help Section

Illustration 10 g03797602
UENR5484-02 15
Operator Level

i06036134

System Status Screen

SMCS Code: 7490

Illustration 11 g03797700

(1) Engine (3) Lube Control

(2) Hydraulic Pump (4) Control Lever (Joystick)

Press the Engine photo (1) to open the Current

Engine Data screen. The Current Engine Data
screen can also be reached by pressing the Engine
symbol on the Start screen.
Press the Hydraulic Pump photo (2) to open the
Hydraulic Pump Data screen. The Hydraulic Pump
Data screen can also be reached by pressing the
Hydraulic symbol on the Start screen.
Press the Lube Control photo (3) to open the Lube
Control Data screen. The Lube Control Data screen
can also be reached by pressing the Lube Pump
symbol on the Start screen.
Press the Control Lever photo (4) to open the Control
Elements Adjusting Data screen.
16 UENR5484-02
Operator Level

Engine

Illustration 12 g03797709

(5) Current Engine Data (7) Engine Oil Change Interval and (9) Faults and Malfunctions (from the Engine
(6) Current Pressure of the Six Main Remaining Operating Hours (until next ECM)
Hydraulic Pumps (Driven by the Engine oil change)
via the pump distribution gearbox.) (8) Ambient Temperature (°C)

Faults and Malfunctions

Information about faults and malfunctions from the
Engine ECM is displayed on the System Status
screen (9). Fault descriptions follow the SAE J1939
standard:

• SPN - Suspect Parameter Number

• FMI - Failure Mode Identifier
The severity of the fault is displayed as well:
Malfunction – A less-significant fault. Should be
eliminated with the next service.
Warning – Should be eliminated immediately to
prevent the engine from serious damages.
Protect – Engine power is automatically reduced to
prevent the engine from serious damages.
Engine Stop – Engine has been stopped
automatically to prevent engine destruction.
UENR5484-02 17
Operator Level

Hydraulics

Illustration 13 g03797734

(10) Hydraulic Pressure in Pilot Hydraulic (11) Hydraulic Pressure Coming from the (12) Bottom Buttons
(Servo) Circuits Hydraulic Main Pumps

Hydraulics - Main Pump Pressure Screen Hydraulic Pressure Coming from the
The Hydraulics - Main Pump Pressure Screen
Hydraulic Main Pumps (1-6)
displays graphically and numerically:
Monitored pressure may vary depending on the
• The hydraulic pressures coming from each of the hydraulic power currently needed for machine
six main pumps operation (controlled by BCS).

• The hydraulic pressures in pilot hydraulic (servo) Bottom Buttons

circuits
When one of the Bottom Buttons is pressed, the
The pointers should be in the green colored sections current screen is exited and a screen with information
of the dial gauges. If a pointer is in the yellow or red about further hydraulic sections is opened:
section, an event/fault has occurred.
• Attachment
The contamination status of the six main hydraulic
pumps is monitored. When contamination occurs, a • Slew
red light is activated. Service personnel should be
notified immediately. • Oil tank

Hydraulic Pressure in Pilot Hydraulic • Travel

(Servo) Circuits
100 Bar Circuit – Pressure should be between 80
bar and 120 bar.
35 Bar Circuit – Pressure should be between 30 bar
and 40 bar.
18 UENR5484-02
Operator Level

Hydraulics - Attachment Screen

Illustration 14 g03797762
Hydraulics - Attachment Screen

The Hydraulics Attachment Screen displays

graphically and numerically the current hydraulic
pressures in the cylinders of the backhoe attachment.
The pointers should be in the green colored section
of the dial gauges. If a pointer is in the red section of
the dial gauge, an event/fault has occurred.
Check the Event List for details. Notify the
responsible service personnel.
HE (Head End) – Piston side of the hydraulic cylinder
RE (Rod End) – Rod side of the hydraulic cylinder
UENR5484-02 19
Operator Level

Hydraulics - Slewing Screen

Illustration 15 g03797782
Slewing Screen

The Hydraulics Slewing Screen displays graphically

and numerically:
• The hydraulic pressure going to the slew motors
when slewing to the right or left

• The hydraulic pressures in pilot hydraulic (servo)

circuit when slewing to the right or left

• The slew brake pressure

The pointers should be in the green colored section
of the dial gauges. If a pointer is in the red section of
the dial gauge, an event/fault has occurred. Check
the Event List for details.
When the slew brake is applied, the slew brake
symbol turns red.
The contamination status of the two slew motors is
monitored. When contamination is monitored, a red
light is activated. Notify the responsible service
personnel.
20 UENR5484-02
Operator Level

Hydraulics - Oil Tank Screen

Illustration 16 g03797792

(13) Pressure of the Two Hydraulic Tank (14) Hydraulic Tank Filling Level (16) Hydraulic Oil Cooling Circuit
Filter Chambers (15) Hydraulic Oil Temperature (°C) Information

Pressure of the Two Hydraulic Tank Filter • Cooler Bar - Hydraulic oil pressure inside the
Chambers (13) – Pressure inside the two Hydraulic radiator. The pointer should be in the green
Tank Filter Chambers is displayed. colored sections of the dial gauge. If the pointer is
in the red section, the radiator may be
The pointer should be in the green colored sections
contaminated. Notify the responsible service
of the dial gauges. If the pointers are in the red
section, the filters are contaminated. If the filters are personnel immediately.
contaminated, replace the filters. Notify the
responsible service personnel immediately. • Cooled °C - Hydraulic oil temperature at the
hydraulic oil radiator outlet. There must be a
Hydraulic Tank Filling Level (14) – The filling level significant difference between the inlet and outlet
of the Hydraulic Tank is displayed: temperature. If not, check the radiator fins for
contamination.
• Low - Check the level indicator tube at the
hydraulic tank. Top OFF the hydraulic oil.
• Low Low - Stop working. Risk of damaging
hydraulic pumps. Call the responsible service
personnel. Top OFF the hydraulic oil.
Hydraulic Oil Temperature (°C) (15) – Hydraulic Oil
Temperature is displayed.

Hydraulic Oil Cooling Circuit (16) – Information

regarding the Hydraulic Oil Cooling Circuit is
displayed in this section.

• Pump Set - The current value which controls the

cooling pump (in mA).

• Cooler °C - The hydraulic oil temperature at the

hydraulic oil radiator inlet.
UENR5484-02 21
Operator Level

Hydraulics - Travel Screen

Illustration 17 g03797827

(17) Travel Speed - Red when slow gear is (18) Track Parking Brakes - Red when travel (19) Track Tension - Red when track tension
activated. parking brakes are applied. is slackened.

The Hydraulics Travel Screen displays graphically

and numerically:
• The hydraulic pressure coming from Pump 4 for
left-hand travel motors

• The hydraulic pressure coming from Pump 3 for

right-hand travel motors
The pointers should be in the green colored sections
of the dial gauges. If the pointers are in the red
section, an event/fault has occurred. Check the Event
list for details.
The deflection angle of the corresponding travel
pedal (left-hand/right-hand) is displayed as well.
22 UENR5484-02
Operator Level

Grease
UENR5484-02 23
Operator Level

Grease - Progressive Grease System Screen

Illustration 18 g03797873

(20) Lube System Status (22) Faults or Malfunctions are marked with
(21) Pressure inside the Grease Lines a Red Dot in this area.

The Progressive Grease System Screen displays If the system detects a fault or malfunction in the
data related to the central lubrication screen. A lubrication system, there will be a red dot in the upper
central gauge (21) displays the pressure inside the right-hand area of the screen (22). Notify the
grease lines. The pointer should be in the green responsible service personnel immediately.
colored section of the dial gauge. If the pointer is in
the red section, an event/fault has occurred. Check
the Event list for details. Notify the responsible
service personnel immediately.
24 UENR5484-02
Operator Level

Malfunctions must be fixed as soon as possible. parts of the equipment when working without
Serious damage may occur to bearings and other lubrication.
i06036104

Service Screens
SMCS Code: 7490

Servosystem Screen

Illustration 19 g03797898

(1) Joystick Symbol (3) Joystick Settings Buttons (5) “Slew Brake Test” Button
(2) Pedal Symbol (4) “More Details” Button

The characteristic curves (ramps) of control levers (1)
and control pedals (2) are adjustable. The adjusted
values are shown here graphically and numerically.
Adjustment is to be done in the “Setup” Menu
(password required).
The functioning of key switches and thumb wheels in
joysticks (3) can be checked as well.
Joystick Symbol (1) – Tapping on a joystick symbol
displays the current value settings assigned to the
left-hand/right-hand joystick.
The function of the key switches in the joystick is
displayed as well.
Pedal Symbol (2) – Tapping on a Pedal symbol
displays the current value settings of the pedal.
Joystick Settings Buttons (3) – Key switches and
thumb wheels in joysticks (3) can be checked by
tapping on the touch-sensitive areas below the
joystick graphic. The color changes from red to
green.
“ More Details”” Button (4) – Pressing the “More
Details” Button leaves the current screen and opens
a screen with all the current values assigned to pedal
and joystick functions.
“ Slew Brake Test”” Button (5) – Pressing the “Slew
Brake Test” Button leaves the current screen and
opens a screen on which the slew brake test can be
performed.
UENR5484-02 25
Operator Level

Service - More Details Screen

Illustration 20 g03797925

(6) Current Values of Left-hand Joystick (7) Current Set Values for the Pedals (8) Current Values of Right-hand Joystick

The left side of the screen (6) displays all actual

current (mA) values for the left-hand joystick. While
moving the joystick, the mA value shown will change.
The mA value represents the current going to the
corresponding value (2Y13), which can be found in
the schematics.
The center part of the screen displays all currently set
values for the pedals. While moving the pedal, the
mA value shown will change.
The right side of the screen (8) displays all actual
current values for the right-hand joystick. While
moving the joystick, the mA value shown will change.
The mA value represents the current going to the
corresponding value (2Y13), which can be found in
the schematics.

Note: Illustration 20 was taken from a test system.

Because of that, the joystick and pedal symbols were
crossed and the current values are zero. On field
machines, the symbols will not be crossed and there
will be values which make sense. In the case of an
Event/Fault, the values may not make sense.
26 UENR5484-02
Operator Level

Service - Slew Brake Test Screen

Illustration 21 g03797951

(9) Preconditions (11) Hydraulic Pressures (13) Hydraulic Pressure Gauges

(10) Start Button (12) Instructions (14) Progress Indicators

A Slew Brake test must be performed on the slewing
system:
• During commissioning of the machine
• After repair work or maintenance work is carried
out
To ensure proper functioning of the slew brake
system, the slew brake test should be performed at
every scheduled maintenance.
Proper functioning of the slew brake system has
influence on machine safety.
Before performing the slew brake test, ensure that
the machine is in a safe workplace where the
machine can rotate 360° without hitting an obstacle.
Check that all personnel have left the area around
the machine. Activate the horn.
To perform the slew brake test, follow the instructions
(12) given on the screen.
Preconditions (9) – Preconditions to be fulfilled
before performing the slew brake test (symbols from
right to left):
• Engine running with more than 1200 rpm
• Servo control switch in dashboard OFF
• Operator seat occupied
Time space to fulfill preconditions is 60 seconds.
Start Button (10) – Button to start the test. Appears
green when the test can be started.
Hydraulic Pressures (11) – Hydraulic pressures in
components of the slewing system.
Instructions (12) – Instructions to perform the slew
brake test.
Hydraulic Pressure Gauges (13) – Instruments
displaying hydraulic pressure in left-hand/right-hand
slewing position.
Progress Indicators (14) – Indicators showing the
progress during testing:
• Pending - red after starting test
• Progress - yellow at 300 bar

• Swing brake applied

UENR5484-02 27
Operator Level

• Passed - green when test OK

i06036121

Documents Screen
SMCS Code: 7490

Help - Viewing PDF Documents

Screen

Illustration 22 g03798000
Help Menu

Technical documentation for the machine is stored in

memory.
Press the button of the appropriate PDF file to open
the file on the screen.
Use sliders and buttons to navigate through the files.
The “Software versions” button opens a screen which
displays the version number of the software installed
in the Monitoring System.

PDF Reader - Functions

After choosing a button on the Help screen, the
corresponding PDF file will be displayed on the
screen with the Build In viewer.
Navigate inside the documents using the navigation
elements on the left side of the screen. See
Illustration 24 .
28 UENR5484-02
Operator Level

Illustration 23 g03798013
Navigation Elements

Illustration 24 g03798020

PDF Reader - Settings Screen • Possibility to invert swipe

In this screen, some settings can be made that • Background color - black or white
influence the appearance of the PDF file viewer:

• Arrangement of the menu bar - left or right side of

the window
UENR5484-02 29
Operator Level

Illustration 25 g03798024

PDF Reader - Search Screen

The files of the machine's Technical Documentation
stored in memory are generic PDF files. Generic PDF
files can be searched for letters, words, or numbers.
This does not work for scanned filed because
scanned files are graphics.
To key in a search term, press the input field “Find
What:” .
The on-screen keyboard will appear.
Enter a search term. Choose the search parameters
and start the search by press the binocular icon (1).

Illustration 26 g03798027

(1) Binocular icon

30 UENR5484-02
Operator Level

Software Version Screen

Most of the electronic components have built-in
microcontrollers which have loaded software.
In this screen, the software version numbers are
listed as well as the serial numbers of the major
components.
This information may be helpful for service personnel
and for ordering spare parts.

Illustration 27 g03798030
UENR5484-02 31
Operator Level

i06036114

Event List Screen

SMCS Code: 7490

Illustration 28 g03798145

(1) Description of Events (3) Sort Buttons (Severity, Status)

(2) Location Button (4) Filter Buttons (Error, Warning, Info)

The Event List Screen lists all of the events/faults
stored in memory since the last delete.
Events and Faults are described with plain text. To
the left of each events/fault there is a colored icon
along with a code and status information. The date
and time of the first recorded appearance of a events/
fault appears in the “Details” column.
Events/Faults are characterized in three classes:
Error – Red icon, Highest severity
Warning – Yellow icon, Middle severity
Info – Green icon, Lowest severity
The Event list can be filtered on these classes by
pressing one of the “Filter” buttons (4).
Location Button (2) – Pressing the “Location” button
opens a screen showing more information related to
the defective component. This makes identification of
the defective component easier and helps in problem
solving.
In this screen, the first event has been pressed and a
gray underlay appears. Pressing the “Location”
button (2) opens a new screen (Illustration 29 ).
Sort Buttons (Severity, Status) (3) – Pressing the
“Sort” buttons sorts the event/fault relative to Severity
(ascending, descending) or Status (active, inactive).
Filter Buttons (Error, Warning, Info) (4) – Pressing
the “Filter” buttons filters the event/fault relative to
Severity (only “Error” , only “Warning” , or only “Info”
).

The list in Illustration 28 is filtered relative to “Error” .

When a list is filtered relative to “Error” , only events/
faults with the highest severity (class Red) are listed.
All other events/faults still in memory.
Description of Events (1) – This area of the screen
displays the Description and Characterization of
events/faults that have occurred on the machine.
This list can be displayed sorted (3) or filtered (4) in
different ways. Longer lists can be scrolled up or
down by sliding the blue bar or by pressing the UP/
DOWN buttons.
32 UENR5484-02
Operator Level

Event List Screen - Location

Illustration 29 g03798163

(5) Back to Previous Screen (6) Screenshot Button

1. On the Event List screen (Illustration 28 ), press

the event/fault in the first line. The event/fault will
highlight in gray.
2. Press the “Location” button (2). Illustration 29 will
appear showing details for the event.
A photo in Illustration 29 shows the location of the
defective component, a description of the fault,
hints on possible causes, and recommendations
on how to solve the problem.
3. Press the “Back to previous screen” button (5) to
go back to the Event list.
UENR5484-02 33
Operator Level

Screenshot - Making and Storing

Illustration 30 g03798186

After pressing the “Screenshot” button (6), the

system produces a graphic file of all the information
visible on the screen. It is useful store this information
for later use.
The screen will show a list of available drives. Select
a drive in which to store the file. The graphics file will
be name automatically and written to the drive.
34 UENR5484-02
Operator Level

i06036106

Setup Login Screen

SMCS Code: 7490

Illustration 31 g03798195

Press the “Setup” button to open a window that will

permit access to the Monitoring System “Service
Level 1” . This section is exclusively for service
personnel. A password is needed to gain access.

i06036124

Data Interfaces
SMCS Code: 7490

Monitoring System - Interfaces

The 6020B Monitoring System comes with different
interfaces which allow communication with external
electronic devices.
Three connectors are located on the rear wall of the
dashboard (left-hand side of the operator seat).

Illustration 32 g03798204
(1) Ethernet, jack type RJ45
(2) USB 2.0, jack type A
(3) Jack D Sub, 9 pins

Ethernet, jack type RJ45 (1) – Used for the

connection of future extensions such as a remote
servicing system.
USB 2.0, jack type A (2) – this jack accepts a USB
stick used to save operating data for evaluation on an
UENR5484-02
external computer.
Jack D Sub, 9 pins (3) – Used to connect with a
diagnosis software with access to the CAN data link.
This connection is reserved for service personnel.
A USB stick can be connected to the USB plug-in
connection (2). Suitable are USB sticks that would
also work on computer with Windows® operating
systems. Format with the NTFS or FAT32 file system.
If a screen page displays the symbol of a camera, all
visible information on this screen page can be saved
as a graphic file (screenshot). For additional
information, refer to Setup Login Screen >
Screenshot - Making and Storing.
i07177595
Data Interfaces
SMCS Code: 7490
Monitoring System - Interfaces
The 6020B Monitoring System comes with different
interfaces which allow communication with external
electronic devices.
Three connectors are located on the rear wall of the
dashboard (left-hand side of the operator seat).
Illustration 33 g03798204
(1) Ethernet, jack type RJ45
(2) USB 2.0, jack type A
(3) Jack D Sub, 9 pins
Ethernet, jack type RJ45 (1) – Used for the
connection of future extensions such as a remote
servicing system.
USB 2.0, jack type A (2) – This jack accepts a USB
stick used to save operating data for evaluation on an
35
Operator Level
external computer.
Jack D Sub, 9 pins (3) – Used to connect with a
diagnosis software with access to the CAN data link.
This connection is reserved for service personnel.
A USB stick can be connected to the USB plug-in
connection (2). Suitable are USB sticks that would
also work on computer with Windows® operating
systems. Format with the NTFS or FAT32 file system.
If a screen page displays the symbol of a camera, all
visible information on this screen page can be saved
as a graphic file (screenshot). For additional
information, refer to Setup Login Screen >
Screenshot - Making and Storing.
i06036111
General Maintenance
SMCS Code: 7490
Monitoring System - Cleaning
Clean dirty screens with a soft, slightly moist cloth. To
remove persistent dirt, use a conventional cleaning
agent for Monitoring System cleaning.
NOTICE: Never use solving or scouring cleaning
agents. These cleaning agents could damage the
surface of the screen.
Do not use compressed air or water under
pressure (high-pressure cleaner or steam
cleaner). This could damage the electronic
components.
Monitoring System - Replace
Battery
Time and date information on the display computer is
stored in a memory sustained by a back-up battery
(Lithium). This battery has a finite lifetime and must
therefore be replaced at regular intervals. The
lifetime of the battery is approximately 10 years.
Monitoring System - Disposal
This electronic device contains substances that might
be harmful to the environment. For example, the
electronic components may contain lead (Pb) and
mercury (Hg).
The background illumination lamps are LED-type
lamps.
The battery for backing up the memory contains
lithium.
Therefore, this device must not be disposed of with
regular household waste. Dispose of properly as
electronic scrap.
36 UENR5484-02
Operator Level

NOTICE: The escaping liquid from a damaged

LCD screen may be harmful.
Do not come in contact with escaping liquids. In
case of skin contact, wash immediately with
warm water and soap.
UENR5484-02 37
Service Level 1

Service Level 1

i06036109

Setup Menu - Service Level 1

SMCS Code: 7490
The setup menus are designed for monitoring and
changing parameters for an individual machine on
site. To access the setup menus, a Level 1 Service
Code is required. A Level 1 Service Code is available
only for service personnel.

Illustration 34 g03798247

(1) General Setup Button (4) Service Level II Menu Button (password
(2) Operating Hours Menu Button protected)
(3) Controller Menu Button (5) Signal Logging Menu Button

Navigate the configuration menus and the controller

main menu with a special tab in the Setup menu.
38 UENR5484-02
Service Level 1

i06036137

Common Setup Menu

SMCS Code: 7490

Illustration 35 g03798286

(1) General Information (3) Change Setup Code (5) Pop-up Window
(2) Time and Date (4) Language Button (6) Cross Control (CC) Settings Menu

The common setup menu provides general

information about the software and general software
settings. i06036107

General Information (1) – Provides general

information about the excavator: Operating Hours Menu
SMCS Code: 7490
• Program version: Software version number
The Operating Hours Menu shows the operating
• Excavator model hours by operation and the resulting minimum time to
the next maintenance interval. In addition, after
• Excavator serial number completed maintenance, the maintenance interval
can be set back to the standard value.
Time and Date (2) – Update the date and time to
local time.
Change Setup Code (3) – Opens a dialog to change
the Level 1 service code for accessing the setup
menus. Use this menu to change the service code.
Make sure that you recognize the new code.
Language Button (4) – Press this button until the
flag related to the desired language is inserted.
Pop-up Window (5) – Opens the pop-up window for
writing back the modified data. If any data has been
changed, press “Yes ” to enable the modification.
Cross Control (CC) Settings Menu (6) – Opens the
CC settings menu. Use these menus to calibrate the
touch display.
UENR5484-02 39
Service Level 1

Illustration 36 g03798340

(1) Operating Time/Percentage (3) Save Button

(2) Next Service (4) Initial Commissioning

Operating Time/Percentage (1) – Shows the
operating time per operation in hours and as a
percentage of the total operating time:
• Total: Total operating hours
• Attachment Operating: Operating time during
which excavator attachment moves
• Traveling: Operating time during which the
excavator travels
• Swinging: Operating time during which the
excavator swings
• Other maintenance intervals are 500, 1000, 5000,
and 10000 operating hours.
Save Button (3) – Saves the selected settings. A
lifetime log can be created which contains the exact
data about when the changes began and in which
interval they were carried out (similar to a check log).
Initial Commissioning (4)
• Precommissioning: Pre-installation checks. To
start commissioning the excavator, press the
“Precommissioning Checks” button when all pre-
installation tests are conducted successfully.

Next Service (2) – Shows the minimum time to next
maintenance and resets the maintenance intervals:
• 100 Service Hours: After successfully completing
the scheduled maintenance following the
excavator's first 100 hours, press the “100h
Service” button to release the excavator for
continuous service.

Illustration 37 g03798435
(5) Checkmark Button

• 250 Service Hours: If the routine excavator

maintenance required after 250 hours has been
successfully completed, press the Checkmark
button (5) to reset the corresponding maintenance
interval to the standard value.
40 UENR5484-02
Service Level 1

i06036117

Signal Logging Menu

SMCS Code: 7490

Illustration 38 g03798471

(1) Graph (3) Start/Stop Recording of Set Signal (4) Open Submenu
(2) Save Button Values (5) Set X-Axis Time Range(s)

The signal logging menu allows you to record by a change in the displayed time period.
different excavator signals and to display those
signals graphically for up to 100 seconds.
Signal Logging Submenu
Graph (1) – Shows the set signal values (as a curve)
over a pre-defined period. Excavator signals can be set via the Signal Logging
submenu.
Save Button (2) – Saves the graph of the recorded
signal values.
Start/Stop recording of set signal values (3) –
Starts and stops the recording of set signal values.

Illustration 39 g03798488
(3) Start/Stop Buttons

Open Submenu (4) – Opens a submenu in which the

signal values can be set for recording.
Set X-Axis Time Range(s) (5) – Set the time period
which should be displayed on the x-axis of the graph.
The time period can be between 3.15 seconds and
100.75 seconds. The recorded period is not affected
UENR5484-02 41
Service Level 1

Illustration 40 g03798500

(6) Signal (7) Red X

Signal (6) – The signals which can be recorded can

either be identified by the ID or the signal name.
Red X (7) – Double click on the Red X to record the
signal:

• Red X: Not Selected

• Green Checkmark: Selected

i06036136

Controllers Menu
SMCS Code: 7490
This menu is the starting point for information on
controllers. Level 1 password protection is sufficient
for reading the data. A Level 2 password is required
for changing the settings.
42 UENR5484-02
Service Level 1

Illustration 41 g03798543

(1) Drive Controller Button (2) Servo Controller Button

Press the Drive Controller Button (1) to call up the Press the Servo Controller Button (2) to call up the
menu for the drive controller. menu for the servo controller.
i06036103

Servo Controller Menu

SMCS Code: 7490

Digital In

Illustration 42 g03798563

(1) Swing Circuit Lock Out Tab (3) Digital Out Tab (5) Digital In Tab
(2) Analog Out Tab (4) Analog In Tab (6) Digital Tab

Swing Circuit Lock Out Tab (1) – Opens the “Swing

Circuit Lock Out” Tab. Analog Out Tab (2) – Opens the “Analog Out” Tab.
UENR5484-02 43
Service Level 1

Digital Out Tab (3) – Opens the “Digital Out” Tab.

Analog In Tab (4) – Opens the “Analog In” Tab.
Digital In Tab (5) – Opens the “Digital In” Tab. In this
tab, the respective button is blue.
Digital Tab (6) – Digital Inputs.

Table 1
Digital Inputs
Hydraulic oil tank full Active if the tank is full.

Hydraulic oil level min Active if the tank is almost empty - operation is still possible.

Hydraulic oil level min min Active if the tank is empty - the engine stops immediately.

Travel lock override Emergency operation: If the ladder is down, traveling or swinging is im-
possible. This state can be bypassed so that it is possible to travel
away from the dangerous area.

Service arm Up Not available in the present model.

Seat contact Active if a person is sitting in the operator seat. If it is not active, the ex-
cavator cannot move.
Ladder Up 1/Up 2 A sensor with two contacts recognizes a defined position of the ladder
(either ladder Up or ladder Down).

Emergency boom Down In an emergency, attachment can move down via residual pressure
saved in the system.

Emergency Stop Emergency OFF button was activated.

Pilot filter contamination Active if the filter is contaminated (contamination switch on the hydraul-
ic tank).

Swing pilot ON Start button must be active in addition to the seat contact so that the
excavator can move.
Travel speed 2 2nd speed travel.

Swing brake Swing brake is active.

Travel brake Travel brake is active.

Lubrication system reset If there is a singular error, reset the system to maintain a proper
operation.

Lubrication pulse Monitoring the lubrication via a proximity switch - the number of piston
strokes is counted (should be seven cycles). If this number is not
reached, an error message is triggered. You can restart the system via
the reset button, but not unlimited. The system also saves the error
after shutdown and is protected against a voltage breakdown.

Grease container empty Active when the container is empty.

Fuel tank full Active when the fuel tank is full.

Service arm active Not available in the present model.

Ignition Active if ignition is ON.

Lighting ladder Active when the ladder light is ON.

Lighting maintenance Active when the maintenance light is ON.

Lighting cabin Active when the cabin light is ON.

(continued)
44 UENR5484-02
Service Level 1

(Table 1, contd)
Digital Inputs
Emergency OFF needs reset Additional safety - when emergency OFF is active, activate the reset
button on the battery cabinet.

Swing motor 1 contamination Active if there is contamination of swing motor 1.

Swing motor 2 contamination Active if there is contamination of swing motor 2.

UENR5484-02 45
Service Level 1

Analog In (Mode A)

Illustration 43 g03798732

(7) Mode Button (8) Currently Selected Tab (9) Analog Inputs

This menu provides information on the analog

sensors to the servo controller.
All sensors are displayed according to the same
principle (left to right).
Sensor Identifier (example: 2B1).
Name of sensor (example: LH swing press. prop.).
Sensor Status:

• Light gray: the value displayed results from an

assigned value - additional indication of its current
status.

• Grayed out: no values are currently assigned -

additional indication that the value is not current.
• Grayed out with red: the current value results from
an assigned value - it indicates a sensor problem -
the value does not correspond to the expected
value.
Measured values: vary according to mode settings. In
mode A, pressure values (in bar) and temperature
values are displayed (Illustration 43 ). In mode B,
current values in mA are displayed (Illustration 44 ).
46 UENR5484-02
Service Level 1

Table 2
Analog A Inputs
LH(1) Swing Pilot Pressure Activate LH large spool.

RH(1) Swing Pilot Pressure Activate RH large spool.

LH Swing Pressure High pressure for LH swing motor movement.

RH Swing Pressure High pressure for RH swing motor movement.

Pilot Pressure 35 bar Source of pilot pressure.

Main Pump 1-6 Pressure Pressure for Main Pumps.

Boom Head End Pressure Pressure for boom cylinder HE(1) .

Boom Rod End Pressure Pressure for boom cylinder RE(1) .

Stick Head End Pressure Pressure for stick cylinder HE.

Stick Rod End Pressure Pressure for stick cylinder RE.

Bucket Head End Pressure Pressure for bucket cylinder HE.

Bucket Rod End Pressure Pressure for bucket cylinder RE.

Hydraulic Oil Filter 1 Pressure in filter 1 (hydraulic tank) - measurement via 10 bar sensor.

Ambient Temperature Ambient Temperature in °C.

Grease Pressure Pump pressure of lubricant (grease).

Hydraulic Oil Filter 2 Pressure in filter 2 (hydraulic tank) - measurement via 10 bar sensor.

Pilot Pressure 100 bar Source of 35 bar pressure (see pilot pressure).

Swing Park Brake Pressure Pressure of 20 bar required for swing brake release.
(1) LH = Left Hand, RH = Right Hand, HE = Head End, RE = Rod End
UENR5484-02 47
Service Level 1

Analog In (Mode B)

Illustration 44 g03798750

(10) Mode Button (11) Currently Selected Tab (12) Analog Inputs

This menu provides information on the analog

sensors to the servo controller.
All sensors are displayed according to the same
principle (left to right).
Sensor Identifier (example: 2B1).
Name of sensor (example: LH swing press. prop.).
Sensor Status:
• Light gray: the value displayed results from an
assigned value - additional indication of its status.
• Grayed out: no values are currently assigned -
additional indication that the value is not current.

• Grayed out with red: the current value results from

an assigned value - it indicates a sensor problem -
the value does not correspond to the expected
value.
Measured values: measured current in mA.
Table 3
Analog B Inputs
LH(1) Swing Pilot Pressure Activate LH large spool.

RH(1) Swing Pilot Pressure Activate RH large spool.

LH Swing Pressure High pressure for LH swing motor movement.

RH Swing Pressure High pressure for RH swing motor movement.

(continued)
48 UENR5484-02
Service Level 1

(Table 3, contd)
Analog B Inputs
Pilot Pressure 35 bar Source of pilot pressure.

Main Pump 1-6 Pressure Pressure for Main Pumps.

Boom Head End Pressure Pressure for boom cylinder HE(1) .

Boom Rod End Pressure Pressure for boom cylinder RE(1) .

Stick Head End Pressure Pressure for stick cylinder HE.

Stick Rod End Pressure Pressure for stick cylinder RE.

Bucket Head End Pressure Pressure for bucket cylinder HE.

Bucket Rod End Pressure Pressure for bucket cylinder RE.

Hydraulic Oil Filter 1 Pressure in filter 1 (hydraulic tank) - measurement via 10 bar sensor.

Ambient Temperature Ambient Temperature in °C.

Grease Pressure Pump pressure of lubricant (grease).

Hydraulic Oil Filter 2 Pressure in filter 2 (hydraulic tank) - measurement via 10 bar sensor.

Pilot Pressure 100 bar Source of 35 bar pressure (see pilot pressure).

Swing Park Brake Pressure Pressure of 20 bar required for swing brake release.
(1) LH = Left Hand, RH = Right Hand, HE = Head End, RE = Rod End
UENR5484-02 49
Service Level 1

Digital Out

Illustration 45 g03798765

(13) Currently Selected Tab (14) Digital Inputs

This menu provides information on the analog

sensors to the servo controller.
All sensors are displayed according to the same
principle (left to right).
Component Identifier (example: 2KH1).
Name of the component (example: swing brake
valve).
Component Status:
• Light gray: the value displayed results from an
assigned value - additional indication of its current
status.
• Grayed out: no values are currently assigned -
additional indication that the value is not current.

• Grayed out with red: the current value results from

an assigned value - it indicates a sensor problem -
the value does not correspond to the expected
value.
Table 4
Digital Inputs

Swing brake valve Activates the pressure for swing brake release.

Pilot Valve Switches two values to reach 35 bar.

Emergency down Currently unavailable.

(continued)
50 UENR5484-02
Service Level 1

(Table 4, contd)
Swing left shift valve Switches OFF swing pilot pressure on the left - additional safety for
swing operation.

Swing right shift valve Switches OFF swing pilot pressure on the right - additional safety for
swing operation.

Travel speed 2 Pressure valve control for 2nd speed travel function.

Swing pressure increase valve Increases pressure limit to achieve higher speed for swing function.

Track tension valve Adjusts track tension.

Lubrication pump Switches lubrication pump to transport lubricant (always active during
swing operation).

Main pumps support valve Provides systems with auxiliary pressure - auxiliary pressure of 50 bar
for the main pumps.

Auxiliary system valve Provides systems with auxiliary pressure - auxiliary pressure of 60 bar
for the main ladder.
Test signal control lamps Active during ignition. Lamp test: all lamps are switched ON for 5 sec-
onds so that defective lamps can be detected.

Cabin lights Displays for 4.1.1 “servo controller” .

Maintenance lights Displays for 4.1.1 “servo controller” .

Boarding lights Displays for 4.1.1 “servo controller” .

Hydraulic oil tank full lamp Active if the tank is full: the hydraulic oil intake stops automatically.

Radio communication Activates radio set - it can be switched ON by activating a button on

the joystick without limiting excavator operation. The radio set can be
used for communication.
Horn Horn.
Travel alarm As soon as the excavator starts moving, you can hear alarm sound,
which you also hear when the ladder moves.

LED travel brake Active if the brake is switched ON - the lamp is integrated into the travel
brake switch.
Lubrication error lamp Active if there is an error in the lubrication system.
UENR5484-02 51
Service Level 1

Analog Out

Illustration 46 g03798832

(15) Currently Selected Tab (16) PWM Outputs

This menu provides information on the analog
sensors to the servo controller.
All sensors are displayed according to the same
principle (left to right).
Component Identifier (example: 2Y13).
Name of the component (example: PV - slew left).
Component Status:
• If the movements are slower than expected, cross-
check the specified value for the related sensor,
the displayed value, and the value measured at
the valve.
• If all the values match, check the hydraulic
system.

• Light gray: the value displayed results from an

assigned value - additional indication of its current
status.

• Grayed out: no values are currently assigned -

additional indication that the value is not current.
• Grayed out with red: the current value results from
an assigned value - it indicates a sensor problem -
the value does not correspond to the expected
value.
Measured Values: Measured current in mA.
PWM (pulse width modulation) – Outputs.

• A high value as the sensor indicates fast

movements.
• Display helps to locate and identify cable breaks
based on the measured current values.
52 UENR5484-02
Service Level 1

Table 5
PWM Outputs
PV(1) - Swing left Value for proportional valve - swinging left.

PV - Swing right Value for proportional valve - swinging right.

PV - Bucket head end 1 & 2 Value for proportional valve - bucket HE(1) 1 & 2.

PV - Bucket rod end 1 & 2 Value for proportional valve - bucket RE(1) 1 & 2.

PV - Travel left backward Value for proportional valve - travel left backward.

PV - Travel left forward Value for proportional valve - travel left forward.

PV - Travel right backward Value for proportional valve - travel right backward.

PV - Travel right forward Value for proportional valve - travel right forward.

PV - Boom rod end 1 & 2 Value for proportional valve - boom rod end 1 & 2.

PV - Boom head end 1 & 2 Value for proportional valve - boom head end 1 & 2.

PV - Boom floating valve Value for proportional valve - boom floating valve. HE and RE are
short-circuited so that the boom moves down under its own weight.

PV - Stick rod end 1 & 2 Value for proportional valve - stick rod end 1 & 2.

PV - Stick head end 1 & 2 Value for proportional valve - stick head end 1 & 2.

Warning buzzer Alarm signal.

PV - Main pump 1 - 6 Value for proportional valve - main pumps 1 - 6.

(1) PV = Proportional Valve, HE = Head End, RE = Rod end.
UENR5484-02 53
Service Level 1

Slew Circuit Lock-Out

Illustration 47 g03798877

(17) Currently Selected Tab (18) Safety Related Components

The “Swing Circuit Lock Out” tab provides

information on the status of the safety-related
excavator components. There are two states or
indicating colors:
• Red: means that a component has a fault.
• Green: means that the component is in working
order.
If one or several components are not active or have
errors (example: “red” ), the swing circuit cannot be
activated.
Table 6 shows a list of safety-related components in
a chain. Each of the listed components is to be ready
for operation so that the excavator swing circuit can
be activated. This table will help detect a defect of a
safety-related component.
Table 6
Safety Related Components
Lever Status display of joystick.

CAN Safety Status display “CAN Safety” .

PLC Status display “PLC” .

Swing Brake Pressure Status display “Swing Brake Pressure” .

Swing Brake Pressure Sensor Status display “Swing Brake Pressure Sensor” .

Ladder Status display “Ladder” .

Servo Pressure 35 bar Sensor Status display “Servo Pressure 35 bar Sensor” .

(continued)
54 UENR5484-02
Service Level 1

(Table 6, contd)
Safety Related Components
Servo Pressure 100 bar Sensor Status display “Servo Pressure 100 bar Sensor” .

Swing Pilot Pressure Status display “Swing Pilot Pressure” .

Swing Pilot Pressure Sensor Status display “Swing Pilot Pressure Sensor” .

Swing High Press LH/RH Status display “Swing High Press LH/RH” .

Swing High Press Sensor Status display “Swing High Press Sensor” .

Main Pump Pressure Status display “Main Pump Pressure” .

Main Pump Pressure Sensor Status display “Main Pump Pressure Sensor” .

Status Status display “Status display of the entire system:” .

- Green: OK (only if all components are displayed in green).
- Red: Defective components - swing circuit cannot be activated.

i06036119

Drive Controller Menu

SMCS Code: 7490

Digital In

Illustration 48 g03798979

(1) I/O Module In (3) Fan Tab (5) Analog Tab

(2) Engine Test Mode (4) Digital Tab (6) I/O Module Out

This menu provides information on digital
components connected to the engine controller.
All components are displayed according to the same
principle (left to right):
Component Identifier, (example: -3SH1).
Component Status:
• Light gray: The value displayed results from an
assigned value - additional indication of its status.
• Grayed out: No values are currently assigned -
additional indication that the value is not current.
• Grayed out with red: The current value results
from an assigned value, indicating a sensor
problem - the value does not correspond to the
expected value.
UENR5484-02 55
Service Level 1

I/O Module In (1) – See Table 7 .

Table 7
I/O Module In
Engine start Starts the engine.

Engine stop Stops the engine.

RPM Up Increases the engine speed.

RPM Down Reduces the engine speed.

Shut OFF oil tank Manual ball valve for oil tank. Shut OFF the tank in case of leaks to pre-
vent the fluid from leaking.

Speed reduction Active if the engine speed is limited to 1000 rpm (example: if the joy-
stick is not moved for 8 seconds). A higher speed reduction is not set,
otherwise the startup from 0 rpm takes too much time.

PDT contamination PDT (Power Drive Transmission) or pump gearbox contamination. Ac-
tive if the PDT is contaminated.
Main pump 1-6 contamination Active if one of the six main pumps is contaminated.

PDT gearbox oil level Switches when the oil is not available.

PDT gearbox oil pressure Monitoring during operation.

Coolant level Active if the coolant is available in the reservoirs.

Main pump 1-6 temperature Temperature switch - switches ON at 92° C (198° F) and switches
OFF at 86° C (187° F).

Air filter 1 & 2 contamination Contamination switch - switches at 64 mbar.

Emergency Stop Emergency OFF button is activated.

Engine Test Mode (2) – Both buttons are for “Engine

Test Mode” . When this test mode is switched ON,
the drive controller sends an “Engine Running” flag
which means that the proportional valves are
supplied with voltage according to the joystick
position (required for production tests).
Fan Tab (3) – Opens the “Fan” tab.
Digital Tab (4) – Opens the “Digital” tab. In the
currently selected tab, the respective button is in
blue.
Analog Tab (5) – Opens the “Analog” tab.
I/O Module Out (6) – See Table 8 .

Table 8
I/O Module Out
LED engine running Active if the engine is running.

LED battery charging Active if the engine is OFF. If there is a problem with a battery, the LED
flashes.
LED engine oil pressure Active if the engine is OFF. If there is a problem with an oil pressure,
the LED flashes.

(continued)
56 UENR5484-02
Service Level 1

(Table 8, contd)
I/O Module Out
LED engine cooling temperature Active if the temperature becomes too high - the LED lights from 99° C
(210° F). To achieve a lower temperature, pump power output is
reduced.
LED engine cool level Active if level is too low.

LED speed reduction Active if there is no movement for approximately 8 seconds.

Engine Start relay Starts the engine or starter, auxiliary relay.

Engine Stop relay Stops the engine, auxiliary relay.

UENR5484-02 57
Service Level 1

Analog In and PWM Out (Mode A)

Illustration 49 g03799010

(7) Analog Inputs (9) Engine Test Mode Tab (11) PWM Outputs
(8) Mode Tab (10) Currently Selected Tab

This menu provides information on digital

components connected to the engine controller.
All components are displayed according to the same
principle (left to right):
Sensor Identifier (example: -3KH2).
Name of the sensor (example: PV - Engine water
cooling).
Component Status:

• Light gray: The value displayed results from an

assigned value - additional indication of its status.

• Grayed out: No values are currently assigned -

additional indication that the value is not current.
• Grayed out with red: The current value results
from an assigned value, indicating a sensor
problem - the value does not correspond to the
expected value.
Measured values: vary according to the sensor type.
Analog Inputs (7) – Measured values: Monitored
value in %, °C, and bar. See Table 9 .
58 UENR5484-02
Service Level 1

Table 9
Analog Inputs
Sensors
Fuel level Fuel level as a percentage (or bar).

Hydraulic oil temperature Hydraulic oil temperature in °C.

PDT oil temperature Gear oil temperature in °C.

Hydraulic oil pressure before cooler Hydraulic oil pressure before cooler in bar.

Hydraulic oil temperature before cooler Hydraulic oil temperature before cooler in °C.

Hydraulic oil temperature after cooler Hydraulic oil temperature after cooler in °C.

Mode Tab (8) – Switches between display mode A

and B.
Engine Test Mode Tab (9) – Both buttons are set for
“Engine Test Mode” . When this test mode is
switched ON, the drive controller sends an “Engine
Running” flag which means that the proportional
valves are supplied with voltage according to the
joystick position (required for production tests).
Currently Selected Tab (10) – Currently Selected
Tab.
PWM Outputs (11) – All proportional valves (PV) are
supplied with 70 mA to keep the caps of the main
control valves constantly full of oil to get better
response from the machine.

A high value for the sensor indicates fast

movements:
• If the movements are slower than expected, cross-
check the related sensor for the specified value,
the displayed value, and the value measured at
the valve.

• If all values match, check the hydraulic system.

Table 10
PWM Outputs
Sensors
PV - Engine water cooling Present current (mA) at proportional valve for engine water cooling.

PV - Hydraulic oil cooling Present current (mA) at proportional valve for hydraulic oil cooling.

PV - Hydraulic oil circle Present current (mA) at proportional valve for hydraulic oil circle.

PV - Reverse water fan Reverses direction of rotation to remove contamination from the fan
blades for water cooling.

PV - Reverse hydraulic oil fan Reverses direction of rotation to remove contamination from the fan
blades for hydraulic oil cooling.
UENR5484-02 59
Service Level 1

Analog In and PWM Out (Mode B)

Illustration 50 g03799056

(12) Sensors with Analog Inputs (14) Engine Test Mode Tab (16) PWM Outputs
(13) Mode Tab (15) Currently Selected Tab

This menu provides information on digital

components connected to the engine controller.
All components are displayed according to the same
principle (left to right):
Terminal identifier of the sensor is connected to the
control cabinet (example: -3KH2).
Name of the sensor (example: PV - Engine water
cooling).
Component Status:

• Light gray: The value displayed results from an

assigned value - additional indication of its status.
• Grayed out: No values are currently assigned -
additional indication that the value is not current.
• Grayed out with red: The current value results
from an assigned value, indicating a sensor
problem - the value does not correspond to the
expected value.
Measured values: Measured current in mA.
Sensors with Analog Inputs (12) – See Table 11 .
60 UENR5484-02
Service Level 1

Table 11
Sensors with Analog Inputs
Sensors
Fuel level
Hydraulic oil temperature

PDT oil temperature Temperature of PDT gearbox oil.

Hydraulic oil pressure before cooler

Hydraulic oil temperature before cooler

Hydraulic oil temperature after cooler

Mode Tab (13) – Switches between display mode A

and B.
Engine Test Mode Tab (14) – Both buttons are set
for “Engine Test Mode” . When this test mode is
switched ON, the drive controller sends an “Engine
Running” flag which means that the proportional
valves are supplied with voltage according to the
joystick position (required for production tests).
Currently Selected Tab (15) – Currently Selected
Tab appears blue.
PWM Outputs (16) – All proportional valves (PV) are
supplied with 70 mA to keep the caps of the main
control valves constantly full of oil to get better
response from the machine.

A high value for the sensor indicates fast

movements:
• If the movements are slower than expected, cross-
check the related sensor for the specified value,
the displayed value, and the value measured at
the valve.

• If all values match, check the hydraulic system.

Table 12
PWM Outputs
Sensors
PV - Engine water cooling Present current (mA) at proportional valve for engine water cooling.

PV - Hydraulic oil cooling Present current (mA) at proportional valve for hydraulic oil cooling.

PV - Hydraulic oil circle Present current (mA) at proportional valve for hydraulic oil circle.

PV - Reverse water fan Reverses direction of rotation to remove contamination from the water
cooling fan blades.

PV - Reverse hydraulic oil fan Reverses direction of rotation to remove contamination from the hy-
draulic oil cooling fan blades.
UENR5484-02 61
Service Level 1

Fan

Illustration 51 g03799086

(17) Water Temperature/IMT (19) Engine Test Mode Tab

(18) Hydraulic Oil Temperature (20) Currently Selected Tab

Water Temperature/IMT (17) Reverse Mode:

Water Temperature/IMT: • Inactive: Shows the status of the reverse mode.
°
• Water: Shows the water temperature in C. • Last reverse time: Shows the time of the last
reverse movement (in hours).
• IMT (Inlet Manifold Temperature): Shows IMT
Temperature in °C. Engine Test Mode (19)
• Fan current: Shows the present fan current in mA. Engine Test Mode:
Reverse mode: • Both buttons are set for “Engine Test Mode” .
When this test mode is switched ON, the drive
• Inactive: Shows the status of the reverse mode. controller sends an “Engine Running” flag which
means that the proportional valves are supplied
• Last reverse time: Shows the time of the last with voltage according to the joystick position
reverse movement (in hours). (required for production tests).
Diagram: Currently Selected Tab (20)
• Shows the relation between the current and
speed: The lower the current, the higher the
speed.
Hydraulic Oil Temperature (18)
Hydraulic Oil Temperature:
• Before cooler: Shows the hydraulic oil temperature
before cooler in °C.

• After cooler: Shows the hydraulic oil temperature

after cooler in °C.

• Fan current: Shows the present current at the fan

in mA.
62 UENR5484-02
Service Level 2

Service Level 2

i06036112

Setup Menu - Service Level 2

SMCS Code: 7490

Illustration 52 g03799312

(1) Copy Files Button (3) Service Level III Button (5) Update Button
(2) Commissioning Button (4) Setup Button

A password is required to navigate to the

configuration menu from the Service Level II menu.
Copy Files Button (1) – Opens the “Copy Files ”
menu. Refer to Systems Operation, “Copy Files
Menu”.
Commissioning Button (2) – Opens the
“Commissioning” menu.
Service Level III Button (3) – Opens the “Service
Level III” menu. The access to this level is protected
by a password.
Setup Button (4) – Opens the “Setup” menu. Refer
to Systems Operation, “Servo Controller Parameters
- Engine Menu”.
Update Button (5) – Opens the “BCS Update” menu.
UENR5484-02 63
Service Level 2

BCS Update

Illustration 53 g03799327

(6) To PLC (7) To BCS

The “BCS Update” menu provides options for

updating the excavator software. The following
alternatives are available:
To PLC (6) – Flash PLC files.

To BCS (7):

• Update documents
• BCS application files

• Commit + shut down

• Shell: Opens the system prompts
64 UENR5484-02
Service Level 2

i06036131

Copy Files Menu

SMCS Code: 7490

Illustration 54 g03799334

(1) USB Stick (2) Arrow Buttons (3) BCS

USB Stick (1) – USB stick shows the content of the

USB device.
Arrow Buttons (2) – Use the Arrow buttons to copy
data from the BCS to the USB stick and vice versa.
BCS (3) – BCS enables you to export data to:

• A USB device
• Desktop

• Database
• Data logging
UENR5484-02 65
Service Level 2

i06036100

Servo Controller Parameters -

Engine Menu
SMCS Code: 7490

Illustration 55 g03799349

(1) Overview of Adjustable Parameters (4) Update Button (8) Servo Control (Pumps) Button
(2) Normalized Torque Load/Feed Forward (5) Drive Control Button (9) Servo Control (Engine) Button
Term (6) Servo Control (General) Button
(3) Save Button (7) Servo Control (Valves) Button

In this menu, you can adjust the parameters for

“Servo Controller 1” . The corresponding switch (9) Drive Control Button (5) – Press this button to
will highlight in blue, which means Active. reach the “Drive Controller Parameters” tab.

Overview of Adjustable Parameters (1):
• Parasitic torque in Nm.
• Underspeed torque ramp-up rate in Nm.
• Underspeed torque ramp-up gain in Nm.
• Engine speed threshold.
• Proportional gain for engine underspeed control.
• Integral gain for engine underspeed.
• Integral underspeed upper limit.
Servo Control (General) Button (6) – Press this
button to reach the “Servo Control Parameters -
General” tab.
Servo Control (Valves) Button (7) – Press this
button to reach the “Servo Control Parameters -
Valves” tab.
Servo Control (Pumps) Button (8) – Press this
button to reach the “Servo Control Parameters -
Pumps” tab.
Servo Control (Engine) Button (9) – Press this
button to reach the “Servo Control Parameters -
Engine” tab.

• Integral underspeed lower limit.

Normalized Torque Load/Feed Forward Term (2)
Save Button (3)
Update Button (4) – The currently set parameters
from the control are read out and then displayed (IST
parameters).
66 UENR5484-02
Service Level 2

i06036096

Servo Controller Parameters -

Pumps Menu
SMCS Code: 7490

Illustration 56 g03799409

(1) General (3) Travel (5) Update Button

(2) Swing (4) Save Button (6) Currently Selected Tab

In this menu, you can set the parameters for “Servo • Flow command ramp for downstroke
Controller 2” . The corresponding switch (6) will be
highlighted in blue, which means Active. Save Button (4):

General (1): • Saves the settings.

• Pump disp. upstroke rate Update Button (5):

• Pump disp. downstroke rate • The currently set parameters from the controllers
are read out and then displayed (IST parameters).
• Pump disp. upper limit
Currently Selected Tab (6):
• Pump disp. lower limit
• Shows currently selected tab.
• Pump calibration offset
• Pump calibration slope

• Max attachment pump current

• Min attachment pump current
Swing (2):
• Flow command ramp for upstroke

• Flow command ramp for downstroke

Travel (3):

• Flow command ramp for upstroke

UENR5484-02 67
Service Level 2

i06036098

Servo Controller Parameters -

Valves Menu
SMCS Code: 7490

Illustration 57 g03799449

(1) Attachment (4) Update Button (7) Attachment Float

(2) Swing (5) Currently Selected Tab (8) General
(3) Save Button (6) Travel

Attachment (1): • Shows currently selected tab.

• Main valve spool upstroke rate limit Travel (6):

• Main valve spool downstroke rate limit • Travel valve spool upstroke rate limit

• Main valve calibration slope • Travel valve spool downstroke rate limit

• Main valve calibration offset Attachment Float (7):

Swing (2): • Float valve spool upstroke rate limit
• Swing valve spool upstroke rate limit • Float valve spool downstroke rate limit
• Swing valve spool downstroke rate limit • Float valve calibration slope
• Swing & travel valve calibration slope • Float valve calibration offset
• Swing & travel valve calibration offset General (8):

Save Button (3): • Max valve driver current

• Saves the settings • Min valve driver current

Update Button (4):

• The currently set parameters from the controllers
are read out and then displayed (IST parameters).
Currently Selected Tab (5):
68 UENR5484-02
Service Level 2

i06036097

Servo Controller Parameters -

General Menu
SMCS Code: 7490

Illustration 58 g03799468

(1) Light Logic (3) Update Button (5) Grease System

(2) Save Button (4) Currently Selected Tab

In this menu you can set lubrication and light • Bucket cylinder cutoff time: time after which
parameters. excavator stops. The bucket can be emptied but
can no longer be filled (to protect the lubrication
Light Logic (1): system).
• Light logic/boarding lighting time: Light for
ascending the ladder is ON for a set amount of
time.
Save Button (2):

• Saves the settings.

Update Button (3):

• The currently set parameters from the controllers

are read out and then displayed (IST parameters).
Currently Selected Tab (4):
• Shows currently selected tab.
Grease System (5):
• Maximum cycle time: In Maximum cycle time, the
impulses are counted. If no impulse is received,
the system assumes an error.

• Repetition time for lubrication cycles: the time

between two cycles.
UENR5484-02 69
Service Level 2

i06036116

Drive Controller Parameters

Menu
SMCS Code: 7490

Illustration 59 g03799498

(1) Engine (4) Save Button (7) Water

(2) Hydraulic Oil (5) Update Button
(3) IMT (6) Currently Selected Tab

Engine (1): • Low Temperature: Temperature-dependant speed

• Engine Automatic Idle: If the excavator does not
move for a certain time (no joystick movement,
etc.), the engine speed is reduced to a certain
value, but not completely. If the engine speed is
completely reduced, it would take too long to bring
the excavator in a fully operational state again.
• Engine Cool Down Time Out: Maximum time
during which the excavator continues operation
(so that there is no heat if fans do not run). After a
set time period, the excavator stops.
Hydraulic Oil (2):
control. See also Systems Operation, “Drive
Controller Menu”.
IMT (Inlet Manifold Temperature) (3): When the
temperature reaches a certain value, the speed
increases to maximum.
• IMT High: Temperature-dependant speed control.
See also Systems Operation, “Drive Controller
Menu”.
• IMT Low: Temperature-dependant speed control.
See also Systems Operation, “Drive Controller
Menu”.

• Fan reverse on start: Immediately changes the Save Button (4):

direction of fan rotation during the excavator start. • Saves the settings
• Fan cleaning duration: Duration of the change in Update Button (5):
the direction of rotation.
• The currently set parameters from the controllers
• Fan cleaning interval: Determines how often the are read out and then displayed (IST parameters).
direction of the rotation changes.
Currently Selected Tab (6):
• High temperature: Temperature-dependant speed
control. See also Systems Operation, “Drive • Shows currently selected tab.
Controller Menu”.
Water (7):
70 UENR5484-02
Service Level 2

• Water cooling fan Reverse on start: Immediately

changes the direction of fan rotation during
excavator start.
• Water cooling fan cleaning duration: Duration of
the change in the direction of rotation.

• Water cooling fan cleaning interval: Determines

how often the direction of the rotation changes.

• Water high temperature: Temperature-dependant

speed control. See also Systems Operation,
“Drive Controller Menu”.

• Water low temperature: Temperature-dependant

speed control. See also Systems Operation,
“Drive Controller Menu”.
UENR5484-02 71
Index Section

Index
C Digital In..........................................................42
Common Setup Menu..........................................38
Controllers Menu.................................................41
Copy Files Menu .................................................64
D Servo Controller Parameters - Valves Menu ..........67
Data Interfaces ............................................. 34–35
Monitoring System - Interfaces.................... 34–35
Documents Screen..............................................27
Help - Viewing PDF Documents Screen.............27
PDF Reader - Functions ...................................27
PDF Reader - Search Screen ...........................29
PDF Reader - Settings Screen ..........................28
Software Version Screen ..................................30
Drive Controller Menu..........................................54
Analog In and PWM Out (Mode A).....................57
Analog In and PWM Out (Mode B).....................59
Digital In..........................................................54
Fan.................................................................61
Drive Controller Parameters Menu........................69
E
Event List Screen ................................................31
Event List Screen - Location .............................32
Screenshot - Making and Storing ......................33
Digital Out .......................................................49
Slew Circuit Lock-Out.......................................53
Servo Controller Parameters - Engine Menu .........65
Servo Controller Parameters - General Menu ........68
Servo Controller Parameters - Pumps Menu .........66
Setup Login Screen.............................................34
Setup Menu - Service Level 1...............................37
Setup Menu - Service Level 2...............................62
BCS Update ....................................................63
Signal Logging Menu...........................................40
Signal Logging Submenu .................................40
Start Screen .........................................................7
Basic Screen .....................................................7
Help Section....................................................14
Lower Section..................................................13
Middle Section.................................................12
Top Section .....................................................10
System Status Screen .........................................15
Engine ............................................................16
Grease............................................................22
Hydraulics .......................................................17
Systems Operation Section....................................4
T
Table of Contents ..................................................3

G
General Information ..............................................4
BCS (Board Control System) ..............................4
BCS Housing.....................................................4
The First Screen After Startup.............................6
General Maintenance ..........................................35
Monitoring System - Cleaning ...........................35
Monitoring System - Disposal ...........................35
Monitoring System - Replace Battery.................35

I
Important Safety Information ..................................2
Introduction ..........................................................4

O
Operating Hours Menu ........................................38
Operator Level ......................................................7

S
Service Level 1 ...................................................37
Service Level 2 ...................................................62
Service Screens..................................................24
Service - More Details Screen...........................25
Service - Slew Brake Test Screen......................26
Servosystem Screen ........................................24
Servo Controller Menu.........................................42
Analog In (Mode A) ..........................................45
Analog In (Mode B) ..........................................47
Analog Out ......................................................51
UENR5484 CAT, CATERPILLAR, their respective logos, “Caterpillar Yellow”, and the POWER EDGE trade
©2018 Caterpillar dress as well as corporate and product identity used herein, are trademarks of Caterpillar and
All Rights Reserved may not be used without permission.

72 July 2018