Health Interface Module Configuration and Operation Guide for Certain Non-Cat© Excavators{7605} Caterpillar

Machine Control and Guidance Products:

HEALTH NON-CAT (S/N: DNK1-UP)

Introduction

This Special Instruction contains information for connection of the health interface module to a Liebherr Excavator machine. This document also contains operation information, once the health interface module is configured, for use with supported Liebherr Excavator machine models.

The supported models are:

• R9250 and R9350 with SW Version BBT06 Version 3.4

• R9250, R9350, and R9400 with SW Version BBT06 Version 3.7

• R996 / R996B with SW Version BBT03 Version 5.4

Refer to Special Instruction, REHS7357, "Installation Guide for the Health Interface Module" for procedures on the installation of the common components for the health interface module.

Refer to Systems Operation, UENR3676, "Health Interface Module Setup and Configuration Guide" for details on the setup and configuration of the health interface module on non-Cat machines.

Refer to Schematic, UENR5446, "Health Interface Module v2.5 Electrical System" for details on the common components of the health interface module.

Refer to Schematic, UENR6429, "Health Interface Module Option for Non-Cat Machines Electrical System" for details on the connection information for the Liebherr Excavator.

Important Safety Information

Do not perform any procedure in this Special Instruction until you have read this Special Instruction and you understand this information. Use only proper tools and observe all precautions that pertain to the use of those tools. Failure to follow these procedures can result in personal injury. The following procedures should also be observed.

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

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

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

Therefore, the warnings in this publication and the warnings that are on the product are not all inclusive. Ensure that any tool, procedure, work method, or operating technique you use that is not recommended by Caterpillar is safe.

Ensure that the product will not be damaged or the product will not be made unsafe by the operation, lubrication, maintenance, or repair procedures used.

Ground the equipment. Improper grounding will result in electrical current paths that are uncontrolled and unreliable. Uncontrolled electrical circuit paths can result in damage to the equipment. Uncontrolled electrical circuit paths can also cause electrical activity that may degrade the electronics and communications. Ensure that all grounds are secure and free of corrosion.

System Overview

The health interface module installed on the machine provides real-time data and event information on the machine. The health interface module for the machine allows office personnel to collect health information and monitor an entire fleet. The health interface module is used in order to enhance the operating efficiencies of a mine site.

System Components

Required Parts

The 443-3538 Control Wiring Gp is required for installation of the health interface module on supported non-Cat machines. The 443-3538 Control Wiring Gp consists of the following installation groups:

• 375-4294 Machine Wiring Gp

• 443-3535 Electronic Control Gp

• 443-3537 Control Wiring Gp

375-4294 Machine Wiring Gp

Refer to Table 1for the list of parts provided in the 375-4294 Machine Wiring Gp .

443-3535 Electronic Control Gp

Refer to Table 2for the list of parts that are included in the 443-3535 Electronic Control Gp . This group includes the ECM, the health interface module software, and configuration file for the machine-specific health interface module.

443-3537 Control Wiring Gp

Refer to Table 3for the list of parts that are included in the 443-3537 Control Wiring Gp . This group contains the machine-specific harness for connection to the health interface module software.

Interconnections

Illustration 1	g03476326
System Interconnections (1) 375-4279 Control Harness As (2) 357-7167 Power Harness As (3) 443-3536 Wiring Harness (4) 343-8444 Power Cable Harness As (5) 343-8446 Power Cable Harness As (6) 382-0995 Network Cable As

Once all of the common hardware components for the health interface module are installed, the health interface module communicates with the non-Caterpillar machine through the RS232 port.

The 443-3536 Wiring Harness connects to the RS232 port on the machine.

Illustration 2	g03735254
Partial connection schematic of A1001 Control Unit (7) RS232 port, "X32 DB9" connection.

Illustration 3	g03735270
Operator station location of "A1001" Control Unit (8) "A1001" Control Unit

Illustration 4	g03476357
Location of X32 RS232 port on control unit "A1001" (9) X32 RS232 port

443-3536 Wiring Harness

Perform the following procedure to connect the 443-3536 Wiring Harness to the RS232 Service Laptop port on the Liehberr machine:

1. Connect the "SERIAL OPTION" branch of the 443-3536 Wiring Harness to the "SERIAL OPTION" branch of the 357-7167 Power Harness As .

2. Open the" A1001" Control Unit, located beside the operator seat. Refer to Illustration 3.

3. Locate the X32 RS232 port on the control unit. Refer to Illustration 4.

   Note: This port is the Service Laptop connection.

4. Connect the "TPI IN" branch of the 443-3536 Wiring Harness to the RS232 port in the "A1001" Control Unit.

   Note: The RS232 port is a "DB9" pin-out connection.

5. Ensure that a dust cap is connected to the "TPI OUT" connector of the 443-3536 Wiring Harness .

Operation

User Interface

Once the 443-3534 Software file for the machine health interface module is uploaded to the ECM, the "INTERFACE" menu tab displays in the main menu.

The "INTERFACE" menu tab page consists of the following menu items:

• "Statistics"

• "Parameters"

• "Active Events"

Illustration 5	g03889557
"INTERFACE" menu tab screen

"Statistics"

Illustration 6	g03889573
"Statistics" page screen

The "Statistics" page provides statistics about the machine data link on the "COM" port.

The following information is displayed in the "Statistics" page:

"Rx Count" - This value is the number of valid messages that have been received by the health interface module from the machine unit since the last reset.

"Tx Count" - This value is the number of messages that have been sent from the health interface module to the machine since the last reset.

"Rx Error Count" - This value is the number of messages that could not be received by the health interface module from the machine unit since the last reset.

"Tx Error Count" - This value is the number of messages that could not be sent from the health interface module to the machine unit since the last reset.

Note: The health interface module software for the machine unit is not designed to send messages to the machine unit. The "Tx Count" value and the "Tx Error Count" value should remain 0. The "Statistics" page displays a default value of 0 for all parameters when the ECM is powered OFF/ON. As soon as data is exchanged between the health interface module and the machine unit, the appropriate count increments by one. If the machine unit stops sending data to the health interface module, the previous values that were displayed remain displayed on the web page. The statistic values are only reset back to 0 if the ECM is power cycled, or the "Clear" button is pressed.

"Parameters"

Illustration 7	g03889579
"Parameters" page screen

The "Parameters" page allows office personnel to view parameters from the machine in real time.

"Active Events"

Illustration 8	g03889599
"Active Events" page screen

The "Active Events" page is used to view active events in real time. The following information is provided for each event:

The following information is available for each active event:

• "Event Name"

• "Severity"

• "Activation Time"

• "Occurrence"

Active events are displayed for as long as the events are active. When an event is no longer active, the event is no longer displayed. Once an event occurs, the activation time is set to the time the event occurred in the "MM/DD/YYYY HH:MM:SS" format. Also, the occurrence increments by one.

If the excavator stops sending data to the health interface module, then the previous values that were displayed remain and are not reset to "No Active Events" or "Data Not Available".

Note: Events data is stored in BBRAM. If the health interface module is powered "OFF", the event data stored in BBRAM will reappear once the health interface module is powered back "ON".

Note: The "Machine communication not as expected" event is raised when the excavator does not respond to queries made by the health interface module. The data packets are not being understood by the health interface module. Perform a key switch power cycle, or refer to the excavator documentation.

The "Communication with machine could not be established" event is raised when communication is lost between the excavator and the health interface module. Verify the physical connection in the 443-3536 Wiring Harness .

"Active Diagnostic Events"

Illustration 9	g03889610
"Active Diagnostic Events" page screen

The "Active Diagnostic Events" page displays active events in real time.

The following information is provided for each active event:

• "Event Name"

• "Severity"

• "Failure Mode"

• "Activation Time"

• "Occurrence"

Active events are displayed as long as the events are active. Once an event is no longer active, the event will no longer display.

Once an event occurs, the activation time is set to the time the event occurred in the "MM/DD/YYYY HH: MM:SS" format. Also, the "Occurrence" count increments by one.

If the excavator stops sending data to the health interface module, the previous values remain and are not reset to "No Active Events" or "Data Not Available".

Note: Event data is stored in Battery-Backed-Up Random Access Memory (BBRAM). If the health interface module is powered off, the event data stored in BBRAM will reappear once the health interface module is powered back on.

The following is a list of possible on-board generated diagnostic events:

Trend data storage memory low - This event describes that 90% of the available memory is consumed.

Trend data storage memory full - This event describes that 95% of the available memory is consumed. A report must be downloaded or data will be lost.

Snapshot stored - This event describes an important machine event triggered a snapshot report.

Snapshot memory full - This event declares not enough memory to store any new snapshots. The report must be downloaded.

Communication with machine could not be established - This event describes that the excavator is not communicating with the health interface module.

If Communication with machine could not be established, perform a key switch power cycle and verify CAN bus connectivity between the machine and the health interface module.