Payload Control System Printer {7494, 749P} Caterpillar

Wheel Loader

938H (S/N: MCC1-UP; MJC1-UP; JKM1-UP; LKM1-UP)

950G Series II (S/N: BAA1-UP; AYB1-UP; AYD1-UP; AYL1-UP; AXR1-UP; AYS1-UP; AXX1-UP)

950H (S/N: N1A1-UP; M1G1-UP; J5J1-UP; K5K1-UP)

962G Series II (S/N: BAB1-UP; BAC1-UP; BAD1-UP; AYE1-UP; AYG1-UP; AXS1-UP; AXY1-UP)

962H (S/N: N4A1-UP; M3G1-UP; J6J1-UP; K6K1-UP)

966G Series II (S/N: AXJ1-UP; AXL1-UP; ANT1-UP; AWY1-UP; ANZ1-UP; AWZ1-UP)

966H (S/N: A6D1-UP; A6G1-UP; A6J1-UP)

972G Series II (S/N: AXC1-UP; AXE1-UP; AXN1-UP; AWP1-UP; AXP1-UP; ANY1-UP)

972H (S/N: A7D1-UP; A7G1-UP; A7J1-UP)

980G Series II (S/N: AXG1-UP; AWH1-UP; AYT1-UP)

980H (S/N: MHG1-UP; A8J1-UP; JMS1-UP)

Introduction

This Special Instruction provides information about the Payload Control System (PCS) printer. This publication provides information for the printer:

• Installation

• Setup

• Maintenance

• To enable to communicate with the payload control system

Safety Section

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Do not operate or work on this machine unless you have read and understand the instructions and warnings in the Operation and Maintenance Manuals. Failure to follow the instructions or heed the warnings could result in injury or death. Contact your Cat dealer for replacement manuals. Proper care is your responsibility.

Installation of the printer, operation of the printer, and the maintenance of the printer must not occur unless the instructions and warnings in this publication have been read and are understood.

There are no serviceable parts that are inside of the printer. Refer to a qualified service technician for any service or any repairs.

Use of genuine Caterpillar^tm replacement parts is required in order to warrant the proper operation and safe operation of the system. Any alteration or any modification of this device will void the warranty. Any alteration or any modification of this device may cause the product to be unsafe to operate.

The print head and the motors get hot during use. Wait until the components cool before touching the components.

Remove the harness connector from the printer in order to ensure that the printer is disconnected from the DC power source. The printer must be disconnected from the DC power source before removing any covers or performing any required cleaning or maintenance.

Connecting the printer to an ungrounded receptacle can result in electrical shock.

Never place the printer near flammable substances. Never place the printer near explosive substances. Do not operate near liquid or spill liquid into the printer at any time.

Installation

Components

Illustration 1	g01524664
317-3728 PCS Printer

Illustration 2	g06296061
537-5523 PCS Printer

Illustration 3	g01524657
PCS 2 Printer Cable

Illustration 4	g01524662
PCS 3 Printer Cables

Illustration 5	g01524666
Mounting Hardware

Required Tools

Table 1

Required Tools
Quantity	Description
1	T 20 Torx Driver
1	T 50 Torx Driver
1	4 mm Allen Wrench

Required Parts

Table 2

PCS 2 317-3721 PCS Printer Service Kit
Qty	Part Number	Description	Serviceable
4	8C-6364	M5X0.8X14 mm Bolt	Y
2	8L-8413	Strap	Y
2	9X-2041	M10X1.5 Truss Head Screw	Y
4	269-2556	8-32 Pan Head Screw	Y
1	233-5041	PCS 2 Harness	Y
1	300-4025	Bracket	Y
1	300-3582	RAM Mounting Kit	Y
1	317-3727	Printer Kit Onboard	Y
300-3582 RAM Mounting Kit Components
2	259-4399	Base	Y
1	270-3311	Clamp Gp	Y
317-3727 Printer Kit Onboard Components
1	317-3728 has been canceled and replaced by 537-5523	Printer	Y
1	317-3730 for use with 317-3728 only. Use 553-1223 with 537-5523 printer.	Paper	Y

Table 3

PCS 3 317-3726 PCS Printer Service Kit
Qty	Part Number	Description	Serviceable
4	8C-6364	M5X0.8X14 mm Socket Head Bolt	Y
2	8L-8413	Strap	Y
2	9X-2041	M10X1.5 Truss Head Screw	Y
4	269-2556	8-32 Pan Head Screw	Y
1	292-4495	PCS 3 Harness Converter	Y
1	315-5000	PCS 3 Harness	Y
1	300-4025	Bracket	Y
1	300-3582	RAM Mounting Kit	Y
1	317-3727	Printer Kit	Y
300-3582 RAM Mounting Kit Components
2	259-4399	Base	Y
1	270-3311	Clamp Gp	Y
317-3727 Printer Kit Onboard Components
1	317-3728 has been canceled and replaced by 537-5523	Printer	Y
1	317-3730 for use with 317-3728 only. Use 553-1223 with 537-5523 printer.	Paper	Y

The PCS 2 (1) has a display that uses a separate keypad. The PCS 3 (2) has a keypad that is located on the display. Refer to Illustration 6.

Illustration 6	g01523753
(1) Display and Keypad for the PCS 2 (2) PCS 3 Display

PCS Kit Ordering Information Guidelines

If the machine is equipped with a PCS 2 system, then the 317-3721 Printer Kit must be ordered. Refer to Illustration 6 to determine the existing PCS system that is on the machine.

If the machine is equipped with a PCS 3 system, then the 317-3726 Printer Kit must be ordered. Refer to Illustration 6 to determine the existing PCS system that is on the machine.

Install Components for Model 950 to Model 980

1. Locate the weld boss (4) that is located in the machine cab. The weld boss is located on the "Roll Over Protection System" (ROPS) post (3) near the floor of the machine cab. Refer to Illustration 7.
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   Illustration 7	g01523773
   (3) ROPS on Right Side of Machine Cab (4) Weld Boss for PCS RAM Mount (5) Floor Mat (6) Operator Console

2. Use the four 8C-6364 Bolts (10) to assemble the RAM ball mount (9) to the mounting plate (11).
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   Illustration 8	g01523776
   (9) RAM Ball Mount (10) 8C-6364 Bolts (11) Mounting Plate

3. Use the two 9X-2041 Screws (14) to assemble the RAM ball assembly (15) to the weld boss (4). Refer to Illustration 9.

   Note: The shorter side (12) of the mounting plate must be installed facing the roof of the machine cab. Refer to Illustration 8.

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   Illustration 9	g01524023
   (4) Weld Mount (14) 9X-2041 Screws (15) RAM Ball Assembly

4. Use the four 269-2556 Screws (16) to assemble the ball assembly (17) to the printer (18).
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   Illustration 10	g01524024
   (16) 269-2556 Screw 8-32 Pan Head (17) Ball Assembly (18) Printer

5. Assemble the RAM clamp (20) to the printer (18) and to the RAM ball assembly (15). Position the printer. Turn the clamp handle (19) in a clockwise direction to tighten the RAM clamp.
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   Illustration 11	g01524025
   (15) RAM Ball Assembly (18) Printer (19) RAM Mount Clamp Handle (20) RAM Mount Clamp

6. Install the cable (21) to the printer (18). Tighten the thumb screws (22) that are on the DE9 connector to secure the connector to the printer (18). Refer to the appropriate "Cable Connection" section for the proper cable connections for each type of configuration.

Illustration 12	g01524027
(18) Printer (21) DE9 Connector (22) Thumb Screws on the Connector

Illustration 13	g01525074

Cable Connections for the PCS 2

1. Ensure that the DE9 connector has been correctly installed to the printer.

2. Screw the Amphenol connector (26) into the connector that is on the side of the PCS 2 display (25). Refer to Illustration 14.

Illustration 14	g01524674
Cable Attached to the PCS 2 Display (25) PCS 2 Display (26) Amphenol Connector

Cable Connections for the PCS 3

1. Ensure that the DE9 connector end of the adapter cable has been correctly installed to the printer.

2. Plug the 292-4495 Wiring Harness (adapter cable) (27) into the printer cable 315-5000 Wiring Harness (28). Refer to Illustration 15.
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   Illustration 15	g01524697
   Adapter Cable Plugged into Printer Cable (27) PCS 3 292-4495 Wiring Harness (28) PCS 3 315-5000 Wiring Harness

3. Remove the machine harness connector (32) from the holder (33). Plug the six pin Deutsche style connector (34) of the printer cable into the machine harness connector (32). The machine harness connector (32) is behind the PCS 3 display (35). Refer to Illustration 16.
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   Illustration 16	g01524699
   (32) Machine Harness Connector (33) Machine Harness Connector Holder (34) Six Pin Deutsche Style Connector (35) PCS 3 Display

4. Secure the printer harness.

Install Components for Model 938H

1. Locate the weld boss (41) that is inside of the machine cab, to the right of the operator's console (40). The weld boss is located on the "Roll Over Protection System" (ROPS) post (42). Refer to Illustration 17.
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   Illustration 17	g01819245
   (40) Operator's Console (41) Weld Boss for PCS RAM Mount (42) ROPS on Right Side of Machine Cab

2. Use the four 8C-6364 Bolts (46) to assemble the RAM ball mount (45) to the mounting plate (47). Refer to Illustration 18.
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   Illustration 18	g01819314
   (45) RAM Ball Mount (46) 8C-6364 Bolts (47) Mounting Plate (48) Short Side of Mounting Plate

3. Use the two 9X-2041 Screws (53) to assemble the mounting plate (47) to the weld boss (41). Refer to Illustration 19.

   Note: The shorter side (48) of the mounting plate must be installed facing the roof of the machine cab. Refer to Illustration 18.

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   Illustration 19	g01819354
   (41) Weld Boss for PCS RAM Mount (47) Mounting Plate (53) 9X-2041 Screws

4. Use the four 269-2556 Screws (54) to assemble the ball assembly (56) to the printer (55). Refer to Illustration 20.
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   Illustration 20	g01819453
   (54) 269-2556 Screws (55) Printer (56) Ball Assembly

5. Assemble the RAM clamp (60) to the printer (55) and to the RAM ball mount (45). Position the printer. Turn the clamp handle (61) in a clockwise direction to tighten the RAM clamp.
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   Illustration 21	g01819474
   (45) RAM Ball Mount (55) Printer (60) RAM Clamp (61) Clamp Handle

6. Install the DE9 cable connector (62) to the printer (55). Tighten the thumb screws (63) that are on the DE9 connector to secure the connector to the printer (55). Refer to the "Cable Connections for the PCS 3" section.

Illustration 22	g01819515
(55) PCS Printer (62) DE9 Connector (63) Thumb Screws on the Connector

Illustration 23	g01820381
Installed Printer

Cable Connections for the PCS 3

1. Ensure that the DE9 connector end of the adapter cable has been correctly installed to the printer.

2. Plug the 292-4495 Wiring Harness (adapter cable) (64) into the printer cable 315-5000 Wiring Harness (65). Refer to Illustration 24.
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   Illustration 24	g01820418
   Adapter Cable Plugged into Printer Cable (64) 292-4495 Wiring Harness (65) 315-5000 Wiring Harness

3. Route harness under floor mat, between seat and console, to the rear of the cab. The connector (68) is located under the 250-7523 Cover (70). The cover is located in the rearward end of the cab. The connector is a six pin Deutsche style connector (68). The six pin Deutsche connector is wired to the PCS electronic control module (ECM).Refer to Illustration 25.

   Note: Care should be taken when the cover is removed and when the cover is installed.

   1. Remove the cover (70) to access the six pin Deutsche connector.

   2. Plug the six pin Deutsche connector (68) into the PCS printer harness.
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   Illustration 25	g01820469
   (68) Six Pin Deutsche Style Connector (69) Back Rest of Operator's Seat (70) Cover

4. Secure the printer harness.

5. Install the cover.

Operation

Load the Paper for the Printer

A roll of paper is supplied with each printer.

Note: Use only genuine Caterpillar paper to have maximum performance and to obtain optimum print quality.

1. To install the paper, first move the "Paper Door Release" (71) to the release position. Refer to Illustration 26.
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   Illustration 26	g01487918
   (71) Paper Door Release Lever

2. Lift the paper door to expose the paper compartment. Refer to Illustration 27.
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   Illustration 27	g01524240
   PCS Printer with Open Access Door, No Paper

3. If there is a cardboard tube in the paper support, then remove the cardboard tube. Discard the cardboard tube. To move the paper support (72), place the right thumb at the bottom of the paper support. Then apply force toward the right. The paper support should move to the right. Load the paper roll. Refer to Illustration 28.

   Note: After the paper roll has been loaded, ensure that the roll rotates freely on the paper support.

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   Illustration 28	g01524241
   (72) Paper Support

4. Unroll enough of the paper to allow the paper to lay across the printer head. Refer to Illustration 29.

   Note: Ensure that the paper is centered on the roller.

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   Illustration 29	g01524250
   Paper Loaded in the PCS Printer

5. Use two thumbs to close the paper compartment door. Refer to Illustration 30. Ensure that both sides of the compartment door are securely closed. The lid for the paper compartment will click when the lid is closed securely.
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   Illustration 30	g01524251
   Proper Method to Close Printer Access Door

6. Press the paper feed button (76) to feed several inches of paper through the paper compartment door. Tear off the excess paper. Refer to Illustration 31 and Illustration 32.

Illustration 31	g01525297
Proper Method to Tear Printer Paper

Printer Operation Characteristics

Illustration 32	g01488393
(73) On/Off Button (74) Power On LED Indicator (75) Error Indicator LED (76) Paper Feed Button

Table 4

Call Out	Function	Description
73	Power Button	The power button is used to turn the printer on or off.
74	Power Indicator LED	Green indicates that the power is on. A flashing green power indicator LED and an error indicator at the same time means that a paper error exists.
75	Error Indicator LED	Yellow flashing indicates that an error has occurred.
76	Paper Feed and Paper Advance Button	Advances paper 32 mm (1.25 inch). Used to clear check paper conditions.

The indicator (80) will change from all green to all red as the paper supply is used. If the indicator (80) is completely green, then a full roll of paper is in place. If the indicator is partially red, then the end of the roll is nearing. If the indicator is completely red, then the paper roll is empty.

Illustration 33	g01524517
(80) Paper Indicator

The End of Paper Roll Warning

As mentioned above, the paper roll indicator (80) will change from green, when the paper roll is full , to red when the roll is empty.

If the printer runs out of paper during a print, then the power on LED (74) will flash and the error LED (75) will also flash. Use the following steps if the printer runs out of paper during a print:

1. Replace the paper as described in the "Load Paper for the Printer" section.

2. The paper feed button (76) must be pressed before being able to print again.

3. Press the paper feed button (76) again to feed the paper through the opening of the paper compartment.

Turn the Printer On or OFF

The printer will automatically be turned on when the machine keyswitch is turned to the ON position. Press the power button (73) to turn the printer off. To turn the printer back on, press the power button that is on the printer. If the printer is on, then the LED (74) that is next to the button will be green. Refer to Illustration 32.

Printer Self Test

Perform the following steps In order to initiate a self test:

1. Ensure that the printer is turned off.

2. Press the paper feed button and hold the paper feed button.

3. While the paper feed button is being pressed, press the power button and release the power button.

4. The power indicator LED (74) and the error indicator (75) will flash once. When the power indicator LED (74) stays illuminated, then release the paper feed button (76). Printing will begin in approximately 5 seconds.

The printer will print a test page with the following information:

• Printer part number

• Paper part number

• Firmware version and release date

• Serial number

• Format Menu

• Options Menu

• Serial interface

• Print head test pattern

Removing Printed Output

There is a serrated tear bar at the point that the paper exits the printer. In most cases, the host application program will issue a form feed command that will feed enough of the paper so that all of the printed information is fed out of the printer. After the printer has finished feeding the paper, then the receipt is ready to be torn off.

If all of the printed message is not fed out of the printer and the host has finished sending data to the printer, then press the paper feed button (76) until a sufficient amount of paper has been fed out of the printer. Tear off the paper. To tear the paper, pull the paper against the tear bar at a slight angle. Continue to pull as the paper is cut by the tear bar. Refer to Illustration 34.

Illustration 34	g01525297
Proper Method to Tear Printer Paper

Printer Maintenance and Troubleshooting

Illustration 35	g01524664
317-3728 PCS Printer

Illustration 36	g06296061
537-5523 PCS Printer

Cleaning the Printer

The printer should be cleaned after printing a few rolls of paper or if there are voids on the printed output. To maintain optimum performance and a longer service life, the print head and the platen roller should be cleaned whenever a new paper roll is loaded.

Clean the Printer Interior Components

Use a thermal head cleaning pen to clean the printer areas as described below. Refer to Illustration 37.

Note: Cotton swabs that are moistened with isopropyl alcohol may also be used.

Illustration 37	g01520276
(83) Tear Bar (84) Print Head (85) Cleaner (86) Paper/Black Mark Sensor (87) Platen Roller

1. The machine must be shut off.

2. Turn off the printer.

3. Disconnect the printer from the DC power source.

4. Open the paper door and remove the paper roll.

5. Use a thermal head cleaning pen to clean the surface of the printer head as shown in Illustration 37.

   Note: Do not use sharp objects to clean the print head. The sharp objects may damage the printer. If the print head is damaged, then the printer will require service. Such damage is not covered under the warranty.

6. The sensor that detects black marks must be cleaned. The sensor is located below the print head.

7. Clean the tear bar.

8. Clean the platen roller.

9. Rotate the platen roller with a finger while cleaning the roller. Clean the entire surface of the roller.

   Note: A build up of paper dust in the printer may be experienced. The paper dust may be removed by using a can of compressed air or by using a reduced power vacuum.

Clean Printer Exterior

1. The machine must be shut off.

2. Turn off the printer.

3. Disconnect the printer from the DC power source.

4. Use a soft cloth that is moistened with a mild detergent to wipe the exterior of the printer.

Test the Printer

Perform a printer self test. Refer to the "Printer Self Test" section of this publication for information.

Troubleshooting

Error Messages

Use Table 5 as a guide to troubleshoot printer related issues.

Table 5

Message	Possible Cause	Solution
The error LED and power LED are flashing and there is one audible beep.	The paper supply is empty.	Install new roll. Follow instructions in the "Load Paper for the Printer" section.
	The sensor is dirty.	Clean the "Black Mark" sensor. Refer to "Clean Printer Interior Components" section.
The error LED is flashing.	The paper door is not fully closed.	Make sure that the door is fully closed. Open the door and close the door again. Ensure that the door "clicks" when it is closed. Check the platen roller for damage.
The printer will not turn on.	The DE9 connector is not plugged in.	Ensure that the connector is securely fastened. Press the printer "ON" button.
	The other end of harness is not plugged in.	Check the connector that is on other end of harness which is plugged into the payload control system.
	Electrostatic discharge	Electrostatic discharge may occur in extreme low humidity conditions. Press the power button to turn the printer on. If the power button does not respond, then the machine must be shut off then disconnect the DE9 connector from printer. Then, connect the DE9 connector to printer once again.
Low Print Quality	Print head dirty	Clean print head. Refer to the "Clean Printer Interior Components" section.
	Low quality or old paper	Verify paper from an approved source. Try a new roll or a new cassette of paper.
The paper is not feeding.	An obstruction is in the paper path or the paper is improperly installed.	Check the paper path and reinstall paper.
	Low-quality paper	Verify that the paper is from approved source.
The paper is not feeding reliably or the print is compressed vertically.	Low-quality paper	Verify that the paper is from an approved source.
	The paper is not loaded correctly.	Check the paper path and reinstall paper.
The print is garbled.	The configuration of the interface is improper.	Verify that the settings for the printer and the host match. Use the printer self test to verify printer setting and to verify that the printer is functioning properly.

Note: Turn the machine on. Check the power status LED (74) to see if the printer is energized.

Service Contact Information

Contact the technical communicator to submit any concerns to the "Dealer Service Network" (DSN).

Specifications

Printing Specifications

1. The printing method is direct thermal. The printer speed is up to 84 mm (3.3 inch) per second of printing.

2. The resolution is 203 dots per inch or 8 dots per millimeter.

3. Printing width is 832 printing elements for up to 104 mm (4.1 inch).

Physical Specifications

Table 6

Physical Specifications of the Printer
Length	20.57 cm (8.1 inch)
Width	16.76 cm (6.6 inch)
Height	7.8740 cm (3.1 inch)
Weight	0.91 kg (2 lb)

Environmental Specifications

1. The operating temperature range is from −40 °C (−40 °F) to 85 °C (185 °F).

2. The storage temperature range is from −40 °C (−40 °F) to 85 °C (185 °F).

3. The humidity range is 10 to 90 percent relative humidity and is not condensing.

4. The environmental rating is IP54 as per the "International Electrotechnical Commission" IEC code 529.

Operator Controls and Indicators

1. Power and error are the only two indicators.

2. The power on button and paper feed button are the only two controls that are provided on the printer.

3. There are three sensors that are included with the printer. There is a sensor for the paper, a paper door open sensor, and black mark detection sensor.

Memory Capacity

1. The flash memory is 1MB of program memory.

2. Random access memory (RAM) is 1MB.

3. EEPROM type memory is available for nonvolatile configuration storage.

Durability and Reliability

The printer can survive multiple 1.23 m (4 ft) foot drops to concrete on each face.

The printer conforms to the IEC 68-2 code. The "Mean Time Between Failures" MTBF is 10,000 hours at 100 percent duty cycle in normal use regulatory approvals.

Regulatory Approvals

The printer conforms to the Federal Communication Commission (FCC).

The printer conforms to the generic Conformite Europeenne (CE) requirements that are in the directive document 2004/108/EC.

Warranty

The printer will have a one year warranty that does include the print head.

Paper for the Printer

1. The paper must be black mark sensing on the printed side, if used.

2. The printer paper roll can be a maximum of 104.7750 mm (4.125 inch) wide.

3. The printer paper rolls can have a maximum outer Diameter of 66.68 mm (2.625 inch).

References

If more PCS information is needed, then refer to the latest revision of the Systems Operation, Testing and Adjusting, and Troubleshooting, SENR6614 or the Operation and Maintenance Manual, SEBU7012 and any other pertinent publications for related information.