D400E Series II Ejector Truck Caterpillar

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The Electronic Monitoring System continuously monitors machine systems. The electronic monitoring system consists of the items that follow:

• An Action Alarm

• Action Light (1)

• Test Switch (2)

• Monitoring Panel (4)

• Gauge Panel (6)

Monitoring panel (4) has seven alert indicators and a display area (5) in order to give information concerning the points in the following list:

• Parking and Secondary Brake

• Brake Oil Pressure

• Battery Charging

• Drive Train Overspeed

• Primary Steering Oil Pressure

• Brake Oil Temperature (Front Axle)

• Brake Oil Temperature (Center Axle)

Gauge panel (6) contains the following items:

• Gauge (engine coolant temperature)

• Gauge (transmission oil temperature)

• Gauge (engine oil pressure)

• Gauge (fuel level)

• Tachometer

• Speedometer

• Actual Gear Indicator

Refer to Operation and Maintenance Manual, "Gauges and Indicators".

The Electronic Monitoring System is designed to alert the operator to an immediate problem with any of the machine systems that are monitored. The Electronic Monitoring System is also designed to alert the operator to an impending problem with any of the machine systems that are monitored.

EMS Functional Test

To ensure the proper operation of the Electronic Monitoring System, check the system daily.

The battery disconnect switch must be in the ON position.

When you turn the engine start switch key from the OFF position to the ON position, the Electronic Monitoring System will perform an automatic self-diagnostic test.

The self-diagnostic test verifies that the outputs (gauges, alert indicators and alarms) are operating correctly.

The internal circuits are automatically checked.

When you turn the engine start switch to the ON position, the alert indicators and the monitoring panel are tested for approximately one second.

1. All alert indicators must flash.

2. The monitoring panel must show the readouts that follow:
   • "°C"

   • "kPa"

   • "MILES"

   • "KM"

   • "RPM"

   • "LITERS"

   • "x10"

   • "888.8.8.8"

   • the symbol for the service hour meter

When you turn the engine start switch to the ON position, the gauge panel is tested for approximately three seconds.

1. The tachometer, the engine coolant temperature gauge, the transmission oil temperature gauge, the engine oil pressure gauge and the fuel level gauge must go through the sequence that follows:
   • move to the middle of the scale.

   • move to the bottom of the scale.

   • move to the top of the scale.

   • move to the final position. The final position depends on the condition of the system that is monitored.

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2. The actual gear indicator must display the two symbols that are shown in the illustration.

3. The speedometer must display "188".

4. "MPH" and "KPH" must be illuminated.

5. The action light must illuminate.

6. The action alarm must sound once.

After three seconds, the gauge panel must operate normally.

Diagnostic Switches

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Two switches are used to access diagnostic information from the machine monitoring system. The switches are labelled:

"S" - SET

"C" - CLEAR

The diagnostic switches are used by service technicians in order to troubleshoot the machine systems.

Note: Do not move the diagnostic switches before consulting your Caterpillar dealer.

Refer to Systems Operation, Testing and Adjusting, RENR3403, "Caterpillar Monitoring Systems Service Manual" for further information.

Test Switch

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Lamp Test (2) - Press the left side of the switch in order to test the top four indicators that are located on display panel (7).

Note: The seven indicators that are located on panel (7) are not part of the Electronic Monitoring System. These indicators must be working correctly.

Operating Mode (3) - Press the right side of the switch in order to scroll through the operating modes. Information is shown in display window (5). The display window provides a readout. The readout shows the number of service hours, engine speed, machine distance (odometer) or diagnostic codes.

Press the right side of the switch. Continue to press the right side of the switch until the service hours are displayed.

Press the right side of the switch again. Machine distance (odometer) must be displayed.

Press the right side of the switch again. Engine speed must be displayed.

Press the right side of the switch again. Diagnostic codes must be displayed.

Note: The diagnostic codes have meaning when you are troubleshooting the system.

Warning Categories

The Electronic Monitoring System provides three warning categories. The first warning category requires only operator awareness. The second warning category requires an operator response. The third warning category requires immediate shutdown of the machine systems.

Warning Category 1

In this category, only the alert indicators will flash. The alert indicator that flashes identifies the machine system that needs attention. The alert indicator requires operator awareness.

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Parking and Secondary Brake (8) - The alert indicator must flash when the parking and secondary brake control is in the ENGAGED position.

Charging System (9) - There is a problem with the electrical charging system. If engine speed is high and if electrical loads are light, the indicator must be off. If the indicator is on, stop at a convenient location and investigate the cause.

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Fuel Level (10) - The fuel level gauge will indicate in the red zone when the fuel level is 10% of the tank capacity.

Warning Category 2

In this category, one of the following conditions will occur:

• An alert indicator and the action light will flash.

• A gauge will show in the red zone and the action light will flash.

A change in machine operation is required in order to eliminate the problem.

If the alert indicator continues after changing the machine operation, do not operate the machine.

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Drive Train (Overspeed) (11) - The machine is increasing speed. The transmission is within 50 rpm of making an upshift. The retardation effect of the engine brake will be temporarily lost because the brake disengages during a gearshift. When the upshift is complete, the engine brake will engage again but the brake will be less effective due to the higher gear that is being engaged. Prevent the upshift by using the service brakes to slow the machine.

Refer to Operation and Maintenance Manual, "Engine Compression Brake Control".

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Coolant Temperature (12) - The coolant temperature gauge will indicate in the red zone and the action light will flash when the coolant temperature exceeds 107 °C (225 °F). Stop the machine at a convenient location and investigate the cause.

Transmission Oil Temperature (13) - The transmission oil temperature gauge will indicate in the red zone and the action light will flash when the transmission oil temperature exceeds 124 °C (255 °F). Stop the machine at a convenient location and investigate the cause.

Warning Category 3

In this category, one of the following conditions will occur.

• The alert indicator will flash. Also, the action light will flash, and the action alarm will sound.

• A gauge will show in the red zone. Also, the action light will flash, and the action alarm will sound.

Immediate shutdown of the machine is required to prevent damage.

Do not operate the machine until the cause has been corrected.

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Parking Brake and Secondary Brake (8) - The parking brake or the secondary brake is engaged while you are operating the machine. Stop the machine immediately. Stop the engine and investigate the cause. Do not operate the machine until the parking brake and the secondary brake are functioning correctly.

Brake Oil Pressure (14) - The brake oil pressure is low. Stop the machine immediately. Stop the engine and investigate the cause. Do not operate the machine until the brake oil pressure is normal.

Charging System (9) - There is a serious problem with the charging circuit. Stop the machine immediately. Stop the engine and investigate the cause. Do not operate the machine until the problem has been corrected.

Primary Steering System (15) - The primary steering system pressure is low. Stop the machine immediately. Stop the engine and investigate the cause. Do not operate the machine until the primary steering system pressure is normal.

Brake Oil Temperature (Front Axle) (16) - The brake oil temperature for the front axle is high. Stop the machine at a convenient location and investigate the cause.

Brake Oil Temperature (Center Axle) (17) - The brake oil temperature for the center axle is high. Stop the machine at a convenient location and investigate the cause.

Engine Oil Pressure (18) - The engine oil pressure is low. The engine oil pressure gauge will indicate in the red zone. Also, the action light will flash and the action alarm will sound. If this happens, the engine oil pressure is below 70 kPa (10 psi). Stop the machine immediately. Stop the engine and investigate the cause. Do not operate the machine until the engine oil pressure is normal.