525C, 535C and 545C Wheel Skidders Machine Monitor System Caterpillar

Instrument Cluster

Illustration 1	g01330067
Instrument Cluster (1) Service Mode Switch (2) Transmission Oil Filter (3) Differential lock (4) Torque converter lockup clutch (5) Brake oil pressure (6) Engine oil pressure (7) Parking brake (8) Machine security system (9) Action lamp (10) Charging system status (11) Secondary steering system (12) Air inlet heater starting aid (13) Engine warning (14) Primary steering system (15) Winch freespool (16) Auto grab (17) Work lights (18) Engine coolant temperature gauge (19) Hydraulic oil temperature gauge (20) Tachometer gauge (21) LCD display (22) Fuel level gauge (23) Torque converter temperature gauge (24) Transmission system

The Instrument Cluster uses different types of devices in order to indicate the status of the machine systems to the machine operator or the service technician. The following devices are used:

• Action alarm

• 16 Warning indicators

• 5 Analog gauges

• 1 LCD display

Action Alarm

The action alarm is driven by the Instrument Cluster through a direct connection on terminal "23" of the Instrument Cluster connector. If a level 2S warning is active, the action alarm will sound a steady tone. A level 2S warning requires an immediate change in machine operation. If a level 3 warning is active, the action alarm will sound an intermittent tone. A level 3 warning requires an immediate safe machine shutdown. The action alarm will sound these tones in order to alert the machine operator that immediate action is required. For more information on the action alarm, refer to Systems Operation, "Warning Operation" in this manual.

Warning Indicators

The LED indicators will illuminate red, green, amber, or blue in order to alert the operator that a certain condition exists in a particular machine system.

Transmission Oil Filter (2) - This indicator indicates that the transmission oil filter should be changed. If this alert indicator flashes, change the transmission oil filter. Refer to Operation and Maintenance Manual, "Transmission Oil Filter - Replace".

Differential Lock (3) - This indicator will illuminate green when differential lock is engaged. This warning is a level 1 warning.

Torque Converter Lockup Clutch (4) - This indicator will illuminate green when the torque converter lockup clutch is engaged.

Brake Oil Pressure (5) - This indicator will illuminate red when the oil pressure switch on the service brake accumulator is open. This will indicate low brake oil pressure. If the engine is running and this warning occurs, a level 3 warning is logged. The action indicator will flash red. The action alarm will activate an intermittent tone. The operator should perform an immediate, safe engine shutdown. If the engine is not running and this warning occurs, a level 2 warning is logged.

Engine Oil Pressure (6) - This indicator will illuminate red when the engine oil pressure is low.

Parking Brake Engaged (7) - This indicator will illuminate when the parking brake is engaged.

Machine Security (8) - If equipped, the indicator will illuminate red when the machine security system is activated and an attempt to start the machine is made.

Action Indicator (9) - The action indicator indicates a malfunction in a machine system. The action indicator flashes either red or amber. The action indicator flashes amber if communication between the Transmission/Chassis ECM and the Instrument Cluster is lost. The action indicator flashes red when a warning level 2, 2S or 3 diagnostic code is active. When the action indicator is flashing, some type of response is required by the operator or the technician. The appropriate response will depend on the severity of the warning. For more information on the action indicator, refer to Systems Operation, "Warning Operation" in this manual.

Charging System (10) - The machine ECM monitors the "R" terminal on the alternator and the system voltage. The indicator will illuminate the red indicator light according to the following conditions:

A level 1 warning will occur if the following conditions are present.

• The key start switch is in the ON position.

• The engine is off.

• The measured voltage is less than 22.0 V or the measured voltage is greater than 31.0 V.

A level 3 warning will occur if the following conditions are present.

• The measured voltage is less than 22.0 V or the measured voltage is greater than 31.0 V.

• The engine is running.

A level 1 warning will occur if the following conditions are present.

• The engine is running.

• The measured voltage is between 22.0 V and 23.8 V or the measured voltage is between 28.5 V and 31.0 V.

A level 1 warning will occur if the following conditions are present.

• The engine is running.

• The measured frequency is less than 90 Hz.

For Warning Category 3, there is a problem with the charging circuit that may cause damage to the machine. Stop the machine immediately and investigate the cause of the problem. Do not operate the machine until the problem has been corrected.

If electrical loads (air conditioning and/or lighting) are high and the engine speed is near idle, increase the engine speed to high idle. This will generate more output from the alternator. If the alert indicator for the electrical system turns off within one minute, the electrical system is probably operating in a normal manner. However, the electrical system may be overloaded during periods of low engine speeds.

Modify the operating cycle in order to prevent overloading the electrical system and discharging the batteries.

Low idle must be set correctly. Adjust for the high side of the Low Idle specification while the most often used electrical loads are turned on. In order to reduce the loads, use the Medium fan speed instead of the High fan speed.

If this procedure does not cause the alert indicator to turn off, move to a convenient location. Investigate the cause.

If the engine speed is near operating speeds and the electrical loads are light, the alert indicator may remain on. If the alert indicator remains on, move to a convenient location. Investigate the cause.

Secondary Steering (11) - This alert indicator will be amber in color when the secondary steering system is active or the secondary steering system is being tested. The alert indicator will be red in color when a problem with the secondary steering system exists.

Starting Aid (12) - This indicator will illuminate amber when the starting aid is active.

Engine Warning (13) - This indicator will illuminate red when the engine ECM detects a diagnostic code or an event code. This indicator will also illuminate red when the fuel pressure is high or low. The engine ECM will send the highest active warning level to the Instrument Cluster. Stop the machine immediately. Stop the engine and investigate the cause.

ReferenceFor a complete list of diagnostic codes that may cause this warning to be activated, refer to the Service Manual Troubleshooting, RENR8952, "Troubleshooting Diagnostic Codes" for the machine that is being serviced.

Primary Steering System (14) - This indicator will illuminate red when the steering pressure switch is open indicating a loss of steering pressure. If this warning occurs and the engine is running, a level 3 warning is logged. The action indicator will flash red. The action alarm will activate an intermittent tone. The operator should perform an immediate, safe engine shutdown. If this warning is activated and the engine is not running, the warning is a level 2.

Winch Freespool (15) - This alert indicator will illuminate green when the winch is in FREESPOOL.

Auto Grab (16) - This indicator will illuminate green when the Auto Grab is active.

Work Lights (17) - This indicator will illuminate blue when the work lights are active.

Transmission System (24) - This indicator indicates that a problem exists in the electronic system of the transmission. If the indicator continues to flash, reduce the load on the machine. Check the system at the earliest possible time.

ReferenceFor a complete list of diagnostic codes that may cause this warning to be activated, refer to the Service Manual Troubleshooting, RENR8952, "Troubleshooting Diagnostic Codes" for the machine that is being serviced.

Gauge Indicators

Five analog gauges on the Instrument Cluster are driven by the machine ECM on the CAN Data Link.

Engine Coolant Temperature Gauge (18) - This gauge indicates the temperature of the engine coolant. If the engine is operating and the gauge needle is positioned in the red warning area on the right hand side of the gauge face, a level 2 warning will occur. If the sensor that is monitoring the engine coolant temperature malfunctions, the gauge needle will deflect to the full right hand position of the warning area on the gauge. Table 1 indicates the coolant temperature values that correspond with the position of the needle on the gauge. Increased temperatures will sound the warning alarm. Machine operation during the sounding of the alarm may damage the engine. Also, machine operation with the pointer in the red zone may damage the engine. Stop the machine in a safe place and investigate the cause.

Hydraulic Oil Temperature Gauge (19) - This gauge indicates the hydraulic oil temperature. If the machine is operating and the gauge needle is positioned in the red warning area on the left hand side of the gauge face, a level 3 warning will be logged. If the sensor that is monitoring the oil temperature malfunctions, the gauge needle will deflect to the full left hand position of the warning area on the gauge.

Tachometer Gauge (20) - This gauge indicates the engine speed in revolutions per minute (RPM). If the sensor that is monitoring the engine speed malfunctions, the gauge needle will deflect to the full right hand position of the warning area on the gauge. Table 2 indicates the engine RPM that will correspond with the position of the needle on the gauge.

Fuel Level Gauge (22) - This gauge indicates the amount of fuel that is in the fuel tank. If the sensor that is monitoring the fuel level malfunctions, the gauge needle will deflect to the full left hand position of the warning area on the gauge. Table 3 indicates the percentage values of the fuel that will correspond with the position of the needle on the gauge.

Torque Converter Temperature Gauge (23) - This gauge indicates the temperature of the torque converter oil. If the engine is operating and the gauge needle is positioned in the red warning area on the right hand side of the gauge face, a level 2 warning will occur. If the sensor that is monitoring the torque converter oil temperature malfunctions, the gauge needle will deflect to the full right hand position of the warning area on the gauge. Table 4 indicates the torque converter oil temperature that corresponds with the position of the needle on the gauge.

LCD Readout

Liquid Crystal Display (LCD) (20) is located on the Instrument Cluster. This LCD provides a digital display of various machine parameters. When the key start switch is in the ON position, the display will be illuminated in order to ensure good visibility. When the data for the display is not known, the display is filled with "---" in order to indicate an error.

During normal operation, the following information can be displayed on the LCD. Press Service Mode Switch (1) in order to change the data that is being displayed on the LCD.

Hour Meter - The hour meter displays the total hours of operation. The "hourglass" icon is displayed on the right side of the value of the hour meter. The icon flashes in order to show that the hour meter is incremental.

Odometer - The odometer displays the total distance that has been travelled during the lifetime of the machine. The distance that is displayed is the total distance that has been travelled in both forward and reverse directions.

Note: Both the hour meter and the odometer are not resettable.

Note: Only the hour meter or the odometer will be shown at one time. Press Service Mode Switch (1) in order to toggle between the hour meter and the odometer.

When the parking brake is engaged, either the service hour meter will be shown or the odometer will be shown. When the parking brake is not engaged, the gear readout is shown.

Gear Number - The gear number represents the actual transmission gear. The gear number is displayed on the right side of the machine speed. The gear number is followed by an "F" in order to designate FORWARD gears or the gear number is followed by an "r" in order to designate REVERSE gears. When the transmission is in NEUTRAL only an "N" is displayed.

Engine RPM - The digital display shows the engine RPM.

Press and hold Service Mode Switch (1) in order to put the Instrument Cluster in Diagnostic Mode or Service Diagnostic Mode. When the Instrument Cluster is in Diagnostic Mode, the following information can be viewed on the LCD.

• Machine voltage

• Current active faults and logged fault codes

• Recorded events

• Coolant temperature

• Hydraulic temperature

• Torque converter temperature

• Fuel level

The following information will scroll on the LCD when the diagnostic information is being viewed.

• Status of Diagnostic Code (Service Mode)

• Modular Identifier (MID) (Service Mode)

• Component Identifier (CID) (Service Mode)

• Failure Mode Identifier (FMI) (Service Mode)

For more information on the diagnostics that are displayed, refer to Systems Operation, "Diagnostic Operation" in this manual.

Switches

Service Mode Switch (1) - This switch is used in order to place the Instrument Cluster in the Service Mode. Refer to the System Operation, "Diagnostic Operation " Section of this Manual for further details.

Note: THE SERVICE MODE OF THE INSTRUMENT CLUSTER SHOULD ONLY BE USED BY A CATERPILLAR QUALIFIED TECHNICIAN.