Basic Components - Overview - CAT

Hydraulic Mining Excavators
CAMP/ SIL – Electric System CAT-6060
02. Basic Components - Overview
Dixio Torrez - 2016

Location and Function of the BCS Screen Service Training
BCS
The Board Control Screen
-Visualizes the machine data
-Includes error memory
-Includes troubleshooting steps

2
Location and Function of the Servo Control System Service Training
SCS
The Servo Control System
-Coordinates the machine controls
-Controls the parking brakes
-Controls the track tensioning system
-Controls the SIL system
-Send signals to the BCS screen

3
Location and Function of the Drive Control System Service Training
DCS
The Drive Control System
-One independent box for each power train
-Controls the engine start/stop function
-Controls the flow of the main pumps
-Controls automatic rev. Reduction
-Cards collect all machine values (pressures,

contaminations, temperatures,…)
-Boxes are interchangeable
4
Location and Function of the Auxiliary System Service Training
ACS
The Auxiliary Control System
-Controls boarding / maintenance lights
-Controls the lubrication system

5
Locations of the Controllers Service Training
Servo Control System
Auxiliary System
Drive Control Left Hand Drive Control Right Hand
6
Terminal Strips Service Training
Upper side
End point 4
End point 3
End point 1 always on the bottom side

or where the locking bracket is.
Locking bracket
End point 2
End point 1
lower side
7
Terminal Strips LED Service Training
Terminal Strip with red indicator LED. The LED is lighting if the Signal is high. High
= +24V
Jumper 0V / GND
0V / GND
Signal +24V
Jumpe
r
Signal +24V
8
Terminal Strips LED Service Training
Terminal Strip with red indicator LED. The LED is lighting if the Signal is high. High
= 0V
+24V
Jumpe
r
+24V
Jumpe
r
Signal 0V / GND
Signal 0V /
GND
9
Terminal Strips Diode Service Training
Terminal Strip with duo-diode for decoupled arrangement
10
Terminal Strips Diode Service Training
Terminal Strip with single-diode for decoupled arrangement
11
WERA®
WERA®
Installation of wires
WERA®
12
Installation and removal of jumpers
13
Harting 6-10 pin Service Training
6-10 pin connectors are numbered
14
Harting 24 pin Service Training
24 pin connector is numbered
13 24
1 12
15
Harting 64 pin Service Training
64 pin connector is letter/number coded D16=64

D1=49
A1=1
A16=16
16
Fuse Breakers 4-25A Service Training
17
Fuse Breakers >25A Service Training
18
Relay Single Contact Service Training
A2 A1
Relay single contact

Terex P/N: 2458747 (24V) 19
Relay Double Contact Service Training
22 12
A2 A1
Relay double contact

P/N: 2710924 (24V) 20
Relay Single Contact Small Version Service Training
Relay small version

P/N: 2764662 (24V) 11
P/N: 2482708 (12V)

14
A1
A2
21
Diode Service Training
22
Hydraulic Oil Temperature Sensor Service Training
Temp Current
Temperature [ °C ]
Current [ mA ]
23
Pressure Sensor 400bar Service Training
Pressure Current
Pressure [ bar ]
Current [ mA ]
24
Pressure Current
Pressure [ bar ]
Current [ mA ]
25
Pressure Current
Pressure [ bar ]
Current [ mA ]
26
Pressure Sensor 2,5bar Service Training
Pressure Current
Pressure [ bar ]
Current [ mA ]
27
Inductive Proximity Switch Service Training
28
Inductive Proximity Switch (two contacts) Service Training
29
Filling Level Switches Service Training
3pin connection.
Pin +: +24VDC power supply
Pin -: 0VDC power supply
Pin S: Switching signal (+24VDC or 0VDC)
30
Pressure Switches Service Training
Normal closed contact Normal open contact

Marked with “A” Marked with “E”
e.g. “0,5 A” e.g. “1,5 E”
31
Contamination Switches Service Training
32
Temperature Switches Swing / Main Pump Service Training
33
Grease System Proximity Switch Service Training
If LED lights orange the

proximity switch is active
34
-1S3 – Ignition On/Off Switch Service Training
-1S3
35
-1S4 – Emergency Engine Stop Switch Service Training
-1S4
36
-1S5 – Emergency Engine Stop Switch Service Training
-1S6 -1S5
37
-1S7 - Emergency Engine Stop Switch Service Training
-1S7
38
-1S8 – Emergency Stop Service Training
-1S8
39
-1S10 – Working Light Cab Service Training
-1S10
40
-1S11 – Working Light Oil Cooler Service Training
-1S11
41
-1S12 – Working Light Rear Service Training
-1S12
42
-1S13 – Working Light Platform Service Training
-1S13
43
-1S14 – Working Light Boom Service Training
-1S14
44
-1S15 - Wiper Service Training
-1S15
45
-1S16 - Washer Service Training
-1S16
46
-1S17 – Tank Lift On Service Training
-1S17
47
-1S30 – Battery Isolator Service Training
-1S30
48
-1S30.1 – Starter Isolator Service Training
-1S30.1
49
-1S32 – Folding Ladder Up/ Down Service Training
-1S32
50
-1S100 – Emergency Stop Reset Service Training
-1S100
51
-2A1 – Servo Controller Service Training
-2A1
52
-2A4 – Joystick LH Service Training
-2A4
53
-2A5 - Foot Pedal LH Service Training
-2A5
54
-2A6 – Foot Pedal Middle Service Training
-2A6
55
-2A7 – Foot Pedal RH Service Training
-2A7
56
-2A8 – Joystick RH Service Training
-2A8
57
-2B2 – Ladder Up Service Training
-2B2
58
-2B7 – Servo Pressure 35bar Service Training
-2B7
59
-2B8 – Hydraulic Filter Monitoring 1 Service Training
-2B8
60
-2B10 – Hydraulic Oil Level min. Service Training
-2B10.1
61
-2B10 – Hydraulic Oil Level min. Service Training
-2B10.2
62
-2B15 – Level Switch Swing Gear 1 Service Training
-2B15
63
-2B16
64
-2B17 – Pressure Swing Motor Swiveling Left Service Training
-2B17
65
-2B18 – Pressure Swing Motor Swiveling Right Service Training
-2B18
66
-2B19 – Temperature Swing Motor Service Training
-2B19
67
-2B20 / 21 – Temperature Sensor Main Pump 1/2 Service Training
-2B20 / 21
68
-2B22 / 23
69
-2B24 / 25
70
-2B26 / 27
71
-2B28
72
-2B29
73
-2B31 – Pilot Pressure Swinging Left (to Balance Valve) Service Training
-2B31
74
-2B32 – Pilot Pressure Swinging Right (to Balance Valve) Service Training
-2B32
75
-2B33 – Pressure Supply Swing Balance Valve Service Training
-2B33
76
-2B38 – Tank Lift monitoring Service Training
-2B38
77
-2B39 – Pilot Pressure Sensor Swinging left (to pump) Service Training
-2B39
78
-2B41 – Pilot Pressure Sensor Swinging right (to pump) Service Training
-2B41
79
-2S1 – Servo Pressure On Service Training
-2S1
80
-2S2 – Travel Stage 2 Service Training
-2S2
81
-2S3 – Swing Break Switch Service Training
-2S3
82
-2S4 – Travel Break Service Training
-2S4
83
-2S5 – Swing Break Override Service Training
-2S5
84
-2S6 – Seat Contact Service Training
-2S6
85
-2S7 – Emergency Lowering Service Training
-2S7
86
-2Y1 – Proportional Valve Bucket fill Service Training
-2Y1
87
-2Y2 – Proportional Valve Bucket empty Service Training
-2Y2
88
-2Y3 – Proportional Valve Boom down pressure Service Training
-2Y3
89
-2Y4 – Proportional Valve Boom down float Service Training
-2Y4
90
-2Y5 – Proportional Valve Boom up Service Training
-2Y5
91
-2Y6 – Proportional Valve Stick in pressure Service Training
-2Y6
92
-2Y7 – Proportional Valve Stick in float Service Training
-2Y7
93
-2Y8 – Proportional Valve Stick out Service Training
-2Y8
94
-2Y9 – Proportional Valve Clam open Service Training
-2Y9
95
-2Y10 – Proportional Valve Clam close Service Training
-2Y10
96
-2Y11 – Proportional Valve traveling right reverse Service Training
-2Y11
97
-2Y12 – Proportional Valve traveling right forward Service Training
-2Y12
98
-2Y13 – Proportional Valve traveling left reverse Service Training
-2Y13
99
-2Y14 – Proportional Valve traveling left forward Service Training
-2Y14
100
-2Y15 – Proportional Valve swiveling left Service Training
-2Y15
2x Spare-
Not used !
101
-2Y16 – Proportional Valve swiveling right Service Training
-2Y16
2x Spare-
Not used !
102
-2Y17 – Switching Valve travel Breaks Service Training
-2Y17
103
-2Y18.1– Switching Servo Pressure Valve (RH- Block) Service Training
-2Y18.1 -2Y18.3- preheating Valve
104
-2Y18.4 – Switching Valve Servo Pressure on (RH – Block) Service Training
-2Y18.4 -2Y18.3- preheating- Valve
105
-2Y19 – Switching Valve Emergency lowering Service Training
-2Y19
106
-2Y20 – Switching Valve Track Tension Service Training
-2Y20
107
-2Y22 – Switching Valve Travel Stage 2 Service Training
-2Y22
108
-2Y23 – Switching Valve Swing Break Service Training
-2Y23
109
-2Y24 – Switching Valve Travel Pressure Booster Service Training
-2Y24
110
-2Y27 – Switching Valve Clam Boost (not used in new Model- bigger Clam Cylinder) Service Training
-2Y27
111
-2Y30 – SIL - Switching Valve Swing Brake– left Service Training
-2Y30
112
-2Y31 – SIL - Switching Valve Swing Brake– right Service Training
-2Y31
113
-2Y36 – Preheating switching Valve Service Training
-2Y36
114
-2Y37
115
-2Y38
116
-2Y46 – Toggle Valve Drive Service Training
-2Y46
117
-3A1 – Drive Controller LH CPU Service Training
-3A1
118
-3A2 – Drive Controller LH I/O Service Training
-3A2
119
-3B1 – Coolant Level min. Engine LH Service Training
-3B1
120
-3B2 – Contamination Switch Main Pump 1 Service Training
-3B2
121
-3B3
122
-3B4
123
-3B5
124
-3B6 – Contamination Switch Swing Pump 1 Service Training
-3B6
125
-3B7
126
-3B8 – Contamination Sensor Pump Drive Gear Box LH Service Training
-3B8
127
-3B9 – Fuel Level Sensor Tank left Service Training
-3B9
128
-3B10 – Temperature Sensor Hydraulic Oil left Service Training
-3B10
129
-3B11 – Temperature Sensor Pump Drive Gear Box LH Service Training
-3B11
130
-3B12 – Charge Pressure Swing left Service Training
-3B12
131
-3B13 – PMS Control Pressure LH Service Training
-3B13
132
-3B14 – Temperature Sensor Swingpump 1 left Service Training
-3B14
133
-3B15 – Temperature Sensor Swingpump 2 left Service Training
-3B15
134
-3B16 - Oil Pressure Switch Pump Drive Gear RH Service Training
-3B16
135
-3B17 – Pump Drive Gearbox – Low Level Sensor - LH Service Training
-3B17
136
-3B18 – Shut off Valve Hydraulic Tank down LH Service Training
-3B18
137
-3B19 – Shut off Valve Hydraulic Tank upper position Service Training
-3B19
138
-3B20/21 – Pressure Switch Engine Air Filter RH Service Training
-3B20/21
139
-3B22 – Pressure Sensor Main Pump 1 Service Training
-3B22
140
-3B23
141
-3B24
142
-3B25
143
-3B31/32 – Pressure Switch Engine Air Filter RH Service Training
-3B31/32
144
-3H1 – LED Battery charge Engine LH Service Training
-3H1
145
-3H2 – LED Oil Pressure Engine LH Service Training
-3H2
146
-3H3 – LED Coolant Temperature Engine LH Service Training
-3H3
147
-3H5 – LED Warning Light Yellow LH Service Training
-3H5
148
-3H6 – LED Stop Light Red LH Service Training
-3H6
149
-3S1 – Switch Engine Start LH Service Training
-3S1
150
-3S2 – Switch Engine Stop LH Service Training
-3S2
151
-3S3 – Switch Idle Timer Engine LH Service Training
-3S3
152
-3S4 – Rev. Reduction Engine Service Training
-3S4
153
-3S5 – Switch Rev. Adjustment Engine LH Service Training
-3S5
154
Proportional Valves for Main Pump Regulation Service Training
-3Y1 / 4Y1
155
Switching Valves for “Servo On“ Service Training
-2Y18
156
Switching Valve for Track Tensioning System Service Training
-2Y20
157
Switching Valve for Travel Pressure Booster Service Training
-2Y24
158
Switching Valve for Clamp Pressure Booster Service Training
-2Y27
159
Switching Valve for Travel Stage 2 Service Training
-2Y22
160
Switching Valve for Travel Brake Service Training
-2Y17
161
Switching Valve for Swing Park Brake Service Training
-2Y23
162
-3Y2 – Proportional Valve Water Cooling Fan Drive Pump LH Service Training
-3Y2
163
-4A1 – Drive Controller RH CPU Service Training
-4A1
164
-4A2 – Drive Controller RH I/O Service Training
-4A2
165
-4B1 – Coolant Level min. Engine RH Service Training
-4B1
166
-4B2
167
-4B3
168
-4B4
169
-4B5
170
-4B6
171
-4B7
172
-4B8 – Contamination Sensor Pump Drive Gear Box RH Service Training
-4B8
173
-4B9 - Fuel Level Sensor Tank right Service Training
-4B9
174
-4B10 – Temperature Sensor Hydraulic Oil right Service Training
-4B10
175
-4B11 – Temperature Sensor Pump Drive Gear Box RH Service Training
-4B11
176
-4B12 – Charge Pressure Swing right Service Training
-4B12
177
-4B13 – PMS Control Pressure RH Service Training
-4B13
178
-4B14 – Temperature Sensor Swingpump 3 right Service Training
-4B14
179
-4B15 – Temperature Sensor Swingpump 4 right Service Training
-4B15
180
-4B16 - Oil Pressure Switch Pump Drive Gear RH Service Training
-4B16
181
-4B17 – Pump Drive Gearbox – Low Level Sensor - RH Service Training
-4B17
182
-4B18 – Shut off Valve Hydraulic Tank down LH Service Training
-4B18
183
-4B20/21 – Pressure Switch Engine Air Filter LH Service Training
-4B20/21
184
-4B22
185
-4B23
186
-4B24
187
-4B28
188
-4B31/32 – Pressure Switch Engine Air Filter LH Service Training
-4B31/32
189
-4H1 – LED Battery charge Engine RH Service Training
-4H1
190
-4H2 – LED Oil Pressure Engine RH Service Training
-4H2
191
-4H3 - LED Coolant Temperature Engine RH Service Training
-4H3
192
-4S1 – Switch Engine Start RH Service Training
-4S1
193
-4S2 – Switch Engine Stop RH Service Training
-4S2
194
-4S3 – Switch Idle Timer Engine RH Service Training
-4S3
195
-4S5 – Switch Rev. Adjustment Engine RH Service Training
-4S5
196
-5A1 – Drive Controller LH CPU Service Training
-5A1
197
-5A2 – Drive Controller RH I/O Service Training
-5A2
198
-5B1 – Hydraulic Oil Level max. Service Training
-5B1
199
-5B2 – Proximity Switch Grease Line A Service Training
-5B2
200
-5B3 – Proximity Switch Grease Line B Service Training
-5B3
201
-5B4.1/4.2 – Contamination Switch- Servo Filter LH Service Training
-5B4.1/4.2
202
-5B5.1/5.2 – Contamination Switch- Servo Filter RH Service Training
-5B4.1/4.2
203
-5B6 – Lube Pressure Sensor Upper carriage Service Training
-5B6
204
-5B7 – Lube Pressure Sensor Under carriage Service Training
-5B7
205
-5B8 – Ambient Temperature Sensor Service Training
-5B8
206
-5B9 – Contamination Switch Swing Motor 1 Service Training
-5B9
207
-5B10
208
-5B11
209
-5B12
210
-5H1 – Back up Alarm Service Training
-5H1
211
-5H2 – Fuel Tank full Engine LH Service Training
-5H2
212
-5H3 – Fuel Tank full Engine RH Service Training
-5H3
213
-5H4 – Grease Container Full Service Training
-5H4
214
-5H20 – Tank Lift on Service Training
-5H20
215
-5H21 – Engine Oil Level max. LH Service Training
-5H21
216
-5H22 – Engine Oil Level max. RH Service Training
-5H22
217
-5S1 – Lubrication Fault Reset UPC/ UNC (Cab) Service Training
-5S1
218
-5S2 – Switch Maintenance Light (Control Panel) Service Training
-5S2
219
-5S3 – Switch Maintenance Light (Cab Module) Service Training
-5S3
220
-5S4 – Switch Maintenance Light (Operators Cab) Service Training
-5S4
221
-5S6 – Switch Light Operators Cab (Operators Cab) Service Training
-5S6
222
-5S7 – Switch Light Operators Cab (Control Panel) Service Training
-5S7
223
-5S8 – Switch Reset Truck Counter Service Training
-5S8
224
-5S9 – Switch Ladder Lighting (Operators Cab) Service Training
-5S9
225
-5S12 – Lubrication Fault Reset UPC/ UNC Service Training
-5S12
226
-5Y1 – Switching Valve Lubrication Pump on UPC Service Training
-5Y1
227
-5Y2 – Lubrication Switch over Valve Line A / Line B Service Training
-5Y2
228
-5Y3 – Lubrication Unloader Valve UPC Service Training
-5Y3
229
-5Y4 – Switching Valve Lubrication Pump on UNC Service Training
-5Y4
230
-5Y5 – Lubrication Unloader Valve UNC Service Training
-5Y5
231
-5Y6 – Valve Tank Lift Up/ Down Service Training
-5Y6
232

Basic Components - Overview - CAT

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Basic Components - Overview - CAT

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Hydraulic Mining Excavators

CAMP/ SIL – Electric System CAT-6060

02. Basic Components - Overview

Dixio Torrez - 2016

The Board Control Screen

-Visualizes the machine data

-Includes error memory

-Includes troubleshooting steps

The Servo Control System

-Coordinates the machine controls

-Controls the parking brakes

-Controls the track tensioning system

-Controls the SIL system

-Send signals to the BCS screen

The Drive Control System

-One independent box for each power train

-Controls the engine start/stop function

-Controls the flow of the main pumps

-Controls automatic rev. Reduction

-Cards collect all machine values (pressures,

-Boxes are interchangeable

-Send signals to the BCS screen

The Auxiliary Control System

-Controls boarding / maintenance lights

-Controls the lubrication system

-Send signals to the BCS screen

Servo Control System

Drive Control Left Hand Drive Control Right Hand

End point 1 always on the bottom side

Terminal Strip with duo-diode for decoupled arrangement

Terminal Strip with single-diode for decoupled arrangement

Installation and removal of jumpers

6-10 pin connectors are numbered

24 pin connector is numbered

64 pin connector is letter/number coded D16=64

Relay single contact

Relay double contact

Relay small version

P/N: 2482708 (12V)

Normal closed contact Normal open contact

If LED lights orange the

-2Y18.1 -2Y18.3- pre- heating Valve

-2Y18.4 -2Y18.3- pre- heating- Valve

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